MOTOTRBOTM TWO-WAY RADIOS

DP3441
BASIC SERVICE
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 replacement level and is typical of some local
service centers, self-maintained customers, and distributors.

Product Safety and RF Exposure Compliance

ATTENTION! Before using this radio, read the guide enclosed with your
radio which contains important operating instructions for
safe usage and RF energy awareness and control for
compliance with applicable standards and regulations.

For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web
site: http://www.motorolasolutions.com

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.
 iii

Document History
The following major changes have been implemented in this manual since the previous edition:

Edition Description Date

68012009027-A Initial Release May 2013

iv Table of Contents

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

Commercial Warranty ....................................................................................x

Limited Warranty......................................................................................................................................... x
MOTOROLA COMMUNICATION PRODUCTS .............................................................................. x
I. What This Warranty Covers And For How Long ..................................................................... x
II. General Provisions ................................................................................................................. x
III. State Law Rights ................................................................................................................... x
IV. How To Get Warranty Service ..............................................................................................xi
V. What This Warranty Does Not Cover.....................................................................................xi
VI. Patent And Software Provisions............................................................................................xi
VII. Governing Law ....................................................................................................................xii

Battery and Charger Warranty ...................................................................xiii

Workmanship Warranty ............................................................................................................................ xiii
Capacity Warranty .................................................................................................................................... xiii

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

1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Radio Description......................................................................................................................... 1-1
1.2.1 DP3441 ........................................................................................................................... 1-2
1.3 Summary of Bands Available ....................................................................................................... 1-3
1.4 Portable Radio Model Numbering Scheme.................................................................................. 1-4
1.5 Model Charts................................................................................................................................ 1-5
1.5.1 VHF Model Chart ............................................................................................................. 1-5
1.5.2 UHF Model Chart............................................................................................................. 1-6
1.6 Specifications............................................................................................................................... 1-7
1.6.1 General ............................................................................................................................ 1-7
1.6.2 Receiver........................................................................................................................... 1-8
1.6.3 Transmitter....................................................................................................................... 1-9
1.6.4 Self-quieter .................................................................................................................... 1-10
1.6.5 GPS ............................................................................................................................... 1-11
1.6.6 Bluetooth........................................................................................................................ 1-11
1.6.7 MIL Standard ................................................................................................................. 1-12
1.6.8 Environmental Specification .......................................................................................... 1-12
Table of Contents v

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 Test Mode .................................................................................................................................... 3-4
3.3.1 Entering Test Mode ......................................................................................................... 3-4
3.3.2 RF Test Mode.................................................................................................................. 3-4
3.3.3 LED Test Mode................................................................................................................ 3-8
3.3.4 Speaker Tone Test Mode ................................................................................................ 3-8
3.3.5 Earpiece Tone Test Mode ............................................................................................... 3-8
3.3.6 Audio Loopback Earpiece Test Mode.............................................................................. 3-8
3.3.7 Battery Check Test Mode ................................................................................................ 3-8
3.3.8 Button/Knob/PTT Test Mode ........................................................................................... 3-9

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
4.5 RF Adaptor Assembly .................................................................................................................. 4-3

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 ..................................................................................................... 5-6
5.6.1 Front Cover from Chassis Disassembly .......................................................................... 5-6
5.6.2 Chassis Disassembly ...................................................................................................... 5-9
5.6.3 Speaker, Microphone, and Universal Connector Flex Disassembly.............................. 5-11
5.6.4 Emergency Button Assembly Dissassembly ................................................................. 5-12
5.7 Radio Reassembly – Detailed ................................................................................................... 5-13
5.7.1 Emergency Button and Speaker Reassembly............................................................... 5-13
5.7.2 Chassis Reassembly ..................................................................................................... 5-15
5.7.3 Bluetooth Antenna Kit Disassembly/Reassembly.......................................................... 5-17
5.7.3.1 Bluetooth Antenna Kit Disassembly ............................................................... 5-17
5.7.3.2 Bluetooth Antenna Kit Reassembly ................................................................ 5-18
5.8 Ensuring Radio Immersibility ..................................................................................................... 5-19
5.8.1 Servicing........................................................................................................................ 5-19
5.8.2 Accidental Immersion .................................................................................................... 5-19
vi Table of Contents

5.8.3 Specialized Test Equipment .......................................................................................... 5-19

5.8.4 Vacuum Pump Kit NLN9839.......................................................................................... 5-19
5.8.5 Pressure Pump Kit NTN4265 ........................................................................................ 5-20
5.8.6 Miscellaneous Hardware ............................................................................................... 5-20
5.8.7 Vacuum Test.................................................................................................................. 5-20
5.8.8 Pressure Test ................................................................................................................ 5-21
5.8.9 Troubleshooting Leak Areas.......................................................................................... 5-22
5.8.9.1 Front Housing ................................................................................................. 5-22
5.8.9.2 Chassis (Main Seal O-ring)............................................................................. 5-23
5.8.9.3 Battery Contact Seal....................................................................................... 5-23
5.8.9.4 Breathing Vent Membrane and Breathing Vent Label .................................... 5-24
5.8.9.5 Battery Maintenance ....................................................................................... 5-24
5.8.10 Troubleshooting Charts ................................................................................................. 5-25
5.9 Radio Exploded Mechanical Views and Parts Lists ................................................................... 5-28
5.9.1 DP3441 Model Exploded View and Parts List ............................................................... 5-28
5.9.2 Torque Chart.................................................................................................................. 5-31

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

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

B.1 Maintenance ................................................................................................................................B-1
B.2 Chip Components ........................................................................................................................B-1
B.3 Component and Parts list.............................................................................................................B-2

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

List of Figures vii

List of Figures

Figure 1-1. DP3441 ............................................................................................................................... 1-2

Figure 1-2. Portable Radio Model Numbering Scheme.......................................................................... 1-4
Figure 2-1. Programming, Testing and Alignment Cable........................................................................ 2-3
Figure 2-2. Pin Layout of Side Connector .............................................................................................. 2-4
Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup .......................................................... 3-2
Figure 3-2. RF Adaptor Plug .................................................................................................................. 3-3
Figure 3-3. Connect RF Adaptor Holder to radio RF input/output port ................................................... 3-3
Figure 4-1. CPS Programming Setup..................................................................................................... 4-1
Figure 4-2. Radio Tuning Equipment Setup ........................................................................................... 4-2
Figure 4-3. RF Plug Label and RF Adaptor Plug Removal..................................................................... 4-3
Figure 4-4. RF Adaptor Holder Align ...................................................................................................... 4-3
Figure 4-5. RF Adaptor Fasten and Slot ................................................................................................ 4-4
Figure 4-6. RF Adaptor in Place ............................................................................................................. 4-4
Figure 5-1. Antenna and Battery removal. ............................................................................................. 5-6
Figure 5-2. Channel Selector and Volume Knob removal. ..................................................................... 5-7
Figure 5-3. Chassis Screw removal........................................................................................................ 5-7
Figure 5-4. Chassis removal .................................................................................................................. 5-8
Figure 5-5. Disconnecting the chassis ................................................................................................... 5-8
Figure 5-6. Main Board and GOB Retainer removal .............................................................................. 5-9
Figure 5-7. O-ring removal ................................................................................................................... 5-10
Figure 5-8. Speaker Removal............................................................................................................... 5-11
Figure 5-9. Emergency Button Disassembly ........................................................................................ 5-12
Figure 5-10. Emergency Button Reassembly......................................................................................... 5-13
Figure 5-11. Speaker Removal............................................................................................................... 5-14
Figure 5-12. O-ring Reassembly............................................................................................................. 5-15
Figure 5-13. Chassis Reassembly.......................................................................................................... 5-16
Figure 5-14. Bluetooth Removal............................................................................................................. 5-17
Figure 5-15. Bluetooth Reassembly ....................................................................................................... 5-18
Figure 5-16. Connector Fitting – Fitting Seal Pump Connector.............................................................. 5-19
Figure 5-17. Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2).............................................. 5-25
Figure 5-18. Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2).............................................. 5-26
Figure 5-19. Troubleshooting Flow Chart for Pressure Test & Leakage Areas ...................................... 5-27
Figure 5-20. DP3441 Exploded View ..................................................................................................... 5-28
Figure B-1. PCB Top View ......................................................................................................................B-2
Figure B-2. PCB Bottom View.................................................................................................................B-2
viii Related Publications

List of Tables

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 ........................................................................................ 3-2
Table 3-2. Test Environments................................................................................................................ 3-4
Table 3-3. Test Frequencies .................................................................................................................. 3-5
Table 3-4. Transmitter Performance Checks......................................................................................... 3-6
Table 3-5. Receiver Performance Checks ............................................................................................ 3-7
Table 4-1. Software Installation Kits Radio Tuning Setup ..................................................................... 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. DP3441 Exploded View Parts List...................................................................................... 5-29
Table 5-4. Additional Part List Information .......................................................................................... 5-30
Table 5-5. Torque Specifications for Screws ....................................................................................... 5-31
List of Tables ix

Related Publications

Product Safety and RF Exposure ................................................................................................ 6864117B25

MOTOTRBO™ DP3441 Non-Display Portable User Guide ..................................................... 68012009018
MOTOTRBO™ DP3441 Non-Display Portable Quick Reference Guide .................................. 68012009019
x Commercial Warranty

Commercial Warranty

Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

MOTOROLA 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: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.

III. State Law Rights

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.
Commercial Warranty xi

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

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 (includ-
ing, 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. Rechargeable batteries if:
- any of the seals on the battery enclosure of cells are broken or show evidence of tamper-
ing.
- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.
H. Freight costs to the repair depot.
I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the Prod-
uct, 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 distrib-
uted from MOTOROLA.
J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
K. Normal and customary wear and tear.

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
xii Commercial Warranty

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 con-
tinue using the Product or parts or to replace or modify the same so that it becomes nonin-
fringing 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.
Battery and Charger Warranty xiii

Battery and Charger Warranty

Workmanship Warranty
The workmanship warranty guarantees against defects in workmanship under normal use and
service.

All MOTOTRBO Batteries Two (2) Years

IMPRES Chargers (Single-Unit and Multi-Unit, Non-Display) Two (2) Years

IMPRES Chargers (Multi-Unit with Display) One (1) Year

Core Chargers (Single-Unit and Multi-Unit, Non-Display) Two (2) Years

Capacity Warranty
The capacity warranty guarantees 80% of the rated capacity for the warranty duration.

Nickel Metal-Hydride (NiMH) or Lithium-Ion (Li-lon) Batteries 12 Months

IMPRES Batteries, When Used Exclusively with IMPRES 18 Months

Chargers
xiv Battery and Charger 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

Do NOT use any form of connector, e.g. wires, crocodile

clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.

1.2 Radio Description

The DP series portable radios are available in various frequency ranges and power levels. See
“Summary of Bands Available” on page 1-3 for Radio Frequency Ranges and Power Levels.
These digital 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: Radio Description

1.2.1 DP3441

Antenna

Channel Selector Knob

On/Off Volume Control Knob

LED Indicator Emergency Button

Universal Connector

PTT Button Speaker

Microphone
Side Button 1
Side Button 2

Figure 1-1. DP3441

• ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counter-
clockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate
counter-clockwise to decrease volume level.
• LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status.
• SIDE BUTTONS – These two buttons are field programmable using CPS.
• CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to
decrement the channel.
• PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call).
• ANTENNA – Provides the needed RF amplification when transmitting or receiving.
• MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated.
• UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be
used with the radio. It has eight points to which specific accessories will connect and be
activated.
• EMERGENCY BUTTON – Turns on and off Emergency Operations.
• SPEAKER – Outputs all tones and audio generated by the radio (e.g. features like keypad
tones and voice audio).
Introduction: Summary of Bands Available 1-3

1.3 Summary of Bands Available

Table below lists all the bands available in this manual. For details, please refer to the Model Charts
section.

Frequency Band Bandwidth Power Level

VHF 136–174 MHz 1W–5W

UHF 403–527 MHz 1W–4W

1-4 Introduction: Portable Radio Model Numbering Scheme

1.4 Portable Radio Model Numbering Scheme

Model No.Example : MD H 6 9 J D C 9 K A 2 A N

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

xy: Custom Housing

AZ: Asia/Australia
LA: Latin America
AA: North America
MD: Europe/Middle East/Africa Unique Variation
N: Standard Package
H: Portable
Version Letter
DP3400 Model Series: 69

Feature Level
1: Standard w/ FM
2. Non-FM
Band 3. CSA IE CEx ATEX
J: 136–174 MHz 4. CQST
R: 403–527 MHz
Primary System Type
A: Conventional
B: Trunking
Power Level C: Analog Only
C: 1.0,2.0,2.5 or 3.5 Watt
D: 4.0–5.0 Watt
Primary Operation
J : Basic (No GPS, no Bluetooth, no
Physical Packages embedded GOB)
C: Low Tier (Plain) K : GPS and Bluetooth
H: Mid Tier (Monochrome Display LKP) L : GPS Only
N: HIgh Tier (Color Display FKP) M: Bluetooth Only
J: 3 Button MOR N : Bluetooth w/ embedded GOB
T: No Display – Limited Tier
Channel Information
8: Variable/Programmable Channel Spacing
w/ unique # of channels
9: Variable/Programmable Channel Spacing

Figure 1-2. Portable Radio Model Numbering Scheme

Introduction: Model Charts 1-5

1.5 Model Charts

1.5.1 VHF Model Chart

DP Series, VHF, 136–174 MHz, 5W

Model Description
MDH69JDC9KA2AN 136–174 MHz , 5W, DP3441 Non Keypad Portable with GPS and BT
Item Description
X PMLD4607_S BC Kit, 136–174 MHz, 5W, MOTOTRBO Non Keypad Portable with GPS and BT
X PMLN6484_ Front Cover Kit, Non Keypad Portable with Bluetooth
X PMAD4119_ VHF Stubby Antenna 136–155 MHz
X PMAD4120_ VHF Stubby Antenna 140–165 MHz
X PMAD4121_ VHF Stubby Antenna 160–174 MHz
NOTE:
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
1-6 Introduction: Model Charts

1.5.2 UHF Model Chart

DP Series, UHF, 403–527 MHz, 4W

Model Description
MDH69RDC9KA2AN 403–527 MHz, 4W, DP3441 Non Keypad Portable with GPS and BT
Item Description
X PMLE4936_S BC Kit, 403–527 MHz, 4W, MOTOTRBO Non Keypad Portable with GPS
X PMLN6484_ Front Cover Kit, Non Keypad Portable with Bluetooth
X PMAE4069_ UHF Stubby Antenna 403–460 MHz
X PMAE4070_ UHF Stubby Antenna 440–490 MHz
X PMAE4071_ UHF Stubby Antenna 470–527 MHz
Introduction: Specifications 1-7

1.6 Specifications
1.6.1 General
General Non Keypad
DP3441

Channel Capacity 32

Frequency VHF: 136 – 174 MHz

UHF: 403 – 527 MHz

Dimensions (HxWxT) w/ 99.8 x 56.0 x 29.7 mm

NiMH battery

Weight
(with LiIon non-FM battery) 248g

Power Supply 7.5 V nominal

FCC Description UHF: AZ489FT4914

VHF: AZ489FT3833

IC Description UHF: 109U-89FT4914

VHF: 109U-89FT3833

Average battery life at 5/5/90 duty cycle with battery saver

enabled in carrier squelch and transmitter in high power.

Core Slim Li-Ion (1600 mAH) Analog: 8.5 hrs

battery Digital: 12.3 hrs

NOTE Weight can have 5% margin of error

1-8 Introduction: Specifications

1.6.2 Receiver

Receiver Non Keypad

DP3441

Frequencies VHF: 136 – 174 MHz

UHF: 403 – 527 MHz

Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz

Frequency Stability (-30°C to +/-0.5 ppm

+60°C)

Analog Sensitivity (12 dB SINAD) 0.3 µV (0.22 uV typical)

Digital Sensitivity (5% BER) 0.25µV

0.19µV (typical)

Intermodulation (TIA603C) 70 dB

Adjacent Channel Selectivity

TIA603 60 dB @ 12.5 kHz, 70 dB @ 20/25 kHz
TIA603C 45 dB @ 12.5 kHz, 70 dB @ 20/25 kHz

Spurious Rejection (TIA603C) 70 dB

Rated Audio 0.5 W

Audio Distortion @ Rated Audio 5%(3% typical)

Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20/25 kHz

Audio Response TIA603D

Conducted Spurious Emission -57 dBm

(TIA603C)
Introduction: Specifications 1-9

1.6.3 Transmitter

Transmitter Non Keypad

DP3441

Frequencies VHF: 136 – 174 MHz

UHF: 403 – 527 MHz

Channel Spacing 12.5 kHz/ 20 kHz/ 25 kHz

Frequency Stability (-30°C to +60°C) +/-0.5 ppm

Power Output (Low Power) 1W

Power Output (High Power) VHF: 5 W

UHF: 4 W

Modulation Limiting +/-2.5 kHz @ 12.5 kHz

+/-4.0kHz @ 20 kHz
+/-5.0 kHz @ 25 kHz

FM Hum and Noise -40 dB @ 12.5 kHz

-45 dB @ 20/25 kHz

Conducted / Radiated Emission -36 dBm < 1 GHz

-30 dBm > 1 GHz

Adjacent Channel Power 60 dB @ 12.5 kHz

70 dB @ 20/25 kHz

Audio Response TIA603D

Audio Distortion 3%

FM Modulation 12.5 kHz: 11K0F3E

25 kHz: 16K0F3E

4FSK Digital Modulation 12.5 kHz Data Only: 7K60F1D and 7K60FXD
12.5 kHz Data & Voice: 7K60F1E and 7K60FXE
Combination of 12.5 kHz Voice and Data: 7K60F1W

Digital Vocoder Type AMBE+2™

Digital Protocol ETSI-TS102361-1

ETSI-TS102361-2
ETSI-TS102361-3

Conforms to:
ETSI TS 102 361 (Parts 1, 2 & 3) – ETSI DMR Standard
ETSI EN 300 086 – ETSI RF Specifications (Analog)
ETSI EN 300 113 – ETSI RF Specifications (Digital)
1999/5/EC (R&TTE – Radio and Telecommunications Terminal Equipment)
2011/65/EU (RoHS 2 – Banned Substances)
2012/19/EU (WEEE – Waste Electrical and Electronic Equipment)
94/62/EC (Packaging and Packaging Waste)
Radio meets applicable regulatory requirements.
1-10 Introduction Specifications

1.6.4 Self-quieter
VHF Self-Quieter Frequencies UHF Self-Quieter Frequencies
139.2 +/- 10 kHz 403.2 +/- 10 kHz
139.52 +/- 10 kHz 412.8 +/- 10 kHz
140.545 +/- 10 kHz 422.4 +/- 10 kHz
143.615 +/- 10 kHz 441.6 +/- 10 kHz
143.84 +/- 10 kHz 460.8 +/- 10 kHz
144.34 +/- 10 kHz 470.4 +/- 10 kHz
144.385 +/- 10 kHz 480 +/- 10 kHz
148.48 +/- 10 kHz 499.2 +/- 10 kHz
148.8 +/- 10 kHz 508.8 +/- 10 kHz
152.575 +/- 10 kHz 518.4 +/- 10 kHz
153.6 +/- 10 kHz
154.625 +/- 10 kHz
158.4 +/- 10 kHz
158.72 +/- 10 kHz
163.2 +/- 10 kHz
167.68 +/- 10 kHz
168 +/- 10 kHz
172.8 +/- 10 kHz
Introduction: Specifications 1-11

1.6.5 GPS

GPS Non Keypad

DP3441

TTFF (Time To First Fix) Cold Start @ ≤ 60 seconds

-130dBm (95%)

TTFF (Time To First Fix) Hot Start @ -130 dBm ≤10 seconds
(95%)

Horizontal Accuracy (2D Accuracy) Cold Start < 5 meters

Accuracy specs are for long-term tracking (95th percentile values > 5 satellites
visible at a nominal -130 dBm signal strength)

1.6.6 Bluetooth

Bluetooth® Display Non-Display

Version Supports Bluetooth 2.1+ EDR Specification

Range Class 2, 10 meters

1-12 Introduction: Specifications

1.6.7 MIL Standard

Military Standards
Applicable 810C 810D 810E 810F 810G*
MIL–STD
Methods Procedures Methods Procedures Methods Procedures Methods Procedures Methods Procedures

Low Pressure 500.1 I 500.2 II 500.3 II 500.4 II 500.5 II

High 501.1 I, II 501.2 I/A1,II/ 501.3 I/A1, II/ 501.4 I/Hot, II/ 501.5 I/A1, II
Temperature A1 A1 Hot
Low 502.1 I 502.2 I/C3, II/ 502.3 I/C3, II/ 502.4 I/C3, II/ 502.5 I, II
Temperature C1 C1 C1
Temperature 503.1 – 503.2 I/A1/C3 503.3 I/A1/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
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, II/3 514.4 I/10, II/3 514.5 I/24 514.6 1/24, II/
Curve-W 5
Shock 516.2 I, II 516.3 I, IV 516.4 I, IV 516.5 I, IV 516.6 I, IV, VI

NOTE *Tested to MIL standard G which supersedes previous version

1.6.8 Environmental Specification

Environmental Specifications

*Operating Temperature -30 °C to +60 °C

Storage Temperature -40 °C to +85 °C

Thermal Shock Per MIL-STD

Humidity Per MIL-STD

ESD IEC 61000-4-2 Level 3

Dust and Water Intrusion IEC 60529 -IP67

Packaging Test MIL-STD 810F and G

* Operating temperature specification with LiIon battery is -10 °C to +60 °C.

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 portable radios.

Table 2-1. Recommended Test Equipment

Equipment Characteristics Example Application

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

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

RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements

Generator * -130 dBm to +10 dBm (www.agilent.com),
FM Modulation 0 kHz to Ramsey RSG1000B
10 kHz (www.ramseyelectronics.com),
Audio Frequency 100 Hz or equivalent
to 10 kHz

Oscilloscope * 2 Channel Leader LS8050 Waveform measurements

50 MHz Bandwidth (www.leaderusa.com),
5 mV/div to 20 V/div Tektronix TDS1001b
(www.tektronix.com),
or equivalent

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

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

Meter 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 No.
RLN4460_ Portable Test Set Enables connection to the audio/accessory jack.
Allows switching for radio testing.

GMVN5141_ Customer Programming Allows servicer to program radio parameters, tune

Software on CD-ROM and troubleshoot radios.

PMKN4115_* Portable Programming Cable This cable connects the radio to a USB port for radio
programming and data applications.

PMKN4117_* Portable Programming, Testing & This cable connects the radio to a USB port for radio
Alignment Cable programming, testing and alignment.

NOTE:
1. This cable does not support external PTT
using test box.
2. This cable does not auto route to external
Audio path once the cable is attached.
3. All test instructions are carried out through
software tool (e.g. CPS, Tuner, etc.)

PMNN4452_ 7.5V Universal Battery Eliminator Connects to radio via battery eliminator cable.

PMLN6154_ RF Adaptor Adapts radio’s antenna port to BNC cabling of test

equipment.

PMLN6422_ RF Cable This cable measures RF related measurements.

66012072001 Chassis and Knob Opener Enables the removal of chassis from radio housing.

PMLN6584_ RF Adaptor Holder Holds RF Adaptor to radio.

NLN9839_ Vacuum Pump Kit Allows servicer to test for leakages.

NTN4265_ Pressure Pump Kit Allows servicer to locate leakages.

5871134M01 Connector Fitting This connector allows the vacuum hose to be

connected to the radio chassis.

3271133M01 Fitting Seal This seal secures the connector fitting to the radio
chassis.

* Version A of the programming cables will not work with the radio.
Test Equipment and Service Aids: Programming, Testing and Alignment Cable 2-3

2.3 Programming, Testing and Alignment Cable

#25 #14

P1

#13 #1

P4

#1 #2
#3 #4
#5 #6
#7 #8

P3

P2

#4 #1

Figure 2-1. Programming, Testing and Alignment Cable

2-4 Test Equipment and Service Aids: Programming, Testing and Alignment Cable

Table 2-3. Pin Configuration of Side Connector

CONNECTION
P1 P2 P3

Pin Pin Pin Function

1 1 VCC (5V)

3 5 DATA+

2 4 DATA-

16 4 8 GROUND

1 and 5 2 EXTERNAL
SPEAKER+

2 and 7 3 EXTERNAL
SPEAKER-

17 6 EXTERNAL MIC+

16 7 EXTERNAL MIC-

#1
#2
#3
#4
#5
#6
#7
#8

Figure 2-2. Pin Layout of Side Connector

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.
Although these radios function in digital and analog modes, all testing is done in analog mode.

3.2 Setup
Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.

Do NOT use any form of connector, e.g. wires, crocodile

clips, and probes, to supply voltage to the radio, other
than the Motorola approved battery eliminator.

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 Test Environments

3-3 Test Frequencies

3-4 Transmitter Performance Checks

3-5 Receiver Performance Checks

3-2 Transceiver Performance Testing: Setup

Table 3-1. Initial Equipment Control Settings

Service Monitor Power Supply Test Set

Monitor Mode: Power Monitor Voltage: 7.5 Vdc Speaker set: A

RF Attn: -70 DC on/standby: Speaker/load:

Standby Speaker

AM, CW, FM: FM Volt Range: 10V PTT: OFF

Oscilloscope Source: Mod Current: 2.5A

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

Setup:
Set up the DMR Transmitter and Receiver Test as per Figure 3-1.
a. Connect the Programming cable to the radio and to the computer.
b. Remove RF Adaptor plug (orange) as shown in Figure 3-2.
c. Connect the RF Adaptor to the 50 Ohm RF Input/Output port of the radio as shown in
Figure 3-3.
Connect the other end of the RF Adaptor to the T/R port of the Radio Test Set 3920 using the RF
cable shown in Figure 3-1.

Ant. Input / Output

PMKN4117_
T/R Port
Programming Cable
Modulated RF Test
Signal / Tx
modulated RF Signal Battery Eliminator
Power Supply

Figure 3-1. DMR Radio Transmitter and Receiver Testing Setup

Transceiver Performance Testing: Setup 3-3

RF Adaptor Plug

RF Plug Label

Figure 3-2. RF Adaptor Plug

RF Adaptor Holder
(PMLN6584_)

Figure 3-3. Connect RF Adaptor Holder to radio RF input/output port

3-4 Transceiver Performance Testing: Test Mode

3.3 Test Mode

3.3.1 Entering Test Mode
1. Turn the radio on.
2. Within 10 seconds after “Self Test” is complete, press Side Button 2 five times in succession.
3. The radio beeps.

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”.
1. Each short press of Side Button 2 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 environments are analog mode as described in Table 3-2.

Table 3-2. Test Environments

No. of
Description Function
Beeps
1 Carrier Squelch RX: if carrier detected
(CSQ) TX: mic audio

2 Tone Private-Line RX: unsquelch if carrier and tone detected

(TPL) TX: mic audio + tone

3 Digital Mode RX: if carrier detected

(DIG) TX: mic audio

4 Unsquelch RX: constant unsquelch

(USQ) TX: mic audio

2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz
and 20 kHz. The radio beeps once when it toggles to 20 kHz, beeps twice for 25 kHz and
beeps three times for 12.5 kHz.
3. Turning of the Channel Knob changes the test channel from 1 to 14 as described in
Table 3-3. The radio beeps in each position.
Transceiver Performance Testing: Test Mode 3-5

Table 3-3. Test Frequencies

Channel
Selector Test
UHF VHF
Switch Channel
Position
1 Low Power TX#1 or #9 403.15 136.075
9 High Power RX#1 or #9 403.15 136.075

2 Low Power TX#2 or #10 423.25 142.575

10 High Power RX#2 or #10 423.25 142.575

3 Low Power TX#3 or #11 444.35 146.575

11 High Power RX#3 or #11 444.35 146.575

4 Low Power TX#4 or #12 465.45 155.575

12 High Power RX#4 or #12 465.45 155.575

5 Low Power TX#5 or #13 485.55 161.575

13 High Power RX#5 or #13 485.55 161.575

6 Low Power TX#6 or #14 506.65 167.575

14 High Power RX#6 or #14 506.65 167.575

7 Low Power TX#7 or #15 526.75 173.975

15 High Power RX#7 or #15 526.75 173.975

8 Low Power TX#8 or #16 527.00 174.000

16 High Power RX#8 or #16 527.00 174.000
3-6 Transceiver Performance Testing: Test Mode

Table 3-4. Transmitter Performance Checks

Communications
Test Name Radio Test Set Comments
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test Test Channel 4 continuously ±201 Hz (UHF)
frequency* carrier squelch transmit
Monitor: Frequency (during the ±68 Hz (VHF)
error performance
Input at RF In/Out check)

Power RF As above As above As above Low Power:

0.9 – 1.5 W (VHF/UHF)
High Power:
4.0 – 4.8 W (UHF)
High Power:
5.0 – 6.0 W (VHF)

Voice Mode: PWR MON 4th As above As above, meter Deviation:

Modulation channel test frequency* selector to mic ≥ 4.0 kHz but ≤ 5.0 kHz
atten to -70, input to RF (25 kHz Ch Sp).
In/Out
Monitor: DVM: AC Volts
Set 1 kHz Mod Out level
for 0.025 Vrms at test
set, 80 mVrms at AC/DC
test set jack

Voice Mode: PWR MON TEST MODE, Remove Press PTT switch on
Modulation 4th channel test Test Channel 4 modulation input radio. Say “four” loudly
(internal) frequency* carrier squelch into the radio mic.
atten to -70, input to RF output at Measure deviation:
In/Out antenna ≥ 4.0 kHz but ≤ 5.0 kHz
(25 kHz Ch Sp)

TPL As above TEST MODE, As above Deviation:

Modulation 4th channel test Test Channel 4 ≥500 Hz but ≤1000 Hz
frequency* TPL (25 kHz Ch Sp).
BW to narrow

RF Power DMR mode. Slot 1 TEST MODE, Key up radio TTR Enable is needed
Power and Slot 2 Power Digital Mode, without and IFR to be set to
transmit modulation using trigger mode with signal
without Tuner level ~1.5 V
modulation

FSK Error DMR Mode. FSK Error TEST MODE, Key up radio with Not Exceed 5%
Digital Mode, O.153 test
transmit with pattern
O.153 test modulation using
pattern Tuner

Magnitude DMR Mode. Magnitude As above As above Not Exceed 1%

Error error
Transceiver Performance Testing: Test Mode 3-7

Table 3-4. Transmitter Performance Checks (Continued)

Communications
Test Name Radio Test Set Comments
Analyzer
Symbol DMR Mode. Symbol As above As above Symbol Deviation
Deviation Deviation should be within 648 Hz
+/- 10% and 1944 Hz
+/- 10%

Transmitter DMR Mode As above As above Transmitter BER should

BER be 0%
* See Table 3-3.

Table 3-5. Receiver Performance Checks

Communications
Test Name Radio Test Set Comments
Analyzer
Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be
Frequency 4th channel test frequency* Test Channel 4 continuously ±201 Hz (UHF)
Monitor: Frequency error carrier squelch transmit (during
Input at RF In/Out output at the performance ±68 Hz (VHF)
antenna check)

Rated Audio Mode: GEN TEST MODE PTT to OFF Set volume control to
Output level: 1.0 mV RF Test Channel 6 (center), meter 2.83 Vrms
6th channel test frequency* carrier squelch selector to Audio
Mod: 1 kHz tone at 3 kHz PA
deviation
Monitor: DVM: AC Volts

Distortion As above, except to As above As above Distortion < 3.0%

distortion

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

(SINAD) lower the RF level for 12 (center) < 0.35 μV
dB SINAD.

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

Squelch (center), meter 2.83 Vrms
Threshold selection to Audio
(only radios PA, speaker/load
with to speaker
conventional
system need As above, except change Out of TEST As above Unsquelch to occur at
to be tested) frequency to a MODE; select < 0.25 μV.
conventional system. a conventional Preferred SINAD =
Raise RF level from zero system 9 – 10dB
until radio unsquelches.

Receiver IFR DMR mode. Signal Test Mode, Read BER using RF level to be
BER generator with O.153 test Digital Mode, Tuner. Adjust RF < 0.35 μV for 5%
pattern receive O.153 level to get 5% BER
test pattern BER
3-8 Transceiver Performance Testing: Test Mode

Table 3-5. Receiver Performance Checks (Continued)

Communications
Test Name Radio Test Set Comments
Analyzer
Receiver IFR DMR Mode. Signal Test Mode, RF level = Adjust volume until
Rated Audio generator with 1031 test Digital Mode, -47 dBm. Vrms = 2.83 V
pattern receive 1031 Set audo analyzer
test pattern to read Vrms.
Adjust volume to
get rated audio

Receiver IFR DMR Mode. Signal As above As above. Then Not exceed 5%
Audio generator with 1031 test set audio analyzer
Distortion pattern to measure
distortion

* See Table 3-3.

3.3.3 LED Test Mode

1. Press and hold Side Button 1 in RF Test Mode. The radio beeps once.
2. Upon any button/key press, the radio lights up the red LED.
3. Consequently, upon any button/key press, the red LED is turned off and the radio turns on the
green LED.
4. Consequently, upon any button/key press, the green LED is turned off the radio shall turn on
both LEDs.

3.3.4 Speaker Tone Test Mode

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

3.3.5 Earpiece Tone Test Mode

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

3.3.6 Audio Loopback Earpiece Test Mode

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

3.3.7 Battery Check Test Mode

1. Press and hold Side Button 1 after Audio Loopback Earpiece Test Mode. The radio beeps
once.
2. The radio LED lights up accordingly; green LED for High Battery Level, orange LED for Mid
Battery Level and blinking red LED for Low Battery Level.
Transceiver Performance Testing: Test Mode 3-9

3.3.8 Button/Knob/PTT Test Mode

1. Press and hold Side Button 1 after Battery Check Test Mode. The radio beeps once.
2. Rotate the Volume Knob; the radio beeps at each position.
3. Rotate the Channel Knob; the radio beeps at each position.
4. Press Side Button 1; the radio beeps; release, the radio beeps.
5. Press Side Button 2; the radio beeps; release, the radio beeps.
6. Press the PTT Switch; the radio beeps; release, the radio beeps.
7. Press Top Button; the radio beeps; release, the radio beeps.
3-10 Transceiver Performance Testing: Test Mode

Notes
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 in a
Windows 2000/XP/7/8 environment. These programs are available in one kit 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. Software Installation Kits Radio Tuning Setup

Description Part Number

MOTOTRBO CPS, Tuner and AirTracer Applications CD GMVN5141_

4.2 Customer Programming Software Setup

The CPS programming setup, shown in Figure 4-1 is used to program the radio.

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

! Computer USB ports can be sensitive to Electrostatic Discharge. Do not touch

exposed contacts on cable when connected to a computer.
Caution

Radio

Programming, Testing
Battery & Alignment Cable
PMKN4117B or later.

Figure 4-1. CPS Programming Setup

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

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

A personal computer (PC), Windows 2000/XP/7/8 and a tuner program are required to tune the
radio. To perform the tuning procedures, the radio must be connected to the PC, Test Box, and test
equipment setup as shown in Figure 4-2.

Battery Service Monitor

Eliminator or Counter
7.5V Reg. Transmit
RF Adaptor
Wattmeter
+12VDC
Power Radio 10 dB Pad Receive
Supply RF Generator
Audio In Tx Audio Generator
Test Box
RLN4460_ Rx Sinad Meter
Programming, Testing &
Alignment Cable
AC Voltmeter
PMKN4117B or later

Figure 4-2. Radio Tuning Equipment Setup

Radio Programming and Tuning: RF Adaptor Assembly 4-3

4.5 RF Adaptor Assembly

1. Remove RF Plug Label and use tweezer to remove the RF Adaptor Plug.

RF Adaptor Plug

RF Plug Label

Figure 4-3. RF Plug Label and RF Adaptor Plug Removal

2. Align RF Adaptor Holder to the antenna opening of the housing. The RF Adaptor Holder
should fit snugly around the outer wall of the antenna opening.

RF Adaptor Holder

Antenna Opening

Figure 4-4. RF Adaptor Holder Align

4-4 Radio Programming and Tuning: RF Adaptor Assembly

3. Fasten the screw provided to hold the RF Adaptor Holder in place. This is followed by slotting
the RF Adaptor into the RF Adaptor Holder slot.

Screw

RF Adaptor

Figure 4-5. RF Adaptor Fasten and Slot

4. The final assembly should look like this.

Figure 4-6. RF Adaptor in Place

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.
• Disassembly and reassembly of the radio.
• Repair procedures and techniques.

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 front
cover, housing assembly and battery case. 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).

!
The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners and other
Caution 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. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front cover or back cover.

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

!
Use all chemicals as prescribed by the manufacturer. Be sure
to follow all safety precautions as defined on the label or
Caution material safety data sheet.

5.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS) 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 circuits and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without first referring to the CMOS CAUTION
paragraph in the Disassembly and Reassembly section of the manual.
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 the Motorola Static
Protection Assembly (part number 0180386A82), which includes a
wrist strap, two ground cords, a table mat, and 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% 217C 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

When damaged parts are replaced, identical parts should be used. If the identical replacement part
is not locally available, check the parts list for the proper Motorola part number and order the part
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.
For soldering components with Hot-Air or infra red solder systems, please check your user guide of
the solder system to get information on solder temperature and time for the different housings of the
integrated circuits and other components.
Disassembly/Reassembly Procedures: Disassembling and Reassembling the Radio – General 5-5

5.5 Disassembling and Reassembling the Radio – General

When disassembling and reassembling the radio, 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 the radio:
• TORX™ T4, T6 and T8 screwdriver
• Chassis and Knob Opener (66012072001)
The following item and tools are required for reassembling the radio:
• Grease (1185937A01)
• TORX™ T4, T6 and T8 screwdriver
• Vacuum Pump Kit (NLN9839) – Radio Immersibility Test
• Pressure Pump Kit (NTN4265) – Radio Immersibility Test
• Connector Fitting (5871134M01) – Radio Immersibility Test
• Fitting Seal (3271133M01) – Radio Immersibility Test
• Seal Port (3286058L01)
• Label Ventilation (5478220A01)
If a unit requires further testing or service than is customarily performed at the basic level, please
send the radio to a Motorola Service Center.
5-6 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

5.6 Radio Disassembly – Detailed

5.6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Remove the battery:
a. Release the battery latches by moving them downwards.
b. Remove the battery from the radio.
3. Remove the antenna by turning it counterclockwise.

Antenna

Battery Latch

Figure 5-1. Antenna and Battery removal.

Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-7

4. Remove the Channel Selector Knob and On/Off Volume Knob from their shafts using the
knob removal tool.

Channel Selector Knob

On/Off Volume Knob

Figure 5-2. Channel Selector and Volume Knob removal.

Screws

Figure 5-3. Chassis Screw removal

5. Separate the chassis from the Front Cover Assembly as follows:
a. Unscrew the screws using a TORX™ T6 screwdriver as shown in Figure 5-3.
b. Lift the chassis up till the max.
5-8 Disassembly/Reassembly Procedures: Radio Disassembly – Detailed

c. Slide the chassis out slowly from the housing as shown in Figure 5-4.

Figure 5-4. Chassis removal

6. Lay the chassis down.

7. Remove the flex from the connector by pulling it out of its connector gently.

Connector

Flex

Figure 5-5. Disconnecting the chassis

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

5.6.2 Chassis Disassembly

1. Remove three screws from the GOB Retainer and two screws from the Main Board with a
TORX™ T8 screwdriver.
2. Lift the GOB retainer and main board from chassis.

Screws
GOB Retainer

Screws

Main Board

Chassis

Figure 5-6. Main Board and GOB Retainer removal

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

3. Remove the main o-ring and Battery Contact Seal.

Main O-Ring

Battery Contact Seal

RF Adaptor Plug

RF Plug Label

Figure 5-7. O-ring removal

4. Remove the RF plug label and RF Adaptor plug.
Disassembly/Reassembly Procedures: Radio Disassembly – Detailed 5-11

5.6.3 Speaker, Microphone, and Universal Connector Flex Disassembly

1. Pull the microphone boot from its seated position.
2. Remove the speaker retainer screw using the TORX T6 screwdriver.
3. Peel-off the universal connector flex circuit escutcheon.
4. Remove the speaker retainer from the speaker assembly.
5. Remove the assembly from the front housing.

Speaker Retainer
Screw

Speaker, Mic and Flex Assembly

Mic Boot

UC Slot

PTT Flex Connector

Figure 5-8. Speaker Removal

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

5.6.4 Emergency Button Assembly Dissassembly

1. The Emergency button can be removed without the use of tools once the speaker retainer is
removed.

Figure 5-9. Emergency Button Disassembly

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

5.7 Radio Reassembly – Detailed

5.7.1 Emergency Button and Speaker Reassembly
1. Slot in the emergency button in its proper slot.

Emergency Button

Figure 5-10. Emergency Button Reassembly

2. Insert the flexes through the speaker retainer so that the speaker retainer is placed directly on
the speaker assembly.

NOTE Ensure all the flexes are above the speaker retainer.
5-14 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Speaker Retainer
Screw

Speaker, Mic and Flex Assembly

Mic Boot

UC Slot

PTT Flex Connector

Figure 5-11. Speaker Removal

3. Slide the universal connector flex into UC slot.

4. Hook in the speaker retainer with speaker assembly at the top left corner of the housing.
5. Affix the appropriate screw on the speaker retainer.
6. Place the mic boot in the appropriate slot.
7. Place a new universal connector escutcheon on the universal connector flex circuit.
Disassembly/Reassembly Procedures: Radio Reassembly – Detailed 5-15

5.7.2 Chassis Reassembly

O-ring reassembly:
i. Ensure that the main O-ring is not twisted and untangle it to its actual form if needed
before performing reassembly.
ii. Insert the notches onto the chassis.
iii. Replace the battery contact seal.

Main O-Ring

Battery Contact Seal

RF Adaptor Plug

RF Plug Label

Figure 5-12. O-ring Reassembly.

1. Place the main board onto the chassis.

2. Tighten the main board screws in the sequence shown in Figure 5-13.
3. Place the GOB retainer on the main board and tighten the screws.
5-16 Disassembly/Reassembly Procedures: Radio Reassembly – Detailed

Screws
GOB Retainer

Screws

Main Board

Chassis

Figure 5-13. Chassis Reassembly

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

5.7.3 Bluetooth Antenna Kit Disassembly/Reassembly

5.7.3.1 Bluetooth Antenna Kit Disassembly

1. Use a Torx 4 screwdriver to unfasten the bluetooth module.
Screw

Bluetooth module

Figure 5-14. Bluetooth Removal

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

5.7.3.2 Bluetooth Antenna Kit Reassembly

1. Place the Bluetooth module in the housing and fasten with a Torx 4 screwdriver.
Screw

Bluetooth Module

Bluetooth Module Slot

Figure 5-15. Bluetooth Reassembly

Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-19

5.8 Ensuring Radio Immersibility

This section discusses radio immersibility concerns, tests, and disassembly and reassembly of the
DP series radios.

5.8.1 Servicing

The DP series radios shipped from the Motorola factory have passed vacuum testing and should be
capable of restoring the watertight integrity of the radio.

It is strongly recommended that the maintenance of the radio be deferred to

! qualified service personnel and service shops. This is of paramount importance

as irreparable damage to the radio can result from service by unauthorized
Caution persons. If disassembly is necessary, unauthorized attempts to repair the radio
may void any existing warranties or extended performance agreements with
Motorola. It is also recommended that immersibility be checked annually by
qualified service personnel/workshop that is authorized by Motorola.

5.8.2 Accidental Immersion

If the radio is accidentally dropped in water, shake the radio to remove the excess water from the
speaker grille and microphone port area before operating; otherwise, the sound may be distorted
until the water has evaporated, or is dislodged from these areas.

5.8.3 Specialized Test Equipment

This section summarizes the specialized test equipment necessary for testing the integrity of the DP
series radios.

To ensure that the radio is truly a watertight unit, special testing, test procedures, and specialized
test equipment are required. The special testing involves a vacuum check of the radio and pressure
testing (troubleshooting) for water leaks if the vacuum check fails. The specialized test equipment/
instrument (Table 2-2 on page 2-2) is authorized by Motorola and needed to perform the vacuum
check and pressure testing, if required. Any equipment/tools/instruments not mentioned in the table
must not be used to perform these test.

5.8.4 Vacuum Pump Kit NLN9839

The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. A connector fitting
(part number 5871134M01) and fitting seal (part number 3271133M01) pump connector, which must
be ordered separately, connects the vacuum hose to the radio’s chassis.

Fitting Seal
(part number
3271133M01)

Connector Fitting
(part number
5871134M01)

Figure 5-16. Connector Fitting – Fitting Seal Pump Connector

5-20 Disassembly/Reassembly Procedures: Ensuring Radio Immersibility

5.8.5 Pressure Pump Kit NTN4265

The pressure pump kit includes a pressure pump with gauge, and a pressure hose. As with the
vacuum pump kit above, the connector fitting - fitting seal pair connects the pressure hose to the
radio’s chassis.

5.8.6 Miscellaneous Hardware

Other items needed for testing the immersibility radio include:

• Large water container

• Deionized (DI) water
• A supply of replacement parts: Main seal O-ring, Battery Contact Seal, Breathing Vent Label
and Breathing Vent Membrane.

5.8.7 Vacuum Test

The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the
radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly
sealed, watertight unit. Before starting the vacuum test:

• Remove the battery.

• Remove the universal connector dustcover to expose the universal connector.
• Remove the breathing vent label and breathing vent membrane.

To conduct the vacuum test:

1. Attach antenna firmly to the radio.

2. Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by
blocking off the open end of the hose and operating the pump a few times. The actual reading
of the gauge at this point is not important; it is important that the gauge pointer remained
steady, indicating no vacuum leaks in the pump.
3. Ensure that the fitting seal is attached to the hose-to-chassis pump connector. Screw the
pump connector into the tapped hole in the chassis.

! Please do not bend or over tighten pump connector to the chassis.

Caution

4. Attach the open end of the hose to the pointed end of the pump connector.
5. Place the radio on a flat surface with the chassis facing upward.
6. Operate the pump until the gauge indicates 6 in. Hg of vacuum on the radio.Observe the
gauge for approximately 1 minute.
• If the needle falls 0.5 in. Hg or less (one scale interval, for example, from 3 in. Hg to 2.5 in.
Hg), then the radio has passed the vacuum test and is approved for immersibility. No
additional testing will be required.
• If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 3 in. Hg to less
than 2.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-21

immersed. Additional troubleshooting of the radio will be required; complete this procedure,
then go to Section 5.8.8 "Pressure Test".
7. Remove the vacuum hose and pump connector from the radio.

5.8.8 Pressure Test

Pressure testing the radio is necessary only if the radio has failed the vacuum test. Do not perform
the pressure test until the vacuum test has been completed. Pressure testing involves creating a
positive pressure condition inside the radio, immersing the radio in water, and observing the radio
for a stream of bubbles (leak). Since all areas of the radio are being checked, observe the entire unit
carefully for the possibility of multiple leaks before completing this test.

To conduct the pressure test:

1. Screw the pump connector (with fitting seal) into the tapped hole in the chassis.
2. Attach one end of the pressure hose to the pump connector and the other end to the pressure
pump.
3. Attach antenna firmly to the radio.
4. Operate the pump until the gauge reads approximately 1 psig.

! Pressure any greater than 1 psig might push air around the main seal
Caution

5. Maintain the pressure at 1 psig and immerse the radio into a water-filled container.
6. Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.

NOTE Some air entrapment may cause the accumulation of bubbles, especially in the grille area,
but the bubbles should not be continuous.

! Please do not bend or over tighten pump connector to the chassis.

Caution

7. Note all of the seal areas that show signs of leakage. Pinpoint the problem(s) to one (or more)
of the following areas:
• Front Housing
• Chassis (Main Seal O-ring)
• Battery Contact Seal
5-22 Disassembly/Reassembly Procedures: Ensuring Radio Immersibility

8. Remove the radio from the water container, and dry the radio thoroughly. Be especially
careful to dry the area around the main seal to prevent contamination of the internal
electronics while the unit is open

! Keep the area around the chassis’s vacuum port dry by ensuring that there is no
water around it.
Caution

9. Remove the pump connector from the chassis.

10. Radio after performing Pressure Test must undergo baking process in a temperature chamber
for constant temperature soaking at 60°C for 1 hour. This is to ensure no moisture is trapped
inside the radio and prevent contamination of the internal electronics after reassembling the
radio.

5.8.9 Troubleshooting Leak Areas

Before repairing any leak, first read all of the steps within the applicable section. This will help to
eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot
only the faulty seal areas listed in Section 5.8.8 "Pressure Test" on page 5-21, and when multiple
leaks exist, in the order listed.

NOTE Before reassembling the radio, always install a new Main seal O-ring, Battery Contact Seal
in the defective area.

5.8.9.1 Front Housing

Do one or both of the following:

1. If a leak occurs at the Lens (Display Models only), Universal Connector, chassis/Housing
interface, PTT button area of the housing, replace the housing. Refer to Section 5.6 "Radio
Disassembly – Detailed" on page 5-6.
a. Remove the housing assembly from the radio.
b. Discard the housing assembly and main seal O-ring.
c. Install a new main seal O-ring around the chassis assembly.
d. Install a new housing assembly to the radio.
e. Inspect the main seal for proper seating.
f. Observe carefully to ensure that the main seal O-ring is not pinched between the
housing and the chassis interface.
2. If the leak occurs at the control top area, remove the knobs in order to determine the leak
location:
a. Conduct the Pressure Test.
b. Identify the leak location.
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-23

5.8.9.2 Chassis (Main Seal O-ring)

To replace the main seal O-ring:

1. Refer to Section 5.6.1 "Front Cover from Chassis Disassembly" on page 5-6, remove the
chassis assembly from the radio.
2. Refer to Section 5.6.2 "Chassis Disassembly" on page 5-9, remove the Main Board from
chassis.
3. Remove the main seal O-ring.
4. Inspect the seal area around the chassis for foreign material that might prevent the main seal
O-ring from sealing properly.
5. Assemble a new O-ring; discard the old O-ring.
6. For detailed O-ring assembly sequence, refer to clause 2, step i. to step viii. of Section 5.7.2
"Chassis Reassembly" on page 5-15.
7. Reassemble the chassis assembly followed by installing into Front Cover. (Refer to Section
5.7 "Radio Reassembly – Detailed" on page 5-13).
8. Inspect the main seal O-ring for proper seating. Observe carefully to ensure that the main
seal O-ring is not pinched between the housing and the chassis.

NOTE When installing the assembled chassis to the Front Cover, ensure the O-ring at the top two
corners are not dislodged from the chassis groove.

5.8.9.3 Battery Contact Seal

To replace the Battery Contact Seal:

1. Refer to Section 5.6 "Radio Disassembly – Detailed" on page 5-6 to remove the Battery
Contact Seal.
2. Remove the Battery Contact Seal from the Chassis.
3. Inspect the Battery Contact Seal, Chassis and surrounding areas for foreign material that
might prevent the Battery Contact Seal from sealing properly.
4. Install a new Battery Contact Seal; discard the old Seal.
5. Replace a new main seal O-ring; discard the old O-ring.
6. Reassemble the chassis assembly followed by installing into Front Cover. (Refer to Section
5.7 "Radio Reassembly – Detailed" on page 5-13).
7. Inspect the main seal O-ring for proper seating. Observe carefully to ensure that the main
seal O-ring is not pinched between the housing and the chassis.

IMPORTANT: Both Label Ventilation (5478220A01) and Gasket (3286058L01) need to

be replaced after vacuum test, pressure test or water leakage
troubleshooting.
5-24 Disassembly/Reassembly Procedures: Ensuring Radio Immersibility

5.8.9.4 Breathing Vent Membrane and Breathing Vent Label

To replace the Breathing Vent Membrane and Breathing Vent Label:

1. Remove the Breathing Vent Label that covers the Breathing Vent Membrane from the
chassis.
2. Remove the Breathing Vent Membrane.
3. Ensure that the chassis’s surface (at the Breathing Vent Label & Breathing Vent Membrane
recessed) is clean, no/minimum scratches and free from any adhesive or other foreign
materials.
4. Install a new Breathing Vent Membrane, covering the vent port hole, in the small recessed
area in the chassis. Ensure that no oily substance come in contact with the seal.
5. Install a new Breathing Vent Label over the Breathing Vent Membrane in the larger recessed
area in the chassis. Press down evenly over the label’s surface to ensure good adhesion.

5.8.9.5 Battery Maintenance

1. As part of an Annual Battery Maintenece Program or as required (when the battery contacts
are dirty or show signs of wear) it is recommended that the Battery‘s Radio-side and Charger-
side contacts are cleaned with DeoxIT®GOLD cleaner/lubricant.
2. DeoxIT®GOLD (Supplier CAIG Labs, P/N G100P) cleaner/lubricant pen has been found to be
very effective at cleaning and extending the life of the battery‘s contacts. DeoxIT®GOLD
cleaner/lubricant is available at numerous electronics suppliers (Radio Shack, McMaster Carr,
Fry’s, etc.) and directly from manufacturer, CAIG Labs, at http://www.caig.com.
3. This pen based package is recommended as it provides better access to the recessed
contacts of the battery. The pen’s tip may need to be modified (trimmed on the sides) to
improve penetration into the battery contact slots. Per the manufacturer’s instructions, shake
the pen until the fluid begins to flow and wipe the battery's contact surface with the felt tip.
After cleaning, inspect the contact surfaces for signs of advanced wear.
4. Advanced contact wear is defined as wear through either the contact platings (gold and
nickel) to the base metal (copper). Copper exposure is characterized by a distinctive orange-
brown metal appearance surrounded by the silvery nickel underplate and gold top coat.
5. In some cases, a magnified (10x minimum) inspection may be required to verify wear through
to the base material. Polishing of the gold or nickel surface is common and is not considered
a need for replacement. In instances where advanced wear is evident, the battery should be
replaced.
6. After cleaning the contact areas of any foreign material, let the lubricant/cleaner dry for 2
minutes. Replace the battery on the radio and test for intermittency by moving the battery
relative to the radio as might occur in regular use.

NOTE Regular maintenance (at least annually) of this area is recommended to ensure
contamination free interface and to prolong the life of the battery contacts.
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-25

5.8.10 Troubleshooting Charts

Start

1. Remove Battery
2. Remove Universal
Connector Dustcover
3. Remove breathing vent label
and membrane

A
1. Attach antenna firmly to the radio.
2. Attach vacuum hose to vacuum
pump
3. Ensure fitting seal is attached to
hose-to-chassis pump connector
4. Screw pump connector into chas-
sis’s tapped hole
5. Attach vacuum hose to pump
connector
6. Place radio on flat surface
7. Operate pump (gauge = 6 in. Hg)

Gauge Full
does not fall equipment for
NO YES
below pressure test Run Pressure Test
0.5 in. Hg procedure
available

YES
NO

1.Replace Breath-
ing Vent label and
Breathing Vent
B
Membrane
2. Radio approved
for immersibility

End

Figure 5-17. Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)

5-26 Disassembly/Reassembly Procedures: Ensuring Radio Immersibility

End
Start

1.Remove pump and Send radio to

connectors from radio Motorola Depot
2. Remove antenna or
3. Separate front housing kit Motorola Service Center

YES

Examined YES Changed YES Changed YES Changed

main O-ring front housing main O-ring back chassis
fitting kit kit

NO NO NO NO

Examine and Replace front Replace main Replace new

reassemble housing kit with O-ring with chassis kit
main O-ring new unit new unit without PCBs

Figure 5-18. Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)

Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-27

Start

1. Remove vacuum hose from

pump connector
2. Attach pressure hose to
pump connector

1. Operate pressure pump

(pressure = 1 psig)
2. Immerse radio into a water- 1. Remove Knobs
filled container

NO

Bubbles from 1. Dry the radio

Continuous YES Lens*/Univer- YES 2. Replace Housing, Main
YES Bubbles from sal Connector/
Series of Front Seal O-Ring, and repeat
bubbles chassis/ steps in Troubleshooting
Housing Housing Inter- Flow Chart for Vacuum Test.
face/ PTT

NO NO * Only for Display Model

1. Dry the radio

2.Replace Breathing
Vent label and
End Breathing Vent
Membrane
3. Radio approved
1. Dry the radio
for immersibility
YES 2. Replace Main Seal O-ring,
Bubbles from and repeat steps in
Chassis Troubleshooting Flow Chart
for Vacuum Test.

NO

1. Dry the radio

NO Bubbles from YES 2. Replace Battery Contact Seal,
Battery Con- Main Seal O-Ring, and repeat
tact Seal steps in Troubleshooting Flow
Chart for Vacuum Test.

Figure 5-19. Troubleshooting Flow Chart for Pressure Test & Leakage Areas
5-28 Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists

5.9 Radio Exploded Mechanical Views and Parts Lists

5.9.1 DP3441 Model Exploded View and Parts List

5.17 3
14
5.16 5.1

5.14 5.2
5.15
5.13 4

5.12

5.3
6.8
5.5
5.6
5.9 5.4
6.7
5.7
5.10
5.8
13 5.11
12
6.6 6.1
11 6.2
10

6.3

6.4

7 6.5

8
9

Figure 5-20. DP3441 Exploded View

Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists 5-29

Table 5-3. DP3441 Exploded View Parts List

Item
Description Part Number
No.

1 Antenna See Chapter 6: Accessories

2 Knob, Frequency 36012004001

3 Knob, Volume 36012005001

4 Product Number Label See Table 5-4: Product Number Label

5 Front Cover Kit See Table 5-4: Front Cover Kit

5.1 Button, Emergency 38012008001

5.2 Name plate 33012026001

5.3 Front housing Assembly 0104057J43

5.4 Label, Front housing 54012348001

5.5 BT/GPS Antenna Module 85012045001

5.6 Mic Membrane with Stiffener Not supported. Please order Item No.5.

5.7 Boot, Microphone Not supported. Please order Item No.5.

5.8 Microphone 50012012001

5.9 Screw, speaker retainer 0386434Z02

5.10 Main Flex Assembly 0104057J44

5.11 Kapton Tape, Flex Not supported. Please order Item No.5.

5.12 Kapton Tape, Speaker Not supported. Please order Item No.5.

5.13 Speaker Retainer Assembly 0104045J57

5.14 Speaker 50012013001

5.15 Mesh, Speaker Not supported. Please order Item No.5.

5.16 Screw, bluetooth board 0371160D01

5.17 UC Escutcheon 33012020001

6 Back Cover Kit See Table 5-4: Back Cover Kit

6.1 Screw, main board 03012073001

6.2 GOB Retainer Assembly 0104059J98

6.3 Main Board Not supported. Please order Item No.6.

6.4 O-ring 32012253001

6.5 Chassis Assembly Kit 0104057J75

6.6 Battery contact seal 32012254001

5-30 Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists

Table 5-3. DP3441 Exploded View Parts List

Item
Description Part Number
No.

6.7 Pad, Thermal 75012234001

6.8 Seal, Top Control Not supported. Please order Item No.6.

7 Screw, housing 0316281H01

8 Gasket 3286058L01

9 Label, Ventilation 5478220A01

10 Battery PMNN4440_

11 Labels Not Field Replaceable

12 RF Adaptor Plug label 33012058001

13 RF Adaptor Plug 38012048001

14 Dust Cover Assembly 0104058J40

Table 5-4. Additional Part List Information

Item Description Part Number

Product Numbering Label DP3441 33012015025

Front Cover Kit Front Cover Kit with BT PMLN6484_

Back Cover Kit Back Kit UHF with BT/GPS PMLE4936_S

Back Kit VHF with BT/GPS PMLD4607_S

Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists 5-31

5.9.2 Torque Chart

Table 5-5 lists the various 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 5-5. Torque Specifications for Screws

Driver/ Torque
Part Number Description
Socket lbs-in N-m
03012073001 Screw, Main Board T8 Torx 3.1 – 3.3 0.35 – 0.37
0386434Z02 Screw, Speaker Retainer T6 Torx 2.3 – 2.5 0.26 – 0.28
0371160D01 Screw, Bluetooth Antenna T4 Torx 0.4 – 0.6 0.05 – 0.07
0316281H01 Screw, Housing Chassis T6 Torx 2.1 – 2.3 0.24 – 0.26
5-32 Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists

Notes
Appendix A EMEA Regional Warranty, Service and
Technical Support

A.1 Warranty and Service Support

Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warranty period, and service/ repair or spare parts support out of warranty.
Any "return for exchange" or "return for repair" by an authorized Motorola Dealer must be
accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an
Authorized Motorola Dealer.

A.1.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only.
In instances where the product is covered under a "return for replacement" or "return for repair"
warranty, a check of the product should be performed prior to shipping the unit back to Motorola.
This is to ensure that the product has been correctly programmed or has not been subjected to
damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources (Please see page A-3). All returns must be accompanied by a Warranty Claim
Form, available from your Customer Services representative. Products should be shipped back in
the original packaging, or correctly packaged to ensure no damage occurs in transit.

A.1.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola's Managed Technical Services (MTS) offers a repair service to both end users and
dealers at competitive prices.
2. MTS supplies individual parts and modules that can be purchased by dealers who are
technically capable of performing fault analysis and repair.
A-2 EMEA Regional Warranty, Service and Technical Support European Radio Support Centre (ERSC)

A.2 European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:

Austria: 08 00 29 75 41 Italy: 80 08 77 387

Belgium: 08 00 72 471 Luxemburg: 08 00 23 27

Denmark: 80 88 58 80 Netherlands: 08 00 22 45 13

Finland: 08 00 11 49 910 Norway: 80 01 11 15

France: 08 00 90 30 90 Portugal: 08 00 84 95 70

Germany: 08 00 18 75 240 Spain: 90 09 84 902

Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307

UK : 08 00 96 90 95 Switzerland: 08 00 55 30 82

Ireland: 18 00 55 50 21 Iceland: 80 08 147

Or dial the European Repair and Service Centre:

Telephone: +49 30 6686 1555
Fax ERSC: +49 30 6686 1579
Email ERSC: ERSC@motorolasolutions.com

Please use these numbers for repair enquiries only.

A.3 Piece Parts

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 cancellations by the supplier. If no Motorola
part number is assigned, the part is normally not available from Motorola, or is not a userserviceable
part. Part numbers appended with an asterisk are serviceable by Motorola Depot only.
Orders for replacement parts, kits and assemblies should be placed directly on Motorola's local
distribution/dealer organisation or via Motorola Online at: http://emeaonline.motorolasolutions.com
* The Radio Products and Solutions Organization (RPSO) was formerly known as the Radio
Products Services Division (RPSD) and/or the Accessories and Aftermarket Division (AAD).
EMEA Regional Warranty, Service and Technical Support Technical Support A-3

A.4 Technical Support

Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions
which may be encountered.

Russia and Armenia – Andrey Nagornykh Central and East Europe – Siggy Punzenberger
Telephone: +7 495 787 8910 Telephone: +49 (0) 6128 70 2342
Fax: +7 495 785 0185 Fax: +49 (0) 6128 95 1096
Email: mwcb47@motorolasolutions.com Email: TFG003@motorolasolutions.com

Middle East and Africa – Wayne Holmes Germany – Customer Connect Team
Telephone: +49 (0) 6126 957 6237 Telephone: +49 (0) 30 6686 1539
Fax: +49 (0) 6126 957 6826 Fax: +49 (0) 30 6686 1916
Email: Email: ESSC@motorolasolutions.com
wayne.holmes@motorolasolutions.com

France – Armand Roy Italy – Ugo Gentile

Telephone: +33 1 6935 7868 Telephone: +39 02 5220 7825
Fax: +33 1 6935 7808 Fax: +39 02 5220 7810
Email: armand.roy@motorolasolutions.com Email: Ugo.Gentile@motorolasolutions.com

France – Laurent Irrmann

Telephone: +33 1 6935 7866
Fax: +33 1 6935 7808
Email:
laurent.irrmann@motorolasolutions.com

A.5 Further Assistance From Motorola

You can also contact the Customer Help Desk through the following web address.
http://www.motorolasolutions.com
A-4 EMEA Regional Warranty, Service and Technical Support Further Assistance From Motorola

Notes
Appendix B Limited Level 3 Servicing

B.1 Maintenance
For details on the following, please refer to 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.

B.2 Chip Components

Use a Hot-Air Repair Station for chip component replacement. Adjust the temperature control to
370°C (700°F), and adjust the airflow to a minimum setting. Airflow can vary due to component
density.
• To remove a chip component:
1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm
(1/8") above the component to be removed.
2. Begin applying the hot air. Once the solder reflows, remove the component using a pair
of tweezers.
3. Using a solder wick and a soldering iron or a power desoldering station, remove the
excess solder from the pads.
• To replace a chip component using a soldering iron:
1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the
solder pads.
2. Using a pair of tweezers, position the new chip component in place while heating the
fresh solder.
3. Once solder wicks onto the new component, remove the heat from the solder.
4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the
component. If necessary, touch up the first side. All solder joints should be smooth and
shiny.
• To replace a chip component using hot air:
1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.
2. Apply a drop of solder paste flux to each pad.
3. Using a pair of tweezers, position the new component in place.
4. Position the hot-air hand piece approximately 0.3 cm (1/8") above the component and
begin applying heat.
5. Once the solder wicks to the component, remove the heat and inspect the repair. All
joints should be smooth and shiny.
B-2 Limited Level 3 Servicing: Component and Parts list

B.3 Component and Parts list

4
SW4044

5
3
2
Figure B-1. PCB Top View

S4030
S4010

7 6

2 14
4 13
5
4
E0800

3
2

3 3 2
4
3

M0800
5 4
3

12 10

7 C4020

6
M4020
2

Figure B-2. PCB Bottom View

Limited Level 3 Servicing: Component and Parts list B-3

Table B-1 Component Parts List

No. Circuit Ref Motorola Part Num. Description

1 SW4044 4086470Z01 Tact Switch

2 M0800 0987378K01 RF Connector, coaxial, female

3 E0800 02012010001 Antenna Nut

4 S4010 40012029001 Frequency Switch

5 S4030 1875103C04 Volume Rotary On/Off Switch

6 M4020 9012098001 Battery Contact Connector

7 F4020 6515076H01 Fuse Fast Blow 3A 24V

B-4 Limited Level 3 Servicing: Component 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.
CPS Customer Programming Software: Software with a graphical user
interface containing the feature set of a radio.
Default A pre-defined set of parameters.
DP 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: Pins whose function is programmable.
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.
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.
VIP Vehicle Interface Port.
Motorola Solutions Malaysia Sdn Bhd,(Co. No. 455657-H)
Plot 2 Bayan Lepas Technoplex Industrial Park
Mukim 12 S.W.D
11900 Penang, Malaysia

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.
May 2013.

www.motorolasolutions.com/mototrbo

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