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Motorola MTM800 FuG ET, Basic Service Manual

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Motorola MTM800 FuG ET Basic Service Manual Download Page 63

Maintenance

6 - 7

Terminal Disassembly and Reassembly 

–

 Detailed

The procedure to remove and replace a Enhanced Control Head, Top Cover or Transceiver Board is 
similar for all models of terminal. A typical procedure is therefore shown followed by specific 
disassembly procedures for Enhanced Control Heads, Remote Head Enhanced and Data 
Expansion Head Enhanced on terminal models.

Enhanced Control Head Removal

1.

Insert the dismantling tool (Motorola part number 6686119B01) in the chamfer between the 
Enhanced Control Head and the terminal assembly.

Figure 6-1   

Typical Enhanced Control Head Removal

2.

Push down the handle of the dismantling tool to pry open the control head until the chassis 

tabs disengage from the Enhanced Control Head at both sides.

3.

Remove the Enhanced Control Head and flexible connection from the terminal assembly.

Figure 6-2   

Flexible Connection Removal

Summary of Contents for MTM800 FuG ET

Page 1: ...68015000183 D 68015000183 EN 2012 Motorola Solutions Inc All rights reserved November2012 MTM5x00 MTM800 FuG MTM800 FuG ET BASIC SERVICE MANUAL 380 430 MHz MT953C MT953CG ...

Page 2: ......

Page 3: ...Manual No 68015000183 Kindly complete the Service Manual Feedback Form on the next page to help us ensure that you receive the most accurate and complete information Fax to 6 04 6124944 The Technical Publications Coordinator Global Customer Documentation R D Department Motorola Penang Your Details Name ContactPerson Company Name Address Telephone No Fax No Email Address How would you like to recei...

Page 4: ...quipment very much so generally yes to some extent no 4 We would appreciate any corrections or recommendations for improving this manual Please include the specific page number s of the diagram or procedure in question 5 General comments suggestions Manual No 68015000183 Fax to 6 04 6124944 The Technical Publications Coordinator Global Customer Documentation R D Department Motorola Penang Complete...

Page 5: ...rogram 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 licens...

Page 6: ...vi COPYRIGHT Notes ...

Page 7: ...e 6 3 on page 6 5 updated part number for the Remote PWA kit on page 6 28 May 2011 68015000183 C Updates include added a note for the new LCD Module part number Table 6 7 Chapter 6 updated diagram Figure 6 1 and terminal disassembly step for Enhanced Control Head Removal Chapter 6 Jun 2012 68015000183 D Updates include added new Ethernet sales model and model descriptions for Model Descriptions ta...

Page 8: ...viii DOCUMENT HISTORY Notes ...

Page 9: ...sues and genetic material Experts in science engineering medicine health and industry work with organisations to develop standards for safe exposure to RF energy These standards provide recommended levels of RF exposure for both workers and the general public These recommended RF exposure levels include substantial margins of protection All Motorola 2 way terminals are designed manufactured and te...

Page 10: ...complies with IEEE and ICNIRP exposure limits for occupational controlled RF exposure environments at duty factors of up to 50 talk 50 listen and is authorised by the IEEE ICNIRP for occupational use In terms of measuring RF energy for compliance with these exposure guidelines your terminal antenna radiates measurable RF energy only while it is transmitting during talking not when it is receiving ...

Page 11: ...xposure requirements in the standards listed above Note Table 1 lists the recommended lateral distance for bystanders in an uncontrolled environment from the body of a vehicle with an approved properly installed transmitting antenna i e monopoles over a ground plane or dipoles at several different ranges of rated radio power for mobile terminals installed in a vehicle Note If you are not sure of t...

Page 12: ...lines and Operating Instructions for Mobile Two Way Terminals Installed as Fixed Site Control Stations If mobile terminal equipment is installed at a fixed location and operated as a control station or as a fixed unit the antenna installation must comply with the following requirements in order to ensure optimal performance and compliance with the RF energy exposure limits in the standards and gui...

Page 13: ...ing precautions be used when installing the terminal 1 Refer to the manufacturer s instructions or other technical bulletins for recommendations on terminal installation 2 Before installing the terminal determine the location of the electronic control modules and their harnesses in the vehicle 3 Route all terminal wiring including the antenna transmission line as far away as possible from the elec...

Page 14: ...e atmospheres referred to above include fuelling areas such as below decks on boats fuel or chemical transfer or storage facilities areas where the air contains chemicals or particles such as grain dust or metal powders Areas with potentially explosive atmospheres are often but not always posted Blasting Caps And Blasting Areas To avoid possible interference with blasting operations turn off your ...

Page 15: ...ADDITIONAL IMPORTANT INFORMATION FOR SERVICING AND INSTALLING THE TERMINAL C a u t i o n Installations Wartungs und Reparaturarbeiten dürfen ausschließlich von autorisiertem und geschultem Personal ausgeführt werden Dieses Gerät ist mit einer Schutzsicherung im Stromversorgungskabel ausgestattet Bei Austausch ausschließlich den Originalwert verwenden WARNUNG Bei Einsetzen von nicht vom Hersteller ...

Page 16: ...xvi Product Safety and RF Exposure Notes ...

Page 17: ...ion xii Compliance and Control Guidelines and Operating Instructions for Mobile Two Way Terminals Installed as Fixed Site Control Stations xii Electromagnetic Interference Compatibility xii Facilities xiii Vehicles xiii Driver Safety xiii OPERATIONAL WARNINGS xiv For Vehicles With Air Bags xiv Potentially Explosive Atmospheres xiv Blasting Caps And Blasting Areas xiv ADDITIONAL IMPORTANT INFORMATI...

Page 18: ...l Test Screen 5 1 9 RF Tests 5 1 10 Receiver Tests 5 1 10 Simulate Base Station registration 5 1 10 RSSI Test 5 1 10 Transmitter Tests 5 1 11 Call Processing Test 5 1 12 Talk Back 5 1 12 Call to Mobile 5 1 12 Duplex Test Phone Private Mode 5 1 13 Digital Duplex Test Tx 5 1 13 Manual Mode Testing 5 1 14 Preparation for Testing 5 1 14 Tests 5 1 14 Service Flow Chart Board Level 5 1 16 Fuses on the M...

Page 19: ...Telephone Style Control Head Reassembly 6 29 Service Aids 6 35 Exploded Views Parts Lists 6 36 Transceiver Exploded View and Parts List 6 36 Enhanced Control Head Exploded View and Parts List 6 38 Data Expansion Head Enhanced Exploded View and Parts List 6 40 Remote Mount Enhanced Control Head Exploded View and Parts List 6 41 Telephone Style Control Head Exploded View and Parts List 6 42 Remote E...

Page 20: ...IX B PRODUCT SPECIFIC INFORMATION Equipment Electrical Ratings B 1 Normal Load Conditions B 1 Fuse Identification B 1 SPEZIELLE PRODUKTINFORMATIONEN Nennwerte für das Funkgerät B 2 Betriebsbedingungen B 2 Sicherungen B 2 ...

Page 21: ...rated by a complete Manual revision or alternatively as additions This manual is divided into the following sections Copyright Document History User Safety Training and General Information CHAPTER 1 Scope and Warranty Information CHAPTER 2 Model Information Accessories CHAPTER 3 Overview CHAPTER 4 Programming the Terminal CHAPTER 5 Test Setup and Testing CHAPTER 6 Maintenance APPENDIX A Replacemen...

Page 22: ...es 68015000289 MTM5x00 Quick Start Guide English 68015000180 MTM5x00 Feature User Guide English only available on MOL http www motorola com emeaonline 68015000284 MTM5x00 Quick Start Guide Lithuanian 68015000285 MTM5x00 Quick Start Guide Arabic 68015000290 MTM5x00 Quick Start Guide Spanish 68015000291 MTM5x00 Quick Start Guide Norwegian 68015000292 MTM5x00 Quick Start Guide Dutch 68015000293 MTM5x...

Page 23: ...uG ET Quick Start Guide English 68015000555 MTM800 FuG MTM800 FuG ET Quick Start Guide German 68015000586 MTM5x00 Feature User Guide English German 68015000585 MTM800 FuG MTM800 FuG ET Feature User Guide English 68015000552 MTM800 FuG MTM800 FuG ET Feature User Guide English German All the Feature User Guides above are only available on MOL http www motorola com emeaonline CPS Start Up Manual 6802...

Page 24: ... correctly programmed or has not been subjected to damage outside the terms of the warranty Prior to shipping any terminal back to the appropriate Motorola warranty depot please contact Customer Resources or your Motorola dealer distributor or reseller All returns must be accompanied by a Warranty Claim Form available from your Customer Service representative or Motorola Online Extranet MOL or you...

Page 25: ...953CG M83PFS6TZ2AN M83PFS6TZ2AG MTM5400 380 430 MHz M CYCLE MTM800 FuG 380 430 MHz M CYCLE M4 MT953C MT953CG M83PFA6TZ5AN M83PFA6TZ5AG MTM5400 380 430 MHz Data MTM800 FuG 380 430 MHz Data M5 MT953C MT953CG M83PFT6TZ6AN M83PFT6TZ6AG MTM5500 380 430 MHz REMOTE MTM800 FuG ET 380 430 REM ETHERNET M6 Typical Model Number M 8 3 P F S 6 T Z 5 A N Position 2 3 1 4 5 7 10 9 11 12 8 6 Type of Unit M Mobile ...

Page 26: ...ax Current 10 8 Vdc 13 2 Vdc 15 6 Vdc Approx 3 5 A Intermodulation Blocking 50 100 kHz 47 dBm 40 dBm Frequency Range DMO MTM5400 MTM800 FuG ENH 380 430 MHz Dimensions HxWxD in mm Spurious Rejection 45 dBm Frequency Stability Transceiver with Enhanced Control Head Dash Mount 60 x 188 x 198 Adjacent Channel Interference Ratio 45 dB Locked to Base Not Locked to Base 100 Hz 1 kHz Weight in grams Frequ...

Page 27: ...ad Data Expansion Head Enhanced Speaker Microphone or Handset Remote Mount cables Standard User Guide and Installation Accessories M6 Remote Mount with Mobile Terminal with Remote Mount Ethernet Enhanced Control Head with Ethernet Data Expansion Head Speaker Microphone or Handset Remote Mount cables Standard User Guide and Installation Accessories The remote mount control heads can be Telephone St...

Page 28: ...t Microphone RMN5111 X X X X X Fist Microphone use together with Junction Box a GMMN4063 X X X X X Impres Visor Microphone RMN5054 X X X X Handset Speaker Microphone HSM b PMMN4070 Xc X Xd X Hearer Speaker Mic with Jack Vol C Emer PMMN4086 X Visor Microphone PMMN4087 X X X X Loudspeakers Part Number M1 M2 M3 M4 M5 M6 Small Loudspeaker 5W use together with Junction Box a GMSN4078 X X X X X X Extern...

Page 29: ...C H 7m RKN4079 X X Remote Mount Cable Terminal to C H 10m PMKN4020 X X Accessories Expansion Cable 2 3m PMKN4029 X X Motorcycle Mount TELCO Cable 2 3m PMKN4030 X Accessories Expansion Cable 4m PMKN4056 X X Tetra Mobile Ethernet Cable 40m PMKN4135 X Tetra Mobile Ethernet Cable 12m PMKN4136 X Tetra Mobile Ethernet Cable 10m PMKN4138 X Tetra Mobile Ethernet Cable 7m PMKN4139 X Tetra Mobile Ethernet C...

Page 30: ... Rear Port PMKN4110 X X X X Programming Cable PMKN4105 X X X X X Active Data Cable a PMKN4104 X Xa X X X USB Programming Cable Mobile Microphone Port HKN6184 X X X X Cable Assembly Micro USB Active Sync 25 124330 01R X Antennas sold with terminals Part Number M1 M2 M3 M4 M5 M6 Antenna Whip Tetra Hinged 380 430 MHz GMAE4253A X X X X X X Antenna Tetra Glass Mount 410 430 MHz GMAE4254A X X X X X X An...

Page 31: ...e footnotes c and d For details on how to make this switch refer to the related instruction leaflet c The golden grounding clip used in this model is 4216931H01 See footnote b d The golden grounding clip used in this model is 4216932H01 See footnote b e Requires Junction Box GMLN5089 f Currently the GCAI handset has insufficient margin to EMC requirements and may require additional protection to p...

Page 32: ...2 8 Model Information Accessories Notes ...

Page 33: ...ion Digital Modulation Technique The MTM5400 MTM800 FuG with Enhanced Control Head is a 380 430 MHz mobile that can operate in dispatch mode It uses several digital technologies for voice and data transmissions Voice transmission Voice transmission is performed using π 4 DQPSK and Time Division Multiple Access TDMA π 4 DQPSK is a modulation technique that transmits information by altering the phas...

Page 34: ...ve packet data using the MTM5400 MTM800 FuG The first is Multi Slot Packet Data MSPD where the data throughput is increased by transmitting in more than one slot per frame but using the older π 4 DQPSK modulation This mode supports continuous transmission The other possibility is the TETRA Enhanced Data System TEDS which uses multi carrier techniques and more complex modulation to achieve higher d...

Page 35: ...Programming the Terminal 4 1 CHAPTER 4 PROGRAMMING THE TERMINAL Note For programming the terminal refer to TETRA Customer Programming Software CPS Start up User Guide Publication No 6802974C10_ ...

Page 36: ...4 2 Programming the Terminal Notes ...

Page 37: ...performance of the MTM5400 with Enhanced Control Head terminal and may cause a new tuning procedure This tuning procedure can only be applied by certain authorized Motorola depots where the appropriate TEST TUNE EQUIPMENT is available The appropriate TEST TUNE EQUIPMENT is a special automated test equipment which is only available at some Motorola factories and Motorola repair centers W A R N I N ...

Page 38: ...5 2 Test Setup Testing Notes ...

Page 39: ...to 13 2 Volts Switch on the terminal Figure 5 1 1 Typical Test Setup Any level 3 repairs can deeply affect the performance of the MTM5400 MTM800 FuG with Enhanced Control Head terminal and may cause a new tuning procedure This tuning procedure can only be applied by certain authorized Motorola depots where the appropriate TEST TUNE EQUIPMENT is available The appropriate TEST TUNE EQUIPMENT is a sp...

Page 40: ...A SVC MON MOB BASE ST DIRECT MODE WADN4173A TETRA SVC MON MOB DIR MODE MPT1327 1343 WADN4233A Table 5 1 2 Test Setup No Test Name Test Setup Terminal Setup Test Conditions Limits 1 IFR System Setup and Manual Test Screen Control Channel For 380 430 MHz terminal 3605 Traffic Channel For 380 430 MHz terminal 3605 Time Slot 3 Country Code 234 Network Code 2392 Base Color 1 Location Area 224 Min Rx Le...

Page 41: ... RMS Max 30 Peak Max 5 Residual 5 Call Processing Talk Back 1 kHz Test Signal Group Mode Range 1 Test Group 1 90dBm 6 Call Processing Call to Mobile Private Mode Private Call Private Mode RF Gen Level Burst Power 90dBm 35 40dBm Timing Error 0 25 Symbols Frequency Error 100 Hz Vector Error Max 10 RMS Max 30 Peak Max 5 Residual 7 Digital Duplex Test Tx RF Gen Level Private Mode 50dBm Burst Power 10 ...

Page 42: ...e IFR 2 Press the Config soft key twice then go to System followed by TETRA Select MS 3 Configure the parameters for the Channel Plan a Press the Config soft key twice then go to Configure followed by Channel Plan and press the Select soft key b Press the Select soft key again and select No Plan press New Plan c Enter the parameters outlined below Channel Plan TETRA 380 0MS Frequency Band 3 300 MH...

Page 43: ...xed B Note The number for Short Subscriber Identity SSI and Group Short Subscriber Identity GSSI base on the number key in the Codeplug of the radio 6 Configure the parameters for the Call Types a Press the Config soft key twice then go to Configure followed by Call Types and press the Select soft key b Enter the parameters outlined below Priority 00 Priority Not Defined Calling Party SSI 100 7 Co...

Page 44: ...VOICE SERVICE SUPPORTED CIRCUIT MODE DATA SERVICE NOT SUPPORTED RESERVED NOT AVAILABLE TETRA PACKET DATA SERVICE NOT AVAILABLE AIR INTERFACE ENCRYPTION NOT AVAILABLE ADVANCED LINK NOT SUPPORTED 10 You have now completed all the important configurations using the configuration menu Note Please store these setting in the IFR to be recalled for future use Configuration of the IFR 2968 System Setup Th...

Page 45: ...ata keys followed by the Lowest Channel soft key k Press the Highest Channel soft key and enter 4000 for 380 430 MHz using the data keys followed by the Highest Channel soft key l Press the Lowest Tx Freq soft key and enter 380 125 for 380 430 MHz using the data keys followed by the MHz key m Press the Duplex Offset soft key and enter 10 for 380 430 MHz using the data keys followed by the MHz key ...

Page 46: ...ERVICE NORMAL MODE TETRA VOICE SERVICE SUPPORTED CIRCUIT MODE DATA SERVICE SUPPORTED RESERVED NOT AVAILABLE SNDCP SERVICE NOT AVAILABLE AIR INTERFACE ENCRYPTION NOT AVAILABLE ADVANCED LINK NOT SUPPORTED Note The displayed values are factory defaults and should not be changed 21 Press the Return soft key 22 Press the Neighbr Cell soft key 23 Verify that the following values are displayed NEIGHBOUR ...

Page 47: ...hereafter enter the control channel Number and press the Control Channel soft key The control channel Number for 380 43 0 MHz is 3605 Rx 421 0125 MHz 3 Press the Traffic Channel soft key Enter 3605 for 380 430 MHz and press the Traffic Channel soft key The marker goes to Timeslot Enter 3 and press the Traffic Channel soft key Note The Traffic Channel number changes automatically after entering the...

Page 48: ...elow the Test Page field must be enabled using the CPS Before carrying out the following steps record the Insertion loss dB of the cable loss value X dB 1 In the IFR Manual Test Mode press the RF Gen Level Soft Key and enter 90 dBm 2 Before testing the terminal should be configured to RSSI mode using the following sequence When performing steps 3 through 6 make sure that you press the control head...

Page 49: ...n a second between every consecutive press 11 Press the navigation key 12 Press the key 13 Press the Menu key 14 Press the Right Navigation key Hereafter there is no need for quick sequence of pressing the control head keys 15 Press Select using the Lower soft key 16 Press Stop using the Lower soft key 17 Press Back using the Upper soft key twice Transmitter Tests Before you start these tests make...

Page 50: ... of the available groups 2 In the IFR Manual Test Mode press the RF Gen Level soft key Enter 90dBm by pressing the data keys and RF Gen Level key 3 Press the PTT press the Talk Back soft key on the IFR and speak into the mic of the terminal for at least 3sec then release PTT You will hear from the terminal speaker the last three seconds of the speech frames before the PTT has been released 4 Press...

Page 51: ...s the Talk Back soft key 4 Speak into the terminal microphone and hear your speech after a short delay from the terminal loudspeaker Note If you need more details press the Duplex Test mode key 5 Press the duplex test Tx soft key The Digital Duplex test results will be displayed on the IFR screen providing you with either one of the following bar charts measurement capabilities showing Tx Power Fr...

Page 52: ...Any key that will be pressed will cause the test to advance from one step to the next You can use the soft keys to go to the next or back to the previous test After a test has started you can press the upper soft key to go back to the start of the current test At any time you can switch off the radio by press ing the On Off key for 2 seconds 1 Press any key to start the first test The display show...

Page 53: ...f the radio lit 16 Press any key consecutively The display shows the LED brightness levels min low med and max Verify the brightness of the orange LED at the right side of the radio 17 Press any key to start the next test The display shows Keypad test 18 Press any key again The display shows all the radio keys 19 Press every key one by one Each key you press causes its respective display to be hig...

Page 54: ...parts refer to the Maintenance chapter Start Power up OK All tests successful Replacement kits available Read the codeplug with the CPS Connect the radio to the IFR Perform all RF call manual tests of chapter TESTING Replace main board and start complete procedure again If no kits have been replaced verify installation integrity Check DC cable and connector Check RF antenna cable connector Check c...

Page 55: ...TP33 R1764 R1360 E1730 Q1708 U1718 R1730 R1725 R1715 R1711 R1741 Q1712 Q1701 C1718 C1730 R1746 R1731 SH400 C1312 C1309 C1307 C1305 C1304 C1311 C1310 R1359 R1729 6 3 6 9 2 13 U1704 U1719 TP20 R447 D402 8 7 3 2 3 2 7 5 3 14 C672 R666 R665 C669 C696 VR100 Q605 Q606 C683 C674 R6107 R6101 R693 R6100 R6102 R6144 R6108 U602 U601 C675 C6112 C698 C6111 C681 C6172 R676 R698 R673 R6167 R6166 R6175 C673 R6104...

Page 56: ...5 1 18 Test Setup Testing for 380 430 MHz Notes ...

Page 57: ... recommended to inspect the interior electronic circuitry Cleaning The following procedures describe the recommended cleaning agents and methods to be used when cleaning the external and internal surfaces of the terminal External surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges compound or grime Internal surfaces circuit boards and components should ...

Page 58: ...inside of the terminal 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 CAUTI...

Page 59: ...tic 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 a floor mat ESD shoes and an ESD chair Wear a conductive wrist strap in series with a 100k resist...

Page 60: ... near connector pins avoid accidentally getting solder in the connector be careful not to form solder bridges between the connector pins closely examine your work for shorts due to solder bridges 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 assem...

Page 61: ...m these moisture sensitive components MS should be stored and shipped in a sealed wrapping dry pack Processing must take place only with dry components when an uninterrupted dry storage can be guaranteed otherwise the components have to be pre baked If a reflow procedure takes place close to MS components the whole board must be pre baked Out of dry package Moisture Sensitivity Level MSL 2 1 year ...

Page 62: ...er 7x 1 92 2 03 Nm 17 18 lb in PCB 2x 1 92 2 03 Nm 17 18 lb in GPS cable nut 0 904 0 09 Nm 8 0 0 8 lb in Enhanced Control Head Screws 0 57 0 046 Nm 5 0 0 4 lb in Remote Mount Ethernet Control Head Middle Screw 1x 0 57 0 046 Nm 5 0 0 4 lb in Remote Ethernet Back Head PCB Screws 3x 0 57 0 046 Nm 5 0 0 4 lb in TSCH Handset PCB Screws 4x 0 25 0 011 Nm 2 2 0 1 lb in TSCH Handset Micro USB Module Screws...

Page 63: ...ansion Head Enhanced on terminal models Enhanced Control Head Removal 1 Insert the dismantling tool Motorola part number 6686119B01 in the chamfer between the Enhanced Control Head and the terminal assembly Figure 6 1 Typical Enhanced Control Head Removal 2 Push down the handle of the dismantling tool to pry open the control head until the chassis tabs disengage from the Enhanced Control Head at b...

Page 64: ... of the top plastic cover until the cover is released from the terminal chassis 3 Lift the top plastic cover from the chassis Transceiver Board Removal 1 Remove the tamper label on the die cast cover Figure 6 4 Tamper Label Removal 2 Remove seven screws from the diecast cover using a T20 TORX driver and remove the die cast cover Dismantling ZWG0130211 O Tool See Detail A Detail A ...

Page 65: ...he diecast cover may be difficult to remove due to the main seal adhesion if the diecast cover has not been removed for a long time The dismantling tool Motorola part number 6686119B01 can be used as a lever to pry and remove the diecast cover CAUTION Do NOT disconnect the GPS cable connector by jerking or pulling the cable instead disconnect by pulling the connector head from the transceiver boar...

Page 66: ...st Cover Removal 1 Remove the dust cover screw using a Phillips screwdriver 2 Remove the dust cover from the chassis Figure 6 8 SIM Dust Cover Removal Reassemble the Terminal Chassis And Transceiver Board torques see page 6 6 1 Inspect the bottom diecast and diecast cover for remnants from the transceiver main seal If necessary remove the remnants using isopropyl alcohol 100 applied on a soft abso...

Page 67: ...oved attach the bulkhead to the bottom of the chassis then tighten the lock nut and the washer with a 5 16 socket driver using a torque of 0 904 Nm 8 lbin 6 Guide the GPS cable into the PCB slot while inserting the transceiver board at an angle approximately 30 into the chassis carefully slide the antenna connector and power connector into their cut outs in the bottom die cast 7 Lower the transcei...

Page 68: ...ure the diecast cover and tighten the seven screws with 1 9 Nm 17 lbin following the sequence shown using a T20 TORXTM driver Figure 6 12 Screw Sequence for Tightening the Diecast Cover 13 Insert the SIM card if applicable and reattach the SIM dust cover 14 Refit the top plastic cover over the assembled terminal chassis Press cover down until it snaps into place CAUTION Ensure that the dust cover ...

Page 69: ...nnector 2 Check that the back housing O ring seal is undamaged and fits properly in the groove Replace the seal if it is damaged refer to the exploded view diagrams and parts list 3 Fit the back housing to the Enhanced Control Head Ensure that the tags on the back housing align with the snap catch grooves on the Enhanced Control Head Press the back housing until it snaps into place 4 Check that th...

Page 70: ... two housings as shown in the following figure Figure 6 15 Enhanced Control Head Back Housing Removal 3 Press the dismantling tool until the snap connectors on the side of the back housing release from the Enhanced Control Head 4 Remove the board from the Enhanced Control Head front housing by unscrewing the screws using a T10 TORX and disassemble the encoder switch flex from the socket on the boa...

Page 71: ...the groove on the front housing 2 Assemble the board to the Enhanced Control Head front housing 3 Assemble the encoder switch flex to the socket on the board 4 Screw the two 8mm self tapping screws and one 14 mm self tapping screw 5 Snap the back housing into the Enhanced Control Head front housing in the orientation shown in Figure 6 17 on page 6 16 NOTE Care should be taken not to touch or conta...

Page 72: ...g the dismantling tool Motorola part number 6686119B01 in the chamfer between the Remote Head Enhanced and the terminal assembly 2 Use the dismantling tool to push and pry until the chassis tabs disengage from the Remote Head Enhanced on both sides 3 Remove the flex CAUTION The terminal must be disconnected from the power supply before commencing any disassembly The Installation Manual should be r...

Page 73: ...hat the terminal chassis O ring seal is undamaged and fits properly in the groove on the bottom diecast Replace the O ring if it is damaged Remote Mount Enhanced Control Head Disassembly To Disassemble the Remote Mount Enhanced Control Head 1 Unscrew the wing screws of the remote trunnion and remove the remote trunnion from the Remote Mount Enhanced Control Head 2 Unscrew the middle screw from the...

Page 74: ... Control Head Remote Mount Enhanced Control Head Reassembly 1 Fit the rubber keypad onto the Remote Mount Enhanced Control Head front housing and ensure that the keypad is correctly aligned and pressed onto the groove of the front housing 2 Assemble the board to the Remote Mount Enhanced Control Head front housing 3 Assemble the encoder switch flex to the socket on the board 4 Screw the two 8mm se...

Page 75: ...To Disassemble the Expansion Board from Expansion Head Housing 1 Remove the board from the expansion head housing by levering the expansion head housing and pulling up on the expansion board 2 Lift the top latch and remove the 40 Pin flex from connector board Figure 6 20 Expansion Head Enhanced Exploded View CAUTION The terminal must be disconnected from the power supply before commencing any disa...

Page 76: ...sion board into the expansion head housing 6 Connect the 12 line flex to the Terminal top small connector 7 Connect the 40 line flex to the Terminal bottom large connector 8 Close the top latch after flex insertion 9 Push the expansion head housing onto the terminal until all the diecast tabs snap firmly into place NOTE For correct orientation the contacts of both flexes should face the PCB Connec...

Page 77: ... Enhanced Control Head front housing Figure 6 21 Motorcycle Enhanced Control Head Exploded View 6 Remove the flex between the remote PCB and Main PCB 7 Remove the board from the Motorcycle Mount Enhanced Control Head front housing by unscrewing the screws using T10 TORXTM and disassemble the encoder switch flex from the socket on the board 8 Remove the board from the Motorcycle Mount Enhanced Cont...

Page 78: ...ousing 8 Screw the middle screw to the back housing Remote Ethernet Expansion Head Disassembly To Disassemble the Remote Ethernet Expansion Head from the Terminal 1 Remove the Remote Ethernet Expansion Head PMLN7009_ from the terminal by inserting the dismantling tool Motorola part number 6686119B01 in the chamfer between the Remote Ethernet Expansion Head and the terminal assembly 2 Use the disma...

Page 79: ...is Ensure the flex is inserted fully before the closing the connector lid 2 Connect the 18pos flex from the Remote Ethernet Expansion Head to the 18pos connector in the terminal on the right facing downwards to the terminal chassis make sure the THIS SIDE UP legend on the flex is facing upwards to the terminal top cover Ensure the flex is inserted fully into the connector 3 Press the Remote Head E...

Page 80: ...bit Figure 6 24 Cradle Back Housing Removal 3 Disassemble the Cradle back housing assembly from front housing assembly as shown in Figure 6 25 on page 6 25 4 Disassemble the Cradle top control flex BTB board to board connector RJ50 flex BTB connector and the wire harness wire to board connector from the Cradle main PCB ZWG0130214 O Cradle Handset ZWG0130215 O Remove these four screws to disassembl...

Page 81: ...screws using a T10 TORX screw bit 6 Remove the spiral cord retainer from the Cradle front housing Figure 6 26 Main PCB Removal 7 Unplug the spiral cord cable wire to board connector from the Cradle main PCB Refer to Figure 6 27 Figure 6 27 Spiral Cord Cable Wire Removal ZWG0130215 O Spiral cord cable ZWG0130215 O Spiral cord retainer ZWG0130215 O Main PCB ...

Page 82: ...screws from the back of the Handset using a T8 TORX screw bit as shown below Figure 6 29 Machined Screws Removal 10 Disassemble the Handset back housing assembly from the Handset front housing assembly 11 Unplug the Handset LCD flex and keypad flex BTB from the Handset main PCB as shown in Figure 6 30 Figure 6 30 LCD and Keypad Flex BTB Removal Strain relief Wire to board connector Make sure the w...

Page 83: ... USB BTB connector from the keypad flex 15 Remove the two screws from the Handset front housing using a T6 TORX screw bit and remove the micro USB module from the Handset front housing Figure 6 32 Micro USB Module Removal 16 Remove the spiral cord retainer from the Handset front housing 17 Remove the keypad retainer by stretching the Handset front housing outwards as shown in Figure 6 33 Figure 6 ...

Page 84: ...the spiral cord cable from the Handset front housing by pushing the two wire to board connectors in vertical position out of the Handset front housing Refer to Figure 6 36 Figure 6 36 Spiral Cord Cable Removal 2 ZWG0130215 O Wire to board connectors Front housing Strain relief Pull out strain relief Push in spiral cord ZWG0130215 O Handset front housing Unplug these 2 wire to board connectors ZWG0...

Page 85: ...he keypad flex as shown in Figure 6 38 Figure 6 38 Wire to Board Connectors 3 Tongue in the two catches and snap the keypad retainer into the Handset front housing Make sure the keypad flex is aligned to the front housing guiding pin as shown in Figure 6 39 4 Push in the spiral cord strain relief into the front housing and pull back the spiral cord at the same time ZWG0130215 O ZWG0130215 O Connec...

Page 86: ...ble the micro USB module into the Handset front housing and fasten the two screws using a T6 TORX screw bit with 1 5 0 1 lb in torque ZWG0130215 O Push the spiral cord strain relief inwards towards front housing Push the spiral cord cable away from front housing Ensure the keypad flex is align to the guiding pin on the front housing ZWG0130215 O Spiral cord retainer ...

Page 87: ... screws to the Handset back housing by using a T7 TORX screw bit with 2 2 0 1 lb in torque Figure 6 42 Handset Back Housing 11 Assemble the LCD flex and keypad flex BTB connector to the Handset main PCB Refer to Figure 6 43 below 12 Assemble the Handset back housing assembly to the Handset front housing assembly by tongue in the back housing assembly to front housing assembly at the top region Fas...

Page 88: ... housing as illustrated in Figure 6 45 Figure 6 45 Spiral Cord Connector 14 Assemble the spiral cord cable retainer to the Cradle front housing Figure 6 46 Spiral Cord Cable Retainer Assembly ZWG0130215 O Machined screws ZWG0130215 O Twist the wire to board connector to vertical position before inserting through the front housing ZWG0130215 O Spiral cord cable retainer ...

Page 89: ...re 6 48 Figure 6 48 Cradle Main PCB Assembly 18 Connect the wire harness wire to board connector top control flex BTB connector and RJ50 flex BTB connector to the Cradle main PCB in sequence 19 Assemble the Cradle back housing assembly to the Cradle front housing assembly by tongue in the back housing assembly to the front housing assembly Fasten the four main screw assembly to the front housing b...

Page 90: ...ck Housing Assembly Installation 1 Figure 6 50 Cradle Back Housing Assembly Installation 2 20 Latch the Handset back on the Cradle as shown in Figure 6 51 below Figure 6 51 Handset Assembly ZWG0130215 O Main screws ZWG0130215 O ZWG0130215 O ...

Page 91: ...ted Table 6 4 Service Aids Motorola Part No Description Application 6666500A01 Housing Eliminator Test Fixture used to bench test the terminal PCB 6686119B01 Dismantling Tool Assists in the removal of terminal Enhanced Control Head 0180320B16 6680321B81 6680321B56 Torx Screw Driver Kit T6 8 10 15 25 Torx Bit Insert Bit extra long T 20 TORX or equivalent Screwdriver with torque meter 5 16 socket dr...

Page 92: ...rts diodes transistors and integrated circuits must be ordered by Motorola part numbers NOTE Terminals with special label OPTION BOARD MOUNTED see dotted lines on figure above are equipped with an additional board inside the transceiver cover plate Refer to the figure next page before disassembling such terminals 2 3 4 5 6 7 10 11 14 15 12 13 16 17 18 19 13 20 21 1 8 9 ...

Page 93: ...antenna connector1 1 Non field replaceable Change main PCB 0986166B03 11 Power connector1 0986165B06 12 Accessory Connector1 0916017H01 13 TORX 20 Screw with O ring 9X M4X0 7 0104023J41 14 Connector assembly 0178042A01 15 Retainer clip 2X 4285702E01 16 Filler pad 75012050001 17 Pressure pad 75012088001 18 Chassis cover gasket 32012065001 19 Chassis cover 27012002001 20 Anti tamper label 5401208200...

Page 94: ...ntrol Head Parts List 1 Item No Description Part No 1 GCAI Cover 1515048C01 2 Keypad Assembly English Keypad Assembly Arabic Keypad Assembly Chinese Keypad Assembly Cyrillic Keypad Assembly Korean Keypad Assembly Bopomofo 7571017L01 7571017L02 7571017L03 7571017L04 7571017L05 7571017L06 3 Head Bridge Assembly 0104025J29 ZWG0130201 O 2 1 3 ...

Page 95: ...616898H01 4 Gore Port 3205472M02 5 Encoder Nut and Seal PMLN5123_ 6 Encoder Assembly 0104025J36 7 LCD Module LCD Module 7271138D01 72012019001 8 LCD Rubber Jacket 7516954H01 9 Emergency Key 3816953H01 10 Emergency Key Frame 0716944H01 11 GCAI Seal 3264133H01 12 Main PWA Kit PMLN5226_ 13 LCD Metal Retainer 4216900H01 14 Chassis 2716937H01 15 Keypad FFC 8471919L01 16 Keypad PWA Kit PMLN5445_ Item No...

Page 96: ...D 3864326B02 4 Protection Caps Bung Telco GLN7306_ 5 Seal Expansion Head not available to customers 6 Screw Protection Caps Bung 4 required 0305137Q02 7 Connector Board PMLN5087A 8 Screw Connector PCB 4 required 0385944A02 9 Flex 40 Pin 8415157H01 10 Expansion Board not part of Housing Kit PMLN4939_ 11 Seal for 10 Pin Telco on PCB 3264291B01 12 Flex 12 Pin 8486127B01 13 Flex 40 Pin 8466543A01 14 S...

Page 97: ...d Exploded View Table 6 9 Remote Mount Enhanced Control Head Parts List Item No Description Part No 1 Remote FFC Main to Remote 8471921L01 2 Remote PWA Kit 0104037J05 3 Remote Back Housing Assembly 0104025J30 4 D Sub Cover 1571012L01 5 Trunnion PMLN4912_ 6 Middle Screw 0371912L01 7 Self Tapping Screw 0316961H01 1 2 3 4 5 6 7 7 ...

Page 98: ...st 1 Item No Description Part No 1 Kit Handset TSCH PMLN6198_ 2 Assembly Front Housing Cradle TSCH Motorola Use Only 3 Assembly Main Board Cradle TSCH Motorola Use Only 4 Retainer Spiral Cord Cable Motorola Use Only 5 Assembly Back Housing Cradle TSCH Motorola Use Only 6 Kit Slim Mounting Bracket Motorola Use Only 7 O ring Main Cradle Motorola Use Only ZWG0130201 O 2 1 7 3 4 5 6 ...

Page 99: ...ousing Handset TSCH Motorola Use Only 4 Cable Assembly Spiral Cord 0104047J66 5 Retainer Spiral Cord Cable Motorola Use Only 6 Sub Assembly Front Housing Handset TSCH Motorola Use Only 7 LCD Module Motorola Use Only 8 Retainer Display with Poron Pad Motorola Use Only 9 Keypad Alphanumeric Motorola Use Only 10 Flex Assembly Keypad Motorola Use Only 11 Retainer Keypad Motorola Use Only 12 Self Tappi...

Page 100: ...5 PMLN6336_ Kit Label Color Code Red set of 5 PMLN6337_ Kit Label Color Code Yellow set of 5 PMLN6338_ Kit Label Color Code Blue set of 5 PMLN6339_ 3 Armlock Latch Motorola Use Only 4 Rubber Bumper 75012170001 5 M3 Screws Latch Retainer 2 required Motorola Use Only 6 Retainer Plate Latch Motorola Use Only 7 Coiled Spring Latch Motorola Use Only 8 Self Tapping Screws Cradle PCB 2 required Motorola ...

Page 101: ...quired 0305137Q02 3 Cover 9 Sub D 3864326B01 4 Seal Poron 9 Sub D Outer 32012180001 5 Ethernet Expansion Head Housing Motorola Use Only 6 Seal Poron dual Ethernet Motorola Use Only 7 Seal Poron 9 Sub D and Ethernet Motorola Use Only 8 Ethernet Expansion PCB Kit Motorola Use Only 9 Screw Connector PCB 4 required Motorola Use Only 10 FPC 40 pins Motorola Use Only 11 FPC 18 pins Motorola Use Only Rem...

Page 102: ... Remote Ethernet PWA Kit Motorola Use Only 3 Remote Ethernet Back Housing Assembly Motorola Use Only 4 D Sub Cover Motorola Use Only 5 Trunnion Motorola Use Only 6 Middle Screw Motorola Use Only 7 Self Tapping Screw Motorola Use Only Remote Mount Ethernet Control Head Refer to APPENDIX A Replacement Parts Kits WARNING Ethernet Expansion Heads are only compatible with Ethernet Remote Heads Do not m...

Page 103: ...mote Mount Cable 7 m RKN4079_ 4 Remote Mount Cable 10 m PMKN4020_ 5 Speaker Extension Cable GMKN4084_ 6 Remote Head Enhanced PMLN4904_ 7 Data Expansion Control Head PMLN4908_ WARNING Ethernet Expansion Heads are only compatible with Ethernet Remote Heads Do not mix Ethernet control head with non Ethernet control heads W A R N I N G Transceiver 10 pin Connector Remote Mount Cable 10 pin Connector F...

Page 104: ...nhanced Control Head Exploded View Table 6 16 Motorcycle Mount Enhanced Control Head Parts List Item No Description Part No 1 Side Cap Screw 0316960H02 2 MC Front Housing Assembly 0104024J34 3 MC Side Cap 3871547L01 4 MC Gore Port 3271555L01 5 MC Back Housing Assembly 0104025J31 6 MC Trunnion 0771445L01 1 3 4 2 5 6 ...

Page 105: ...e 5 m PMKN4140_ Tetra Mobile Ethernet Cable 7 m PMKN4139_ Tetra Mobile Ethernet Cable 10 m PMKN4138_ Tetra Mobile Ethernet Cable 12 m PMKN4136_ Tetra Mobile Ethernet Cable 40 m PMKN4135_ Ferrite Clamp 3 required 91012044001 NOTE For optimum performance please use Ethernet cables with Ethernet Remote Heads WARNING Ethernet Expansion Heads are only compatible with Ethernet Remote Heads Do not mix Et...

Page 106: ...6 50 Maintenance The Ethernet Remote Mount can be configured with the following configurations below 1 Single TSCH 2 Dual TSCH 3 Single RECH 4 Dual RECH 5 TSCH and RECH ...

Page 107: ...overs Level 1 and Level 2 Maintenance at Level 1 maintenance you replace the transceiver and or accessories and send the faulty transceiver and or accessories to higher level of maintenance at level 2 maintenance a transceiver board is replaced The mobiles are programmed at the factory They cannot be tuned at the field service level Level 3 Maintenance All Radio Support Depots are level 3 service ...

Page 108: ...C motorolasolutions com EMEA Systems Support Centre ESSC The Systems Support Centre is available at Piece Parts Some replacement parts spare parts and or product information can be ordered directly If a complete Motorola part number is assigned to the part it is available from Motorola Radio Products and Solutions Organization RPSO If no part number is assigned the part is not normally available f...

Page 109: ...renced spare parts should be directed to the Customer Care Organization of Motorola s local area representation Orders for replacement parts kits and assemblies should be placed directly on Motorola s local distribution organization or via the Extranet site Motorola Online at http www motorola com emeaonline ...

Page 110: ...700 Piece Parts To order parts in Latin America and the Caribbean contact your local Motorola CGISS representative MOTOROLA INC Latin American Countries Region 789 International Parkway Sunrise FL 33325 USA 954 723 8959 MOTOROLA DE ARGENTINA Ave del Libertador 1855 B1638BGE Vicente Lopez Buenos Aires Argentina 5411 4317 5300 MOTOROLA DE LOS ANDES C A Ave Francisco de Miranda Centro Lido Torre A Pi...

Page 111: ...o Ecuador 5932 264 1627 MOTOROLA DE MEXICO S A Calle Bosques de Alisos 125 Col Bosques de Las Lomas 05120 México D F México 52 555 257 6700 MOTOROLA DEL PERU S A Ave República de Panama 3535 Piso 11 San Isidro Lima 27 Peru 511 211 0700 Technical Support Some replacement parts spare parts and or product information can be ordered directly If a complete Motorola part number is assigned to the part i...

Page 112: ...30 MHz MTM5400 MTM800 FuG 380 430 CLEAR1 PMUE4495_Z X X X X X MTM5400 MTM800 FuG 380 430 CLEAR PMUE4495_S X X X X X MTM5400 MTM800 FuG 380 430 TEA12 PMUE4496_S X X X X X MTM5400 MTM800 FuG 380 430 TEA22 PMUE4497_S X X X X X MTM5400 MTM800 FuG 380 430 TEA32 PMUE4498_S X X X X X MTM5400 MTM800 FuG 380 430 CLEAR MAINBOARD3 PMUE4495_W X X X X X MTM5400 MTM800 FuG 380 430 TEA1 MAINBOARD2 3 PMUE4496_W X...

Page 113: ...TEA1 SIM E2EE2 PMUE4512_S X X X X X MTM5400 MTM800 FuG 380 430 TEA2 SIM E2EE2 PMUE4513_S X X X X X MTM5400 MTM800 FuG 380 430 TEA3 SIM E2EE2 PMUE4514_S X X X X X Enhanced Control Head Kits Dash Desk Mount English Keypad PMWN4009_ X X Chinese Keypad PMWN4010_ X X Korean Keypad PMWN4011_ X X Arabic Keypad PMWN4012_ X X BoPoMoFo Keypad PMWN4013_ X X Cyrillic Keypad PMWN4014_ X X English Keypad Hungar...

Page 114: ...MKN4056_ X X Cable Ethernet MTM5400 MTM800 FuG 40 m PMKN4135_ X Cable Ethernet MTM5400 MTM800 FuG 12 m PMKN4136_ X Cable Ethernet MTM5400 MTM800 FuG 10 m PMKN4138_ X Cable Ethernet MTM5400 MTM800 FuG 7 m PMKN4139_ X Cable Ethernet MTM5400 MTM800 FuG 5 m PMKN4140_ X Cable Ethernet MTM5400 MTM800 FuG 3 m PMKN4141_ X Remote Ethernet Control Head Y Cable with Fuse 2 A PMKN4133_ X Telephone Style Contr...

Page 115: ...t Parts Kits A 9 CAUTION The following parts that MUST be replaced every time the radio is disassembled Pre driver heat sink thermal pad part number 75012083001 2pcs RF PA thermal pad part number 75012082001 1pc ...

Page 116: ...A 10 Replacement Parts Kits Notes ...

Page 117: ...MO 380 430 MHz MT912M DMO 380 430 MHz MT912M Receiver Frequency Range 380 430 MHz MT912M Normal Load Conditions Rated RF Power 10 Watts Rated Audio Power 13 Watts 4 Ohms 6 Watts 8 Ohms Antenna Impedance 50 Ohms Operating Temp Range 30 to 60 C Operating Time Continuous Intermittent Note In general the terminal transmit and receive time operating cycle time is determined by the communication system ...

Page 118: ...MT912M Empfänger Nennfrequenzbereich 380 430 MHz MT912M Betriebsbedingungen HF Nennleistung 10 Watt Lautsprecher Nennleistung 13 Watt an 4 Ohm 6 Watt an 8 Ohm Antennenimpedanz 50 Ohm Betriebstemperatur Bereich 30 to 60 C Betriebszeit fortwährend periodisch Hinweis Im allgemeinen wird die Sende und Empfangsszeit Betriebszeit des Funkgerätes durch das Funksystem bestimmt Bei Überlastung bzw extensiv...

Page 119: ......

Page 120: ... 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 2010 2012 Motorola Solutions Inc All rights reserved November 2012 68015000183 D 68015000183 ...

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