Motorola Mototrbo Dr3000 Repeater Basic 6866576d03 A Manual

							
MOTOTRBO™ Repeater
DR 3000 Repeater
Professional Digital Two-Way Radio System
Basic Service Manual 
						

							Title PageDR 3000
UHF Range 1
MOTOTRBO
™ Repeater
Basic Service Manual
M
6866576D03-A 
						

							Foreword
This manual covers all models of the MOTOTRBO Repeater, 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, 
Motorola Authorized Dealers, self-maintained customers, and distributors.
For details on repeater operation or component-level troubleshooting, refer to the applicable manuals available separately. 
Product Safety and RF Exposure Compliance
ATTENTION!
This repeater is restricted to occupational use only to satisfy ICNIRP/FCC RF energy exposure 
requirements. Before using this product, read the RF energy awareness information and operating 
instructions in the Product Safety and RF Exposure booklet enclosed with your product (Motorola 
Publication part number 6866537D37) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, and other accessories, visit the following web site which 
lists approved accessories: http://www.motorola.com/governmentandenterprise
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored in 
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain 
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in 
any form the copyrighted computer 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 and the Stylized M logo are registered in the U.S. Patent & Trademark Office. All other product or service 
names are the property of their respective owners.
© 2007 by Motorola, Inc.
All rights reserved.
Before using this product, read the operating instructions 
for safe usage contained in the Product Safety and RF 
Exposure booklet enclosed with your product.
!
C a u t i o n 
						

							iii
6866576D03-AFebruary 21, 2007
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
6866576D03-AInitial ReleaseFeb. 2007 
						

							iv
February 21, 20076866576D03-A
Notes 
						

							Table of Contentsv
6866576D03-AFebruary 21, 2007
Table of Contents
Foreword .........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ ii
Computer Software Copyrights ................................................................................................................... ii
Document Copyrights .................................................................................................................................. ii
Disclaimer .................................................................................................................................................... ii
Trademarks ................................................................................................................................................. ii
Document History ........................................................................................ iii
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Repeater Description ................................................................................................................... 1-1
1.3 MOTOTRBO Repeater Model Numbering Scheme ..................................................................... 1-2
1.4 UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model Chart ..................................... 1-3
1.5 Specifications............................................................................................................................... 1-4
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 Cables  .................................................................................................................. 2-2
Chapter 3 Transceiver Performance Testing ..................................... 3-1
3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
Chapter 4 Repeater Tuning and Programming .................................. 4-1
4.1 Introduction .................................................................................................................................. 4-1
4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 Repeater Tuning Setup................................................................................................................ 4-2
Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1
5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures .......................................................................................................5-1
5.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
5.4 Repair Procedures and Techniques — General .......................................................................... 5-3
5.5 Disassembling and Reassembling the Repeater — General ...................................................... 5-4 
						

							viTable of Contents
February 21, 20076866576D03-A
5.6 Disassembly Procedures — Detailed .......................................................................................... 5-4
5.6.1 Disassembly of Cover......................................................................................................5-4
5.6.2 Disassembly of Repeater Indicator Board ....................................................................... 5-5
5.6.3 Disassembly of Fan .........................................................................................................5-6
5.6.4 Removing Transmit Radio ............................................................................................... 5-7
5.6.4.1 Removing Thermal Pad and Heatsink .............................................................. 5-8
5.6.5 Removing Receive Radio, Power Supply and Connector Board Assembly .................... 5-8
5.6.5.1 Disassembly of Receive Radio ....................................................................... 5-10
5.6.5.2 Disassembly of Connector Board Assembly ................................................... 5-10
5.6.5.3 Disassembly of Power Supply ........................................................................ 5-10
5.7 Transmit and Receive Radio Disassembly — Detailed ............................................................. 5-11
5.7.1 Transceiver Board and Receiver Board Removal ......................................................... 5-11
5.8 Transmit and Receive Radio Reassembly — Detailed .............................................................. 5-14
5.8.1 Transceiver Board and Receiver Board Reassembly .................................................... 5-15
5.8.2 Thermal Pad Replacement Procedure .......................................................................... 5-19
5.8.3 Reassembly of Receive Radio, Power Supply and Connector Board Assembly........... 5-21
5.8.3.1 Reassembly of Power Supply ......................................................................... 5-21
5.8.3.2 Reassembly of Receive Radio........................................................................ 5-21
5.8.3.3 Reassembly of Connector Board Assembly ................................................... 5-21
5.8.3.4 Reassembly of the Receive Bracket Assembly to the Enclosure ................... 5-21
5.8.4 Reassembly of Transmit Radio...................................................................................... 5-22
5.8.4.1 Replacing the Thermal Pad and Heatsink ...................................................... 5-22
5.8.4.2 Reassembly of the Transmit Bracket Assembly to the Enclosure .................. 5-22
5.8.5 Reassembly of Fan ........................................................................................................ 5-23
5.8.6 Reassembly of Repeater Indicator Board ...................................................................... 5-23
5.8.7 Reassembly of Cover .................................................................................................... 5-23
5.9 Repeater Exploded Mechanical Views and Parts Lists.............................................................. 5-24
5.10 Torque Chart .............................................................................................................................. 5-27
Chapter 6 Basic Troubleshooting ....................................................... 6-1
6.1 Introduction .................................................................................................................................. 6-1
6.1.1 High Power RF Precaution .............................................................................................. 6-1
6.2 Replacement Service Kit Procedures ..........................................................................................6-1
6.3 LED Indicator Descriptions .......................................................................................................... 6-2
Appendix A EMEA Regional Warranty, Service and Support .............. A-1
A.1 Warranty and Service Support .....................................................................................................A-1
A.2 European Radio Support Centre (ERSC) ....................................................................................A-2
A.3 Piece Parts...................................................................................................................................A-2
A.4 Technical Support ........................................................................................................................A-3
A.5 Further Assistance From Motorola...............................................................................................A-3
Glossary ......................................................................................... Glossary-1 
						

							viiiList of Figures
February 21, 20076866576D03-A
List of Figures
Figure 1-1. Repeater Model Numbering Scheme ................................................................................... 1-2
Figure 2-1. Mobile & Repeater Rear Programming Cable PMKN4010_ ................................................ 2-2
Figure 2-2. Mobile & Repeater Rear Programming, Testing & Alignment Cable PMKN4016_............... 2-3
Figure 4-1. Customer Programming Software Setup from Rear Accessory Connector ......................... 4-1
Figure 4-2. Repeater Tuning Equipment Setup ......................................................................................4-2
Figure 5-1. Removing Top Cover of Repeater Enclosure ....................................................................... 5-4
Figure 5-2. Disconnecting Ethernet Cable and Flex Cable .................................................................... 5-5
Figure 5-3. Repeater Indicator Board Disassembly ................................................................................5-6
Figure 5-4. Fan Orientation..................................................................................................................... 5-6
Figure 5-5. Tx Radio Disassembly ......................................................................................................... 5-7
Figure 5-6. Receive Radio Removal....................................................................................................... 5-9
Figure 5-7. Die Cast Cover Removal.................................................................................................... 5-11
Figure 5-8. Accessory Connector Removal ..........................................................................................5-12
Figure 5-9. RF/DC Retention Clips Removal ........................................................................................5-12
Figure 5-10. Transceiver Board Removal ............................................................................................... 5-13
Figure 5-11. Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover............................... 5-14
Figure 5-12. Transceiver Board with Thermal Pads ............................................................................... 5-14
Figure 5-13. Replacing GPS Plug .......................................................................................................... 5-15
Figure 5-14. Placing the Transceiver Board in the Chassis.................................................................... 5-15
Figure 5-15. Inserting RF/DC Retention Clips ........................................................................................ 5-16
Figure 5-16. Inserting Accessory Connector .......................................................................................... 5-16
Figure 5-17. Assembling of PA Pad and O-ring ...................................................................................... 5-17
Figure 5-18. Assembling Die Cast Cover onto Chassis ......................................................................... 5-18
Figure 5-19. Screw Sequence to Tighten Die Cast Cover ...................................................................... 5-19
Figure 5-20. Replacing Thermal Pads .................................................................................................... 5-19
Figure 5-21. Aligning Driver Pad on Chassis.......................................................................................... 5-20
Figure 5-22. Placing Thermal Pads on PA and Transistor Components ................................................ 5-20
Figure 5-23. Fan Orientation................................................................................................................... 5-23
Figure 5-24. Repeater Assembly Exploded View ................................................................................... 5-24
Figure 5-25. Receive Bracket and Radio Assembly Exploded View ...................................................... 5-25
Figure 5-26. Transmit Bracket and Radio Assembly Exploded View...................................................... 5-25
Figure 5-27. Front Panel Complete Assembly Exploded View ............................................................... 5-26 
						

							List of Tablesix
6866576D03-AFebruary 21, 2007
List of Tables
Table 1-1. Frequency Ranges and Power Levels ................................................................................. 1-1
Table 2-1. Recommended Test Equipment ...........................................................................................2-1
Table 2-2. Service Aids ......................................................................................................................... 2-2
Table 3-1. Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2. Receiver Performance Checks ............................................................................................ 3-2
Table 4-1. Repeater Software Program Kits ......................................................................................... 4-1
Table 5-1. Lead Free Solder Wire Part Number List ............................................................................. 5-3
Table 5-2. Lead Free Solder Paste Part Number List ........................................................................... 5-3
Table 5-3. Repeater Exploded View Parts List....................................................................................5-26
Table 5-4. Torque Specifications for Nuts and Screws ........................................................................ 5-27
Table 6-1. LED Indicator Descriptions................................................................................................... 6-2 
						

							xRelated Publications
February 21, 20076866576D03-A