Yaesu FTM-400DR/DE Manual

Specications
Exploded View & Miscellaneous Parts
Block Diagram
Alignment
Board Unit (Schematics, Layouts & Parts)
MAIN Unit
PANEL Unit
DSP Unit
144/430 MHz 50 W Dual-Band Transceiver
FTM-400DR/DE
TECHNICAL SUPPLEMENT
©2014 YAESU MUSEN CO., LTD. EH034M90B
YAESU MUSEN CO., LTD.
Tennozu Parkside Building
2-5-8 Higashi-Shinagawa, Shinagawa-ku, Tokyo 140-0002 Japan
YAESU USA
6125 Phyllis Drive, Cypress, CA 90630, U.S.A.
YAESU UK
Unit 12, Sun Valley Business Park, Winnall Close
Winchester, Hampshire, SO23 0LB, U.K.
Introduction
This manual provides the technical information necessary for
servicing the FTM-400DR/DE 144/430 MHz 50 W Dual Band
Transceiver.
Servicing this equipment requires expertise in handing surface-
mount chip components. Attempts by non-qualified persons
to service this equipment may result in permanent damage not
covered by the warranty, and may be illegal in some countries.
Two PCB layout diagrams provided for each double-sided
board in this transceiver. Each side of the board is referred to
by the type of the majority of components installed on that side
("Side A" or "Side B"). In most cases one side has only chip
components, and the other has either a mixture of both chip and
leaded components (trimmers, coils, electrolytic capacitors,
ICs, etc.), or leaded components only.
While we believe the information in this manual to be correct,
YAESU assumes no liability for damage that may occur as a
result of typographical or other errors that may be present. Your
cooperation in pointing out any inconsistencies in the technical
information would be appreciated.
Important Note
1) This transceiver was assembled using Pb (lead) free solder, based on the RoHS specication.
Only lead-free solder (Alloy Composition: Sn-3.0Ag-0.5Cu) should be used for repairs performed on this apparatus. The solder stat-
ed above utilizes the alloy composition required for compliance with the lead-free specication, and any solder with the above alloy
composition may be used.
2) Risk of explosion if battery is replaced by an incorrect type. Dispose of used batteries according to the instructions.
Contents

FTM-400DR/DE Technical Supplement
Specications
SPECIFICATIONS-1
General
Frequency Range:
TX 144 - 146 MHz or 144 - 148 MHz
430 - 440 MHz or 430 - 450 MHz
RX 108 - 137 MHz (Air Band)
137 - 174 MHz (144 MHz HAM)
174 - 400 MHz (GEN1)
400 - 480 MHz (430 MHz HAM)
480 - 999.99 MHz (GEN2)
Channel Steps: 5, 6.25, 8.33, 9, 10, 12.5, 15, 20, 25, 50, 100 kHz
(8.33 kHz: only for Air Band, 9 kHz: only for AM Radio)
Frequency Stability: ±2.5 ppm (–4 °F to +140 °F [–20 °C to +60 °C])
Emission Type: F1D, F2D, F3E, F7W
Supply Voltage: Norminal 13.8 V DC, negative ground
Current Consumption: 0.5 A (receive)
11 A (50 W TX, 144 MHz)
12 A (50 W TX, 430 MHz)
Operating Temperature: –4 °F to +140 °F (–20 °C to +60 °C)
Case Size (W x H x D): Radio unit: 5.5” (W) × 1.6” (H) × 4.9” (D) (140 × 40 × 125 mm) w/o fan
Controller: 5.5” (W) × 2.8” (H) × 0.8” (D) (140 × 72 × 20 mm)
Weight (approx.): 2.64 lbs (1.2 kg) with radio unit, controller, control cable
Transmier
RF Power Output: 50 / 20 / 5 W
Modulation Type: F1D, F2D, F3E : Variable Reactance modulation
F7W: 4 FSK (C4FM)
Spurious Emission: At least 60 dB below

FTM-400DR/DE Technical Supplement
Specications
SPECIFICATIONS-2
Receiver
Circuit Type: Double-Conversion Super heterodyne
Intermodiate Frequencies: A Band: 1 st: 47.25 MHz, 2 nd: 450 kHz
B Band: 1 st: 44.85 MHz, 2 nd: 450 kHz
Sensitivity: 108 - 137 MHz (AM) 0.8μV typ for 10 dB SN
137 - 140 MHz (FM) 0.2μV for 12 dB SINAD
140 - 150MHz (FM) 0.2μV for 12 dB SINAD
150 - 174 MHz (FM) 0.25μV for 12 dB SINAD
174 - 222 MHz (FM) 0.3μV typ for 12 dB SINAD
222 - 300 MHz (FM) 0.25μV typ for 12 dB SINAD
300 - 336 MHz (AM) 0.8μV typ for 10 dB SINAD
336 - 420 MHz (FM) 0.25μV for 12 dB SINAD
420 - 470 MHz (FM) 0.2μV typ for 12 dB SINAD
470 - 520 MHz (FM) 0.2μV for 12 dB SINAD
800 - 900 MHz (FM) 0.4μV typ for 12 dB SINAD
900 - 999.99 MHz (FM) 0.8μV typ for 12 dB SINAD
Cellular blocked (USA only)
Digital mode
140 - 150 MHz (Digital) 0.19μV typ for BER 1%
420 - 470 MHz (Digital) 0.19μV typ for BER 1%
Squelch sensitivity: 0.16μV (144/430 MHz)
Selectivity: AM, FM 12 kHz/35 kHz (−6 dB/−60 dB)
AF Output: 3 W (8 Ω, THD10%, 13.8 V) internal speaker
8 W (4 Ω, THD10%, 13.8 V) Optional MLS-200-M10
AF output impedance: 4 - 16 Ω
Strength of secondary radio waves: 4 nW and below
Performance specications are nominal, unless otherwise indicated, and are subject to change without no-
tice. Measured in accordance with TIA/EIA-603.

EXPLODED VIEW-1 FTM-400DR/DE Technical Supplement
Exploded View & Miscellaneous Parts
RA140640A
FRONT COVER
RA1568800
SHEET(MIC)
RA0924400
SPONGE RUBBER(BT)
PANEL-UNIT
Q7000649
REF. YAESU P/N Description Qty.
①U20205007 BINDING HEAD SCREW M2.6X5B 2
②U31208007 OVAL HEAD SCREW M2.6X8B 8
③U20318007 BINDING HEAD SCREW M3X18B 4
④U70003007 PLAIN WASHER FW3B 4
⑤U20308002 BINDING HEAD SCREW M3X8NI 2
⑥U44308001 PAN HEAD TAPTITE-B M3X8 15
⑦U03310002 SEMS SCREW ASM3X10NI 4
⑧U24212007 BIND HEAD TAPTITE-B M2.6X12B 4
⑨U07240202 PAN HEAD SCREW M2X4NI#2 4
⑩U24206002 BIND HEAD TAPTITE-B M2.6X6NI 4
⑪U31206007 OVAL HEAD SCREW M2.6X6B 4
⑫U20208007 BINDING HEAD SCREW M2.6X8B 1
⑬U9900171 PLAIN WASHER FW2.6X7.5X0.5B 1
⑭U04510007 PAN HEAD(SEMS) SCREW HSM5X10B 1
Non-designated parts are available only as part of a designated assembly.
①
⑬
⑫
①
②
③
⑦
⑦
⑦⑦
⑥⑥⑥
⑥
⑥
⑥
⑥
⑥
⑥
⑥
⑥
⑥
⑥
⑥
⑨
⑨
⑨
⑨
⑧
⑧
⑧
⑧
⑪
⑪
⑪
⑪
⑩
⑩
⑩⑩
④
④
④
④
⑤
RA140630A
RUBBER KNOB(PWR)
RA1434600
DOUBLE FACE(HOLDER)
RA1434500
HOLDER PLATE(H034)
RA133910A
ENCODER KNOB(ASSY)
RA1339400
VOLUME KNOB (ASSY)
RA134050A
REAR PANEL
RA140620A
RUBBER KNOB(D)
RA1340000
LCD SPACER (A)
RA1340100
LCD SPACER (B)
RA0446200
LEAF SPRING
RA026680C
CHASSIS
S5000288
FAN GUARD K-G04D02-4HA
M2090053
FAN
P1091158
CONNECTOR
RA1406600
GROUND PLATE(FET)
RA1406500
SHIELD CASE COVER
RA1457300
ELEC. COND TAPE
RA0924400
SPONGE RUBBER(BT)
RA1317000 (CE Version)
COVER(C-MJ4)
RA1316900 (CE Version)
SHEET(SP-JACK)
RA123300A (CE Version)
COVERSP-JACK
RA1563700 (CE Version)
SHEET(40X25)
RA1550600
SP HOLDER(H034M)
RA1560700
SHEET(SP66)
RA131710A
SPONGE RUBBER(SP-CE)
RA1550700
SP NET(66)
M4090229
SPEAKER 66S-A3627
RA1406700
SPONGE RUBBER(VU)
RA02132A0
HIMERON TAPE
②
②
②
②
②
②
②
RA15505000
CASE(H034M)
RA1260500 (CE Version)
COVER(C-MJ6)
RA1563800 (CE Version)
SHEET(21.5X18.5)
③
③
③
⑤
RA0438700
RUBBER
RA1316600
PLATE(FET)
RA1058400
GASKET(6612)
⑥
RA135370B
FRONT PANEL (PRINT)
RA1339900
BRACKET (GPS)
Q7000642
GPS MODULE GPS-76A
CQ0189003 (USA)
CQ0189004 (EXP)
CQ0189005 (EU)
CQ0189006 (AUS)
PANEL ASSY
CS2204101
CASE ASSY
RA1339700 (CE Version)
COVER (JACK)
⑭

BLOCK DIAGRAM-1 FTM-400DR/DE Technical Supplement
Block Diagram

FTM-400DR/DE Technical Supplement
Alignment
ALIGNMENT-1
Introduction and Precautions
The FTM-400DR/FTM-400DE has been carefully
aligned at the factory for performance across the
specified amateur bands. Realignment should
therefore not be necessary except in the event of a
component failure. All component replacement and
service should be performed only by an authorized
YAESU representative, or the warranty policy may
be voided.
The following procedures cover the sometimes crit-
ical and tedious adjustments that are not normally
required once the transceiver has left the factory.
However, if damage occurs and some parts are re-
placed, realignment may be required. If a sudden
problem occurs during normal operation, it is like-
ly due to component failure; realignment should
not be done until after the faulty component has
been replaced.
We recommend that servicing be performed only
by authorized YAESU service technicians, who are
experienced with the circuitry and fully equipped
for repair and alignment. Therefore, if a fault is
suspected, contact the dealer from whom the trans-
ceiver was purchased for instructions regarding re-
pair. Authorized YAESU service technicians realign
all circuits and make complete performance checks
to ensure compliance with factory specifications
aer replacing any faulty components.
Those who do undertake any of the following
alignments are cautioned to proceed at their own
risk. Problems caused by unauthorized aempts at
realignment are not covered by the warranty pol-
icy. Also, YAESU must reserve the right to change
circuits and alignment procedures in the interest of
improved performance, without notifying owners.
Under no circumstances should any alignment be
attempted unless the normal function and opera-
tion of the transceiver are clearly understood, the
cause of the malfunction has been clearly pinpoint-
ed and any faulty components replaced, and the
need for realignment determined to be absolutely
necessary.
Required Test Equipment
RF Signal Generator with calibrated output level
at 1 GHz
Deviation Meter (linear detector)
 In-line Wameter with 5% accuracy at 1 GHz
 50-ohm, 100-W RF Dummy Load
 8-ohm AF Dummy Load
Regulated DC Power Supply adjustable from
11.5 to 16 V DC, 15 A
Frequency Counter: 0.2-ppm accuracy at
1 GHz
AF Signal Generator
AC Voltmeter
DC Voltmeter: high impedance
VHF/UHF Sampling Coupler
SINAD Meter
Important Notice
Do not adjust the alignment menus that are
not mentioned in this manual.

FTM-400DR/DE Technical Supplement
Alignment
ALIGNMENT-2
Alignment Preparation & Precautions
A 100-W RF dummy load and in-line wattmeter
must be connected to the main antenna jack in all
procedures that call for transmission; alignment
is not possible with an antenna. After complet-
ing one step, read the next step to see if the same
test equipment is required. If not, remove the test
equipment (except dummy load and wattmeter,
if connected) before proceeding. Correct align-
ment requires the transceiver and test equipment
be maintained at a constant ambient temperature
between 68 ~ 86 °F (20 ~ 30 °C). When the trans-
ceiver is brought into the shop from hot or cold air,
it should be allowed some time to come to room
temperature before alignment. Whenever possible,
alignments should be made with oscillator shields
and circuit boards rmly axed in place. Also, the
test equipment must be thoroughly warmed up be-
fore beginning.
Note: Signal levels in dB referred to in the alignment
procedure are based on 0 dBμ=0.5 μV (closed circuit).
Test Setup
Set up the test equipment as shown below for
transceiver alignment. Maintain the supply voltage
at13.8V DC for all steps.
Internal System Alignment Routine
This uses a programmed routine in the transceiver
which simplies many previously complex discrete
component seings and adjustments with digital-
ly-controlled seings via Microphone buons.
To enter the Alignment mode:
1. Press and hold in the [F(MW)]and [GM)]keys
while turning the transceiver on.
2. Press the [POWER(LOCK)]key.
"LOCK" will appear in the display.
3. Press the keys of the Microphone in the follow-
ing sequence.
[0]à[3]à[4]à[0]à[3]à[4]
4. Press the [POWER(LOCK)]key.
"UNLOCK" will appear in the display.
5. The transceiver is now in the "Alignment
mode".
MIC Jack
50-ohm
Dummy Load
Freq. Counter
Deviation
Meter
AC Voltmeter
AF Generator
AC Voltmeter
Inline
Wattmeter
Sampling
Coupler
Regulated
13.8V PSU

FTM-400DR/DE Technical Supplement
Alignment
ALIGNMENT-3
VCO VCV Adjustment
Connect the DC voltmeter to TP1503 (MAIN) and
TP1502 (SUB). Referring to the table below, turn
the transceiver to each frequency listed. Conrm
that the correct voltage is present, or adjust the list-
ed seing for the required voltage.
MAIN
Tune to: TX/RX for
440.05 MHz RX 2.6 ± 0.25 V
440.05 MHz TX 2.1 ± 0.25 V
146.05 MHz RX 1.4 - 0.25 V/+0.30 V
146.05 MHz TX 2.2 ± 0.25 V
130.00 MHz RX 0.35 ~ 0.70 V
174.00 MHz RX 0.40 ~ 0.70 V
299.99 MHz RX 5.0 ~ 6.1 V
549.95 MHz RX 3.5 ~ 5.3 V
550.00 MHz RX 0.15 ~ 0.35 V
SUB
Tune to: TX/RX for
440.05 MHz RX 2.6 ± 0.30 V
146.05 MHz RX 1.2 - 0.25 V/+0.30 V
130.00 MHz RX 0.55 V
174.00 MHz RX 0.5 ~ 0.90 V
299.99 MHz RX 5.0 ~ 6.2 V
549.95 MHz RX 3.5 ~ 5.2 V
550.00 MHz RX 0.15 ~ 0.35 V
DC Voltmeter
1. Set the power supply voltage to 13.8 V.
2. Press the [P1]key of the Microphone to set the
alignment menu Item to "Adj 10 BAT".
3. Press the [P3]key of the Microphone, to save
the new seing.
TP1502
TP1503

FTM-400DR/DE Technical Supplement
Alignment
ALIGNMENT-4
TX Power Adjustment
1. Press the [P1]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".
2. Set the transceiver frequency to 440.050 MHz.
3. Press the [F(MW)]key, then press the [Tx PWR]
to select "LO".
4. Press the [F(MW)]key.
5. Press the PTT switch to activate the transmier,
adjust the DIAL knob (Band B) so that RF Power
Meter reading is 5.3 W (± 0.5 W).
6. Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 DRV".
7. Adjust the DIAL knob (Band B) to set the DRV
to "9AH".
8. Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".
9. Press the [F(MW)]key, then press the [Tx PWR]
to select "MD".
10.Press the [F(MW)]key.
11.Press the PTT switch to activate the transmier,
adjust the DIAL knob (Band B) so that RF Power
Meter reading is 20 W (± 0.5 W).
12.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 DRV".
13.Adjust the DIAL knob (Band B) to set the DRV
to "B0H".
14.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".
15.Press the [F(MW)]key, then press the [Tx PWR]
to select "HI".
16.Press the [F(MW)]key.
17.Press the PTT switch to activate the transmier,
adjust the DIAL knob (Band B) so that RF Power
Meter reading is 50 W (± 0.5 W).
18.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 DRV".
19.Adjust the DIAL knob (Band B) to set the DRV
to "D0H".
20.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".
21.Set the transceiver frequency to 146.050 MHz.
22.Press the [F(MW)]key, then press the [Tx PWR]
to select "LO".
23.Press the [F(MW)]key.
24.Press the PTT switch to activate the transmier,
adjust the DIAL knob (Band B) so that RF Power
Meter reading is 5 W (± 0.5 W).
25.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 DRV".
26.Adjust the DIAL knob (Band B) to set the DRV
to "CFH".
27.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".
28.Press the [F(MW)]key, then press the [Tx PWR]
to select "MD".
29.Press the [F(MW)]key.
30.Press the PTT switch to activate the transmier,
adjust the DIAL knob (Band B) so that RF Power
Meter reading is 20 W (± 0.5 W).
31.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 DRV".
32.Adjust the DIAL knob (Band B) to set the DRV
to "DAH".
33.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".
34.Press the [F(MW)]key, then press the [Tx PWR]
to select "HI".
35.Press the [F(MW)]key.
36.Press the PTT switch to activate the transmier,
adjust the DIAL knob (Band B) so that RF Power
Meter reading is 50 W (± 0.5 W).
37.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 DRV".
38.Adjust the DIAL knob (Band B) to set the DRV
to "EFH".
39.Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 02 PWR".

FTM-400DR/DE Technical Supplement
Alignment
ALIGNMENT-5
PLL Reference Frequency Adjustmen t
1. Press the [P1]key of the Microphone to set the
alignment menu Item to "Adj 00 REF/A".
2. Set the transceiver frequency to 435.050 MHz.
3. Press the [F(MW)]key, then press the [Tx PWR]
to select "LO".
4. Press the [F(MW)]key.
5. Press the PTT switch to activate the transmit-
ter, adjust the DIAL knob (Band B), if necessary,
so the counter frequency is within 100 Hz of
435.050MHz.
6. Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 00 REF/B".
7. Connect the frequency counter fed through
the0.001μF capactor to the TP1501.
8. Adjust adjust the DIAL knob (Band B), as need-
ed, so that thecounter frequency reading is
390.200 MHz (±100Hz).
RF Front-end Tuning
1. Connect the DC voltmeter to TP1001 (BAND
A) and TP1002 (BAND B) on the MAIN unit,
then inject a 439.050 MHz signal at a level of +10
dBμV (with 1kHz modulation ± 3.5 kHz devia-
tion) from the RF signal generator.
2. Set the transceiver frequency to 439.050 MHz.
3. Press the [P1]key of the Microphone to set the
alignment menu Item to "Adj 01 TUN/A".
4. Adjust the DIAL knob (Band B) for maximum
deflection on the DC Voltmeter and then turn
the dialin the opposite direction until the meter
deection drops slightly lower than maximum.
5. Set the transceiver and RF signal generator fre-
quency to 145.050 MHz.
6. Adjust the DIAL knob (Band B) for maximum
deflection on the DC Voltmeter and then turn
the dialin the opposite direction until the meter
deection drops slightly lower than maximum.
7. Set the RF signal generator frequency to
439.050MHz.
8. Set the transceiver frequency to 439.050 MHz of
the Band B.
9. Press the [P2]key of the Microphone to set the
alignment menu Item to "Adj 01 TUN/B".
10.Adjust the DIAL knob (Band B) for maximum
deflection on the DC Voltmeter and then turn
the dialin the opposite direction until the meter
deection drops slightly lower than maximum.
11.Set the transceiver and RF signal generator fre-
quency to 145.050 MHz.
12.Adjust the DIAL knob (Band B) for maximum
deflection on the DC Voltmeter and then turn
the dialin the opposite direction until the meter
deection drops slightly lower than maximum.
TP1501TP1001 TP1002