MOTOROLA, the Stylized M Logo, and Radius are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2004 Motorola, Inc. All rights reserved. Printed in U.S.A.
i CM200/CM300/PM400 Radios Basic Service Manual 6802966C15-A Issue: August, 2004
ii Foreword This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the equipment described and is current as of the printing date. Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions. Note: Before operating or testing these units, please read the Product Safety and RF Exposure Compliance section.
iii Table of Contents Foreword......................................................................................................................... ii Computer Software Copyrights ....................................................................................... ii Document Copyrights ..................................................................................................... ii Disclaimer ....................................................................................................
iv 7.3 Control Heads Assembly........................................................................... 2-13 7.4 Control Head Fitting .................................................................................. 2-13 7.5 Option Board Installation ........................................................................... 2-14 8.0 Radio Exploded Mechanical Views and Parts Lists........................................... 2-15 8.1 Radio Assembly - 1-25 W Models ..........................................
v 1.9 Peripherals ..................................................................................................6-4 2.0 Accessory Connector Pin Function......................................................................6-5 3.0 Microphone Connector Pin Function....................................................................6-6 Chapter 7 MODEL CHART AND TEST SPECIFICATION 1.0 Low Power Radios ...............................................................................................7-1 1.
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vii SAFETY INFORMATION Product Safety and RF Exposure Compliance ! Note: Before using this product, read the operating instructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio. Caution ATTENTION! This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
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Chapter 1 INTRODUCTION 1.0 Scope of Manual This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the equipment described and is current as of the printing date. Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions. NOTE Before operating or testing these units, please read the Safety Information Section in the front of this manual. 2.
1-2 INTRODUCTION 3.0 Replacement Parts Ordering 3.1 Basic Ordering Information When ordering replacement parts or equipment information, the complete identification number should be included. This applied to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, a sufficient description of the desired component to identify it. 3.
Radio Model Information 3.6 1-3 Parts Identification Radio Products and Services Division (RPSD)* (United States and Canada) 1-800-422-4210, menu 3 * The Radio Products and Services Division (RPSD) was formerly known as the Accessories and Aftermarket Division (AAD) Radio Model Information The model number and serial number are located on a label attached to the back of your radio. You can determine the RF output power, frequency band, protocols, and physical packages.
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Chapter 2 MAINTENANCE 1.0 Introduction This chapter provides details about the following: 2.0 • Preventive maintenance (inspection and cleaning). • Safe handling of CMOS and LDMOS devices. • Disassembly and reassembly of the radio. • Repair procedures and techniques. • Installation of Option Boards. Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 2.
2-2 MAINTENANCE 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 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.
Repair Procedures and Techniques — General 4.0 2-3 Repair Procedures and Techniques — General 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 from the nearest Motorola Parts center listed in the “Piece Parts” section in Chapter 1 of this manual.
2-4 6.0 MAINTENANCE Radio Disassembly - Detailed The procedure to remove and replace a Control Head, Top Cover or Transceiver Board is similar for all models of radio. A typical procedure is therefore shown followed by specific disassembly procedures for Control Heads on radio models without a display and radio models fitted with a display. 6.1 Control Head Removal NOTE Ensure that the volume knob is in the OFF position before disassembling the radio. Volume Knob Removal 1.
Radio Disassembly - Detailed 2-5 Figure 2-2 Control Head Removal 3. To free the control head, disconnect the flat cable from the chassis assembly See Figure 2-3.
2-6 6.2 MAINTENANCE Top Cover Removal 1. Place the radio in a vertical position as shown in Figure 2-4. Figure 2-4 Top Cover Removal (Chassis Vertical). 2. Insert the flat screw driver near the ‘T’ and push the plastic cover up until it pops over the ‘T’ mount boss. Perform the same function on the ‘T’ location on the other side of the chassis. 3. Next place the radio in a horizontal position as shown in Figure 2-5 and insert the flat screw driver into the slot to release the upper cover.
Radio Disassembly - Detailed 6.3 2-7 Main Shield Removal 1. Insert the screw driver in the gap between the main shield and chassis (speaker cutout area) and push the shield up. See Figure 2-6. 2. Lift the cover from the chassis. Figure 2-6 Main Shield Removal 6.4 PA Shield and DC Cable Removal 1. Remove the three screws that attach the PA shield to PCB, and remove the PA shield. 2. Remove the accessory Connector cap. 3.
2-8 MAINTENANCE Figure 2-8 PA Shield and DC Cable Removal (for High Power Models) 6.5 PA Clip and Main PCB Removal (for Low Power Models) 1. Remove the screw that attaches the PA clip to the chassis. See Figure 2-9. 2. Remove the PA clip. 3. Remove all the screws that fix the PCB to the chassis. 4. Loosen the M2 screw (about 3 to 4 turns) on the RF connector using hex tool (Part number: 6680334F39). 5. Loosening this screw, enables you to unscrew the RF connector from outside. 6.
Radio Disassembly - Detailed 6.6 Main PCB Removal (for High Power Models) 1. Remove the PA screws. See Figure 2-10. 2. Remove all the screws that fix the PCB to the chassis. 3. Loosen the M2 screw (about 3 to 4 turns) on the RF connector using hex tool (Part number: 6680334F39). 4. Loosening this screw, enables you to unscrew the RF connector from outside. 5. Carefully remove the main PCB in a diagonal manner.
2-10 6.7 MAINTENANCE Disassembly of Control Head - CM200 1. Disconnect the flat cable from the Control Head PCB connector. See Figure 2-11. 2. Remove the PCB from the keypad assembly. 3. Remove the LENs from the rubber keypad assembly. 4. Remove the keypad assembly from the control head housing by lifting it up from the face side. 5. Disconnect the speaker socket and remove the speaker from the keypad assembly.
Radio Disassembly - Detailed 6.8 2-11 Disassembly of Control Heads - CM300/PM400 1. Disconnect the flat cable from the Control Head PCB connector. See Figure 2-12. 2. Remove the PCB from the keypad assembly. 3. Remove the LCD assembly from the rubber keypad assembly. 4. Remove the keypad assembly from the control head housing by lifting it up from the face side. 5. Disconnect the speaker socket and remove the speaker from the keypad assembly.
2-12 MAINTENANCE 7.0 Radio Assembly 7.1 Chassis Assembly (for Low Power Models) 1. Ensure that the Fuji Poly Thermal Pad is on the small pedestal located on the PA compartment of the chassis. 2. Verify that the potentiometer is soldered properly. 3. Take the main PCB and smear thermal paste on LDMOS Power Amplifier, TO220, and Audio Power Amplifier. 4. Slide the main board diagonally into the chassis. 5. Tighten all eight screws (Torx T10). 6.
Radio Assembly 2-13 10. Take the main shield and place it on the chassis. Check that the corners of the main shield are seated properly on the corner supports. 11. Take the main seal and place it inside the top cover. Verify that the main seal is seated properly on its placement ribs and all around the groove. 12. Take the upper cover, place it properly on the chassis, and push it down. Three click sounds are heard from both sides and back. 7.3 Control Heads Assembly 1.
2-14 7.5 MAINTENANCE Option Board Installation 1. Follow the disassembly procedure in paragraphs 6.1 to 6.3. 2. Remove and discard the 4xM3 screws holding the main pcb and replace with the 4 spacers provided. Torque the spacers to 10 lbs. 3. Insert the jumper flex into the connector on the option board. Notice the orientation of the right-angle flex circuit. 4. Insert the other end of the jumper flex into the connector on the main pcb. 5. Fold the flex circuit under the option board. 6.
Radio Exploded Mechanical Views and Parts Lists 2-15 8.0 Radio Exploded Mechanical Views and Parts Lists 8.1 Radio Assembly - 1-25 W Models Figure 2-14 Radio Assembly - 1-25 W Models Table 2-1 Radio Assembly Parts List - 1-25 W Models Item No.
2-16 8.2 MAINTENANCE Radio Assembly - 25-40 W/25-45 W Models Figure 2-15 Radio Assembly - 25-40 W/25-45 W Models Table 2-2 Radio Assembly Parts List - 25-40 W/25-45 W Models Item No. Description Part Number 1 Upper Cover 1589224U01 2 Main Seal 3289329U01 3 Main Shield 2689338U01 4 PA Shield 2689337U01 5 Screw 0310943J12 6 VHF Main PCB (45W) UHF Main PCB (40W) See Chapter 7 Model Charts and Specifications.
Radio Exploded Mechanical Views and Parts Lists 8.
2-18 MAINTENANCE 8.4 Control Head - CM300/PM400 1 4 5 7 2 3 11 6 8 9 10 Figure 2-17 Control Head - CM300/PM400 Table 2-4 Control Head CM300/PM400 Parts List Item no Description Part No.
Service Aids 9.0 2-19 Service Aids Table 2-5 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 2-5 Service Aids Motorola Part No. Description Application RLN4460_ Portable Test Set Enables connection to audio/accessory jack. Allows switching for radio testing.
2-20 10.0 MAINTENANCE Test Equipment Table 2-6 lists test equipment required to service the radio and other two-way radios . Table 2-6 Recommended Test Equipment Motorola Part No.
Programming/Test Cable - RKN4083_ 2-21 11.0 Programming/Test Cable - RKN4083_ P1 (Male) To Radio Test Set 1 13 13 14 J1 (Female) To RIB RLN4008 25 25 1 14 1000 +_ 50mm Cable 1000 +_ 50mm Cable J2 (Female) To Mobile Radio Accessory Connector 1 19 17 20 18 Viewed from Front (pin end) of Connector 2 Note: Use with Adapter Cable FKN8113_ FLO830308-0 FL0830308O Figure 2-18 Programming/Test Cable J2 Mobile Radio Accessory Connector SPEAKER EXTERNAL MIC DIGITAL IN 1 (EXT.
2-22 12.0 MAINTENANCE Adapter Cable - FKN8113_ 16-pin Female To Radio Accessory Connector 20-pin Male To Prog/Test Cable RKN4083_ 1 2 SPEAKER EXTERNAL MIC 3 4 3 EXT.PTT 4 EXT ALARM FLAT TX AUDIO SENSITIVITY 5 BUS+ (FOR CPS AND FLASHING) GND 6 7 5 6 FLAT TX AUDIO DIG IN 7 GND 8 9 DIG I/O DIG IN 10 IGNITION SPEAKER - 1 EXTERNAL MIC 2 EXT.
Chapter 3 TRANSCEIVER PERFORMANCE TESTING 1.0 General These radios meet published specifications through their manufacturing process by utilizing highaccuracy 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. 2.0 Setup Supply voltage is provided using a power supply (13.8 Vdc for low power models, 13.
3-2 3.0 TRANSCEIVER PERFORMANCE TESTING RF Test Mode When the radio is operating in its normal environment, it is not possible to test all individual aspects of the transmitter and receiver performance. Therefore a special “test mode” is used to allow the service technician to perform certain functional tests on the product. A control head fuctional test mode is also available. To enter test mode (display radios): 1. Turn the radio on. 2.
RF Test Mode 3-3 Table 3-3 Test Channel Spacing Number of Beeps Channel Spacing 1 25 kHz 2 12.5 kHz 3 20 kHz Table 3-4 Test Frequencies Channel Display Test Channel VHF (136-162 MHz) VHF (146-174 MHz) UHF (438-470 MHz) UHF (465-495 MHz) 1 Low Power 8 High Power TX#1 or #8 RX#1 or #8 136.125 146.025 438.025 465.225 2 Low Power 9 High Power TX#2 or #9 RX#2 or #9 140.275 150.700 443.300 470.225 3 Low Power 10* High Power TX#3 or #10 RX#3 or #10 144.675 155.300 448.700 475.
3-4 TRANSCEIVER PERFORMANCE TESTING Table 3-5 Transmitter Performance Checks (Continued) Test Name Communications Analyzer Radio Test Set Comment Voice Modulation Mode: PWR MON 4th channel test frequency* atten to -70, input to RF In/ Out Monitor: DVM, AC Volts Set 1kHz Mod Out level for 800mVrms at test set, 800mVrms at AC/DC test set jack As above As above, meter selector to mic Deviation: 2.5 kHz Max. (12.5 kHz Ch. Sp). 4 kHz Max. (20 kHz Ch. Sp). 5 kHz Max. (25 kHz Ch. Sp).
RF Test Mode 3-5 Table 3-6 Receiver Performance Checks Test Name Communications Analyzer Radio Test Set Comment Reference Frequency Mode: PWR MON 4th channel test frequency* Monitor: Frequency error Input at RF In/Out TEST MODE, Test Channel 4 carrier squelch output at antenna PTT to continuous (during the performance check) Frequency error to be: ±186 Hz VHF1 ±200 Hz VHF2 ±568 Hz UHF2 ±600 Hz UHF3 Rated Audio Mode: GEN Output level: 1.
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Chapter 4 RADIO TUNING AND PROGRAMMING 1.0 Introduction This chapter provides an overview of the Customer Programming Software (CPS) and tuner program designed for use in a Windows 98/ME/NT/2000 environment. NOTE Refer to the CPS on-line help files for programming procedures.
4-2 3.0 RADIO TUNING AND PROGRAMMING CPS Programming/Flashing Setup Ribless The CPS programming setup, shown in Figure 4-2 is used to program and flash the radio using the Radio front Telco connector.
CPS Programming Setup with RIB (Accessory Connector) 5.0 4-3 CPS Programming Setup with RIB (Accessory Connector) The CPS programming setup, shown in Figure 4-4 is used to program the radio using the Radio rear accessory connector. Adapter Cable FKN8113 ACC Radio DC RF Power Supply DB15 Programming/Test Cable DB25 RKN4083 Tx Data Rx Data Gnd RIB RLN-4008 Cable 3080369B72 (9 PIN) Cable 3080369B71 (25 PIN) Figure 4-4 CPS Programming Setup Cable with RIB and Rear Adapter Cable 6.
4-4 7.0 RADIO TUNING AND PROGRAMMING Radio Tuning Setup A personal computer (PC), Windows 95/98/NT and a tuner program are required to tune the radio. To perform the tuning procedures, the radio must be connected to the PC, radio interface box (RIB), and test equipment setup as shown in Figure 4-6.
Chapter 5 POWER UP SELF-TEST 1.0 Error Codes Turning on the radio starts a self-test routine that checks the RAM, ROM checksum, EEPROM hardware, and EEPROM checksum. If these checks are successful, the radio generates two highpitched self-test pass tones. If the self-test is not successful, one low-pitched tone is heard. Radios with displays are able to display the error codes. Following are the possible errors and the related connections.
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Chapter 6 ACCESSORIES & CONNECTOR PIN FUNCTIONS 1.0 Accessories To order, refer to Chapter 1 (paragraph 3.0 - ‘Replacement Parts Ordering’) of this manual. 1.1 Antennas VHF HAD4006_ 136 - 144 MHz, 1/4 Wave Roof Mount HAD4007_ 144 - 150.8 MHz, 1/4 Wave Roof Mount HAD4008_ 150.8 - 162 MHz, 1/4 Wave Roof Mount HAD4009_ 162 - 174 MHz, 1/4 Wave Roof Mount RAD4000_ 136 - 174 MHz, 3 dB Gain (No Mount) HAD4014_ 140 - 174 MHz, 3.
6-2 1.2 1.3 ACCESSORIES & CONNECTOR PIN FUNCTIONS Audio HMN3596_ Compact Palm Microphone (Std.
Accessories 1.4 1.5 1.6 1.
6-4 1.8 1.
Accessory Connector Pin Function 2.0 6-5 Accessory Connector Pin Function Pin Function Description 1 External Speaker (-) Connect external 8 or 4 ohms speaker to pin 1 and 16. Caution: Bridge-type output. Neither pin 1 or 16 is grounded. 2 External Mic Audio Input impedence:500 ohms 80 mV rms at 1 kHz for 60% deviation. This path is enabled when external mic PTT is keyed. 3 External Mic PTT 4 Programmable Output Defaults to External Alarm. Provides an active high to 13.
6-6 ACCESSORIES & CONNECTOR PIN FUNCTIONS 3.0 Microphone Connector Pin Function Pin Function 1 9.3V 2 Boot/DTMF Keypad Column This pin function depends on the voltage applied to pin 3 (See pin 3, Hook description). When configured as “Boot”, applying 5V to this pin will set the radio to Boot state. When configured as “DTMF Keypad Column”, this pin will carry column voltages generated by the DTMF microphone (RMN5029).
Chapter 7 MODEL CHART AND TEST SPECIFICATION 1.0 Low Power Radios 1.
7-2 MODEL CHART AND TEST SPECIFICATION 1.
Low Power Radios 1.3 7-3 Specifications General Specification Frequency Range: VHF2 UHF2 146-174 MHz 438-470 MHz Frequency Stability (-30°C to +60°C, 25°C Ref.) ±2.5 PPM Channel Capacity: CM200 - 4 CM300 - 32 PM400 - 64 Channel Spacing: 12.5/20/25 kHz Power Supply: Dimensions (L x W x H) Weight FCC Description Operating Temperature 13.8 Vdc (11 Vdc - 16.6 Vdc) negative Vehicle ground 4.65” X 6.67” X 1.73” (118mm X 169.5mm X 44mm) 2.25 lbs (1.
7-4 MODEL CHART AND TEST SPECIFICATION Transmitter Specification VHF2 UHF2 Power Output 1-25W Conducted/Radiated Emissions: -36 dBm < 1 GHz -30 dBm > 1 GHz Audio Response: (from 6 dB/oct. Pre-Emphasis, 300 to 3000Hz) TIA603 and CEPT Tx Audio Distortion < 3% Modulation Limiting: ±2.5 kHz @ 12.5 kHz ±4.0 kHz @ 20 kHz ±5.0 kHz @ 25 kHz FM Hum and Noise: -40 dB@12.5 kHz -45 dB@25 kHz -35 dB@12.5 kHz -40 dB@25 kHz Receiver Specification VHF2 UHF2 0.35 µV @ 12.5 kHz 0.
High Power Radios 7-5 2.0 High Power Radios 2.1 136-162 MHz CM300 Model Chart VHF1, 25-45 W, 136-162 MHz Model AAM50JQF9AA1AN Description CM300 136-162 MHz, 25-45 W, 32 CH Item Description X PMUD1946_ CM300 Super Tanapa VHF1, 25-45 W, 32 CH X PMUD1962_ CM300 Tanapa VHF1, 25-45 W, 32 CH X PMLN4599_ Control Head X PMUD1962_S CM300 VHF1 Service Board X 6881096C22 CM300 User Guide (bilingual) X HKLN4220 CM300 User Guide CMROM (bilingual) x = Indicates one of each is required. 2.
7-6 MODEL CHART AND TEST SPECIFICATION 2.
High Power Radios 2.4 7-7 465-495 MHz PM400 Model Chart UHF3, 25-40 W 465-495 MHz Model AAM50SPF9AA3AN Description PM400 465-495 MHz, 25-40 W, 64 CH Item Description X PMUE2092_ PM400 Super Tanapa UHF3, 25-40 W, 64 CH X PMUE2038_ PM400 Tanapa UHF3,25- 40 W, 64 CH X FLN3108_AN Control Head X PMUE2038_S PM400 UHF3 Service Board X 6881096C32 PM400 User Guide (bilingual) X HKLN4219 PM400 User Guide CDROM (bilingual) x = Indicates one of each is required.
7-8 2.5 MODEL CHART AND TEST SPECIFICATION Specifications General Specification Frequency Range: VHF1 VHF2 UHF2 UHF3 136-162 MHz 146-174 MHz 438-470 MHz 465-495 MHz Frequency Stability (-30°C to +60°C, 25°C Ref.) Channel Capacity: ±2.5 PPM CM300 - 32 Channel Spacing: Power Supply: 13.6 Vdc (10.88 Vdc - 16.32 Vdc) negative Vehicle ground 4.65” X 6.67” X 1.73” (118mm X 169.5mm X 44mm) Weight Operating Temperature 2.25 lbs (1.
High Power Radios 7-9 Transmitter Specification Power Output VHF1 VHF2 UHF2 25-45 W 25-40 W Conducted/Radiated Emissions: -26 dBm Audio Response: (from 6 dB/oct. Pre-Emphasis, 300 to 3000Hz) TIA603 and CEPT Tx Audio Distortion < 3% Modulation Limiting: ±2.5 kHz @ 12.5 kHz ±4.0 kHz @ 20 kHz ±5.0 kHz @ 25 kHz FM Hum and Noise: UHF3 -40 dB@12.5 kHz -45 dB@25 kHz -35 dB@12.5 kHz -40 dB@25 kHz Receiver Specification VHF1 VHF2 UHF2 UHF3 0.35 µV @ 12.5 kHz 0.
7-10 MODEL CHART AND TEST SPECIFICATION 3.0 MIL Standards MIL STDS 810 C, D, and E: Applicable to UHF and VHF Specifications (8.2 and 8.4) Military Standards 810 C, D, & E: Parameters/Methods/Procedures 810C Applicable MIL-STD Methods 810D Procedures Methods Procedures 810E Methods Procedures Temperature Shock 503.1 I 503.2 I 503.3 I Solar Radiation 505.1 I 505.2 I 505.3 I Rain 506.1 I 506.2 I 506.3 I Salt Fog 509.1 I 509.2 I (48 hours) 509.3 I (48 hours) Dust 510.
Glossary G-i GLOSSARY Glossary of Terms Term Definition ALC Automatic Level Control: a circuit in the transmit RF path that controls RF power amplifier output, provides leveling over frequency and voltage, and protects against high VSWR (Voltage Standing Wave Ratio). ASF IC Audio Signalling Filter Integrated Circuit with voice compander. CD Compact Disk. CMP Compression. CPS Customer Programming Software. CSQ Carrier Squelch. DTMF Dual-Tone Multifrequency. DPL Digital Private-Line™.
G-ii Glossary OSW Outbound Signalling Word: data transmitted on the control channel from the central controller to the subscriber unit. PC Board Printed Circuit Board PL Private-Line® tone squelch: a continuous sub-audible tone that is transmitted along with the carrier. PLL Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider.
Glossary G-iii UHF Ultra High Frequency µP Microprocessor VCO Voltage-Controlled Oscillator: an oscillator whereby the frequency of oscillation can be varied by changing a control voltage.
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MOTOROLA, the Stylized M Logo, and Radius are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2004 Motorola, Inc. All rights reserved. Printed in U.S.A.
