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.
Table of Contents Foreword... ii Computer Software Copyrights ... ii Document Copyrights ... ii Disclaimer ... ii Product Safety and RF Exposure Compliance ...vii Chapter 1 INTRODUCTION 1.0 Scope of Manual ...1-1 2.0 Warranty and Service Support...1-1 2.1 Warranty Period and Return Instructions ...1-1 2.2 After Warranty Period...1-1 3.0 Replacement Parts Ordering ...1-2 3.1 Basic Ordering Information...1-2...
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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 ... 2-15 8.2 Radio Assembly - 25-40 W/25-45 W Models ... 2-16 8.3 Control Head - CM200 ...
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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 1.1 146-174 MHz CM200/CM300/PM400 Model Chart...7-1 1.2 438-370 MHz CM200/CM300/PM400 Model Chart...7-2 1.3 Specifications ...7-3 2.0 High Power Radios ...7-5 2.1 136-162 MHz CM300 Model Chart...7-5 2.2 146-174 MHz CM200/CM300/PM400 Model Chart...7-5...
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. C a u t i o n This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
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.
Replacement Parts Ordering 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.
Radio Model Information 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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Introduction This chapter provides details about the following: Preventive maintenance (inspection and cleaning). • Safe handling of CMOS and LDMOS devices. • Disassembly and reassembly of the radio. • Repair procedures and techniques. • Installation of Option Boards. • Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...
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.
Repair Procedures and Techniques — General 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”...
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.
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Radio Disassembly - Detailed Figure 2-2 Control Head Removal To free the control head, disconnect the flat cable from the chassis assembly See Figure 2-3. Main PCB Connector Figure 2-3 Flat Cable Removal...
Top Cover Removal Place the radio in a vertical position as shown in Figure 2-4. Figure 2-4 Top Cover Removal (Chassis Vertical). Insert the flat screw driver near the ‘T’ and push the plastic cover up until it pops over the ‘T’ mount boss.
Radio Disassembly - Detailed Main Shield Removal 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. Lift the cover from the chassis. PA Shield and DC Cable Removal Remove the three screws that attach the PA shield to PCB, and remove the PA shield.
Figure 2-8 PA Shield and DC Cable Removal (for High Power Models) PA Clip and Main PCB Removal (for Low Power Models) Remove the screw that attaches the PA clip to the chassis. See Figure 2-9. Remove the PA clip. Remove all the screws that fix the PCB to the chassis.
Radio Disassembly - Detailed Main PCB Removal (for High Power Models) Remove the PA screws. See Figure 2-10. Remove all the screws that fix the PCB to the chassis. Loosen the M2 screw (about 3 to 4 turns) on the RF connector using hex tool (Part number: 6680334F39).
2-10 Disassembly of Control Head - CM200 Disconnect the flat cable from the Control Head PCB connector. See Figure 2-11. Remove the PCB from the keypad assembly. Remove the LENs from the rubber keypad assembly. Remove the keypad assembly from the control head housing by lifting it up from the face side.
Radio Disassembly - Detailed Disassembly of Control Heads - CM300/PM400 Disconnect the flat cable from the Control Head PCB connector. See Figure 2-12. Remove the PCB from the keypad assembly. Remove the LCD assembly from the rubber keypad assembly. Remove the keypad assembly from the control head housing by lifting it up from the face side. Disconnect the speaker socket and remove the speaker from the keypad assembly.
2-12 Radio Assembly Chassis Assembly (for Low Power Models) Ensure that the Fuji Poly Thermal Pad is on the small pedestal located on the PA compartment of the chassis. Verify that the potentiometer is soldered properly. Take the main PCB and smear thermal paste on LDMOS Power Amplifier, TO220, and Audio Power Amplifier.
Radio Assembly 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 prop- erly on its placement ribs and all around the groove.
2-14 Option Board Installation Follow the disassembly procedure in paragraphs 6.1 to 6.3. Remove and discard the 4xM3 screws holding the main pcb and replace with the 4 spacers provided. Torque the spacers to 10 lbs. Insert the jumper flex into the connector on the option board. Notice the orientation of the right-angle flex circuit.
Radio Exploded Mechanical Views and Parts Lists Radio Exploded Mechanical Views and Parts Lists Radio Assembly - 1-25 W Models Table 2-1 Radio Assembly Parts List - 1-25 W Models Item No. Upper Cover Main Seal Bumper Main Shield PA Shield Screw PA Clip VHF Main PCB...
2-16 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. Upper Cover Main Seal Main Shield PA Shield Screw VHF Main PCB (45W) UHF Main PCB (40W) Connector Jack: Mini UHF...
Radio Exploded Mechanical Views and Parts Lists Control Head - CM200 Item no Control Head PCB Lens Keypad Control Head Plastic Knob Spring (part of knob - item 6) Knob, Volume Speaker Flat Cable (not shown) Nameplate Figure 2-16 Control Head CM200 Table 2-3 Control Head CM200 Parts List Description Part No...
2-18 Control Head - CM300/PM400 Table 2-4 Control Head CM300/PM400 Parts List Item no Control Head PCB Light Guide Elastomeric Connector LCD Holder Keypad Speaker Control Head Plastic CM300 PM400 Knob Spring (part of Knob - item 10) Knob Lens: CM300 PM400 Flat Cable (Not Shown)
Service Aids 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. Motorola Part RLN4460_ Portable Test Set...
2-20 10.0 Test Equipment Table 2-6 lists test equipment required to service the radio and other two-way radios Motorola Part No. Description R2000, R2600 Service Monitor R2400, or R2001 with trunking option for Pri- vacy Plus™ and Smartnet Sys- † tems™...
Programming/Test Cable - RKN4083_ 11.0 Programming/Test Cable - RKN4083_ FLO830308-0 P1 (Male) J1 (Female) To Radio To RIB Test Set RLN4008 1000 50mm Cable 1000 50mm Cable J2 (Female) To Mobile Radio Accessory Connector Viewed from Front (pin end) of Connector Note: Use with Adapter Cable FKN8113_ Figure 2-18 Programming/Test Cable J2 Mobile...
2-22 12.0 Adapter Cable - FKN8113_ FLAT TX AUDIO SENSITIVITY BUS+ (FOR CPS AND FLASHING) SWITCHED BATTERY VOLTAGE 16-pin Female 20-pin Male To Radio To Prog/Test Accessory Cable Connector RKN4083_ SPEAKER - EXTERNAL MIC EXT. PTT SPEAKER + Viewed from Front (pin end) of Connector Figure 2-20 Pin Configuration of FKN8113...
TRANSCEIVER PERFORMANCE TESTING General These radios meet published specifications through their manufacturing process by utilizing high- accuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule. Setup Supply voltage is provided using a power supply (13.8 Vdc for low power models, 13.6 Vdc for high power models).
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.
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RF Test Mode Channel Display 1 Low Power TX#1 or #8 8 High Power RX#1 or #8 2 Low Power TX#2 or #9 9 High Power RX#2 or #9 3 Low Power TX#3 or #10 10* High Power RX#3 or #10 4 Low Power TX#4 or #11 11* High Power...
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Table 3-5 Transmitter Performance Checks (Continued) Test Name Communications Analyzer Voice Mode: PWR MON Modulation 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 Voice...
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RF Test Mode Test Name Communications Analyzer Reference Mode: PWR MON Frequency 4th channel test frequency* Monitor: Frequency error Input at RF In/Out Rated Audio Mode: GEN Output level: 1.0mV RF 4th channel test frequency* Mod: 1kHz tone at 3kHz deviation Monitor: DVM: AC Volts Distortion As above, except to distortion...
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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. Table 4-1 Software Installation Kits Radio Tuning Setup CPS Programming/Flashing Setup with RIB The CPS programming setup, shown in Figure 4-1 is used to program and flash the radio using the Radio front Telco connector.
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. 8-pin Telco FKN8096 Data =Programming FKN8096 Boot = Flashing 10-pin Telco Figure 4-2 CPS Programming/Flashing Setup Cable with Internal RIB CPS Programming Setup with RIB (with Telco Connector) The CPS programming setup, shown in Figure 4-3 is used to program the radio using the Radio front Telco connector.
CPS Programming Setup with RIB (Accessory Connector) 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 Programming/Test Cable RKN4083 Figure 4-4 CPS Programming Setup Cable with RIB and Rear Adapter Cable CPS Programming Setup with RIB The CPS programming setup, shown in Figure 4-5 is used to program the radio using the Radio rear...
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. ELM Adapter cable FKN8113 Figure 4-6 Radio Tuning Test Equipment Setup with External RIB...
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 high- pitched 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.
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Accessories Control Station HPN4002_ HPN4001_ HMN3000_ RLN5390_ RLN5391_ RLN5492 RLN5493 Public Address RLN5288_ HKN9324_R HSN1000_R Cables HKN9327_R HKN4137_ HKN4191_ Mounting GLN7324_ GLN7317_ FTN6083_ HLN8097_ HLN9227_ RLN4779_ Desktop Power Supply 1-25 W Desktop Power Supply 25-60 W Black Desk Microphone Desktop Tray with Speaker Desktop Tray without Speaker Low Power Control Station Kit (1-25 W) (includes power supply, desktop tray, and desk mic)
Microphone Connector Pin Function Function 9.3V Boot/DTMF Keypad Column Hook Ground Mic. Audio THIS PAGE INTENTIONALLY LEFT BLANK Mic. PTT SCI/DTMF Keypad Row Handset Rx Audio ACCESSORIES & CONNECTOR PIN FUNCTIONS Regulated 9.3V Supply (50mA max.) This pin function depends on the voltage applied to pin 3 (See pin 3, Hook description).
MODEL CHART AND TEST SPECIFICATION Low Power Radios 146-174 MHz CM200/CM300/PM400 Model Chart VHF2, 1-25 W, 146-174 MHz Model AAM50KNC9AA1AN AAM50KNF9AA1AN AAM50KNF9AA3AN Item PMUD1871_ PMUD1873_ PMUD1904_ FLD1933_ PMUD1882_ PMUD1882_ PMLN4598_ PMLN4599_ FLN3108_AN FLD1933_S PMUD1882_S PMUD1882_S 6902966C30 6881096C22 6881096C32 HKLN4220 HKLN4219 x = Indicates one of each is required.
Low Power Radios Specifications Specification Frequency Range: Frequency Stability (-30°C to +60°C, 25°C Ref.) Channel Capacity: Channel Spacing: Power Supply: Dimensions (L x W x H) Weight FCC Description Operating Temperature Storage Temperature Thermal Shock High Humidity Packing Test General VHF2 146-174 MHz ±2.5 PPM...
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Specification Power Output Conducted/Radiated Emissions: Audio Response: (from 6 dB/oct. Pre-Emphasis, 300 to 3000Hz) Tx Audio Distortion Modulation Limiting: FM Hum and Noise: Specification Sensitivity (12 dB SINAD): Intermodulation: Adjacent Channel Selectivity: Spurious Response Rated Audio Power Audio Distortion Hum and Noise: Audio Response Conducted Spurious Emission per FCC Part 15:...
High Power Radios High Power Radios 136-162 MHz CM300 Model Chart VHF1, 25-45 W, 136-162 MHz Model AAM50JQF9AA1AN Item PMUD1946_ PMUD1962_ PMLN4599_ PMUD1962_S 6881096C22 HKLN4220 x = Indicates one of each is required. 146-174 MHz CM200/CM300/PM400 Model Chart VHF2, 25-45 W, 146-174 MHz Model AAM50KQC9AA1AN AAM50KQF9AA1AN...
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438-470 MHz CM200/CM300/PM400 Model Chart UHF2, 25-40 W, 438-470 MHz Model AAM50RPC9AA1A AAM50RPF9AA1AN AAM50RPF9AA3AN Item PMUE2007_ PMUE2010_ PMUE2091_ PMUE2032_ PMUE2034_ PMUE2034_ PMLN4598_ PMLN4599_ FLN3108_AN PMUE2032_S PMUE2034_S PMUE2034_S 6902966C30 6881096C22 6881096C32 HKLN4220 HKLN4219 x = Indicates one of each is required. MODEL CHART AND TEST SPECIFICATION Description CM200 438-470 MHz, 25-40 W, 4 CH...
High Power Radios 465-495 MHz PM400 Model Chart UHF3, 25-40 W 465-495 MHz Model AAM50SPF9AA3AN Item PMUE2092_ PMUE2038_ FLN3108_AN PMUE2038_S 6881096C32 HKLN4219 x = Indicates one of each is required. Description PM400 465-495 MHz, 25-40 W, 64 CH Description PM400 Super Tanapa UHF3, 25-40 W, 64 CH PM400 Tanapa UHF3,25- 40 W, 64 CH Control Head PM400 UHF3 Service Board...
Specifications Specification Frequency Range: Frequency Stability (-30°C to +60°C, 25°C Ref.) Channel Capacity: Channel Spacing: Power Supply: Dimensions (L x W x H) Weight FCC Description Operating Temperature Storage Temperature Thermal Shock High Humidity Packing Test General VHF1 VHF2 136-162 MHz 146-174 MHz CM300 - 32 13.6 Vdc (10.88 Vdc - 16.32 Vdc) negative Vehicle ground...
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High Power Radios Specification Power Output Conducted/Radiated Emissions: Audio Response: (from 6 dB/oct. Pre-Emphasis, 300 to 3000Hz) Tx Audio Distortion Modulation Limiting: FM Hum and Noise: Specification Sensitivity (12 dB SINAD): Intermodulation: Adjacent Channel Selectivity: Spurious Response Rated Audio Power Audio Distortion Hum and Noise: Audio Response...
7-10 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 Applicable Methods MIL-STD Temperature Shock 503.1 Solar Radiation 505.1 Rain 506.1 Salt Fog 509.1 Dust 510.1...
Glossary GLOSSARY Glossary of Terms Term Automatic Level Control: a circuit in the transmit RF path that controls RF power amplifier output, provides leveling over frequency and voltage, and pro- tects against high VSWR (Voltage Standing Wave Ratio). ASF IC Audio Signalling Filter Integrated Circuit with voice compander.
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G-ii Outbound Signalling Word: data transmitted on the control channel from the central controller to the subscriber unit. PC Board Printed Circuit Board Private-Line® tone squelch: a continuous sub-audible tone that is transmitted along with the carrier. Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a refer- ence, usually after passing through a frequency divider.
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Glossary Ultra High Frequency µP Microprocessor Voltage-Controlled Oscillator: an oscillator whereby the frequency of oscillation can be varied by changing a control voltage. VCOBIC Voltage-Controlled Oscillator Buffer Integrated Circuit Very High Frequency VSWR Voltage Standing Wave Ratio G-iii...
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