Nikon CM200 User Manual
Radius CM200
™
/
CM300
™
& Motorola PM400
™
Commercial Series
Mobile Radio Basic Service Manual
CM200/CM300/PM400
Radios
i
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 th e 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.
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer prog r ams stor ed
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, estoppe l, 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.
MOTOROLA, The Stylized M logo, and Radius are trademarks of Motorola, Inc.
All other product or servic e na m es are the property of their respective owners.
© 2004 Motorola, Inc. All rights reserved. Printed in U.S.A.
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
3.2 Motorola Online ...........................................................................................1-2
3.3 Mail Orders..................................................................................................1-2
3.4 Telephone Orders .......................................................................................1-2
3.5 Fax Orders .................................................................................................. 1-2
3.6 Parts Identification.......................................................................................1-3
4.0 Radio Model Information......................................................................................1-3
iii
Chapter 2 MAINTENANCE
1.0 Introduction ..........................................................................................................2-1
2.0 Preventive Maintenance ......................................................................................2-1
2.1 Inspection ....................................................................................................2-1
2.2 Cleaning Procedures...................................................................................2-1
3.0 Safe Handling of CMOS and LDMOS Devices ....................................................2-2
4.0 Repair Procedures and Techniques — General ..................................................2-3
5.0 Disassembling and Reassembling the Radio — General ....................................2-3
6.0 Radio Disassembly - Detailed..............................................................................2-4
6.1 Control Head Removal ................................................................................2-4
6.2 Top Cover Removal ....................................................................................2-6
6.3 Main Shield Removal ..................................................................................2-7
6.4 PA Shield and DC Cable Removal..............................................................2-7
6.5 PA Clip and Main PCB Removal (for Low Power Models) ..........................2-8
6.6 Main PCB Removal (for High Power Models) ............................................. 2-9
6.7 Disassembly of Control Head - CM200 .....................................................2-10
6.8 Disassembly of Control Heads - CM300/PM400....................................... 2-11
7.0 Radio Assembly.................................................................................................2-12
7.1 Chassis Assembly (for Low Power Models) ..............................................2-12
7.2 Chassis Assembly (for High Power Models) .............................................2-12
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 .............................................................2-15
8.2 Radio Assembly - 25-40 W/25-45 W Models ............................................2-16
8.3 Control Head - CM200 .............................................................................. 2-17
8.4 Control Head - CM300/PM400 ..................................................................2-18
9.0 Service Aids.......................................................................................................2-19
10.0 Test Equipment..................................................................................................2-20
11.0 Programming/Test Cable - RKN4083_ .............................................................. 2-21
12.0 Adapter Cable - FKN8113_ ...............................................................................2-22
Chapter 3 TRANSCEIVER PERFORMANCE TESTING
1.0 General ................................................................................................................3-1
2.0 Setup ................................................................................................................... 3-1
3.0 RF Test Mode ......................................................................................................3-2
Chapter 4 RADIO TUNING AND PROGRAMMING
1.0 Introduction ..........................................................................................................4-1
2.0 CPS Programming/Flashing Setup with RIB .......................................................4-1
3.0 CPS Programming/Flashing Setup Ribless ......................................................... 4-2
4.0 CPS Programming Setup with RIB (with Telco Connector)................................. 4-2
5.0 CPS Programming Setup with RIB (Accessory Connector) ................................4-3
6.0 CPS Programming Setup with RIB ...................................................................... 4-3
7.0 Radio Tuning Setup .............................................................................................4-4
7.1 Initial Test Equipment Control Settings .......................................................4-4
Chapter 5 POWER UP SELF-TEST
1.0 Error Codes ......................................................................................................... 5-1
Chapter 6 ACCESSORIES & CONNECTOR PIN FUNCTIONS
1.0 Accessories ......................................................................................................... 6-1
1.1 Antennas ..................................................................................................... 6-1
1.2 Audio ........................................................................................................... 6-2
1.3 Alarms and Accessories..............................................................................6-2
1.4 Control Station.............................................................................................6-3
1.5 Public Address ............................................................................................ 6-3
1.6 Cables ......................................................................................................... 6-3
1.7 Mounting......................................................................................................6-3
1.8 Data - CES Wireless Technologies .............................................................6-4
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
2.3 438-470 MHz CM200/CM300/PM400 Model Chart.....................................7-6
2.4 465-495 MHz PM400 Model Chart..............................................................7-7
2.5 Specifications .............................................................................................7-8
3.0 MIL Standards....................................................................................................7-10
v
GLOSSARY ...................................................................................... G-i
vi
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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
ATTENTION!
This radio is restricted to occupational use only to satisfy 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 radio (Motorola Publication part number
68P81095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which
lists approved accessories: http://www.motorola.com/cgiss/index.shtml.
vii
viii
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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.
Chapter 1
INTRODUCTION
NOTE
Before operating or testing these units, please read the Safety Infor mation Section in the
front of this manual.
2.0 Warranty and Service Support
Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warr anty p eriod, and service/ repair or spare parts support out of warran ty.
Any "return for exchange" or "return for repair" by an authorised Motorola Dealer must be
accompanied by a Warranty Claim Form. Warranty Claim Fo rms are obtained by contacting an
Authorized Motorola Dealer.
2.1 Warranty Period and Return Instructions
The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only.
In instances where the product is covered under a "return for replacement" or "return for repair"
warranty, a check of the product should be performed prior to shipping the unit back to Motorola.
This is to ensure that the product has been correctly programmed or has not been subjected to
damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be
accompanied by a Warranty Claim Form, available fr om your Customer Services representative.
Products should be shipped back in the original packaging, or correctly packaged to ensure no
damage occurs in transit.
2.2 After Warranty Period
After the Warr anty period, Motorola continues to support its products in two ways.
1. Motorola's Radio Products and Services Division (RPSD) off ers a repair service to both end users
and dealers at competitive prices.
2. Radio Products and Services Division (RPSD) supplies individual parts and modules that can be
purchased by dealers who are technically capable of performing fault analysis and repair.
* The Radio Products and Services Division (RPSD) was formerly knows as the Accessories and
Aftermarket Division (AAD)
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 componen t 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.
3.2 Motorola Online
Motorola online users can access our on-line catalog at:
HTTPS://WWW.MOTOROLA.COM/BUSINESSONLINE
To register for online access, please call 800-814-0601 (for U.S. and Canada Service Centers only).
3.3 Mail Orders
Send written orders to the following addresses:
Replacement Parts/Test
Equipment/Manuals/Crystal
Service Items:
Motorola, Inc.
Radio Products and Services Division
Attention: Order Processing
2200 Galvin Dr.
Elgin, IL 60123
U.S.A.
3.4 Telephone Orders
Radio Products and Services Division (RPSD)
(United States and Canada)
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
847-538-8023 (International Orders
U.S. Federal Government Markets Division (USFGMD)
1-800-826-1913 Federal Government Parts - Credit Card Only
8:30 AM to 5:00 PM (Eastern Standard Time)
Federal Government Orders: International Orders:
Motorola, Inc.
U.S. Federal Government
Markets Division
Attention: Order Processing
7230 Parkway Drive
Landover , MD21076
U.S.A.
Motorola, Inc.
Radio Products and Services
Division
Attention: Order Processing
2200 Galvin Dr.
Elgin, IL 60123
U.S.A.
3.5 Fax Orders
Radio Products and Services Division (RPSD)
(United States and Canada)
1-800-622-6210
847-576-3023 (International)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchased Orders)
Radio Model Information 1-3
3.6 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)
4.0 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. The
example below shows one mobile radio model number and its specific characteristics.
Table 1-1 Radio Model Number (Example: AAM50KNC9AA1)
Type of
Unit
AA M 50 J
Model
Series
Freq.
Band
VHF1
(136-162
MHz)
M = Mobile
AA = Country Code
VHF2
(146-174
MHz)
UHF2
(438-470
MHz)
UHF3
(465-495
MHz)
Power
Level
1-25 WCCM2009Program-
K
25-40 WFCM300
R
25-45 W
S
N
P
Q
Physical
Packages
PM400
Channel
Spacing
mable
Protocol
AA
Conven-
tional
MDC
Feature
Level
1
4/32 mini-U
3
64 mini-U
1-4 INTRODUCTION
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1.0 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.
2.0 Preventive Maintenance
The radios do not require a scheduled preventive maintenance program; however, periodic visual
inspection and cleaning is recommended.
2.1 Inspection
Chapter 2
MAINTENANCE
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.
2.2 Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the front
cover and housing assembly. These surfaces should be cleaned whenever a periodic visual
inspection reveals the presence of smudges, grease, and/or grime.
NOTE
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (70% by volume).
CAUTION: The effects of certain chemicals and their vapors can have harmful results on
certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.
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. 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
top cover.
NOTE
Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
3.0 Safe Handling of CMOS and LDMOS Devices
Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent
device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without first referring to the following
CAUTION statement.
CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are
properly grounded. Take the following precautions when working on this unit:
• Store and transport all CMOS devices in conductive material so that all exposed
leads are shorted together. Do not insert CMOS devices into conventional plastic
“snow” trays used for storage and transportation of other semiconductor devices.
• Ground the working surface of the service bench to protect the CMOS device. We
recommend using the Motorola Static Protection Assembly (part number
0180386A82), which includes a wrist strap, two ground cords, a table mat, and a
floor mat.
• Wear a conductive wrist strap in series with a 100k resistor to ground.
(Replacement wrist straps that connect to the bench top covering are Motorola part
number 4280385A59)
• Do not wear nylon clothing while handling CMOS devices.
• Do not insert or remove CMOS devices with power applied. Check all power
supplies used for testing CMOS devices to be certain that there are no voltage
transients present.
• When straightening CMOS pins, provide ground straps for the apparatus used.
• When soldering, use a grounded soldering iron.
• If at all possible, handle CMOS devices by the package and not by the leads. Prior
to touching the unit, touch an electrical ground to remove any static charge that you
may have accumulated. The package and substrate may be electrically common. If
so, the reaction of a discharge to the case would cause the same damage as
touching the leads.
Repair Procedures and Techniques — General 2-3
4.0 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.
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.
When soldering near the RF connector, potentiometer, 16-pin and 20-pin connectors:
• Avoid accidentally getting solder in the connector.
• Be careful not to form solder bridges between the connector pins.
• Examine your work closely for shorts due to solder bridges.
5.0 Disassembling and Reassembling the Radio — General
Since these radios may be disassembled and reassembled with the use of only 14 (board to casting)
screws, it is important to pay particular attention to the snaps and tabs, and how parts align with
each other.
The following tools are required for disassembling/assembling the radio:
• Small flat blade screwdriver
• Phillips small 1# screwdriver
• TORX™ T9 screwdriver
• TORX™ T10 screwdriver
• Torque screwdriver set
• Torque spanner
• Hex tool (part no. 6680334F39)
If a unit requires more complete testing or service than is customarily performed at the basic level,
send this unit to a Motorola Authorized Service Center. (See Chapter 1 for a list of authorized
service centers.)
The following disassembly procedures should be performed only if necessary:
2-4 MAINTENANCE
6.0 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
Volume Knob Removal
Ensure that the volume knob is in the OFF position before disassembling the radio.
1. Insert the flat screwdriver between the control head plastic and the volume knob and push the
volume knob upwards. See Figure 2-1.
Figure 2-1 Volume Knob Removal.
2. Insert the flat screw driver (4 mm maximum) into the slot and push the plastic up.
Do the same with the second slot to free the control head from the chassis assembly. See
Figure 2-2.
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.
Main PCB Connector
Figure 2-3 Flat Cable Removal
2-6 MAINTENANCE
6.2 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.
Figure 2-5 Top Cover Removal (Chassis Horizontal)
Radio Disassembly - Detailed 2-7
6.3 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. Remove the two screws that attach the DC power cable to the PCB and pull it out from the
side.
DC
Cable
DC Cable
Accessory
Connector
Cap
Fixing Screws
(2)
PA Shield
Fixing Screws (3)
Figure 2-7 PA Shield and DC Cable Removal (for Low Power Models)
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