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Motorola PM1200 Basic Service Manual

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  • Page 3 PM1200 Mobile Radio Basic Service Manual Motorola, Inc. 1301 E. Algonquin Rd. 6880309U09-A Schaumburg, IL 60196-1078 USA...
  • Page 4: Foreword

    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.
  • Page 5: Document History

    Document History The following major changes have been implemented in this manual since the previous edition: Edition Description Date 6880309U09-A Initial Release Oct. 2007...
  • Page 6 Notes...
  • Page 7: Table Of Contents

    Model Numbering, Charts, and Specifications........xviii Mobile Radio Model Numbering Scheme ....................xviii PM1200 Low Band (A) 29.7–37MHz 120 Watt Model Chart ..............xix PM1200 Low Band (B) 37–50MHz 120 Watt Model Chart ................xx PM1200 Low-Band (A) 29.7–37MHz Radio Specifications ..............xxi PM1200 Low Band (B) 37–50MHz Radio Specifications ................
  • Page 8 Test Equipment, Service Aids, and Tools......4-1 Recommended Test Equipment ....................4-1 Service Aids and Recommended Tools ..................4-2 Field Programming Equipment ....................4-3 4.3.1 PM1200 Field Programming .................... 4-3 4.3.1.1 Field-Programming Items ................. 4-3 Chapter 5 Radio Alignment and Programming Procedures ..... 5-1 Introduction of Radio Alignment Procedures ................
  • Page 9 6.2.2.1.1 PM1200 Control Head Back Housing Disassembly ......6-2 6.2.2.1.2 PM1200 Control Head Panel-Interface Unit Board Kit Disassembly 6-4 6.2.2.1.3 PM1200 Control Head Display Unit Board Kit Disassembly .... 6-5 6.2.2.1.4 PM1200 Control Head VR Unit Board Kit Disassembly ....6-5 6.2.2.1.5 PM1200 Control Head Key Unit Board Kit Disassembly ....
  • Page 10 Transmitter Troubleshooting ......................7-2 Receiver Troubleshooting ......................7-3 Chapter 8 Functional Block Diagrams and Connectors ....8-1 PM1200 Functional Block Diagram 1................... 8-2 PM1200Functional Block Diagram 2.................... 8-3 PM1200 Functional Block Diagram 3................... 8-4 PM1200 Connection Diagram ...................... 8-5 Transmitter Block Diagram ......................8-6 Synthesizer Block Diagram ......................
  • Page 11 Motorola Online ...........................A-1 Mail Orders ..........................A-1 Telephone Orders ........................A-1 Fax Orders ...........................A-1 Parts Identification ........................A-2 Product Customer Service ......................A-2 Appendix B Motorola Service Centers...........B-1 Servicing Information ........................B-1 Motorola Service Center ......................B-1 Motorola Federal Technical Center .....................B-1 Glossary ..................Glossary-1 Index ..................... Index-1...
  • Page 12 List of Figures List of Figures Figure 5-1. AF Test Adapter Schematics ....................5-3 Figure 5-2. Radio RF Test Equipment Setup ..................5-5 Figure 5-3. Power On Start Screen......................5-6 Figure 5-4. Adjustment Data Screen ...................... 5-6 Figure 5-5. RX Tune Alignment Screen....................5-7 Figure 5-6.
  • Page 13 Figure 6-89. Attach Option Board to Interface Board ................6-46 Figure 6-90. Sequence for Installing Top Cover Screws ................ 6-47 Figure 6-91. Chassis Thermal Compound Locations ................6-47 Figure 7-1. Transceiver Rear Accessory Connector Pin Configuration ..........7-1 Figure 8-1. PM1200 Functional Block Diagram..................8-2 6880309U09-A October 26, 2007...
  • Page 14 List of Figures Figure 8-2. PM1200 Functional Block Diagram 2 ................... 8-3 Figure 8-3. PM1200 Functional Block Diagram 3 ................... 8-4 Figure 8-4. PM1200 Connection Diagram ....................8-5 Figure 8-5. Transmitter Block Diagram....................8-6 Figure 8-6. Synthesizer Block Diagram ....................8-7 Figure 8-7.
  • Page 15 List of Tables xiii List of Tables Table 1-1. PM1200 Radio Frequency Ranges and Power Levels ............1-1 Table 4-1. Recommended Motorola Test Equipment ................4-1 Table 4-2. Recommended Non-Motorola Test Equipment ..............4-1 Table 4-3. Service Aids for PM1200 Board-Level Troubleshooting ............4-2 Table 4-4.
  • Page 16 Related Publications Related Publications PM1200 Mobile Radio User Guide CD ..................6880309U08 PM1200 Mobile Radio Installation Manual................... 6880309U11 PM1200 Mobile CPS Installation Guide..................6880309U29 PM1200 Mobile Radio User Kit.....................HKLN4350_ October 26, 2007 6880309U09-A...
  • Page 17: Commercial Warranty

    Product Accessories One (1) Year Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period.
  • Page 18: State Law Rights

    Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.
  • Page 19: Patent And Software Provisions

    A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim; B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and C.
  • Page 20: Model Numbering, Charts, And Specifications

    174 to 210MHz 1.0 to 1.6GHz Conventional 190 to 235MHz 1.5 to 2.0GHz Privacy Plus * For PM1200 "B" in Position 4 represents Clear SMARTNET 29.7-37MHz. Advanced Conventional Stat-Alert * For PM1200 "C" in Position 4 represents Enhanced Privacy Plus 37-50MHz.
  • Page 21: Pm1200 Low Band (A) 29.7-37Mhz 120 Watt Model Chart

    Model Numbering, Charts, and Specifications PM1200 Low Band (A) 29.7–37MHz 120 Watt Model Chart Model Description AAM32BMD9PW5AN PM1200 29.7–37 MHZ 120W 250CH Item Description HKUB4000_ Standard Tanapa 29.7–37 MHz 120 Watt HKLN4331_ PM1200 Control Head HKLN4334_ Remote Control Head Trunnion Kit HKLN4335_ Main Unit Brd Kit 29.7–37 MHz 120W...
  • Page 22: Pm1200 Low Band (B) 37-50Mhz 120 Watt Model Chart

    Model Numbering, Charts, and Specifications PM1200 Low Band (B) 37–50MHz 120 Watt Model Chart Model Description AAM32CMD9PW5AN PM1200 37–50MHZ 120W 250CH Item Description HKUB4001_ Standard Tanapa 37– 50 MHz 120 Watt HKLN4331_ PM1200 Control Head HKLN4334_ Remote Control Head Trunnion Kit HKLN4336_ Main Unit Brd Kit 37–50 MHz 120W...
  • Page 23: Pm1200 Low-Band (A) 29.7-37Mhz Radio Specifications

    Model Numbering, Charts, and Specifications PM1200 Low-Band (A) 29.7–37MHz Radio Specifications GENERAL RECEIVER TRANSMITTER FCC Designations: AZ492FT1629 Frequency Range: Frequency Range: Low Band A: 29.7–37 MHz Low Band A: 29.7–37 MHz Temperature Range: Operating: -30°C to +60°C Channel Spacing: 20 kHz...
  • Page 24: Pm1200 Low Band (B) 37-50Mhz Radio Specifications

    Model Numbering, Charts, and Specifications PM1200 Low Band (B) 37–50MHz Radio Specifications GENERAL RECEIVER TRANSMITTER FCC Designations: AZ492FT1630 Frequency Range: Frequency Range: Low Band B: 37–50 MHz Low Band A: 37–50 MHz Temperature Range: Operating: -30°C to +60°C Channel Spacing:...
  • Page 25: Chapter 1 Introduction

    – – The PM1200 radio is among the most sophisticated two-way radios available. They have a new robust design for radio users who need high performance, quality, and reliability in their daily communications. This new architecture provides the capability of supporting a multitude of legacy...
  • Page 26: Pm1200 Control Head Descriptions

    Introduction: PM1200 Control Head Descriptions PM1200 Control Head Descriptions The control head used with the PM1200 radio has microprocessor circuitry that operates the standard and optional features built into the system. The following illustration shows a typical PM1200 control head.
  • Page 27: Chapter 2 Basic Maintenance

    Chapter 2 Basic Maintenance Introduction This section of the manual describes preventive maintenance, handling precautions, and some basic repair procedures and techniques. Each of these topics provides information vital to the successful operation and maintenance of your radio. Preventive Maintenance Radios are shipped from the factory with a worst-case frequency error of: •...
  • Page 28: Cleaning External Plastic Surfaces

    Basic Maintenance: Handling Precautions 2.2.2.1 Cleaning External Plastic Surfaces The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. A soft, absorbent, lint-free cloth or tissue should be used to remove the solution and dry the radio.
  • Page 29 • Make skin contact with a conductive work surface first and maintain this contact when the device is set down or picked up. • Always wear a conductive wrist strap when servicing this equipment. The Motorola part number for a replacement wrist strap that connects to the table mat is 4280385A59.
  • Page 30 Basic Maintenance: Handling Precautions Notes October 26, 2007 6880309U09-A...
  • Page 31: Chapter 3 Basic Theory Of Operation

    Chapter 3 Basic Theory of Operation Introduction The PM1200 radio combines the controller and RF sections into a single board and contains the following modules: • Daughtercard • RX VCO module • TX VCO module It is important to correctly identify the malfunctioning region before replacing expensive modules. To assist with radio repair, descriptions of the sections contained on the PM1200 uniboard are listed below.
  • Page 32: Controller Section

    3.3.1 Introduction The PM1200 transceiver is primarily a dwi-board design, RF sections and power amplifier sections. The controller section will be discussed here in basic terms, to assist in the overall understanding of what is contained in the controller section, and a simplified purpose of its elemental parts. Some limited warnings and recommendations are offered to prevent common repair-induced damage.
  • Page 33: Control Head Assembly

    The Volume Selector Knob allows a linear step of the volume and the Power Button integrates the On/Off function. 3.4.3.3 Telco Connector PM1200 currently supports programming through the Telco Connector as well as operation of the basic palm microphone and keypad microphone. 3.4.3.4 Emergency Microphone The applications processor operates the emergency microphone if the emergency feature is activated.
  • Page 34: Analog Mode Of Operation

    Basic Theory of Operation: Analog Mode of Operation Analog Mode of Operation 3.5.1 General Reception and transmission are switched by “RX” and “TX” lines from the microprocessor unit (MPU). The receiver uses a double-conversion superheterodyne circuitry, with a 17.7 MHz 1st IF and 450 kHz 2nd IF.
  • Page 35: Transmit Operation

    Basic Theory of Operation: Radio-Frequency Power Amplifier (RF PA) and Output Network (ON) 3.5.3 Transmit Operation Transmitter Voice audio from the microphone is delivered via the Mic (Jack) Unit to the MAIN Unit, after passing through amplifier Q3039/Q2108 (NJM2902V), pre-emphasis, limiter (IDC instantaneous deviation control), and LPF Q2001 (NJM2902V);...
  • Page 36: Gain Stages

    Basic Theory of Operation: Radio-Frequency Power Amplifier (RF PA) and Output Network (ON) 3.6.1 Gain Stages The controlled stage consists of a two-stage, integrated amplifier with external matching, which amplifies the input signal from the VCO buffer and provides drive to the PA-UNIT driver stage. The next driver stage, Q6004 and Q6005 has a fixed gate bias similar to Q6001.
  • Page 37: Pll Synthesizer

    Basic Theory of Operation: PLL Synthesizer PLL Synthesizer The 1st LO maintains stability from the PLL synthesizer by using a 17.25 MHz reference signal from crystal X1001. PLL synthesizer IC Q1029 (SA7025DK) consists of a prescaler, a reference counter, a swallow counter, a programmable counter, a serial data input port to set these counters based on the external data, a phase comparator, and a charge pump.
  • Page 38 Basic Theory of Operation: PLL Synthesizer Notes October 26, 2007 6880309U09-A...
  • Page 39: Chapter 4 Test Equipment, Service Aids, And Tools

    The Characteristics column is included so that equivalent equipment can be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended.
  • Page 40: Service Aids And Recommended Tools

    Refer to the tables in this section for a listing and description of the service aids and tools designed specifically for servicing this family of radios, as well as the more common tools required to disassemble and properly maintain the radio. These kits and/or parts are available from the Motorola parts division offices listed in Appendix A.
  • Page 41: Field Programming Equipment

    The PM1200 radios use a flash-memory device to store information about frequencies, squelch codes, signaling codes, time-out timer durations, and other parameters. The PM1200 radios can be programmed in the field any number of times without removing the flash memory from the radio.
  • Page 42 Test Equipment, Service Aids, and Tools: Field Programming Equipment Notes October 26, 2007 6880309U09-A...
  • Page 43: Chapter 5 Radio Alignment And Programming Procedures

    Procedures Introduction of Radio Alignment Procedures The PM1200 has been carefully aligned at the factory for the specified performance across the frequency range specified for each version. Realignment should therefore not be necessary except in the event of a component failure, or alteration of version.
  • Page 44: Required Test Equipment

    Radio Alignment and Programming Procedures: Required Test Equipment Required Test Equipment RF signal generator: calibrated output level at 100 MHz (0 dBμ =1.0 μV - terminated circuit) • Signal Generator (HP 8657A) • Modulation Analyzer (HP 8901B) • Audio Analyzer (8903B) •...
  • Page 45: Alignment

    Radio Alignment and Programming Procedures: Alignment Because of the bridge audio amplifier circuit used in the radio, it is necessary to construct and use a simple audio load test adapter as shown in the schematic diagram above, when conducting receiver alignment steps.
  • Page 46: Pll Reference Frequency

    Radio Alignment and Programming Procedures: Alignment 5.4.3 PLL Reference Frequency With the wattmeter, dummy load and frequency counter connected to the antenna jack, and select band center frequency channel, key the transmitter and adjust TC1001 on the Main Unit, if necessary, so the counter frequency is within ±100 Hz of the channel center frequency for the transceiver version.
  • Page 47: Squelch Threshold

    Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 5.4.6.1 Squelch Threshold 1. Select band center frequency channel, and the RF signal generator turned to the same frequency, set the generator for ± 3.0 kHz deviation with 1 kHz tone modulation, and set the output level for -8 dBμ...
  • Page 48: Rx Tune Alignment

    Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 5. Left-click the Auto ADJ mode button. The "Power On Start" screen appears. Figure 5-3. Power On Start Screen 6. Within 20 seconds after clicking the Auto ADJ mode button, press the Power button to turn the radio on.
  • Page 49: Sql Alignment

    Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 6. Repeat the same procedure to fine tune the Rx Tune Alignment on each operating frequency programmed for the radio, using the Frequency offset slide bars associated with the various channels.
  • Page 50: Sql Tight Alignment

    Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 8. Left-click Reflect to record the Squelch Threshold data. Figure 5-6. SQL Alignment Screen 5.5.4.2 SQL Tight Alignment 1. Left-click SQL Tight to align the Squelch Tight Level. 2. Toggle the Programmable SQL Function Button and rotate the Channel Knob to SQL 12.
  • Page 51: Tx Power Alignment

    Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 5.5.5 TX Power Alignment 1. Left-click the Tx Power tab to align the Transmitter Power Output. 2. Left-click the Hi Power, then left-click PTT On to trigger the radio to transmit.
  • Page 52: Tpl Deviation

    5-10 Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 5. Repeat the same procedure to fine adjust the Maximum Deviation [±4.1 kHz (±0.1 kHz)] for each operating frequency, using the Frequency offset slide bars associated with the various channels.
  • Page 53: Writing The Alignment Data To The Radio

    Radio Alignment and Programming Procedures: PM1200 Radio Alignment Software 5-11 5.5.7 Writing The Alignment Data to the Radio 1. Left-click Radio Apply to write the alignment data into the radio. The Radio Alignment Software writing progress bar is shown in Figure 5-9.
  • Page 54: Introduction Of Programming Procedures

    5-12 Radio Alignment and Programming Procedures: Introduction of Programming Procedures Introduction of Programming Procedures This section provides an overview of the Customer Programming Software (CPS) designed for use in Windows 2000/XP environment. Refer to the the CPS Installation Guide for the installation and programming procedures of the software.
  • Page 55: Chapter 6 Disassembly/Reassembly Procedures

    Introduction This section details the procedures necessary to remove and replace the printed circuit board in the PM1200 radio. After troubleshooting and determining what needs to be replaced, disconnect the test equipment, the antenna cable, and the power cable. Disconnect the power cable from the radio before opening and removing the PCB.
  • Page 56: Control Head Boards Disassembly/Reassembly

    Figure 9-1. “PM1200 Control Head Exploded View” on page 9-2. 6.2.2.1.1 PM1200 Control Head Back Housing Disassembly 1. Turn off the radio. 2. Lay the control head face down on a clean, flat surface and be careful not to scratch or mar the display.
  • Page 57: Figure 6-2. Removing Remote Radio Control Cable From Back Housing

    Disassembly/Reassembly Procedures: Replacement Procedures NOTE: Be careful not to damage the mating connector while unplugging the remote control cable. Remote Radio Control Cable Figure 6-2. Removing Remote Radio Control Cable from Back Housing 6. After unplugging the remote radio control cable connector, use a CR-V PH2 screwdriver to remove the 4 binding head screws M4x8 SUS B [34] with the 4 o-rings [33] from the back housing assembly [29].
  • Page 58: Pm1200 Control Head Panel-Interface Unit Board Kit Disassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 6.2.2.1.2 PM1200 Control Head Panel-Interface Unit Board Kit Disassembly 1. Carefully separate the foam [27] from the speakerphone jack at the panel-interface unit board kit [25]. 2. Using a CR-V PH2 screwdriver, remove the 2 binding head screws M3x8 SUS B [8] from the front housing assembly [10].
  • Page 59: Pm1200 Control Head Display Unit Board Kit Disassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 6.2.2.1.3 PM1200 Control Head Display Unit Board Kit Disassembly 1. Carefully separate the rubber packing [11] from the front housing assembly [10]. 2. Carefully separate the speaker mating connector from the display unit board kit [22] as shown Figure 6-5.
  • Page 60: Pm1200 Control Head Key Unit Board Kit Disassembly

    NOTE: Be careful not to damage the mating connector on the key unit board kit [16] while lifting the control head board. 6.2.2.1.5 PM1200 Control Head Key Unit Board Kit Disassembly 1. Lay the rear side of the front housing assembly [10] facing upward.
  • Page 61: Pm1200 Control Head Reassembly

    Figure 6-9. Removing the Speaker Fittings from Internal Speaker Bosses 6.2.2.2 PM1200 Control Head Reassembly 6.2.2.2.1 PM1200 Control Head Key Unit Board Kit Reassembly 1. To reassemble, ensure that the functional keypad [12] is fully seated into the front housing.
  • Page 62: Pm1200 Internal Speaker Reassembly

    6-12. Figure 6-12. Installing Volume Knob and Channel Selector Knob 6.2.2.2.3 PM1200 Internal Speaker Reassembly 1. Lay the rear side of the front housing assembly [10] facing upward. 2. Insert the internal speaker to the front housing assembly as shown in Figure 6-13.
  • Page 63: Pm1200 Control Head Display Unit Board Kit Reassembly

    6-14. Figure 6-14. Installing the Internal Speaker Screws 6.2.2.2.4 PM1200 Control Head Display Unit Board Kit Reassembly 1. Lay the rear side of the front housing assembly [10] facing upward. 2. Insert the channel group knob [4] and power knob [13] to the front housing assembly [10].
  • Page 64: Pm1200 Control Head Panel-Interface Unit Board Kit Reassembly

    Figure 6-17. Connecting Speaker Mating Connector. 7. Carefully seal the front housing assembly [10] with the rubber packing [11]. 6.2.2.2.5 PM1200 Control Head Panel-Interface Unit Board Kit Reassembly 1. Carefully connect the connection cable to the mating connector on the rear of display unit...
  • Page 65: Pm1200 Control Head Back Housing Reassembly

    8. Carefully insert the foam [27] to the speakerphone jack at the panel-interface unit board kit [25]. 6.2.2.2.6 PM1200 Control Head Back Housing Reassembly 1. Carefully join the back housing assembly [29] to the front housing assembly [10]. 6880309U09-A...
  • Page 66: Figure 6-19. Back Housing Screw Sequence

    6-12 Disassembly/Reassembly Procedures: Replacement Procedures 2. Using a CR-V PH2 torque driver to fasten the 4 binding head screws M4x8 SUS B [34] and the 4 o-rings [33] to the back housing assembly [29] following the sequence following the sequence as shown in Figure 6-19.
  • Page 67: Figure 6-21. Installing Remote Radio Control Cable To Back Housing

    Disassembly/Reassembly Procedures: Replacement Procedures 6-13 NOTE: Be careful not to damage the mating connector while plugging in the remote radio control cable. Remote Radio Control Cable Figure 6-21. Installing Remote Radio Control Cable to Back Housing 6. Neatly bundle the exposed cable wiring, and then install the cable strain relief plate [32] and gasket [31] into the place.
  • Page 68: Radio Disassembly/Reassembly

    Begin with the chassis. Thoroughly inspect the chassis gasketing for damage and verify all chassis thermal compound are in place. 6.2.3.1 Transceiver Front Panel Disassembly/Reassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 9-2. “PM1200 Radio Exploded View” on page 9-3. 6.2.3.1.1 Transceiver Front Panel Disassembly 1.
  • Page 69: Figure 6-25. Removing Screws From Top Cover

    Disassembly/Reassembly Procedures: Replacement Procedures 6-15 5. Using a CR-V PH2 screwdriver, remove 7 binding head screws M3x6 SUS B [23] from the top cover [24] as shown in Figure 6-25. Save them for later use. Figure 6-25. Removing Screws from Top Cover 6.
  • Page 70: Transceiver Front Panel Reassembly

    6-16 Disassembly/Reassembly Procedures: Replacement Procedures 12. Carefully disconnect the connection cable from the RF-Interface unit board kit [7] as shown in Figure 6-27. Figure 6-27. Removing Connection Cable 13. Carefully separate the front panel [4] and rubber packing [5] from the radio. 6.2.3.1.2 Transceiver Front Panel Reassembly 1.
  • Page 71: Figure 6-29. Installing Front Panel Screws

    Disassembly/Reassembly Procedures: Replacement Procedures 6-17 4. Using a CR-V PH2 torque driver, fasten the 2 binding head screws M3x6 SUS [6] to the front panel [4] as shown in Figure 6-29. (Torqued to 3.5–4.6 kgf*cm/ 3–4 in. lbs). Figure 6-29. Installing Front Panel Screws 5.
  • Page 72: Figure 6-31. Sequence For Installing Top Cover Screws

    6-18 Disassembly/Reassembly Procedures: Replacement Procedures 9. Using a CR-V PH2 torque driver, fasten the 7 binding head screws, M3x6 SUS B [23] to the top cover [24] following the sequence as shown in Figure 6-31. (Torqued to 5.8–6.9 kgf*cm/ 5–6 in. lbs). Figure 6-31.
  • Page 73: Rf-Interface Board Kit Disassembly/Reassembly

    5.8–6.9kgf*cm/ 5–6 in. lbs). Figure 6-33. Sequence for Installing Cable Relief Plate Screws 6.2.3.2 RF-Interface Board Kit Disassembly/Reassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 9-2. “PM1200 Radio Exploded View” on page 9-3. 6.2.3.2.1 RF-Interface Board Kit Disassembly 1.
  • Page 74: Rf-Interface Board Kit Reassembly

    3. After installing the RF-Interface board kit, reassemble the front panel by following the steps outlined in 6.2.3.1.2: “Transceiver Front Panel Reassembly” on page 6-16. 6.2.3.3 Main-Unit Board Kit Disassembly/Reassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 9-2. “PM1200 Radio Exploded View” on page 9-3. 6.2.3.3.1 Main-Unit Board Kit Disassembly IMPORTANT: See “Option Board Disassembly/Reassembly”...
  • Page 75: Figure 6-36. Removing Screws From Main-Unit Board Kit

    Disassembly/Reassembly Procedures: Replacement Procedures 6-21 3. Using a CR-V PH2 screwdriver, remove the 2 SEMS screws, HSM3x6 NI [17] from the main-unit board kit [13] as shown in Figure 6-36. Figure 6-36. Removing Screws from Main-Unit Board Kit 4. Carefully separate the two power wire assembly wires [37] from the original location. 5.
  • Page 76: Figure 6-38. Removing Mating Connection From Main-Unit Board Kit

    6-22 Disassembly/Reassembly Procedures: Replacement Procedures 6. Unplug the mating connector [C] of the wire assembly [27] from the main-unit board kit [13] as shown in Figure 6-38. Mating Connector [C] Figure 6-38. Removing Mating Connection from Main-Unit Board Kit 7. Separate the holder [15] from the chassis [11] as shown in Figure 6-39.
  • Page 77: Figure 6-40. Desolder Tx And Rx Wires

    Disassembly/Reassembly Procedures: Replacement Procedures 6-23 8. Carefully desolder the brown 2-wire assemby [16] (Tx and Rx wires) as shown in Figure 6-40. RX WIRE INSULATED WIRE GROUND WIRE TX WIRE TP1 002 (RX) TP1 005 TP1 004 (GND) TP1 003 (GND) (TX) Figure 6-40.
  • Page 78: Main-Unit Board Kit Reassembly

    6-24 Disassembly/Reassembly Procedures: Replacement Procedures 10. Separate the main-unit board kit [13] by holding the metal cover as shown in Figure 6-42 lifting up the back of the PCB. Figure 6-42. Removing the Main-Unit Board Kit 11. Slide the main board towards the back of the chassis [11] and carefully lift it out of the chassis.
  • Page 79: Figure 6-44. Position Of Electronic Component - Q2018

    Disassembly/Reassembly Procedures: Replacement Procedures 6-25 4. Before reassembling the PCB to the chassis [11], put some thermal compound to the back of the electronic component (Q2018) as shown in Figure 6-44. NOTE:Refer section 6.3: Chassis Thermal Compound Replacement Procedure on page 6-47.
  • Page 80: Figure 6-46. Sequence For Installing Main-Unit Board Kit Screws

    6-26 Disassembly/Reassembly Procedures: Replacement Procedures 6. Using a CR-V PH2 torque driver, fasten the 6 taptite screws, M3x8 NI [14] following the sequence as shown in Figure 6-46. (Torqued to 9.8–10.9 kgf*cm/ 8.5–9.5 in. lbs) Figure 6-46. Sequence for Installing Main-Unit Board Kit Screws 7.
  • Page 81: Figure 6-48. Inserting Holder To Fix The Electronic Component

    Disassembly/Reassembly Procedures: Replacement Procedures 6-27 8. Insert and press the holder [15] to fix the electronic component (Q2018). Figure 6-48. Inserting Holder to Fix the Electronic Component 9. Connect the mating connector [A] of wire assembly 160mm 20P26P [26] and the mating connector [C] of wire assembly [27] to the main-unit board kit [13] as shown in Figure 6-49.
  • Page 82: Pa-Unit Board Kit Disassembly/Reassembly

    6.2.3.1.2: “Transceiver Front Panel Reassembly” on page 6-16. 6.2.3.4 PA-Unit Board Kit Disassembly/Reassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 9-2. “PM1200 Radio Exploded View” on page 9-3. 6.2.3.4.1 PA-Unit Board Kit Disassembly 1. Ensure all accessory connections, power, antenna, and microphone are unplugged.
  • Page 83: Figure 6-52. Lifting The Top Cover

    Disassembly/Reassembly Procedures: Replacement Procedures 6-29 3. Carefully remove the top cover [24] by lifting both side edges. It may be necessary to gently pry the cover off using a plastic tool Figure 6-52. Plastic Tool Figure 6-52. Lifting the Top Cover 4.
  • Page 84: Figure 6-54. Removing Power Wire Assembly From The Chassis

    6-30 Disassembly/Reassembly Procedures: Replacement Procedures 5. Carefully remove the power wire assembly [37] by using a pair of long nose pliers to push the power wire assembly connector inward as shown in Figure 6-54. Power Wire Assembly Figure 6-54. Removing Power Wire Assembly from the Chassis 6.
  • Page 85: Figure 6-57. Desoldering Antenna Connector And Earth Plate From Pa-Unit Board Kit

    Disassembly/Reassembly Procedures: Replacement Procedures 6-31 8. Carefully desolder the antenna connector [32] and earth plate [33] from the PA-unit board kit [20] and remove them from the chassis [11] as shown in Figure 6-56. Earth Plate Antenna Connector Figure 6-57. Desoldering Antenna Connector and Earth Plate from PA-Unit Board Kit 9.
  • Page 86: Figure 6-59. Removing 5 Sems Screws From Pa-Unit Board Kit

    6-32 Disassembly/Reassembly Procedures: Replacement Procedures 10. Using a CR-V PH2 screwdriver, remove the 5 SEMS screws, ASM3x8 NI [22] from the PA-unit board kit [20] as shown in Figure 6-59. Figure 6-59. Removing 5 SEMS Screws from PA-Unit Board Kit. 11.
  • Page 87: Figure 6-61. Removing Taptite Screws From Pa-Unit Board Kit

    Disassembly/Reassembly Procedures: Replacement Procedures 6-33 12. Using a CR-V PH2 screwdriver, remove another 6 taptite screws M3x8 NI [14] from the PA-unit board kit [20] as shown in Figure 6-61. Figure 6-61. Removing Taptite Screws from PA-Unit Board Kit. 13. Remove the PA-Unit board kit [20] by holding the edges of the PCB and lift it out of the chassis.
  • Page 88: Pa-Unit Board Kit Reassembly

    6-34 Disassembly/Reassembly Procedures: Replacement Procedures 6.2.3.4.2 PA-Unit Board Kit Reassembly 1. Use a soft cloth to remove any remaining residue. Put the thermal compound to the chassis as shown in Figure 6-62. NOTE: Refer 6.3: “Chassis Thermal Compound Replacement Procedure” on page 6-47.
  • Page 89: Figure 6-64. Connecting Power Wire Assembly To Main-Unit Board Kit

    Disassembly/Reassembly Procedures: Replacement Procedures 6-35 Do not over torque the screws. It may damage the semiconductors and transistors C a u t i o n Figure 6-64. Connecting Power Wire Assembly to Main-Unit Board Kit 5. Using a CR-V PH2 torque driver, fasten the 4 SEMS screws, SM3x8 NI [21] following the sequence as shown in Figure 6-65.
  • Page 90: Figure 6-66. Sequence For Installing Taptite Screws On Pa-Unit Board Kit

    6-36 Disassembly/Reassembly Procedures: Replacement Procedures 6. Using a CR-V PH2 torque driver, fasten 6 taptite screws M3x8 NI [14] follow the sequence as shown in Figure 6-66. (Torqued to 9.8–10.9 kgf*cm/ 8.5–9.5 in. lbs). Figure 6-66. Sequence for Installing Taptite Screws on PA-Unit Board Kit 7.
  • Page 91: Figure 6-68. Sequence For Installing Binding Head Screws On Pa-Unit Board Kit

    Disassembly/Reassembly Procedures: Replacement Procedures 6-37 8. Using a CR-V PH2 torque driver, fasten the 2 binding head screws, M3x6 SUS [6] to the assemble earth plate [33] and the antenna connector [32] to the chassis [11] as shown in Figure 6-68.
  • Page 92: Figure 6-70. Connecting Mating Connector To Pa-Unit Board Kit

    6-38 Disassembly/Reassembly Procedures: Replacement Procedures 10. Connect the mating connector [D] of wire assembly [27] to the PA-unit board kit [20] as shown Figure 6-70. Mating Connector [D] Figure 6-70. Connecting Mating Connector to PA-Unit Board Kit. 11. Push the power wire assembly [37] from within the chassis through the provided opening. Figure 6-71.
  • Page 93: Figure 6-72. Connecting Power Wire Assembly To Pa-Unit Board Kit

    Disassembly/Reassembly Procedures: Replacement Procedures 6-39 12. Place the power wire assembly [37] to the terminal by using a CR-V PH2 torque driver and fasten the taptite screw, M3x8 NI [14] to the PA-unit board kit [20]. (Torqued to 9.8–10.9 kgf*cm/ 8.5–9.5 in. lbs). Figure 6-72.
  • Page 94: Connector-Unit Board Kit Disassembly/Reassembly

    5–6 in. lbs). Figure 6-74. Sequence for Installing Top Cover Screws 6.2.3.5 Connector-Unit Board Kit Disassembly/Reassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 9-2. “PM1200 Radio Exploded View” on page 9-3. 6.2.3.5.1 Connector-Unit Board Kit Disassembly 1. Before disassembling the FR-Interface board kit, perform a complete PA-Unit Board Kit disassembly by following the steps outlined in 6.2.3.4.1: “PA-Unit Board Kit Disassembly”...
  • Page 95: Figure 6-75. Removing Lock Plate

    Disassembly/Reassembly Procedures: Replacement Procedures 6-41 2. After completing the PA-Unit Board Kit disassemble procedure, remove the lock plate [28] from the connector assembly [30] by using a pair of long nose pliers as shown in Figure 6-75. Figure 6-75. Removing Lock Plate 3.
  • Page 96: Connector-Unit Board Kit Reassembly

    6-42 Disassembly/Reassembly Procedures: Replacement Procedures 5. Separate the connector-unit board kit [29] from the chassis [11]. 6. Separate the mating connector [B] of the wire assembly 160mm 20P26P [26] from the connector-unit board kit [29] as shown in Figure 6-78. Figure 6-78.
  • Page 97: Figure 6-80. Sequence For Installing Connector-Unit Board Kit Screws

    Disassembly/Reassembly Procedures: Replacement Procedures 6-43 3. Using a CR-V PH2 torque driver, fasten the 2 taptite screws, M3x8 NI [14] to the connector-unit board kit [29] as shown in Figure 6-80 (Torqued to 9.8–10.9 kgf*cm/ 8.5–9.5 in. lbs). Figure 6-80. Sequence for Installing Connector-Unit Board Kit Screws 4.
  • Page 98: Option Board Disassembly/Reassembly

    6-34. 6.2.3.6 Option Board Disassembly/Reassembly NOTE:The two types of option boards available are: the PM1200 Quik Call II Decoder Option Board (HKLN4346_) and the PM1200 Digital ANI Encoder Option Board (HKLN4347_). These option boards need to be installed together with an Interface Board (HKLN4345_).
  • Page 99: Option Board Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 6-45 4. Separate the Interface Board and Option Board (Digital ANI Encoder Option Board/ Quik-Call II Decoder Option Board) from the main-unit board kit Figure 6-85. OPTION BOARD Figure 6-85. Removing Interface Board and sOption Board 5.
  • Page 100: Figure 6-87. Installing Interface Board To Chassis

    6-46 Disassembly/Reassembly Procedures: Replacement Procedures 4. Attach the Interface Board onto the Main Unit PCB. Then, using a CR-V PH2 torque driver, fasten the provided taptite screw M2.6X6 to the chassis as shown in Figure 6-87 (Torqued to 3.5–4.6 kgf*cm/ 3–4 in. lbs). Interface Board Figure 6-87.
  • Page 101: Chassis Thermal Compound Replacement Procedure

    Disassembly/Reassembly Procedures: Chassis Thermal Compound Replacement Procedure 6-47 7. Place the top cover on the chassis and seat it properly. Compress the cover and chassis together to squeeze the foam into place and make torquing the screws easier. 8. Using a CR-V PH2 torque driver, fasten the 7 binding head screws, M3x6 SUS B to the top cover following the sequence as shown in Figure 6-90 (Torqued to 5.8–6.9 kgf*cm/...
  • Page 102: Fastener Torque Chart

    6-48 Disassembly/Reassembly Procedures: Fastener Torque Chart Table 6-2. Chassis Thermal Pad Parts Item No. Part No. Description 1110022D23 Silicone Thermal Compound 1. Use a soft cloth to remove any remaining residue. Alcohol may also be used, if necessary. 2. The thermal compound is applied to both the chassis surface and the PCB surface. 3.
  • Page 103 Disassembly/Reassembly Procedures: Fastener Torque Chart 6-49 Table 6-3. Fastener Torque Chart (Continued) Repair Repair Part Number Description Torque Torque Where Used (kgf*cm) (in.lbs.) – – 0308800H44 Screw, Binding Head Top Cover screw M3x6 SUS B with Nylok 6880309U09-A October 26, 2007...
  • Page 104 6-50 Disassembly/Reassembly Procedures: Fastener Torque Chart Notes October 26, 2007 6880309U09-A...
  • Page 105: Chapter 7 Basic Troubleshooting

    Chapter 7 Basic Troubleshooting Introduction This chapter contains troubleshooting charts which can help isolate a problem to the board level. Board-level troubleshooting does not attempt to isolate problems to the component level. When performing both transmit and, especially, receive tests, it is still possible that equipment might be damaged by the radio transmitter.
  • Page 106: Replacement Board Procedures

    Basic Troubleshooting: Replacement Board Procedures Replacement Board Procedures Once a problem has been isolated to a specific board, use one of the following recommended repair procedures: • Install a good board from your inventory into the radio. • Order a replacement board from Radio Products Services Division. Refer to “Appendix A Replacement Parts Ordering”...
  • Page 107: Receiver Troubleshooting

    Basic Troubleshooting: Receiver Troubleshooting Receiver Troubleshooting Table 7-2 can help troubleshoot problems that might occur in the receiver section of your radio. Table 7-2. Receiver Troubleshooting Chart Correction or Test (Measurements Taken at Symptom Possible Cause Room Temperature) Radio does not Blown power fuse Check the fuse in the DC cable.
  • Page 108 Basic Troubleshooting: Receiver Troubleshooting Notes October 26, 2007 6880309U09-A...
  • Page 109: Chapter 8 Functional Block Diagrams And Connectors

    Chapter 8 Functional Block Diagrams and Connectors This chapter contains the PM1200 digital mobile radio functional block diagrams and connector locations. Table 8-1. Table of Functional Block Diagrams and Connectors Page Figure Name Figure 8-1. PM1200 Functional Block Diagram Figure 8-2. PM1200 Functional Block Diagram 2 Figure 8-3.
  • Page 110: Pm1200 Functional Block Diagram 1

    Functional Block Diagrams and Connectors: PM1200 Functional Block Diagram 1 PM1200 Functional Block Diagram 1 IF SW PA-UNIT MAIN-UNIT IF1:17.7MHz Q1031 Q1032 2SK508 1SV262 (x4) 1SV262 (x4) Q1040 Q6801 3SK131 D1008 D1002 (RX) SPM5001 D1009 Q6802 MC1350D D1003 RF AMP...
  • Page 111: Pm1200Functional Block Diagram 2

    Q3039 Q3008 NJM2068V RT1N241M NJM2068V 13.4S PANEL-INTERFACE-UNIT MIC 9V REG GAIN CNTL LEVEL DET Q3045 D3005 Q3038 2SB1132Q IMX1 15S226 Q3046 MM1216EN SP0001 RX AF TX AF CNTL OTHERS Figure 8-2. PM1200 Functional Block Diagram 2 6880309U09-A October 26, 2007...
  • Page 112: Pm1200 Functional Block Diagram 3

    Functional Block Diagrams and Connectors: PM1200 Functional Block Diagram 3 PM1200 Functional Block Diagram 3 PANEL-INTERFACE-UNIT RF-INTERFACE-UNIT MIC AUD Q4002 Q4007 1/4 MIC_AUD (J4001) 2SJ125D NJM2902V FR_PTT MIC AUD (J4001) (J5001) Q4009 IMD3 SW CNTL MIC_AUD MIC AUD Q4003 Q4007 1/4...
  • Page 113: Pm1200 Connection Diagram

    Functional Block Diagrams and Connectors: PM1200 Connection Diagram PM1200 Connection Diagram PA-UNIT P7004 J1002 J6001 (T9206976) P0090646 P0090646 KEY-UNIT J7001 (120W) J4003 TP6002 P1091329 J3401 P0090409 IN/OUT P1091014 J3001 TX/RX TX/RX P0091300 J4006 (T9206923) REF POWER REF POWER SQLB JP1001...
  • Page 114: Transmitter Block Diagram

    Functional Block Diagrams and Connectors: Transmitter Block Diagram Transmitter Block Diagram To Reciver Hamonics POWER DETECT Filter ANT-SW TXVB L6009, L6010, L6011, C6042 D6006, D6007 Q2026 C6043, C6044, C6045 RL6001 L6007 Q1008,Q1010 C6047,C6074,C6075 PIN 26 Matching Network T6004 PRE DRIVE DRIVE AMP FINAL AMP Q6004,Q6005...
  • Page 115: Synthesizer Block Diagram

    Functional Block Diagrams and Connectors: Synthesizer Block Diagram Synthesizer Block Diagram Pin 5 LOOP FILTER Q2026 C732,C733, Pin 14 RX VCO PLL IC C734,C735, Pin 1 Out put Q1029 Q1015 R716,R717 Pin 2 Pin 16 Pin 3 Q1029 Pin 8 RX SW TX VCO Q1022...
  • Page 116: Transmit Audio Block Diagram

    Functional Block Diagrams and Connectors: Transmit Audio Block Diagram Transmit Audio Block Diagram MUTE- Q2026 DTMF TONE Pin 3 TONE-GEN by CPU(Q2026) Q2008 MOD. ADJ AF-AMP AF-AMP MIC MUTE MOD. Q2019 Q2001 300Hz 3KHz Q3039 Q2108 Q2017 Q2001 Q5012 5 Order LPF Q4007 Q3008 MUTE-...
  • Page 117: Radio Connector Locations

    Functional Block Diagrams and Connectors: Radio Connector Locations Radio Connector Locations Figure 8-8. Remote-Mount Radio Connector Locations 6880309U09-A October 26, 2007...
  • Page 118: Figure 8-9. Pa Unit Board Connector Location

    8-10 Functional Block Diagrams and Connectors: Radio Connector Locations (cont.) Radio Connector Locations (cont.) Figure 8-9. PA Unit Board Connector Location October 26, 2007 6880309U09-A...
  • Page 119: Chapter 9 Exploded Views And Parts Lists

    Chapter 9 Exploded Views and Parts Lists This chapter contains the exploded views and associated parts lists for the PM1200 digital mobile radio and accessories. Tables containing pushbutton parts lists are also included at the end of this chapter. Table 9-1. Table of Exploded Views...
  • Page 120: Pm1200 Control Head Exploded View

    Exploded Views and Parts Lists: PM1200 Control Head Exploded View PM1200 Control Head Exploded View Table 9-2. PM1200 Control Head Parts List Item No. Motorola Part No. Description 3608800H07 Volume Knob 3608800H08 Channel Selector Knob Keycap (Group) 34 x 4...
  • Page 121: Pm1200 Radio Exploded View

    Exploded Views and Parts Lists: PM1200 Radio Exploded View PM1200 Radio Exploded View Table 9-3. PM1200 Radio Parts List Item No. Motorola Part No. Description 0308800H24 Screw, Binding Head Screw M4x8 Sus B 6408800H09 Cable Strain Relief Plate 3208800H10 Gasket...
  • Page 122 Exploded Views and Parts Lists: PM1200 Radio Exploded View Notes October 26, 2007 6880309U09-A...
  • Page 123: Appendix A Replacement Parts Ordering

    Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model number in which the part is used. Motorola Online Motorola Online users can access our online catalog at http://www.motorola.com/businessonline To register for online access, please call 1-800-422-4219 (for U.S. and Canada Service Centers only).
  • Page 124: Parts Identification

    Replacement Parts Ordering: Parts Identification Parts Identification Radio Products and Solutions Organization* (United States and Canada) 1-800-422-4210 Product Customer Service Radio Products and Solutions Organization (United States and Canada) 1-800-927-2744 * The Radio Products and Solutions Organization (RPSO) was formerly known as the Radio Products Services Division (RPSD) and/or the Accessories and Aftermarket Division (AAD).
  • Page 125: Appendix B Motorola Service Centers

    If a unit requires further complete testing, knowledge and/or details of component level troubleshooting or service than is customarily performed at the basic level, please send the radio to a Motorola Service Center as listed below. Motorola Service Center 45D Butterfield Trail...
  • Page 126 Motorola Service Centers: Motorola Federal Technical Center Notes October 26, 2007 6816532H01-A...
  • Page 127: Glossary

    Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and some terms are merely generic in nature. Term Definition See analog-to-digital conversion.
  • Page 128 Glossary-2 Term Definition Data communication Definition for device (such as radio) data communications using the equipment RS232 protocol. The correct data communication wiring requires the device’s TX pins (output) to connect to the RX pins (input) and the RTS pins (output) to connect to the CTS pins (input). It is incorrect to attach device pins having the same name to each other.
  • Page 129 FLASHport A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again.
  • Page 130 SPI data line from a peripheral to the MCU. Master Out Slave In SPI data line from the MCU to a peripheral. See microcontroller unit. Motorola Digital Communications. See Megahertz. Megahertz One million cycles per second. Used especially as a radio-frequency unit.
  • Page 131 Glossary-5 Term Definition programming cable A cable that allows the CPS to communicate directly with the radio using RS232. PROM See Programmable Read-Only Memory. See Push-to-Talk. Push-to-Talk The switch or button usually located on the left side of the radio which, when pressed, causes the radio to transmit.
  • Page 132 Glossary-6 Term Definition RPCIC Regulator/power control IC. See real-time clock. Receive. RX DATA Recovered digital data line. See Serial Audio Port. Serial Audio Port SSI to and from the CODEC used to transfer transmit and receive audio data. Serial Peripheral A serial interface comprised of two data lines and a clock line.
  • Page 133 Glossary-7 Term Definition Ultra-High Frequency. See voltage-controlled oscillator. voice encoder The DSP-based system for digitally processing analog signals, and includes the capabilities of performing voice compression algorithms or voice encoding. voltage-controlled An oscillator in which the frequency of oscillation can be varied by oscillator changing a control voltage.
  • Page 134 Glossary-8 Notes October 26, 2007 6880309U09-A...
  • Page 135: Index

    ............1-1 radio care and handling instructions, general ... 2-2 fastener torque values ..........6-48 receiver field programming troubleshooting ............. 7-3 equipment ............. 4-3 replacement parts, ordering ........A-1 functional block diagram, PM1200 ......8-2 replacement, chassis, thermal compound ....6-47...
  • Page 136 ............3-4 controller section ........... 3-2 output network section components ...... 3-5 view, exploded overview ..............3-1 PM1200 (120 W) ........... 9-3 PLL synthesizer ............. 3-7 radio-frequency power amplifier circuit protection ..........3-6 components ............3-5 DC interconnect ..........3-6 warning, caution, and danger notations ....
  • Page 138 Motorola, Inc. 1301, E. Algonquin Rd. Schaumburg, IL 60196-1078, U.S.A. MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. ©2007 Motorola, Inc.