Motorola PM1200 Basic Service Manual Download

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viii

Table of Contents

October 26, 2007

6880309U09-A

6.2.3

Radio Disassembly/Reassembly ................................................................................... 6-14
6.2.3.1 Transceiver Front Panel Disassembly/Reassembly ....................................... 6-14

6.2.3.1.1 Transceiver Front Panel Disassembly............................................ 6-14
6.2.3.1.2 Transceiver Front Panel Reassembly ............................................ 6-16

6.2.3.2 RF-Interface Board Kit Disassembly/Reassembly.......................................... 6-19

6.2.3.2.1 RF-Interface Board Kit Disassembly .............................................. 6-19
6.2.3.2.2 RF-Interface Board Kit Reassembly ............................................... 6-20

6.2.3.3 Main-Unit Board Kit Disassembly/Reassembly .............................................. 6-20

6.2.3.3.1 Main-Unit Board Kit Disassembly ................................................... 6-20
6.2.3.3.2 Main-Unit Board Kit Reassembly.................................................... 6-24

6.2.3.4 PA-Unit Board Kit Disassembly/Reassembly ................................................. 6-28

6.2.3.4.1 PA-Unit Board Kit Disassembly ...................................................... 6-28
6.2.3.4.2 PA-Unit Board Kit Reassembly....................................................... 6-34

6.2.3.5 Connector-Unit Board Kit Disassembly/Reassembly...................................... 6-40

6.2.3.5.1 Connector-Unit Board Kit Disassembly .......................................... 6-40
6.2.3.5.2 Connector-Unit Board Kit Reassembly........................................... 6-42

6.2.3.6 Option Board Disassembly/Reassembly ........................................................ 6-44

6.2.3.6.1 Option Board Disassembly ............................................................. 6-44
6.2.3.6.2 Option Board Reassembly.............................................................. 6-45

6.3

Chassis Thermal Compound Replacement Procedure.............................................................. 6-47

6.4

Fastener Torque Chart............................................................................................................... 6-48

Chapter 7

Basic Troubleshooting ....................................................... 7-1

7.1

Introduction .................................................................................................................................. 7-1

7.2

Accessory Connectors ................................................................................................................. 7-1
7.2.1

20-Pin Accessory Connector ........................................................................................... 7-1

7.3

Replacement Board Procedures.................................................................................................. 7-2

7.4

Transmitter Troubleshooting ........................................................................................................ 7-2

7.5

Receiver Troubleshooting ............................................................................................................ 7-3

Chapter 8

Functional Block Diagrams and Connectors ................... 8-1

8.1

PM1200 Functional Block Diagram 1........................................................................................... 8-2

8.2

PM1200Functional Block Diagram 2............................................................................................ 8-3

8.3

PM1200 Functional Block Diagram 3........................................................................................... 8-4

8.4

PM1200 Connection Diagram...................................................................................................... 8-5

8.5

Transmitter Block Diagram .......................................................................................................... 8-6

8.6

Synthesizer Block Diagram.......................................................................................................... 8-7

8.7

Transmit Audio Block Diagram .................................................................................................... 8-8

8.8

Radio Connector Locations.......................................................................................................... 8-9

8.9

Radio Connector Locations (cont.) ............................................................................................ 8-10

Chapter 9

Exploded Views and Parts Lists ........................................ 9-1

9.1

PM1200 Control Head Exploded View......................................................................................... 9-2

9.2

PM1200 Radio Exploded View .................................................................................................... 9-3

Summary of Contents for PM1200

Page 1: ......

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

Page 4: ...xclusive 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 permis...

Page 5: ...iii 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: ...iv Notes ...

Page 7: ...nd Software Provisions xvii VII Governing Law xvii 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 xxii Chapter 1 Introduction 1 1 1 1 Notations Used i...

Page 8: ...hone and Speaker section 3 3 3 4 3 1 Display 3 3 3 4 3 2 Keypad and Volume Selector Knob 3 3 3 4 3 3 Telco Connector 3 3 3 4 3 4 Emergency Microphone 3 3 3 4 3 5 Internal Speaker 3 3 3 5 Analog Mode of Operation 3 4 3 5 1 General 3 4 3 5 2 Receive Operation 3 4 3 5 3 Transmit Operation 3 5 3 6 Radio Frequency Power Amplifier RF PA and Output Network ON 3 5 3 6 1 Gain Stages 3 6 3 6 2 Circuit Prote...

Page 9: ...gnment Software 5 11 5 6 Introduction of Programming Procedures 5 12 5 6 1 CPS Programming Setup 5 12 Chapter 6 Disassembly Reassembly Procedures 6 1 6 1 Introduction 6 1 6 2 Replacement Procedures 6 1 6 2 1 Required Tools and Supplies 6 1 6 2 2 Control Head Boards Disassembly Reassembly 6 2 6 2 2 1 PM1200 Control Head Disassembly 6 2 6 2 2 1 1 PM1200 Control Head Back Housing Disassembly 6 2 6 2 ...

Page 10: ... 40 6 2 3 5 2 Connector Unit Board Kit Reassembly 6 42 6 2 3 6 Option Board Disassembly Reassembly 6 44 6 2 3 6 1 Option Board Disassembly 6 44 6 2 3 6 2 Option Board Reassembly 6 45 6 3 Chassis Thermal Compound Replacement Procedure 6 47 6 4 Fastener Torque Chart 6 48 Chapter 7 Basic Troubleshooting 7 1 7 1 Introduction 7 1 7 2 Accessory Connectors 7 1 7 2 1 20 Pin Accessory Connector 7 1 7 3 Rep...

Page 11: ... A 2 Motorola Online A 1 A 3 Mail Orders A 1 A 4 Telephone Orders A 1 A 5 Fax Orders A 1 A 6 Parts Identification A 2 A 7 Product Customer Service A 2 Appendix B Motorola Service Centers B 1 B 1 Servicing Information B 1 B 2 Motorola Service Center B 1 B 3 Motorola Federal Technical Center B 1 Glossary Glossary 1 Index Index 1 ...

Page 12: ... Speaker Bosses 6 9 Figure 6 14 Installing the Internal Speaker Screws 6 9 Figure 6 15 Insert Channel Group Knob and Power Knob to Front Housing 6 9 Figure 6 16 Display Unit Board Screw Sequence 6 10 Figure 6 17 Connecting Speaker Mating Connector 6 10 Figure 6 18 Installing Connection Cable Display Unit Board Connector 6 11 Figure 6 19 Back Housing Screw Sequence 6 12 Figure 6 20 Installing Speci...

Page 13: ...rd Kit 6 35 Figure 6 65 Installing Sequence for PA Unit Board Kit Screws 6 35 Figure 6 66 Sequence for Installing Taptite Screws on PA Unit Board Kit 6 36 Figure 6 67 Resolder Tx and Rx Wire to PA Unit Board Kit 6 36 Figure 6 68 Sequence for Installing Binding Head Screws on PA Unit Board Kit 6 37 Figure 6 69 Resoldering Antenna Connector and Earth Plate 6 37 Figure 6 70 Connecting Mating Connecto...

Page 14: ... 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 Transmit Audio Block Diagram 8 8 Figure 8 8 Remote Mount Radio Connector Locations 8 9 Figure 8 9 PA Unit Board Connector Location 8 10 Figure 9 1 PM1200 Control Head Exploded View 9 2 Figure 9 2 PM1200 Radio Exploded View 9 3 ...

Page 15: ...ded Non Motorola Tools for Board Level Troubleshooting 4 2 Table 4 6 PM1200 Radio Field Programming Items 4 3 Table 5 1 Alignment Channel Frequencies 5 3 Table 5 2 Transmit Output Power 5 9 Table 6 1 Required Tools and Supplies 6 1 Table 6 2 Chassis Thermal Pad Parts 6 48 Table 6 3 Fastener Torque Chart 6 48 Table 7 1 Transmitter Troubleshooting Chart 7 2 Table 7 2 Receiver Troubleshooting Chart 7...

Page 16: ...ober 26 2007 6880309U09 A 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_ ...

Page 17: ...de in a separate agreement between MOTOROLA and the original end user purchaser MOTOROLA does not warrant the installation maintenance or service of the Product MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by MOTOROLA which is attached to or used in connection with the Product or for operation of the Product with any ancillary equipment and all such equipment...

Page 18: ...amage from improper testing operation maintenance installation alteration modification or adjustment D Breakage or damage to antennas unless caused directly by defects in material workmanship E A Product subjected to unauthorized Product modifications disassemblies or repairs includ ing without limitation the addition to the Product of non Motorola supplied equipment which adversely affect perform...

Page 19: ...r the lifetime of the Product or parts as established by MOTOROLA MOTOROLA will have no liability with respect to any claim of patent infringement which is based upon the combination of the Product or parts furnished hereunder with software apparatus or devices not furnished by MOTOROLA nor will MOTOROLA have any liability for the use of ancillary equipment or software not furnished by MOTOROLA wh...

Page 20: ...ed Type I Trunked Type II FDMA Digital Dual Mode TDMA Digital Dual Mode Single Sideband Global Positioning Satellite Capable Amplitude Companded Sideband ACSB Digital Dispatch Programmable Digital Interconnect Digital Multi Service 9600 Capable TDMA FDMA Frequency Division Multiple Access TDMA Time Division Multiple Access Position 9 Primary SystemType Conventional Privacy Plus Clear SMARTNET Adva...

Page 21: ...t X HKLN4335_ Main Unit Brd Kit 29 7 37 MHz 120W X HKLN4337_ Connector Unit Board Kit 29 7 37 MHz 120W X HKLN4338_ PA Unit Board Kit 37 50 MHz 120W X HKLN4339_ Spare Fuse X HKLN4340_ Power Cable 20 feet X HKLN4341_ Remote Mount Kit 20 feet X HKLN4342_ Tranceiver Trunnion Kit X HKLN4350_ PM1200 Users Guide Kit X HKLN4373_ Connector Unit Board Kit X HKLN4374_ RF Interface Board Kit X AARMN4025_ Stan...

Page 22: ... HKLN4336_ Main Unit Brd Kit 37 50 MHz 120W X HKLN4337_ Connector Unit Board Kit 29 7 37 MHz 120W X HKLN4338_ PA Unit Board Kit 37 50 MHz 120W X HKLN4339_ Spare Fuse X HKLN4340_ Power Cable 20 feet X HKLN4341_ Remote Mount Kit 20 feet X HKLN4342_ Tranceiver Trunnion Kit X HKLN4350_ PM1200 Users Guide Kit X HKLN4373_ Connector Unit Board Kit X HKLN4374_ RF Interface Board Kit X AARMN4025_ Standard ...

Page 23: ...l Spacing 70 dB Modulation Limiting Control Head 3 11 x 7 78 x 3 31 20 kHz Channel Spacing 5 0 kHz 79 mm x 197 60 mm x 84 07 mm High Power Radio Transceiver 3 15 x 7 56 x 12 07 Intermodulation per EIA Specifications 80 mm x 192 mm x 306 50 mm Measured in the Analog Mode 70 dB FM Hum and Noise 20 kHz Channel Spacing 43 dB Weight Spurious Rejection 90 dB Control Head 1 28 lb 0 58 kg High Power Radio...

Page 24: ...pacing 70 dB Modulation Limiting Control Head 3 11 x 7 78 x 3 31 20 kHz Channel Spacing 5 0 kHz 79 mm x 197 60 mm x 84 07 mm High Power Radio Transceiver 3 15 x 7 56 x 12 07 Intermodulation per EIA Specifications 80 mm x 192 mm x 306 50 mm Measured in the Analog Mode 70 dB FM Hum and Noise 20 kHz Channel Spacing 43 dB Weight Spurious Rejection 90 dB Control Head 1 28 lb 0 58 kg High Power Radio Tr...

Page 25: ...ay 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 and advanced features resulting in a more cost effective two way radio communications solution CAUTION indicates a potentially hazardous situation which if not avoided migh...

Page 26: ...hannel is busy DSC Indicator This lamp blinks orange when the position of Volume Selector Knob and or Channel Selector Knob differs the pre set position Channel Group Keys Changes the current channel group Telco Connector Connects the microphone to the control head Volume Selector Knob Changes the audio volume Channel Selector Knob Changes the operating channel Emergency Microphone When the emerge...

Page 27: ...or performance and interference with other users operating on adjacent channels 2 2 1 Inspection Check that the external surfaces of the radio are clean and that all external controls and switches are functional A detailed inspection of the interior electronic circuitry is not needed NOTE Verify that all dust covers are in place 2 2 2 Cleaning The following procedures describe the recommended clea...

Page 28: ...autions Avoid physical abuse do not pound drop or throw the radio Exposed parts such as controls and connectors might be damaged Operating the radio without an antenna cable attached may lead to radio failure and may void the warranty 2 2 4 RF Power Amplifier RF PA Heatsinking Never transmit unless the printed circuit board PCB DC and RF connector clips and internal screws are installed in the cha...

Page 29: ...s are not readily available observing the following techniques will minimize the chance of damage If a static sensitive device is to be temporarily set down use a conductive surface for placement of the device 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 T...

Page 30: ...October 26 2007 6880309U09 A 2 4 Basic Maintenance Handling Precautions Notes ...

Page 31: ...ration the control head assembly is attached to the RF INTERFACE UNIT via a flex Each unit is used to communicate with the RF deck RF INTERFACE UNIT Remote mount only Provides interface to remote control head assembly Connects to the RF deck via a flex Power Amplifier PA section contains the antenna switch directional coupler detector and amplifier s Front End Receiver section contains the presele...

Page 32: ... hardware allows a computer to program the radio s features maintain an active control of the RF sections and make necessary mode and audio adjustments as related to feedback from a control head device 3 3 2 2 Voltage Regulation The uniboard contains the following voltage regulators 9 V 5 V and 13 6V The radio s A supply is regulated down to additional supplies for various blocks frequency generat...

Page 33: ...erface Keypad STN Display Volume Selector Knob Microphone and Speaker section 3 4 3 1 Display The display includes an 8 character alpha numeric section showing channel and group names status and identity information and error messages seven icons OPT Horn Alert Public Address Speaker Selectable Tone Monitor and Scan 3 4 3 2 Keypad and Volume Selector Knob The control head assembly processes all me...

Page 34: ...elay RL6001 for delivery to the receiver front end in the MAIN Unit Signals within the frequency range of the transceiver are then passed through a varactor tuned band pass filter consisting of T1001 T1002 T1003 and T1004 before RF amplification by Q1006 GN010100R The amplified RF is then band pass filtered again by varactor tuned resonators T1001 T1002 T1003 and T1004 to ensure pure in band input...

Page 35: ...w pass filter circuit and ultimately to the antenna connector RF output power from the final amplifier is sampled by a CM coupler and is rectified by D6006 D6007 MA729X2 The resulting DC is fed through Automatic Power Controller Q1038 NJM2902V Q1001 2SC4154E Q1004 2SB1132Q to control the gain of the transmitter RF amplifier and thus regulate the power output Generation of spurious products by the ...

Page 36: ...tection RF PA final stage drain current RF PA final stage temperature RF PA control voltage and battery voltage are sensed by the power control circuitry If a fault condition is detected the control voltage is reduced which cuts back the output power to a level that is safe for the particular conditions 3 6 3 DC Interconnect The DC connector P7001 carries the B supply for the entire board This sup...

Page 37: ...o the VCO as a voltage with phase error controlling and stabilizing the oscillating frequency This synthesizer also operates as a modulator during transmit The RX VCO comprises Q1015 2SK508 and D1017 D1016 HVU306A x 2 It oscillates between 47 7 and 54 7 MHz according to the programmed receiving frequency The TX VCO is comprised of Q1016 2SC4226 and D1015 D1016 D1013 D1012 HVU300A x 4 It oscillates...

Page 38: ...October 26 2007 6880309U09 A Notes 3 8 Basic Theory of Operation PLL Synthesizer ...

Page 39: ... MHz Oscilloscope Agilent Two channel 100MHz bandwidth 200 Msample rate sec 2MB memory channel Waveform measurements R 2670 with options as applicable System Analyzer This item will substitute for items with an asterisk Frequency deviation meter and signal generator for wide range troubleshooting and alignment Table 4 2 Recommended Non Motorola Test Equipment Model Number Description Application H...

Page 40: ...ng Software Programming and radio alignment software on CD AARKN4081_ Telco Programming Cable Used for programming PM1200 High Power through control head Table 4 4 Recommended Motorola Tools for Board Level Troubleshooting Motorola Part Number Tools and Supplies 0180386A82 Anti static grounding kit 8180384S04 Chassis eliminator High Power 1185984D01 Electromagnetic Interference EMI metallic shield...

Page 41: ...memory from the radio To program the radio connect Telco CPS Programming cable AARKN4081_ to the Telco connector Refer to the CPS Installation Guide for installation and setup procedures for the software 4 3 1 1 Field Programming Items Once the computer is connected to the radio the prompts provided by the programming software can be followed The following items available through the Radio Product...

Page 42: ...October 26 2007 6880309U09 A Notes 4 4 Test Equipment Service Aids and Tools Field Programming Equipment ...

Page 43: ...technicians realign all circuits and make complete performance checks to ensure compliance with factory specifications after replacing any faulty components Those who do undertake any of the following alignments are cautioned to proceed at their own risk Problems caused by unauthorized attempts at realignment are not covered by the warranty policy Also Motorola must reserve the right to change cir...

Page 44: ...ore proceeding Correct alignment requires that the ambient temperature be the same as that of the transceiver and test equipment and that this temperature be held constant between 20 and 30 C 68 to 86 F When the transceiver is brought into the shop from hot or cold air it should be allowed some time for thermal equalization with the environment before alignment If possible alignments should be mad...

Page 45: ...e Main Unit and the negative lead to chassis ground 2 Set the transceiver to the high band edge frequency channel then adjust trimmer capacitor T1005 on the Unit for 7 0 V on the voltmeter 3 Key the transmitter and adjust trimmer capacitor T1006 on the Unit for 7 0 V on the voltmeter 4 Next select to the low edge frequency channel and confirm about 1 8 V 1 5 V to 2 1 V on the voltmeter 5 Key the t...

Page 46: ...r maximum deviation from the computer for 4 2 kHz 0 1 kHz deviation as indicated on the deviation meter 5 4 5 2 CTCSS Modulation Level 1 Select band center frequency channel with 151 4 Hz CTCSS encode and reduce the AF generator injection to zero 2 Key the transmitter and adjust by control commands for CTCSS deviation from the computer for 0 7 kHz 0 05 kHz deviation as indicated on the deviation m...

Page 47: ... 2 Follow the instructions given by the installation Wizard 5 5 2 Equipment Setup and Radio Alignment Software Execution 1 To perform the alignment procedures the radio must be connected to the computer and the test equipment set as shown in Figure 5 2 Figure 5 2 Radio RF Test Equipment Setup 2 Turn off the radio 3 Click the Start button 4 Select Program Motorola PM1200 Tools Radio Alignment Softw...

Page 48: ... RX Tune Alignment 1 Left click the Rx Tune tab to align the Rx Tune Circuit 2 Inject an on channel signal to the radio at 47 dBm with 3 0 kHz deviation of a 1 kHz audio tone to verify the radio is receiving the desired frequency 3 Adjust to the rated audio by rotating the Volume Knob to 6 32 V 4 Reduce the RF Signal Generator output to the Center frequency of the operating band to a level around ...

Page 49: ... tab to align the Squelch Circuit 2 Left click SQL Threshold to align the Squelch Threshold Level 3 Toggle the Programmable SQL Function Button and rotate the Channel Knob to SQL 1 4 Inject an on channel signal to the radio at 47 dBm with 3 0 kHz deviation of a 1 kHz audio tone to verify the radio is receiving the desired frequency 5 Adjust to the rated audio by rotating the Volume Knob to 6 32 V ...

Page 50: ...Hz deviation of a 1 kHz audio tone 6 Adjust the RF signal until the radio is totally muted 7 Left click Reflect to record the Squelch Tight data 5 5 4 3 SQL RSSI Alignment 1 Left click SQL RSSI to align the Squelch RSSI Level 2 Inject an on channel signal to the radio at 47 dBm with 3 0 kHz deviation of a 1 kHz audio tone to verify the radio is receiving the desired frequency 3 Adjust to the rated...

Page 51: ...programmed operating frequencies using the Frequency offset slide bars associated with the various channel frequencies 5 Left click Low Power then repeat steps 3 and 4 for the Low Power mode Figure 5 7 TX Power Alignment Screen 5 5 6 TX Deviation Alignment 5 5 6 1 Maximum Deviation 1 Left click the Deviation tab to align the Transmitter Deviation 2 Left click Max Dev 3 Inject a 1000 mV 1 kHz tone ...

Page 52: ...lue slide bar upward or downward while pressing and holding in the left mouse button 5 Repeat the same procedure to fine adjust the TPL Deviation 0 75 kHz 0 03 kHz for each operating frequency using the Frequency offset slide bars associated with the various channels 5 5 6 3 DPL Deviation 1 Select the band center frequency channel with DPL 023 enabled and reduce the AF generator injection to zero ...

Page 53: ...n 5 5 8 Exiting the Radio Alignment Software 1 Left click Exit to close the Radio Alignment Software 2 If the present alignment data has not been written to the radio the user will be prompted a confirmation window 3 If the user decides not to write the alignment data to the radio the original setting data will be written back The writing progress bar as shown in Figure 5 9 will appear The radio s...

Page 54: ...ing procedures of the software 5 6 1 CPS Programming Setup Follow the CPS programming setups as shown in Figure 5 10 and Figure 5 11 to program the radio NOTE Refer to the appropriate program on line help file for detailed programming procedures Figure 5 10 CPS Programming Setup with RIB Figure 5 11 CPS Programming Setup Cable with Internal RIB ACC DC DC Power Supply RIB RLN 4008 Tx Data Rx Data G...

Page 55: ... Alignment and Programming Procedures 6 2 Replacement Procedures 6 2 1 Required Tools and Supplies Disconnect the power cable from the radio before opening and removing the PCB Failure to remove power can result in unit damage caused by transients or accidental shorts as well as presenting a shock hazard After performing alignment procedures always exit the SERVICE menu entirely to the MAIN MENU t...

Page 56: ...ul not to scratch or mar the display 3 Using a CR V PH2 screwdriver remove the 4 binding head screws M4x8 SUS B 34 from the cable strain relief plate 32 as shown in Figure 6 1 Figure 6 1 Removing Screws from Cable Strain Relief Plate 4 Carefully separate the cable strain relief plate 32 and gasket 31 from the back housing assembly 29 5 Carefully disconnect the remote radio control cable from the m...

Page 57: ...e 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 7 Using a special nut driver first remove the special nut 26 then remove the ear cap 30 from the back housing assembly 29 as shown in Figure 6 3 Figure 6 3 Removing Special Nut from Speaker Phone Jack 8 Carefully separate the back hous...

Page 58: ...ly 10 3 Lay the bottom side of control head facing upward on a clean flat surface 4 Using a CR V PH2 screwdriver remove the 2 binding head screws M3x8 SUS B 8 with the 2 o rings 9 from the front housing assembly 10 5 Carefully separate the frame 28 from the front housing assembly 10 6 Carefully disconnect the connection cable from the mating connector on the rear of display unit board kit 22 as sh...

Page 59: ...unit board kit 22 at the front housing assembly 10 4 After all the screws have been removed gently lift up the display unit board kit 22 from the front housing assembly 10 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 4 PM1200 Control Head VR Unit Board Kit Disassembly 1 Remove the channel group knob 4 and power knob 13...

Page 60: ...5 PM1200 Control Head Key Unit Board Kit Disassembly 1 Lay the rear side of the front housing assembly 10 facing upward 2 Using a CR V PH1 screwdriver remove the 3 taptite screws M2 6x6 17 from the key unit board kit 16 at the front housing assembly 10 3 After all the screws have been removed gently lift up the key unit board kit 16 rubber telco seal 14 and mic holder 15 from the front housing ass...

Page 61: ... Ensure that the rubber telco seal 14 is properly fitted to the telco connector and the mic holder 15 is also properly fitted to the emergency mic at key unit board kit 16 3 Place the key unit board kit 16 to the housing by seating the PCB surface to the screw bosses Ensure that the aligning boss protrudes through the PCB Refer to Figure 6 10 Figure 6 10 Key Unit Board Screws Sequence 4 Using CR V...

Page 62: ... nut 7 to the channel selector switch at VR unit board kit 18 as shown in Figure 6 11 torqued to 7 5 8 6 kgf cm 6 5 7 5 in Ibs Figure 6 11 Installing Special Nut to Channel Selector Switch 5 Attach the volume knob 1 and channel selector knob 2 as shown in Figure 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...

Page 63: ...ling Speaker Fittings and Screws to Internal Speaker Bosses NOTE Fasten the taptite head screws by following the sequence as shown in Figure 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...

Page 64: ...e driver fasten the 6 taptite head screws M2 6x6 17 following the sequence shown in Figure 6 16 torqued to 3 5 4 6 kgf cm 3 4 in Ibs Figure 6 16 Display Unit Board Screw Sequence 6 Carefully connect the speaker wire to the mating connector as shown in Figure 6 5 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 PM120...

Page 65: ... 8 to the front housing assembly 10 torqued to 3 5 4 6 kgf cm 3 4 in Ibs 5 Lay the bottom side of control head facing upward on a clean flat surface 6 Using a CR V PH2 torque driver fasten the 2 binding head screws M3x8 SUS B 8 with the 2 o rings 9 to the front housing assembly 10 torqued to 3 5 4 6 kgf cm 3 4 in Ibs 7 Lay the control head facing downward on a clean flat surface being careful not ...

Page 66: ... as shown in Figure 6 19 Torqued to 5 8 6 9 kgf cm 5 6 in lbs Figure 6 19 Back Housing Screw Sequence 3 Insert the ear cap to the speaker phone jack at panel interface unit board kit 25 4 Using a special nut driver fasten the special nut 26 as shown in Figure 6 20 Torqued to 4 6 5 8 kgf cm 4 5 in lbs Figure 6 20 Installing Special Nut to Speaker Phone Jack 5 Carefully plug in the remote radio cont...

Page 67: ...ntrol 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 7 Using a CR V PH2 torque driver fasten the 4 binding head screws M4x8 SUS B 34 to the cable relief plate 32 follow the sequence as shown in Figure 6 21 Torqued to 5 8 6 9 kgf cm 5 6 in lbs Figure 6 22 Installing Screws to Cable Strain Relief Plate Rem...

Page 68: ...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 Ensure all accessory connections power antenna and microphone are unplugged 2 Using a CR V PH2 screwdriver remove the 4 binding head screws M4x8 SUS B 1 from the cable strain relief plate 2 as shown in Figure 6 23 Figure 6 23 Removing Screws from Cable Strain Relief ...

Page 69: ...may be necessary to gently pry the cover off using a plastic tool Figure 6 26 Lifting the Top Cover 7 Using a CR V PH2 screwdriver remove the 2 binding head screws M3x6 SUS 6 from the transceiver front panel 4 8 Lay the top of the radio facing downward on a clean flat surface 9 Using a CR V PH2 screwdriver remove the 2 binding head screws M3x6 SUS B 9 with 2 o ring 10 from the front panel 10 Lay t...

Page 70: ...moving 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 Seal the front panel 4 with the rubber packing 5 2 Carefully connect the connection cable to the RF Interface unit board kit 7 as shown in Figure 6 28 Figure 6 28 Installing the Connection Cable 3 Carefully mate the front panel 4 to the front of the tra...

Page 71: ...e top of the radio facing downward on a clean flat surface 6 Using a CR V PH2 torque driver fasten the 2 binding head screws M3x6 SUS B 9 with 2 o ring 10 to the front panel as shown in Figure 6 29 Torqued to 3 5 4 6 kgf cm 3 4 in lbs Figure 6 30 Installing Bottom Screws to Front Panel 7 Lay the top of the radio facing upward 8 Place the top cover 24 on the chassis 11 and seat it properly Compress...

Page 72: ...igure 6 31 Torqued to 5 8 6 9 kgf cm 5 6 in lbs Figure 6 31 Sequence for Installing Top Cover Screws 10 Carefully plug in the remote radio control cable to the mating connector red color on the front panel 4 as shown in Figure 6 32 Figure 6 32 Installing Remote Radio Control Cable to Front Panel 11 Neatly bundle the exposed cable wiring and then install the gasket 3 and cable strain relief plate 2...

Page 73: ...acketed 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 Disassemble the front panel by following the steps outlined in 6 2 3 1 Transceiver Front Panel Disassembly Reassembly on page 6 14 2 Place the rear of the front panel facing upward on a flat surface and remove the 4 taptite head screws M2 6x6 8 wit...

Page 74: ...t Screws 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...

Page 75: ...it 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 Unplug the mating connector A on the wire assembly 160mm 20P26P 26 from the main unit board kit 13 as shown in Figure 6 37 Figure 6 37 Removing Screws from Main Unit Board Kit 1 2 Mating Connector A ...

Page 76: ...ug the mating connector C of the wire assembly 27 from the main unit board kit 13 as shown in Figure 6 38 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 Figure 6 39 Removing Holder from Chassis Mating Connector C ...

Page 77: ...x and Rx wires as shown in Figure 6 40 Figure 6 40 Desolder Tx and Rx Wires 9 Using a CR V PH2 screwdriver remove the 6 taptite screws M3x8 NI 14 from the chassis 11 as shown in Figure 6 41 Figure 6 41 Removing Screws from Main Unit Board Kit RX WIRE INSULATED WIRE GROUND WIRE TP1 002 RX TX GND GND TP1 005 TP1 004 TP1 003 TX WIRE 1 2 5 6 3 4 ...

Page 78: ...ard kit 13 by the edges only and store it in an antistatic bag 6 2 3 3 2 Main Unit Board Kit Reassembly To assemble your radio 1 Prior to reassembly the radio inspect the poron pads 12 18 and poron pad VCO 19 for damage or dirt Refer to Chapter 9 Exploded Views and Parts Lists for the correct part numbers and replace parts as necessary 2 Take out the main unit board kit 13 from the antistatic bag ...

Page 79: ...hassis Thermal Compound Replacement Procedure on page 6 47 Figure 6 44 Position of Electronic Component Q2018 5 Tilt the main unit board kit 13 and slide it into place insert the connector through the opening provided Gently push down the PCB to fully seat it Ensure the main unit board kit alignment holes are positioned over the chassis alignment bosses and the Main unit board kit is fully seated ...

Page 80: ...46 Sequence for Installing Main Unit Board Kit Screws 7 Carefully resolder the 2 wires Tx and Rx wires as shown in Figure 6 47 Figure 6 47 Resolder Tx and Rx Wires to Main Unit Board Kit Ensure the wires are soldered correctly to the PCB the insulated wires solder to TP1 002 RX and TP1 003 TX and ground wire solder to TP1 001 GND and TP1 004 GND 1 2 5 6 3 4 C a u t i o n RX WIRE INSULATED WIRE GRO...

Page 81: ...ic 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 Figure 6 49 Connect Mating Connector to Main Unit Board Kit Mating Connector C Mating Connector A ...

Page 82: ... 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 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 unplug...

Page 83: ...dges It may be necessary to gently pry the cover off using a plastic tool Figure 6 52 Figure 6 52 Lifting the Top Cover 4 Using a CR V PH2 screwdriver remove 3 SEMS screws HSM3x6 NI 17 and a taptite screw M3x8 NI 14 from the radio as shown in Figure 6 53 Figure 6 53 Removing Screws from Main Unit Board Kit and PA Unit Board Kit Plastic Tool 1 2 3 4 ...

Page 84: ...igure 6 54 Removing Power Wire Assembly from the Chassis 6 Separate the mating connector D of wire assembly 27 from the PA unit board kit 20 as shown in Figure 6 55 Figure 6 55 Removing Mating Connection from PA Unit Board Kit 7 Using a CR V PH2 screwdriver remove the 2 binding head screws M3x6 SUS 6 from the antenna connector 32 as shown in Figure 6 56 Figure 6 56 Removing Screws from Antenna Con...

Page 85: ...20 and remove them from the chassis 11 as shown in Figure 6 56 Figure 6 57 Desoldering Antenna Connector and Earth Plate from PA Unit Board Kit 9 Carefully desolder the brown 2 wire assembly Tx and Rx wires as shown in Figure 6 58 Figure 6 58 Desoldering Tx and Rx Wires Earth Plate Antenna Connector RX WIRE TX WIRE RX GND INSULATED WIRE GROUND WIRE INSULATED WIRE GROUND WIRE TX GND ...

Page 86: ... 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 Using a CR V PH2 screwdriver remove the 4 SEMS screws SM3x8 NI 21 from the PA unit board kit 20 as shown in Figure 6 60 Figure 6 60 Removing 4 SEMS Screws from PA Unit Board Kit 1 2 3 4 5 1 2 3 4 ...

Page 87: ...H2 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 Store it in an antistatic bag 1 2 3 4 5 6 ...

Page 88: ...he replacement PA unit There should not be any transistor fins vent shape and crack at the solder joint points 3 Place the PA unit board kit 20 into place by gently pushing down the PCB to fully seat it as shown in Figure 6 63 Move the PCB gently 2 or 3 times to exclude any air gaps between both surfaces Ensure that the PA unit board kit alignment holes are positioned over the chassis alignment bo...

Page 89: ...er fasten the 4 SEMS screws SM3x8 NI 21 following the sequence as shown in Figure 6 65 Torqued to 5 8 6 9 kgf cm 5 6 in lbs Figure 6 65 Installing Sequence for PA Unit Board Kit Screws Do not over torque the screws It may damage the semiconductors and transistors Do not over torque the screws It may damage the semiconductors and transistors C a u t i o n 1 2 3 4 5 C a u t i o n 1 2 3 4 ...

Page 90: ...ce for Installing Taptite Screws on PA Unit Board Kit 7 Carefully resolder the 2 wires Tx and Rx wires as shown in Figure 6 67 Figure 6 67 Resolder Tx and Rx Wire to PA Unit Board Kit Ensure that the wires are soldered correctly to the PCB with the insulated wires solder to TP1 002 RX and TP1 003 TX and ground wire solder to TP1 001 GND and TP1 004 GND 1 2 3 4 5 6 C a u t i o n RX WIRE TX WIRE RX ...

Page 91: ... plate 33 and the antenna connector 32 to the chassis 11 as shown in Figure 6 68 Torqued to 3 5 4 6 kgf cm 3 4 in lbs Figure 6 68 Sequence for Installing Binding Head Screws on PA Unit Board Kit 9 Carefully resolder the antenna connector 32 and the earth plate 33 to the PCB as shown in Figure 6 69 Figure 6 69 Resoldering Antenna Connector and Earth Plate 1 2 Earth Plate Antenna Connector ...

Page 92: ...ector D of wire assembly 27 to the PA unit board kit 20 as shown in Figure 6 70 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 Figure 6 71 Inserting Power Wire Assembly into the Chassis Mating Connector D ...

Page 93: ... cm 8 5 9 5 in lbs Figure 6 72 Connecting Power Wire Assembly to PA Unit Board Kit 13 Place the power wire assembly 37 to the terminal by using a CR V PH2 torque driver and fasten the 3 SEMS screws HSM3x6 NI 17 to the main unit board kit 13 and PA unit board kit 20 follow the sequence Torqued to 5 8 6 9 kgf cm 5 6 in lbs Figure 6 73 Inserting Power Wire Assembly into the Chassis Make sure the powe...

Page 94: ...p cover 24 follow the sequence as shown in Figure 6 74 Torqued to 5 8 6 9 kgf cm 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 ...

Page 95: ...ng a pair of long nose pliers as shown in Figure 6 75 Figure 6 75 Removing Lock Plate 3 Pull the connector assembly 30 out of the Connector Unit Board Kit 29 as shown in Figure 6 76 Figure 6 76 Removing Connector Assembly 4 Using a CR V PH2 screwdriver remove the 2 taptite screws M3x8 NI 14 from the connector unit board kit 29 as shown in Figure 6 77 Figure 6 77 Removing Taptite Screws from Connec...

Page 96: ...om the connector unit board kit 29 as shown in Figure 6 78 Figure 6 78 Removing Mating Connection from Connector Unit Board Kit 6 2 3 5 2 Connector Unit Board Kit Reassembly 1 Connect the mating connector B of the wire assembly 160mm 20P26P 26 to the connector unit board kit 29 as shown in Figure 6 79 Figure 6 79 Removing Mating Connection from Connector Unit Board Kit 2 Place the connector unit b...

Page 97: ...0 9 kgf cm 8 5 9 5 in lbs Figure 6 80 Sequence for Installing Connector Unit Board Kit Screws 4 Attach the connector assembly 30 to the connector unit board kit 29 as shown in Figure 6 79 Figure 6 81 Installing Connector Assembly 5 Attach the lock plate 28 to the connector assembly 30 as shown in Figure 6 82 Ensure that the lock plate 28 clamp the connector assembly 30 properly Figure 6 82 Install...

Page 98: ...rd HKLN4347_ These option boards need to be installed together with an Interface Board HKLN4345_ NOTE Bracketed numbers are identical to item numbers shown in Figure 9 2 PM1200 Radio Exploded View on page 9 3 6 2 3 6 1 Option Board Disassembly 1 Ensure all the accessory connections power antenna and microphone are unplugged 2 Using a CR V PH2 screwdriver remove the 7 binding head screws M3x6 SUS B...

Page 99: ...nd Option Board by holding the edges of the PCB and lift them out of the chassis Store them in an antistatic bag 6 2 3 6 2 Option Board Reassembly 1 Handle the interface board and option board by the edges only and take them out from the antistatic bag 2 Attach the thinner foam to the Interface Board as shown in Figure 6 86 by first separating the adhesive cover from the bottom of the foam Figure ...

Page 100: ...own in Figure 6 87 Torqued to 3 5 4 6 kgf cm 3 4 in lbs Figure 6 87 Installing Interface Board to Chassis 5 Attach the thicker foam on top of the connector of option board as shown in Figure 6 88 by first removing the adhesive cover Figure 6 88 Paste Foam to Option Board 6 Attach the option board to the Interface Board as shown in Figure 6 89 Figure 6 89 Attach Option Board to Interface Board Inte...

Page 101: ... 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 5 6 in lbs Figure 6 90 Sequence for Installing Top Cover Screws 6 3 Chassis Thermal Compound Replacement Procedure Follow the following procedures when replacing the chassis thermal compounds Figure 6 91 C...

Page 102: ...ut 7 5 8 6 6 5 7 5 Channel Selector Switch HKLN4372_ Special Nut Supplied with Panel Interface Board Kit 4 6 5 8 4 5 Speakerphone Jack 0308800H22 Screw Taptite screw M2 6x6 3 5 4 6 3 4 Key Unit Board Kit Display Unit Board Kit Internal Speaker 0308800H21 Screw Binding Head screw M3x6 SUS B 3 5 4 6 3 4 Control Head Front Housing Transceiver Front Panel Bottom 0308800H24 Screw Binding Head screw M4x...

Page 103: ...assembly Procedures Fastener Torque Chart 6 49 0308800H44 Screw Binding Head screw M3x6 SUS B with Nylok 5 8 6 9 5 6 Top Cover Table 6 3 Fastener Torque Chart Continued Part Number Description Repair Torque kgf cm Repair Torque in lbs Where Used ...

Page 104: ...October 26 2007 6880309U09 A Notes 6 50 Disassembly Reassembly Procedures Fastener Torque Chart ...

Page 105: ... is still possible that equipment might be damaged by the radio transmitter Besides a possible radio failure the radio might also transmit while in receive under the following conditions trunking mode affiliation missing emergency jumper a defective PTT button or other unintentional PTT activations With the exception of some inputs on service monitors a suitable attenuator rated at 100 W or more s...

Page 106: ... Transmitter Troubleshooting Chart Symptom Possible Cause Correction or Test Measurements Taken at Room Temperature No RF Power Output Microphone Is the PTT switch being pressed correctly If yes there is a possibility that there is no contact inside the microphone Power current capacity Check whether there is a drop in supplied voltage Distorted Modulation Frequency Setting Check to ensure the cor...

Page 107: ...eceiver Audio or Receive Does Not Unsquelch Code Plug Check the codeplug to ensure correct frequency and signaling PL DPL is enabled by using CPS Speaker Check for speaker leads shorted to ground or open speaker wires Replace if necessary Audio Distorted or Not Loud Enough Codeplug Ensure the codeplug is properly configured including bandwidth and signaling Synthesizer Not On Frequency Working Che...

Page 108: ...October 26 2007 6880309U09 A Notes 7 4 Basic Troubleshooting Receiver Troubleshooting ...

Page 109: ...gure Name 8 2 Figure 8 1 PM1200 Functional Block Diagram 8 3 Figure 8 2 PM1200 Functional Block Diagram 2 8 4 Figure 8 3 PM1200 Functional Block Diagram 3 8 5 Figure 8 4 PM1200 Connection Diagram 8 6 Figure 8 5 Transmitter Block Diagram 8 7 Figure 8 6 Synthesizer Block Diagram 8 8 Figure 8 7 Transmit Audio Block Diagram 8 9 Figure 8 8 Remote Mount Radio Connector Locations 8 10 Figure 8 9 PA Unit ...

Page 110: ...x4 Q1040 SPM5001 RF AMP Q1027 2SC5415E BUFFER AMP Q1021 2SC5107 O RX OSC Q1015 3SK508 K52 D1016 D1017 HVU306A x2 TX OSC Q1016 2SC4226 D1012 D1013 D1014 D1015 HVU300A x4 NOISE AMP Q2003 NJM2902V LPF Q2019 CXA1846N IF AMP Q1035 2SC4215Y BPF IF1 17 7MHz NB XF1001 XF1002 IF SW Q1031 Q1032 2SK508 Q6801 3SK131 Q6802 MC1350D Q6803 2SC4116GR Q6804 2SC4116GR Q6805 2SC4116GR Q6806 2SC4116GR Q6807 2SA1586Y Q...

Page 111: ...4S 13 4V FR_PTT D_BUSY J2001 J4006 J4002 J5006 JP1001 P8001 RF INTERFACE UNIT PANEL INTERFACE UNIT MAIN UNIT SIO J3008 J3009 CLK SHIFT CRYSTAL DATA BUFFER DATA BUFFER TXD RXD BUSY_O BUSY_I P_SW MIC_AUD SP TX AF RX AF CNTL OTHERS 5 0V GAIN CNTL LEVEL DET CLONE MIC_MUTE SWITCH MIC_MUTE SWITCH Q3008 RT1N241M Q3039 NJM2068V Q3039 NJM2068V Q3026 RT1N241M Q3031 2SB1132Q Q3019 2SC4154E Q3013 IMD3 Q3004 Q...

Page 112: ...SA1602A BUFF Q4014 2SA1602A BUFF Q4021 1 2 NJM2904V AMP Q4021 1 2 NJM2904V AMP Q4020 2SB1132Q SW CNTL Q4019 NJM78L0SUA REG Q4017 RT1N241M SW CNTL Q4012 IMD3 SW CNTL Q4016 2SA1602A BUFF Q4018 RT1N241M FVPP CNTL Q4010 D4002 FMA1 BAS316 FVPP CNTL Q4009 IMD3 SW CNTL Q4011 MC2848 SW CNTL Q4008 IMD3 SW CNTL Q4003 2SJ125D SW AF1 J4003 MIC_AUD SIO VCC P_SW SIO D_BUSY FPMC FR_PTT 13 4V 13 4V VOL_C FP_MUTE ...

Page 113: ... 7 8 1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 16 17 18 19 20 22 24 21 23 26 25 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 16 17 18 19 20 22 24 2...

Page 114: ...11 C6042 C6043 C6044 C6045 C6047 C6074 C6075 RL6001 ANT SW FINAL AMP Q6006 Q6007 DRIVE AMP Q6004 Q6005 PRE DRIVE AMP Q6001 ATTEN D1032 P in VCO To Reciver REF POWER CNTL T6004 APC Q1004 Q1001 ANT ADJ HIGH LOW POWER Q1038 Q1038 BUFF AMP POWER CNTL Q1038 Q2026 PIN 30 TXVB SW Q1008 Q1010 Q2026 PIN 26 Q1038 FWD POWRE CNTL D6006 D6007 L6007 POWER DETECT Matching Network Hamonics Filter ...

Page 115: ...Figure 8 6 Synthesizer Block Diagram RX VCO Q1015 TX VCO Q1016 LOOP FILTER C732 C733 C734 C735 R716 R717 RX SW Q1022 TX SW Q1020 REGULATOR Q1036 PLL IC Q1029 OSC 17 25MH zQ1033 SUB AUDIO MODULATOR D1025 D1029 T R Q2026 PIN 13 VCO Out put SWB Q2026 Pin 16 Pin 1 Pin 2 Pin 3 Q1029 Pin 8 Pin 14 Pin 5 TX AUDIO Tone GEN Q2026 PIN 31 5V ...

Page 116: ...0309U09 A 8 7 Transmit Audio Block Diagram Figure 8 7 Transmit Audio Block Diagram DTMF TONE LPF AF AMP HPF MIC MUTE MIC Q2108 Q3008 TONE GEN by CPU Q2026 Q2001 MUTE CON MOD ADJ Q2019 5 Order LPF to MOD 300Hz 3KHz Q2001 Q3014 Pin 18 AF AMP Q3039 Q5012 Q4007 Q2008 Q2017 LIM Pin 3 Q2026 MUTE CON ...

Page 117: ...Functional Block Diagrams and Connectors Radio Connector Locations 8 9 6880309U09 A October 26 2007 8 8 Radio Connector Locations Figure 8 8 Remote Mount Radio Connector Locations ...

Page 118: ...8 10 Functional Block Diagrams and Connectors Radio Connector Locations cont October 26 2007 6880309U09 A 8 9 Radio Connector Locations cont Figure 8 9 PA Unit Board Connector Location ...

Page 119: ...ted 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 Figure Name 9 2 Figure 9 1 PM1200 Control Head Exploded View 9 3 Figure 9 2 PM1200 Radio Exploded View ...

Page 120: ...08800G99 Front Housing Assembly 11 3208800H14 Rubber Packing 12 3808800H04 Functional Keypad 13 3808800H13 Power Knob 14 3208800H11 Rubber Telco Seal 15 1408800H12 Mic Holder 16 HKLN4370_ Key Unit Board Kit 17 0308800H22 Screw Taptite Screw M2 6x6 18 HKLN4371_ VR Unit Board Kit 19 Hex Nut 20 5008800G97 Internal Speaker 21 5808800H15 Speaker Fitting 22 HKLN4369_ Display Unit Board Kit 23 0308800H23...

Page 121: ...1 11 2708800H27 Chassis 12 7508800H28 Poron Pad 13 HKLN4335_ Main Unit Board Kit 29 7 37 MHz 120 W HKLN4336_ Main Unit Board Kit 37 50 MHz 120 W 14 0308800H40 Screw Taptite Screw M3x8 Ni 15 5808800H29 Holder 16 3008800H36 Wire Assembly Brown Not Shown 17 0308800H41 Screw Sems Screw HSM 3x6 Ni 18 7508800H30 Poron Pad 19 7508800H31 Poron Pad VCO 20 HKLN4337_ PA Unit Board Kit 29 7 37 Mhz 120 W HKLN4...

Page 122: ...9 4 Exploded Views and Parts Lists PM1200 Radio Exploded View October 26 2007 6880309U09 A Notes ...

Page 123: ...s please call 1 800 422 4219 for U S and Canada Service Centers only International customers can obtain assistance at http www motorola com businessonline A 3 Mail Orders Mail orders are only accepted by the US Federal Government Markets Division USFGMD Motorola 7031 Columbia Gateway Drive 3rd Floor Order Processing Columbia MD 21046 U S A A 4 Telephone Orders Radio Products and Solutions Organiza...

Page 124: ...ns Organization United States and Canada 1 800 422 4210 A 7 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: ... level troubleshooting or service than is customarily performed at the basic level please send the radio to a Motorola Service Center as listed below B 2 Motorola Service Center 45D Butterfield Trail El Paso TX 79906 Tel 1 800 227 6772 B 3 Motorola Federal Technical Center 4395 Nicole Drive Lanham MD 20706 Tel 1 800 969 6680 Fax 1 800 784 4133 ...

Page 126: ...October 26 2007 6816532H01 A B 2 Motorola Service Centers Motorola Federal Technical Center Notes ...

Page 127: ...nverts analog signals into digital data See also DAC automatic level control A circuit in the transmit RF path that controls RF power amplifier output provides leveling over frequency and voltage and protects against high VSWR band Frequencies allowed for a specific purpose baseband interface port Synchronous serial interface to the transceiver board used to transfer transmit and receive audio dat...

Page 128: ...onverter A device that converts digital data into analog signals See also ADC Digital Private Line A type of digital communications that utilizes privacy call as well as memory channel and busy channel lock out to enhance communication efficiency digital signal processor A microcontroller specifically designed for performing the mathematics involved in manipulating analog information such as sound...

Page 129: ... rewritten to again and again FMR See Field Manual Revision Field Manual Revision A publication that provides supplemental information for its parent publication before it is revised and reissued FPGA Field Programmable Gate Array frequency Number of times a complete electromagnetic wave cycle occurs in a fixed unit of time usually one second frequency generation unit This unit generates ultra sta...

Page 130: ...ins RAM and ROM components as well as communications and programming components and peripherals MISO See Master In Slave Out MOSI See Master Out Slave In multiplexer An electronic device that combines several signals for transmission on some shared medium e g a telephone wire MUX See multiplexer oscillator An electronic device that produces alternating electric current and commonly employs tuned c...

Page 131: ...ata has been written onto a ROM chip it cannot be removed and can only be read real time clock A module that keeps track of elapsed time even when a computer is turned off receiver Electronic device that amplifies RF signals A receiver separates the audio signal from the RF carrier amplifies it and converts it back to the original sound waves Receiver Back End IC A custom integrated circuit provid...

Page 132: ...rcuits when received signal levels fall below a pre determined value With carrier squelch all channel activity that exceeds the radio s preset squelch level can be heard SRAM See static RAM SSI See Synchronous Serial Interface Standby mode An operating mode in which the radio is muted but still continues to monitor data static RAM A type of memory used for volatile program data memory that does no...

Page 133: ...oice encoder The DSP based system for digitally processing analog signals and includes the capabilities of performing voice compression algorithms or voice encoding voltage controlled oscillator An oscillator in which the frequency of oscillation can be varied by changing a control voltage Term Definition ...

Page 134: ...October 26 2007 6880309U09 A Glossary 8 Notes ...

Page 135: ...ield programming equipment 4 3 functional block diagram PM1200 8 2 H handling precautions 2 2 heatsinking precautions RF PA 2 2 M maintenance cleaning external plastic surfaces 2 2 general 2 1 internal circuit boards and components 2 2 general radio care 2 2 handling instructions 2 2 inspection 2 1 preventive 2 1 manual notations 1 1 revisions ii mode analog operation 3 4 model numbering scheme xv...

Page 136: ...power amplifier circuit protection 3 6 components 3 5 DC interconnect 3 6 gain stages 3 6 surrounding controller region emergency 3 2 introduction 3 2 voltage regulation 3 2 tools required disassembly reassembly 6 1 tools recommended 4 2 torque values fastener 6 48 trademark information ii transmit audio block diagram 8 8 transmitter block diagram 8 6 troubleshooting 7 2 troubleshooting introducti...

Page 137: ......

Page 138: ...in 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 All rights reserved October 2007 ...

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