Motorola Cm Radio Basic Manual

							Commercial Series
CM Radios
Basic Service Manual
6866545D11-O
Issue: October 2003 
						

							ii
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored 
in semiconductor memories or other media. Laws in the United States and other countries preserve for 
Motorola certain exclusive rights for copyrighted computer programs, including 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 or reproduced in 
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola 
products shall not be deemed to grant, either directly or by implication, estoppel or otherwise, any license 
under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive 
royalty-free license to use that arises by operation of law in the sale of a product. 
						

							iii
SAFETY INFORMATION
Read this information before using your radio.
PRODUCT SAFETY AND RF EXPOSURE FOR MOBILE TWO-WAY RADIOS
INSTALLED IN VEHICLES OR AS FIXED SITE CONTROL STATIONS.
This document provides information and instructions for the safe and efficient operation of Motorola 
Mobile Two-Way Radios.
 The information provided in this document supersedes information 
contained in user guides published prior to February 2002.
COMPLIANCE WITH RF ENERGY EXPOSURE STANDARDS
Note:This Radio is intended for use in occupational/controlled applications, where users have been 
made aware of the potential for exposure and can exercise control over their exposure. This radio 
device is NOT authorized for general population, consumer or similar use.
This user safety booklet includes useful information about RF exposure and helpful instructions on 
how to control your RF exposures.
Your Motorola radio is designed and tested to comply with a number of national and international 
standards and guidelines regarding human exposure to radio frequency electromagnetic energy. This
radio complies with IEEE and ICNIRP exposure limits for occupational/controlled RFexposure 
environments at usage factors of up to 50% talk–50% listen. In terms of measuring RF energy for 
compliance with the IEEE/ICNIRP exposure guidelines, your radio radiates measurable RF energy 
only while it is transmitting (during talking), not when it is receiving (listening) or in standby mode.
Your Motorola two-way radio complies with the following RF energy exposure
standards and guidelines:

United States Federal Communications Commission, Code of Federal Regulations; 47 CFR part 2 
sub-part J

American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers 
(IEEE) C95. 1-1992

Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999 Edition

International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998

Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radiofrequency Electro-
magnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999

Australian Communications Authority Radiocommunications (Electromagnetic Radiation - Human 
Exposure) Standard 2001 

ANATEL, Brasil Regulatory Authority, Resolution 256 (April 11, 2001) “additional requirements for 
SMR, cellular and PCS product certification.” 
						

							iv
COMPLIANCE AND CONTROL GUIDELINES AND OPERATING INSTRUCTIONS FORMOBILE TWO-WAY RADIOS INSTALLED IN VEHICLES
To control your exposure and ensure compliance with the occupational/controlled environment  
exposure limits, always adhere to the following procedures:

To transmit (talk), push the Push-To-Talk (PTT) button; to receive, release the PTT button. Transmit 
only when people outside the vehicle are at least the minimum lateral distance away from a properly 
installed, externally-mounted antenna and from the vehicle body. Table 1 lists the minimum distance 
for bystanders in an uncontrolled environment from the transmitting antenna and from the vehicle 
body  a t se ve ra l d if f ere nt ran ges of  ra ted ra dio  po wer  for  mobile r adi os ins ta lled  in  a  ve h icl e.

Install mobile antennas at the centre of the roof and centre of the trunk deck. These mobile installa-
tion guidelines are limited to metal body vehicles. The antenna installation must additionally be in 
accordance with: 
a. The requirements of the antenna manufacturer/supplier 
b. Instructions in the Radio Installation Manual.

Use only Motorola-approved supplied or replacement antenna. Use of non–Motorola - approved  
antennas, modifications, or attachments could damage the radio and may violate 
IEEE/ICNIRP 
regulations. For a list of Motorola-approved antennas, visit the following web site :
http://moleurope.comm.mot.com/member/commerce 
For additional information on exposure requirements or other training information, visit 
http://www.motorola.com/rfhealth.
COMPLIANCE AND CONTROL GUIDELINES AND OPERATING INSTRUCTIONS FOR MOBILE TWO-WAY RADIOS INSTALLED AS FIXED SITE CONTROL STATIONS
If mobile radio equipment is installed at a fixed location and  operated as a control station or as a fixed 
unit, the antenna installation must comply with the following requirements in order to ensure optimal 
performance and compliance with the RF energy exposure in the standards and guidelines listed 
above:

The antenna must be mounted outside the building on the roof or a tower if at all possible.

As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in 
accordance with applicable regulatory requirements and may require additional compliance actions 
such as site survey measurements, signage, and site access restrictions in order to insure that 
exposure limits are not exceeded.  Ta b l e 1 :
Rated Power and Distances
Rated Power of Vehicle-Installed Mobile Two-Way Radio Minimum Distance from
Transmitting Antenna Minimum Lateral Distance
From Vehicle Body
Less than 7Watts20 cm (8 Inches)20 cm (8 Inches)
7 to 15 Watts 30.5 cm (1 Foot) 20 cm (8 Inches)
16 to 39 Watts61 cm (2 Feet)20 cm (8 Inches)
40 to 110 Watts 91.5 cm (3 Feet) 20 cm (8 Inches) 
						

							v
ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY
NOTE: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if 
inadequately shielded, designed or otherwise configured for electromagnetic compatibility. It may be 
necessary to conduct compatibility testing to determine if any electronic equipment used in or around 
vehicles or near fixed site antenna is sensitive to external RF energy or if any procedures need to be 
followed to eliminate or mitigate the potential for interaction between the radio transmitter and the 
equipment or device.
Facilities
To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any
facility where posted notices instruct you to do so.  Hospitals or health care facilities may be 
using equipment that is sensitive to external RF energy.
Ve hicles
To avoid possible interaction between the radio transmitter and any vehicle electronic control 
modules, for example, ABS, engine, or transmission controls, the radio should be installed only by an 
experienced installer and that the following precautions be used when installing the radio: 
1.
Refer to the manufacturer’s instructions or other technical bulletins or recommendations on radio installation. 
2.Before installing the radio, determine the location of the electronic control modules and their harnesses in 
the vehicle.
3.3. Route all radio wiring, including the antenna transmission line, as far away as possible from the electronic 
control units and associated wiring.
Driver Safety
Check the laws and regulations on the use of radios in the area where you drive. Always obey them.
When using your radio while driving, please:

Give full attention to driving and to the road.

Pull off the road and park before making or answering a call if driving conditions so require. 
OPERATIONAL WARNINGS
For Vehicles With An Air Bag
Do not mount or place a mobile radio in the area over an air bag or in the air bag deployment area. Air 
bags inflate with great force. If a radio is placed in the air bag deployment area and the air bag 
inflates, the radio may be propelled with great force and cause serious injury to occupants of the 
vehicle.
Potentially Explosive Atmospheres
Turn off your radio prior to entering any area with a potentially explosive atmosphere. Sparks in a 
potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even 
death.
The areas with potentially explosive atmospheres referred to above include fuelling areas such as 
below decks on boats, fuel or chemical transfer or storage facilities, areas where the air contains 
chemicals or particles, such as grain, dust or metal powders.  Areas with potentially explosive 
atmospheres are often but not always posted.
Blasting Caps And Areas
To avoid possible interference with blasting operations, turn off your radio when you are near 
electrical blasting caps, in a blasting area, or in areas posted: 
Turn off two-way radio. Obey all signs and instructions. 
						

							vi
For radios installed in vehicles fueled by liquefied petroleum gas, refer to the (U.S.) National Fire 
Protection Association standard, NFPA 58, for storage, handling, and/or container information. For a 
copy of the LP-gas standard, NFPA 58, contact the National Fire Protection Association, One Battery 
Park, Quincy, MA. 
						

							vii
Ta b l e o f C o n t e n t s
SAFETY INFORMATION ........................................................................................iii
Chapter 1 INTRODUCTION
1.0 Scope of Manual .................................................................................................. 1-1
2.0 Warranty and Service Support ............................................................................. 1-1
2.1 Warranty Period and Return Instructions ....................................................... 1-1
2.2 After Warranty Period ..................................................................................... 1-1
2.3 European Radio Support Centre (ERSC) ....................................................... 1-2
2.4 Piece Parts ..................................................................................................... 1-2
2.5 Technical Support........................................................................................... 1-3
3.0 Radio Model Information ...................................................................................... 1-4
Chapter 2 MAINTENANCE
1.0 Introduction .......................................................................................................... 2-1
2.0 Preventive Maintenance ...................................................................................... 2-1
2.1 Inspection ....................................................................................................... 2-1
2.2 Cleaning Procedures ...................................................................................... 2-1
3.0 Safe Handling of CMOS and LDMOS Devices .................................................... 2-2
4.0 Repair Procedures and Techniques — General .................................................. 2-3
5.0 Disassembling and Reassembling the Radio — General .................................... 2-3
6.0 Radio Disassembly - Detailed .............................................................................. 2-4
6.1 Control Head Removal ................................................................................... 2-4
6.2 Top Cover Removal........................................................................................ 2-6
6.3 Main Shield Removal...................................................................................... 2-7
6.4 PA Shield and DC Cable Removal ................................................................. 2-7
6.5 PA Clip and Main PCB Removal .................................................................... 2-8
6.6 Disassembly of Control Head - CM140/CM340.............................................. 2-9
6.7 Disassembly of Control Head - CM160/CM360............................................ 2-10
7.0 Radio Assembly ................................................................................................. 2-11
7.1 Chassis Assembly ........................................................................................ 2-11
7.2 Control Heads -Assembly ............................................................................. 2-11
7.3 Control Head Fitting...................................................................................... 2-11
8.0 Radio Exploded Mechanical Views and Parts Lists ........................................... 2-12
8.1 Radio Assembly - 25W Models .................................................................... 2-12
8.2 Control Head - CM140/CM340 ..................................................................... 2-13
8.4 Control Head - CM160/CM360 ..................................................................... 2-14
9.0 Service Aids ....................................................................................................... 2-15
10.0 Test Equipment .................................................................................................. 2-17
11.0 Programming/Test Cable - RKN4083_ .............................................................. 2-18
12.0 Adapter Cable - FKN8113_................................................................................ 2-19 
						

							viii
Chapter 3 TRANSCEIVER PERFORMANCE TESTING
1.0 General ................................................................................................................ 3-1
2.0 Setup ................................................................................................................... 3-1
3.0 RF Test Mode (5-Tone Radios) ........................................................................... 3-2
4.0 RF Test Mode (MDC Radios) .............................................................................. 3-5
Chapter 4 RADIO TUNING AND PROGRAMMING
1.0 Introduction .......................................................................................................... 4-1
2.0 CPS Programming/Flashing Setup with RIB ....................................................... 4-1
3.0 CPS Programming/Flashing Setup Ribless ......................................................... 4-2
4.0 CPS Programming Setup with RIB (Telco Connector) ........................................ 4-2
5.0 CPS Programming Setup with RIB (Accessory Connector) ................................ 4-3
6.0 CPS Programming Setup with RIB ...................................................................... 4-3
7.0 Radio Tuning Setup  ............................................................................................ 4-4
7.1 Initial Test Equipment Control Settings .......................................................... 4-4
Chapter 5 POWER UP SELF-TEST
1.0 Error Codes (5-Tone Radios) .............................................................................. 5-1
2.0 Error Codes (MDC Radios).................................................................................. 5-2
Chapter 6 ACCESSORIES & CONNECTOR PIN FUNCTIONS
1.0 Accessories ......................................................................................................... 6-1
2.0 Accessory Connector Pin Functions .................................................................... 6-4
3.0 Microphone Connector Pin Functions.................................................................. 6-5
Chapter 7 MODEL CHART AND TEST SPECIFICATION
1.0 Model Chart (UHF1 403-440 MHz) ...................................................................... 7-1
2.0 Model Chart (UHF2 438-470 MHz) ...................................................................... 7-2
3.0 Model Chart (VHF2 146-174 MHz) ...................................................................... 7-3
4.0 Model Chart (Midband 66-88 MHz) ..................................................................... 7-4
5.0 Model Chart (UHF2 438-470 MHz - High Power) ................................................ 7-5
6.0 Model Chart (VHF2 146-174 MHz - High Power) ................................................ 7-6
7.0 Specifications ...................................................................................................... 7-7
GLOSSARY............................................................................................ i 
						

							Chapter 1
INTRODUCTION
1.0 Scope of Manual
This manual is intended for use by service technicians familiar with similar types of equipment. It 
contains service information required for the equipment described and is current as of the printing 
date. Changes which occur after the printing date may be incorporated by a complete Manual 
revision or alternatively as additions.
2.0 Warranty and Service Support
Motorola offers long term support for its products. This support includes full exchange and/or repair 
of the product during the warranty period, and service/ repair or spare parts support out of warranty. 
Any return for exchange or return for repair by an authorised Motorola Dealer must be 
accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an 
Authorised Motorola Dealer.
2.1 Warranty Period and Return Instructions
The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or 
Reseller contract. These conditions may change from time to time and the following notes are for 
guidance purposes only.
In instances where the product is covered under a return for replacement or return for repair 
warranty, a check of the product should be performed prior to shipping the unit back to Motorola. 
This is to ensure that the product has been correctly programmed or has not been subjected to 
damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact 
Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be 
accompanied by a Warranty Claim Form, available from your Customer Services representative. 
Products should be shipped back in the original packaging, or correctly packaged to ensure no 
damage occurs in transit. 
2.2 After Warranty Period
After the Warranty period, Motorola continues to support its products in two ways. 
1.Motorolas Radio Aftermarket and Accessory Division (AAD) offers a repair service to both 
end users and dealers at competitive prices. 
2.AAD supplies individual parts and modules that can be purchased by dealers who are 
technically capable of performing fault analysis and repair.
NOTEBefore operating or testing these units, please read the Safety Information Section in the
front of this manual. 
						

							1-2INTRODUCTION
2.3 European Radio Support Centre (ERSC)
The ERSC Customer Information Desk is available through the following service numbers: 
Austria: 08 60 29 75 41 Italy:  80 08 77 387
Belgium:  08 00 72 471 Luxemburg:  08 00 23 27
Denmark:  80 88 05 72  Netherlands: 08 00 22 45 13
Finland: 08 00 11 49 910 Norway:  80 01 11 15
France: 08 00 90 30 90 Portugal:  08 00 84 95 70
Germany: 08 00 18 75 240 Spain:  90 09 84 902
Greece: 00 80 04 91 29 020 Sweden:  02 07 94 307
UK : 08 00 96 90 95 Switzerland: 08 00 55 30 82
Ireland: 18 00 55 50 21 Iceland:  80 08 147 
Or dial the European Repair and Service Centre: 
Tel: +49 30 6686 1555
Please use these numbers for repair enquiries only.
2.4 Piece Parts
Some replacement parts, spare parts, and/or product information can be ordered directly. If a  
complete Motorola part number is assigned to the part, it is available from Motorola Radio 
Aftermarket and Accessory Division (AAD). If no part number is assigned, the part is not normally 
available from Motorola. If the part number is appended with an asterisk, the part is serviceable by 
Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable 
parts are available for that kit or assembly. 
All part orders should be directed to : Motorola GmbH 
Customer Care
Am Bo rs ig tu rm  130
13507 Berlin
Germany.