Motorola Radius Cm200 Cm300 Pm400 Basic 6802966c15 A Manual

							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 
Authorized Motorola Dealer.
2.1 Warranty Period and Return Instructions
The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or 
Reseller contract. These conditions may change from time to time and the following notes are for 
guidance purposes only.
In instances where the product is covered under a return for replacement or return for repair 
warranty, a check of the product should be performed prior to shipping the unit back to Motorola. 
This is to ensure that the product has been correctly programmed or has not been subjected to 
damage outside the terms of the warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact 
Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be 
accompanied by a Warranty Claim Form, available 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 Products and Services Division (RPSD) offers a repair service to both end users 
and dealers at competitive prices. 
2.Radio Products and Services Division (RPSD) supplies individual parts and modules that can be 
purchased by dealers who are technically capable of performing fault analysis and repair.
* The Radio Products and Services Division (RPSD) was formerly knows as the Accessories and 
Aftermarket Division (AAD)
NOTEBefore operating or testing these units, please read the Safety Information Section in the
front of this manual. 
						

							1-2INTRODUCTION
3.0 Replacement Parts Ordering
3.1 Basic Ordering Information
When ordering replacement parts or equipment information, the complete identification number 
should be included. This applied to all components, kits, and chassis. If the component part number is 
not known, the order should include the number of the chassis or kit of which it is a part, a sufficient 
description of the desired component to identify it.
3.2 Motorola Online
Motorola online users can access our on-line catalog at:
HTTPS://WWW.MOTOROLA.COM/BUSINESSONLINE
To register for online access, please call 800-814-0601 (for U.S. and Canada Service Centers only).
3.3 Mail Orders
Send written orders to the following addresses:
3.4 Telephone Orders
Radio Products and Services Division (RPSD)
(United States and Canada)
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
847-538-8023 (International Orders
U.S. Federal Government Markets Division (USFGMD)
1-800-826-1913 Federal Government Parts - Credit Card Only
8:30 AM to 5:00 PM (Eastern Standard Time)
3.5 Fax Orders
Radio Products and Services Division (RPSD)
(United States and Canada)
1-800-622-6210
847-576-3023 (International)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchased Orders)
Replacement Parts/Test 
Equipment/Manuals/Crystal 
Service Items:Federal Government Orders:International Orders:
Motorola, Inc.
Radio Products and Services Division
Attention: Order Processing
2200 Galvin Dr.
Elgin, IL 60123
U.S.A.Motorola, Inc.
U.S. Federal Government
Markets Division
Attention: Order Processing
7230 Parkway Drive
Landover, MD21076
U.S.A.
Motorola, Inc.
Radio Products and Services 
Division
Attention: Order Processing
2200 Galvin Dr.
Elgin, IL 60123
U.S.A. 
						

							Radio Model Information1-3
3.6 Parts Identification
Radio Products and Services Division (RPSD)*
(United States and Canada)
1-800-422-4210, menu 3
* The Radio Products and Services Division (RPSD) was formerly known as the Accessories and 
Aftermarket Division (AAD)
4.0 Radio Model Information
The model number and serial number are located on a label attached to the back of your radio. You 
can determine the RF output power, frequency band, protocols, and physical packages. The 
example below shows one mobile radio model number and its specific characteristics.
Table 1-1   Radio Model Number (Example: AAM50KNC9AA1)
Type of 
UnitModel 
SeriesFreq. 
BandPower 
LevelPhysical 
PackagesChannel 
SpacingProtocolFeature 
Level
AAM50J
VHF1
(136-162 
MHz)
N
1-25 WC
CM2009
Program-
mableAA
Conven-
tional
MDC1
4/32 mini-U
3
64 mini-U
K
VHF2
(146-174 
MHz)
P
25-40 WF
CM300
PM400
R
UHF2
(438-470 
MHz)
Q
25-45 W
S
UHF3
(465-495 
MHz)
 AA = Country Code
M = Mobile 
						

							1-4INTRODUCTION
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							Chapter 2
MAINTENANCE
1.0 Introduction
This chapter provides details about the following:
•Preventive maintenance (inspection and cleaning).
•Safe handling of CMOS and LDMOS devices.
•Disassembly and reassembly of the radio.
•Repair procedures and techniques.
•Installation of Option Boards.
2.0 Preventive Maintenance
The radios do not require a scheduled preventive maintenance program; however, periodic visual 
inspection and cleaning is recommended.
2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches 
are functional. It is not recommended to inspect the interior electronic circuitry.
2.2 Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used 
when cleaning the external and internal surfaces of the radio. External surfaces include the front 
cover and housing assembly. These surfaces should be cleaned whenever a periodic visual 
inspection reveals the presence of smudges, grease, and/or grime. 
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild 
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit 
boards and their components is isopropyl alcohol (70% by volume).
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to 
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the 
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, 
or crevices.
NOTEInternal surfaces should be cleaned only when the radio is disassembled for service or
repair.
CAUTION: The effects of certain chemicals and their vapors can have harmful results on 
certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.
! 
						

							2-2MAINTENANCE
Cleaning Internal Circuit Boards and Components
Isopropyl alcohol (100%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge 
embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the 
dislodged material out and away from the inside of the radio. Make sure that controls are not soaked 
with alcohol. Do not use high-pressure air to hasten the drying process since this could cause the 
liquid to collect in unwanted places. After completing of the cleaning process, use a soft, absorbent, 
lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or 
top cover.
3.0 Safe Handling of CMOS and LDMOS Devices
Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and 
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting 
in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent 
device damage during disassembly, troubleshooting, and repair. 
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity 
conditions. DO NOT attempt to disassemble the radio without first referring to the following 
CAUTION statement. 
NOTEAlways use a fresh supply of alcohol and a clean container to prevent contamination by 
dissolved material (from previous usage).
CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are 
properly grounded. Take the following precautions when working on this unit:
•Store and transport all CMOS devices in conductive material so that all exposed 
leads are shorted together. Do not insert CMOS devices into conventional plastic 
“snow” trays used for storage and transportation of other semiconductor devices.
•Ground the working surface of the service bench to protect the CMOS device. We 
recommend using the Motorola Static Protection Assembly (part number 
0180386A82), which includes a wrist strap, two ground cords, a table mat, and a 
floor mat.
•Wear a conductive wrist strap in series with a 100k resistor to ground. 
(Replacement wrist straps that connect to the bench top covering are Motorola part 
number 4280385A59)
•Do not wear nylon clothing while handling CMOS devices.
•Do not insert or remove CMOS devices with power applied. Check all power 
supplies used for testing CMOS devices to be certain that there are no voltage 
transients present.
•When straightening CMOS pins, provide ground straps for the apparatus used.
•When soldering, use a grounded soldering iron.
•If at all possible, handle CMOS devices by the package and not by the leads. Prior 
to touching the unit, touch an electrical ground to remove any static charge that you 
may have accumulated. The package and substrate may be electrically common. If 
so, the reaction of a discharge to the case would cause the same damage as 
touching the leads.
! 
						

							Repair Procedures and Techniques — General 2-3
4.0 Repair Procedures and Techniques — General
Parts Replacement and Substitution
When damaged parts are replaced, identical parts should be used. If the identical replacement part 
is not locally available, check the parts list for the proper Motorola part number and order the part 
from the nearest Motorola Parts center listed in the “Piece Parts” section in Chapter 1 of this manual.
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not 
accessible, some special considerations are required when soldering and unsoldering components. 
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise 
care to avoid pulling the plated circuit out of the hole.
When soldering near the RF connector, potentiometer, 16-pin and 20-pin connectors:
•Avoid accidentally getting solder in the connector.
•Be careful not to form solder bridges between the connector pins.
•Examine your work closely for shorts due to solder bridges.
5.0 Disassembling and Reassembling the Radio — General
Since these radios may be disassembled and reassembled with the use of only 14 (board to casting) 
screws, it is important to pay particular attention to the snaps and tabs, and how parts align with 
each other.
The following tools are required for disassembling/assembling the radio:
•Small flat blade screwdriver
•Phillips small 1# screwdriver
•TORX™ T9 screwdriver
•TORX™ T10 screwdriver
•Torque screwdriver set
•Torque spanner
•Hex tool (part no. 6680334F39)
If a unit requires more complete testing or service than is customarily performed at the basic level, 
send this unit to a Motorola Authorized Service Center. (See Chapter 1 for a list of authorized 
service centers.)
The following disassembly procedures should be performed only if necessary: 
						

							2-4MAINTENANCE
6.0 Radio Disassembly - Detailed
The procedure to remove and replace a Control Head, Top Cover or Transceiver Board is similar for 
all models of radio. A typical procedure is therefore shown followed by specific disassembly 
procedures for Control Heads on radio models without a display and radio models fitted with a 
display.
6.1 Control Head Removal
Volume Knob Removal
1. Insert the flat screwdriver between the control head plastic and the volume knob and push the 
volume knob upwards. See Figure 2-1.
Figure 2-1 Volume Knob Removal.
2. Insert the flat screw driver (4 mm maximum) into the slot and push the plastic up. 
Do the same with the second slot to free the control head from the chassis assembly. See 
Figure 2-2.
NOTEEnsure that the volume knob is in the OFF position before disassembling the radio. 
						

							Radio Disassembly - Detailed2-5
Figure 2-2 Control Head Removal
3. To free the control head, disconnect the flat cable from the chassis assembly See Figure 2-3.
Figure 2-3 Flat Cable Removal
Main PCB Connector 
						

							2-6MAINTENANCE
6.2 Top Cover Removal
1. Place the radio in a vertical position as shown in Figure 2-4.
Figure 2-4 Top Cover Removal (Chassis Vertical).
2. Insert the flat screw driver near the ‘T’ and push the plastic cover up until it pops over the ‘T’ 
mount boss. Perform the same function on the ‘T’ location on the other side of the chassis.
3. Next place the radio in a horizontal position as shown in Figure 2-5 and insert the flat screw 
driver into the slot to release the upper cover.
Figure 2-5 Top Cover Removal (Chassis Horizontal)