Motorola PM1200 User manual

MPM1200
Mobile Radio
Basic Service Manual
Motorola, Inc.
1301 E. Algonquin Rd.
Schaumburg, IL 60196-1078 USA 6880309U09-A

Foreword
This manual covers all models of the PM1200 Low Band Radio, unless otherwise specified. It includes all the information
necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance
procedures. This level of service goes down to the board replacement level and is typical of some local service centers,
self-maintained customers, and distributors.
For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A
list of related publications is provided in the section, “Related Publications,” on page xiv.
Product Safety and RF Exposure Compliance
ATTENTION!
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
Before using this product, read the RF energy awareness information and operating instructions in the
Product Safety and RF Exposure section in the user guide (Motorola Publication part number
6880309U08) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site
which lists approved accessories: http://www.motorola.com/governmentandenterprise/
Manual Revisions
Changes which occur after this manual is printed are described in FMRs/PMRs (Field/Publication Manual Revisions).
These FMRs/PMRs provide complete replacement pages for all added, changed, and deleted items. To obtain
FMRs/PMRs, go to http://motorola.com/businessonline.
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, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA and the Stylized M logo are registered in the US Patent & Trademark Office. All other product or service
names are the property of their respective owners.
© 2007 by Motorola, Inc.
Before using this product, read the operating instructions
for safe usage contained in the Product Safety and RF
Exposure booklet enclosed with your radio.
!
C a u t i o n

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

iv
Notes

Table of Contents v
6880309U09-A October 26, 2007
Table of Contents
Foreword.........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ii
Manual Revisions ........................................................................................................................................ii
Computer Software Copyrights ...................................................................................................................ii
Document Copyrights ..................................................................................................................................ii
Disclaimer....................................................................................................................................................ii
Trademarks .................................................................................................................................................ii
Document History ........................................................................................ iii
Commercial Warranty ..................................................................................xv
Limited Warranty .......................................................................................................................................xv
MOTOROLA COMMUNICATION PRODUCTS .............................................................................xv
I. What This Warranty Covers And For How Long ....................................................................xv
II. General Provisions ................................................................................................................xv
III. State Law Rights ................................................................................................................. xvi
IV. How To Get Warranty Service ............................................................................................ xvi
V. What This Warranty Does Not Cover................................................................................... xvi
VI. Patent And 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 in This Manual .................................................................................................... 1-1
1.2 Radio Description ........................................................................................................................ 1-1
1.3 PM1200 Control Head Descriptions ............................................................................................ 1-2
1.3.1 PM1200 Control Head ..................................................................................................... 1-2
1.3.2 PM1200 Controls............................................................................................................. 1-2
Chapter 2 Basic Maintenance.............................................................. 2-1
2.1 Introduction .................................................................................................................................. 2-1
2.2 Preventive Maintenance .............................................................................................................. 2-1
2.2.1 Inspection ........................................................................................................................ 2-1
2.2.2 Cleaning .......................................................................................................................... 2-1
2.2.2.1 Cleaning External Plastic Surfaces .................................................................. 2-2

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2.2.2.2 Cleaning Internal Circuit Boards and Components........................................... 2-2
2.2.3 General Radio Care and Handling Precautions............................................................... 2-2
2.2.4 RF Power Amplifier (RF PA) Heatsinking ........................................................................ 2-2
2.3 Handling Precautions................................................................................................................... 2-2
Chapter 3 Basic Theory of Operation ................................................. 3-1
3.1 Introduction .................................................................................................................................. 3-1
3.2 General Overview ........................................................................................................................ 3-1
3.3 Controller Section ........................................................................................................................ 3-2
3.3.1 Introduction ...................................................................................................................... 3-2
3.3.2 Surrounding Controller Region ........................................................................................ 3-2
3.3.2.1 Introduction ....................................................................................................... 3-2
3.3.2.2 Voltage Regulation ........................................................................................... 3-2
3.3.2.3 Emergency........................................................................................................ 3-2
3.4 Control Head Assembly ............................................................................................................... 3-3
3.4.1 Controller ......................................................................................................................... 3-3
3.4.2 Power Management (Power Control Microcontroller and Voltage Regulators) ............... 3-3
3.4.2.1 Voltage Regulators ........................................................................................... 3-3
3.4.3 User Interface (Keypad, STN Display, Volume Selector Knob, Microphone 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 Protection ............................................................................................................. 3-6
3.6.3 DC Interconnect............................................................................................................... 3-6
3.6.4 DCS Demodulator............................................................................................................3-6
3.6.5 CTCSS encoder/decoder................................................................................................. 3-6
3.6.6 MPU................................................................................................................................. 3-6
3.6.7 EEPROM ......................................................................................................................... 3-6
3.7 PLL Synthesizer........................................................................................................................... 3-7
Chapter 4 Test Equipment, Service Aids, and Tools......................... 4-1
4.1 Recommended Test Equipment .................................................................................................. 4-1
4.2 Service Aids and Recommended Tools ....................................................................................... 4-2
4.3 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
5.1 Introduction of Radio Alignment Procedures ............................................................................... 5-1
5.2 Required Test Equipment ............................................................................................................ 5-2

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6880309U09-A October 26, 2007
5.3 Alignment Preparation & Precautions..........................................................................................5-2
5.4 Alignment .................................................................................................................................... 5-3
5.4.1 PLL & Transmitter............................................................................................................ 5-3
5.4.2 PLL VCV.......................................................................................................................... 5-3
5.4.3 PLL Reference Frequency............................................................................................... 5-4
5.4.4 Transmitter Output Power LVHF ..................................................................................... 5-4
5.4.5 Transmitter Deviation ......................................................................................................5-4
5.4.5.1 Microphone Audio Modulation Level ................................................................ 5-4
5.4.5.2 CTCSS Modulation Level ................................................................................. 5-4
5.4.5.3 DCS Modulation Level ...................................................................................... 5-4
5.4.6 Receiver .......................................................................................................................... 5-4
5.4.6.1 Squelch Threshold............................................................................................ 5-5
5.5 PM1200 Radio Alignment Software ............................................................................................. 5-5
5.5.1 Installing the Radio Alignment Software.......................................................................... 5-5
5.5.2 Equipment Setup and Radio Alignment Software Execution........................................... 5-5
5.5.3 RX Tune Alignment ......................................................................................................... 5-6
5.5.4 SQL Alignment ................................................................................................................ 5-7
5.5.4.1 SQL Threshold Alignment ................................................................................ 5-7
5.5.4.2 SQL Tight Alignment ........................................................................................ 5-8
5.5.4.3 SQL RSSI Alignment ........................................................................................ 5-8
5.5.5 TX Power Alignment........................................................................................................ 5-9
5.5.6 TX Deviation Alignment ................................................................................................... 5-9
5.5.6.1 Maximum Deviation .......................................................................................... 5-9
5.5.6.2 TPL Deviation ................................................................................................. 5-10
5.5.6.3 DPL Deviation................................................................................................. 5-10
5.5.7 Writing The Alignment Data to the Radio ...................................................................... 5-11
5.5.8 Exiting the Radio Alignment 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
6.2.2.1.2 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 .................. 6-6
6.2.2.1.6 PM1200 Control Head Internal Speaker Disassembly ..................... 6-6
6.2.2.2 PM1200 Control Head Reassembly ................................................................. 6-7
6.2.2.2.1 PM1200 Control Head Key Unit Board Kit Reassembly................... 6-7
6.2.2.2.2 PM1200 Control Head VR Unit Board Kit Reassembly .................... 6-7
6.2.2.2.3 PM1200 Internal Speaker Reassembly............................................ 6-8
6.2.2.2.4 PM1200 Control Head Display Unit Board Kit Reassembly ............. 6-9
6.2.2.2.5 PM1200 Control Head Panel-Interface Unit Board Kit
Reassembly.................................................................................... 6-10
6.2.2.2.6 PM1200 Control Head Back Housing Reassembly ........................ 6-11

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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