Motorola CP200 Basic Service Manual

MOTOROLA, The Stylized M logo, and Radius are trademarks of Motorola, Inc.

All other product or service names are the property of their respective owners.

*6880309N61*

6880309N61-B

CP150

™

/CP200

™

Commercial Series

Two-Way Radio Basic Service Manual

i

TABLE OF CONTENTS

Section Product Safety and RF Exposure Compliance .........................v

Section 1 Introduction.............................................................................. 1-1

1.1 Scope of Manual..................................................................................................1-1

1.2 Warranty..............................................................................................................1-1

1.2.1 Warranty Period and Return Instructions...............................................1-1

1.2.2 After Warranty Period ............................................................................1-1

1.3 Replacement Parts Ordering...............................................................................1-2

1.3.1 Basic Ordering Information....................................................................1-2

1.3.2 Motorola Online......................................................................................1-2

1.3.3 Mail Orders ............................................................................................1-2

1.3.4 Telephone Orders..................................................................................1-2

1.3.5 Fax Orders.............................................................................................1-2

1.3.6 Parts Identification .................................................................................1-2

1.3.7 Product Customer Service.....................................................................1-3

1.4 Technical Support................................................................................................1-3

1.5 Radio Model Information......................................................................................1-4

Section 2 Maintenance............................................................................. 2-1

2.1 Introduction..........................................................................................................2-1

2.2 Preventive Maintenance......................................................................................2-1

2.2.1 Inspection...............................................................................................2-1

2.2.2 Cleaning Procedures .............................................................................2-1

2.3 Safe Handling of CMOS and LDMOS Devices....................................................2-2

2.4 Disassembling and Reassembling the Radio — General....................................2-3

2.5 Radio Disassembly — Detailed...........................................................................2-3

2.5.1 Front Cover from Chassis Disassembly.................................................2-3

2.5.2 Dust Cover Disassembly........................................................................2-5

2.5.3 Speaker Disassembly............................................................................2-5

2.5.4 PTT Disassembly...................................................................................2-6

2.5.5 Chassis Disassembly.............................................................................2-6

2.6 Radio Reassembly — Detailed............................................................................2-7

2.6.1 Chassis Assembly/Reassembly.............................................................2-7

2.6.2 PTT Reassembly ...................................................................................2-7

ii

2.6.3 Speaker Reassembly.............................................................................2-8

2.6.4 Dust Cover Assembly.............................................................................2-8

2.6.5 Chassis and Front Cover Reassembly...................................................2-8

2.7 Mechanical View and Parts List .........................................................................2-11

2.7.1 CP150/CP200 Exploded View and Parts List.......................................2-11

2.8 Test Equipment, Service Aids, and Service Tools .............................................2-13

Section 3 Transceiver Performance Testing.......................................... 3-1

3.1 General ................................................................................................................3-1

3.2 Power-Up Self Test..............................................................................................3-1

3.3 RF Test Mode ......................................................................................................3-2

Section 4 Radio Alignment Procedures ................................................. 4-1

4.1 Introduction ..........................................................................................................4-1

4.2 CPS Programming Setup.....................................................................................4-1

4.3 Radio Tuning Setup .............................................................................................4-2

4.3.1 Initial Test Equipment Control Settings..................................................4-3

4.4 Transmitter Alignment Options.............................................................................4-3

4.4.1 Reference Oscillator Warp.....................................................................4-3

4.4.2 Modulation Balance Attenuation.............................................................4-4

4.4.3 Transmit Power Tuning..........................................................................4-6

4.4.4 VCO Attenuation ....................................................................................4-8

4.4.5 DTMF Deviation Tuning .......................................................................4-10

4.4.6 MDC1200 Deviation Tuning (MDC radios only)...................................4-11

4.5 Receiver Tuning.................................................................................................4-11

4.5.1 Rated Volume Tuning...........................................................................4-12

4.5.2 Squelch Tuning ....................................................................................4-13

4.5.3 RSSI System Level Tuning ..................................................................4-14

4.5.4 RSSI Display Tuning............................................................................4-15

4.6 Utilities................................................................................................................4-15

4.6.1 Program Serial No................................................................................4-15

4.6.2 Temp Comp Data Read .......................................................................4-15

4.6.3 Temp Comp Data Write........................................................................4-15

4.7 Radio-to-Radio Cloning......................................................................................4-15

Section 5 Power Up Self-Test.................................................................. 5-1

iii

Section 6 Accessories.............................................................................. 6-1

6.1 Antennas..............................................................................................................6-1

6.2 Carrying Accessories...........................................................................................6-1

6.3 Chargers..............................................................................................................6-1

6.4 Batteries...............................................................................................................6-1

6.5 Surveillance Accessories.....................................................................................6-2

6.6 Headsets..............................................................................................................6-2

6.7 Remote Speaker Microphones............................................................................6-3

6.8 Ear Microphone Systems.....................................................................................6-3

6.9 Miscellaneous......................................................................................................6-3

6.10 Manuals...............................................................................................................6-3

Section 7 Model Charts and Test Specifications.................................. 7-1

7.1 VHF 136-162 MHz...............................................................................................7-1

7.2 VHF 146-174 MHz...............................................................................................7-2

7.3 VHF Specifications ..............................................................................................7-3

7.4 UHF 403-440 MHz...............................................................................................7-4

7.5 UHF 438-470 MHz...............................................................................................7-5

7.6 UHF 465-495 MHz...............................................................................................7-6

7.7 UHF Specifications..............................................................................................7-7

7.8 MIL Standards .....................................................................................................7-8

iv

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Safety-v

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 booklet enclosed with your radio (Motorola Publication part number

68P81095C98) 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/cgiss/index.shtml.

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

Safety-vi

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1-1

Section 1

INTRODUCTION

1.1 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.

1.2 Warranty

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 authorized Motorola Dealer must be accompanied by

a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola

Dealer.

1.2.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer, 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.

1.2.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.

1. Motorola's 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)

NOTE

Before operating or testing these units, please read the Product Safety and RF Exposure

Compliance section in the front of this manual.

1-2 Replacement Parts Ordering

1.3 Replacement Parts Ordering

1.3.1 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.

1.3.2 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).

1.3.3 Mail Orders

Send written orders to the following addresses:

1.3.4 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)

1.3.5 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)

1.3.6 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)

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.

Technical Support 1-3

1.3.7 Product Customer Service

Customer Response Center

(Non-technical Issues)

1-800-247-2346

FAX: 1-800-247-2347

1.4 Technical Support

Technical support is available to assist the dealer/distributor in resolving any malfunction which may

be encountered. Initial contact should be by telephone wherever possible. When contacting Motorola

Technical Support (Customer Resources), be prepared to provide the product model number and the

unit’s serial number.

Motorola Radio Support Center

3761 South Central Avenue

Rockford, IL 61102-4294

1-800-227-6772

1-815-489-1000

Motorola Toronto Service Center

400 Matheson Blvd. W,

Mississauga, Ontario, Canada L5R 3M1

1-800-543-3222

1-416-756-5841

1-888-331-9872 (Fax)

Motorola U.S. Federal Government Depot

4395 Nicole Drive

Lanham, MD 20706

1-800-969-6680

1-301-731-6676

1-4 Radio Model Information

1.5 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 portable radio model number and its specific characteristics.

Table 1-1 Radio Model Number (Example: AAH50KDC9AA1AN)

Type of

Unit

Model

Series

Freq.

Band

Power

Level

Physical

Packages

Channel

Spacing

Protocol

Feature

Level

Model

Revision

Model

Package

AA H 50 J

VHF1

(136-162

MHz)

K

VHF2

(146-174

MHz)

Q

UHF1

(403-440

MHz)

R2

UHF2

(438-470

MHz)

S

UHF3

(465-495

MHz)

D

4W or 5W

C

2W

C

No

Display

9

Program-

mable

AA

Conventional

1=4 Ch.

2=16 Ch.

AN

AA = Motorola Internal Use

H = Portable

2-1

Section 2

MAINTENANCE

2.1 Introduction

This section 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

2.2 Preventive Maintenance

The radios do not require a scheduled preventive maintenance program; however, periodic visual

inspection and cleaning is recommended.

2.2.1 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.

2.2.2 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, housing assembly and battery case. 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.

NOTE:

Internal 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 plas-

tics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.

!

2-2 Safe Handling of CMOS and LDMOS Devices

Cleaning Internal Circuit Boards and Components

Isopropyl alcohol (70%) 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 or tunable

components 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 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 back cover.

2.3 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.

NOTE:

Always 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 RSX-

4015.)

• 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.

!

Disassembling and Reassembling the Radio — General 2-3

2.4 Disassembling and Reassembling the Radio — General

Since these radios may be disassembled and reassembled with the use of only four (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 the radio (see Section 2.8 for a list of service aids):

• knob remover/chassis opener

• penknife-size screwdriver

• TORX™ T6 screwdriver

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 Section 1 for a list of authorized service

centers.

The following disassembly procedures should be performed only if necessary:

• Chassis Disassembly

• Speaker Disassembly

• PTT Disassembly

2.5 Radio Disassembly — Detailed

2.5.1 Front Cover from Chassis Disassembly

1. Turn off the radio.

2. Remove the battery (Figure 2-1):

a. Slide the battery latch into the unlock position. Disengage by pushing downward and

holding the latch towards the front of the radio.

b. With the battery latch disengaged, slide the battery down from the top of the radio about

1/2 in. Once the battery is free from the battery rails, lift it directly away from the radio.

c. Remove the battery from the radio.

3. Remove the antenna.

Figure 2-1. Battery Removal

Battery Latch

2-4 Radio Disassembly — Detailed

4. Pry off the volume and channel selector knobs from their shafts using the knob remover/chassis

opener tool (Motorola part # 6686533Z01) (Figure 2-2).

5. Separate the chassis from the front housing assembly by using the knob remover/chassis opener

tool. Place the broad side of the opener into the slots located at the base of the radio (Figure 2-3).

Press the handle of the opener downwards. This pressing action forces the thin inner plastic wall

toward the base of the radio, releasing the two chassis base tabs.

6. Pull the chassis assembly out of the front cover.

7. Unplug the speaker wire assembly from the 2-pin connector.

Figure 2-2. Knob Removal

NOTE:

Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.

Figure 2-3. Chassis Removal

CAUTION: Marring the front cover O-ring sealing area will prevent the radio from sealing

properly. If the O-ring is damaged, replace it with a new one.

NOTE:

The speaker wire assembly connecting the front housing assembly, and the chassis pre-

vent you from completely separating the two units.

Radio Chassis

Knob Remover/

Chassis Opener

!

Radio Disassembly — Detailed 2-5

2.5.2 Dust Cover Disassembly

a. Gently pry the top of the dust cover away from the body of the radio. (See Figure 2-4.)

b. Rotate the dust cover 90° in a counter clockwise direction to allow the key to be

removed.

c. Separate the dust cover away from the body of the radio. The dust cover key is fragile;

apply only light pressure to the key while removing the dust cover.

Figure 2-4. Dust Cover Removal

2.5.3 Speaker Disassembly

1. Remove the two screws from the speaker retainer using a T6 Torx screwdriver.

2. Lift the speaker out from the front housing.

NOTE:

The speaker is held in place with a retainer bracket. Be careful not to damage the speaker

when removing the retainer bracket.

Figure 2-5. Removal Speaker-Microphone Assembly

k

ey

c. Separate dust

cover from body.

b. Rotate dust cover 90

° to

a. Pry dust cover from body.

allow key to be removed.

Retainer Bracket

Speaker

Radio Housing

Wire Connector

2-6 Radio Disassembly — Detailed

2.5.4 PTT Disassembly

1. If required, the PTT (Figure 2-6) can be disassembled using a small screwdriver, as follows:

a. Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab.

b. Pry the PTT away from the radio housing.

c. Inspect the two hooks. If bent or broken, the PTT must be replaced.

d. Remove the PTT seal.

2.5.5 Chassis Disassembly

1. Remove the O-ring.

2. Use a Torx™ screwdriver with a T6 bit to remove the four screws (Figure 2-7) holding the main

board to the chassis.

Figure 2-6. PTT Removal

CAUTION: Refer to the CMOS CAUTION paragraph (see 3.3) before removing the main board. Be sure

to use Electrostatic Discharge protection when handling circuit boards.

Figure 2-7. Removal of Main Board from Chassis

Flat Blade

Screwdriver

PTT Seal

Ta b

Tab

Hooks

!

Main Board

Radio Chassis

Audio Jack Shroud

Microphone Assembly

Radio Reassembly — Detailed 2-7

3. The microphone boot assembly can be unplugged from the main board. If you are replacing the

microphone, remove it from the rubber boot.

4. The audio jack shroud can be removed from the main board.

5. Lift the main board from the chassis (Figure 2-7).

6. Remove the battery contact seal.

2.6 Radio Reassembly — Detailed

2.6.1 Chassis Assembly/Reassembly

1. Replace the battery contact seal (if necessary) surrounding the battery contact.

2. Remove the old Interface Pad from the chassis by scraping off the pad and adhesive with a

straight razor. Use rubbing alcohol and a cloth to completely remove the adhesive from the chas-

sis surface. With the chassis clean and dry, add a new Interface Pad to the chassis.

3. Place the main circuit board straight down on top of the chassis.

4. Use the T6 Torx screwdriver to fasten the screws holding the main board to the chassis. Tighten

to 3 in/lb.

5. Replacing the O-ring.

a. If you have the older chassis (2786389Z01) use the older O-ring (3286431Z02). Position

the O-ring in the top groove by the volume/frequency switches. Stretch the O-ring to

place it into the retaining groove at the bottom end of the chassis.

b. If you have the newer chassis (2786389Z02) use the newer O-ring (3286431Z05). Posi-

tion the O-ring with the plug on the right side (speaker connector side). Push the plug all

the way into the chassis slot until it is touching the chassis flange. Repeat for the left

side. Stretch the O-ring to place it into the retaining groove at the top and bottom end of

the chassis.

6. Replace the audio jack shroud.

7. Replace the microphone boot assembly.

2.6.2 PTT Reassembly

1. Place the PTT seal over the ridge around the top hole. Press down to seat the seal around the

ridge.

2. Place the bottom tab in the slot inside the front housing PTT opening. Slightly slide down the PTT

and bow it by placing one finger under the middle of the PTT, so that the top tab can be aligned

and inserted into the top slot (Figure 2-8a).

NOTE:

Be sure the battery contact seal protrudes through the chassis and is not pinched under the

chassis.

2-8 Radio Reassembly — Detailed

3. Press the PTT assembly against the front cover opening (Figure 2-8b).

2.6.3 Speaker Reassembly

1. Align the speaker as shown in Figure 2-9.

2. Insert the top of the speaker under the two rails in the housing.

3. Place the speaker retainer bracket onto the two screw bosses. Make sure the tab fits into the

retainer bracket slot.

4. Use the T6 Torx screwdriver to fasten the screws holding the retainer bracket to the front cover.

Tighten to 2 in/lb.

2.6.4 Dust Cover Assembly

a. Insert the dust cover key into the housing at a 90° angle.

b. Rotate the dust cover 90° in a clockwise direction to allow the key to fully insert into the

housing.

c. Press the key and dust cover into the housing.

2.6.5 Chassis and Front Cover Reassembly

1. Dress and connect the speaker wires.

a. Form the wires into an “M” shape so it can collapse on itself like an accordion with all of

the wire up in the top corner of the radio away from the shields. Place three bends in the

wires spaced approximately 1cm apart to give the wire an “M” shape (Figure 2-11).

Figure 2-8. PTT Assembly

Figure 2-9. Speaker Assembly

NOTE:

Care should be taken when dressing the speaker wires to avoid pinching them between the

speaker magnet and shield, under the microphone boot or between the accessory

connector and housing.

a. Place bottom tab into bottom slot.

Place top tab into top slot.

b. Push down on ribs toward bottom

of radio so hooks do not get crushed.

Rails

Screw Bosses

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