Motorola CP140 Basic Service Manual
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Motorola CP140 Basic Service Manual

Commercial series
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See also: Detailed Service Manual , User Manual
Commercial Series
CP140/CP160/CP180
Portable Radios
Basic Service Manual
6866550D17-A
Issue: October 2004

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Summary of Contents for Motorola CP140

  • Page 1 Commercial Series CP140/CP160/CP180 Portable Radios Basic Service Manual 6866550D17-A Issue: October 2004...

  • Page 2: Computer Software Copyrights

    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...

  • Page 3: Safety Information

    Read this information before using the radio. PRODUCT SAFETY AND RF EXPOSURE FOR PORTABLE TWO-WAY RADIOS. This document provides information and instructions for the safe and efficient operation of Motorola Portable Two-Way Radios. The information provided in this document supersedes information contained in user guides published prior to February 2002.
  • Page 4 Compliance with RF Exposure Standards Your Motorola two-way radio is designed and tested to comply with a number of national and International standards and guidelines (listed below) for human exposure to radio frequency electromagnetic energy. This radio complies with the IEEE (FCC) and ICNIRP exposure limits for occupational/controlled RF exposure environments at operating duty factors of up to 50% talk- 50% listen and is authorized by the IEEE/ICNIRP for occupational use only.
  • Page 5 Motorola - approved antennas, batteries and accessories may exceed IEEE/ICNIRP RF exposure guidelines. For a list of Motorola-approved antennas, batteries, and other accessories please see your dealer or local Motorola contact. Your nearest dealer can be found at the following web site: http://www.motorola.com/cgiss/emea/dealerlocator.html Additional Information For additional information on exposure requirements or other training information, visit http://www.motorola.com/rfhealth.
  • Page 6 ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY NOTE: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately shielded, designed or otherwise configured for electromagnetic compatibility. 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.

  • Page 7: Operational Warnings

    OPERATIONAL WARNINGS Vehicles with an air bag Refer to vehicle manufacturer's manual prior to installation of electronic equipment to avoid interference with air bag wiring. WARNING: Do not place a portable radio in the area over an air bag or in the air bag deployment area.

  • Page 8: Intrinsically Safe Radio Information

    Warnings for Radios Approved as Intrinsically Safe Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and the intrinsic safety approval labelling (FM, UL, CSA, CENELEC or ATEX). Radios will not be upgraded to this capability and labeled once they have been shipped to the field.
  • Page 9 The manual PN referenced on the Intrinsically Safe Approval Label identifies the approved Accessories and or options that can be used with that portable radio unit. Using a non Motorola intrinsically safe battery and or accessory with the Motorola approved radio unit will void the intrinsically safe approval of that radio unit.

  • Page 11: Table Of Contents

    Table of Contents Table of Contents Safety Information..................iii Chapter 1 Model Charts and Test Specifications ......1-1 Radio Model Information........................ 1-1 Model Chart for VHF 136-162 MHz ....................1-2 Model Chart for VHF 146-174 MHz ....................1-3 VHF Specifications ........................1-4 Model Chart for UHF 403-440 MHz ....................
  • Page 12 Table of Contents Chapter 6 Full Keypad Model Disassembly and Re-assembly ................ 6-1 Introduction ............................ 6-1 Preventive Maintenance ........................ 6-1 6.2.1 Inspection.......................... 6-1 6.2.2 Cleaning Procedures ......................6-1 Safe Handling of CMOS and LDMOS Devices ................6-2 Disassembling and Re-assembling the Radio — General............. 6-3 6.4.1 Radio Disassembly —...
  • Page 13 Chassis and Front Cover Re-assembly ............8-10 8.4.3.5 PTT Re-assembly .................... 8-12 Mechanical View and Parts List....................8-13 8.5.1 CP140 Non-Keypad Exploded View and Parts List ............8-13 Chapter 9 Troubleshooting Tables ............. 9-1 Power-Up Error Codes ........................9-1 Operational Error Codes........................ 9-1 Troubleshooting Table for Receiver....................
  • Page 14 Table of Contents...

  • Page 15: Chapter 1 Model Charts And Test Specifications

    Chapter 1 Model Charts and Test Specifications 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.

  • Page 16: Model Chart For Vhf 136-162 Mhz

    Model Chart for VHF1 136-162 MHz CP100 Series, VHF1, 136-162 MHz Model Description MDH65JDC9AA2AN CP140, 136-162 MHz, 5 W, 16 Ch. Non-Display Model MDH65JDF9AA3AN CP160, 136-162 MHz, 5 W, 32 Ch. Limited Keypad Model MDH65JDH9AA4AN CP180, 136-162 MHz, 5 W, 64 Ch. Full Keypad Model...

  • Page 17: Model Chart For Vhf 146-174 Mhz

    Model Chart for VHF2 146-174 MHz CP100 Series, VHF2, 146-174 MHz Model Description MDH65KDC9AA2AN CP140, 146-174 MHz, 5 W, 16 Ch. Non-Display Model MDH65KDF9AA3AN CP160, 146-174 MHz, 5 W, 32 Ch. Limited Keypad Model MDH65KDH9AA4AN CP180, 146-174 MHz, 5 W, 64 Ch. Full Keypad Model...

  • Page 18: Vhf Specifications

    VHF Specifications VHF Specifications General Transmitter RF Output High Frequency: 136-162 MHz NiMH @ 7.5 V: 146-174 MHz Frequency: 136-162 MHz Channel Capacity: 16, 32, or 64 Channels 146-174 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/20/25 kHz Dimensions with: Freq.

  • Page 19: Model Chart For Uhf 403-440 Mhz

    Model Chart for UHF1 403-440 MHz CP100 Series, UHF1, 403-440 MHz Model Description MDH65QDC9AA2AN CP140, 403-440 MHz, 4 W, 16 Ch. Non-Display Model MDH65QDF9AA3AN CP160, 403-440 MHz, 4 W, 32 Ch. Limited Keypad Model MDH65QDH9AA4AN CP180, 403-440 MHz, 4 W, 64 Ch. Full Keypad Model...

  • Page 20: Model Chart For Uhf 438-470 Mhz

    Model Chart for UHF2 438-470 MHz CP100 Series, UHF2, 438-470 MHz Model Description MDH65RDC9AA2AN CP140, 438-470 MHz, 4 W, 16 Ch. Non-Display Model MDH65RDF9AA3AN CP160, 438-470 MHz, 4 W, 32 Ch. Limited Keypad Model MDH65RDH9AA4AN CP180, 438-470 MHz, 4 W, 64 Ch. Full Keypad Model...

  • Page 21: Model Chart For Uhf 465-495 Mhz

    Model Chart for UHF3 465-495 MHz CP100 Series, UHF3, 465-495 MHz Model Description MDH65SDC9AA2AN CP140, 465-495 MHz, 4 W, 16 Ch. Non-Display Model MDH65SDF9AA3AN CP160, 465-495 MHz, 4 W, 32 Ch. Limited Keypad Model MDH65SDH9AA4AN CP180, 465-495 MHz, 4W, 64 Ch. Full Keypad Model...

  • Page 22: Uhf Specifications

    UHF Specifications UHF Specifications General Transmitter Frequency: 403-440 MHz RF Output High 438-470 MHz NiMH @ 7.5 V: 465-495 MHz Frequency: 403-440 MHz Channel Capacity: 16, 32, or 64 Channels 438-470 MHz 7.5 Volts ±20% Power Supply: 465-495 MHz Dimensions with: Channel Spacing: 12.5/20/25 kHz High Capacity Li-Ion,...

  • Page 23: Mil Standards

    Model Charts and Test Specifications: MIL Standards MIL Standards Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications (8.2 and 8.4) Military Standards 810 C, D, E, & F: Parameters/Methods/Procedures 810C 810D 810E 810F Applicable Methods...
  • Page 24 1-10 Model Charts and Test Specifications: MIL Standards...

  • Page 25: Chapter 2 Theory Of Operation

    Chapter 2 Theory Of Operation Introduction This chapter provides a basic theory of operation for the radio components. Major Assemblies • Transceiver Board – contains all transmit, receive, and audio circuitry. • Display (Limited and Full Keypad models only) – 8 characters (14 segments star burst) and 10 icons with backlighting, liquid-crystal display (LCD).

  • Page 26: Transmitter

    Theory Of Operation: Major Assemblies The IFIC is a low-voltage monolithic FM IF system incorporating a mixer/oscillator, two limiting IF amplifiers, quadrature detector, logarithmic received signal strength indicator (RSSI), voltage regulator and audio, and RSSI Op Amps. The second LO frequency, 44.395 MHz, is determined by a crystal oscillator.

  • Page 27: Chapter 3 Test Equipment, Service Aids, And Service Tools

    Chapter 3 Test Equipment, Service Aids, and Service Tools Test Equipment Table 3-1 lists test equipment required to service the CP100 Series Portable Radios. Table 3-1. Recommended Test Equipment Motorola Part No. Description Characteristics Application R2600 series Comms System This item will substitute for...

  • Page 28: Service Aids

    Table 3-2 lists service aids recommended for working on the CP100 Series Portable Radios. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.
  • Page 29 Test Equipment, Service Aids, and Service Tools: Service Aids Programming/Test Cable 25 POSITION 25 POSITION MALE CONNECTOR FEMALE CONNECTOR 36.0” CABLE 36.0” CABLE Figure 3-1. Programming/Test Cable 25 pin Male D Connector Components molded inside 2.5mm stereo and 3.5mm Orange 3.5mm Tip (Speaker +) Blue...
  • Page 30 Test Equipment, Service Aids, and Service Tools: Service Aids...

  • Page 31: Chapter 4 Performance Checks

    Chapter 4 Performance Checks General These radios meet published specifications through their manufacturing process by utilizing high- accuracy laboratory-quality test equipment. The recommended field service equipment is as accurate as the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 32: Rf Test Mode

    Performance Checks: RF Test Mode Supply voltage can be connected from the battery eliminator. The equipment required for alignment procedures is connected as shown in the Radio Performance Checks Setup diagram (Figure 4-1). Initial equipment control settings should be as indicated in Table 4-1 and should be the same for all performance checks and tuner alignment procedures.
  • Page 33 Performance Checks: RF Test Mode To enter test mode: 1. Turn the radio on. Within ten seconds after the self test is complete (self test tone is heard), press SB2 (Side Button 2 in Figure 4-2) five times in succession. If the self test complete tone is not heard, see Error Codes information in Chapter 9.
  • Page 34 Performance Checks: RF Test Mode Table 4-4. Test Frequencies VHF1 VHF2 UHF1 UHF 2 UHF3 Channel Selector Test Channel (136-162 (146-174 (403-440 (438-470 (465-495 Switch Position MHz) MHz) MHz) MHz) MHz) 1 Low Power TX#1 or #8 136.625 146.625 403.625 438.625 465.625 8 High Power...
  • Page 35 Performance Checks: RF Test Mode Table 4-6. Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode: PWR MON TEST MODE, PTT to continu- Frequency error to be Frequency Test Channel 4 ous (during the ±200 Hz VHF 4th channel test frequency carrier squelch performance...
  • Page 36 Performance Checks: RF Test Mode Notes:...

  • Page 37: Introduction

    Chapter 5 Radio Tuning and Programming Introduction This chapter provides an overview of the Commercial Series Customer Programming Software (CPS) and the Global Tuner as designed for use in a Windows® 98/NT4/2000/ME/XP environment. Both cover all the functions of the traditional Radio Service Software (RSS) package. They are both available in the CPS and Global Tuner (CD ROM) Kit (RVN4191).

  • Page 38: Radio Tuning Setup

    Radio Tuning and Programming: Radio Tuning Setup Radio Tuning Setup A Windows 98/NT4/2000/ME/XP PC (personal computer) and Global Tuner are required to tune the radio. To perform the tuning procedures, the radio must be connected to the PC, RIB (Radio Interface Box) and Universal Test Set as shown in Figure 5-2 below.

  • Page 39: Initial Test Equipment Control Settings

    Radio Tuning and Programming: Radio-to-Radio Cloning 5.3.1 Initial Test Equipment Control Settings The initial test equipment control settings are listed in Table 5-1. Table 5-1. Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode: Power Monitor Speaker set: A Voltage: 13.2 Vdc RF Attenuation: -70 Speaker/load:...
  • Page 40 Radio Tuning and Programming: Radio-to-Radio Cloning Procedure: 1. Turn source and target radios off. 2. Connect cloning cable (PMKN4003) to the side connector of both radios. 3. Turn on the destination radio. 4. Press and hold the two side buttons at the same time on the source radio and then power up the source radio (Figure 5-3).

  • Page 41: Chapter 6 Full Keypad Model Disassembly And Re-Assembly

    Chapter 6 Full Keypad Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 42: Safe Handling Of Cmos And Ldmos Devices

    • 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.

  • Page 43: Disassembling And Re-Assembling The Radio - General

    Scribe 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 Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...
  • Page 44 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Remove the antenna. 4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis opener tool (Motorola part # 6686533Z01). (Figure 6-2).
  • Page 45 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Note: The speaker wire assembly microphone wire assembly and keypad flex cable connector connecting the front housing assembly and the chassis prevent the two units from being completely separated 7.

  • Page 46: Dust Cover Disassembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.1.2 Dust Cover Disassembly 1. Gently pry the top of the dust cover away from the body of the radio. (See Figure 6-6). 2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed. 3.

  • Page 47: Keyboard Removal

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.1.4 Keyboard Removal 1. Carefully pry the four keypad retainer locking tabs free from the housing use a scribe. Note: Use care when removing the keypad retainer to prevent damage to the keyboard flex cable.

  • Page 48: Chassis Disassembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Hooks Flat Blade Screwdriver PTT Seal Figure 6-9. PTT Removal 6.4.1.6 Chassis Disassembly CAUTION: Refer to the CMOS CAUTION paragraph (see 6.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

  • Page 49: Radio Re-Assembly - Detailed

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6.4.2 Radio Re-assembly - Detailed 6.4.2.1 Dust Cover Re-assembly 1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 6-11).
  • Page 50 6-10 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Microphone Boot Microphone Recess Microphone Position Figure 6-12. Microphone Re-assembly 4. Locate the speaker tab and align it with the tab opening in the front housing (Figure 6-13).

  • Page 51: Keypad And Lcd/Keyboard Re-Assembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-11 6.4.2.3 Keypad and LCD/Keyboard Re-assembly 1. Attach the flex cable from the LCD module to the keyboard, if not already attached (Figure 6-15). 2. Remove protective mylar from window and from keypad, if present. 3.

  • Page 52: Keyboard Retainer Re-Assembly

    6-12 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6. Attach the flex cable into the connector on the keypad board, if not already connected. 7. Bend the flex cable as shown (Figure 6-15) 6.4.2.4 Keyboard Retainer Re-assembly 1.

  • Page 53: Chassis And Front Cover Re-Assembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-13 Audio Jack Shroud Frequency & (Replace after Plugging Volume Switches in Speaker and Mic) Main Board Interface Pad Flex Cable Connector Radio Chassis Battery Contact Seal O-Ring Figure 6-17.
  • Page 54 6-14 Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Speaker Connector Microphone Connector Shroud Figure 6-18. Microphone and Speaker Wires Re-assembly 2. Position the radio (Figure 6-19), and reconnect the flex connector from the keyboard into the con- nector located on the bottom of the main board, pushing up the 2 end tabs.

  • Page 55: Ptt Re-Assembly

    Full Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-15 5. Snap chassis assembly completely into the top of the front cover (Figure 6-20) until it settles in place. Radio Chassis Figure 6-20. Fastening the Chassis 6.

  • Page 56: Mechanical View And Parts List

    6-16 Full Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List Mechanical View and Parts List 6.5.1 CP180 Full-Keypad Exploded View and Parts List Figure 6-22. CP180 Full Keypad Radio Exploded View...
  • Page 57 Item Description Item Description Part Number Part Number See Section 6 Antenna NON-REFERENCED ITEMS 3680530Z02 Knob, Frequency 3386625Z01 Nameplate, Motorola 1386440Z03 Escutcheon, Top; 64 Ch. 3386623Z07 Nameplate, CP180 Not Field Antenna Adaptor/Seal Repairable (Optional) 1586391Z03 Housing, Full, with Lens 3586621Z01...
  • Page 58 6-18 Full Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List Notes:...

  • Page 59: Chapter 7 Limited Keypad Model Disassembly And Re-Assembly

    Chapter 7 Limited Keypad Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 60: Safe Handling Of Cmos And Ldmos Devices

    • 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.

  • Page 61: Disassembling And Re-Assembling The Radio - General

    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 Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...
  • Page 62 7-4 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 4. Pry off the volume and channel selector knobs from their shafts using the knob remover/chassis opener tool (Motorola part # 6686533Z01) (Figure 7-2). Figure 7-2. Antenna and Knob Removal Note: Both knobs slide on and off.
  • Page 63 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-5 6. Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case. (Figure 7-4).

  • Page 64: Dust Cover Disassembly

    7-6 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.1.2 Dust Cover Disassembly 1. Gently pry the top of the dust cover away from the body of the radio. (See Figure 7-6). 2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed. 3.

  • Page 65: Keyboard Removal

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-7 7.4.1.4 Keyboard Removal 1. Carefully pry the four keypad retainer locking tabs free from the housing use a scribe. Note: Use care when removing the keypad retainer to prevent damage to the keyboard flex cable. 2.

  • Page 66: Ptt Disassembly

    7-8 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.1.5 PTT Disassembly 1. If required, the PTT (Figure 7-9) can be disassembly using a small screwdriver, as follows: Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab. Pry the PTT away from the radio housing.

  • Page 67: Radio Re-Assembly - Detailed

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-9 Audio Jack Shroud Main Board Flex Cable Connector Radio Chassis O-Ring Figure 7-10. Removal of Main Board from Chassis 7.4.3 Radio Re-assembly - Detailed 7.4.3.1 Dust Cover Re-assembly 1.
  • Page 68 7-10 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Insert the Boot and microphone sub-assembly into the microphone recess in the housing and route wires as shown in Figure 7-12. Microphone Boot Microphone Recess Microphone Position Figure 7-12.

  • Page 69: Keypad And Lcd/Keyboard Re-Assembly

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-11 7.4.3.3 Keypad and LCD/Keyboard Re-assembly 1. Attach the flex cable connector from the LCD module to the keyboard, if not already attached (Figure 7-15). 2. Remove protective mylar from window and from keypad, if present. 3.

  • Page 70: Keyboard Retainer Re-Assembly

    7-12 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7.4.3.4 Keyboard Retainer Re-assembly 1. Insert the flex cable connector through the slot at the bottom of the keyboard retainer (Figure 7- 16). Figure 7-16. Keyboard Retainer Re-assembly 2.

  • Page 71: Chassis And Front Cover Re-Assembly

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-13 Audio Jack Shroud Frequency & (Replace after Plugging Volume Switches in Speaker and Mic) Main Board Interface Pad Radio Chassis Battery Contact Seal O-Ring Figure 7-17. Installation of Main Board onto Chassis 7.4.3.6 Chassis and Front Cover Re-assembly 1.
  • Page 72 7-14 Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Speaker Connector Microphone Connector Shroud Figure 7-18. Microphone and Speaker Wires 2. Position the radio (Figure 7-19) and reconnect the flex cable connector from the keyboard into the connector located on the bottom of the main board, pushing up the 2 end tabs.

  • Page 73: Ptt Re-Assembly

    Limited Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-15 5. Snap chassis assembly completely into the top of the front cover (Figure 7-20) until it settles in place. Radio Chassis Figure 7-20. Fastening the Chassis 6.

  • Page 74: Mechanical View And Parts List

    7-16 Limited Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List Mechanical View and Parts List 7.5.1 CP160 Limited-Keypad Exploded View and Parts List Figure 7-22. CP160 Limited Keypad Radio Exploded View...
  • Page 75 Item Description Item Description Part Number Part Number See Section 6 Antenna NON-REFERENCED ITEMS 3680530Z02 Knob, Frequency 3386625Z01 Nameplate, Motorola 1386440Z03 Escutcheon, Top; 32 Ch.. 3386623Z06 Nameplate, CP160 Not Field Antenna Adaptor/Seal Repairable (Optional) 1586391Z02 Housing, Limited, with Lens 3586621Z01...
  • Page 76 7-18 Limited Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List Notes:...

  • Page 77: Chapter 8 Non-Keypad Model Disassembly And Re-Assembly

    Chapter 8 Non-Keypad Model Disassembly and Re-assembly Introduction This section provides details about the following: • Preventive maintenance (inspection and cleaning) • Safe handling of CMOS and LDMOS devices • Disassembly and re-assembly of the radio • Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program;...

  • Page 78: Safe Handling Of Cmos And Ldmos Devices

    • 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.

  • Page 79: Disassembling And Re-Assembling The Radio - General

    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 Appendix B for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...
  • Page 80 Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 3. Remove the antenna. 4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis opener tool (Motorola part # 6686533Z01). (Figure 8-2) Figure 8-2.

  • Page 81: Dust Cover Disassembly

    Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6. Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case. (Figure 8-4). Rotate the chassis counterclockwise out of the housing and position next to the housing. Take care not to damage the speaker and microphone wires that are still connected to the chassis (Figure 8-4).

  • Page 82: Speaker And Microphone Disassembly

    Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 8.4.1.3 Speaker and Microphone Disassembly Note: The speaker is held in place with a retainer bracket. Be careful not to damage the speaker when removing the retainer bracket. 1.

  • Page 83: Chassis Disassembly

    Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Flat Blade Screwdriver Hooks PTT Seal Figure 8-7. PTT Removal 8.4.2 Chassis Disassembly CAUTION: Refer to the CMOS CAUTION paragraph (8.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

  • Page 84: Radio Re-Assembly - Detailed

    Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 8.4.3 Radio Re-assembly - Detailed 8.4.3.1 Dust Cover Re-assembly 1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 8-9).

  • Page 85: Chassis Assembly/Re-Assembly

    Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Note: Make sure the speaker and microphone wires are routed tightly between the speaker bas- ket and the housing post 6. Insert one end of the speaker retainer into the slot in the front housing (See Figure 8-11).

  • Page 86: Chassis And Front Cover Re-Assembly

    8-10 Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General Audio Jack Shroud Frequency & (Replace after Plugging Volume Switches in Speaker and Mic) Main Board Interface Pad Radio Chassis Battery Contact Seal O-ring Figure 8-12. Installation of Main Board onto Chassis 8.4.3.4 Chassis and Front Cover Re-assembly 1.
  • Page 87 Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 8-11 Speaker Connector Microphone Connector Shroud Figure 8-13. Microphone and Speaker Wires Re-assembly Radio Chassis Figure 8-14. Fastening the Chassis 4. Snap chassis assembly completely into the top of the front cover (Figure 8-14) until it settles in place.

  • Page 88: Ptt Re-Assembly

    8-12 Non-Keypad Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 8.4.3.5 PTT Re-assembly 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...

  • Page 89: Mechanical View And Parts List

    Non-Keypad Model Disassembly and Re-assembly: Mechanical View and Parts List 8-13 Mechanical View and Parts List 8.5.1 CP140 Non-Keypad Exploded View and Parts List Figure 8-16. CP140 Non-Keypad Radio Exploded View...
  • Page 90 1586437Z01 Shroud, Audio Jack 5586445Z02 Latch Assembly 4105944K01 Spring, Latch; 2 Used 3886441Z01 Cap, Dust 3286432Z01 Seal, Control Shaft 3386443Z01 Label, Escutcheon Seal 6186446Z02 Lightpipe 3680529Z01 Knob, Volume 0386434Z01 Screw, Speaker Retainer NON-REFERENCED ITEMS 3386625Z01 Nameplate, Motorola 3386623Z05 Nameplate, CP140...

  • Page 91: Chapter 9 Troubleshooting Tables

    Chapter 9 Troubleshooting Tables Power-Up Error Codes During radio power-up, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as an error code on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted.

  • Page 92: Troubleshooting Table For Receiver

    Troubleshooting Tables: Troubleshooting Table for Receiver Troubleshooting Table for Receiver Table 9-3 lists the possible causes of, and corrections for, receiver problems. Table 9-3. Receiver Troubleshooting Table Corrective or Test Symptom Possible Causes (Measurements at Room Temperature) Radio Dead; Display Does 1.

  • Page 93: Troubleshooting Table For Transmitter

    Troubleshooting Tables: Troubleshooting Table for Transmitter Troubleshooting Table for Transmitter Table 9-4 lists the possible causes of, and corrections for, transmitter problems. Table 9-4. Transmitter Troubleshooting Table Corrective or Test Symptom Possible Causes (Measurements at Room Temperature) No RF Power Out 1.
  • Page 94 Troubleshooting Tables: Troubleshooting Table for Transmitter Notes:...

  • Page 95: Appendix A Accessories

    Appendix A Accessories Antennas HAD9338_R VHF Heliflex Antenna 16cm (136-162 MHz) NAD6502_R VHF Heliflex Antenna 14cm (146-174 MHz) HAD9742 VHF Stubby Antenna, 9cm (146-162 MHz) HAD9743 VHF Stubby Antenna, 9cm (162-174 MHz) NAE6522_R UHF Heliflex Stubby Antenna 9cm (438-470 MHz) NAE6483_R Flexible Whip Antenna (403-520 MHz) 8505816K24...

  • Page 96: Audio Accessories

    Accessories: Batteries NNTN4496_R NiCd, 1100 mAh NNTN4497_R Li-lon, High Cap, 1800 mAh NNTN4851_R NiMH, 1400 mAh NNTN4852_R NiMH FM, 1300 mAh NNTN4970_R Slim Li-Ion, 1600 mAh Audio Accessories HMN9752 Earpiece with Volume Control, 1-Wire (plastic earloop) (Beige) HMN9727 Earpiece without Volume Control, 1-Wire (plastic earloop) (Beige) RLN4894 Earpiece without Volume Control, 1-Wire (plastic earloop) (Black) HMN9754...

  • Page 97: Remote Speaker Microphones

    Accessories: Headsets RLN5411 Ultra-Lite Breeze Behind the Head Headset PMMN4001 Ultra-Lite Earset with Mic and PTT HMN9013 Lightweight Headset w/o In-line PTT RMN4016 Lightweight Headset with In-line PTT RLN5238 Lightweight Headset with In-line PTT, NFL Style HMN9021 Medium Weight Over the Head Dual Muff Headset HMN9022 Medium Weight Behind the Head Dual Muff Headset BDN6647...
  • Page 98 Accessories: Manuals 6866550D01_ CP140/CP160/CP180 Basic User Guide - Multi-Language GMLN1091A CP140/CP160/CP180 Basic User Guide - Multi-Language CDROM GMLN1092B CP100 Series Product Manual - English GMLN1093B CP100 Series Product Manual - French GMLN1094B CP100 Series Product Manual - Russian GMLN1098B CP100 Series Product Manual - English/French/Russian CDROM...

  • Page 99: Appendix B Warranty, Service Support, And Replacement Parts

    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.

  • Page 100: European Radio Support Centre

    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.

  • Page 101: Technical Support

    Warranty, Service Support, and Replacement Parts: Technical Support Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions which may be encountered. UK/Ireland - Richard Russell Telephone: +44 (0) 1256 488 082 Fax: +44 01256 488 080 Email: BRR001@email.mot.com...
  • Page 102 Warranty, Service Support, and Replacement Parts:...

  • Page 103: Glossary

    Micro Controller Unit MRTI Motorola Radio-Telephone Interconnect: a system that provides a repeater connection to the Public Switched Telephone Network (PSTN). The MRTI allows the radio to access the telephone network when the proper access code is received.
  • Page 104 Term Definition Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider. Push-To-Talk: the switch located on the left side of the radio; when pressed, causes the radio to transmit. Random Access Memory: the radio’s RAM is loaded with a copy of the EEPROM data.

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