Motorola CP150 Basic Service Manual
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Motorola CP150 Basic Service Manual

Commercial series
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CP150
/CP200
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Commercial Series
Two-Way Radio Basic Service Manual

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Summary of Contents for Motorola CP150

  • Page 1 CP150 /CP200 ™ ™ Commercial Series Two-Way Radio Basic Service Manual...

  • Page 3: Table Of Contents

    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...
  • Page 4 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...
  • Page 5 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 .......................
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  • Page 7: Product Safety And Rf Exposure Compliance

    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.
  • Page 8 Safety-vi This page intentionally left blank...

  • Page 9: Section 1 Introduction

    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 10: Replacement Parts Ordering

    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).

  • Page 11: Product Customer Service

    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.

  • Page 12: Radio Model Information

    Radio Model Information 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 Model...

  • Page 13: Section 2 Maintenance

    Section 2 MAINTENANCE 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 Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended.

  • Page 14: 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 15: Disassembling And Reassembling 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 Section 1 for a list of authorized service centers. The following disassembly procedures should be performed only if necessary: •...
  • Page 16 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). Figure 2-2. Knob Removal NOTE: Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.

  • Page 17: Dust Cover Disassembly

    Radio Disassembly — Detailed 2.5.2 Dust Cover Disassembly Gently pry the top of the dust cover away from the body of the radio. (See Figure 2-4.) Rotate the dust cover 90° in a counter clockwise direction to allow the key to be removed.

  • Page 18: Ptt Disassembly

    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: Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab. Pry the PTT away from the radio housing. Inspect the two hooks.

  • Page 19: Radio Reassembly - Detailed

    Radio Reassembly — Detailed 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.

  • Page 20: Speaker Reassembly

    Radio Reassembly — Detailed 3. Press the PTT assembly against the front cover opening (Figure 2-8b). a. Place bottom tab into bottom slot. b. Push down on ribs toward bottom Place top tab into top slot. of radio so hooks do not get crushed. Figure 2-8.
  • Page 21 Radio Reassembly — Detailed a. Insert dust cover key into housing at 90° angle. Figure 2-10. Dust Cover Assembly Bend the wires up from the speaker so the wires are positioned toward the top of the radio (Figure 2-11). Figure 2-11. Bend the Wires into an “M”...
  • Page 22 2-10 Radio Reassembly — Detailed 2. Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover. Look through the accessory connector opening to make certain that the wires are not pinched. 3. Push the chassis assembly completely into the top of the front cover (Figure 2-13) until it settles in place. Radio Chassis Figure 2-13.

  • Page 23: Mechanical View And Parts List

    Mechanical View and Parts List 2-11 Mechanical View and Parts List 2.7.1 CP150/CP200 Exploded View and Parts List Figure 2-14. CP150/CP200 Radio Exploded View...
  • Page 24 Seal, main O-ring 7586436Z02 Pad, PA interface 0386434Z01 Screws, speaker retainer; 2 used 0786433Z02 Retainer, speaker 5005679X04 Speaker 3586092Z02 Felt, speaker 4586439Z01 PTT, plastic 3886489Z01 PTT, rubber NON-REFERENCED ITEMS 3386488Z01 Nameplate, Motorola 3386409Z01 Nameplate, Radius CP200 3386409Z02 Nameplate, Radius CP150...

  • Page 25: Test Equipment, Service Aids, And Service Tools

    SINAD meter with With RMS audio voltmeter Table 2-2 lists service aids recommended for working on the CP150/CP200 Radio. 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 26 2-14 Test Equipment, Service Aids, and Service Tools Table 2-2 Service Aids (Continued) Motorola Part Description Application AAPMKN4003 Radio-to-Radio Cloning Cable Allows a radio to be duplicated from a master radio by transferring programmed data from the master radio to the other.
  • Page 27 Test Equipment, Service Aids, and Service Tools 2-15 Table 2-3 Recommended Service Tools (Continued) Motorola Part Description Application R1319A ChipMaster (110 V) Surface mount removal and assembly of surface mounted integrated circuits and/or rework station R1321A ChipMaster (220 V) shields. Includes 5 nozzles.
  • Page 28 2-16 Test Equipment, Service Aids, and Service Tools Programming/Test Cable 25 POSITION 25 POSITION MALE CONNECTOR FEMALE CONNECTOR 36.0” CABLE 36.0” CABLE Figure 2-15. Programming/Test Cable 25 pin Male D Connector Components molded inside 2.5mm stereo and 3.5mm Orange 3.5mm Tip (Speaker +) Blue 3.5mm...

  • Page 29: Section 3 Transceiver Performance Testing

    Section 3 TRANSCEIVER PERFORMANCE TESTING General These radios meet published specifications through their manufacturing process by utilizing high- accuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 30: Rf Test Mode

    Monitor Vol: 1/4 CW RF Test Mode When the CP150/CP200 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment using a special routine, called RF TEST MODE.
  • Page 31 RF Test Mode To enter test mode: 1. Turn the radio on. 2. Within ten seconds after the self test is complete (self test tone is heard), press SB2 (Side Button 2 in Figure 3-2) five times in succession. If the self test complete tone is not heard, see Error Codes information in Section 5.
  • Page 32 RF Test Mode Table 3-4 Test Frequencies VHF 1 VHF 2 UHF 1 UHF 2 UHF 3 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...
  • Page 33 RF Test Mode Table 3-5 Receiver Performance Checks (Continued) Test Name Communications Analyzer Radio Test Set Comments Noise RF level set to 1mV RF As above PTT to OFF Set volume control to Squelch (center), meter 3.2Vrms Threshold selection to (only radios Audio PA, spkr/ with conven-...
  • Page 34 RF Test Mode Table 3-6 Transmitter Performance Checks (Continued) Communications Test Name Radio Test Set Comments Analyzer PL/DPL As above TEST MODE, As above Deviation: ≥ Modulation 4th channel test frequency Test Channel 4 VHF, UHF 500Hz ≤ BW to narrow 1000Hz (25 kHz Ch Sp).

  • Page 35: Section 4 Radio Alignment Procedures

    Section 4 RADIO ALIGNMENT PROCEDURES 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 36: Radio Tuning Setup

    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 4-2. Refer to online help files for the tuning procedures.

  • Page 37: Initial Test Equipment Control Settings

    Transmitter Alignment Options 4.3.1 Initial Test Equipment Control Settings The initial test equipment control settings are listed in Table 4-1. Table 4-1 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: DC on/standby:...

  • Page 38: Modulation Balance Attenuation

    Transmitter Alignment Options 1. Under Tx Align menu, select Reference Oscillator Warp (Figure 4-3). 2. There is only 1 frequency point shown which is always the last non-0 transmit frequency point, which will normally be F7. 3. Click on the slider thumb and press PTT Toggle to key up the radio at the corresponding fre- quency point.
  • Page 39 Transmitter Alignment Options Figure 4-4. Modulation Balance Window Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low frequency port) lines. The compensation algorithm is critical to the operation of signaling schemes that have very low frequency components (Digital Private-Line) and could result in distorted waveforms if improperly adjusted.

  • Page 40: Transmit Power Tuning

    Transmitter Alignment Options 4.4.3 Transmit Power Tuning Note: The maximum available power level given in the table below must not be exceeded. There are separate alignment procedures for High and Low power. Note: When checking the RF power output of the radio with a test set, always use a pad of at least 30 dB attached to the radio end of the RF cable.
  • Page 41 Transmitter Alignment Options Table 4-3 Transmit High/Low Power Level RF Band (MHz) Model Number High Power(W) Low Power (W) 4 Channel VHF 136-162 MHz H50JDC9AA1AN 5.2-5.5 1.1-1.3 16 Channel VHF 136-162 MHz H50JDC9AA2AN 5.2-5.5 1.1-1.3 4 Channel VHF 146-174 H50KCC9AA1AN 16 Channel VHF 146-174 H50KCC9AA2AN 4 Channel VHF 146-174...

  • Page 42: Vco Attenuation

    Transmitter Alignment Options 5. Press PTT Toggle again to key up the radio at the selected frequency point. 6. Repeat steps 3-5 for the remaining test frequencies (F2-F7). 7. Press Program to store the softpot values into the radio’s codeplug. 8.

  • Page 43: Vco Attenuation 20 Khz

    Transmitter Alignment Options 4. Record the deviation obtained. 5. Adjust the slider; adjust the spin control or key in softpot values (press ENTER to confirm) for the frequency point until the deviation is within the range specified in 8.. 6. Dekey the radio (Press the PTT Toggle button). Choose the next frequency, key up and repeat steps 3 to 6 until all seven tuning points are done.

  • Page 44: Dtmf Deviation Tuning

    4-10 Transmitter Alignment Options 4.4.5 DTMF Deviation Tuning This tuning option controls the Dual Tone MultiFrequency deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning the DTMF. Figure 4-7.

  • Page 45: Mdc1200 Deviation Tuning (Mdc Radios Only)

    Receiver Tuning 4-11 4.4.6 MDC1200 Deviation Tuning (MDC radios only) This tuning option controls the MDC1200 Signaling deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning this feature.

  • Page 46: Rated Volume Tuning

    4-12 Receiver Tuning 4.5.1 Rated Volume Tuning Note: When using test box RLN4460, the received audio output is taken from the AC/DC METER OUT terminals with the METER OUT rotary switch set to RX. The rated audio tuning procedure automatically configures the radio for 25 KHz. This means that a 3 kHz (for 25 kHz channel spacing) deviation must always be used, irrespective of the radio channel bandwidth.

  • Page 47: Squelch Tuning

    Receiver Tuning 4-13 4.5.2 Squelch Tuning Note: 1. Squelch tuning can only be accomplished after reference oscillator warping. 2. When using the test box RLN4460, the received audio output is taken from the AC/ DC METER OUT terminals with the METER OUT rotary switch set to RX. It is recommended that Rated Volume Tuning be performed so the the correct 10 dB SINAD level can be obtained.

  • Page 48: Rssi System Level Tuning

    4-14 Receiver Tuning 4. Adjust the softpot value by using the slider, keying in the edit box or using the spin controls. Press ENTER to confirm the selection or use the spin controls. Do this until the radio is totally unmuted. Verify the squelch closing by inputting a signal level of 4 dB lower than that of the 10 dB SINAD level.

  • Page 49: Rssi Display Tuning

    Utilities 4-15 4.5.4 RSSI Display Tuning 1. Under the Rx Align menu, select RSSI Display Tuning. 2. Inject an on channel signal to the radio at -47 dBm at the frequency listed. Modulated the signal with a 1 kHz tone at 60% deviation (3 kHz) to verify the radio is receiving the desired frequency. RSSI tuning is only done at 25 kHz channel spacing.
  • Page 50 4-16 Radio-to-Radio Cloning 4. Press and hold the two side buttons at the same time on the source radio and then power up the source radio (Figure 4-3). Both radios produce a “clone-entry” tone. 5. Release both side buttons, 1 and 2. 6.

  • Page 51: Section 5 Power Up Self-Test

    Section 5 POWER UP SELF-TEST Turning on the radio using the on/off volume control starts a self-test routine which checks the RAM, EEPROM hardware and EEPROM checksum. Pressing and holding SB1 while turning on the radio causes the self-test routine to check for the ROM checksum as well. If these checks are successfully completed, the radio will generate the Self-Test Pass Tone.
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  • Page 53: Section 6 Accessories

    Section 6 ACCESSORIES Antennas 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) 8505816K26 UHF Heliflex Stubby Antenna 7.1cm (470-520 MHz) NAE6483_R Flexible Whip Antenna (403-520 MHz) Carrying Accessories...

  • Page 54: Surveillance Accessories

    Surveillance Accessories Surveillance 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 Earpiece with Microphone & PTT Combined, 2-Wire (Beige) RLN4895 Earpiece with Microphone &...

  • Page 55: Remote Speaker Microphones

    Portable Radio Hanger for door panels up to 2.75 to 3.25 inch (slides over and hangs from the door panel in vehicle, radio belt clip required) 6.10 Manuals 6880309N60 CP150/CP200 User Guide, English/French 6880309N62 CP150/CP200 Detailed Service Manual, English HKLN4220 CP150/CP200 User Guide CDROM, English/French...
  • Page 56 Manuals This page intentionally left blank...

  • Page 57: Section 7 Model Charts And Test Specifications

    Section 7 MODEL CHARTS AND TEST SPECIFICATIONS VHF 136-162 MHz CP200, VHF, 136-162 MHz Model Description AAH50JDC9AA1AN CP200, 136-162 MHz, 5 W, 4 Ch. AAH50JDC9AA2AN CP200, 136-162 MHz, 5 W, 16 Ch. Item Description PMUD1981_ CP200, 136-162 MHz, 5 W, 4 Ch. X PMUD1982_ CP200, 136-162 MHz, 5 W, 16 Ch.

  • Page 58: Vhf 146-174 Mhz

    CP200, Back Cover Kit. 146-174 MHz, 4 Ch. X PMLD4205_ CP200, Back Cover Kit, 146-174 MHz, 16 Ch. PMLD4206_ CP150, Back Cover Kit, 146-174 MHz, 4 Ch. PMLD4207_ CP150, Back Cover Kit, 146-174 MHz, 16 Ch. PMLN4552_ Plain, Front Housing Kit, 4 Ch.

  • Page 59: Vhf Specifications

    VHF Specifications VHF Specifications General Transmitter Frequency: 136-162 MHz RF Output High 146-174 MHz NiMH @ 7.5V: Channel Capacity: 4 or 16 Channels Frequency: 136-162 MHz 146-174 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/20/25 kHz Battery Dimensions: with Freq.

  • Page 60: Uhf 403-440 Mhz

    UHF 403-440 MHz UHF 403-440 MHz CP200, UHF, 403-440 MHz Model Description AAH50QDC9AA1AN CP200, 403-440 MHz, 4 W, 4 Ch. AAH50QDC9AA2AN CP200, 403-440 MHz, 4 W, 16 Ch. Item Description PMUE1984_ CP200, 403-440 MHz, 4 W, 4 Ch. X PMUE1985_ CP200, 403-440 MHz, 4 W, 16 Ch.

  • Page 61: Uhf 438-470 Mhz

    CP200, Back Cover Kit,. 438-470, 4 Ch. X PMLE4254_ CP200, Back Cover Kit, 438-470 MHz, 16 Ch. PMLE4256_ CP150, Back Cover Kit, 438-470 MHz, 4 Ch. PMLE4257_ CP150, Back Cover Kit, 438-470 MHz, 4 Ch. PMLN4552_ Plain, Front Housing Kit, 4 Ch.

  • Page 62: Uhf 465-495 Mhz

    UHF 465-495 MHz UHF 465-495 MHz CP200, UHF, 465-495 MHz Model Description AAH50SDC9AA1AN CP200, 465-495 MHz, 4 W, 4 Ch. AAH50SDC9AA2AN CP200, 465-495 MHz, 4 W, 16 Ch. Item Description PMUE1986_ CP200, 465-495 MHz, 4 W, 4 Ch. X PMUE1987_ CP200, 465-495 MHz, 4 W, 16 Ch.

  • Page 63: Uhf Specifications

    UHF Specifications UHF Specifications General Transmitter Frequency: 403-440 MHz RF Output High 438-470 MHz NiMH @ 7.5V: 465-495 MHz Frequency: 403-440 MHz Channel Capacity: 4 or 16 Channels 438-470 MHz 465-495 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/20/25 kHz Battery Dimensions: with Freq.

  • Page 64: Mil Standards

    MIL Standards MIL Standards Table 7-1 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 Procedures Methods Procedures Methods Procedures...

  • Page 65: Glossary Of Terms

    Micro Controller Unit MRTI Motorola Radio-Telephone Interconnect: a system that provides a repeater connection to the Public Switched Telephone Network (PSTN). The MRTI al- lows the radio to access the telephone network when the proper access code is received.
  • Page 66 Term Definition Private-Line® tone squelch: a continuous sub-audible tone that is transmitted along with the carrier. Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a ref- erence, 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.
  • Page 68 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. © 2004 Motorola, Inc. All rights reserved. Printed in U.S.A. *6880309N61* 6880309N61-B...

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