Motorola CP185 Basic Service Manual
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Motorola CP185 Basic Service Manual

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  • Page 3 Service Manuals need to be updated accordingly. If you wish to be informed of these updates, kindly fill in and fax us your details. Fax to: 6-04-6194467 The Technical Publications Coordinator, Global Customer Documentation, R&D Department, Motorola Penang. Your Details Name/Contact Person: Company Name: Address: Telephone No.: Fax No.:...
  • Page 4 Kindly take a few moments to provide feedback on this manual. Thank you for your cooperation. Fax to: 6-04-6194467 The Technical Publications Coordinator, Global Customer Documentation, R&D Department, Motorola Penang. 1. Please check all the appropriate boxes: Disassembly Procedures Alignment Procedures...

  • Page 5: Computer Software Copyrights

    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 royalty-free license to use that arises by operation of law in the sale of a product.

  • Page 6: Safety

    Quick Reference Card enclosed with your radio (Motorola Publication part number 68007024011) to ensure compliance with RF energy exposure limits. For a list of Motorola-approved antennas, and other accessories, visit the following web site which lists approved accessories: http://www.motorola.com/business...

  • Page 7: Document History

    DOCUMENT HISTORY The following major changes have been implemented in this manual since the previous edition: Edition Description Date 68007024004-A Initial edition Oct. 2008 68007024004-B Added VHF 136 – 174 MHz information Feb. 2009 68007024004-C Updated Section 5.5 and Section 5.7 Sept.
  • Page 8 Document History Notes...

  • Page 9: Table Of Contents

    Table of Contents Table of Contents Copyright ......................i Safety ......................ii Document History ..................iii Chapter 1 Model Charts and Test Specifications ......1-1 Radio Model Information........................ 1-1 Model Chart for UHF2, 435–480 MHz ................... 1-2 Model Chart for VHF, 136–174 MHz .................... 1-3 UHF2 Specifications ........................
  • Page 10 6.4.2.4 Chassis and Front Housing Reassembly............6-14 Torque List ........................... 6-14 Mechanical View and Parts List ....................6-15 6.6.1 CP185 View and Parts List ..................... 6-15 Chapter 7 Maintenance – CP185 ............7-1 Introduction ............................ 7-1 Preventive Maintenance ........................ 7-1...
  • Page 11 Chassis and Front Housing Reassembly............7-17 Torque List........................... 7-17 Mechanical View and Parts List....................7-18 7.7.1 CP185 (Non Keypad with Channel Knob) Exploded View and Parts List....... 7-18 Chapter 8 Troubleshooting Tables ............. 8-1 Error Codes ........................... 8-1 Troubleshooting Table for Receiver....................8-2 Troubleshooting Table for Transmitter...................
  • Page 12 Figure 6-16. Main Circuit Board, O-ring and Battery Contact Seal Reassembly ........ 6-13 Figure 6-17. Sub Circuit Board and Accessory Bracket Reassembly..........6-13 Figure 6-18. Chassis Assembly and Front Housing Assembly Reassembly ........6-14 Figure 6-19. CP185 Exploded View....................6-15 Figure 6-20. “20” Marking on Front Housing..................6-17 Figure 7-1.
  • Page 13 Figure 7-18. Main Circuit Board, Finger Strips, O-ring and Battery Contact Seal Reassembly (UHF2)..........................7-16 Figure 7-20. Chassis Assembly and Front Housing Assembly Reassembly ........7-17 Figure 7-21. CP185 (Non Keypad) Radio Exploded View ..............7-18 Figure 7-22. “20” Marking on Front Housing..................7-20...
  • Page 14 Lead Free Solder Wire Part Number List ................ C-1 Table C-2. Lead Free Solder Paste Part Number List............... C-1 Related Publications CP185 Series Radios User Guide (English, French Canadian) ......6878080A01 CP185 Series Radios Quick Reference Card (English, French Canadian)..68007024011 CP185 Series Basic Service Manual............... 68007024004...

  • Page 15: Notations Used In This Manual

    Notations Used in This Manual Notations Used in This Manual Throughout the text in this publication, you will notice the use of the following notations. These notations are used to emphasize that safety hazards exist, and due care must be taken and observed. An operational procedure, practice, or condition that isessential to emphasize.
  • Page 16 Summary of Bands Available Summary of Bands Available Table below lists all the bands available in this manual. For details, please refer to the Model Charts section. Frequency Band Bandwidth Power Level UHF1 403 – 447 MHz 2W or 4W UHF2 435 –...

  • Page 17: 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 18: Model Chart For Uhf2, 435-480 Mhz

    Model Chart for UHF2, 435–480 MHz CP185, UHF2, 435 – 480 MHz Model escription AAH03RDC8AB7AN CP185 435 – 480M 4W 12.5/25K 16C NKP AAH03RDC4AB7AN CP185 435 – 480M 4W 12.5K 16C NKP AAH03RDF8AA7AN CP185 435 – 480M 4W 12.5/25K 16C AAH03RDF8AB7AN CP185 435 –...

  • Page 19: Model Chart For Vhf, 136-174 Mhz

    Model Chart for VHF, 136–174 MHz CP185, VHF, 136 – 174 MHz Model Description AAH03KEC8AB7AN CP185 136 – 174M 5W 12.5/25K 16C NKP AAH03KEC4AB7AN CP185 136 – 174M 5W 12.5K 16C NKP AAH03KEF8AA7AN CP185 136 – 174M 5W 12.5/25K 16C AAH03KEF8AB7AN CP185 136 –...

  • Page 20: Uhf2 Specifications

    Model Charts and Test Specifications: UHF2 Specifications UHF2 Specifications General Transmitter UHF2 UHF2 RF Output High Frequency: 435 – 480 MHz NiMH @ 7.5 V: Channel Capacity: 16 Channels Frequency: 435 – 480 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/25 kHz Dimensions: Freq.

  • Page 21: Vhf Specifications

    Model Charts and Test Specifications: VHF Specifications VHF Specifications General Transmitter RF Output High Frequency: 136 – 174 MHz NiMH @ 7.5 V: Channel Capacity: 16 Channels Frequency: 136 – 174 MHz 7.5 Volts ±20% Power Supply: Channel Spacing: 12.5/25 kHz Dimensions: Freq.
  • Page 22 Model Charts and Test Specifications: VHF Specifications Notes...

  • Page 23: 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 • Main PCB – Contains the RF circuits which comprises receiver, transmitter, phase-locked loop (PLL) frequency synthesizer, micro controller, power supply, audio and digital circuits •...

  • Page 24: Rx Front End

    Theory Of Operation: Major Assemblies 2.2.1.1 RX Front End UHF1 : Receiver Front-end consists of a low pass filter, a pre-selector filter, a low noise RF Amplifier and a Post-selector filter. Incoming RF signal from the antenna is applied through the Harmonics Low Pass Filter (C426, C427, C428, C429, C445, C446, L409, L410 and L411) and passes through the transmit/receive switch (CR301) and a varactor-tuned 2-pole pre-selector filter (C351, C361, CR307, CR314, L320 and L324, ) before routed to an RF amplifier (Q301).

  • Page 25: Rx Back End

    Theory Of Operation: Major Assemblies 2.2.1.2 RX Back End UHF1 : RF signal from RX front-end is then directed to a Double Balanced Mixer (CR316, L329 and L333). 1st LO signal from VCO is filtered by an injection filter (C325, C326, C387, L310 and L331) to remove harmonics.

  • Page 26: Transmitter

    Theory Of Operation: Major Assemblies 2.2.2 Transmitter The radio's TX Power Amplifier system is a three stage amplifier which is able to amplify the VCO output up to the permitted maximum transmit power levels (UHF: 4W, VHF: 5W). SWB+ BAT+ Power Control Current Detect CR401...

  • Page 27: Phase Lock Loop Synthesizer

    Theory Of Operation: Major Assemblies 2.2.3 Phase Lock Loop Synthesizer The Phase Lock Loop (PLL) synthesizer subsystem consists of the reference oscillator (VCTCXO), VCO, PLL IC, Charge pump and Loop filter. TX VCO Circuit To PA Driver FL701 TX Out Modulating Synthesizer Charge...

  • Page 28: Rx Audio Circuit

    Theory Of Operation: Major Assemblies 2.2.4 RX Audio Circuit The RX audio circuit consists of Audio Processor IC, Audio amp, speakers & Sub-tone system. Audio Processor IC (AK2347) RXA1 RX LPF TX/RX HPF Audio IN Scrambler / Expander (from IF IC) Descrambler emphasis pin 24...

  • Page 29: Tx Audio Circuit

    Theory Of Operation: Major Assemblies 2.2.5 TX Audio Circuit The TX audio circuit is comprised of microphones, LPF, Audio Processor IC, and TX Sub-tone system. 4 Order LPF (Fc=4KHz) (Audio IN) Audio Processor IC (AK2347) U501-C,D TX/RX HPF TXA1 Scrambler/ Com- Pre- Limiter...

  • Page 30: Microcontroller

    Theory Of Operation: Major Assemblies The TX audio enters the radio via the internal MIC or external MIC. This TX Audio is filtered through a 4th order 4 kHz Low-pass filter (U501-C & D) which prevents aliasing noise from ASIC. TX Audio enters the Audio Processor IC which is then directed to an internal Amplifier (TX A1) for gain adjustment of audio signal.

  • Page 31: Power Supply

    Theory Of Operation: Major Assemblies 2.2.7 Power Supply There are 4 voltage supplies in this radio: SWB+, 3.3 V, 5 V and 10 V. SWB+ voltage is distributed to SW/Vol 1, Final PA (Q403 via R417) and APC circuit (U401). The 3.3 V regulated supply (U506) is applied to CPU (U101), EEPROM (U104), DTMF IC (U103), Audio processor IC (U102), microphone biasing circuit and LCD/keypad driver.
  • Page 32 2-10 Theory Of Operation: Major Assemblies Notes...

  • Page 33: 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 radios. Table 3-1. Recommended Test Equipment Description Characteristics Application System analyzer This item will substitute Frequency/deviation meter and for items with an asterisk signal generator for wide-range troubleshooting and alignment Fluke 87 digital...

  • Page 34: Service Aids

    Test Equipment, Service Aids, and Service Tools: Service Aids Service Aids Table 3-2. lists service aids recommended for working on the CP185 Series 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 35: Figure 3-1. Programming/Test Cable (Pmdn4077_R)

    Test Equipment, Service Aids, and Service Tools: Service Aids Programming/Test Cable 2.5mm stereo USB connection type Figure 3-1. Programming/Test Cable (PMDN4077_R) 2.5mm stereo 2.5mm stereo Figure 3-2. Cloning Cable (PMDN4076_R) VBUS VBUS TX_D To Computor RX_D 2.5mm stereo > 4, 5, 6 USB_CONNECTOR IC : CP2102 RX / TX data...
  • Page 36 Test Equipment, Service Aids, and Service Tools: Service Aids Notes...

  • Page 37: 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 38: Table 4-1. Radio Operation In Test Mode

    Performance Checks: LCD/LED/Button/Volume Knob Test Mode Table 4-1. Radio Operation in Test Mode Button LCD Indication Backlight Tone Solid Green • ON when button is , Right pressed. • OFF following button released (after a short period of inactivity). Solid Red –...

  • Page 39: Led/Button/Volume Knob Test Mode (Non Keypad Models)

    Performance Checks: LED/Button/Volume Knob Test Mode (Non Keypad Models) LED/Button/Volume Knob Test Mode (Non Keypad Models) 1. Make sure the radio is turned off. 2. Turn on the radio and immediately press Side Programmable Button 2 (SPB2) 3 times. The LED turns solid red.
  • Page 40 Performance Checks: LED/Button/Volume Knob Test Mode (Non Keypad Models) Notes...

  • Page 41: Chapter 5 Radio Programming And Tuning

    Chapter 5 Radio Programming and Tuning Introduction This chapter provides an overview of the CP185 Series Customer Programming Software (CPS) and ® the CP/EP/P Tuner as designed for use in a Windows 2000/XP/Vista environment. Both cover all the functions of the traditional Radio Service Software (RSS) package.

  • Page 42: Radio Tuning Setup

    Radio Programming and Tuning: Radio Tuning Setup 3. Radio functionality inherent in one radio cannot be cloned to another radio that does not contain the same functionality. Tuning and alignment information are not transferable and are not affected by cloning. Procedure: 1.

  • Page 43: Initial Test Equipment Control Settings

    Program/Test Cable PMDN4077_R Note: 1. Use PMDN4040BR or higher for tuning the CP185 Series radios as PMDN4040AR cannot be used to perform this function. 2. Use PMDN4171_R for tuning the CP185 Series radios when using the service monitor R2600 series.

  • Page 44: Transmitter Alignment Options

    Radio Programming and Tuning: Transmitter Alignment Options Transmitter Alignment Options 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 45: Transmit High Power Tuning

    Radio Programming and Tuning: Transmitter Alignment Options 5.5.1 Transmit High Power Tuning 1. Click the Read icon to initiate communication with the radio. 2. Under the Alignment menu, select Tx Power, then select High (Figure 5-3. Tx High Power Window (High Power)). 3.

  • Page 46: Transmit Modulation Tuning

    Radio Programming and Tuning: Transmitter Alignment Options 8. Repeat steps 4–6 for the remaining test frequencies (F2–F5). 9. Press Program to commit the softpot values into the codeplug. 10. Exit the Transmit Low Power function. 11. Proceed to Adjust Modulation. Figure 5-4.
  • Page 47 Radio Programming and Tuning: Transmitter Alignment Options iii. Tx Pwr Zero: Zero Input Port: RF In Ext Tx Key: Off AF An1 In: FM Demod vii. Filter 1: 50 Hz HPF viii. Filter 2: 15 kHz LPF De-Emphasis: 750us Detector: Pk+-Max AFGen1 Freq: 1.0000 kHz xii.

  • Page 48: Transmit 12.5 Khz Modulation Tuning

    Radio Programming and Tuning: Transmitter Alignment Options d. On R2600, select “AUD” under “CURSOR ZONE”: Fixed 1kHz: 0.100V. Enable (~) Synth: Disable (x) iii. DTMF: Disable (x) External: Disable (x) 5.5.3.2 Transmit 12.5 kHz Modulation Tuning 1. Under the Alignment menu, select Tx Modulation, then select Mod. 12.5 kHz (Figure 5-5.

  • Page 49: Transmit 25 Khz Modulation Tuning

    Radio Programming and Tuning: Transmitter Alignment Options 5.5.3.3 Transmit 25 kHz Modulation Tuning 1. Under the Alignment menu, select Tx Modulation, then select Mod. 25 kHz (Figure 5-6. Tx Modulation 25 kHz Window). 2. Press PTT Toggle and switch to PTT on the test box. This will key up the radio at the F1. 3.

  • Page 50: Transmit Mdc Signaling System Modulation Tuning

    5-10 Radio Programming and Tuning: Transmit MDC Signaling System Modulation Tuning Transmit MDC Signaling System Modulation Tuning There are 2 variations of Transmit MDC Signaling System Modulation Tuning, namely 12.5 kHz and 25 kHz. Table 5-4. Transmit MDC Signaling System Modulation Tuning Channel Spacing (kHz) Tuning Range (kHz) 12.5...

  • Page 51: Transmit Mdc Signaling System 12.5 Khz Modulation Tuning

    Radio Programming and Tuning: Transmit MDC Signaling System Modulation Tuning 5-11 Mode: STANDARD iii. Dev: (Reading for Transmit Modulation) c. On R2600, select "RF" under "CURSOR ZONE": RF Control: MONITOR Preset: -- iii. B/W: NB Freq: Frequency Point (F1–F5) on Tuner Output Lvl: 20 dBm Gen RF Out: RF I/O vii.

  • Page 52: Transmit Mdc Signaling System 25 Khz Modulation Tuning

    5-12 Radio Programming and Tuning: Receiver Tuning 5.6.3 Transmit MDC Signaling System 25 kHz Modulation Tuning 1. Under the Alignment menu, select Tx Signaling System, then select MDC 25 KHz (Figure 5-8. Tx MDC Signaling System Modulation 25 kHz Window). 2.
  • Page 53 Radio Programming and Tuning: Receiver Tuning 5-13 c. Using the “CURSOR CONTROL”, key in the items below: RF Gen Freq: Frequency Point (F1 – F5) on Tuner Amplitude: -128dBm iii. Atten Hold: Off Output Port: RF Out AFGen1 Freq: 1.0000 kHz AFGen1 To: 1.5 kHz for 12.5 kHz channel spacing, 3.0 kHz for 25 kHz channel spacing vii.

  • Page 54: Receive 12.5 Khz-Band Normal Squelch Tuning

    5-14 Radio Programming and Tuning: Receiver Tuning 5.7.2 Receive 12.5 kHz Band Normal Squelch Tuning 1. Under the Alignment menu, select Rx Squelch, then select Squelch 12.5 kHz-band Normal. (Figure 5-9. Rx 12.5 kHz-band Normal Squelch Tuning Window). 2. Apply a RF signal (with 1 kHz tone at 1.5 kHz deviation) for current frequency point with minimum amplitude, -128 dBm (F1 being the first).

  • Page 55: Receive 25 Khz-Band Normal Squelch Tuning

    Radio Programming and Tuning: Receiver Tuning 5-15 Figure 5-10. Rx 12.5 kHz-band Tight Squelch Tuning Window 5.7.4 Receive 25 kHz Band Normal Squelch Tuning 1. Under the Alignment menu, select Rx Squelch, then select Squelch 25 kHz-band Normal. (Figure 5-11. Rx 25 kHz-band Normal Squelch Tuning Window). 2.

  • Page 56: Receive 25 Khz-Band Tight Squelch Tuning

    5-16 Radio Programming and Tuning: Receiver Tuning Figure 5-11. Rx 25 kHz-band Normal Squelch Tuning Window 5.7.5 Receive 25 kHz Band Tight Squelch Tuning 1. Under the Alignment menu, select Rx Squelch, then select Squelch 25 kHz-band Tight. (Figure 5-12. Rx 25 kHz-band Tight Squelch Tuning Window). 2.

  • Page 57: Utilities

    Radio Programming and Tuning: Utilities 5-17 Figure 5-12. Rx 25 kHz-band Tight Squelch Tuning Window Utilities 5.8.1 Program Serial No. The Program Serial No. option under the Utilities heading allow the radio serial number to be programmed. However, the serial number of a particular radio can only be programmed if it was originally blank.

  • Page 58: Front Panel Feature And Button Configuration Mode (Keypad Models Only)

    5-18 Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) Front Panel Feature and Button Configuration Mode (Keypad Models Only) 5.9.1 Introduction This mode allows you to change the feature parameters to enhance the use of your radio. Note Please use the CPS to program additional setting on the radio.

  • Page 59: Editing Front Panel Programming Mode Parameters

    Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) 5-19 5.9.5 Editing Front Panel Programming Mode Parameters A. Non-MDC1200 and Non-QCII Models Table 5-6. Front Panel Programming Mode Parameters: Non-MDC1200 & Non-QCII Models 1st Level 2nd Level Main Menu Setting...
  • Page 60 5-20 Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) Table 5-6. Front Panel Programming Mode Parameters: Non-MDC1200 & Non-QCII Models (Continued) 1st Level 2nd Level Main Menu Setting Remarks Sub-Menu Sub-Menu TX PL CH-001 ... Transmit PL (Transmit TPL/ CH-016...

  • Page 61: Table 5-7. Front Panel Programming Mode Parameters: Mdc1200 & Qcii Models

    Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) 5-21 B. MDC1200 and QCII Models Table 5-7. Front Panel Programming Mode Parameters: MDC1200 & QCII Models 1st Level 2nd Level Main Menu Setting Remarks Sub-Menu Sub-Menu BCKLIGHT AUTO...
  • Page 62 5-22 Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) Table 5-7. Front Panel Programming Mode Parameters: MDC1200 & QCII Models (Continued) 1st Level 2nd Level Main Menu Setting Remarks Sub-Menu Sub-Menu PROG BTN SIDE 1S UNASSIGN (Unassigned) Program Side Button 1 –...
  • Page 63 Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) 5-23 Table 5-7. Front Panel Programming Mode Parameters: MDC1200 & QCII Models (Continued) 1st Level 2nd Level Main Menu Setting Remarks Sub-Menu Sub-Menu FRONT 2S - same as above - Program Front Button 2 –...
  • Page 64 5-24 Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode (Keypad Models Only) Notes...

  • Page 65: Chapter 6 Maintenance - Cp185

    Chapter 6 Maintenance – CP185 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 •...

  • Page 66: 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 4280385A59.) •...

  • Page 67: Disassembling And Reassembling The Radio - General

    If a unit requires further testing or service than is customarily performed at the basic level, please send the unit to a Motorola Authorized Service Center listed in Appendix B. Note: Numbers in parentheses ( ) refer to item numbers in Figure 6-19, on page 6-15.

  • Page 68: Radio Disassembly - Detailed

    Maintenance – CP185: Disassembling and Reassembling the Radio – General 6.4.1 Radio Disassembly – Detailed 6.4.1.1 Front Housing From Chassis Disassembly 1. Turn off the radio. 2. Remove the Battery (27): Release the battery latch by moving it into the unlock position.

  • Page 69: Figure 6-3. Knobs Removal

    Maintenance – CP185: Disassembling and Reassembling the Radio – General 4. Remove the Volume Knob (4) and Channel Knob (5) from their shafts using the Chassis and Knob Opener. (Refer Figure 6-3). Volume Knob Channel Knob Chassis and Knob Opener Figure 6-3.

  • Page 70: Figure 6-5. Speaker Wire And Flexible Cable Connection

    Maintenance – CP185: Disassembling and Reassembling the Radio – General Slide the rear chassis downwards, and away from the front housing. Be careful not to damage the Flexible Cable (35) and speaker wire underneath. (Refer Figure 6-5). Speaker Wire Flexible Cable Figure 6-5.

  • Page 71: Chassis Assembly Disassembly

    Maintenance – CP185: Disassembling and Reassembling the Radio – General Push the latches on the Front Circuit Board (37) sideways to the right to release the flexible cable from the connector. (Refer Figure 6-7). Latches Figure 6-7. Unlatch the Flexible Cable 6.4.1.2 Chassis Assembly Disassembly...

  • Page 72: Front Circuit Board, Display Module And Keypad Disassembly

    Maintenance – CP185: Disassembling and Reassembling the Radio – General 7. Remove the Main Circuit Board from the Chassis. Refer to the CMOS CAUTION paragraph under Section 6.3 before removing the main board. Be sure to use ESD protection when handling the circuit boards.

  • Page 73: Speaker Disassembly

    Maintenance – CP185: Disassembling and Reassembling the Radio – General 4. Remove the LCD (34), Poron Pad (40) and Keypad (39) from the Front Housing. (Refer Figure 6-11). Keypad Poron Pad Figure 6-11. LCD and Keypad Removal Note: The poron pad will be damaged during disassembly. A new poron pad is needed for reassembly.

  • Page 74: Figure 6-12. Speaker Removal

    6-10 Maintenance – CP185: Disassembling and Reassembling the Radio – General 5. Remove the Speaker Felt (6) from the grille area. (Refer Figure 6-12). Speaker Retainer Speaker Insulator Speaker Speaker Felt Figure 6-12. Speaker Removal...

  • Page 75: Radio Reassembly - Detailed

    Maintenance – CP185: Disassembling and Reassembling the Radio – General 6-11 6.4.2 Radio Reassembly – Detailed 6.4.2.1 Speaker Reassembly 1. Place the Speaker Felt (6) onto the grille area. 2. Align the speaker wire at three o'clock position and push down the speaker until fully adhere onto the front housing.

  • Page 76: Chassis Assembly Reassembly

    6-12 Maintenance – CP185: Disassembling and Reassembling the Radio – General 3. Place and align the Poron Pad (40) onto the poron pad slot. Apply force around the Poron Pad and ensure it is perfectly seated onto the slot. 4. Place the Front Circuit Board (37) straight down on top of the LCD and keypad. Align the front circuit board to the four housing ribs.

  • Page 77: Figure 6-16. Main Circuit Board, O-Ring And Battery Contact Seal Reassembly

    Maintenance – CP185: Disassembling and Reassembling the Radio – General 6-13 5. Tighten the RF Support Screw (17) with a flat head screw torque to 1.91 Ib-in – 2.17 Ib-in. (Refer Table 6-1 on page 6-14 for torque in other units).

  • Page 78: Chassis And Front Housing Reassembly

    6-14 Maintenance – CP185: Torque List 6.4.2.4 Chassis and Front Housing Reassembly 1. Assembly the chassis assembly to the Front Housing Assembly (1) as follow: Lay the chassis assembly beside to the Front Housing Assembly. Insert the Flexible Cable (35) from the main circuit board into the connector on the front circuit board.

  • Page 79: Mechanical View And Parts List

    Maintenance – CP185: Mechanical View and Parts List 6-15 Mechanical View and Parts List 6.6.1 CP185 View and Parts List Figure 6-19. CP185 Exploded View...
  • Page 80 6-16 Maintenance – CP185: Mechanical View and Parts List Item Motorola Kit Number Description Quantity PMDN4182_R Front Housing (Top Escutcheon), Limited Keypad PMDN4096_R Name Plate (CP185) PMDN4193_R Double Molded Cover, PTT PMDN4102_R Knob, Volume PMDN4101_R Knob, Channel PMDN4100_R Felt, Speaker...

  • Page 81: Figure 6-20. "20" Marking On Front Housing

    Maintenance – CP185: Mechanical View and Parts List 6-17 Item Motorola Kit Number Description Quantity PMDN4123_R Module, Liquid Crystal Display PMDN4109_R Flexible Cable, Main Circuit Board PMDN4119_R Screw, Tapping PMDN4131_R Front Circuit Board, LKP PMDN4113_R Cover, Dust PMDN4118_R Keypad, Limited Keypad...
  • Page 82 6-18 Maintenance – CP185: Mechanical View and Parts List Notes...

  • Page 83: Chapter 7 Maintenance - Cp185

    Chapter 7 Maintenance – CP185 (Non Keypad Model) 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 •...

  • Page 84: 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 4280385A59.) •...

  • Page 85: Repair Procedures And Techniques - General

    When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number. Orders for replacement parts which are listed in the “Parts List” section of this manual, should be placed directly on Motorola’s local distribution organization or via Motorola Online...
  • Page 86 Maintenance – Non Keypad Model: Repair Procedures and Techniques – General When soldering near the connector pins: • Avoid accidentally getting solder in the connector. • Be careful not to form solder bridges between the connector pins. • Examine your work closely for shorts due to solder bridges. Chip Components Use the RLN4062 Hot-Air Repair Station for chip component replacement.
  • Page 87 Maintenance – Non Keypad Model: Repair Procedures and Techniques – General Shields Removing and replacing shields is recommended to be done with the Air Blower, BOSCH GHG 603 or equivalent. • To remove the shield: 1. Place the circuit board in the circuit board holder. 2.

  • Page 88: Disassembling And Reassembling The Radio

    If a unit requires further testing or service than is customarily performed at the basic level, please send the unit to a Motorola Authorized Service Center listed in Appendix B. Note: Numbers in parentheses ( ) refer to item numbers in Table 7-4 on page 7-19.

  • Page 89: Radio Disassembly - Detailed

    Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 7.5.1 Radio Disassembly – Detailed 7.5.1.1 Front Housing From Chassis Disassembly 1. Turn off the radio. 2. Remove the Battery (27): Release the battery latch by moving it into the unlock position. Slide the Battery downwards.

  • Page 90: Figure 7-3. Knobs Removal

    Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 4. Remove the Volume Knob (4) and Channel Knob (5) from its shaft using the Chassis and Knob Opener. (Refer Figure 7-3). Volume Knob Channel Knob Chassis and Knob Opener Figure 7-3.

  • Page 91: Figure 7-5. Speaker Wire And Flexible Cable Connection

    Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio Slide the rear chassis downwards, and away from the front housing. Be careful not to damage the Flexible Cable (34) and speaker wire underneath. (Refer Figure 7-5). Speaker Wire Flexible Cable Figure 7-5.

  • Page 92: Chassis Assembly Disassembly

    7-10 Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio Push the latches on the Front Circuit Board (36) sideways to the right to release the flexible cable from the connector. (Refer Figure 7-7). Latches Figure 7-7. Unlatch the Flexible Cable 7.5.1.2 Chassis Assembly Disassembly 1.

  • Page 93: Figure 7-9. Main Circuit Board, Finger Strips, O-Ring And Battery Contact Seal Removal (Uhf1)

    Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 7-11 7. Remove the Main Circuit Board from the Chassis. Refer to the CMOS CAUTION paragraph under Section 7.3 before removing the main board. Be sure to use ESD protection when handling the circuit boards. 8.

  • Page 94: Front Circuit Board And Poron Pad Disassembly

    7-12 Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 7.5.1.3 Front Circuit Board and Poron Pad Disassembly 1. Remove the five screws holding the Front Circuit Board (36) to the front housing with a Phillips screwdriver. 2. Remove the Front Circuit Board from the Front Housing. (Refer Figure 7-11). Circuit Board Figure 7-11.

  • Page 95: Radio Reassembly - Detailed

    Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 7-13 5. Remove the Speaker Felt (6) from the grille area (Refer Figure 7-13). Speaker Retainer Speaker Insulator Speaker Speaker Felt Figure 7-13. Speaker Removal 7.5.2 Radio Reassembly – Detailed 7.5.2.1 Speaker Reassembly 1.

  • Page 96: Front Circuit Board And Poron Pad Reassembly

    7-14 Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 7.5.2.2 Front Circuit Board and Poron Pad Reassembly 1. Place and align the Poron Pad (38) onto the poron pad slot. Apply force around the Poron Pad and ensure it is perfectly seated onto the slot. (Refer Figure 7-15). Poron Pod Figure 7-15.

  • Page 97: Chassis Assembly Reassembly

    Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio 7-15 7.5.2.3 Chassis Assembly Reassembly 1. Fit the Battery Contact Seal (24) onto the battery contact slot. 2. Align and assemble the finger strips for assembly. 3. Fit the main O-ring (20) onto the chassis as follow: Ensure that the main O-ring is not twisted.

  • Page 98: Figure 7-19. Sub Circuit Board And Accessory Bracket Reassembly

    7-16 Maintenance – Non Keypad Model: Disassembling and Reassembling the Radio Figure 7-18. Main Circuit Board, Finger Strips, O-ring and Battery Contact Seal Reassembly (UHF2) 7. Insert the Sub Circuit Board Flexible Cable (12) into the respective connectors at the top of the main circuit board.

  • Page 99: Chassis And Front Housing Reassembly

    Maintenance – Non Keypad Model: Torque List 7-17 7.5.2.4 Chassis and Front Housing Reassembly 1. Assembly the Chassis Assembly to the Front Housing Assembly (1) as follow: Lay the Chassis Assembly beside to the Front Housing Assembly. Insert the Flexible Cable (34) from the main circuit board into the connector on the front circuit board.

  • Page 100: Mechanical View And Parts List

    7-18 Maintenance – Non Keypad Model: Mechanical View and Parts List Mechanical View and Parts List 7.7.1 CP185 (Non Keypad with Channel Knob) Exploded View and Parts List Figure 7-21. CP185 (Non Keypad) Radio Exploded View...

  • Page 101: Table 7-4. Parts List (Non Keypad With Channel Knob)

    Sub Circuit Board, w Channel PMDN4112_R Crab Eye Nut, Volume and Channel PMDN4134_R Switch, Tact PMDE4056_R Main Circuit Board (CP185 – PMUE3745_AN) PMDE4058_R Main Circuit Board (CP185 – PMUE3743_AN) PMDD4032_R Main Circuit Board (CP185 – PMUD2935_AN) PMDD4034_R Main Circuit Board (CP185 – PMUD2933_AN)

  • Page 102: Figure 7-22. "20" Marking On Front Housing

    7-20 Maintenance – Non Keypad Model: Mechanical View and Parts List Table 7-4. Parts List (Non Keypad with Channel Knob) (Continued) Item Motorola Kit Number Description Quantity PMDN4109_R Flexible Cable, Main Circuit Board PMDN4119_R Screw, Tapping PMDN4179_R Front Circuit Board, NKP...
  • Page 103 Maintenance – Non Keypad Model: Mechanical View and Parts List 7-21 3. This kit consists of tact switch, antenna bracket, PCB finger strip, battery contact and audio jack. 4. This kit consists of microphone and microphone seal. 5. This kit is only applicable for UHF1. 6.
  • Page 104 7-22 Maintenance – Non Keypad Model: Mechanical View and Parts List Notes...

  • Page 105: Chapter 8 Troubleshooting Tables

    Check the connection between source and destination between source and radios. destination radios failed. Make sure follow the correct cloning procedures. If message reoccurs, send radio to nearest Motorola Service Centre. TIME OUT Time Out Error – No Check the connection between source and destination communication between radios.

  • Page 106: Troubleshooting Table For Receiver

    Radio Dead; Display Does 1. Dead Battery Replace with charged battery. Not Turn On 2. On/Off Switch Send radio to nearest Motorola Service Centre. 3. Regulators 4. Regulator fault Radio Dead; Display Turns Transceiver Board Send radio to nearest Motorola Service Centre.

  • Page 107: Troubleshooting Table For Transmitter

    No RF Power Out 1. Tx Power Level or Check Tx power level and frequency programming (from Frequency tuner). 2. No Injection To Power Send radio to nearest Motorola Service Centre. Amplifier 3. Antenna Switch/ Connector No Modulation; Distortion 1. Programming...
  • Page 108 Troubleshooting Tables: Troubleshooting Table for Transmitter Notes...

  • Page 109: Appendix A Accessories

    Appendix A Accessories Antennas NAD6502_R VHF Heliflex Antenna (146 – 174 Mhz) PMAD4049_ VHF Helical Antenna (146 – 174 MHz) NAE6483_R UHF Whip Antenna, 16.5 cm (403 – 520 MHz) PMAE4016_ UHF Whip Antenna (403 – 520 MHz) Audio Accessories AARLN4885_ Receive Only Earbud for Remote Speaker Microphone Only 3.5 mm Adapter HMN9013_...

  • Page 110: Belt Clip

    90 – 264 V, SMPS with NA/LA country plug PMLN5228_ TriChem Single Unit Charger base PMLN5398_ Single Unit Charger Base with switch mode power supply (Kit) Note: Certain accessories may not be available at the time of publication. For latest information on accessories, visit:http://www.motorola.com/governmentandenterprise.

  • Page 111: 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 112 Warranty, Service Support, and Replacement Parts: Warranty 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 113: Appendix C Repair Procedures And Techniques - General

    When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number. Orders for replacement parts which are listed in the “Parts List” section of this manual, should be...

  • Page 114: Rigid Circuit Boards

    Repair Procedures and Techniques – General Rigid Circuit Boards This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not accessible, some special considerations are required when soldering and unsoldering components. The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise care to avoid pulling the plated circuit out of the hole.
  • Page 115 Repair Procedures and Techniques – General Shields Removing and replacing shields is recommended to be done with the Air Blower, BOSCH GHG 603 or equivalent. • To remove the shield: Place the circuit board in the circuit board holder. Add solder paste flux around the base of the shield. Position the heat-focus head onto the shield.
  • Page 116 Repair Procedures and Techniques – General Notes...

  • Page 117: 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 allows the radio to access the telephone network when the proper access code is received.
  • Page 118 Glossary of Terms 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 reference, usually after passing through a frequency divider. Push-To-Talk: the switch located on the left side of the radio;...
  • Page 120 © 2008―2010 Motorola Inc. All rights reserved. Motorola Technology Sdn Bhd (Co. No. 455657-H) Plot 2 Bayan Lepas Technoplex Industrial Park Mukim 12 S.W.D 11900 Penang, Malaysia Printed in Malaysia June 2010 *68007024004* 68007024004-D...

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