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Motorola Commercial Series, Basic Service Manual

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Motorola Commercial Series Basic Service Manual Download Page 84

7-16

Mechanical View and Parts List

December, 2009

68009328001-A

Item

Motorola

Part

Number

Description

1

See Appendix 
A

Antenna

2

3680530Z02

Knob, Frequency

3

1386440Z03

Escutcheon, Top

4

03012009001

Screw M1.6X.64  
Self-tapping

5

15012016002

Housing, Limited, with Lens

6

35012012001

Speaker, Felt

7

3886489Z02 

PTT, Rubber

8

4586439Z01

PTT, Plastic

9

5005679X06

Speaker Assembly

10

42012006001

Retainer Speaker

11

3586621Z04

Felt, Microphone

12

05012002001

Boot, Microphone

13

0186639Z04

Microphone Plug Assembly

14

0104034J49

Display/Keypad Flex Circuit 
Assembly - Limited

16

1586437Z02 

Shroud, Audio Jack

17

3286431Z05

Seal, Main O-ring

18

7586436Z02

Pad, PA Interface

19

2786389Z02

Chassis

20

3286435Z01

Seal, Battery Contact Block

21

0304726J05

Screws, Chassis; 4 Used

25

75012007002

Keypad, Limited

26

5586445Z03

Latch Assembly

27

4116105H01

Spring, Latch; 2 Used

28

3886441Z02

Cap, Dust

29

3286432Z01

Seal, Control Shaft

30

0386434Z02

Screw, Speaker Retainer

31

3386443Z01

Label, Escutcheon Seal

32

6186446Z02

Lightpipe

33

3680529Z01

Knob, Volume

NON-REFERENCED ITEMS

54012047001

Nameplate, Motorola

Item

Motorola

Part

Number

Description

Summary of Contents for Commercial Series

Page 1: ......

Page 2: ......

Page 3: ...CP200XLS Portable Radio Basic Service Manual VHF 136 162 MHz VHF 146 174 MHz UHF 403 440 MHz UHF 438 470 MHz UHF 465 495 MHz Motorola Inc 1301 E Algonquin Road Schaumburg IL 60196 68009328001 A ...

Page 4: ...ified reverse engineered or distributed in any manner without the express written permission of Motorola Furthermore the purchase of Motorola products shall not be deemed to grant either directly or by implication estoppel or otherwise any license under the copyrights patents or patent applications of Motorola except for the normal non exclusive license to use that arises by operation of law in th...

Page 5: ...iii Document History The following major changes have been implemented in this manual since the previous edition Edition Description Date 68009328001 A Initial Release Dec 2009 ...

Page 6: ...iv Notes ...

Page 7: ... MHz 1 5 1 6 Model Chart for UHF2 438 470 MHz 1 6 1 7 Model Chart for UHF3 465 495 MHz 1 7 1 8 UHF Specifications 1 8 1 9 MIL Standards 1 9 Chapter 2 Theory Of Operation 2 1 2 1 Introduction 2 1 2 2 Major Assemblies 2 1 2 2 1 Receiver 2 1 2 2 2 Transmitter 2 2 Chapter 3 Test Equipment Service Aids and Service Tools 3 1 3 1 Test Equipment 3 1 3 2 Service Aids 3 2 Chapter 4 Performance Checks 4 1 4 ...

Page 8: ...Tuning 5 12 5 5 2 Squelch Tuning 5 13 5 5 2 1 Manual Squelch Tuning 5 13 5 5 2 2 Auto Tune 5 14 5 5 3 RSSI System Level Tuning 5 14 5 5 4 RSSI Display Tuning 5 15 5 6 Utilities 5 15 5 6 1 Program Serial No 5 15 5 6 2 Temp Comp Data Read 5 15 5 6 3 Temp Comp Data Write 5 15 5 7 Radio to Radio Cloning 5 15 Chapter 6 Full Keypad Model Disassembly and Re assembly 6 1 6 1 Introduction 6 1 6 2 Preventiv...

Page 9: ...he Radio General 7 3 7 4 1 Radio Disassembly Detailed 7 3 7 4 1 1 Front Cover from Chassis Disassembly 7 3 7 4 1 2 Dust Cover Disassembly 7 6 7 4 1 3 Speaker and Microphone Disassembly 7 6 7 4 1 4 Keyboard Removal 7 7 7 4 1 5 PTT Disassembly 7 7 7 4 2 Chassis Disassembly 7 8 7 4 3 Radio Re assembly Detailed 7 9 7 4 3 1 Dust Cover Re assembly 7 9 7 4 3 2 Speaker Re assembly 7 9 7 4 3 3 Keypad and D...

Page 10: ... Warranty B 1 B 2 1 Warranty Period and Return Instructions B 1 B 2 2 After Warranty Period B 1 B 3 Replacement Parts Ordering B 1 B 3 1 Basic Ordering Information B 1 B 3 2 Motorola Online B 2 B 3 3 Mail Orders B 2 B 3 4 Telephone Orders B 2 B 3 5 Fax Orders B 2 B 3 6 Parts Identification B 2 B 3 7 Product Customer Service B 3 B 4 Technical Support B 3 Glossary G 1 ...

Page 11: ...1 Battery Removal 6 3 Figure 6 2 Antenna and Knob Removal 6 4 Figure 6 3 Chassis Removal 6 4 Figure 6 4 Keyboard Flex Connection 6 5 Figure 6 5 Microphone and Speaker Connections 6 5 Figure 6 6 Dust Cover Disassembly 6 6 Figure 6 7 Removal Speaker Microphone Assembly 6 6 Figure 6 8 Keypad Removal 6 7 Figure 6 10 Removal of Main Board from Chassis 6 8 Figure 6 9 PTT Removal 6 8 Figure 6 11 Dust Cap...

Page 12: ...e 7 11 Dust Cap Re assembly 7 9 Figure 7 12 Speaker Re assembly 7 9 Figure 7 13 Display Keypad Module Re assembly 1 7 10 Figure 7 14 Display Keypad Module Re assembly 2 7 11 Figure 7 15 Microphone Re assembly 7 11 Figure 7 16 Installation of Main Board onto Chassis 7 12 Figure 7 17 Microphone and Speaker Re assembly 7 13 Figure 7 18 Keyboard Flex Cable Connection 7 13 Figure 7 19 Fastening the Cha...

Page 13: ...able 4 5 Receiver Performance Checks 4 4 Table 4 4 Test Frequencies 4 4 Table 4 6 Transmitter Performance Checks 4 5 Table 5 1 Initial Equipment Control Settings 5 3 Table 5 2 Reference Oscillator Specifications 5 4 Table 5 3 Transmit High Low Power Level 5 7 Table 5 4 Deviation Specifications 5 10 Table 5 5 Squelch Deviation Values 5 13 Table 9 1 Power Up Error Code Display 9 1 Table 9 2 Operatio...

Page 14: ...xi Table of Contents December 2009 68009328001 A Notes ...

Page 15: ...ne portable radio model number and its specific characteristics Table 1 1 Radio Model Number Example AAH50JDH9AA6AN Type of Unit Model Series Freq Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package AA H 50 J VHF 136 162 MHz K VHF 146 174 MHz Q 403 440 MHz R UHF 438 470 MHz S UHF 465 495 MHz D 4 W or 5 W F Limited Keypad H Full Keypad 9 Pro gramma...

Page 16: ...mited Keypad Model X PMUD2486_ CP200XLS 136 162 MHz 5W 128Ch Full Keypad Model X X PMLN4278_ Back Cover Kit X PMLN5562_ Limited Keypad Front Housing Kit X PMLN5556_ Full Keypad Front Housing Kit X X NNTN4496_R NiCd Battery 1100 mAH X X NNTN4497_R Li Ion Battery 1800 mAH X X NNTN4851_ NiMh Battery 1400 mAH X X NNTN4970 Slim Li Ion Battery 1600 mAH X X WPLN4138_R Rapid 90 Min Desktop Charger with US...

Page 17: ...mited Keypad Model X PMUD2488_ CP200XLS 146 174 MHz 5W 128 Ch Full Keypad Model X X PMLN4281_ Back Cover Kit X PMLN5562_ Limited Keypad Front Housing Kit X PMLN5556_ Full Keypad Front Housing Kit X X NNTN4496_R NiCd Battery 1100 mAH X X NNTN4497_R Li Ion Battery 1800 mAH X X NNTN4851_ NiMh Battery 1400 mAH X X NNTN4970 Slim Li Ion Battery 1600 mAH X X WPLN4138_R Rapid 90 Min Desktop Charger with U...

Page 18: ...acity NiCd High Capacity Li Ion NiMH Std Slim Li Ion Capacity mAh 1100 1800 1400 1600 5 W 8 Hrs 14 Hrs 10 Hrs 12 Hrs 1 W 9 Hrs 19 Hrs 13 Hrs 17 Hrs VHF RF Output NiMH 7 5 V Low 1 W High 5 W Frequency 136 162 MHz 146 174 MHz Channel Spacing 12 5 20 25 kHz Freq Stability 30 C to 60 C 0 00025 Spurs Harmonics 36 dBm 1 GHz 30 dBm 1 GHz Audio Response from 6 dB oct Pre emphasis 300 to 3000 Hz 1 3 dB Aud...

Page 19: ... Keypad Model X PMUE3489_ CP200XLS 403 440 MHz 4W 128 Ch Full Keypad Model X X PMLE4334_ Back Cover Kit X PMLN5562_ Limited Keypad Front Housing Kit X PMLN5556_ Full Keypad Front Housing Kit X X NNTN4496_R NiCd Battery 1100 mAH X X NNTN4497_R Li Ion Battery 1800 mAH X X NNTN4851_ NiMh Battery 1400 mAH X X NNTN4970 Slim Li Ion Battery 1600 mAH X X WPLN4138_R Rapid 90 Min Desktop Charger with US Plu...

Page 20: ...d Keypad Model X PMUE3487_ CP200XLS 438 470 MHz 4 W 128Ch Full Keypad Model X X PMLE4335_ Back Cover Kit X PMLN5562_ Limited Keypad Front Housing Kit X PMLN5556_ Full Keypad Front Housing Kit X X NNTN4496_R NiCd Battery 1100 mAH X X NNTN4497_R Li Ion Battery 1800 mAH X X NNTN4851_ NiMh Battery 1400 mAH X X NNTN4970 Slim Li Ion Battery 1600 mAH X X WPLN4138_R Rapid 90 Min Desktop Charger with US Pl...

Page 21: ... Keypad Model X PMUE3469_ CP200XLS 465 495 MHz 4 W 128Ch Full Keypad Model X X PMLE4336_ Back Cover Kit X PMLN5562_ Limited Keypad Front Housing Kit X PMLN5556_ Full Keypad Front Housing Kit X X NNTN4496_R NiCd Battery 1100 mAH X X NNTN4497_R Li Ion Battery 1800 mAH X X NNTN4851_ NiMh Battery 1400 mAH X X NNTN4970 Slim Li Ion Battery 1600 mAH X X WPLN4138_R Rapid 90 Min Desktop Charger with US Plu...

Page 22: ...NiCd High Capacity Li Ion NiMH Std Slim Li Ion Capacity mAh 1100 1800 1400 1600 4 W 8 Hrs 14 Hrs 10 Hrs 12 Hrs 1 W 9 Hrs 19 Hrs 13 Hrs 17 Hrs UHF RF Output NiMH 7 5 V Low 1 W High 4 W Frequency 403 440 MHz 438 470 MHz 465 496 MHz Channel Spacing 12 5 20 25 kHz Freq Stability 30 C to 60 C 0 00025 Spurs Harmonics 36 dBm 1 GHz 30 dBm 1 GHz Audio Response from 6 dB oct Pre emphasis 300 to 3000 Hz 1 3 ...

Page 23: ...cedures Methods Procedures Low Pressure 500 1 1 500 2 2 500 3 2 500 4 1 High Temper ature 501 1 1 2 501 2 1 2 501 3 1 2 501 4 1 2 Low Temperature 502 1 1 502 2 1 2 502 3 1 2 501 4 1 2 Temperature Shock 503 1 1 503 2 1 503 3 1 503 4 1 Solar Radia tion 505 1 1 505 2 1 505 3 1 505 4 1 Rain 506 1 1 2 506 2 1 2 506 3 1 2 506 4 1 Humidity 507 1 2 507 2 2 3 507 3 2 3 507 4 3 Salt Fog 509 1 1 509 2 1 509 ...

Page 24: ...October 2009 68009328001 A Notes 1 10 Model Charts and Test Specifications MIL Standards ...

Page 25: ...irst routed through the harmonic filter and antenna switch part of the transmitter circuitry before being applied to the receiver front end The receiver front end consists of a preselector filter RF amplifier interstage filter and a double balanced first mixer Figure 2 2 The mixer output is applied to a diplexer network which matches the 44 85 MHz IF signal to the crystal filter and terminates the...

Page 26: ...haracteristic required by the quadrature detector with 90 degree phase shift occurring at 455 kHz The output of the IFIC is the recovered audio signal which is fed to the audio IC for amplification and signal conditioning The output of the audio IC is injecting into the audio PA which drives the 24 Ohm speaker 2 2 2 Transmitter When the radio is transmitting microphone audio is passed through the ...

Page 27: ... 32 segment bar graph with backlit display Digital voltmeter is recommended for AC DC voltage and current measurements Fluke 85 RF probe 500 MHz 30 VAC max Use with Fluke 87 digital multi meter for RF voltage measurements R1377A AC voltmeter 1 mV to 300 mV 10 mega ohm input impedance Audio voltage measurements R1611A Dual channel 100 MHz oscilloscope Agillent Two channel 100 MHz bandwidth 200 M sa...

Page 28: ...RLN4008 Radio Interface Box Enables communications between the radio and the computer s serial communications adapter 5886564Z01 RF Adaptor Adapts radio s antenna port to BNC cabling of test equipment 0180305K08 Shop Battery Eliminator Interconnects radio to power supply HSN9412 Wall Mounted Power Supply Used to supply power to the RIB 120 VAC 3080369B71 or 3080369B72 Computer Interface Cable Use ...

Page 29: ...5 SMD tool kit included with R1319A R1319A ChipMaster 110 V Surface mount removal and assembly of surface mounted integrated circuits and or rework station shields Includes 5 nozzles R1321A ChipMaster 220 V ChipMaster Nozzles 6680332E83 PLCC 28 nozzle Soldering and Un soldering IC s 6680332E82 PLCC 44 nozzle 6680332E94 PLCC 52 nozzle 6680332E96 PLCC 84 nozzle 6680334E67 QFP 160 nozzle 6680333E46 S...

Page 30: ...LE CONNECTOR 25 POSITION MALE CONNECTOR 36 0 CABLE 36 0 CABLE P1 P2 P3 P2 25 pin Male D Connector Components molded inside 1 5 24 7 20 8 15 16 9 47 ohm 33K 1UF 16V 5 Orange Blue White Spiral Yellow P1 2 5mm stereo and 3 5mm 1 2 5 3 4 3 5mm Tip Speaker 3 5mm Sleeve 2 5mm Tip Microphone 2 5mm 2 5mm Center P3 25 pin Female D Connector 1 15 4 11 1 2 3 4 5 3 5mm mono 2 5mm stereo To Test Box To Test Bo...

Page 31: ...elf 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 If the self test is not successful a Self Test Fail Tone is heard Supply voltage can be connected from the battery e...

Page 32: ...entire band at both high and low transmit power if applicable at various channel spacings and with different coded or carrier squelch types Any customer specific programming in the radio will not be changed or affected by use of the RF Test Mode Figure 4 2 Side Button Locations Table 4 1 Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode Power Monitor Spkr set A ...

Page 33: ...environment as shown in Table 4 4 5 Press the PTT on a test channel to cause the radio to transmit at the test frequency for the channel Table 4 2 Test Environments No of Beeps Description Function 1 GKC Carrier Squelch RX unsquelch if carrier detected TX mic audio 1 BKC Tone Private Line RX unsquelch if carrier and tone 192 8 Hz detected TX mic audio tone 192 8 Hz 2 BKC Digital Private Line RX un...

Page 34: ...de PWR MON 4th channel test frequency Monitor Frequency error Input at RF In Out TEST MODE Test Channel 4 carrier squelch output at antenna PTT to continu ous during the performance check Frequency error to be 186 Hz VHF1 200 Hz VHF2 525 Hz UHF1 568 Hz UHF2 600 Hz UHF3 Rated Audio Mode GEN Output level 1 0m V RF 4th channel test frequency Mod 1 kHz tone at 3 kHz deviation Monitor DVM AC Volts TEST...

Page 35: ... to RF In Out Monitor DVM AC Volts Set 1 kHz Mod Out level for 0 025 Vrms at test set 80m Vrms at AC DC test set jack As above As above meter selector to mic Deviation VHF UHF 4 0 kHz but 5 0 kHz 25 kHz Ch Sp Voice Modulation internal Mode PWR MON 4th channel test frequency atten to 70 input to RF In Out TEST MODE Test Channel 4 carrier squelch Output at antenna Remove modula tion input Press PTT ...

Page 36: ...October 2009 68009328001 A Notes 4 6 Performance Checks RF Test Mode ...

Page 37: ...er 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 5 2 CPS Programming Setup Refer to online help files for the CPS Programming procedures See Figure 5 1 for CPS Programming Setup Figure 5 1 CPS Programming Setup RIB RLN4008 RIB Power Supply RLN4460 Test Box Rx Gnd Data Tx Data Radio Battery Computer Int...

Page 38: ...e help files for the tuning procedures Note Radio Setup Requirement Ensure at least one Conventional Personality Channel is programmed on the radio for Global Tuner to function properly Figure 5 2 Radio Tuning Setup Service Monitor or Counter Wattmeter Audio Generator Sinad Meter AC Voltmeter 30 dB Pad 30 dB Pad Battery Eliminator Power Supply Audio In Tx Rx Receive Transmit RF Generator BNC RF Ad...

Page 39: ...rations 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 Speaker DC on standby Standby AM CW FM FM PTT OFF Volt Range 20 V Oscilloscope Source Mod Oscilloscope Horizontal 10 mSec Div Oscilloscope Vertical 2 5 kHz Div Oscilloscope Trigger Auto Monitor Image Hi Monitor BW Nar Mo...

Page 40: ...e to the indicated transmit frequency Refer to Table 5 2 6 Dekey the radio by pressing PTT Toggle 7 Program the warp value into the radio by pressing the Program button 8 Exit the Reference Oscillator Warp function 5 4 2 Modulation Balance Attenuation Table 5 2 Reference Oscillator Specifications RF Band Target VHF Band 1 136 162 MHz 162 Hz VHF Band 2 146 174 MHz 174 Hz UHF Band 1 403 440 MHz 436 ...

Page 41: ...quency point 3 Inject 80 Hz at an amplitude of 1 78 V 4 Record the deviation obtained Typical values should range from 1 70 2 30 kHz Modulation is only tuned in the 25 kHz channel spacing mode 5 Inject 3 kHz Set the amplitude to 1 5 V 6 Change the modulation balance attenuation setting until the Tx deviation is as recorded in step 4 7 Inject 80 Hz at an amplitude of 1 78 V 8 Check the deviation ag...

Page 42: ...hecking 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 This will avoid an RF mismatch and ensure a stable RF reading that will not change with varying lengths of connecting cable Figure 5 5 Transmit Power Window High Power ...

Page 43: ...uning do the following 1 Under the Tx Align menu select Transmit Power and then select Low 2 Press PTT Toggle This will key the radio up at 1st test frequency F1 3 Adjust the power level to be as defined by country power level specifications by moving the slider spin control or keying in values in the edit control press ENTER to confirm your selection after typing in the softpot value 4 Press PTT ...

Page 44: ... 12 5 and 20 kHz channels determines only the offset to the previously tuned deviation for 25 kHz tuning channel spacing For 12 5 and 20kHz channels only the last non 0 transmit frequency point normally F7 is used for tuning The 30 kHz channel bandwidths that use 5 0 kHz maximum system deviation are covered by the 25 kHz tuning When using test box RLN4460 Set the METER OUT toggle switch to the MIC...

Page 45: ...ss PTT Toggle to key up the radio at the last non 0 transmit frequency point normally F7 3 Inject 1 kHz at an appropriate level until 2 3 V rms is measured at the AC DC METER radio input if using test box RLN4460 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...

Page 46: ...ng obtained while tuning the DTMF 1 Under Tx Align select DTMF Deviation Figure 5 7 2 Press PTT Toggle to key the radio Monitor the deviation obtained 3 Adjust the slider spin or edit control press ENTER to confirm your selection send a softpot value until a deviation of 3 1 3 4 kHz is obtained 4 Press PTT Toggle again to dekey the radio 5 Program the softpot value into the radio by pressing Progr...

Page 47: ...lect MDC1200 Signaling Figure 5 8 2 Press PTT Toggle to key the radio up Monitor the deviation obtained 3 Adjust the slider spin or edit control press ENTER to confirm the selection send a softpot value until a deviation of 3 3 3 7 kHz is obtained 4 Press PTT Toggle again to dekey the radio 5 Program the softpot value into the radio by pressing the Program 6 Exit the MDC1200 Deviation function 5 5...

Page 48: ...lue or via the spin controls Repeat this until 500 mW 3 46 V audio power is obtained Rated Audio tuning is only done for 25 kHz channel spacing 4 Press Program to commit the softpot value into the radio 5 Exit the rated volume tuning function 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 a...

Page 49: ...Manual Squelch Tuning for procedure or by Auto Squelch see Manual Squelch Tuning for procedure To obtain 10 dB unmute the radio first by dragging the corresponding slider value to 1 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...

Page 50: ...elch attenuation The following steps describe the auto tune process 1 Select current frequency point F1 being the first then press Auto Tune 2 Repeat Steps 3 4 of the Manual Squelch Tuning section for frequency points F2 F7 5 5 3 RSSI System Level Tuning 1 Under the Rx Align menu select RSSI Tuning Figure 5 11 2 Inject an on channel signal to the radio at 47 dBm at the frequency listed Modulate th...

Page 51: ...serial number of the radio was not blank then access to the screen will be denied 5 6 2 Temp Comp Data Read The Temp Comp Data Read command will read the Temp Compensation data out from the radio and then display it on a dialog screen The data displayed is in 4 byte Hexadecimal form i e 0 9 A F e g A5 E9 33 3A 5 6 3 Temp Comp Data Write The Temp Comp Data Write command will write user Temp Compens...

Page 52: ...de buttons at the same time on the source radio and then power up the source radio Figure 5 12 Both radios produce a clone entry tone 5 Release both side buttons 1 and 2 6 When cloning is completed the source radio produce s a clone exit tone and both the source and destination radios reset 7 Turn both radios off 8 Disconnect the cloning cable from both radios and turn them on for normal operation...

Page 53: ...de the front cover housing assembly and battery case These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges grease and or grime The only recommended agent for cleaning the external radio surfaces is a 0 5 solution of a mild dishwashing detergent in water The only factory recommended liquid for cleaning the printed circuit boards and their components ...

Page 54: ... fresh supply of alcohol and a clean container to prevent contamination by dissolved material from previous usage CAUTION This radio contains static sensitive devices Do not open the radio unless you are properly grounded Take the following precautions when working on this unit Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert ...

Page 55: ... 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 Chassis Disassembly Speaker Disassembly PTT Disassembly 6 4 1 Radio Disassembly Detailed 6 4 1 1 Front Cover From Chassis Disassembly 1 Turn off the radi...

Page 56: ...pener into the slots located at the base of the radio Figure 6 3 Press the handle on the opener downwards This pressing action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs Figure 6 2 Antenna and Knob Removal Note Both knobs slide on and off However the knobs are designed to fit very tightly on the shaft Figure 6 3 Chassis Removal Note The spea...

Page 57: ...t 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 6 5 9 Unplug the speaker wire assembly from the 2 pin connector on the chassis 10 Unplug the microphone wire assembly from the socket on the chassis 11 Move the chassis away from the housing and place on a clean work surface CAUTION Marring the f...

Page 58: ...r Disassembly 6 4 1 3 Speaker and Microphone Disassembly 1 Remove the screw from the speaker retainer using a T6 Torx screwdriver Figure 6 7 2 Lift the retainer off the speaker sliding end of retainer out of corner slot on the housing 3 Lift the speaker out from the front housing 4 Carefully lift microphone assembly out of housing Note The speaker is held in place with a retainer bracket Be carefu...

Page 59: ...wdriver as follows a Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab b Pry the PTT away from the radio housing c Inspect the two hooks If bent or broken the PTT must be replaced d Remove the PTT seal CAUTION Refer to the CMOS CAUTION paragraph 6 3 before removing the main board Be sure to use Electrostatic Discharge protection when handling circuit boards Figure 6 8...

Page 60: ...r with a T6 bit to remove the four screws Figure 6 10 holding the main board to the chassis 3 The audio jack shroud can be removed from the main board 4 Lift the main board from the chassis Figure 6 10 5 Remove the battery contact seal Figure 6 9 PTT Removal Figure 6 10 Removal of Main Board from Chassis Flat Blade Screwdriver PTT Seal Tab Tab Hooks Main Board Radio Chassis Audio Jack Shroud O Rin...

Page 61: ...seated properly onto the recess 4 Press the cap again to ensure it fully covers the opening for the audio jack 6 4 2 2 Speaker Re assembly 1 Check that the speaker felt is in position and not damaged If damaged replace felt 2 Thread wires through the speaker retainer 3 Orientate the speaker into the housing so that the wires point at approximately a 10 o clock direc tion Figure 6 12 Note Make sure...

Page 62: ...the housing 4 Press hooks on the keypad into the slots in the housing 5 Remove the protective mylar liner from the LCD if present 6 Place the Display Keyboard Module into the housing by positioning the LCD glass to the display frame see Figure 6 13 7 Use the two keypad posts to align the Display Keyboard Module 8 Screw in the two screws along the top first followed by the two screws on the sides T...

Page 63: ... If damaged replace felt 2 Insert the microphone sub assembly into the microphone boot 3 Orientate the boot and microphone sub assembly into the microphone recess in the housing so that the wires point at approximately 5 o clock direction Figure 6 15 then route wires as shown in Figure 6 15 4 Secure with Kapton tape in location shown in Figure 6 15 Figure 6 14 Display Keypad Module Re assembly 2 F...

Page 64: ...e volume frequency switches Stretch the O ring to place it into the retaining groove at the bottom end of the chassis b If you have the newer chassis 2786389Z02 use the newer O ring 3286431Z05 Position the O ring with the plug on the right side speaker connector side Push the plug all the way into the chassis slot until it is touching the chassis flange Repeat for the left side Stretch the O ring ...

Page 65: ...6 16 2 Position the radio Figure 6 18 and reconnect the flex connector from the keyboard into the connector located on the bottom of the main board pushing up the 2 end tabs 3 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 between shroud and housing...

Page 66: ... using the knob removal chassis opener and dress O ring properly 7 Snap the bottom of the chassis into the front cover 8 Check that O ring is visible at the corners 9 Re assemble the knobs antenna and battery 6 4 2 7 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 op...

Page 67: ...assembly Mechanical View and Parts List 6 15 6 5 Mechanical View and Parts List 6 5 1 CP200XLS Full Keypad Exploded View and Parts List Figure 6 21 CP200XLS Full Keypad Radio Exploded View 1 2 33 3 32 31 29 5 28 27 7 8 25 14 4 6 9 10 11 12 13 18 17 19 20 26 30 16 21 ...

Page 68: ...rophone 13 0186639Z04 Microphone Plug Assembly 14 0104034J96 Display Keypad Flex Circuit Assembly Full 16 1586437Z02 Shroud Audio Jack 17 3286431Z05 Seal Main O ring 18 7586436Z02 Pad PA Interface 19 2786389Z02 Chassis 20 3286435Z01 Seal Battery Contact Block 21 0304726J05 Screws Chassis 4 Used 25 75012007001 Keypad Full 26 5586445Z03 Latch Assembly 27 4116105H01 Spring Latch 2 Used 28 3886441Z02 ...

Page 69: ...lude the front cover housing assembly and battery case These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges grease and or grime The only recommended agent for cleaning the external radio surfaces is a 0 5 solution of a mild dishwashing detergent in water The only factory recommended liquid for cleaning the printed circuit boards and their component...

Page 70: ...a fresh supply of alcohol and a clean container to prevent contamination by dissolved material from previous usage CAUTION This radio contains static sensitive devices Do not open the radio unless you are properly grounded Take the following precautions when working on this unit Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert...

Page 71: ...ce 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 Chassis Disassembly Speaker Disassembly PTT Disassembly 7 4 1 Radio Disassembly Detailed 7 4 1 1 Front Cover from Chassis Disassembly 1 Turn off the radio 2 Remov...

Page 72: ... 7 3 Press the handle of the opener downwards This pressing action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs 6 Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft just clear the top of the case Figure 7 4 Figure 7 2 Antenna and Knob Removal Note Both knobs slide on and off However the knobs are...

Page 73: ...microphone wires that are still connected to the chassis Figure 7 5 9 Unplug the speaker wire assembly from the 2 pin connector on the chassis 10 Unplug the microphone wire assembly from the socket on the chassis 11 Move the chassis away from the housing and place on a clean work surface Note The speaker wire assembly microphone wire assembly and keypad flex cable connecting the front housing asse...

Page 74: ...ver Disassembly 7 4 1 3 Speaker and Microphone Disassembly 1 Remove the screw from the speaker retainer using a T6 Torx screwdriver Figure 7 7 2 Lift the retainer off the speaker sliding end of retainer out of corner slot on the housing 3 Lift the speaker out from the front housing 4 Carefully lift microphone assembly out of housing Note The speaker is held in place with a retainer bracket Be care...

Page 75: ...PTT Disassembly 1 If required the PTT Figure 7 9 can be disassembly using a small screwdriver as follows a Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab b Pry the PTT away from the radio housing c Inspect the two hooks If bent or broken the PTT must be replaced d Remove the PTT seal CAUTION Refer to the CMOS CAUTION paragraph 7 3 before removing the main board Be ...

Page 76: ...he audio jack shroud can be removed from the main board 4 Lift the main board from the chassis Figure 7 10 5 Remove the battery contact seal Figure 7 9 PTT Removal CAUTION Refer to the CMOS CAUTION paragraph see 3 3 before removing the main board Be sure to use Electrostatic Discharge protection when handling circuit boards Figure 7 10 Removal of Main Board from Chassis Flat Blade Screwdriver PTT ...

Page 77: ...s seated properly onto the recess 4 Press the cap again to ensure it fully covers the opening for the audio jack 7 4 3 2 Speaker Re assembly 1 Check that the speaker felt is in position and not damaged If damaged replace felt 2 Thread wires through the speaker retainer 3 Orientate the speaker into the housing so that the wires point at approximately a 10 o clock direc tion Figure 7 12 Note Make su...

Page 78: ...n the housing 4 Press hooks on the keypad into the slots in the housing 5 Remove the protective mylar liner from the LCD if present 6 Place the Display Keyboard Module into the housing by positioning the LCD glass to the display frame see Figure 7 13 7 Use the two keypad posts to align the Display Keyboard Module 8 Screw in the two screws along the top first followed by the two screws on the sides...

Page 79: ...ed If damaged replace felt 2 Insert the microphone sub assembly into the microphone boot 3 Orientate the boot and microphone sub assembly into the microphone recess in the housing so that the wires point at approximately 5 o clock direction Figure 7 15 then route wires as shown in Figure 7 15 4 Secure with Kapton tape in location shown in Figure 7 15 Figure 7 14 Display Keypad Module Re assembly 2...

Page 80: ...tretch the O ring to place it into the retaining groove at the bottom end of the chassis b If you have the newer chassis 2786389Z02 use the newer O ring 3286431Z05 Position the O ring with the plug on the right side speaker connector side Push the plug all the way into the chassis slot until it is touching the chassis flange Repeat for the left side Stretch the O ring to place it into the retainin...

Page 81: ...roud onto accessory connector Figure 7 17 2 Position the radio Figure 7 18 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 3 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...

Page 82: ...l is pinched separate the chassis from the housing using the knob removal chassis opener and dress O ring properly 7 Snap the bottom of the chassis into the front cover 8 Check that O ring is visible at the corners 9 Re assemble the knobs antenna and battery 7 4 3 7 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 bott...

Page 83: ...ssembly Mechanical View and Parts List 7 15 7 5 Mechanical View and Parts List 7 5 1 CP200XLS Limited Keypad Exploded View and Parts List Figure 7 21 CP200XLS Limited Keypad Radio Exploded View 1 2 33 3 32 31 29 5 28 27 7 8 25 14 4 6 9 10 11 12 13 18 17 19 20 26 30 16 21 ...

Page 84: ...ophone 13 0186639Z04 Microphone Plug Assembly 14 0104034J49 Display Keypad Flex Circuit Assembly Limited 16 1586437Z02 Shroud Audio Jack 17 3286431Z05 Seal Main O ring 18 7586436Z02 Pad PA Interface 19 2786389Z02 Chassis 20 3286435Z01 Seal Battery Contact Block 21 0304726J05 Screws Chassis 4 Used 25 75012007002 Keypad Limited 26 5586445Z03 Latch Assembly 27 4116105H01 Spring Latch 2 Used 28 388644...

Page 85: ...hat a service technician should be contacted Use Table 9 2 to aid in understanding particular operational error codes Table 9 1 Power Up Error Code Display Error Code Possible Causes Corrective Action RAM ERR RAM Test Failure Retest radio by turning if off and tuning it on again If message reoccurs replace main board or send radio to depot ROM ERR ROM checksum is wrong Reprogram FLASH memory and r...

Page 86: ... depot No Receive Audio or Receiver Does Not Unmute Programming 1 Does the transmitted signal match the receiver configuration PL DPL etc 2 With the monitor function enabled can the radio be unmuted Audio Distorted or Not Loud Enough Synthesizer Not On Frequency Check synthesizer frequency by measuring the transmitter frequency realign it off by more than 150 Hz VHF 500 Hz UHF RF Sensitivity Poor ...

Page 87: ...l or Frequency Check Tx power level and frequency programming from tuner 2 No Injection To Power Amplifier Send radio to depot Antenna Switch Connector No Modulation Distortion Modulation 1 Programming Check deviation and compensation settings using the tuner 2 Transceiver Board Send radio to depot Bad Microphone Sensitivity 1 Check Deviation and Compensation Realign if necessary 2 Microphone Send...

Page 88: ...December 2009 68009328001 A Notes 9 4 Troubleshooting Tables Troubleshooting Table for Transmitter ...

Page 89: ...ited Display models RLN5383 Leather Case with Belt Loop For Non Display models RLN5384 Leather Case with 2 1 2 inch Swivel for Non Display models RLN5385 Leather Case with 3 inch Swivel for Non Display models HLN9701 Nylon Case with Belt Loop For all models HLN8255 3 inch Spring Action Belt Clip RLN5644 2 inch Spring Action Belt Clip NTN5243 Shoulder Strap for Hard Leather Cases attaches to D Shap...

Page 90: ... Earbud Single Wire Receive Only Black NTN8370 Extreme Noise Kit NTN8371 Low Noise Kit RLN4760 Small Custom Clear Earpiece Right Ear RLN4763 Small Custom Clear Earpiece Left Ear RLN4761 Medium Custom Clear Earpiece Right Ear RLN4764 Medium Custom Clear Earpiece Left Ear RLN4762 Large Custom Clear Earpiece Right Ear RLN4765 Large Custom Clear Earpiece Left Ear 5080384F72 Replacement Noise Attenuati...

Page 91: ...one with VOX PTT Interface Module 0180358B38 Ring PTT Switch for Ear Microphone Systems BDN6646 BDN6706 0180300E83 Body PTT Switch for Ear Microphone Systems BDN6646 BDN6706 0180300E25 Ear Guard with Adjustable Loop 0180358B32 Ear Holder Small Black 0180358B33 Ear Holder Medium Black 0180358B34 Ear Holder Large Black 0180358B35 Ear Holder Small Clear 0180358B36 Ear Holder Medium Clear 0180358B37 E...

Page 92: ...October 2009 68009328001 A Notes A 4 Accessories ...

Page 93: ...acement 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 B 2 2 After Warranty Period After the Warranty period Motorola continues to support its products in two ways 1 Motorola s Radio Products and...

Page 94: ... PM Eastern Standard Time B 3 5 Fax Orders Radio Products and Services Division RPSD United States and Canada 1 800 622 6210 847 576 3023 International USFGMD Federal Government Orders 1 800 526 8641 For Parts and Equipment Purchased Orders B 3 6 Parts Identification Radio Products and Services Division RPSD United States and Canada 1 800 422 4210 menu 3 The Radio Products and Services Division RP...

Page 95: ...d Initial contact should be by telephone wherever possible When contacting Motorola Technical Support Customer Resources be prepared to provide the product model number and the unit s serial number Motorola Radio Support Center 3761 South Central Avenue Rockford IL 61102 4294 1 800 227 6772 1 815 489 1000 Canadian Technical Logistics Centre 400 Matheson Blvd W Mississauga Ontario Canada L5R 3M1 1 ...

Page 96: ...December 2009 68009328001 A Notes B 4 Warranty Service Support and Replacement Parts Technical Support ...

Page 97: ...nide a type of crystalline material used in some semiconductors GKC Good Key Chirp ISW Inbound Signalling Word data transmitted on the control channel from a subscriber unit to the central control unit LH DATA Longhorn Data a bidirectional 0 5V RS 232 line protocol that uses the microcontroller s integrated RS 232 asynchronous serial communications interface SCI peripheral LLE Low Level Expander s...

Page 98: ...round Softpot A computer adjustable electronic attenuator Software Computer programs procedures rules documentation and data pertaining to the operation of a system SPI clock and data lines Serial Peripheral Interface how the microcontroller communicates to modules and ICs through the CLOCK and DATA lines Squelch Muting of audio circuits when received signal levels fall below a pre determined valu...

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