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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 6124944 The Technical Publications Coordinator, Global Customer Documentation, R&D Department, Motorola Penang. Your Details Name/Contact Person: Company Name: Address: Telephone No.: Fax No.:...
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Kindly take a few moments to provide feedback on this manual. Thank you for your cooperation. Fax to: 6 6124944 The Technical Publications Coordinator, Global Customer Documentation, R&D Department, Motorola Penang. 1. Please check all the appropriate boxes: Disassembly Procedures Alignment Procedures Exploded...
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...
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...
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 ........................
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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 Troubleshooting Tables ............. 7-1 Error Codes............................ 7-1 Troubleshooting Table for Receiver....................7-2...
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Table of Contents Appendix A Accessories .................A-1 Appendix B Warranty, Service Support, and Replacement Parts ..B-1 Scope of Manual..........................B-1 Warranty ............................B-1 B.2.1 Warranty Period and Return Instructions................B-1 B.2.2 After Warranty Period .......................B-1 B.2.3 Piece Parts ........................B-2 Appendix C Repair Procedures and Techniques – General ....C-1 Glossary of Terms..................
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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...
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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...
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.
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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 UHF2 435 – 480 MHz 2W or 4W 136 –...
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.
Model Charts and Test Specifications: Model Chart for UHF2, 435–480 MHz Model Chart for UHF2, 435–480 MHz CP185, UHF2, 435 – 480 MHz Model Description CP185 435 – 480M 4W 12.5/25K 16C AAH03RDF8AA7AN Item Description X PMUE3139_ CP185 435 – 480M 4W 12.5/25K 16C X PMDE4023_R 435 –...
Model Charts and Test Specifications: Model Chart for VHF, 136–174 MHz Model Chart for VHF, 136–174 MHz CP185, VHF, 136 – 174 MHz Model Description AAH03KEF8AA7AN CP185 136 – 174M 5W 12.5/25K 16C Item Description X PMUD2444_ 136 – 174M 5W 12.5/25K 16CH X PMDD4020_R 136 –174M 5W PCB –...
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 •...
Theory Of Operation: Major Assemblies 2.2.1.1 RX Front End UHF2 : 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 (L409 –...
Theory Of Operation: Major Assemblies 2.2.1.3 RX Squelch The mute (squelch) circuitry switches off the audio amplifier when no audio is detected from the recovered audio. The squelch circuit main components are U202 & U201. U202 will adjust the squelch circuit sensitivity depending on Noise level from recovered audio. Noise level is amplified by internal amplifier of U201 to help U202 decide the squelch circuit sensitivity.
Theory Of Operation: Major Assemblies The APC (Auto Power Control) keeps the current supplied to Final PA (Q403) constant. Resistor, R417 is used for current sensing. The voltage difference ratio of R423 to R417 is amplified through U401 and passed to Q404 and Q405 to produce constant power output to the antenna. Do not exceed the maximum allowed bias voltage of the device.
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 Com- Pre- Limiter...
Theory Of Operation: Major Assemblies The output audio signal of Audio Processor IC is directed to volume control switch (SW/VOL1) controlled by user and is finally amplified by U601BTL Audio Amplifier to a sufficient level to drive either the external or internal speaker. 2.2.6 Microcontroller The microprocessor or CPU includes Microprocessor (U101), EEPROM and support components.
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Theory Of Operation: Major Assemblies Notes...
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 Motorola Part No. Description Characteristics Application R2600 series System analyzer This item will substitute...
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.
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 Figure 3-3.
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Test Equipment, Service Aids, and Service Tools: Service Aids Notes...
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.
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Performance Checks: LCD/LED/Button/Volume Knob Test Mode Table 4-1. Radio Operation in Test Mode (Continued) Button LCD Indication Backlight Tone SPB1 • ON when button is (Side pressed. Programmable • OFF after a short Button 1) period of inactivity (even if the button is continuously being pressed).
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.
Audio Analyzer RX Low Battery Eliminator PMDN4080_R Power Supply RX/TX data 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. Figure 5-2. Radio Tuning Setup...
Radio Programming and Tuning: Transmitter Alignment Options 5.4.1 Initial Test Equipment Control Settings The initial test equipment control settings are listed in Table 5-1. Table 5-1. Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode: Power Monitor Impedance: 24 Voltage: 7.5 Vdc RF Attenuation:...
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.
Radio Programming and Tuning: Transmitter Alignment Options 5.5.2 Transmit Low Power Tuning 1. Click the Read icon to initiate communication with the radio. 2. Under the Alignment menu, select Tx Power, then select Low (Figure 5-4. Tx Low Power Window (Low Power)). 3.
Radio Programming and Tuning: Transmitter Alignment Options 5.5.3.2 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. This will key up the radio at the F1. 3.
Radio Programming and Tuning: Receiver Tuning Receiver Tuning There are 4 variations of Receive Squelch Tuning: 12.5 kHz-Band Normal Squelch, 12.5 kHz-Band Tight Squelch, 25 kHz-Band Normal Squelch and 25 kHz-Band Tight Squelch. Table 5-4. Receiver Squelch Tuning Squelch Type Tuning Range (dB) Normal 6 –...
Radio Programming and Tuning: Receiver Tuning 5.6.2 Receive 12.5 kHz Band Tight Squelch Tuning 1. Under the Alignment menu, select Rx Squelch, then select Squelch 12.5 kHz-band Tight. (Figure 5-8. Rx 12.5 kHz-band Tight Squelch Tuning Window). 2. Apply a RF signal for current frequency point with minimum amplitude, -128 dBm (F1 being the first).
5-10 Radio Programming and Tuning: Receiver Tuning 5.6.3 Receive 25 kHz Band Normal Squelch Tuning 1. Under the Alignment menu, select Rx Squelch, then select Squelch 25 kHz-band Normal. (Figure 5-9. Rx 25 kHz-band Normal Squelch Tuning Window). 2. Apply a RF signal for current frequency point with minimum amplitude, -128 dBm (F1 being the first).
Radio Programming and Tuning: Receiver Tuning 5-11 5.6.4 Receive 25 kHz Band Tight Squelch Tuning 1. Under the Alignment menu, select Rx Squelch, then select Squelch 25 kHz-band Tight. (Figure 5-10. Rx 25 kHz-band Tight Squelch Tuning Window). 2. Apply a RF signal for current frequency point with minimum amplitude, -128 dBm (F1 being the first).
5-12 Radio Programming and Tuning: Utilities Utilities 5.7.1 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.
Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode 5-13 Press Side Programmable Button 1 to either return to previous menu level or to exit the selection parameter without change. 5.8.5 Editing Front Panel Programming Mode Parameters Table 5-5. Front Panel Programming Mode Parameters 1st Level 2nd Level Main Menu...
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5-14 Radio Programming and Tuning: Front Panel Feature and Button Configuration Mode Table 5-5. Front Panel Programming Mode Parameters (Continued) 1st Level 2nd Level Main Menu Setting Remarks Sub-Menu Sub-Menu TX PL CH-001 ... Transmit PL (Transmit TPL/ CH-016 TPL 067.0 001 ...
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 •...
• 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.) •...
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.
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 (31): Release the battery latch by moving it into the unlock position.
Maintenance – CP185: Disassembling and Reassembling the Radio – General 4. Remove the Volume Knob (7) and Channel Knob (8) from their shafts using the Chassis and Knob Opener. (Refer Figure 6-3). Volume Knob Channel Knob Chassis and Knob Opener Figure 6-3.
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 (39) and speaker wire underneath. (Refer Figure 6-5). Speaker Wire Flexible Cable Figure 6-5.
Maintenance – CP185: Disassembling and Reassembling the Radio – General Push the latches on the Front Circuit Board (41) 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...
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.
Maintenance – CP185: Disassembling and Reassembling the Radio – General 4. Remove the LCD (38), Poron Pad (44) and Keypad (43) 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.
6-10 Maintenance – CP185: Disassembling and Reassembling the Radio – General 5. Remove the Speaker Felt (9) from the grille area. (Refer Figure 6-12). Speaker Retainer Speaker Insulator Speaker Speaker Felt Figure 6-12. Speaker Removal...
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 (9) 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.
6-12 Maintenance – CP185: Disassembling and Reassembling the Radio – General 3. Place the Front Circuit Board (41) straight down on top of the LCD and keypad. Align the front circuit board to the four housing ribs. Press the top right edge of the front circuit board to ensure the microphone sealing rubber is fully seated in place.
Maintenance – CP185: Disassembling and Reassembling the Radio – General 6-13 5. Tighten the RF Support Screw (20) 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).
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 (39) from the main circuit board into the connector on the front circuit board.
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...
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6-16 Maintenance – CP185: Mechanical View and Parts List Item Motorola Kit Number Description Quantity PMDN4097_R Front Housing, Limited Keypad PMDN4096_R Name Plate (CP185) PMDN4124_R Double Molded Cover, PTT PMDN4089_R Seal, Volume and Channel Knob PMDN4088_R Adhesive, Top Control PMDN4103_R...
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Maintenance – CP185: Mechanical View and Parts List 6-17 Item Motorola Kit Number Description Quantity PMDN4107_R Screw, Machine 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...
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6-18 Maintenance – CP185: Mechanical View and Parts List Notes...
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.
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.
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...
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Troubleshooting Tables: Troubleshooting Table for Transmitter Notes...
90 – 264 V, SMPS with NA/LA country plug PMLN5228_R Tri-Chem 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/business.
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.
Technical Services (MTS). If no part number is assigned, the part is not normally available from Motorola. If the part number is appended with an asterisk, the part is serviceable by Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable parts are available for that kit or assembly.
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 and order the part from the nearest Motorola Communications parts center listed in the “Piece Parts” section of this manual.
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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.
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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.
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Repair Procedures and Techniques – General Notes...
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.
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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; when pressed, causes the radio to transmit.