Professional Radio GM300 Series Basic Service Manual 68P64115B51 Issue: July 2000
ii Computer Software Copyrights The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or reproduce in any form, the copyrighted computer program.
iii SAFETY INFORMATION Read this information before using your radio. SAFE AND EFFICIENT OPERATION OF MOTOROLA TWO-WAY RADIOS This document provides information and instructions for the safe and efficient operation of Motorola Portable and Mobile Two-Way Radios. The information provided in this document supersedes the general safety information contained in user guides published prior to 1 January 1998.
iv The table below lists the minimum distance for several different ranges of rated radio power. Table 1 Rated Power and Distance Rated Power of Vehicle-Installed Mobile Two-Way Radio Minimum Distance from Transmitting Antenna 7 to 15 Watts 30.5 cm (1 Foot) 16 to 50 Watts 61 cm (2 Feet) More than 50 Watts 91.5 cm (3 Feet) Mobile Antenna Installation Install the vehicle antenna external to the vehicle and in accordance with: a. The requirements of the antenna manufacturer/supplier b.
v Table of Contents SAFETY INFORMATION........................................................................................iii Chapter 1 INTRODUCTION 1.0 Scope of Manual ..................................................................................................1-1 2.0 Warranty and Service Support.............................................................................1-1 2.1 Warranty Period and Return Instructions .......................................................1-1 2.
vi 8.0 Radio Exploded Mechanical Views and Parts Lists ........................................... 3-11 8.1 Radio Assembly - 25W Models .................................................................... 3-11 8.2 Radio Assembly - 60W Models .................................................................... 3-12 8.3 Control Head - GM340 ................................................................................. 3-13 8.4 Control Head - GM360 ..........................................................
Chapter 1 INTRODUCTION 1.0 Scope of Manual This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the equipment described and is current as of the printing date. Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions. NOTE Before operating or testing these units, please read the Safety Information Section in the front of this manual. 2.
1-2 2.
Warranty and Service Support 2.5 1-3 Technical Support Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions which may be encountered. UK/Ireland - Richard Russell Telephone: +44 (0) 1256 488 082 Fax: +44 01256 488 080 Email: BRR001@email.mot.com Central/East Europe - Siggy Punzenberger Telephone: +49 (0) 6128 70 2342 Fax: +49 (0) 6128 95 1096 Email: TFG003@email.mot.
1-4 3.0 INTRODUCTION 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.
Chapter 2 MODEL CHART AND TEST SPECIFICATION 1.
2-2 MODEL CHART AND TEST SPECIFICATION 2.
Model Chart (Low Band 29-50 MHz) 3.0 2-3 Model Chart (Low Band 29-50 MHz) GM Series Low Band 29-50 MHz Model MDM25BKF9AN5_E Description GM360 LB1, 29.0-36.0 MHz, 40-60W, 255 Ch MDM25CKF9AN5_E GM360 LB2, 36.0-42.0 MHz, 40-60W, 255 Ch MDM25DKF9AN5_E GM360 LB3, 42.0-50.
2-4 2.4 MODEL CHART AND TEST SPECIFICATION Specifications General Specification Frequency Range: Frequency Stability (-30°C to +60°C, 25°C Ref.) VHF UHF LB1, LB2, LB3 136-174 MHz 403-470 MHz 29.7-36.0 MHz 36.0-42.0 MHz 42.0-50.0 MHz ±2.5 PPM ±2 PPM ±5.0 PPM Channel Capacity: GM340 - 6 GM360 - 255 GM380 - 255 Channel Spacing: 12.5/20/25 kHz Power Output: Power Supply: 1-25W 1-25W 40-60W 13.2Vdc (10.8 - 15.
Specifications 2-5 Transmitter Specification VHF UHF Modulation Limiting: ±2.5 kHz @ 12.5 kHz ±4.0 kHz @ 20 kHz ±5.0 kHz @ 20/25 kHz FM Hum and Noise: -40 dB@12.5 kHz -45 dB@ 20/25 kHz Conducted/Radiated Emissions: LB1, LB2, LB3 -36 dBm < 1 GHz -30 dBm > 1 GHz Adjacent Channel Power -26 dBm -60dB @12.5, -70dB @ 20/25kHz Audio Response: ( 300 to 3000Hz) +1, -3dB Audio Distortion: @ 1000 Hz, 60% Rated Maximum Deviation: 3% Typical Receiver Specification VHF UHF 0.30µV (0.
2-6 MODEL CHART AND TEST SPECIFICATION
Chapter 3 MAINTENANCE 1.0 Introduction This chapter provides details about the following: 2.0 Preventive maintenance (inspection and cleaning). Safe handling of CMOS and LDMOS devices. Disassembly and reassembly of the radio. Repair procedures and techniques. Installation of Option Boards. Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 2.
3-2 MAINTENANCE Cleaning Internal Circuit Boards and Components Isopropyl alcohol (70%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the dislodged material out and away from the inside of the radio. Make sure that controls or tunable components are not soaked with alcohol.
Repair Procedures and Techniques — General 4.0 3-3 Repair Procedures and Techniques — General Parts Replacement and Substitution 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.
3-4 6.0 MAINTENANCE Radio Disassembly - Detailed The procedure to remove and replace a Control Head, Top Cover or Transceiver Board is similar for all models of radio. A typical procedure is therefore shown followed by specific disassembly procedures for Control Heads on radio models without a display and radio models fitted with a display. 6.1 Control Head Removal 1. Insert the dismantling tool in the groove between the control head and the radio assembly as shown in Figure 3-1. 2.
Radio Disassembly - Detailed 3-5 Flexible Connection ZWG0130210-O Figure 3-2 Flexible Connection Removal 4. 6.2 Remove the flexible connection from the socket on the control head board. Top Cover Removal 1. Insert the dismantling tool in the middle of the radio assembly side groove as shown in Figure 3-3. 2. Press on the dismantling tool until the snap connectors on the side of the cover release from the radio chassis. 3. Lift the top cover from the chassis.
3-6 6.3 MAINTENANCE Transceiver Board Removal 1. Remove the screws securing the diecast cover to the chassis, using the T20 TORX™ driver as shown in Figure 3-4. 2. Lift the cover from the chassis. Screws (6 on 25W models) (9 on 60W models) Diecast Cover Radio Chassis ZWG0130212-O Figure 3-4 Diecast Cover Removal. 3.
Radio Disassembly - Detailed 6.4 3-7 Disassembly of Control Head - GM340 (without display) 1. To dismount the control head housing from the back housing, insert the dismantling tool in the groove between the two housings as shown in Figure 3-6. ZWG0130214-O Figure 3-6 Control Head Back Housing Removal 2. Press the dismantling tool until the snap connectors on the side of the back housing release from the control head. 3. Disconnect the speaker socket.
3-8 MAINTENANCE ZWG0130216-O Figure 3-8 Board, Keypad and Speaker Removal 6. 6.5 Remove the speaker from the control head housing. Disassembly of Control Heads - GM360 and GM380 (with display) 1. Dismount the control head housing from the back housing as described for control heads without displays, Figure 3-6 and 3-7. 2. On the GM360, disconnect the speaker socket and pull out the speaker (with speaker tube) by stretching the control head housing, Figure 3-9.
Radio Assembly 5. 3-9 Remove the display and the top and bottom elastomeric connectors from the control head housing (GM360 only). NOTE Care should be taken not to touch or contaminate the conductive pads on the under side of the keypad, the elastomeric connectors or the conductive contacts on the printed circuit board . 7.0 Radio Assembly 7.1 Control Head - GM340 1. Locate the speaker in the control head and press it into place as shown in Figure 3-8. 2.
3-10 7.3 7.4 MAINTENANCE Radio Chassis and Transceiver Board 1. Inspect the transceiver board chassis and if required reapply thermal grease to the heatsink area on the chassis and heat dissipating devices. You may have to remove damaged thermal pads from the chassis and devices prior to applying the grease. 2. Insert the transceiver board at an angle (approximately 30°) into the chassis taking care to slide the antenna connector and accessory connector into their cut-outs in the chassis. 3.
Radio Exploded Mechanical Views and Parts Lists 3-11 8.0 Radio Exploded Mechanical Views and Parts Lists 8.1 Radio Assembly - 25W Models 10 9 8 7 6 5 4 15 13 3 14 16 12 1 11 2 Figure 3-10 Radio Assembly - 25W Models Table 3-1 Radio Assembly Parts List - 25W Models Item No.
3-12 8.2 MAINTENANCE Radio Assembly - 60W Models 10 8 9 7 5 4 6 3 13 12 1 11 2 Figure 3-11 Radio Assembly 60W Models Table 3-2 Radio Assembly Parts List - 60W Models Item No.
Radio Exploded Mechanical Views and Parts Lists 8.
3-14 8.4 MAINTENANCE Control Head - GM360 10 11 4 12 2 9 13 7 8 5 6 1 3 ZWG0130200-A Figure 3-13 Control head - GM360 Table 3-4 Control Head GM360 Parts List Item no Description Part No. 1 Housing Front Gasket, Lens, Lightguide 1586088B01 2 Knob, Volume 3686098B02 3 Label 1364279B14 4 Speaker 5086126B01 5 Tube, Speaker with Gasket 3786107B01 6 Keypad, including: Keypad Button 7586091B02 3886134B-- 7 LCD Glass 7286104B01 8 Frame LCD 0786099B01 9 Conn.
Radio Exploded Mechanical Views and Parts Lists 8.
3-16 9.0 MAINTENANCE Service Aids Table 3-6 lists the service aids recommended for working on the radio. While all of these items are available from Motorola, most are standard workshop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 3-6 Service Aids Motorola Part No. Description Application RLN4460_ Portable Test Set Enables connection to audio/accessory jack. Allows switching for radio testing.
Test Equipment 10.0 3-17 Test Equipment Table 3-7 lists test equipment required to service the radio and other two-way radios. Table 3-7 Recommended Test Equipment Motorola Part No.
3-18 MAINTENANCE 11.0 Programming/Test Cable - RKN4083_ P1 (Male) To Radio Test Set 1 13 13 14 J1 (Female) To RIB RLN4008 25 25 1 14 1000 +_ 50mm Cable 1000 +_ 50mm Cable J2 (Female) To Mobile Radio Accessory Connector 1 19 17 20 18 Viewed from Front (pin end) of Connector 2 FL0830308O FLO830308-0 Figure 3-15 Programming/Test Cable J2 Mobile Radio Accessory Connector SPEAKER EXTERNAL MIC DIGITAL IN 1 (EXT. PTT) DIGITAL OUT 2 (EXT.
Chapter 4 TRANSCEIVER PERFORMANCE TESTING 1.0 General These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule. 2.0 Setup Supply voltage is provided using a 13.2Vdc power supply.
4-2 3.0 TRANSCEIVER PERFORMANCE TESTING RF Test Mode When the radio is operating in its normal environment, the radio’s microcontroller controls the RF channel selection, transmitter key-up, and receiver muting. However, when the unit is on the bench for testing, alignment, or repair, it is removed from its normal environment and cannot receive commands from its system. Therefore, the internal microcontroller does not key the transmitter or unmute the receiver.
RF Test Mode 4-3 Table 4-2 Test Environments No.
4-4 TRANSCEIVER PERFORMANCE TESTING Table 4-4 Test Frequencies Test Mode Test Channel Low Power Test Channel High Power TX 1 8 136.025 RX 1 8 TX 2 RX VHF UHF LB1 LB2 LB3 403.025 29.725 36.025 42.025 136.050 403.050 29.750 36.050 42.050 9 142.325 414.150 30.225 37.125 43.225 2 9 142.350 414.175 30.325 37.225 43.125 TX 3 10 148.625 425.325 31.025 38.225 44.525 RX 3 10 148.650 425.350 31.125 38.325 44.425 TX 4 11 154.975 436.475 32.125 39.125 46.
RF Test Mode 4-5 Table 4-5 Transmitter Performance Checks (Continued) Test Name Communications Analyzer Radio Test Set Comment Voice Modulation Mode: PWR MON 4th channel test frequency* atten to -70, input to RF In/ Out Monitor: DVM, AC Volts Set 1kHz Mod Out level for 800mVrms at test set, 800mVrms at AC/ DC test set jack As above As above, meter selector to mic Deviation: 2.5 kHz Max. (12.5 kHz Ch. Sp). 4 kHz Max. (20 kHz Ch. Sp). 5 kHz Max. (25 kHz Ch. Sp).
4-6 TRANSCEIVER PERFORMANCE TESTING Table 4-6 Receiver Performance Checks Test Name Communications Analyzer Radio Test Set Comment Reference Frequency Mode: 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 continuous (during the performance check) Frequency error to be ±150 Hz VHF ±150 Hz UHF ±150 Hz LB Rated Audio Mode: GEN Output level: 1.
Chapter 5 RADIO TUNING AND PROGRAMMING 1.0 Introduction This chapter provides an overview of the Customer Programming Software (CPS) and tuner program which are designed for use in a Windows 95/98 environment. These programs are available in separate kits as listed in the Table 5-1. An Installation instruction manual is also included with each kit. NOTE Refer to the appropriate program on-line help files for the programming procedures.
5-2 RADIO TUNING AND PROGRAMMING Radio ACC DC RF +13,2VDC Power Supply Tx Data Rx Data Gnd Programming Cable RKN4081 DB25 ZWG0130339-0 Figure 5-2 CPS Programming Setup Cable with Internal RIB Radio ACC Adapter Cable RLN4853 Programming Cable RKN4081 DC RF Tx Data Rx Data Gnd DB25 +13,2VDC Power Supply ZWG0130340-0 Figure 5-3 CPS Programming Setup Cable with Internal RIB and Rear Adapter Cable
Radio Tuning Setup 3.0 5-3 Radio Tuning Setup A personal computer (PC), Windows 95/98 and a tuner program are required to tune the radio. To perform the tuning procedures, the radio must be connected to the PC, radio interface box (RIB), and test equipment setup as shown in Figure 5-4.
5-4 RADIO TUNING AND PROGRAMMING
Chapter 6 POWER UP SELF-TEST 1.0 Error Codes Turning on the radio starts a self-test routine that checks the radio functionality. If the checks are successful, the radio generates a high-pitched self-test pass tone. If the self-test is not successful, one low-pitched (300Hz) error tone is heard and the RED LED flashes several times to indicate the reason for the failure (see Table 6-1 below). After flashing the error code, the LED remains off for 5 seconds and then repeats the error code.
6-2 POWER UP SELF-TEST
