Professional Radio GP1280 Basic Service Manual 68P64115B27A Issue: June 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 SAFETY INFORMATION OPERATIONAL WARNINGS Vehicles with an air bag ! WARNING: Do not place a portable radio in the area over an air bag or in the air bag deployment area. Air bags inflate with great force. If a portable radio is placed in the air bag deployment area and the air bag inflates, the radio may be propelled with great force and cause serious injury to occupants of vehicle.
v Table of Contents 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 2.2 After Warranty Period .....................................................................................1-1 2.
vi 8.0 Option Board Installation ................................................................................... 3-12 9.0 Mechanical View and Parts List......................................................................... 3-14 9.1 GP1280 Exploded View and Parts List ........................................................ 3-14 10.0 Service Aids ....................................................................................................... 3-16 11.0 Test Equipment............................
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. Table 1-1 Radio Model Number (Example: MDH25KDC9AA3AE) MD H MD = Motorola Internal Use H = Portable Type of Model Unit Series 25 Freq.
Chapter 2 INTRINSICALLY SAFE RADIO INFORMATION 1.0 FMRC Approved Equipment Anyone intending to use a radio in a location where hazardous concentrations of flammable material exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500 (hazardous [classified] locations).
2-2 INTRINSICALLY SAFE RADIO INFORMATION 2.0 Repair of FMRC Approved Products REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF THE USER You should not repair or relabel any Motorola manufactured communication equipment bearing the FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC Approval standard for repairs and service (“Class Number 3605”). You may want to consider using a repair facility that operates under 3605 repair service approval.
Repair of FMRC Approved Products 2.3 2-3 Do Not Substitute Options or Accessories The Motorola communications equipment certified by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or options, or both. This Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit.
2-4 INTRINSICALLY SAFE RADIO INFORMATION
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 MAINTENANCE If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Center. (See Chapter 1 for a list of authorized service centers.) The following disassembly procedures should be performed only if necessary: Chassis Assembly Disassembly (Paragraph 6.2) Keypad, Display, and Keypad/Option Board Disassembly (Paragraph 6.3) Speaker, Microphone, and Universal Connector Flex Disassembly (Paragraph 6.
Radio Disassembly — Detailed 4. 3-5 Pull the volume and channel selector knobs off of their shafts. Knobs Figure 3-2 Knob Removal NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts. 5. Separate the chassis from the internal electronics front cover assembly as follows: a. Insert a small, flat-blade screwdriver, or similar instrument, in between the thin retaining wall and the chassis at the bottom of the radio.
3-6 MAINTENANCE 6. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis. 7. Lift the latches on the main circuit board to release the flexes from their connectors. Latches Flex Connectors Figure 3-4 Unlatch Flex Connectors 6.2 Chassis Assembly Disassembly 1. Use a TORX™ screwdriver with a T6 head to remove the four screws holding the main board to the chassis.
Radio Disassembly — Detailed 6.3 3-7 Keypad, Display, and Keypad/Option Board Disassembly 1. If the disassembly of the keypad, the keypad printed circuit board, or the display is required, lift the microphone flex circuit up, and carefully remove the microphone and its boot from the front cover pocket. (See Figure 3-6.) 2. Lay this flex circuit to one side. 3. To remove the keypad retainer shield: a.
3-8 MAINTENANCE 7. The keypad/option board, and the keypad, can be removed without the use of tools. Retainer 1 Display Module 2 Keypad/Option Board 3 Keypad Radio Body Figure 3-7 Removing the Keypad Retainer and Other Boards from the Radio Body NOTE At this point, the Option Board Installation Procedure should be performed, if necessary. 6.4 Speaker, Microphone, and Universal Connector Flex Disassembly 1. Turn the screw at the bottom of the dustcover counterclockwise with your fingers.
Radio Disassembly — Detailed 3-9 Notch In Speaker @ 12:00 Speaker Universal Connector Tail Speaker Orientation Tab @ 12:00 Microphone Boot Microphone Speaker Microphone Flex Circuit Assembly 6. 6.5 Figure 3-8 Removal Speaker-Microphone Assembly After the universal connector tail of the speaker-microphone assembly is removed, the assembly can be completely removed. If it is necessary to replace the speaker or microphone, or both, do it while the flex circuit is removed from the front cover.
3-10 6.6 MAINTENANCE Control Top Disassembly 1. To remove the control top assembly, place a screwdriver next to the antenna boss, and pry it against the control top escutcheon. This will lift the control top escutcheon away from its double-sided adhesive. Grab the double-sided adhesive near the volume potentiometer, and lift it away. 2. Remove the control top seal, emergency button, and transmit light pipe. 7.0 Radio Reassembly — Detailed 7.1 PTT Reassembly 7.2 1.
Radio Reassembly — Detailed 3-11 NOTE Pull the speaker-microphone flex circuit out of harm’s way during reassembly. 4. Re-insert the microphone and boot into the pocket in the front cover. 5. Lay the speaker-microphone flex on top of keypad/option board retainer. Catches Retainer Figure 3-10 Lock retainer catches to the radio’s body 7.5 Chassis Assembly Reassembly 1. Slide on the ground contact (if necessary) on the top corner boss of the chassis. 2. Replace the O-ring.
3-12 MAINTENANCE 5. Push the chassis assembly completely into the top of the front cover until it settles in place. 6. Be sure the O-ring is properly seated. 7. Snap the bottom of the chassis into the front cover. 8. Reassemble the knobs, dust cover, antenna, and battery. Radio Chassis Figure 3-11 Fastening the Chassis 8.0 Option Board Installation 1. With the keypad retainer removed, the keypad backer board can be removed without the use of tools. 2.
Option Board Installation 3-13 Retainer Jumper Flex TO KP Keypad/Option Board Display Flex Figure 3-12 Changing the Keypad/Option Board 6. Reassemble the option board to the front cover assembly. 7. Insert the display flex circuit into the connector on the option board. 8. Insert the jumper flex circuit into the connector on the option board. Notice the orientation of the flex circuit. Arrows on the jumper flex point to the correct way of inserting the flex into the connector. 9.
3-14 MAINTENANCE Mechanical View and Parts List 9.1 GP1280 Exploded View and Parts List 25 23 22 16 8 9 10 7 6 11 12 4 5 3 2 1 15 13 14 17 18 19 20 21 24 26 28 27 30 31 29 32 33 34 36 38 35 37 39 40 41 42 43 44 9.
Mechanical View and Parts List Item Motorola Part Number 3-15 Description Item Motorola Part Number Description 1 See Chapter 6 Antenna 30 6062884G01 Backup Battery 2 3280529Z01 Knob, Volume 31 0304726J04 Screw 3 3280530Z01 Knob, Frequency 32 3980667Z01 Contact, Finger (For UHF) 4 1380525Z01 Escutcheon, Top (16CH) 33 Typical Ctrl/RF Board Assembly 1380525Z03 Escutcheon, Top (Dotted) 34 8485615Z01 Flex, Keypad/Controller 5 3380644Z01 Escutcheon, Label 35 1480652Z01 I
3-16 10.0 MAINTENANCE Service Aids Table 3-1 lists the service aids recommended for working on the GP1280 Radio. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 3-1 Service Aids Motorola Part No. Description Application RLN4460_ Portable Test Set Enables connection to the audio/accessory jack. Allows switching for radio testing.
Test Equipment 3-17 11.0 Test Equipment Table 3-2 lists test equipment required to service the GP1280 Radio and other two-way radios. Table 3-2 Recommended Test Equipment Motorola Part No.
3-18 MAINTENANCE 12.
Programming/Test Cable 3-19 25 Pos Male D Connector Side Connector 1 1 5 2 2 7 3 8 4 15 5 20 6 16 7 9 8 9 10 11 18 12 25 13 25 Pos Female D Connector 15 1 4 11 Figure 3-16 Wiring of the Connectors
3-20 MAINTENANCE
Chapter 4 PERFORMANCE TESTING 1.0 Introduction The receiver and transmitter performance tests are contained in Tables 4-1 and 4-2 respectively. Refer to Chapter 5 for the test equipment set up. Note that all test measurements are taken at 25°C. 2.0 Receiver Performance Tests The receiver performance tests are described in Table 4-1 below.
4-2 3.0 PERFORMANCE TESTING Transmitter Performance Tests The transmitter performance tests are described in Table 4-2 below.
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 2.1 RADIO TUNING AND PROGRAMMING Initial Test Equipment Setup The supply voltage is connected to the radio using a Motorola battery eliminator, P/N 0180305G54. The initial test equipment (Figure 5-1) control settings are listed in Table 5-2. NOTE Refer to appropriate program on-line help files for the tuning procedures. Table 5-2 Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode: Power Monitor Speaker set: A Voltage: 7.
Chapter 6 MODEL CHART AND TEST SPECIFICATION 1.
6-2 2.0 MODEL CHART AND TEST SPECIFICATION Specifications - Professional GP1280 Radio Data is specified for +25°C unless otherwise stated. General Specifications Channel Capacity 16 (Conventional) Power Supply Rechargeable battery 7.5v Dimensions: H x W x D (mm) With standard high capacity NiMH battery With ultra high capacity NiMH battery With NiCD battery With Lilon battery Height excluding knobs 152 x 57.5 x 37.5 152 x 57.5 x 40.0 152 x 57.5 x 40.0 152 x 57.5 x 33.
Specifications - Professional GP1280 Radio 6-3 Transmitter *Frequencies - Full Bandsplit VHF: 136-174 MHz UHF: 403-470 MHz UHF2: 450-527 MHz Channel Spacing 12.5/20/25 kHz Frequency Stability (-25°C to +55°C, +25° Ref.) ±2.5 ppm (VHF, UHF) ±5.0 ppm (UHF2) Power 136 - 174 MHz: 1-5W 403 - 470 MHz: 1-4W 450 - 527 MHz: 1-4W Modulation Limiting ±2.5 @ 12.5 kHz ±4.0 @ 20 kHz ±5.
6-4 MODEL CHART AND TEST SPECIFICATION
Chapter 7 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 two high-pitched self-test pass tones, or a musical tone (selected in CPS). If the self-test is not successful, one low-pitched tone is heard. Radios with displays are able to display the error codes. The displayed error codes and related corrections are listed in Table 7-1.
7-2 POWER UP SELF-TEST
