Professional Radio GP300 Series Basic Service Manual 68P64115B18B 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 Views and Parts Lists......................................................................3-14 9.1 GP320/GP340 ..............................................................................................3-14 9.2 GP360/GP380 ..............................................................................................3-16 10.0 Service Aids ...............................
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 centre 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 Centre. (See Chapter 1 for a list of authorized service centres.) 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 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. Compliant Ground Contact Main Board Radio Chassis O-ring Retaining Features Figure 3-5 Remove Main Board from Chassis 2. ! Lift the main board from the chassis (See Figure 3-5).
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 Display Module Keypad/Option Board 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. 3-11 Insert the “top hooks” of the keypad retainer into the slots below the speaker (above the display) in the front cover. Snap all four of the retainer arm tabs in place in the front cover. 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.
3-12 7.6 MAINTENANCE Chassis and Front Cover Reassembly 1. Align the chassis assembly end-to-end with the front cover assembly. 2. Insert the tails of the flex circuits into their respective connectors at the bottom of the front cover. 3. Push down the latches on the connectors to hold the flex circuits to the main board. 4. Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover. 5.
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 Views and Parts Lists 9.1 GP320/GP340 16 15 13 14 10 11 9 8 7 6 5 12 4 3 2 1 17 19 21 18 22 20 23 24 25 26 27 29 28 30 31 32 33 34 35 9.
Mechanical Views and Parts Lists Item Motorola Part Number 3-15 Description 1 See Chapter 6 Antenna 2 3680529Z01 Knob, Volume 3 3680530Z01 Knob, Frequency 4 1380525Z01 1380525Z02 Escutcheon, Top - GP340 Escutcheon, Top - GP320 5 3380644Z01 6 Item Motorola Part Number Description 18 3586057A01 Felt Speaker 19 1480577C01 Boot, Microphone 20 5085962A02 Speaker 21 5013920A04 Microphone 22 8480549Z01 Flex, UC Escutcheon, Label 23 2113740A41 Capacitor, 33pF 3280533Z01 328
3-16 15 10 11 9 8 7 6 5 12 4 3 2 13 14 16 17 18 20 19 22 24 21 25 23 26 29 27 30 28 32 31 33 35 34 36 37 38 39 40 41 GP360/GP380 1 9.
Mechanical Views and Parts Lists Item Motorola Part Number 3-17 Description 1 See Chapter 6 Antenna 2 3680529Z01 Knob, Volume 3 3680530Z01 Knob, Frequency 4 1380525Z03 Escutcheon, Top 5 3380644Z01 Escutcheon, Label 6 3280533Z01 Seal, Control Top 7 6180527Z01 Litepipe, Tx 8 1364279B04 1364279B05 Front, label GP360 Front, label GP380 9 1586059A01 Dust Cover, Universal Connector 10 1386058A01 Escutcheon, Universal Flex 11 1580666Z04 Front Cover with Keypad (DTMF) 12 Not F
3-18 MAINTENANCE 10.0 Service Aids Table 3-1 lists service aids recommended for working on the GP300 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. 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 3-19 11.0 Test Equipment Table 3-2 lists test equipment required to service the GP300 Series Radios and other two-way radios. Table 3-2 Recommended Test Equipment Motorola Part No.
3-20 MAINTENANCE 12.
Programming/Test Cable 3-21 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 3-17 Wiring of the Connectors
3-22 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 MODEL CHART AND TEST SPECIFICATION 2.
Model Chart (LB) 3.0 6-3 Model Chart (LB) Professional GP300 Series (LB) Model Description MDH25BEC9AN3_E GP340 LB1 29.7-42 MHz 6W 16-Ch MDH25BEH9AN6_E GP380 LB1 29.
6-4 4.0 MODEL CHART AND TEST SPECIFICATION Model Chart (300R1) Professional GP300 Series (300R1) Model MDH25EDC9AN3_E Description GP340 300R1 300-350 MHz 4W Item Description X X PMLD4141_ PMLN4216_ GP340 300R1 Back Cover Kit GP340 300R1 Front Cover Kit X 6864110B13_ GP340 Basic User Guide X PMAD4022_ VHF 9cm (300-344 MHz) Antenna X HNN9008_ Battery, NiMH Standard x = Indicates one of each is required.
Specifications - Professional GP300 Series Radios 5.0 6-5 Specifications - Professional GP300 Series Radios Data is specified for +25°C unless otherwise stated. General Specifications Channel Capacity GP320 GP340 GP360 GP380 1 16 255 255 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 137 x 57.5 x 37.5 137 x 57.5 x 40.0 137 x 57.5 x 40.
6-6 MODEL CHART AND TEST SPECIFICATION Transmitter *Frequencies - Full Bandsplit Channel Spacing UHF/VHF/300R1 VHF 136-174 MHz UHF 403-470 MHz 300R1 300-350MHz LB LB1 29.7-42 MHz LB2 35-50 MHz 12.5/20/25 kHz Frequency Stability (-25°C to +55°C, +25° Ref.) ±2.5 ppm @ 12.5kHz ±5.0 ppm @ 25 kHz ±5.0 ppm (300R1) Power 136 - 174 MHz: 1-5W 403 - 470 MHz: 1-4W 300 - 350 MHz: 1-4W Modulation Limiting FM Hum & Noise ±10ppm 1-6W ±2.5 @ 12.5 kHz ±4.0 @ 20 kHz ±5.
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 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 7-1 below). After flashing the error code, the LED remains off for 5 seconds and then repeats the error code.
7-2 POWER UP SELF-TEST
