Motorola GM300 Service manual

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. Accordingly, any copyrighted Motorola computer
programs contained in the Motorola products described in this manual may not be copied or reproduced 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
royalty-free license to use that arises by operation of law in the sale of a product.

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.

For information regarding radio use in hazardous areas, please refer to the Factory Mutual (FM)
approval manual supplement.

EXPOSURE TO RADIO FREQUENCY ENERGY

Your Motorola Two-Way Radio, which generates and radiates radio frequency (RF) electromagnetic
energy (EME), is designed to comply with the following National and International Standards and
Guidelines regarding exposure of human beings to radio frequency electromagnetic energy:



Federal Communications Commission Report and Order No. FCC 96-326 (August 1996)



American National Standards Institute (C95.1 - 1992)



National Council on Radiation Protection and Measurements (NCRP-1986)



International Commission on Non-Ionizing Radiation Protection (ICNRP- 1986)



European Committee for Electrotechnical Standardization (CENELEC):

iii

ENV 50166-1 1995 E Human exposure to electromagnetic fields Low

frequency (0 Hz to 10 kHz)

- ENV 50166-2 1995 E Human exposure to electromagnetic fields High
frequency (10 kHz to 300 GHz)

- Proceedings of SC211/B

1996

“Safety Considerations for Human Exposure to

EMFs from Mobile Telecommunication Equipment
(MTE) in the Frequency Range 30MHz - 6 GHz.”
(EMF - Electro-Magnetic Fields)

To assure optimal radio performance and to ensure that your exposure to radio frequency
electromagnetic energy is within the guidelines in the above standards, always adhere to the following
procedures:

ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY

NOTE

Nearly every electronic device is susceptible to electromagnetic interference (EMI) if
inadequately shielded, designed, or alternately configured for electromagnetic compatibility.



To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any facility
where posted notices instruct you to do so. Hospital or health facilities may be using equipment that
is sensitive to external RF energy .



When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be
in accordance with airline regulations or crew instructions.

Mobile Radio Operation and EME Exposure

To assure optimal radio performance and that human exposure to radio frequency electromagnetic
energy is within the guidelines referenced in this document, transmit only when people inside and
outside the vehicle are at least the minimum distance away from a properly installed,
externally-mounted antenna.

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

7to15Watts 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. Instructions in the radio installation manual.

Control Station Operation

When radio equipment is used to operate as a control station, it is important that the antenna be
installed outside the building and away from places where people may be in close proximity.

NOTE

Refer to Table 1 for rated power and minimum distance values for transmitting
antennas.

OPERATIONAL WARNINGS

Potentially explosive atmospheres

WARNING:Turn off your Two-Way radio when you are in any area with a potentially explosive
atmosphere, unless it is a radio type especially qualified for use in such areas. Sparks in a

!

potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or
even death.

Minimum Distance from

Transmitting Antenna

Blasting caps and areas

WARNING: To avoid possible interference with blasting operations, turn off your radio when
you are near electrical blasting caps. In a “blasting area” or in areas posted “turn off two-

!

way radio”, obey all signs and instructions.

NOTE

The areas with potentially explosive atmospheres referred to above include fuelling areas
such as: below decks on boats; fuel or chemical transfer or storage facilities; areas where
the air contains chemicals or particles, such as grain, dust or metal powders; and any other
area where you would normally be advised to turn off your vehicle engine. Areas with
potentially explosive atmospheres are often but not always posted.

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

2.2 After Warranty Period.....................................................................................1-1

2.3 European Radio Support Centre (ERSC).......................................................1-2

2.4 Piece Parts.....................................................................................................1-2

2.5 Technical Support...........................................................................................1-3

3.0 Radio Model Information......................................................................................1-4

Chapter 2 MODEL CH ART AND TEST SPECIFICATION

1.0 Model Chart (UHF 403-470 MHz)........................................................................2-1

2.0 Model Chart (VHF 136-174 MHz) ........................................................................2-2

3.0 Model Chart (Low Band 29-50 MHz) ................................................................... 2-3

2.4 Specifications ......................................................................................................2-4

v

Chapter 3 MAINTENANCE

1.0 Introduction..........................................................................................................3-1

2.0 Preventive Maintenance ......................................................................................3-1

2.1 Inspection.......................................................................................................3-1

2.2 Cleaning Procedures......................................................................................3-1

3.0 Safe Handling of CMOS and LDMOS Devices....................................................3-2

4.0 Repair Procedures and Techniques — General..................................................3-3

5.0 Disassembling and Reassembling the Radio — General....................................3-3

6.0 Radio Disassembly - Detailed.............................................................................. 3-4

6.1 Control Head Removal ...................................................................................3-4

6.2 Top Cover Removal........................................................................................3-5

6.3 Transceiver Board Removal...........................................................................3-6

6.4 Disassembly of Control Head - GM340 (without display)...............................3-7

6.5 Disassembly of Control Heads - GM360 and GM380 (with display) ..............3-8

7.0 Radio Assembly...................................................................................................3-9

7.1 Control Head - GM340 ...................................................................................3-9

7.2 Control Heads - GM360 and GM380..............................................................3-9

7.3 Radio Chassis and Transceiver Board.........................................................3-10

7.4 Control Head Fitting......................................................................................3-10

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 .................................................................................3-14

8.5 Control Head - GM380 .................................................................................3-15

9.0 Service Aids.......................................................................................................3-16

10.0 Test Equipment..................................................................................................3-17

11.0 Programming/Test Cable - RKN4083_..............................................................3-18

Chapter 4 TRANSCEIVER PERFORMANCE TESTING

1.0 General................................................................................................................4-1

2.0 Setup ...................................................................................................................4-1

3.0 RF Test Mode......................................................................................................4-2

Chapter 5 RADIO TUNING AND PROGRAMMING

1.0 Introduction..........................................................................................................5-1

2.0 CPS Programming Setup ....................................................................................5-1

3.0 Radio Tuning Setup.............................................................................................5-3

3.1 Initial Test Equipment Control Settings ..........................................................5-3

Chapter 6 POWER UP SELF-TEST

1.0 Error Codes .........................................................................................................6-1

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.

Chapter 1

INTRODUCTION

NOTE

Before operating or testing these units, please read the Safety Information Section in the
front of this manual.

2.0 Warranty and Service Support

Motorola offers long term support for its products. This support includes full exchange and/or repair
of the product during the warranty period, and service/ repair or spare parts support out of warranty.
Any "return for exchange" or "return for repair" by an authorised Motorola Dealer must be
accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an
Authorised Motorola Dealer.

2.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or
Reseller contract. These conditions may change from time to time and the following notes are for
guidance purposes only.

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.

Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact
Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be
accompanied by a Warranty Claim Form, available from your Customer Services representative.
Products should be shipped back in the original packaging, or correctly packaged to ensure no
damage occurs in transit.

2.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.

1. Motorola's Radio Aftermarket and Accessory Division (AAD) offers a repair service to both
end users and dealers at competitive prices.

2. AAD supplies individual parts and modules that can be purchased by dealers who are
technically capable of performing fault analysis and repair.

1-2 INTRODUCTION

2.3 European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:
Austria: 06 60 75 41 Italy: 16 78 77 387
Belgium: 08 00 72 471 Luxemburg: 08 00 23 27
Denmark: 80 01 55 72 Netherlands: 60 22 45 13
Finland: 08 00 11 49 10 Norway: 80 01 11 15
France: 05 90 30 90 Portugal: 05 05 49 35 70
Germany: 01 30 18 75 24 Spain: 90 09 84 902
Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307
UK: 0800969095 Switzerland: 1553082
Ireland: 18 00 55 50 21 Iceland: 80 08 147

Or dial Customer Care Centre:

Tel: [phone]

Please use these numbers for repair enquiries only.

2.4 Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly. If a
complete Motorola part number is assigned to the part, it is available from Motorola Radio
Aftermarket and Accessory Division (AAD). 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.

All part orders should be directed to :

Motorola GmbH
European Parts Department
65232 Taunusstein
Germany.

Warranty and Service Support 1-3

2.5 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: [phone]
Fax: [phone]
Email: [e-mail]

Central/East Europe - Siggy Punzenberger
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Northern Europe -BjornRambert
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Germany

Telephone: [phone]
Fax: [phone]
Email: [e-mail]

France - Lionel Lhermitte
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Italy - Ugo Gentile
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Africa & Middle East - Ralph Schubert
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

1-4 INTRODUCTION

3.0 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: MDM25KHC9AN1AE)

Typeof

Unit

MD M 25 K

Model

Series

Freq.

Band

VHF

(136-

174MHz)

M = Mobile

MD = Motorola Internal Use

UHF1

(403-

470MHz)

LB1

(29.7-

36.0MHz)

Power

Level

1-25WCGM140

R

40-60WFGM160

B

H

K

Physical

Packages

GM340
GM640

GM360
GM660

N

GM380

GM1280

Channel
Spacing

9

Program-

mable

Protocol

AA

Conventional

MDC

AN

5 Tone

CK

MPT

Feature

Level

1

GM140
GM340
GM640

5

GM160
GM360

GM660.

8

GM380

GM1280

Model

Revision

AE

Model

Package

C

LB2

(36.0-

42.0MHz)

D

LB3

(42.0-50.0

MHz)

MODEL CHART AND TEST SPECIFICATION

1.0 Model Chart (UHF 403-470 MHz)

GM Series UHF 403-470 MHz

Model Description

MDM25RHC9AN1_E GM340, 403-470 MHz, 1-25W, 6 Ch

MDM25RHF9AN5_E GM360, 403-470 MHz, 1-25W, 255 Ch

MDM25RHN9AN8_E GM380, 403-470 MHz, 1-25W, 255 Ch

Item Description

X GCN6112_ Control Head GM340

X GCN6120_ Control Head GM360

X GCN6121_ Control Head GM380

X IMUE6015_ Tanapa GM340

X IMUE6015_ Tanapa GM360

X IMUE6038_ Tanapa GM380
XXXENBN4056_ Packaging,WarisMobile
X X X GLN7324_ Low Profile Mounting Trunion
XXXHKN4137_ 12VPowerCable1-25W
X X X MDRMN4025_ Enhanced Compact Microphone
X 6864110B80 User Guide, GM340

X 6864110B81 User Guide, GM360

X 6864110B82 User Guide, GM380

Chapter 2

X = Indicates one of each is required

2-2 MODEL CHART AND TEST SPECIFICATION

2.0 Model Chart (VHF 136-174 MHz)

GM Series VHF 136-174 MHz

Model Description

MDM25KHC9AN1_E GM340, 136-174 MHz, 1-25W, 6 Ch

MDM25KHF9AN5_E GM360, 136-174 MHz, 1-25W, 255 Ch

MDM25KHN9AN8_E GM380, 136-174 MHz, 1-25W, 255 Ch

Item Description

X GCN6112_ Control Head GM340

X GCN6120_ Control Head GM360

X GCN6121_ Control Head GM380
X IMUD6013_ Tanapa GM340

X IMUD6013_ Tanapa GM360

X IMUD6024_ Tanapa GM380
XXXENBN4056_ Packaging,WarisMobile
X X X GLN7324_ Low Profile Mounting Trunion
XXXHKN4137_ 12VPowerCable1-25W
X X X MDRMN4025_ Enhanced Compact Microphone
X 6864110B80 User Guide, GM340

X 6864110B81 User Guide, GM360

X 6864110B82 User Guide, GM380

X = Indicates one of each is required

Model Chart (Low Band 29-50 MHz) 2-3

3.0 Model Chart (Low Band 29-50 MHz)

GM Series Low Band 29-50 MHz

Model Description

MDM25BKF9AN5_E 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, 42.0-50.0 MHz, 40-60W, 255 Ch

Item Description

XXXGCN6120_ ControlHead,GM360
X IMUB6003_ Tanapa GM360, LB1

X IMUB6004_ Tanapa GM360, LB2

X IMUB6005_ Tanapa GM360, LB3
XXXENBN4056_ Packaging,WarisMobile
X X X HKN9402_ 12V Power Cable
XXXMDRMN4025_ EnhancedCompactMicrophone
X X X RLN4774_ 3 Point Mount
XXX6864110B81_ UserGuide,GM360

X = Indicates one of each is required

2-4 MODEL CHART AND TEST SPECIFICATION

2.4 Specifications

General

Specification VHF UHF LB1, LB2, LB3

Frequency Range: 136-174 MHz 403-470 MHz 29.7-36.0 MHz

36.0-42.0 MHz

42.0-50.0 MHz

Frequency Stability
(-30°Cto+60°C, 25°CRef.)

Channel Capacity:

Channel Spacing: 12.5/20/25 kHz
Power Output: 1-25W 1-25W 40-60W
Power Supply: 13.2Vdc (10.8 - 15.6 Vdc) negative vehicle ground

Dimensions (L X W X H)

UHF/VHF 1-25W

GM340

GM360

GM380

Low Band 40-60W

GM360

±2.5 PPM ±2 PPM ±5.0 PPM

GM340 - 6
GM360 - 255
GM380 - 255

177mm X 176mm X 56mm (add 8mm for Volume Knob)

(6.97” X 6.93” X 2.2” - add 0.3” for Volume Knob)

186mm X 179mm X 59mm (add 9mm for Volume Knob)

(7.32” X 7.05” X 2.34” - add 0.35” for Volume Knob)

188mm X 185mm X 72mm (add 7mm for Volume Knob)

(7.4” X 7.28” X 2.83” - add 0.27” for Volume Knob)

250mm X 179mm X 59mm (add 9mm for Volume Knob)

(9.8” X 7.05” X 2.34” - add 0.35” for Volume Knob)

Weight:

Low power (1-25W)
High power (40-60W)

Operating Temperature -30to60oC

Sealing Passes rain testing to IP54

Shock and Vibration Meets MIL-STD 810-C,D&E

Dust Meets MIL-STD 810-C,D&E

Humidity Meets MIL-STD 810-C,D&E

1400 g (3.15 lbs)

2064 g (4.3 lbs )

and TIA/EIA 603

and TIA/EIA 603

and TIA/EIA 603