Motorola GM-300_series_basic 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: +49 6128 70 2164
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: +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.com
Northern Europe -BjornRambert Telephone: +46 8 735 9282 Fax: +46 8 735 9280 Email: TCW275X@email.mot.com
Germany
Telephone: +49 (0) 6128 70 2266 Fax: +49 (0) 6128 95 1685 Email: cgiss.emea@europe.mot.com
France - Lionel Lhermitte Telephone: +33 1 6929 5722 Fax: +33169295904 Email: TXE037@email.mot.com
Italy - Ugo Gentile Telephone: +39 0 2822 0325 Fax: +39028220334 Email: C13864@email.mot.com
Africa & Middle East - Ralph Schubert Telephone: +33 (0)4 4230 5887 Fax: +33 (0)4 4230 4784 Email: ralph.schubert@Motorola.com
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
Specifications 2-5
Transmitter
Specification VHF UHF LB1, LB2, LB3
Modulation Limiting: ±2.5 kHz @ 12.5 kHz
±4.0 kHz @ 20 kHz
±5.0 kHz @ 20/25 kHz
FM Hum and Noise: -40dB@12.5kHz
-45dB@20/25kHz
Conducted/Radiated Emissions:
Adjacent Channel Power -60dB @12.5,
Audio Response: ( 300 to 3000Hz)
Audio Distortion: @ 1000 Hz, 60% Rated Maximum Deviation:
-36 dBm < 1 GHz
-30 dBm > 1 GHz
-70dB @ 20/25kHz
3% Typical
-26 dBm
+1, -3dB
Receiver
Specification VHF UHF LB1, LB2, LB3
Sensitivity (12dBSINAD):
(ETS) Intermodulation : (ETS) >65dB;>70dBinBaseMode >65 dB Adjacent Channel
Selectivity: (ETS)
80 dB @ 25 kHz 75 dB @ 20 kHz
65 dB @ 12.5 kHz
0.30µV(0.22µVTypical)
75 dB @ 25 kHz 70 dB @ 20 kHz
65 dB @ 12.5 kHz
80 dB @ 25 kHz 75 dB @ 20 kHz
65 dB @ 12.5 kHz
Spurious Rejection: (ETS) 80 dB @ 20/25 kHz
75 dB @ 12.5 kHz
Rated Audio: (ETS) 3W Internal (GM340/GM360)
Audio Distortion @ Rated Audio:
Hum and Noise: -40 dB @ 12.5 kHz
Audio Response: ( 300 to 3000Hz)
Conducted Spurious Emission per FCC Part 15:
75 dB @ 20/25 kHz
70 dB @ 12.5 kHz
13W External
3% Typical
-45 dB @ 20/25 kHz
+1, -3dB
-57 dBm <1 GHz
-47 dBm >1 GHz
80 dB @ 20/25 kHz
75 dB @ 12.5 kHz
2-6 MODEL CHART AND TEST SPECIFICATION

1.0 Introduction

This chapter 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.
Installation of Option Boards.

2.0 Preventive Maintenance

The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended.

2.1 Inspection

Chapter 3

MAINTENANCE

Check that the external surfaces of the radio are clean, and that all external controls and switches are functional. It is not recommended to inspect the interior electronic circuitry.

2.2 Cleaning Procedures

The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the radio. External surfaces include the front cover , housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime.
NOTE
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water.The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (70% by volume).
CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Av oid using aerosol sprays, tuner cleaners, and other chemicals.
!
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices.
Internal surfaces should be cleaned only when the radio is disassembled for service or repair.
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. Do not use high-pressure air to hasten the drying process since this could cause the liquid to collect in unwanted places. After completing of the cleaning process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or back cover.
NOTE
Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).

3.0 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity conditions. DO NOT attempt to disassemble the radio without first referring to the following CAUTION statement.
CAUTION:This radio contains static-sensitive devices. Do not open the radio unless you are properly grounded. Take the following precautions when working on this unit:
!
Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together. Do not insert CMOS devices into conventional plastic “snow” trays used for storage and transportation of other semiconductor devices.
Ground the working surface of the service bench to protect the CMOS device. We recommend using the Motorola Static Protection Assembly (part number 0180386A82), which includes a wrist strap, two ground cords, a table mat, and a floor mat.
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 RSX4015_.)
Do not wear nylon clothing while handling CMOS devices.
Do not insert or remove CMOS devices with power applied. Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present.
When straightening CMOS pins, provide ground straps for the apparatus used.
When soldering, use a grounded soldering iron.
If at all possible, handle CMOS devices by the package and not by the leads. Prior to touching the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.
Repair Procedures and Techniques — General 3-3

4.0 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.
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.
When soldering near the 20-pin and 40-pin connectors:
Avoid accidentally getting solder in the connector.
Be careful not to form solder bridges between the connector pins.
Examine your work closely for shorts due to solder bridges.

5.0 Disassembling and Reassembling the Radio — General

Since these radios may be disassembled and reassembled with the use of only four (board to casting) screws, it is important to pay particular attention to the snaps and tabs, and how parts align with each other.
The following tools are required for disassembling the radio:
Small flat blade screwdriver
Dismantling Tool (Motorola Part No. 6686119B01)
TORX™ T20 screwdriver
If a unit requires more complete testing or service than is customarilyperformed 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:
3-4 MAINTENANCE

6.0 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 showninFigure3-1.
2. Press on the dismantling tool until the snap connectors on the side of the control head release from the radio assembly.
Dismantling Tool
Figure 3-1 Typical Control Head Removal.
3. Pull the control head away from the radio assembly as shown in Figure 3-2.
ZWG0130209-O
Radio Disassembly- Detailed 3-5
Flexible Connection
ZWG0130210-O
Figure 3-2 Flexible Connection Removal
4. Remove the flexible connection from the socket on the control head board.

6.2 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.
Dismantling Tool
ZWG0130211-O
Figure 3-3 Top Cover Removal.
3-6 MAINTENANCE

6.3 Transceiver Board Removal

1. Remove the screws securing the diecast cover to the chassis, using the T20 TORX™ driver asshowninFigure3-4.
2. Lift the cover from the chassis.
Screws (6 on 25W models)
Diecast Cover
Radio Chassis
(9 on 60W models)
ZWG0130212-O
Figure 3-4 Diecast Cover Removal.
3. Slowly lift the transceiver board on the edge at the front of the radio (the edge that mates with the control head) and pull gently toward the front of the radio as shown in Figure 3-5. Take care to slide the antenna connector and power connector out of the chassis towards the front.
CAUTION: The thermal grease or pads can act as an adhesive and cause the leads of the heat dis­sipating devices to be over stressed if the board is lifted too quickly.
Lift
Antenna Connector
Figure 3-5 Transceiver Board Removal
ZWG0130213-O
Radio Disassembly- Detailed 3-7

6.4 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.
ZWG0130215-O
Figure 3-7 Control Head Board Removal
4. Remove the board from the control head housing by stretching the control head housing and pulling up on the board as shown in Figure 3-7 and 3-8.
5. Remove the keypad from the control head housing by lifting up the rubber keypad.
NOTE
Care should be taken not to touch or contaminate the conductive pads on the under side of the keypad or the conductive contacts on the printed circuit board.
3-8 MAINTENANCE
ZWG0130216-O
Figure 3-8 Board, Keypad and Speaker Removal
6. Remove the speaker from the control head housing.

6.5 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.
NOTE
The speaker and speaker tube are glued together to form one unit. (GM360 only)
ZWG0130218-O
Figure 3-9 Speaker and Speaker Tube Removal
3. Remove the board from the control head housing by stretching the control head housing and pulling up on the board.
4. Remove the keypad from the control head housing by lifting up the rubber keypad.
Radio Assembly 3-9
5. 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. Insert the keypad intothe controlhead ensuringthat the keypad keys and connector cut-out fit correctly.
NOTE
Care should be taken not to touch or contaminate the conductive pads on the underside of the keypad.
3. On the board, rotate the on/off control spindle fully counter-clockwise.
4. Also, rotate the volume knob on the housing fully counter-clockwise
5. Align the board with the control head and insert the on/off control spindle through the hole in the keypad.
6. Locate the two snap tags on the board in the grooves in the control head and press the board into place until all of the tags snap into place.
7. Connect the speaker connector to the connector on the board.

7.2 Control Heads - GM360 and GM380

1. On the GM360 only,locate the display in the control head ensuring that the two cut-outs in the display are aligned with their corresponding indentations, then press the display into place. Insert the top and bottom elastomeric connector strips into the spaces above and below the display respectively.
NOTE
Care should be taken not to touch or contaminate the conductive pads on the underside of the display and the elastomeric connectors (GM360 only).
2. Fit the rubber keypad onto the board ensuring that the on/off control and microphone connector on the board locate correctly with the cut-outs in the keypad.
3. On the board, rotate the on/off control spindle fully counter-clockwise.
4. Also, rotate the volume knob on the front housing fully counter-clockwise.
5. Align the board with the control head, inserting the on/off control spindle and microphone connector through the holes in the control head.
6. Ensure that the keypad, on/off control spindle and microphone connector are aligned with the control head then press the board into place until it clicks.
7. On the GM360, insert the speaker tube and speaker into the control head and press it in until it clicks.Connect the speaker connector to the board.
3-10 MAINTENANCE

7.3 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. Lower the transceiver board onto the chassis and align the two locating holes in the board with the locating pins in the chassis.
4. Secure the cover to the chassis with the six screws previously removed.
5. Torque the six screws to 1.9 NM (17 in lbs) using the T20 TORX™ driver. Begin with the two screws located in the middle of the chassis followed by the four outer screws. Since the screws usually take a set, torque the screws a second time (1.9 NM) in the same order.
6. Refit the top cover over the assembled radio chassis. Press the cover down until it snaps into place.

7.4 Control Head Fitting

1. Align the “0” mark on the flex with the “0” mark on the chassis to the socket on the radio assemblyasshowninFigure3-2.
2. Check that the back housing o-ring seal is undamaged and fitted in the groove. Replace the seal if it is damaged (refer to the exploded view diagrams and parts list).
3. Fit the back housing to the control head. Ensure that the tags on the back housing align with the snap catch grooves on the control head. Press the back housing into place until it snaps into place.
4. Check that the radio chassis o-ring seal is undamaged and fitted in the groove on the chassis assembly. Replace the seal if it is damaged.
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
7
56
13
14
12
11
16
Figure 3-10 Radio Assembly - 25W Models
Table 3-1 Radio Assembly Parts List - 25W Models
Item No. Description Part Number
8
4
15
3
1
2
ZWG0130202-A
1 Chassis 25W 2786082B02 2 Gasket, Controlhead 3202620Y01 3 Main PCB (items 4 to 10 included) 4 Antenna Connector with Gasket, BNC 0986166B01 5 Power Connector 0986165B01 6 Connector 20 PIN 0986105B01 7 Connector Assembly 2886122B02 8 Gasket Cover 3202607Y01
9 Connector 1580922V01 10 Gasket Accessory Connector 3202606Y01 11 Gasket Cover 25W 3286086B01 12 Cover 25W 1586084B01 13 Cover, Plastic 25W 1586083B01
14 Screw T20, 6x (M4) 0310911A30
15 Screw T8 Power Device Fastner
0310911A12
(some models only)
16 Silicon Pressurepad, Powerdevices
7586187B01
(25W coveronly)
3-12 MAINTENANCE

8.2 Radio Assembly - 60W Models

10
9
7
6
13
12
11
8
5
4
3
1
2
ZWG0130203-A
Figure 3-11 Radio Assembly 60W Models
Table 3-2 Radio Assembly Parts List - 60W Models
Item No. Description Part Number
1 Chassis 60W 2786149B01
2 Gasket, Controlhead 3202620Y01
3 Main PCB (items 4, 5 and 8 included)
4 Antenna Connector, Mini UHF 0986166B02
5 Power Connector 0986165B01
6 Connector 20 PIN 0986105B01
7 Connector Assembly 2886122B01
8 Gasket Cover,Connector 3202607Y01
9 Connector 1580922V01 10 Gasket Accessory Connector 3202606Y01 11 Gasket Cover 60W 3286152B01 12 Cover 60W 1586150B01 13 Cover, Plastic 60W 1586151B01
Screw T20, 9x (not shown) 0310911A30
Radio Exploded Mechanical Views and Parts Lists 3-13

8.3 Control Head - GM340

10
7
8
5
1
2
3
6
4
Figure 3-12 Control Head GM340
Table 3-3 Control Head GM340 Parts List
Item no Description Part No
1 Housing Front, including:
Gasket, Lens, Lightguide 2 Knob, Volume 3686098B02 3 Label 1364279B13 4 Speaker 5086126B01 5 Keypad, including
Keypad Button 6 PCB Kit GLN7350_ 7 Potentiometer 1805911V02 8 10 PIN Microphone Jack 2864287B01 9 Flex 12 Position Connector
(Controlhead to Radio)
10 Backhousing,including:
Back Housing O-ring
Back Housing ,Grounding Clip
1586086B01
7586089B01 3886133B--
8486127B01
1586092B02 3286094B01 3286217B01
9
ZWG0130198-A
3-14 MAINTENANCE

8.4 Control Head - GM360

10
11
12
2
13
7
6
1
3
8
9
Figure 3-13 Controlhead - GM360
Table 3-4 Control Head GM360 Parts List
Item no Description Part No.
1 Housing Front
Gasket, Lens, Lightguide
2 Knob, Volume 3686098B02 3 Label 1364279B14 4 Speaker 5086126B01 5 Tube, Speaker with Gasket 3786107B01 6 Keypad, including:
Keypad Button
7 LCD Glass 7286104B01 8 Frame LCD 0786099B01 9 Conn. Elastomeric (Top and Bottom) 2886130B01
10 Back Housing, including: 1586093B02
Back Housing, O-ring 3286094B01
Back Housing, Grounding Clip 3986218B01
11 PCB Kit GLN7353_ 12 Potentiometer 1805911V02 13 10 PIN Micphone Jack 2864287B01
(not shown) Flex, 12 Position Connector
(Controlhead to Radio)
1586088B01
7586091B02 3886134B--
2886130B02
8486127B01
4
5
ZWG0130200-A
Radio Exploded Mechanical Views and Parts Lists 3-15

8.5 Control Head - GM380

10
9
4 7
6
2
8
5
1
3
Figure 3-14 Control Head - GM380
Table 3-5 Control Head GM380 Parts List
Item No Description Part No
1 Housing Front, including:
Gasket, Lens, Lightguide 2 Knob, Volume 3686098B02 3 Label 1364279B15 4 LCD Module 5164313B01 5 Keypad, including:
Keypad Button 6 PCB Kit GLN7361_ 7 Potentiometer 1805911V02 8 10 PIN Microphone Jack 2864287B01 9 Flex, 24 Position connector 8464346B02
10 Backhousing,including: 1564305B01
Back housing O-ring
Grounding Clip, left
Grounding Clip, right
(not shown) Flex, 12 Position Connector
(Controlhead to Radio)
1564304B01
7564314B01 3886134B--
3286094B01 3908450X02 3908451X02
8486127B01
ZWG0130201-A
3-16 MAINTENANCE

9.0 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
MotorolaPart
No.
RLN4460_ Portable Test Set Enables connection to audio/accessory jack.
RKN4081_ Programming Cable with
Internal RIB
RLN4853_ 10 to 20 Pin Adapter Connects RKN4081_ to the radio accessory
RKN4083_ Mobile Programming/Test Cable Connects radio to RIB (RLN4008_). GTF374_ Program Cable Connects RIB to Radio microphone input RLN4008_ Radio Interface Box Enables communications between radio and
HLN8027_ Mini UHF to BNC Adaptor Adapts radio antenna port to BNC cabling of
GPN6133_ Power Supply Provides the radio with power when bench
EPN4040_ Wall-Mounted Power Supply Used to supply power to the RIB (UK). EPN4041_ Wall-Mounted Power Supply Used to supply power to the RIB (Euro)
Description Application
Allows switching for radio testing. Includes radio interface box (RIB) capability.
connector.
computer’s serial communications adapter.
test equipment.
testing.
8180384J59 Housing Eliminator (short) Test Fixture used to bench test the radio pcb 8180384J60 Housing Eliminator (medium) Test Fixture used to bench test the radio pcb 8180384J61 Housing Eliminator (long) Test Fixture used to bench test the radio pcb 3080369B71 Computer Interface Cable Connects the RIB to the Computer (25-pin) 3080369B72 Computer Interface Cable Connects the RIB to the Computer (9-pin)
(Use for IBM PC AT - other IBM models use the B71 cable above)
6686119B01 Removal Tool Assists in the removal of radio control head.
Test Equipment 3-17

10.0 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.
R2600_NT Comms System
R2680_NT Comms System
*R1072_ Digital Multimeter AC/DC voltage and current
*R1377_ AC Voltmeter 100
WADN4133 Delay
Description Characteristics Application
Analyzer(non MPT)
Analyzer (MPT1327) to be ordered with RLN1022_ (H/W) RLN1023_ (S/W)
Oscilloscope
This monitor will substitute for items with an asterisk *
This monitor will substitute for items with an asterisk *
µVto300V,
5Hz-1MHz, 10 Megohm input impedance
2 Channel 40 MHz bandwidth, 5mV/cm-20V/cm
Frequency/deviation meter and signal generator for wide­range troubleshooting and alignment
Frequency/deviation meter and signal generator for wide­range troubleshooting and alignment
measurements Audiovoltage
measurements
Waveform measurements
R1440_ 0180305F17
0180305F31 0180305F40 RLN4610_
T1013_ S1339_ RF Millivolt Meter 100mV to 3 VRF,
R1011_/220V 220V Power
Wattmeter, Plug-in Elements
Plug-in Elements Plug-in Elements Carry case
RF Dummy Load
Supply
Thruline 50-Ohm,
±5% accuracy
10W, 25 - 60 MHz 10W, 100 - 250 MHz 10W, 200 - 500 MHz Wattmeter and 6elements
10 kHz to 1.2 GHz 0-40V, 0-40A Programmable
Transmitter power output measurements
RF level measurements
3-18 MAINTENANCE

11.0 Programming/Test Cable - RKN4083_

1
14
+
_
1000 50mm
Cable
1
19 20
2
P1 (Male) To Radio
Test Set
13
25
1000 50mm
To Mobile Radio
17 18
Cable
J2 (Female)
Accessory Connector
Viewed from
Front (pin end)
of Connector
J1 (Female)
To RIB
RLN4008
13
25
+
_
1
14
FL0830308O
Figure 3-15 Programming/Test Cable
FLO830308-0
SPEAKER -
EXTERNAL MIC
DIGITAL IN 1 (EXT. PTT)
DIGITAL OUT 2 (EXT. ALARM)
FLAT TX AUDIO SENSITIVITY
DIGITAL IN 3/MPT MAP 27 RX
DIGITAL IN/OUT 4/MPT MAP 27 TX
DIGITAL IN 5 w WAKEUP (EMG)
FLAT/FILTERED RX AUDIO
SWITCHED BATTERY VOLTAGE
BUS + (FOR CPS AND FLASHING)
FL0830307O
IGNITION
DIGITAL IN/OUT 7
DIGITAL IN/OUT 8
SPEAKER +
BOOT CONTROL
GND
RSSI
N/C
N/C
J2 Mobile
Radio
Accessory
Connector
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
P1
To Radio
Test Set
RLN4460
J1
To RIB
RLN4008
1
2
5
7
10
15
16
18
19
20
25
1
4
11
12
15
25
AUDIO +
AUDIO -
AUDIO +
AUDIO -
MIC AUDIO
MIC AUDIO
GND
VOL CTRL
DISC
PTT
BOOT CTRL
GND
BIAS
BUS -
SW B +
BUS +
BOOT CTRL
Figure 3-16 Pin Configuration of the Side Connector
FLO830307-0

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 manufacturers recommended calibration schedule.

2.0 Setup

Supply voltage is provided using a 13.2Vdc power supply. The equipment required for alignment procedures is connected as shown in the Radio Tuning Test Setup Diagram, Chapter 5, Figure 5-4.
Initial equipment control settings should be as indicated in Table 4-1. The remaining tables in this chapter contain the following related technical data:
Chapter 4

TRANSCEIVER PERFORMANCE TESTING

Table Number Title
4-2 Test Environments 4-3 Test Channel Spacing 4-4 Test Frequencies 4-5 Transmitter Performance Checks 4-6 Receiver Performance Checks
Table 4-1 InitialEquipment Control Settings
Service Monitor Test Set Power Supply
Monitor Mode: Power Monitor Spkr set: A Voltage: 13.2Vdc RF Attn: -70 Spkr/load:
Speaker AM,CW,FM:FM PTT: OFF Volt Range: 20V Oscilloscope Source: Mod
Oscilloscope Horiz: 10mSec/Div Oscilloscope Vert: 2.5kHz/Div Oscilloscope Tr ig: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: mid CW Monitor Vol: 1/4 CW
DC On/Standby: Standby
Current: 20A
4-2 TRANSCEIVER PERFORMANCE TESTING

3.0 RF Test Mode

When the radio is operating in its normal environment, the radios 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. This prevents the use of a normal tuning procedure. To solve this problem, a special test modeis incorporated into the radio.
To enter test mode (display radios):
1. Turn the radio on.
2. Within ten seconds after the self test is complete, press button P2, five times in succession.
3. After CSQ CHXX SP25appears in the display, the radio is on channel XX, carrier squelch
mode, 25 kHz channel spacing.
4. Each additional press of P2 scrolls through to the next channel spacing and a corresponding set of tones are sounded.
5. Pressing P1 scrolls through and accesses test environments as shown in Table 4-2.
6. Pressing P2 for three seconds switches the radio to the control head test mode. LCD Test
appears on the display.
7. Pressing P1 causes the radio to turn on all the dots of the first character. Another P1 press turns on all the dots of the next character and so on until the last character.
8. Pressing P1 at the end of the LCD test activates the Icon Test. The next P1 press turns on the first icon.
9. Pressing P1 at the end of the Icon test activates the button test. Pressing any button (except P1) or any keypad button during the LCD test or Icon test immediately activates this test.
10. Pressing P2 for 3 seconds in the control head test mode causes the radio to return to the RF test mode.
To enter test mode (non display radios):
1. Turn the radio on.
2. Within ten seconds after the self test is complete, press button P2, five times in succession.
3. All LEDs turn on for a short period to indicate the entry of the test mode.
4. Each additional press of P2 scrolls through to the next channel spacing and a corresponding
set of tones are sounded.
5. Pressing P1 scrolls through and accesses test environments as shown in Table 4-2.
6. Pressing button 1 (up) or button 2 (down) scrolls through and accesses test channels as
shown in Table 4-4. The LEDs above the buttons 1 to 4 indicate the channel number in binary form.
7. Pressing P2 for three seconds activates the button test.
8. Pressing P2 again for three seconds causes the radio to return to the RF test mode.
XX = channel number (01 - 14)
RF Test Mode 4-3
Table 4-2 Test Environments
No. of
Beeps
1
(high pitch)
Description Function
Carrier Squelch (CSQ)
RX: unsquelch if carrier detected TX: mic audio
11 CMP RX: constant unsquelch
TX: mic audio
12 LLE RX: constant unsquelch
TX: mic audio
5 Unsquelch
(UNSQ)
2 Digital
Private-Line (DPL)
1 Tone
Private-Line (TPL)
3 Dual-Tone multiple
frequency (DTMF)
RX: constant unsquelch TX: mic audio
RX: unsquelch if carrier and digital code (131) detected TX: mic audio + digital code (131)
RX: unsquelch if carrier and tone (192.8Hz) detected TX: mic audio + tone (192.8Hz)
RX: unsquelch if carrier detected TX: selected DTMF tone pair
9 MPT 0 RX: unsquelch if carrier detected
TX: 1200 baud with data “0”
10 MPT 1 RX: unsquelch if carrier detected
TX: 1200 baud with data “1”
4 MPT 3 RX: speaker muted, high tone sounds when below sequence
detected TX: 1200 baud with bit pattern aa aa c4 d7 d2 90 49 f1 f1 bb f5 c7
6 Select 5 CCIR
(SV-C)
RX: speaker muted, high tone sounds when below sequence detected TX: CCIR sequence 1124, 1275, 1446, 1640, 1860 Hz
7Select5ZVEI
(SV-Z)
RX: speaker muted, high tone sounds when below sequence detected TX: CCIR sequence 1060, 1270, 1530, 1830, 2200 Hz
8 Data Mode
(EXT)
13 Base Station Mode
(B-ST)
RX: unsquelch if carrier detected TX: flat TX audio
RX: constant unsquelch TX: mic audio
Table 4-3 Test Channel Spacing
Number of Beeps Channel Spacing
1 25 kHz
212.5kHz 3 20 kHz
4-4 TRANSCEIVER PERFORMANCE TESTING
Table 4-4 Test Frequencies
Test
Mode
Test
Channel
Low Power
Test
Channel
High Power
VHF UHF LB1 LB2 LB3
TX 1 8 136.025 403.025 29.725 36.025 42.025 RX 1 8 136.050 403.050 29.750 36.050 42.050 TX 2 9 142.325 414.150 30.225 37.125 43.225 RX 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 46.125 RX 4 11 155.025 436.525 32.225 39.225 46.025 TX 5 12 161.225 447.650 33.025 40.225 47.525 RX 5 12 161.250 447.675 33.125 40.325 47.425 TX 6 13 167.525 458.825 34.225 41.025 48.125 RX 6 13 167.550 458.850 34.325 41.125 48.025 TX 7 14 173.950 469.950 35.950 41.950 49.950 RX 7 14 173.975 469.975 35.975 41.975 49.975
Table 4-5 Transmitter Performance Checks
Test Name
Reference Frequency
Communications
Analyzer
Mode: PWR MON 4th channel test frequency* Monitor: Frequency error
Radio Test Set Comment
TEST MODE, Test Channel 4 carrier squelch
PTT to continuous (during the performance
Frequency error: ±150 Hz VHF, ±150 Hz UHF ±150 Hz LB
check)
Input at RF In/Out
Power RF As above As above As above Low Power:
0.8-1.4W High Power: 25-30W (VHF 403-470MHz). Low Power: 40-47W High Power: 60-70W (LB)
RF Test Mode 4-5
Table 4-5 Transmitter Performance Checks (Continued)
Test Name
Voice Modulation
Voice Modulation (internal)
DTMF Modulation
Communications
Analyzer
Mode: PWR MON 4th channel test frequency* atten to -70, input to RF In/ Out Monitor: DVM, AC Volts Set 1kHz Mod Outlevel for 800mVrms at test set, 800mVrms at AC/ DC test set jack
Mode: PWR MON 4th channel test frequency* atten to -70, input to RF In/ Out
As above, 4th channel test frequency*
Radio Test Set Comment
As above As above,
meter selector to mic
Deviation:
2.5 kHz Max. (12.5 kHz Ch. Sp). 4kHzMax. (20 kHz Ch. Sp). 5kHzMax. (25 kHz Ch. Sp).
TEST MODE, Test Channel 4 carrier squelch output at antenna
Remove modulation input
Deviation:
2.5 kHz Max. (12.5 kHz Ch. Sp.). 4kHzMax. (20 kHz Ch. Sp.). 5kHzMax. (25 kHz Ch. Sp.).
TEST MODE, Test Channel 4 DTMF output at antenna
As above Deviation:
1.4-1.9 kHz (12.5 kHz Ch. Sp.).
2.3-3.0 kHz (20 kHz Ch. Sp.).
2.9-3.8 kHz (25 kHz Ch. Sp.).
PL/DPL Modulation
*SeeTable4-4
As above 4th channel test frequency* BW to narrow
TEST MODE, Test Channel 4 TPL DPL
As above Deviation:
0.25-0.5 kHz (12.5 kHz Ch. Sp.).
0.4-0.8 kHz (20 kHz Ch. Sp.)
0.5-1.0 kHz (25 kHz Ch. Sp.).
4-6 TRANSCEIVER PERFORMANCE TESTING
Table 4-6 Receiver Performance Checks
Test Name
Reference Frequency
Rated Audio Mode: GEN
Distortion As above, except to
Sensitivity (SINAD)
Noise Squelch Threshold (only radios with conventional system need to be tested)
Communications
Analyzer
Mode: PWR MON 4th channel test frequency* Monitor: Frequencyerror Input at RF In/Out
Output level: 1.0mV RF 4th channel test frequency* Mod: 1kHz tone at 3kHz deviation Monitor: DVM: AC Volts
distortion As above,except SINAD,
lower the RF level for 12dB SINAD.
RF levelset to 1mV RF As above PTT to OFF
Radio Test Set Comment
TEST MODE, Test Channel4 carriersquelch output at antenna
TEST MODE Test Channel4 carrier squelch
As above As above Distortion
As above PTT to OFF
PTT to continuous (during the performance check)
PTT to OFF (center),meter selector to Audio PA
(center)
(center),meter selection to Audio PA, spkr/ load to speaker
Frequency error to be ±150 Hz VHF ±150 Hz UHF ±150 Hz LB
Set volume control to
8.12Vrms
<5.0% RF input to be
<0.3µV
Set volume control to
3.16Vrms
*SeeTable4-4
As above,except change frequency to a conventional system. Raise RF level from zero until radio unsquelches.
out of TEST MODE; select a conventional system
As above Unsquelch to
occur at <0.25µV. Preferred SINAD = 9-10dB

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.
Chapter 5

RADIO TUNING AND PROGRAMMING

NOTE
Refer to the appropriate program on-line help files for the programming procedures.
Table 5-1 Software Installation Kits Radio Tuning Setup
Description Kit Number
EMEA CD ENLN4115_ Software Installation Manual 68P64113B14_

2.0 CPS Programming Setup

The CPS programming setups, shown in Figures 5-1 through 5-3, are used to program the radio.
NOTE
Refer to appropriate program on-line help files for the programming procedures.
ACC
DC
Radio
RF
+13,2VDC
Power
Supply
Programming Cable RKN4081
DB25
RIB
RLN-4008
DB15
Cable 3080369B72 (9 PIN) Cable 3080369B71 (25 PIN)
Tx Data Rx
Data
Gnd
Figure 5-1 CPS Programming Setup with RIB
ZWG0130338-0
5-2 RADIO TUNING AND PROGRAMMING
ACC
DC
Radio
RF
Programming Cable RKN4081
+13,2VDC
Power
Supply
DB25
Tx Data Rx Data
Gnd
ZWG0130339-0
Figure 5-2 CPS Programming Setup Cable with Internal RIB
Adapter
Cable
RLN4853
ACC
DC
Radio
RF
Programming
+13,2VDC
Power
Supply
Cable
RKN4081
DB25
Tx Data Rx Data
Gnd
ZWG0130340-0
Figure 5-3 CPS Programming Setup Cable with Internal RIB and Rear Adapter Cable
Radio Tuning Setup 5-3

3.0 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.
Test Box
RLN4460
ACC
DC
Radio
RF
Mini UHF
to BNC
HLN8027
Program/ RKN4083
+13,2VDC
Power
Supply
30 dB Pad
Test Cable
RLN-4008
RIB
Cable 3080369B72 (9 PIN) Cable 3080369B71 (25 PIN)
Figure 5-4 Radio Tuning Test Equipment Setup with External RIB

3.1 Initial Test Equipment Control Settings

DB15
Audio In
Transmit
Receive
Tx
Audio Generator
Rx
Sinad M eter
AC Voltmeter
Tx Data Rx Data
Gnd
RF Generator
Service Monitor or Counter
Wattmeter
ZWG0130336-0
The initial test equipment control settings are listed in Table 5-2.
Table 5-2 InitialEquipment Control Settings
Service Monitor Test Set Power Supply
Monitor Mode: Power Monitor Speaker set: A Voltage: 13.2Vdc RF Attenuation: -70 Speaker/load:
Speaker AM,CW,FM:FM PTT: OFF Volt Range: 20V Oscilloscope Source: Mod
Oscilloscope Horizontal: 10mSec/Div Oscilloscope Vertical: 2.5 kHz/Div Oscilloscope Trigger: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: mid CW Monitor Volume: 1/4 CW
DC on/standby: Standby
Current: 20A
5-4 RADIO TUNING AND PROGRAMMING

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. The LED sequence and the error tone continue until the radio is switched off. Radios with displays are also able to display error codes. The meaning of the LED indication, the displayed error codes and the related corrections are listed in Table 6-1.
Chapter 6

POWER UP SELF-TEST

Table 6-1 Power-up Error Codes
If the error code
displayed is…
Test 1 Failed Once Hardware codeplug error,
Test 2 Failed Twice Select 5 Application Vector
Test 3 Failed Three times Codeplug Checksum error. Reprogram codeplug and retest the
Test 4 Failed Four times Codeplug Version Error. Reprogram codeplug using the
Test 5 Failed Five times ROM Checksum test failure. Turn radio off then on again. If the
Test 6 Failed Six times RAM Checksum test failure. Turn the radio off then on again. If the
The LED
flashes...
then, there is a... T o correct the problem...
Reprogram codeplug. If message possibly codeplug structure mismatch or non-existant codeplug.
corrupted.
re-occurs, replace main board o r
return it to the nearest Motorola
depot.
Reprogram codeplug and retest the
radio.
radio.
correct version and retest the radio.
message re-occurs replace the main
board or return it to the nearest
Motorola depot.
message re-occurs replace the main
board or return it to the nearest
Motorola depot.
Test 7 Failed --- --- Reserved “Test 8 Failed Eight times Radio Model Number failure. Reprogram codeplug for correct
model.
No Display. Display module is not
connected. Display module faulty.
300Hz Tone and Flashing LED. (Radio with no display).
Radio failure or invalid codeplug as described above.
Check connection between main
board and the display module
Replace display module.
Turn the radio off then on again.
Confirm that there is a 300Hz fail
tone and count the number of flashes
made by the LED. Make the relevant
correction as described above
6-2 POWER UP SELF-TEST
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