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 EHuman exposure to electromagnetic fields Low
frequency (0 Hz to 10 kHz)
- ENV 50166-2 1995 EHuman 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
7to15Watts30.5 cm (1 Foot)
16 to 50 Watts61 cm (2 Feet)
More than 50 Watts91.5 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.
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.
2.0Warranty 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.
2.1Warranty 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.
2.2After 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.
1-2INTRODUCTION
2.3European Radio Support Centre (ERSC)
The ERSC Customer Information Desk is available through the following service numbers:
Austria:06 60 75 41Italy:16 78 77 387
Belgium:08 00 72 471Luxemburg:08 00 23 27
Denmark:80 01 55 72Netherlands:60 22 45 13
Finland:08 00 11 49 10Norway:80 01 11 15
France:05 90 30 90Portugal:05 05 49 35 70
Germany:01 30 18 75 24Spain:90 09 84 902
Greece:00 80 04 91 29 020Sweden:02 07 94 307
UK:0800969095Switzerland:1553082
Ireland:18 00 55 50 21Iceland:80 08 147
Or dial Customer Care Centre:
Tel: +49 6128 70 2164
Please use these numbers for repair enquiries only.
2.4Piece 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 Support1-3
2.5Technical 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
Africa & Middle East - Ralph Schubert
Telephone: +33 (0)4 4230 5887
Fax: +33 (0)4 4230 4784
Email: ralph.schubert@Motorola.com
1-4INTRODUCTION
3.0Radio 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)
XIMUB6005_Tanapa GM360, LB3
XXXENBN4056_Packaging,WarisMobile
XXXHKN9402_12V Power Cable
XXXMDRMN4025_EnhancedCompactMicrophone
XXXRLN4774_3 Point Mount
XXX6864110B81_UserGuide,GM360
X = Indicates one of each is required
2-4MODEL CHART AND TEST SPECIFICATION
2.4Specifications
General
SpecificationVHFUHFLB1, LB2, LB3
Frequency Range:136-174 MHz403-470 MHz29.7-36.0 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:1-25W1-25W40-60W
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
SealingPasses rain testing to IP54
Shock and VibrationMeets MIL-STD 810-C,D&E
DustMeets MIL-STD 810-C,D&E
HumidityMeets 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
Specifications2-5
Transmitter
SpecificationVHFUHFLB1, 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
SpecificationVHFUHFLB1, 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
2-6MODEL CHART AND TEST SPECIFICATION
1.0Introduction
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.
2.0Preventive Maintenance
The radios do not require a scheduled preventive maintenance program; however, periodic visual
inspection and cleaning is recommended.
2.1Inspection
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.
2.2Cleaning 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.
3-2MAINTENANCE
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).
3.0Safe 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 — General3-3
4.0Repair 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.
5.0Disassembling 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:
3-4MAINTENANCE
6.0Radio 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.
6.1Control 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- Detailed3-5
Flexible
Connection
ZWG0130210-O
Figure 3-2 Flexible Connection Removal
4.Remove the flexible connection from the socket on the control head board.
6.2Top 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.
3-6MAINTENANCE
6.3Transceiver 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- Detailed3-7
6.4Disassembly 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.
3-8MAINTENANCE
ZWG0130216-O
Figure 3-8 Board, Keypad and Speaker Removal
6.Remove the speaker from the control head housing.
6.5Disassembly 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 Assembly3-9
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 .
7.0Radio Assembly
7.1Control 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.
7.2Control 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.
3-10MAINTENANCE
7.3Radio 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.
7.4Control 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 Lists3-11
8.0Radio Exploded Mechanical Views and Parts Lists
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 SetEnables connection to audio/accessory jack.
RKN4081_Programming Cable with
Internal RIB
RLN4853_10 to 20 Pin AdapterConnects RKN4081_ to the radio accessory
RKN4083_Mobile Programming/Test Cable Connects radio to RIB (RLN4008_).
GTF374_Program CableConnects RIB to Radio microphone input
RLN4008_Radio Interface BoxEnables communications between radio and
HLN8027_Mini UHF to BNC AdaptorAdapts radio antenna port to BNC cabling of
GPN6133_Power SupplyProvides the radio with power when bench
EPN4040_Wall-Mounted Power SupplyUsed to supply power to the RIB (UK).
EPN4041_Wall-Mounted Power SupplyUsed to supply power to the RIB (Euro)
DescriptionApplication
Allows switching for radio testing.
Includes radio interface box (RIB) capability.
connector.
computer’s serial communications adapter.
test equipment.
testing.
8180384J59Housing Eliminator (short)Test Fixture used to bench test the radio pcb
8180384J60Housing Eliminator (medium)Test Fixture used to bench test the radio pcb
8180384J61Housing Eliminator (long)Test Fixture used to bench test the radio pcb
3080369B71Computer Interface CableConnects the RIB to the Computer (25-pin)
3080369B72Computer Interface CableConnects the RIB to the Computer (9-pin)
(Use for IBM PC AT - other IBM models use
the B71 cable above)
6686119B01Removal ToolAssists in the removal of radio control head.
Test Equipment3-17
10.0Test 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_NTComms System
R2680_NTComms System
*R1072_Digital MultimeterAC/DC voltage and current
*R1377_AC Voltmeter100
WADN4133Delay
DescriptionCharacteristicsApplication
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
Figure 3-16 Pin Configuration of the Side Connector
FLO830307-0
1.0General
These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment. The recommended field service equipment approaches
the accuracy of the manufacturing equipment with few exceptions. This accuracy must be
maintained in compliance with the manufacturer’s recommended calibration schedule.
2.0Setup
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:
When the radio is operating in its normal environment, the radio’s microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting. However, when the unit is on the bench
for testing, alignment, or repair, it is removed from its normal environment and cannot receive
commands from its system. Therefore, the internal microcontroller does not key the transmitter or
unmute the receiver. This prevents the use of a normal tuning procedure. To solve this problem, a
special “test mode” is 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 SP25” appears 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 Mode4-3
Table 4-2 Test Environments
No. of
Beeps
1
(high pitch)
DescriptionFunction
Carrier Squelch
(CSQ)
RX: unsquelch if carrier detected
TX: mic audio
11CMPRX: constant unsquelch
TX: mic audio
12LLERX: constant unsquelch
TX: mic audio
5Unsquelch
(UNSQ)
2Digital
Private-Line (DPL)
1Tone
Private-Line (TPL)
3Dual-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
9MPT 0RX: unsquelch if carrier detected
TX: 1200 baud with data “0”
10MPT 1RX: unsquelch if carrier detected
TX: 1200 baud with data “1”
4MPT 3RX: 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”
6Select 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
8Data Mode
(EXT)
13Base Station Mode
(B-ST)
RX: unsquelch if carrier detected
TX: flat TX audio
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
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 RFAs abovePTT to OFF
RadioTest SetComment
TEST MODE,
Test Channel4
carriersquelch
output at
antenna
TEST MODE
Test Channel4
carrier squelch
As aboveAs aboveDistortion
As abovePTT 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 aboveUnsquelch to
occur at
<0.25µV.
Preferred
SINAD =
9-10dB
1.0Introduction
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
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 Setup5-3
3.0Radio 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.
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”OnceHardware codeplug error,
“Test 2 Failed”TwiceSelect 5 Application Vector
“Test 3 Failed”Three timesCodeplug Checksum error.Reprogram codeplug and retest the
“Test 4 Failed”Four timesCodeplug Version Error.Reprogram codeplug using the
“Test 5 Failed”Five timesROM Checksum test failure.Turn radio off then on again. If the
“Test 6 Failed”Six timesRAM 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 timesRadio 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
6-2POWER UP SELF-TEST
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