Motorola GP300 Service manual

Professional Radio

GP300 Series

Basic Service Manual

68P64115B18B

Issue: June 2000

ii

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored
in semiconductor memories or other media. Laws in the United States and other countries preserve for Motor­ola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or repro­duce in any form, the copyrighted computer program. 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 informationbefore using your radio.

SAFE AND EFFICIENT OPERATION OF MOTOROLA TWO-WAY RADIOS

This documentprovides 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.

Forinformation regarding radio use in hazardous areas, please referto 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:



FederalCommunications 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):

- ENV 50166-1 1995 E Human exposure to electromagnetic fields Low
frequency(0Hzto10kHz)

iii

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

- Proceedings of SC211/B 1996 “SafetyConsiderationsfor Human Exposure to EMFs from
Mobile TelecommunicationEquipment (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:

PORTABLE RADIO OPERATION AND EME EXPOSURE



When transmittingwith a portable radio,hold radio in a vertical position with the
microphone 2.5 to 5.0 centimeters (one to two inches) away from the mouth. Keep
antenna at least 2.5 centimeters (one inch) from your head or body when transmit­ting.



If you wear a portable two-way radio on your body, ensure that the antenna is at
least 2.5 centimeters (one inch) from the body when transmitting.

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 electromagneticinterference 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.

2.5 to 5.0 cm
(1 to 2 in.)

iv SAFETY INFORMATION

OPERATIONAL WARNINGS

Vehicles with an air bag

WARNING: Do not place a portable radio in the area over an air bag or in the air bag deploy­ment area. Air bags inflate with great force. If a portable radio is placed in the air bag deploy-

!

ment area and the air bag inflates, the radio may be propelled with great force and cause
serious injury to occupants o f vehicle.

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 (e.g. FM or

!

Cenelec approved). Sparks in a potentially explosive atmosphere can cause an explosion or
fire resulting in bodily injur y or even death.

Batteries

WARNING: Do not replace or recharge batteries in a potentially explosive atmosphere. Con­tact sparking may occur while installing or removing batteries and cause an explosion.

!

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”orinareasposted“turn off two-way

!

radio”, obey all signs and instructions.

NOTE

OPERATIONAL CAUTIONS

Damaged antennas

Batteries

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.

CAUTION: Do not use any portable two-way r adio that has a damaged antenna. If a damaged
antenna comes into contact with your skin, a minor burn ca n result.

!

CAUTION: All batteries can cause property d amage and/or bodily injury such as burns if a
conductive material such as jewelry, keys or beaded chains touch exposed terminals. The

!

conductive material may complete an electrical circuit (short circuit) and become quite hot.
Exercise care in handling any charged battery, particularly when placing it inside a pocket,
purse or other container with metal objects.

Table of Contents

Chapter 1 INTRODUCTION

1.0 Scope of Manual..................................................................................................1-1

2.0 Warranty and Service Support ............................................................................1-1

2.1 Warranty Period and Return Instructions.......................................................1-1

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

2.3 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 INTRINSICALLY SAFE RADIO INFORMATION

1.0 FMRC Approved E quipment................................................................................2-1

2.0 Repair of FMRC Approved Products...................................................................2-2

2.1 Repair.............................................................................................................2-2

2.2 Relabelling .....................................................................................................2-2

2.3 Do Not Substitute Options or Accessories.....................................................2-3

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 H andling 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 Front Cover from Chassis Disassembly.........................................................3-4

6.2 Chassis Assembly Disassembly ....................................................................3-6

6.3 Keypad, Display, and Keypad/Option Board Disassembly ............................3-7

6.4 Speaker, Microphone, and Universal Connector Flex Disassembly ..............3-8

6.5 PTT Disassembly...........................................................................................3-9

6.6 Control Top Disassembly.............................................................................3-10

7.0 Radio Reassembly — Detailed..........................................................................3-10

7.1 PTT Reassembly..........................................................................................3-10

7.2 Control Top Reassembly..............................................................................3-10

7.3 Speaker, Microphone, and Universal Connector Flex Reassembly.............3-10

7.4 Keypad, Display, and Keypad Option Board Reassembly...........................3-10

7.5 Chassis Assembly Reassembly...................................................................3-11

7.6 Chassis and Front Cover Reassembly.........................................................3-12

vi

8.0 Option Board Installation....................................................................................3-12

9.0 Mechanical Views and Parts Lists......................................................................3-14

9.1 GP320/GP340 ..............................................................................................3-14

9.2 GP360/GP380 ..............................................................................................3-16

10.0 Service Aids .......................................................................................................3-18

11.0 Test Equipment..................................................................................................3-19

12.0 Programming/Test Cable ...................................................................................3-20

Chapter 4 PERFORMANCE TESTING

1.0 Introduction ..........................................................................................................4-1

2.0 Receiver Performance Tests................................................................................4-1

3.0 Transmitter Performance Tests............................................................................4-2

Chapter 5 RADIO TUNING AND PROGRAMMIN G

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

2.0 Global Radio Tuning Setup..................................................................................5-1

2.1 Initial Test Equipment Setup...........................................................................5-2

3.0 CPS Programming Setup.....................................................................................5-2

Chapter 6 MODEL CHART AND TEST SPECIFICATION

1.0 Model Chart (UHF)...............................................................................................6-1

2.0 Model Chart (VHF)...............................................................................................6-2

3.0 Model C hart (LB)..................................................................................................6-3

4.0 Model C hart (300R1)............................................................................................6-4

5.0 Specifications - Professional GP300 Series Radios ............................................6-5

Chapter 7 POWER UP SELF-TEST

1.0 Error C odes..........................................................................................................7-1

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 availablethrough the followingservice 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:

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 enquiries should be directed to:

Tel: [phone]

Motorola GmbH
European Parts Department
65232 Taunusstein
Germany.

Warranty and Service Support 1-3

2.5 Technical Support

Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions
which may be encountered.

UK/Ireland - Richard Russell
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

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

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

Germany - Karin Struck
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

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

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

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

1-4 INTRODUCTION

3.0 Radio Model Information

The model number and serial number are located on a label attached to the back of your radio. You
can determine the RF output power, frequency band, protocols, and physical packages. The
example below shows one portable radio model number and its specific characteristics.

Table 1-1 Radio Model Number (Example: MDH25KDC9AA3AE)

Typeof

Unit

MD H 25 K

Model

Series

Freq.

Band

VHF

(136-

174MHz)

H =Portable

MD = Motorola Internal Use

UHF1

(403-

470MHz)

UHF2

(450-527

MHz)

Power

Level

4-5WCGP140,

R

5-6WHGP380,

S

D

E

Physical

Packages

GP320,
GP340,
GP640.

GP680

N

GP1280

Channel
Spacing

9

Program-

mable

Protocol

AA

Conventional

MDC

AN

Conventional

5 Tone

CK

MPT

Feature

Level

O

GP320

3

GP140,
GP340,
GP640.

5

GP360

Model

Revision

AE

Model

Package

B

LB1

29-42MHz

C

LB2

35-50MHz

E

300R1

(300-

350MHz)

F

GP360

PW

MPT/5T

6

GP380,

GP680

8

GP1280

INTRINSICALLY SAFE RADIO INFORMATION

1.0 FMRC Approved Equipment

Anyone intending to use a radio in a location where hazardous concentrations of flammable material
exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and
with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500
(hazardous [classified] locations).

An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers
and the products approved by FMRC for use in such locations. FMRC has also issued a voluntary
approval standard for repair service (“Class Number 3605”).

FMRC Approval labels are attached to the radio to identify the unit as being FM
Approved for specified hazardous atmospheres. This label specifies the hazardous
Class/Division/Group along with the part number of the battery that must be used.
Depending on the design of the portable unit, this FM label can be found on the
back of the radio housing or the bottom of the radio housing.Their Approval mark is shown above.

WARNING: Do not operate radio communications equipment in a hazardous atmosphere
unless it is a type especially qualified (e.g. FMRC Approved) for such use. An explosion or

!

fire may result.

Chapter 2

FM

APPROVED

WARNING: Do not operate the FMRC Approved Product in a hazardous atmosphere if it has
been physically damaged (e.g. cracked housing). An explosion or fire may result.

WARNING: Do not replace or charge batteries in a hazardous atmosphere. Contact sparking
may occur while installing or removing batteries and cause an explosion or fire.

WARNING: Do not r eplace or change accessories in a hazardous atmosphere. Contact
sparking may occur while installing or removing accessories and cause an explosion or fire.

WARNING:Do not operate the FMRC Approved P roduct unit in a hazardous location with the
accessory contacts exposed. Keep the connector cover in place when accessories are not
used.

WARNING: Turn radio off before removing or installing a battery or accessory.
WARNING: D o not disassemble the FMRC Approved Product unit in any way that exposes

the internal electrical circuits of the unit.

Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability
and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the field.

A modification changes the unit’s hardware from its original design configuration. Modifications can
only be done by the original product manufacturer at one of its FMRC audited manufacturing
facilities.

WARNING: Failure to use an FMRC Approved Product unit with an FMRC Approved battery
or FMRC Approved accessories specifically approved for that product may result in the

!

dangerously unsafe condition of an unapproved radio combination being used in a
hazardous location.

Unauthorized or incorrect modification of an FMRC Approved Product unit will negate the Approval
rating of the product.

2-2 INTRINSICALLY SAFE RADIO INFORMATION

2.0 Repair of FMRC Approved Products

REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF
THE USER

You should not repair or relabel any Motorola manufactured communication equipment bearing the
FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC
Approval standard for repairs and service (“Class Number 3605”).

You may want to consider using a repair facility that operates under 3605 repair service approval.

WARNING: Incorrect repair or relabelling of any FMRC Approved Product unit could
adversely affect the Approval rating of the unit.

!

WARNING: Use of a radio that i s not intrinsically safe in a hazardous atmosphere could
result in serious injury or death.

FMRC’s Approval Standard Class Number 3605 is subject to change at any time without notice to
you, so you may want to obtain a current copy of 3605 from FMRC. Per the December, 1994
publication of 3605, some key definitions and service requirements are as follows:

2.1 Repair

A repair constitutes something done internally to the unit that would bring it back to its original
condition Approved by FMRC. A repair should be done in an FMRC Approved facility.

Items not considered as repairs are those in which an action is performed on a unit which does not
require the outer casing of the unit to be opened in a manner which exposes the internal electrical
circuits of the unit. You do not have to be an FMRC Approved Repair Facility to perform these
actions.

2.2 Relabelling

The repair facility shall have a method by which the replacement of FMRC Approval labels are
controlled to ensure that any relabelling is limited to units that were originally shipped from the
Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the
repair facility. An FMRC Approval label shall be ordered from the original manufacturer as needed to
repair a specific unit. Replacement labels may be obtained and applied by the repair facility
providing satisfactory evidence that the unit being relabelled was originally an FMRC Approvedunit.

Verification may include, but is not limited to: a unit with a damaged Approval label, a unit with a
defective housing displaying an Approval label, or a customer invoice indicating the serial number of
the unit and purchase of an FMRC Approved model.

Repair of FMRC Approved Products 2-3

2.3 Do Not Substitute Options or Accessories

The Motorola communications equipment certified by Factory Mutual is tested as a system and
consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or
options, or both. This Approved portable and battery combination must be strictly observed. There
must be no substitution of items, evenif the substitute has been previously Approved with a different
Motorola communications equipment unit. Approved configurations are listed in the FM Approval
guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped with
FM Approved radio and battery combination from the manufacturer. The Approval guide, or the
Approval standard Class Number 3605 document for repairs and service, can be ordered directly
through Factory Mutual Research Corporation located in Norwood, Massachusetts.

2-4 INTRINSICALLY SAFE RADIO INFORMATION

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.

Chapter 3

MAINTENANCE

2.1 Inspection

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. Avoid using aerosol sprays, tuner cleaners, and other chemicals.

!

Cleaning External Plastic Surfaces

Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.

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.

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
componentsare not soakedwith 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 centre 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.

Flexible Circuits

The flexible circuits are made from a different material than the rigid boards, and require different
soldering techniques. Excessive prolonged heat on a flexible circuit can damage the material.
Therefore, avoid excessive heat and excessive bending.

For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700
degree tip, and use small diameter solder such as ST-633. The smaller size solder will melt faster
and require less heat to be applied to the circuit.

To replace a component on a flexible circuit:

1. Grasp with seizers (hemostats) the edge of the flexible circuit near the part to be removed.

2. Pull gently.

3. Apply the tip of the soldering iron to the component connections while pulling with the seizers.

NOTE

Do not attempt to puddle-out components. Prolonged application of heat may damage the
flexible circuit.

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 disassemblingthe radio:



Small flat blade screwdriver



penknife-size screwdriver



TORX™ T6 screwdriver

3-4 MAINTENANCE

If a unit requires more complete testing or service than is customarily performed at the basic level,
send this unit to a Motorola Authorized Service Centre. (See Chapter 1 for a list of authorized
service centres.)

The following disassembly procedures should be performed only if necessary:
Chassis Assembly Disassembly (Paragraph 6.2)
Keypad, Display, and Keypad/Option Board Disassembly (Paragraph 6.3)
Speaker, Microphone, and Universal Connector Flex Disassembly (Paragraph 6.4)
PTT Disassembly (Paragraph 6.5)
Control Top Disassembly (Paragraph 6.6)

6.0 Radio Disassembly — Detailed

6.1 Front Cover from Chassis Disassembly

1. Turn off the radio.

2. Remove the battery:

a. Pull down on the two battery-release buttons.
b. With the buttons pulled down, the top of the battery will fall from the radio.
c. Remove the battery from the radio.

Battery Release
Buttons

3. Remove the antenna.

Figure 3-1 Battery Removal

Radio Disassembly — Detailed 3-5

4. Pull the volume and channel selector knobs off of their shafts.

Knobs

Figure 3-2 Knob Removal

NOTE

Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts.

5. Separate the chassis from the internal electronics front cover assembly as follows:
a. Insert a small, flat-blade screwdriver, or similar instrument, in between the thin retaining

wall and the chassis at the bottom of the radio. Do not mar the O-ring sealing area on the
housing.

b. Slowly pry the bottom of the chassis from the cover by pushing the small flat-blade

screwdriver down, and rotating the handle of the tool over and behind the base of the
radio. This prying action forces the thin inner plastic wall toward the base of the radio,

releasing the two chassis base tabs.

Radio Chassis

Figure 3-3 Chassis Removal

CAUTION: Marring the front cover O-ring sealing a rea will prevent the radio from
sealing properly.

!

NOTE

Flexible ribbon circuits (flexes) connecting the front cover assembly and the chassis
prevent you from completely separating the two units. Display radios and radios with
option boards have two flexes.

6. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis.

3-6 MAINTENANCE

7. Lift the latches on the main circuit board to release the flexes from their connectors.

Latches

Flex Connectors

Figure 3-4 Unlatch Flex Connectors

6.2 Chassis Assembly Disassembly

1. Use a TORX™ screwdriver with a T6 head to remove the four screws holding the main board

to the chassis.

Compliant

Ground
Contact

O-ring

Retaining

Features

Figure 3-5 Remove Main Board from Chassis

Main Board

Radio Chassis

2. Lift the main board from the chassis (See Figure 3-5).

CAUTION: Refer to the CMOS CAUTION paragraph on page 2 before removing the main
board. Be sure to use ESD protection when handling circuit boards.

!

3. Remove the four small O-ring retainers from their slots in the chassis. Note the alignment of
the retainers for reassembly.

4. Remove the O-ring.

5. Slide off the ground contact from the top corner boss of the radio chassis.

Radio Disassembly — Detailed 3-7

6.3 Keypad, Display, and Keypad/Option Board Disassembly

1. If the disassembly of the keypad, the keypad printed circuit board, or the display is required,

lift the microphone flex circuit up, and carefully remove the microphone and its boot from the
front cover pocket. (See Figure 3-6.)

2. Lay this flex circuit to one side.

3. To remove the keypad retainer shield:

a. Insert the tip of a “penknife size,” flat blade screwdriver in the opening at the end of the

keypad retainer arm tab.

b. Pry the tab away from the side of the front cover until it moves past the ledges on the

side wall. Duplicate this procedure for each of the four retainer arm tabs.

Speaker-Microphone

Flex Circuit Tail

Keypad Retainer

Arm Tabs (4)

Flat Blade

Screwdriver

Retainer

Top Hooks

Retainer

Figure 3-6 Remove Retainer

4. Note that the two “top hooks” are still held underneath the front cover—right below the

speaker. Lift the keypad retainer out of the front cover; then, lift and pivot the two hooks out of
the front cover.

5. Ifdisassembly involves the removal of the display module, disconnect the display flex from the
keypad option board connector by lifting the latch on the connector. (This is similar to the pro­cess for releasing the flexes.)

6. The display module is attached to the front cover with a double-sided adhesive pad. Carefully
pull up on the display module, using a small screwdriver , if necessary, and remove it from the

front cover. Use a new piece of double-sided adhesive to re-mount the display to the cover.

CAUTION: Take care not to damage the display. Do not cut, bend, or pinch the heat seal.
Display modules contain CMOS devices. Be sure to use ESD protection.

!

3-8 MAINTENANCE

7. The keypad/option board, and the keypad, can be removed without the use of tools.

Retainer

Display Module

Keypad/Option Board

Keypad

Radio Body

Figure 3-7 Removing the Keypad Retainer and Other Boards from the Radio Body

NOTE

At this point, the Option Board Installation Procedure should be performed, if necessary.

6.4 Speaker, Microphone, and Universal Connector Flex Disassembly

1. Turn the screw at the bottom of the dustcover counterclockwise with your fingers. Lift the dust-

cover out of its pocket.

NOTE

NOTE

The dustcover must be removed to remove the speaker-microphone assembly flex circuit.
The speaker is held in place with a two-legged retainer bracket. The bracket legs are
secured by the front cover slots. Be careful not to damage the speaker when removing the
retainer bracket.

2. Usinga screwdriver, push down on the portion of the speaker retainer bracketpointing toward
the bottom of the radio. Then, remove the retainer by slightly pushing it toward the top of the
radio until you slide it past the front cover slot.

3. Pull the rubber microphone boot from its seated position. Unless you are replacing the micro­phone, leave it in the boot.

The speaker-microphone assembly flex circuit goes through the front cover wall to the out­side wall. To replace this assembly, you must peel-off the universal connector escutcheon
label. The existing escutcheon cannot be reassembled; a new part must be used. (See item
number10 on the explodedview drawing.)

4. Peel-off the universal connector flex circuit escutcheon (label).

5. Pry the flex circuit (adhesive held) backer board away from the front cover, and remove the

universal connector tail of the speaker-microphone assembly through its opening in the front
cover.

Radio Disassembly — Detailed 3-9

Notch In

Speaker @ 12:00

Speaker

Universal Connector

Tail

Microphone Boot

Microphone

Speaker Microphone

Flex Circuit Assembly

Speaker Orientation

Tab @ 12:00

Figure 3-8 Removal Speaker-Microphone Assembly

6. After the universal connector tail of the speaker-microphone assembly is removed, the

assembly can be completely removed. If it is necessary to replace the speaker or
microphone, or both, do it while the flex circuit is removed from the front cover. When
reassembling the microphone in its boot, make sure the microphone port faces the round hole
in the bottom of the boot.

6.5 PTT Disassembly

1. If required, the PTT bezel, and the PTT seal assembly, can be disassembled using a small

screwdriver, as follows:

PTT Bezel

Tab

a. Pry back the T-tab found inside the front cover (in between the four buttons on the PTT

assembly).

b. Remove the PTT bezel by slightly bowing it until the top and bottom tabs are released

from the slots in the front cover.

"T" Shaped Retainer Tab

Tab

PTT Seal

Figure 3-9 PTT Removal

c. The PTT seal can be easily lifted from the bezel without the use of tools.

3-10 MAINTENANCE

6.6 Control Top Disassembly

1. To remove the control top assembly , place a screwdriver next to the antenna boss, and pry it

against the control top escutcheon. This will lift the control top escutcheon away from its
double-sided adhesive. Grab the double-sided adhesive near the volume potentiometer, and
lift it away.

2. Remove the control top seal, emergency button, and transmit light pipe.

7.0 Radio Reassembly — Detailed

7.1 PTT Reassembly

1. Replace transmit light pipe and control top seal.

2. Place a new control top escutcheon adhesive against the front cover. Press the control top

escutcheon tightly against the adhesive.

3. Put the PTT seal in the PTT bezel.

7.2 Control Top Reassembly

1. Place the bezel top tab in the top slot inside the front cover PTT opening. Slightly bow the

bezel so that the bottom tab can fall inside the bottom slot.

2. Press the PTT assembly against the front cover opening.

NOTE

Look inside the front cover to make sure the T-tab is fully engaged with the front cover. If
necessary, press the T-tab toward the top of the radio until it becomes fully engaged.

7.3 Speaker, Microphone, and Universal Connector Flex Reassembly

1. Feed the universal connector tail of the speaker-microphone flex assembly through the open-

inginthesidewallofthefrontcover.

2. Peel-off the adhesive liner on the back of the universal connector tail of the flex circuit. Attach
the flex tail to the front cover using the guide pins for correct alignment.

3. Replace the universal connector escutcheon. Make sure that all the connector openings align
with the gold pads on the flex circuit.

4. Align the notch in the speaker at the twelve o’clock position with the tab on the front cover.
(See Figure 3-8.)

5. Place the speaker retainer bracket into the hole on the top of the front cover, and bend the
retainer down to fit underneath the boss below the speaker.

7.4 Keypad, Display, and Keypad Option Board Reassembly

1. If you are replacing the display, use a new double-sided adhesive display pad (item number

17 on the exploded view diagram).

2. Replace the keypad, and the keypad/option board. Make sure the display module flex tail is
connected correctly to the connector on the keypad/option board.

Radio Reassembly — Detailed 3-11

3. Insert the “top hooks” of the keypadretainer into the slots below the speaker (above the
display) in the front cover. Snap all four of the retainer arm tabs in place in the front cover.

NOTE

Pull the speaker-microphone flex circuit out of harm’s way during reassembly.

4. Re-insert the microphone and boot into the pocket in the front cover.

5. Lay the speaker-microphone flex on top of keypad/option board retainer.

Catches

Retainer

Figure 3-10 Lock retainer catches to the radio’s body

7.5 Chassis Assembly Reassembly

1. Slide on the ground contact (if necessary) on the top corner boss of the chassis.

2. Replace the O-ring. The tabs on the O-ring should reach around the chassis and point down.

3. Stretch the O-ring to place it into the retaining pocket at the bottom end of the chassis.

NOTE

NOTE

When properly assembled, the retainers on the O-ring should align with the slots on the
chassis. If this is not the case, remove and replace the O-ring until it is aligned with the
chassis and completely seated in place around the perimeter.

4. Ensure that the antenna nut insulator is correctly replaced by pushing it all the way to the top
of the antenna nut.

5. Replace the battery contact seal (if necessary) surrounding the battery contact.

6. Place the main circuit board straight down on top of the chassis.

Be sure the battery contact seal protrudes through the chassis and is not pinched under the
chassis.

7. Use the T6 TORX screwdriver to fastenthe screws holding the main board to the chassis.

3-12 MAINTENANCE

7.6 Chassis and Front Cover Reassembly

1. Align the chassis assembly end-to-end with the front cover assembly.

2. Insert the tails of the flex circuits into their respective connectors at the bottom of the front

cover.

3. Push down the latches on the connectors to hold the flex circuits to the main board.

4. Slide the volume potentiometer and frequency switch shafts into their respective holes in the

front cover.

5. Push the chassis assembly completely into the top of the front cover until it settles in place.

6. Be sure the O-ring is properly seated.

7. Snap the bottom of the chassis into the front cover.

8. Reassemble the knobs, dust cover, antenna, and battery.

Radio Chassis

Figure 3-11 Fastening the Chassis

8.0 Option Board Installation

1. With the keypad retainer removed, the keypad backer board can be removed without the use

of tools.

2. Remove the jumper flex from the connector on the keypad board. Notice the orientation of the
flex to the connector. Arrows on the jumper flex point to the correct way of inserting the flex
into the connector.

3. Discard the keypad backer board.

4. The “breakaway” tab at the top of all option boards contains an extra row of keys and is used

to accommodate other radio models.

5. Break-off and discard the option board tab, taking care not to damage the option board. Trim
any tab fragments that may remain on the option board.

Option Board Installation 3-13

Retainer

Jumper Flex

Keypad/Option

Board

TO KP

Display Flex

Figure 3-12 Changing the Keypad/Option Board

6. Reassemble the option board to the front cover assembly.

7. Insert the display flex circuit into the connector on the option board.

8. Insert the jumper flex circuit into the connector on the option board. Notice the orientation of

the flex circuit. Arrows on the jumper flex point to the correct way of inserting the flex into the
connector.

9. Replace the retainer by placing the two top hooks into the slots below the speaker in the front
cover; then, pivot the retainer into the front cover. Ensure that all four tab arms snap correctly
into the front cover.

10. With the keypad option board, display, and retainer correctly in place, the front cover
assembly can now be reassembled as described in Paragraph 7.6 (Chassis and Front Cover
Reassembly).

3-14 MAINTENANCE

9.0 Mechanical Views and Parts Lists

9.1 GP320/GP340

35

34

33

32

31

30

28

29

27

26

24

20

18

19

14

13

2

3

1

4

756

8

16

15

11

25

23

22

21

17

12

10

9

Figure 3-13 Radio Exploded Mechanical View (GP320/GP340)

Mechanical Views and Parts Lists 3-15

Motorola

Item

Part

Description

Number

1 See Chapter6Antenna

2 3680529Z01 Knob, Volume
3 3680530Z01 Knob, Frequency
4 1380525Z01

1380525Z02
5 3380644Z01 Escutcheon, Label
6 3280533Z01

3280533Z02
7 6180527Z01 Litepipe, Tx
8 1364279B02

1364279B03
9 1586059A01 Dust Cover,Universal

10 1386058A01 Escutcheon, Universal

11 1580666Z03 Front Cover, Basic

1580666Z04 Front Cover with Keypad

1580666Z06 Front Cover - GP320
12 Not Field

Replaceable

Escutcheon, Top - GP340
Escutcheon, Top - GP320

Seal, Control Top - GP340
Seal, Control Top - GP320

Front, label - GP320
Front, label - GP340

Connector

Flex

(DTMF)

Escutcheon, FM

Motorola

Item

Part

Description

Number

18 3586057A01 Felt Speaker
19 1480577C01 Boot, Microphone
20 5085962A02 Speaker
21 5013920A04 Microphone
22 8480549Z01 Flex, UC
23 2113740A41 Capacitor, 33pF
24 4280504Z01 Retainer, Speaker
25 0304726J04 Screw
26 See Chapter6BackCoverKitinclchassis

main board

27 8480475Z02 Flex, Keypad/Controller -

GP340
28 1480652Z01 Insulator, Antenna
29 7580556Z01 Pad, Thermal
30 3280534Z01 Seal, Contact
31 3280536Z01 Gasket, O-Ring
32 3980698Z01 Contact, Ground,

Compliant, VHF
33 2780518Z01 Chassis
34 See Chapter6Battery

13 7580532Z01

7580532Z03

*

14 1380528Z01

1380528Z03

*

4285672Z01

Keypad, Side Control ­GP340
Keypad, Side Control ­GP320

Bezel, Side Control ­GP340

Bezel, Side Control ­GP320

Retaining clip - GP320

*

15 7580620Z03

7580620Z04
16 0104007J99 Keypad Board Assembly
17 4280498Z01 Retainer, Keypad PCB

Keypad, Blank
Keypad, Full

35 HLN9714 Beltclip

*It is recommended that if any of these

components need replacing, all three new
componentsshouldbeorderedat the same time
to avoidpossible mis-match of parts.

3-16 MAINTENANCE

9.2 GP360/GP380

41

40

39

38

37

36

34

35

31

28

27

23

21

22

19

18

17

14

13

2

3

1

4

16

15

30

29

26

25

24

20

33

32

12

756

8

11

10

9

Figure 3-14 Radio Exploded Mechanical View (GP360/GP380)

Mechanical Views and Parts Lists 3-17

Motorola

Item

Part

Description

Number

1 See Chapter6Antenna

2 3680529Z01 Knob, Volume
3 3680530Z01 Knob, Frequency
4 1380525Z03 Escutcheon, Top
5 3380644Z01 Escutcheon, Label
6 3280533Z01 Seal, Control Top
7 6180527Z01 Litepipe, Tx
8 1364279B04

1364279B05
9 1586059A01 Dust Cover,Universal

10 1386058A01 Escutcheon, Universal

Front, label GP360
Front, label GP380

Connector

Flex

Motorola

Item

Part

Description

Number

27 4280504Z01 Retainer, Speaker
28 1480503Z01 Boot, Backup Battery
29 6062884G01 Backup Battery
30 0304726J04 Screw
31 3980667Z01 Contact, finger
32 See Chapter6Back Cover Kit incl.

chassis main board

33 8480475Z02

8480475Z01

34 1480652Z01 Insulator, Antenna
35 7580556Z01 Pad, Thermal
36 3280534Z01 Seal, Contact

Flex, Keypad/Controller
GP360
Flex, Keypad/Controller
GP380

11 1580666Z04 Front Cover with Keypad

(DTMF)

12 Not Field

Replaceable
13 7580532Z01 Keypad, Side Control
14 1380528Z01 Bezel, Side Control
15 7580620Z05 Keypad
16 0104007J99 Keypad Board Assembly
17 7580540Z01 Pad, Display
18 5104949J07 LCD Module
19 7580637Z01 Pad, LCD Back
20 4280498Z01 Retainer, Keypad PCB
21 3586057A01 Felt Speaker
22 1480577C01 Boot, Microphone
23 5085962A02 Speaker
24 5013920A04 Microphone

Escutcheon, FM

37 3280536Z01 Gasket, O-Ring
38 3980698Z01 Contact, Ground,

Compliant
39 2780518Z01 Chassis
40 See Chapter6Battery

41 HLN9714 Beltclip

25 8480549Z01 Flex, UC
26 2113740A41 Capacitor, 33pF

3-18 MAINTENANCE

10.0 Service Aids

Table 3-1 lists service aids recommended for working on the GP300 Series Radios. While all of
these items are available from Motorola, most are standard shop equipment items, and any
equivalent item capable of the same performance may be substituted for the item listed.

Table 3-1 Service Aids

Motorola

Part No.

RLN4460_ Portable Test Set Enables connection to the audio/accessory

RKN4075_ Ribless Programming Cable Connects radio to Computer.
RKN4074_ Programming Cable/Test

Cable

RLN4008_ Radio Interface Box (RIB) Enables communications between the radio

HLN9756_ BNC Adaptor Adapts radio’s antenna port to BNC cabling

HKN9743_ MAP27 Cable Connects radio to computer for MAP27

HLN9742_ Flash Upgrade Adapter Provides connections to the computer or RIB

0180305G54 Shop Battery Eliminator Interconnects radio to power supply.
8180384F66 Bench Test Housing Eliminator

for long housing.

Description Application

jack. Allows switching for radio testing.

Connects radio to RIB (RLN4008_).

and the computer’s serial communications
adapter.

of test equipment.

applications in MPT requirements.

programming /test cable

Provides for troubleshooting of the radio
when the housing is removed.

8180384F68 Bench Test Housing Eliminator

for short housing.
RLN4510 Battery Eliminator 7.5V Interconnects radio to power supply.
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)
3080369B71 or

3080369B72

Computer Interface Cable Use B72 for the IBM PC AT. All other IBM

Provides for troubleshooting of the radio
when the housing is removed.

models use B71. Connects the computer’s
serial communications adapter to the RIB.
(RLN4008_)

Test Equipment 3-19

11.0 Test Equipment

Table 3-2 lists test equipment required to service the GP300 Series Radios and other two-way radios.

Table 3-2 Recommended Test Equipment

MotorolaPart

No.

R2600_NT Comms System

R2680_NT
to be ordered
with
RLN1022_ (H/W)
RLN1023_ (S/W)

*R1072_ Digital Multimeter AC/DC voltage and current

*R1377_ AC Voltmeter 100

WADN4133_ Delay

R1440_
0180305F22

0180305F30
0180305F39
RLN4610_

*T1013_

Description Characteristics Application

Analyzer
(non MPT)

Comms System
Analyzer
(MPT1327)

Oscilloscope

Wattmeter,
Plug-in Element

Plug-in Element
Plug-in Element
Carry case

RF Dummy Load

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

Thruline 50-Ohm,
accuracy
10W, 50 - 125 MHz
10W, 100 - 250 MHz
10W, 200 - 500 MHz
Wattmeter and
6elements

±5%

Frequency/deviation meter
and signal generator for
wide-range troubleshooting
and alignment

Frequency/deviation meter
and signal generator for
wide-range troubleshooting
and alignment

measurements
Audiovoltage

measurements

Waveform measurements

Transmitter power output
measurements

S1339_ RF Millivolt Meter 100mV to 3 VRF,

10 kHz to 1.2 GHz

S1348_ 220V Power

Supply

0-20V, 5A Programmable

RF level measurements

3-20 MAINTENANCE

12.0 Programming/Test Cable

1metre
Cable

1metre

Cable

Side
Connector

Figure 3-15 Programming T est/Cable

Internal
Connections

External Speaker + Brown

1

External Speaker - Dark Blue

2

Option B + Red

3

External Mic Grey

4

Option Select 2 Light Blue

5

Option Select 1 Tan

6

Ground Black

7

Receive Data Yellow

8

Transmit Data Pink

9

RSSI Orange

10

Tx Audio / Rx Audio Violet

11

Boot Control Green

12

Not Used White

13

Pin Outs

1
2
3
4
5
6
7
8
9
10
11
12
13

Figure 3-16 Pin Configuration of the Side Connector

Programming/Test Cable 3-21

25 Pos Male D
Connector

Side Connector

1

1

2
3
4
5
6
7
8
9
10
11
12
13

25 Pos Female
D Connector

15
1
4
11

5
2
7
8
15
20
16
9

18
25

Figure 3-17 Wiring of the Connectors

3-22 MAINTENANCE

1.0 Introduction

The receiver and transmitter performance tests are contained in Tables 4-1 and 4-2 respectively.
Refer to Chapter 5 for the test equipment set up. Note that all test measurements are taken at 25°C.

2.0 Receiver Performance Tests

The receiver performance tests are described in Table 4-1 below.

Table 4-1 Receiver Performance Checks

Chapter 4

PERFORMANCE TESTING

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
Monitor: Frequency error
InputatRFIn/Out

Output level: 1.0mV RF
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts

distortion
As above, except SINAD,

lower the RF level for 12dB
SINAD.

RF level set to 1mV RF As above PTT to OFF

As above, except change
frequency to a conventional
system. Raise RF level from
zero until radio unsquelches.

Radio Test Set Comments

TEST MODE,
Test Channel
4 carrier
squelch
output at
antenna

TEST MODE
Test Channel
4 carrier
squelch

As above As above Distortion 3.0%

As above PTT to OFF

out of TEST
MODE; select
a
conventional
system

PTT to
continuous
(during the
performance
check)

PTT to OFF
(centre), meter
selector to
Audio PA

(center)

(center), meter
selection to
Audio PA, spkr/
load to speaker

As above Unsquelchto occur at

Frequencyerror to be

±200Hz VHF
±600Hz UHF

Set volume control to

3.16Vrms

Typical
RF input to be

µV

0.25

Set volume control to

3.16Vrms

µV.

<0.25
Preferred SINAD =
9-10dB

4-2 PERFORMANCE TESTING

3.0 Transmitter Performance Tests

The transmitter performance tests are described in Table 4-2 below.

Table 4-2 Transmitter Performance Checks

Test Name

Reference
Frequency

Power RF As above As above As above Ref er to Mainte-

Voice
Modulation

Voice
Modulation
(internal)

Communications

Analyzer

Mode: PWR MON
Monitor: Frequency error
Input at RF In/Out

Mode: PWR MON
atten to -70, input to
RF In/Out
Monitor: DVM, AC Volts
Set1kHzModOutlevelfor

0.025Vrms at test set,
80mVrms at AC/DC test set
jack

Mode: PWR MON
atten to -70, input to RF
In/Out

Radio T est Set Comments

TEST MODE,
Test Channel
4carrier
squelch

As above As above,meter

TEST MODE,
Test Channel
4carrier
squelch
output at
antenna

PTT to continu­ous (during the
performance
check)

selector to mic

Remove
modulation
input

Frequencyerror to be

±200Hz VHF
±600Hz UHF

nance Specifications
Deviation:

VHF, UHF,

≥ 4.0kHz but
≤ 5.0kHz.

(25 kHz Ch Sp)

Press PTT switch on
radio. Say “four”
loudly into the radio
mic. Measure
deviation: VHF, UHF,

≥ 4.0kHz but
≤ 5.0kHz

(25 kHz Ch Sp)

DTMF
Modulation

PL/DPL
Modulation

As above, TEST MODE,

Test Channel
4DTMF
output at
antenna

As above
BW to narrow

TEST MODE,
Test
Channel 4
TPL
DPL

As above Deviation:

VHF, UHF,

≥ 3.05kHz but
≤ 3.45kHz

(25 kHz Ch Sp).

As above De v iation:

VHF, UHF,

≥500Hz but
≤ 1000Hz.

(25 kHz Ch Sp).

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_
Installation Card 68P64113B14_

2.0 Global Radio Tuning Setup

A personal computer (PC) using Windows 95/98 and a global 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 shown in Figure 5-1.

RF Adaptor
HLN9756

3.5 mm to
Ferrule BNC

20 dB Pad

Program / Test Cable

RKN 4074

+12VDC

Power

Supply

Battery
Eliminator

7.5V Reg.

RLN4510

Battery Block

0180305G54

Radio

Test Box

RLN4460

Transmit

Receive

Audio In

RF Generator

Tx

Audio Generator

Rx

ServiceMonitor

or Counter

Wattmeter

Sinad Meter

AC Voltmeter

AC Plug

120/230 Vac

RIB

RLN-4008

RIB Power Supply

DB15 DB9

Computer Interface
Cable 3080369B72

Figure 5-1 Radio Tuning Test Equipment Setup

Tx Data

Rx

Data

Gnd

5-2 RADIO TUNING AND PROGRAMMING

2.1 Initial Test Equipment Setup

The supply voltage is connected to the radio using a Motorola battery eliminator, P/N 0180305G54.
The initial test equipment (Figure 5-1) control settings are listed in Table 5-2.

NOTE

Refer to appropriate program on-line help files for the tuning procedures.

Table 5-2 Initial Equipment Control Settings

Service Monitor Test Set Power Supply

Monitor Mode: Power Monitor Speaker set: A Voltage: 7.5Vdc
RF Attenuation: -70 Speaker/load:

AM,CW,FM:FM PTT: OFF Volt Range: 10V
Oscilloscope Source: Mod

Oscilloscope Horizontal: 10mSec/Div
OscilloscopeVertical: 2.5kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: mid CW
Monitor Volume: 1/4 CW

3.0 CPS Programming Setup

Speaker

DC on/standby:
Standby

Current: 2.5A

The CPS programming setup, shown in Figure 5-2, is used to program the radio codeplug.

NOTE

Refer to appropriate program on-line help files for the codeplug programming procedures.

Battery
Block
0180305G54

+12VDC

Power
Supply

Radio

Battery
Eliminator

7.5V Reg.

RLN4510

Test Box

RLN4460

Program/

Test Cable

RKN4074

DB15

RIB

RLN4008

Computer Interface

Cable

3080369B72

RIB Power Supply

120/230 Vac

Ribless
Programming
Cable RKN4075

DB9

Tx Data

Rx
Data

Gnd

Figure 5-2 CPS Programming Setup

MODEL CHART AND TEST SPECIFICATION

1.0 Model Chart (UHF)

Professional GP300 Series (UHF)

Model Description

MDH25RDC9AN0_E GP320 UHF 403-470MHz 4W 1-Ch

MDH25RDC9AN3_E GP340 UHF 403-470MHz 4W 16-Ch

MDH25RDF9AN5_E GP360 UHF 403-470MHz 4W 255-Ch

MDH25RDH9AN6_E GP380 UHF 403-470MHz 4W 255-Ch

Chapter 6

Item Description

X
X

X
X

X
X

X
X

X 6864110B12_ GP320 Basic User Guide

X 6864110B13_ GP340 Basic User Guide

X 6864110B16_ GP360 Basic User Guide

X 6864110B18_ GP380 Basic User Guide
XXXX NAE6483_ UHFWhip(403-470MHz)Antenna
X X X X HNN9008_ Battery, NiMH Standard

x = Indicates one of each is required.

PMLE4140_
PMLN4253_

PMLE4137_
PMLN4216_

PMLE4141_
PMLN4302_

PMLE4138_
PMLN4304_

GP320 UHF Back Cover Kit
GP320 UHF Front Cover Kit

GP340 UHF Back Cover Kit
GP340 UHF Front Cover Kit

GP360 UHF Back Cover Kit
GP360 UHF Front Cover Kit

GP380 UHF Back Cover Kit
GP380 UHF Front Cover Kit

6-2 MODEL CHART AND TEST SPECIFICATION

2.0 Model Chart (VHF)

Professional GP300 Series (VHF)

Model Description

MDH25KDC9AN0_E GP320 VHF 136-174MHz 5W 1-Ch

MDH25KDC9AN3_E GP340 VHF 136-174MHz 5W 16-Ch

MDH25KDF9AN5_E GP360 VHF 136-174MHz 5W 255-Ch

MDH25KDH9AN6_E GP380 VHF 136-174MHz 5W 255-Ch

Item Description

X
X

X
X

X
X

X
X

X 6864110B12_ GP320 Basic User Guide

X 6864110B13_ GP340 Basic User Guide

X 6864110B16_ GP360 Basic User Guide

X 6864110B18_ GP380 Basic User Guide
XXXX PMAD4023_ VHF14cm(150-161MHz)Antenna
X X X X HNN9008_ Battery, NiMH Standard

x = Indicates one of each is required.

PMLD4121_
PMLN4253_

PMLD4117_
PMLN4216_

PMLD4119_
PMLN4302_

PMLD4118_
PMLN4304_

GP320 VHF Back Cover Kit
GP320 VHF Front Cover Kit

GP340 VHF Back Cover Kit
GP340 VHF Front Cover Kit

GP360 VHF Back Cover Kit
GP360 VHF Front Cover Kit

GP380 VHF Back Cover Kit
GP380 VHF Front Cover Kit

Model Chart (LB) 6-3

3.0 Model C har t (LB)

Professional GP300 Series (LB)

Model Description

MDH25BEC9AN3_E GP340 LB1 29.7-42 MHz 6W 16-Ch

MDH25BEH9AN6_E GP380 LB1 29.7-42 MHz 6W 255-Ch

MDH25CEC9AN3_E GP340 LB2 35-50 MHz 6W 16-Ch

MDH25CEH9AN6_E GP380 LB2 35-50 MHz 6W 255-Ch

Item Description

X
X

X
X

X
X

X
X

X X 6864110B13_ GP340 Basic User Guide

X X 6864110B18_ GP380 Basic User Guide
XXXX NAB6064_ Low/MidBand(29-50MHz)Heliflex,TrimmableAntenna
X X X X HNN9008_ Battery, NiMH Standard

PMLB4006_
PMLN4216_

PMLB4016_
PMLN4304_

PMLB4012_
PMLN4216_

PMLB4017_
PMLN4304_

GP340 LB1 Back Cover Kit
GP340 LB1 Front Cover Kit

GP380 LB1 Back Cover Kit
GP380 LB1 Front Cover Kit

GP340 LB2 Back Cover Kit
GP340 LB2 Front Cover Kit

GP380 LB2 Back Cover Kit
GP380 LB2 Front Cover Kit

6-4 MODEL CHART AND TEST SPECIFICATION

4.0 Model Chart (300R1)

Professional GP300 Series (300R1)

Model Description

MDH25EDC9AN3_E GP340 300R1 300-350 MHz 4W

Item Description

X
X

X 6864110B13_ GP340 Basic User Guide
X PMAD4022_ VHF 9cm (300-344 MHz) Antenna
X HNN9008_ Battery, NiMH Standard

x = Indicates one of each is required.

PMLD4141_
PMLN4216_

GP340 300R1 Back Cover Kit
GP340 300R1 Front CoverKit

Specifications - Professional GP300 Series Radios 6-5

5.0 Specifications - Professional GP300 Series Radios

Data is specified for +25°C unless otherwise stated.

General Specifications

Channel Capacity

GP320
GP340
GP360
GP380

Power Supply Rechargeable battery 7.5v
Dimensions: H x W x D (mm)

With standard high capacity NiMH battery
With ultra high capacity NiMH battery
With NiCD battery
With Lilon battery

Weight:(gm)

With Standard high capacity NiMH battery
With Ultra high capacity NiMH battery
With NiCD battery
With Lilon battery

Average Battery Life @5/5/90 Cycle:

With Standard high capacity NiMH battery
With Ultra high capacity NiMH battery
With NiCD battery
With Lilon battery

Sealing: Withstands rain testing per

Shock and Vibration: Protection provided via impact

Dust and Humidity: Protection provided via environment

1
16
255
255

Height excluding knobs
137 x 57.5 x 37.5
137 x 57.5 x 40.0
137 x 57.5 x 40.0
137 x 57.5 x 33.0

GP320/GP340 GP360/GP380

420 428
500 508
450 458
350 358

Low Power High Power
11 hours 8 hours
14 hours 11 hours
12 hours 9 hours
11 hours 8 hours

MIL STD 810 C/D /E and IP54

resistant housing exceeding MIL STD
810-C/D /E and TIA/EIA 603

resistant housing exceeding MIL STD
810 C/D /E and TIA/EIA 603

6-6 MODEL CHART AND TEST SPECIFICATION

Transmitter UHF/VHF/300R1 LB

VHF 136-174 MHz

*Frequencies - Full Bandsplit

Channel Spacing 12.5/20/25 kHz

Frequency Stability
(-25°Cto+55°C, +25° Ref.)

Power

Modulation Limiting

FM Hum & Noise -40 dB typical

Conducted/Radiated Emission

Adjacent Channel Power

Audio Response (300 - 3000 Hz) +1 to -3 dB

Audio Distortion

UHF 403-470 MHz
300R1 300-350MHz

±2.5 ppm @ 12.5kHz

±5.0 ppm @ 25 kHz

±5.0 ppm (300R1)

136 - 174 MHz: 1-5W
403 - 470 MHz: 1-4W
300 - 350 MHz: 1-4W

±2.5 @ 12.5 kHz

±4.0 @ 20 kHz
±5.0 @ 25 kHz

-36 dBm <1 GHz

-30 dBm >1 GHz

-60 dB @ 12.5 kHz

-70 dB @ 25 kHz

<5% typical (300R1)

LB1 29.7-42 MHz
LB2 35-50 MHz

<3% typical

±10ppm

1-6W

Receiver UHF/VHF/300R1 LB

*Frequencies - Full Bandsplit

Channel Spacing 12.5/20/25 kHz
Sensitivity (12 dB SINAD) EIA

Sensitivity (20 dB SINAD) ETS
Intermodulation EIA 65 dB

Adjacent Channel Selectivity
Spurious Rejection >70 dB

Rated Audio 0.5W
Audio Distortion @ Rated Audio <3% typical

Hum & Noise
Audio Response (300 - 3000 Hz) +1 to -3 dB

Conducted Spurious Emission

VHF 136-174 MHz
UHF 403-470 MHz
300R1 300-350 MHz

0.25 µV typical

0.35 µV typical (300R1)

0.50 µV typical

60 dB @ 12.5 kHz

70 dB @ 25 kHz

-45dB@12.5kHz

-50 dB @ 20/25 kHz

-57 dBm <1 GHz

-47 dBm >1 GHz
ETS 300 086

LB1 29.7-42 MHz
LB2 35-50 MHz

*Availability subject to the laws and regulations of individual countries.

1.0 Error Codes

Turning on the radio starts a self-test routine that checks the radio functionality. If the checks are
successful, the radio generates a high-pitched self-test pass tone. If the self-test is not successful,
one low-pitched (300Hz) error tone is heard and the RED LED flashes several times to indicate the
reason for the failure (see Table 7-1 below). After flashing the error code, the LED remains off for 5
seconds and then repeats the error code. 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 7-1.

Chapter 7

POWER UP SELF-TEST

Table 7-1 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. Turnthe radio off then on again. If the

The LED

flashes...

then, there is a... To correct the problem...

Reprogram codeplug. If message
possibly codeplug structure
mismatch or non-existant
codeplug.

corrupted.

re-occurs, replace main board or

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

7-2 POWER UP SELF-TEST