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.