Motorola GP300 Service manual

4.5 (2)

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.

iii

SAFETY INFORMATION

Read this information before using your radio.

SAFE AND EFFICIENT OPERATION OF MOTOROLA TWO-WAY RADIOS

This document provides information and instructions for the safe and efficient operation of Motorola Portable and Mobile Two-Way Radios. The information provided in this document supersedes the general safety information contained in user guides published prior to 1 January 1998.

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

EXPOSURE TO RADIO FREQUENCY ENERGY

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

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

American National Standards Institute (C95.1 - 1992)

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

International Commission on Non-Ionizing Radiation Protection (ICNRP1986)

European Committee for Electrotechnical Standardization (CENELEC):

- ENV 50166-1 1995 E

Human exposure to electromagnetic fields Low

 

frequency (0 Hz to 10 kHz)

- ENV 50166-2 1995 E

Human exposure to electromagnetic fields High

 

frequency (10 kHz to 300 GHz)

- Proceedings of SC211/B 1996

“Safety Considerations for Human Exposure to EMFs from

 

Mobile Telecommunication Equipment (MTE) in the Fre-

 

quency 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

2.5 to 5.0 cm (1 to 2 in.)

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

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

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 deploy-

!ment area. Air bags inflate with great force. If a portable radio is placed in the air bag deployment area and the air bag inflates, the radio may be propelled with great force and cause serious injury to occupants of 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 injury or even death.

Batteries

WARNING: Do not replace or recharge batteries in a potentially explosive atmosphere. Con-

!tact 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” or in areas posted “turn off two-way radio”, obey all signs and instructions.

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

OPERATIONAL CAUTIONS

Damaged antennas

CAUTION: Do not use any portable two-way radio that has a damaged antenna. If a damaged

!antenna comes into contact with your skin, a minor burn can result.

Batteries

CAUTION: All batteries can cause property damage 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.

v

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 Equipment................................................................................

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

Chapter 3

MAINTENANCE

 

1.0

Introduction..........................................................................................................

3-1

2.0

Preventive Maintenance ......................................................................................

3-1

 

2.1

Inspection.......................................................................................................

3-1

 

2.2

Cleaning Procedures......................................................................................

3-1

3.0

Safe Handling of CMOS and LDMOS Devices....................................................

3-2

4.0

Repair Procedures and Techniques — General..................................................

3-3

5.0

Disassembling and Reassembling the Radio — General....................................

3-3

6.0

Radio Disassembly — Detailed ...........................................................................

3-4

 

6.1

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 PROGRAMMING

 

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 Chart (LB) ..................................................................................................

6-3

4.0

Model Chart (300R1)............................................................................................

6-4

5.0

Specifications - Professional GP300 Series Radios ............................................

6-5

Chapter 7 POWER UP SELF-TEST

 

1.0

Error Codes ..........................................................................................................

7-1

Chapter 1

INTRODUCTION

1.0Scope 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.

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

2.0Warranty and Service Support

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

2.1Warranty Period and Return Instructions

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

In instances where the product is covered under a "return for replacement" or "return for repair" warranty, a check of the product should be performed prior to shipping the unit back to Motorola. This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty.

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

2.2After Warranty Period

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

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

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

1-2

INTRODUCTION

 

 

2.3European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:

Austria:

06 60 75 41

Italy:

16 78 77 387

Belgium:

08 00 72 471

Luxemburg:

08 00 23 27

Denmark:

80 01 55 72

Netherlands:

60 22 45 13

Finland:

08 00 11 49 10

Norway:

80 01 11 15

France:

05 90 30 90

Portugal:

05 05 49 35 70

Germany:

01 30 18 75 24

Spain:

90 09 84 902

Greece:

00 80 04 91 29 020

Sweden:

02 07 94 307

UK:

08 00 96 90 95

Switzerland:

1 55 30 82

Ireland:

18 00 55 50 21

Iceland:

80 08 147

Or dial Customer Care Centre:

Tel: +49 6128 70 2618

Please use these numbers for repair enquiries only

2.4Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly. If a complete Motorola part number is assigned to the part, it is available from Motorola Radio Aftermarket and Accessory Division (AAD). If no part number is assigned, the part is not normally available from Motorola. If the part number is appended with an asterisk, the part is serviceable by Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable parts are available for that kit or assembly.

All enquiries should be directed to:

Motorola GmbH

European Parts Department

65232 Taunusstein

Germany.

Warranty and Service Support

1-3

 

 

2.5Technical Support

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

UK/Ireland - Richard Russell

Telephone: +44 (0) 1256 488 082

Fax: +44 01256 488 080

Email: BRR001@email.mot.com

Central/East Europe - Siggy Punzenberger

Telephone: +49 (0) 6128 70 2342

Fax: +49 (0) 6128 95 1096

Email: TFG003@email.mot.com

Scandinavia - Bjorn Rambert

Telephone: +46 8 735 9282

Fax: +46 8 735 9280

Email: TCW275X@email.mot.com

Germany - Karin Struck

Telephone: +49 (0) 6128 70 2248

Fax: +49 (0) 6128 95 1082

Email: CKS026@email.mot.com

France - Lionel Lhermitte

Telephone: +33 1 6929 5722

Fax: +33 1 6929 5904

Email: TXE037@email.mot.com

Italy - Ugo Gentile

Telephone: +39 0 2822 0325

Fax: +39 0 2822 0334

Email: C13864@email.mot.com

Africa & Middle East - Ralph Schubert

Telephone: +33 (0)4 4230 5887

Fax: +33 (0)4 4230 4784

Email: ralph.schubert@Motorola.com

Motorola GP300 Service manual

1-4

INTRODUCTION

 

 

3.0Radio Model Information

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

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

 

Type of

Model

 

Unit

Series

MD

H

25

Internal Use

H = Portable

MD = Motorola

 

Freq.

Power

Physical

Channel

Protocol

Feature

Model

Model

Band

Level

Packages

Spacing

Level

Revision

Package

 

K

D

C

9

AA

O

A

E

VHF

4-5W

GP140,

Program-

Conventional

GP320

 

 

(136-

 

GP320,

mable

MDC

 

 

 

174MHz)

 

GP340,

 

 

 

 

 

 

 

GP640.

 

 

 

 

 

 

 

 

 

 

 

 

 

R

E

H

AN

3

UHF1

5-6W

GP380,

Conventional

GP140,

(403-

 

GP680

5 Tone

GP340,

470MHz)

 

 

 

GP640.

S

 

N

 

CK

5

UHF2

 

GP1280

 

MPT

GP360

(450-527

 

 

 

 

 

MHz)

 

 

 

 

 

 

 

 

 

 

 

B

 

F

 

PW

6

LB1

 

GP360

 

MPT/5T

GP380,

29-42MHz

 

 

 

 

GP680

 

 

 

 

 

 

C

 

 

 

 

8

LB2

 

 

 

 

GP1280

35-50MHz

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

300R1

 

 

 

 

 

(300-

 

 

 

 

 

350MHz)

 

 

 

 

 

 

 

 

 

 

 

Chapter 2

INTRINSICALLY SAFE RADIO INFORMATION

1.0FMRC 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

FM

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

APPROVED

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.

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 replace 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 Product 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: Do 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

 

 

2.0Repair 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 is 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:

2.1Repair

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.

2.2Relabelling

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 Approved unit.

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

 

 

2.3Do 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, even if 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

 

 

Chapter 3

MAINTENANCE

1.0Introduction

This chapter provides details about the following:

Preventive maintenance (inspection and cleaning)

Safe handling of CMOS and LDMOS devices

Disassembly and reassembly of the radio

Repair procedures and techniques

Installation of Option Boards

2.0Preventive Maintenance

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

2.1Inspection

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

2.2Cleaning Procedures

The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the radio. External surfaces include the front cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime.

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

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

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.

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