Motorola GP1280 Series Basic Service Manual Download Page 38 | Manualshive

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MAINTENANCE

9.4

GP388

Figure 3-17

Radio Exploded Mechanical View (GP388)

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Summary of Contents for GP1280 Series

Page 1: ...Professional Radio GP300 Series Basic Service Manual 68P64115B18C Issue Nov 2001 ...

Page 2: ...he 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 prod ucts shall not be deemed to grant either directly or by implication estoppel or otherwise any license under the co...

Page 3: ...quency Range from 3 kHz to 300 GHz 1999 Australian Communications Authority Radiocommunications Electromagnetic Radiation Human Exposure Standard 1999 applicable to wireless phones only To assure optimal radio performance and make sure human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards always adhere to the following procedures Phone o...

Page 4: ... the radio is turned ON not carry the radio in the breast pocket use the ear opposite the pacemaker to minimize the potential for interference turn the radio OFF immediately if you have any reason to suspect that interference is taking place Hearing Aids Some digital wireless radios may interfere with some hearing aids In the event of such interference you may want to consult your hearing aid manu...

Page 5: ... 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 WARNING To avoid ...

Page 6: ...vi SAFETY INFORMATION ...

Page 7: ...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 Con...

Page 8: ... 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 3 3 0 Model Chart LB 6 4 4 0 Model Chart 300R1 6 5 5 ...

Page 9: ... 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 appropr...

Page 10: ...ial Customer Care Centre Tel 49 6128 70 2618 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 fro...

Page 11: ... 2342 Fax 49 0 6128 95 1096 Email TFG003 email mot com Scandinavia Telephone 46 8 735 9282 Fax 46 8 735 9280 Email TCW275X email mot com Germany Customer Connect Team Telephone 49 0 6128 70 2248 Fax 49 0 6128 95 1082 Email cgiss emea europe 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...

Page 12: ...ype of Unit Model Series Freq Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package MD H 25 GP140 GP320 GP340 GP640 GP360 GP380 GP680 GP1280 38 GP344 GP388 K VHF 136 174MHz D 4 5W C GP140 GP320 GP340 GP344 GP640 9 Program mable AA Conventional MDC O GP320 A E R UHF1 403 470MHz E 5 6W H GP380 GP388 GP680 AN Conventional 5 Tone 3 GP140 GP340 GP344 GP6...

Page 13: ...ne by the original product manufacturer at one of its FMRC audited manufacturing facilities Unauthorized or incorrect modification of an FMRC Approved Product unit will negate the Approval rating of the product 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 WARNI...

Page 14: ...g 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 ...

Page 15: ... 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...

Page 16: ...2 4 INTRINSICALLY SAFE RADIO INFORMATION ...

Page 17: ...de 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 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 ...

Page 18: ...r to prevent contamination by dissolved material from previous usage 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 t...

Page 19: ...ible 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 siz...

Page 20: ...aph 6 3 Speaker Microphone and Universal Connector Flex Disassembly Paragraph 6 4 PTT Disassembly Paragraph 6 5 Controller Board Disassembly GP344 GP388 Paragraph 6 6 Control Top Disassembly Paragraph 6 7 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...

Page 21: ...is prying action forces the thin inner plastic wall toward the base of the radio releasing the two chassis base tabs 6 Lay the chassis down Rotate the front cover backward and slightly away from the chassis Figure 3 2 Knob Removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts Figure 3 3 Chassis Removal CAUTION Marring the front cover O ring sealing ...

Page 22: ...nt 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 Figure 3 4 Unlatch Flex Connectors Figure 3 5 Remove Main Board from Chassis 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 Latches Flex Connectors Flex Connector Latch GP...

Page 23: ...speaker Lift the keypad retainer out of the front cover then lift and pivot the two hooks out of the front cover 5 If disassembly 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 pro cess for releasing the flexes 6 The display module is attached to the front cover with a double...

Page 24: ...rsal connector tail of the speaker microphone assembly through its opening in the front cover 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 NOTE The dustcover must be removed to remove the speaker microphone assembly flex circuit The speaker is held in place with a two legged ...

Page 25: ...ll screwdriver as follows 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 c The PTT seal can be easily lifted from the bezel without the use of tools Figure 3 8 Removal Speaker Microphone Assembly Figure 3 9 PTT Removal Speaker ...

Page 26: ...eon 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 Control Top Reassembly 1 Replace transmit light pipe and control top seal 2 Place a new control top escutcheon adhesive against the fro...

Page 27: ...ront 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 5 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 GP360 380 item number 14 GP388 on the exploded view diagram 2 Replace the...

Page 28: ...enna 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 7 Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis Figure 3 11 Lock retainer catches to the radio s body NOTE When properly assembled the retainers on the O ring should align with the slots on the chassis I...

Page 29: ...s 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 F...

Page 30: ...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 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...

Page 31: ...r 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 7 Chassis and Front Cover Reassembly ...

Page 32: ...TENANCE 9 0 Mechanical Views and Parts Lists 9 1 GP320 GP340 Figure 3 14 Radio Exploded Mechanical View GP320 GP340 8 9 10 11 12 13 14 15 16 18 19 20 21 22 24 23 25 26 27 28 29 30 31 33 34 35 7 5 6 2 3 4 1 32 17 ...

Page 33: ...Z06 Front Cover GP320 12 Not Field Replaceable Escutcheon FM 13 7580532Z01 7580532Z03 Keypad Side Control GP340 Keypad Side Control GP320 14 1380528Z01 1380528Z03 Bezel Side Control GP340 Bezel Side Control GP320 4285672Z01 Retaining clip GP320 15 7580620Z03 7580620Z04 Keypad Blank Keypad Full 16 0104007J99 Keypad Board Assembly 17 4280498Z01 Retainer Keypad PCB 18 3586057A01 Felt Speaker 19 14805...

Page 34: ...3 18 MAINTENANCE 9 2 GP360 GP380 Figure 3 15 Radio Exploded Mechanical View GP360 GP380 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 26 28 29 30 31 32 33 34 35 36 37 39 40 41 7 5 6 2 3 4 1 38 ...

Page 35: ...embly 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 25 8480549Z01 Flex UC 26 2113740A41 Capacitor 33pF 27 4280504Z01 Retainer Speaker 28 1480503Z01 Boot Backup Battery 29 6062884G01 Backup Battery 30 0304726J04 Screw 31 3980667Z01...

Page 36: ...3 20 MAINTENANCE 9 3 GP344 Figure 3 16 Radio Exploded Mechanical View GP344 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 5 1 2 3 4 ...

Page 37: ... Knob 10 1302012P06 Top Plastic Plate 11 3385906Z01 Top Sheet 12 3202000P15 Top Seal Rubber 13 3502416P03 Speaker Mesh 14 Part of Item 7 PTT Rubber 15 Part of Item 7 PTT Plastic Cover 16 5005679X01 Speaker 17 1480577C01 Boot Microphone 18 8404079G01 Flex PCB Universal 19 8404051G07 Controller Board 20 0385913Z01 4 M2x4 Philips Screws 21 0302020P05 1 M2x1 Philips Screw 22 8404078G01 Flex PCB RF Con...

Page 38: ...3 22 MAINTENANCE 9 4 GP388 Figure 3 17 Radio Exploded Mechanical View GP388 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 4 1 5 1 6 1 7 1 8 2 0 1 9 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 1 3 ...

Page 39: ... 7580540Z01 LCD Front Pad 15 5104949J11 LCD Module 16 7586096Z01 Main Keypad 17 4086199Z01 Keypad Polydome 18 8404056G01 Controller Board 19 8404078G01 Flex RF Controller 20 3586092Z01 Speaker Felt 21 1480577C01 Microphone Boot 22 5013920A04 Microphone 23 5086094Z01 Speaker 24 8486095Z01 Flex Universal Connector 25 4286097Z01 Keypad Retainer 26 0386104Z01 Screw 27 1480503Z01 Backup Battery Boot 28...

Page 40: ...t to BNC cabling of test equipment HKN9743_ MAP27 Cable Connects radio to computer for MAP27 applications in MPT requirements HLN9742_ Flash Upgrade Adapter Provides connections to the computer or RIB programming test cable 0180305G54 Shop Battery Eliminator Interconnects radio to power supply 8180384F66 Bench Test Housing Eliminator for long housing Provides for troubleshooting of the radio when ...

Page 41: ...risk Frequency deviation meter and signal generator for wide range troubleshooting and alignment R1072_ Digital Multimeter AC DC voltage and current measurements R1377_ AC Voltmeter 100 µV to 300 V 5Hz 1MHz 10 Megohm input impedance Audio voltage measurements WADN4133_ Delay Oscilloscope 2 Channel 40 MHz bandwidth 5 mV cm 20 V cm Waveform measurements R1440_ 0180305F22 0180305F30 0180305F39 RLN461...

Page 42: ... 340 360 380 RKN4074_ GP344 388 JMKN4123_ External Speaker Brown 1 1 External Speaker Dark Blue 2 2 Option B Red 3 3 External Mic Grey 4 4 Option Select 2 Light Blue 5 5 Option Select 1 Tan 6 6 Ground Black 7 7 Receive Data Yellow 8 8 Transmit Data Pink 9 9 RSSI Orange 10 10 Tx Audio Rx Audio Violet 11 11 Boot Control Green 12 12 Not Used White 13 13 Internal Connections Pin Outs ...

Page 43: ...5 GP320 340 360 380 1 2 5 7 8 9 16 18 19 20 21 22 25 15 AUDIO AUDIO MIC AUDIO GND VOL CTRL DISC PTT OPT SEL INT EXT BOOT CTRL 1 4 15 25 11 GND BIAS BUS BOOT CTRL BUS 1 2 3 4 5 6 8 9 10 11 12 13 7 EXT SPKR EXT SPKR OPTION B EXT MIC OPT SEL 2 OPT SEL 1 RX DATA TX DATA RSSI XMIT RX AUDIO BOOT CTRL N C GND P2 TO RADIO TEST SET RLN4460 P1 TO RADIO UNIVERSAL CONNECTOR J1 TO RIB RLN4008 10K GP344 388 ...

Page 44: ...3 28 MAINTENANCE ...

Page 45: ...0mV RF Mod 1kHz tone at 3kHz deviation Monitor DVM AC Volts TEST MODE Test Channel 4 carrier squelch PTT to OFF centre meter selector to Audio PA Set volume control to 3 16Vrms GP320 340 360 380 3 46Vrms GP344 388 Distortion As above except to distortion As above As above Distortion 3 0 Typical Sensitivity SINAD As above except SINAD lower the RF level for 12dB SINAD As above PTT to OFF center RF ...

Page 46: ...70 input to RF In Out Monitor DVM AC Volts Set 1kHz Mod Out level for 0 025Vrms at test set 80mVrms at AC DC test set jack As above As above meter selector to mic Deviation VHF UHF 4 0kHz but 5 0kHz 25 kHz Ch Sp Voice Modulation internal Mode PWR MON atten to 70 input to RF In Out TEST MODE Test Channel 4 carrier squelch output at antenna Remove modulation input Press PTT switch on radio Say four ...

Page 47: ...ed to the PC radio interface box RIB and test equipment shown in Figure 5 1 Figure 5 1 Radio Tuning Test Equipment Setup NOTE Refer to the appropriate program on line help files for the programming procedures Description Kit Number EMEA CD ENLN4115_ Installation Card 68P64113B14_ Wattmeter Audio Generator Sinad Meter AC Voltmeter 20 dB Pad Battery Block Power Supply Audio In Tx Rx Receive T ransmi...

Page 48: ...r Speaker set A Voltage 7 5Vdc RF Attenuation 70 Speaker load Speaker DC on standby Standby AM CW FM FM PTT OFF Volt Range 10V Oscilloscope Source Mod Oscilloscope Horizontal 10mSec Div Oscilloscope Vertical 2 5kHz Div Oscilloscope Trigger Auto Monitor Image Hi Monitor BW Nar Monitor Squelch mid CW Monitor Volume 1 4 CW Current 2 5A NOTE Refer to appropriate program on line help files for the code...

Page 49: ...er Kit X X PMLE4137_ PMLN4216_ GP340 UHF Back Cover Kit GP340 UHF Front Cover Kit X X JMHE4001_ PMHE4006_ GP344 UHF Back Cover Kit GP344 UHF Front Cover Kit X X PMHE4004_ PMHE4008_ GP344 UHF2 Back Cover Kit GP344 UHF2 Front Cover Kit X X PMLE4141_ PMLN4302_ GP360 UHF Back Cover Kit GP360 UHF Front Cover Kit X X PMLE4138_ PMLN4304_ GP380 UHF Back Cover Kit GP380 UHF Front Cover Kit X X PMHE4010_ PM...

Page 50: ... X X NAE6483_ UHF Whip 403 470 MHz Antenna X PMAE4008_ UHF2 Whip 450 527 MHz Antenna X X X JMNN4023__ Battery Li Ion Standard X X X X HNN9008_ Battery NiMH Standard Professional GP300 Series UHF Model Description x Indicates one of each is required ...

Page 51: ... VHF Front Cover Kit X X JMHD4005_ PMHD4004_ GP344 VHF Back Cover Kit GP344 VHF Front Cover Kit X X PMLD4119_ PMLN4302_ GP360 VHF Back Cover Kit GP360 VHF Front Cover Kit X X PMLD4118_ PMLN4304_ GP380 VHF Back Cover Kit GP380 VHF Front Cover Kit X X PMHD4006_ PMHD4005__ GP388 VHF Back Cover Kit GP388 VHF Front Cover Kit X 6864110B12_ GP320 Basic User Guide X 6864110B13_ GP340 Basic User Guide X 68...

Page 52: ...Description X X PMLB4006_ PMLN4216_ GP340 LB1 Back Cover Kit GP340 LB1 Front Cover Kit X X PMLB4016_ PMLN4304_ GP380 LB1 Back Cover Kit GP380 LB1 Front Cover Kit X X PMLB4012_ PMLN4216_ GP340 LB2 Back Cover Kit GP340 LB2 Front Cover Kit X X PMLB4017_ PMLN4304_ GP380 LB2 Back Cover Kit GP380 LB2 Front Cover Kit X X 6864110B13_ GP340 Basic User Guide X X 6864110B18_ GP380 Basic User Guide X X X X NA...

Page 53: ...ption MDH25EDC9AN3_E GP340 300R1 300 350 MHz 4W Item Description X X PMLD4141_ PMLN4216_ GP340 300R1 Back Cover Kit GP340 300R1 Front Cover Kit 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 ...

Page 54: ...0 Weight gm With Standard high capacity NiMH battery With Ultra high capacity NiMH battery With NiCD battery With Lilon battery GP320 GP340 GP360 GP380 420 428 500 508 450 458 350 358 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 Low Power High Power 11 hours 8 hours 14 hours 11 hours 12 hours 9...

Page 55: ...Emission 36 dBm 1 GHz 30 dBm 1 GHz Adjacent Channel Power 60 dB 12 5 kHz 70 dB 25 kHz Audio Response 300 3000 Hz 1 to 3 dB Audio Distortion 3 typical 5 typical 300R1 Receiver UHF VHF 300R1 LB Frequencies Full Bandsplit VHF 136 174 MHz UHF 403 470 MHz 300R1 300 350 MHz LB1 29 7 42 MHz LB2 35 50 MHz Channel Spacing 12 5 20 25 kHz Sensitivity 12 dB SINAD EIA Sensitivity 20 dB SINAD ETS 0 25 µV typica...

Page 56: ...55 5 x 35 5 101 5 x 55 5 x 38 0 Weight gm With Standard Lilon battery With high capacity Lilon battery GP344 GP388 250 265 270 285 Average Battery Life 5 5 90 Cycle With Standard Lilon battery With high capacity Lilon battery Low Power High Power 9 hours 7 hours 13 hours 10 hours Sealing Withstands rain testing per MIL STD 810 C D E and IP54 Shock and Vibration Protection provided via impact resis...

Page 57: ...gh 5W Low 1W High 4W Spurs Harmonics 36 dBm 1 GHz 30 dBm 1 GHz FM Hum Noise 40 dB typical Audio Response 300 3000 Hz 1 to 3 dB Audio Distortion 5 typical Receiver VHF UHF1 UHF2 Frequencies Full Bandsplit VHF 136 174 MHz UHF1 403 470 MHz UHF2 450 527 MHz Channel Spacing 12 5 20 25 kHz Sensitivity 12 dB SINAD EIA 0 35 µV typical Intermodulation ETS 65 dB Adjacent Channel Selectivity 60 dB 12 5 kHz 7...

Page 58: ...6 10 MODEL CHART AND TEST SPECIFICATION ...

Page 59: ...eturn it to the nearest Motorola depot Test 2 Failed Twice Select 5 Application Vector corrupted Reprogram codeplug and retest the radio Test 3 Failed Three times Codeplug Checksum error Reprogram codeplug and retest the radio Test 4 Failed Four times Codeplug Version Error Reprogram codeplug using the correct version and retest the radio Test 5 Failed Five times ROM Checksum test failure Turn rad...

Page 60: ...7 2 POWER UP SELF TEST ...

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