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Radio Disassembly — Detailed

3-5

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.

3.

Remove the antenna.

Figure 3-1

Battery Removal

Battery Release
Buttons

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Summary of Contents for GP200 Series

Page 1: ...Professional Radio GP200 500 Series Basic Service Manual 68P64115B64 ...

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: ...sion on Non Ionizing Radiation Protection ICNIRP 1998 Ministry of Health Canada Safety Code 6 Limits of Human Exposure to Radiofrequency Electromagnetic Fields in the Frequency 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...

Page 4: ...ndations are consistent with those of the U S Food and Drug Administration Persons with pacemakers should ALWAYS keep the radio more than 15 cms from their pacemaker when 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 t...

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: ...troduction 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 4 6 0 Radio Disassembly Detailed 3 5 6 1 Front Cover from Chassis Disassembly 3 5 6 2 Chassis Assembly Disassembly 3 7 6 3 Keypad Display and Keypad Option...

Page 8: ...r Performance Tests 4 5 5 0 Transmitter Performance Tests 4 6 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 800 MHz 6 1 2 0 Model Chart UHF 403 470 MHz 6 2 3 0 Model Chart VHF 136 174 MHz 6 3 4 0 Specifications Professional ...

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: ...er Care Centre Tel 49 6128 70 2618 Please use these numbers for repair enquiries only 2 4 Parts Identification and Ordering Request for help in identification of non referenced spare parts should be directed to the Customer Care Organisation of Motorola s local area representation Orders for replacement parts kits and assemblies should be placed directly on Motorola s local distribution organisati...

Page 11: ...n Regional Repair Operations Telephone 7 095 785 01 89 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: ...ic characteristics Table 1 1 Radio Model Number Example MDH25RDC9GB3AE Type of Unit Model Series Freq Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package MD H 25 GP240 GP280 GP540 GP580 R UHF1 403 470MHz D 4 5W C GP240 GP540 9 Program mable FB Privacy Plus 3 GP240 GP540 A E P 300 400 MHz C 3W H GP280 GP580 6 Non Pro gramma ble FC Smart Zone 6 GP28...

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: ...it 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 e...

Page 20: ...tely 1 8 0 3cm above the shield Turn on the heater and wait until the shield lifts off the circuit board Once the shield is off turn off the heat grab the part with a pair of tweezers and turn off the vacuum pump Remove the circuit board from the R 1070 s circuit board holder To replace the shield add solder to the shield if necessary using a micro tipped soldering iron Next rub the soldering iron...

Page 21: ...ector 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 3 Remove the antenn...

Page 22: ... 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 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 fr...

Page 23: ...our 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 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 w...

Page 24: ...pad 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 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 sided adhesive pad Careful...

Page 25: ...rd away from the front cover and remove the universal 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 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 secur...

Page 26: ...PTT seal assembly can be disassembled using a small 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 Mi...

Page 27: ...connector tail of the speaker microphone flex assembly through the open ing in the side wall of the front cover 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...

Page 28: ...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 7 Use the T6 TORX screwdriver to fasten the screws holding the main board to the chassis NOTE Pull the speaker microphone flex circuit out of ha...

Page 29: ...ches 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 ...

Page 30: ... 8 0 Mechanical Views and Parts Lists 8 1 GP240 GP540 Figure 3 12 Radio Exploded Mechanical View GP240 GP540 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 ZMY0130405 O ...

Page 31: ...pad Side Control 14 1386324Z01 Bezel Side Control 15 7585265Z03 Keypad Blank 16 0104007J99 Keypad Board Assembly 17 4286266Z01 Retainer Keypad PCB 18 3586057A01 Felt Speaker 19 1480577C01 Boot Microphone 20 5085738Z03 Speaker 21 5013920A04 Microphone 22 8480549Z06 Flex UC 23 2113740A41 Capacitor 33pF 24 4280504Z01 Retainer Speaker 25 0304726J04 Screw 26 See Chapter 6 Back Cover Kit incl chassis ma...

Page 32: ...3 16 MAINTENANCE 8 2 GP280 GP580 Figure 3 13 Radio Exploded Mechanical View GP280 GP580 8 9 10 11 12 13 14 15 16 17 18 19 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 20 ...

Page 33: ...Dust Cover Universal Connector 10 1386058A01 Escutcheon Universal Flex 11 1586335Z02 Front Cover Display with Full Keypad DTMF 12 Not Field Replaceable Escutcheon FM 13 7580532Z01 Keypad Side Control 14 1386324Z01 Bezel Side Control 15 7586265Z03 Keypad 16 0104007J99 Keypad Board Assembly 17 7580540Z01 Pad Display 18 5104949J07 LCD Module 19 7580637Z01 Pad LCD Back 20 4286266Z01 Retainer Keypad PC...

Page 34: ...ables communications between the radio and the computer s serial communications adapter 5885705M01 BNC Adaptor Adapts radio s antenna port to BNC cabling of test equipment 5880384G68 SMA to BNC Adaptor Adapts radio s antenna port to BNC cabling of test equipment 800MHz only HLN9742_ Flash Upgrade Adapter Provides connections to the computer or RIB programming test cable RLN4510_ Battery Elliminato...

Page 35: ...in the Field WADN4133_ Oscilloscope Analog 2 Channel 40MHz bandwidth 5mV cm 20 V cm Waveform measurements R1072_ Digital Multimeter AC DC voltage and current measurements R1377_ AC Voltmeter 100µV to 300V 5Hz 1MHz 10Mohm input impedance Audio voltage measurements R1440_ 0180305F29 0180305F38 0180305F46 RLN5417_ T1013_ Wattmeter Plug in Element Plug in Element Plug in Element Carry case for Wattmet...

Page 36: ...ally controlled soldering Iron For WADN4055_ soldering Iron For WADN4055_ soldering Iron 1010041A86 Solder RMA type 63 37 0 5mm diameter 1 lb spool 0180386A78 Illuminated magnifying glass with lens attachment 0180386A82 Anti static grounding kit Used during all radio assembly and disassembly procedures 0180303E45 SMD tool kit incl probers and brush R1321_ Shields and surface mounted component and ...

Page 37: ...TOR 1 1 13 13 1 14 25 25 14 13 2 12 J1 TO RIB RLN4008 36 Cable 36 Cable 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 Connecti...

Page 38: ... 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 FL0830062O 10K ...

Page 39: ... all test measurements are taken at 25 C 2 0 Setup The supply voltage can be connected from the battery eliminator The equipment required for alignment procedures is connected as shown in the Radio Tuning Test Setup diagram shown in Chapter 5 Initial equipment control settings should be as indicated in the following table and should hold for all alignment procedures except as noted in Table 4 1 Ta...

Page 40: ...ccess test environments as shown in Table 4 2 6 Pressing SB2 for 3 seconds will switch the radio to the Control Head Test mode LCD TEST appears on the display 7 Pressing SB1 will cause the radio to turn on all the dots of the first character Another SB1 press will turn on all the dots of the next character and so on until the last character character 14 8 Pressing SB1 at the end of the LCD test wi...

Page 41: ...37 1 release view 137 0 19 Pressing SB2 for 3 seconds in the Control Head Test mode will cause the radio to return to the RF Test mode Table 4 2 Test Environments Item No No of Beeps Description Function 1 1 BKC Carrier Squelch RX unsquelch if carrier detected TX mic audio 2 1 BKC Tone Private Line RX unsquelch if carrier and tone 192 8Hz detected TX mic audio tone 192 8Hz 3 2 BKC Digital Private ...

Page 42: ... 225 161 225 501 325 501 325 6 Low Power 13 High Power TX 6 or 13 RX 6 or 13 388 320 388 320 460 025 460 025 167 525 167 525 514 150 514 150 7 Low Power 14 High Power TX 7 or 14 RX 7 or 14 399 980 399 980 469 975 469 975 173 825 173 825 526 975 526 975 15 High Power 16 High Power TX 15 or 16 RX 15 or 16 399 980 399 980 469 975 469 975 173 825 173 825 526 975 526 975 Channel Selector Switch Positio...

Page 43: ...lts TEST MODE Test Channel 4 carrier squelch PTT to OFF centre meter selector to Audio PA Set volume control to 3 16Vrms Distortion As above except to distortion As above As above Distortion 3 0 Sensitivity SINAD As above except SINAD lower the RF level for 12dB SINAD As above PTT to OFF center RF input to be 0 35µV Noise Squelch Threshold only radios with conventional system need to be tested RF ...

Page 44: ... 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 loudly into...

Page 45: ...s the radio must be connected 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 CPS and TUNER CD GMVN4001_ CPS Instructions 6864113B32_ TUNER Instructions 6864113B31_ Wattmeter Audio Generator Sinad Meter AC Voltmeter 10 ...

Page 46: ...sed to program the radio codeplug Figure 5 2 CPS Programming Setup NOTE Refer to appropriate program on line help files for the tuning procedures NOTE Refer to appropriate program on line help files for the codeplug programming procedures RIB RLN4008 RIB Power Supply RLN4460 Test Box Rx Gnd Data Tx Data Radio Battery Computer Interface Cable Program RKN4074 Test Cable 3080369B72 DB15 DB9 120 230 V...

Page 47: ...c User Guide X X 6864120B16 GP240 GP280 User Guide ENG RUS FR TUR X X 6864120B17 GP240 GP280 User Guide GER SPA POR IT X X 6864120B18 GP240 GP280 User Guide SWE NL DAN FIN X X 6864120B19 GP240 GP280 User Guide CZ PL HU RO X X 68P64120B20_ GP540 GP580 Basic User Guide X X 6864120B21 GP540 GP580 User Guide ENG RUS FR TUR X X 6864120B22 GP540 GP580 User Guide GER SPA POR IT X X 6864120B23 GP540 GP580...

Page 48: ...User Guide ENG RUS FR TUR X X 6864120B17 GP240 GP280 User Guide GER SPA POR IT X X 6864120B18 GP240 GP280 User Guide SWE NL DAN FIN X X 6864120B19 GP240 GP280 User Guide CZ PL HU RO X X 6864120B20_ GP540 GP580 Basic User Guide X X 6864120B21 GP540 GP580 User Guide ENG RUS FR TUR X X 6864120B22 GP540 GP580 User Guide GER SPA POR IT X X 6864120B23 GP540 GP580 User Guide SWE NL DAN FIN X X 6864120B24...

Page 49: ...asic User Guide X X 6864120B16 GP240 GP280 User Guide ENG RUS FR TUR X X 6864120B17 GP240 GP280 User Guide GER SPA POR IT X X 6864120B18 GP240 GP280 User Guide SWE NL DAN FIN X X 6864120B19 GP240 GP280 User Guide CZ PL HU RO X X 6864120B20_ GP540 GP580 Basic User Guide X X 6864120B21 GP540 GP580 User Guide ENG RUS FR TUR X X 6864120B22 GP540 GP580 User Guide GER SPA POR IT X X 6864120B23 GP540 GP5...

Page 50: ...With Ultra high capacity NiMH battery With NiCD battery With Lilon battery GP240 GP540 GP280 GP580 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 hours 11 hours 8 hours Sealing Withstands rain testi...

Page 51: ... 5 20 25 kHz Frequency Stability 30 C to 60 C 25 Ref 1 5 ppm 2 5 ppm Power 403 470 MHz 1 4W 806 825 MHz 1 2 5W 851 870 MHz 1 2 0W 1 5W Modulation Limiting 2 5 12 5 kHz 4 0 20 kHz 5 0 25 kHz FM Hum Noise UHF 45 dB 12 5 kHz 50 dB 20 25 kHz 800 MHz 40 dB typical 45 dB 12 5 kHz 50 dB 20 25 kHz Spurious Harmonics Conducted Radiated Emission 403 470 MHz 36dBm 1GHz 30 dBm 1GHz 800 MHz 36 dBm 36dBm 1GHz 3...

Page 52: ... 403 470 MHz 800MHz 851 870 MHz 136 174 MHz Channel Spacing UHF 12 5 20 25 kHz 800MHz 20 25kHz 12 5 20 25 kHz Sensitivity 12 dB SINAD EIA 0 35 µV Intermodulation EIA 65dB Adjacent Channel Selectivity 70dB Frequency Stability 30 C to 60 C 25 Ref 1 5 ppm 2 5 ppm Spurious Rejection 70 dB Image Rejection 70 dB Audio Output 5 Distortion 0 5W Audio Distortion Rated Audio 3 typical ...

Page 53: ...EPROM ERROR 01 02 NON FATAL External EEPROM checksum error Bad external codeplug data FAIL 01 84 FATAL External EEPROM checksum blank Unprogrammed external codeplug data FAIL 01 88 FATAL External RAM error Defective RAM FAIL 01 90 FATAL Hardware failure Defective IC FAIL 01 92 FATAL Internal EEPROM checksum error Bad internal codeplug data Defective microcontroller ERROR 01 12 NON FATAL Internal E...

Page 54: ...7 2 POWER UP SELF TEST ...

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