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Motorola GP320 Series, Basic Service Manual

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Motorola GP320 Series Basic Service Manual Download Page 33

Radio Reassembly — Detailed

3-13

7.6

Chassis and Front Cover Reassembly

1.

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

2.

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

3.

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

4.

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

5.

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

6.

Be sure the O-ring is properly seated.

7.

Snap the bottom of the chassis into the front cover.

8.

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

Figure 3-11 

Fastening the Chassis

Radio Chassis

GP320/340/360/380

Summary of Contents for GP320 Series

Page 1: ...Professional Radio GP300 Series Basic Service Manual 6864115B18 D Issue September 2007 www k radio ru ...

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: ...ure for both workers and the general public These recommended RF exposure levels include substantial margins of protection All Motorola two way radios are designed manufactured and tested to ensure they meet government established RF exposure levels In addition manufacturers also recommend specific operating instructions to users of two way radios These instructions are important because they info...

Page 4: ...omagnetic Radiation Human Exposure Standard 2003 ANATEL ANNEX to Resolution No 303 of July 2 2002 Regulation of limitation of exposure to electrical magnetic and electromagnetic fields in the radio frequency range between 9 KHz and 300 GHz and Attachment to resolution 303 from July 2 2002 RF Exposure Compliance and Control Guidelines and Operating Instructions To control your exposure and ensure c...

Page 5: ...ur radio product as you would a wireless telephone Speak directly into the microphone Approved Accessories Use only Motorola approved supplied or replacement antennas batteries and accessories Use of non Motorola approved antennas batteries and accessories may exceed IEEE ICNIRP RF exposure guidelines For a list of Motorola approved antennas batteries and other accessories please see your dealer o...

Page 6: ... 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 taking place Hearing Aids Some digital wirel...

Page 7: ...osion or fire resulting in bodily injury or even death 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 Areas with potentially explosive atmospheres are often but not always posted WARNING ...

Page 8: ...o communications equipment in a hazardous atmosphere unless it is a type especially qualified for example FM UL CSA or CENELEC or ATEX approved An explosion or fire may result Do not operate a radio unit that has been approved as intrinsically safe product in a hazardous atmosphere if it has been physically damaged for example cracked housing An explosion or fire may result Do not replace or charg...

Page 9: ...d with a different Motorola communications equipment unit Approved configurations are listed by the Approving Agency FM UL CSA CENELEC or ATEX The Intrinsically Safe Approval Label affixed to radio refers to the intrinsically safe classification of that radio product and the approved batteries that can be used with that system The manual PN referenced on the Intrinsically Safe Approval Label ident...

Page 10: ...x THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ...ction 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 7 6 3 Keypad Display and Keypad Option Board Disassembly 3 8 6 4 Speaker Microphone and Unive...

Page 12: ...on 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 Specification...

Page 13: ... 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 14: ...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 15: ...mot com Email cgiss emea europe mot com Middle East and Africa Wayne Holmes Italy Ugo Gentile Telephone 27 11 800 7922 Telephone 39 0 2822 0325 Fax 27 11 800 7923 Fax 39 0 2822 0334 Email radiosupport za motorola com Email C13864 email mot com France Armand Roy France Laurent Irrmann Telephone 33 1 6935 7868 Telephone 33 1 6935 7866 Fax 33 1 6935 7808 Fax 33 1 6935 7808 Email armand roy motorola c...

Page 16: ...vel Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package MD H 25 K VHF 136 174MHz D 3 5W C GP140 GP320 GP330 GP240 GP340 GP540 GP640 9 Program mable AA Conventional MDC O GP320 A E R UHF 1 403 470MHz 2 GP330 S UHF 2 450 527MHz E 5 6W H GP280 GP380 GP580 GP680 6 Non Programm able AN Conventional 5 Tone 3 GP140 GP240 GP340 GP540 GP640 T UHF 1 NB 450 470MHz C 2 2 5W N...

Page 17: ...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 18: ...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 19: ... 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 20: ...2 4 INTRINSICALLY SAFE RADIO INFORMATION ...

Page 21: ... 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 is isopropyl alcohol 70 by volume Cleaning External Plastic Surfaces Apply the 0 5 detergent water solution sparingly with a stiff ...

Page 22: ...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 23: ...g techniques Excessive prolonged heat on a flexible circuit can damage the material Therefore avoid excessive heat and excessive bending For parts replacement use the ST 1087 Temperature Controlled Solder Station with a 600 700 degree tip and use small diameter solder such as ST 633 The smaller size solder will melt faster and require less heat to be applied to the circuit To replace a component o...

Page 24: ...marily performed at the basic level send this unit to a Motorola Authorized Service Centre See Chapter 1 for a list of authorized service centres The following disassembly procedures should be performed only if necessary Chassis Assembly Disassembly Paragraph 6 2 Keypad Display and Keypad Option Board Disassembly Paragraph 6 3 Speaker Microphone and Universal Connector Flex Disassembly Paragraph 6...

Page 25: ...nics front cover assembly as follows a Insert a small flat blade screwdriver or similar instrument in between the thin retaining wall and the chassis at the bottom of the radio Do not mar the O ring sealing area on the housing Figure 3 1 Battery Removal Figure 3 2 Knob Removal NOTE Both knobs slide on and off However they are supposed to fit very tightly on their shafts Battery Release Buttons Kno...

Page 26: ...down Rotate the front cover backward and slightly away from the chassis 7 Lift the latches on the main circuit board to release the flexes from their connectors Figure 3 3 Chassis Removal CAUTION Marring the front cover O ring sealing area will prevent the radio from sealing properly NOTE Flexible ribbon circuits flexes connecting the front cover assembly and the chassis prevent you from completel...

Page 27: ...g 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 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 Main Board Compliant G...

Page 28: ...ht below the speaker Lift the keypad retainer out of the front cover then lift and pivot the two hooks out of the front cover 5 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 process for releasing the flexes 6 The display module is attached to the front cover w...

Page 29: ...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 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 sp...

Page 30: ...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 31: ...esive liner on the back of the universal connector tail of the flex circuit Attach the flex tail to the front cover using the guide pins for correct alignment 3 Replace the universal connector escutcheon Make sure that all the connector openings align with the gold pads on the flex circuit 4 Align the notch in the speaker at the twelve o clock position with the tab on the front cover See Figure 3 ...

Page 32: ...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 Figure 3 10 Lock retainer catches to the radio s body NOTE When properly assembled the retainers on the O ri...

Page 33: ...he connectors to hold the flex circuits to the main board 4 Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover 5 Push the chassis assembly completely into the top of the front cover until it settles in place 6 Be sure the O ring is properly seated 7 Snap the bottom of the chassis into the front cover 8 Reassemble the knobs dust cover antenna a...

Page 34: ...ion board 6 Reassemble the option board to the front cover assembly 7 Insert the display flex circuit into the connector on the option board 8 Insert the jumper flex circuit into the connector on the option board Notice the orientation of the flex circuit Arrows on the jumper flex point to the correct way of inserting the flex into the connector 9 Replace the retainer by placing the two top hooks ...

Page 35: ... 4 3 2 Start up the CPS and read the radio s codeplug 3 Choose Miscellaneous from the Per Radio drop down menu 4 In the Miscellaneous dialog box click on the Global and choose Voice Storage from the Option Board Type 5 Choose Signalling Definition from the Per Radio drop down menu In the Signalling Defini tion dialog box click on the Voice Storage check box to activate voice storage ...

Page 36: ...ny other desired Voice Storage related check boxes 7 Choose Button Definition from the Per Radio drop down menu In the Button Definition dia log box configure your radio s relevant programmable buttons to activate the desired Voice Storage function 8 Choose Per Personality from the Per Personality drop down menu Click on the Option Board check box ...

Page 37: ...Mechanical Views and Parts Lists 3 17 9 0 Mechanical Views and Parts Lists 9 1 GP320 GP340 Figure 3 13 Radio Exploded Mechanical View GP320 GP340 ...

Page 38: ...L01 Insulator 16 1485924Z01 Insulator board GP340 17 7586481Z01 Pad retainer GP340 18 4286266Z01 Retainer Keypad PCB GP340 19 3586057A03 Felt Speaker 20 1480577C01 Boot Microphone 21 5085738Z10 5085738Z03 Speaker EPP Speaker non EPP 22 5015027H01 Microphone 23 7586477Z01 Poron Pad 24 8415169H01 8415169H02 Flex UC 25 1405307X01 Insulator kapton 26 4286410Z01 Retainer Speaker 27 2113944C81 Capacitor...

Page 39: ...Mechanical Views and Parts Lists 3 19 9 2 GP360 GP380 Figure 3 14 Radio Exploded Mechanical View GP360 GP380 ...

Page 40: ...4949J19 LCD module 20 7580637Z01 Pad LCD Back 21 4286266Z01 Retainer Keypad PCB 22 3586057A03 Felt Speaker 23 1480577C01 Boot Microphone 24 5085738Z10 Speaker 25 5015027H01 Microphone 26 7586477Z01 Poron Pad 27 8415169H01 8415169H02 Flex UC 28 1405307X01 Insulator kapton 29 2113944C81 Capacitor 24pF 30 3113944F54 Capacitor 33pF 31 4286410Z01 Retainer Speaker 32 1480503Z01 Boot Backup Battery 33 75...

Page 41: ...Mechanical Views and Parts Lists 3 21 9 3 GP330 Figure 3 15 Radio Exploded Mechanical View GP330 ...

Page 42: ...471531L01 Insulator 17 1480577C01 Boot Microphone 18 5085738Z10 Speaker 19 5015027H01 Mini Electret Microphone 20 2113944F54 Capacitor 33pF 21 8415169H01 8415169H02 Flex Universal Connector 22 7586477Z01 Pad Poron 23 2113944C81 Capacitor 24pF 24 4286410Z01 Retainer Speaker 25 1405307X01 Insulator kapton 26 3916290H01 Foam Conductive 27 7580671Z01 Pad Flexible circuit 28 7580671Z03 Pad Flexible Fle...

Page 43: ... radio s antenna port 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 troubleshootin...

Page 44: ...sk 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 RLN4610_...

Page 45: ...able 1 metre Cable RKN4074_ 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 46: ...3 26 MAINTENANCE Figure 3 18 Wiring of the Connectors 1 2 3 4 5 6 7 8 9 10 11 12 13 15 1 4 11 25 Pos Female D Connector 25 Pos Male D Connector Side Connector 1 5 2 7 8 15 20 16 9 18 25 ...

Page 47: ...00Hz UHF Rated Audio Mode GEN Output level 1 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 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 ce...

Page 48: ...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 49: ...es 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 EMEA CD ENLN4115_ Installation Card 6864113B14_ Wattmeter Audio Generator Sinad Meter AC Voltmeter 20 dB Pad Battery Block Power Supply Audi...

Page 50: ...or Mode Power Monitor 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 hel...

Page 51: ...Cover Kit X X PMLE4137_ PMLN4216_ GP340 UHF Back Cover Kit GP340 UHF 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 6864110B12_ GP320 Basic User Guide X 6864110B13_ GP340 Basic User Guide X 6864110B16_ GP360 Basic User Guide X 6864110B18_ GP380 Basic User Guide X X X NAE6483_ UH...

Page 52: ...55_ PMLN5135_ GP330 VHF Back Cover Kit GP330 VHF Front Cover Kit X X PMLD4117_ PMLN4216_ GP340 VHF Back Cover Kit GP340 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 6864110B12_ GP320 Basic User Guide X 6866546D21_ GP330 Basic User Guide X 6864110B13_ GP340 Basic User Guide...

Page 53: ...n 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 NAB6064_ Low...

Page 54: ...el Description 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 55: ...7 5 x 33 0 Weight gm With Standard high capacity NiMH battery With Ultra high capacity NiMH battery With NiCD battery With Lilon battery GP320 GP330 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 h...

Page 56: ...n 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 typical 0 35 ...

Page 57: ...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 58: ...7 2 POWER UP SELF TEST ...

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