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6881086C09-O

March, 1997

Table of Contents

GP68 Portable Radios Service Manual

Schematic Diagrams and Circuit Board Details

Circuit Board Details for PMLD4036A/PMLD4037A VHF RF Board, 20/25/12.5 KHz . . . . . . . . . . . . . . . . . . . 1
Parts List for PMLD4036A/PMLD4037A VHF RF Board, 20/25/12.5 KHz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Schematic Diagram for PMLD4036A/PMLD4037A VHF RF Board, 20/25/12.5 KHz. . . . . . . . . . . . . . . . . . . . . 3

Circuit Board Details for PMLE4023B/PMLE4024B UHF RF Board, 20/25/12.5 KHz. . . . . . . . . . . . . . . . . . . . . 4

Parts List for PMLE4023B/PMLE4024B UHF RF Board, 20/25/12.5 KHz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Schematic Diagram for PMLE4023B/PMLE4024B UHF RF Board, 20/25/12.5 KHz . . . . . . . . . . . . . . . . . . . . . . 6

Circuit Board Details for PMLN4059A & PMCD4001A Controller Board, VHF 12.5/20/25 KHz . . . . . . . . . . . 7

Parts List for PMLN4059A & PMCD4001A Controller Board, VHF 12.5/20/25 KHz . . . . . . . . . . . . . . . . . . . . . 8

Schematic Diagram for PMLN4059A & PMCD4001A Controller Board, VHF 12.5/20/25KHz . . . . . . . . . . . . . 9

Circuit Board Details for PMCE4000A & PMCE4002A Controller Board, UHF 12.5/20/25 KHz. . . . . . . . . . . 10

Parts List for PMCE4000A & PMCE4002A Controller Board, UHF 12.5/20/25 KHz . . . . . . . . . . . . . . . . . . . . . 11
Schematic Diagram for PMCE4000A & PMCE4002A Controller Board, UHF 12.5/20/25KHz. . . . . . . . . . . . . 12
Circuit Board Details for PMLN4061 Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Parts List for PMLN4061 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Schematic Diagram for PMLN4061 Display Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Exploded View Parts List for GP68 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

GP68 Exploded Mechanical View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Battery Charger Standard Rate (10 Hour) Exploded View and Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Battery Charger Standard Rate (10 Hour) Circuit Board, Schematic Diagram and Parts List . . . . . . . . . . . . . . 19

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Summary of Contents for GP68

Page 1: ...GP68 Portable Radios Service Manual UHF 6881086C09 O March 1997 ...

Page 2: ...Motorola 8000 W Sunrise Blvd Ft Lauderdale FL 33322 6881086C09 O 6881086C09 ...

Page 3: ... copyrighted computer program Accordingly any copyrighted Motor ola 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 copy...

Page 4: ...quipment xi Test Set Service Cable xii Radio Model Information xii Section 1 Radio Disassembly Assembly Overview 1 1 Disassemble Radio 1 1 Remove Battery 1 1 Remove RadioÕs Chassis 1 1 Remove RF Board 1 1 Remove Controller Board 1 2 Remove Display Board 1 3 Reassemble Radio 1 3 Replace Controller Board and Display Board 1 3 Replace RadioÕs Chassis 1 3 Replace Battery Knobs and Antenna 1 4 Torque S...

Page 5: ...aptive Power ControlTM Technology 2 4 RF Board 2 5 Receiver 2 5 Intermediate Frequency IF 2 5 Transmitter 2 6 Power levelling 2 6 Frequency Generation Circuitry 2 6 Synthesizer 2 7 VCO 2 7 Display Board 2 7 The GP60 Series Radio Alignment Procedures 2 7 RSSI Threshold Adjustment 2 7 Low Port Modulation 2 8 VCO Deviation Adjustment 2 8 Transmitter Power Adjustment 2 8 Reference Oscillator Warp Adju...

Page 6: ...are not cloned 4 2 To Clone a Radio 4 2 Error Conditions 4 3 Programming the GP68 Radio 4 4 Operator Controls and Indicators 4 4 Programming the Radio Parameters 4 4 To Program a Channel 4 4 To Verify a Programmed Channel 4 4 To Enable or Disable PTT ID Transmission 4 5 To Change the Default Squelch Modes 4 5 To Select the Frequency Step Size 4 5 To Select a Receive Frequency 4 6 Using the Keypad ...

Page 7: ... Controller Board VHF 12 5 20 25 KHz 7 Parts List for PMLN4059A PMCD4001A Controller Board VHF 12 5 20 25 KHz 8 Schematic Diagram for PMLN4059A PMCD4001A Controller Board VHF 12 5 20 25KHz 9 Circuit Board Details for PMCE4000A PMCE4002A Controller Board UHF 12 5 20 25 KHz 10 Parts List for PMCE4000A PMCE4002A Controller Board UHF 12 5 20 25 KHz 11 Schematic Diagram for PMCE4000A PMCE4002A Controll...

Page 8: ...ehicle communication equipment should be performed by a pro fessional installer technician qualified in the requirements for such installations An air bag s size shape and deployment area can vary by vehicle make model and front compartment configuration e g bench seat vs bucket seats Contact the vehicle manufacturer s cor porate headquarters if necessary for specific air bag information for the v...

Page 9: ...t you should be able to order the part through Motorola Parts and Service Division If only a generic part is listed the part is not normally available through Motorola If no parts list is shown generally no user serviceable parts are available for the kit Latin America Technical Support Technical Support 8000 W Sunrise Blvd Ft Lauderdale FL 33322 Tel 1 800 694 2161 954 723 3008 Spanish 954 723 300...

Page 10: ...5 kHz keypad Model P93VNB00H2AA P93VNB20H2AA Item Description X PMLD4036 GP68 VHF RF Board 20 25 khz X PMLD4037 GP68 VHF RF Board 12 5 khz X X PMLN4059 GP68 Controller Board X X PMLN4061 GP68 Display Board X X PMAD4015 VHF 14cm Antenna 155 174 MHz X X 6881086C10 GP68 User Manual X X PMLN4049 Front Cover keypad GP68 VHF 136 174 MHz X Indicates one of each required ...

Page 11: ...5 kHz keypad Model P94VNB00H2AA P94VNB20H2AA Item Description X PMLE4023 GP68 UHF RF Board 20 25 khz X PMLE4024 GP68 UHF RF Board 12 5 khz X X PMCE4000 GP68 Controller Board X X PMLN4061 GP68 Display Board X X NAE6483A UHF Whip Antenna 430 470 MHz X X 6881086C10 GP68 User Manual X X PMLN4049 Front Cover keypad GP68 UHF 430 470 MHz X Indicates one of each required ...

Page 12: ... Plug PMLN4069 Charger Insert Batteries PMNN4000 NiCd Rechargeable High Capacity Battery Pack PMNN4001 NiCd Rechargeable Medium Capacity Battery Pack Audio Signalling Accessories HMN9787_R Light Weight Headset with Swivel Boom Microphone without VOX BDN6647 Medium Weight Headset with Swivel Boom Microphone without VOX BDN6706 Ear Microphone with VOX interface VOX included HMN9725_R Remote Speaker ...

Page 13: ...ng per IP54 Shock Vibration Impact resistance polycarbonate housing passes TIA RS 603 VHF UHF RF Output NiCd 7 5V Low 1W High 5W Low 1W High 4W Frequency 136 174 MHz 430 470 MHz Channel spacing 25 kHz 12 5kHz 25 kHz 12 5kHz Freq Stability 30 C to 60 0005 0005 00025 Spurs Harmonics Second Harmonic 60 dB 50dB 60 dB 50dB Audio Response from 6 dB oct Pre Emphasis 300 to 3000Hz 1 3 dB 1 3 dB Audio Dist...

Page 14: ...N9216 to plug into a XT style communications port HLN9087 External Antenna Adapter Con verts RF port to BNC Power and sensitivity measurement 01 80304E45 Battery Eliminator Allows use of Power Supply 81 80377E77 Housing Eliminator Allows component level analysis Motorola Model No Description Characteristics Application R2200 R2400 or R2001 with trunking option Service Monitor This monitor will sub...

Page 15: ... and the antenna screws off counterclockwise Figure 1 3 2 Remove the two screws at the back of the chassis Figure 1 3 3 Slide the chassis downwards a little and lift it away from the front housing Figure 1 3 NOTE Please note that the flat ribbon cable still connects the controller board and the RF board Be careful not to strain this cable while separating the chassis from the front housing 4 Unlat...

Page 16: ...rs at the side of the radio 3 Unlatch the latch levers on the controller board and remove the ribbon cable as well as the flex tail from the connectors Figure 1 6 4 Use a TORX head screwdriver to remove the screw Figure 1 6 5 Gently lift the bottom of the controller board to disconnect it from the display board Figure 1 6 6 Ease the controller board downwards and lift it away from the housing Figu...

Page 17: ... angle Care should be taken as the volume and channel shafts are inserted into the openings of control top Figure 1 8 4 Fasten the Controller board to the housing with the TORX head screw Figure 1 8 5 Insert the tail from the speaker flex into the connector and lock the latch on the connector Figure 1 8 6 Snap on the PTT lever 7 Replace the dust covers covering the acces sories and cloning connect...

Page 18: ... careful to loop the flex ribbon cable properly when assembling the chassis onto the housing Replace Battery Knobs and Antenna 1 Replace battery pack by sliding the pack in place 2 Slide battery cover latches towards the front panel to lock 3 Replace both control knobs and antenna Figure 1 9 Replace Radio s Chassis ...

Page 19: ...hart Refer to G68 Exploded Mechanical View on page 17 for locations of screws PART NUM BER DESCRIPTION SIZE TORQUE IN LB EXP VIEW NUMBER 0304726J01 Screw Torx T 6 M2 X 0 4 X 5 mm 2 0 to housing front 2 5 to chassis 24 0304725J02 Screw Machine Metric Flat Head 90 Deg M2 X 0 4 X 4 mm 2 5 33 0304726J01 Screw Self Tapping M2 X 0 4 X 4 mm 2 5 34 ...

Page 20: ...1 6 6881086C09 O March 1997 Radio Disassembly Assembly GP68 Portable Radios Service Manual ...

Page 21: ...er ifies that clockY401 is operational When the reset line goes high U401 s hardware delays briefly to allowY401 to stabi lize then the software begins executing port assignments RAM checking and initialization A fixed delay of 100 mS is added to allow the audio circuitry to settle Next an alert beep is generated and the steady state software begins to exe cute buttons are read radio circuits are ...

Page 22: ...tion of option board Tx audio through connector J403 Pre emphasis is 6 dB octave with a corner frequency of 6600 Hz Crossover gain is 0 dB at 1 kHz with passband gain head room of 17 5 dB Limiter Audio Filter IC The audio filter IC U451 contains the limiter circuit which prevents over deviation of the RF carrier by symmetrically clipping the peaks of the modulating voltage Audio from the pre empha...

Page 23: ...g purposes and to conserve power Noise Squelch Attenuator The Audio Filter IC U451 contains a 16 step programmable digital squelch attenuator between U451 16 and U451 18 Noise squelch setting is a user programmable option see user manual with open squelch at step 0 and tight squelch at step 15 Option Interface The option interface provides the ability to interface Motor ola designed and third part...

Page 24: ...ectional port PD5 In the GP60 Series Radio this is the CLOCK output from the microcontroller for loading all internal subsystems as well as option boards that require synchronous serial transfers Option boards requiring a multi byte transfer may use this output as the CLOCK source for uploading internal option board registers on power up channel change or for reading serial control requests J403 1...

Page 25: ... oper ate with a 50 ohm input termination while the output termi nation is the input impedance of the RF amplifier that follows it The VHF pre selector is also a 2 pole 0 1 dB Chebyshev bandpass design but with shunt series coupled resonator topology This topology provides fairly symmetrical attenu ation around the center frequency of 155 MHz The 3 dB bandwidth is approximately 60 MHz Center of ba...

Page 26: ...L on their second MMBR951L stages The antenna switch circuit consists of two PIN diodes CR101 and CR102 a pi network C145 L115 and part of C140 and a current limiting resistor R115 The UHF cir cuit contains one additional capacitor C149 which is used to tune out CR102 s lead inductance In the transmit mode TxB is applied to the circuit to bias the diodes on To enable the Tx signal to go to the ant...

Page 27: ... After frequency comparison in the syn thesizer a resultant STEERING LINE VOLTAGE is received at the VCO This voltage is a DC voltage between 3 and 11 Volts when the PLL is locked on frequency In the receive mode U251 pin 5 is grounded This activates the receive VCO by enabling the receive oscillator and the receive buffer of U251 On VHF radios the rf signal at U251 pin 2 is run through a low pass...

Page 28: ...xternal mic using the radio test box The Modulation Analyzer should be set as follows Use the up down arrow keys to change the deviation setting and the F6 key to toggle the PTT Transmitter Power Adjustment Tuning Frequency Automatic Frequency displayed on Tuning screen Power Level VHF 1 W and 5 W UHF 1 W and 4 W For power tuning it is important to ensure that the DC Voltage MUST be maintained und...

Page 29: ...ontrol Battery Monitor From Battery SCI BUS Harmonic Filter Receiver 1st Mixer IF 2nd Mixer Demodulator Synthesizer VCO Reference Oscilator RF PA Analog Control Steering VCO Mod Warp Prescaler Squelch Adjust Rx Audio Fast Detect Carrier Detect Adapt Rx Battery Saver Lock Detect Clock Shift Tx SPI BUS Tx Audio LEDs Antenna From Battery Reset 5V µP 2 1 MHz Lowspeed Detector Audio Filter IC 5 Volt Re...

Page 30: ...ss Filter Filter Bandpass 3 Pole Detected audio From Antenna Switch 5V RX 5V RX 2nd LO 4 Pole Ceramic 4 Pole Ceramic TRANSMITTER BLOCK DIAGRAM Pin 5V Tx Pre driver Driver TX B Final Coupler Antenna Switch Harmonic Filter Power Control To Receiver IF IC Buffer VCTL B IDAC Block Diagram for Receiver and Transmitter ...

Page 31: ...DIAGRAM GND VC VCC TRB DATA CLK CEX MODIN VCC DC5V XTAL1 XTL2 WARP PREIN VCP REFERENCE OSCILLATOR VOLTAGE MULTIPLIER VOLTAGE CONTROLLED OSCILLATOR 2 POLE LOOP FILTER U251 VCOBIC DATA U401 PIN 52 CLOCK U401 PIN 53 SYNEN U401 PIN 11 MODIN U451 PIN S 19 20 5V U302 PIN S 1 2 5 6 7 8 3 12 19 22 23 14 15 16 20 32 VMULT2 VMULT1 CPBIASS1 SUPFOUT AUX3 MODOUT IADAPT IOUT GND FREFOUT LOCK 2 11 4 13 21 30 29 ...

Page 32: ...IAGRAM DET AUDIO Rx in 325 mV RMS PL DPL IN PL DPL clock Alert tone in Unattn Rx out PL DPL decorder out Rx out PA audio Rated audio 250 mW RMS Max power 0 5 Watt From Rx out AFIC TX AUDIO AFIC BLOCK DIAGRAM 15 khz 6 db oct 3 khz PRE EMPH AMP LIMITER dev 3khz 25k PL DPL 1 pole LP Fc 1 khz PL Filter 6 pole LP Fc 252 5 hz Smoothing filter 1 pole LP Fc 6050 hz 6 bit PL DPL encoder DPL Filter 3 pole L...

Page 33: ... Attach the microphoneÕs accessory connector to the accessory connector on top of the radio 2 While listening to the accessory speaker turn the radio on 3 Operate radio according to operating instruc tions supplied with the radio NOTE The microphone will perform best if it is worn as shown in Figure 3 1 Handling Precautions To avoid damage to circuits observe the following handling shipping and se...

Page 34: ...the test equipment to the unit before connecting the test probe Similarly disconnect the test probe prior to removing the ground lead If the microphone cartridge is removed from the unit place it on a conductive surface such as a sheet of aluminium foil which is connected to ground through 100k ohms of resistance WARNING If the aluminium foil is connected directly to ground be cautious of possible...

Page 35: ...01 Lever PTT 4 3505152J01 Grille cloth 5 1105461R01 Adhesive 6 0180703Y70 Coil cord connector 7 0180703Y67 PCB Includes electrical parts 8 3905834K06 Switch dome PTT S1 9 3205231Q01 Seal dome 10 1405219Q01 Boot microphone 11 0180703Y69 Microphone assembly 12 5005910P05 Speaker LS1 13 7505283Q02 Pad speaker 14 3205690R01 Gasket 15 6405689R01 Plate housing mounting 16 0300139982 Screw Phillips 2 56 ...

Page 36: ...f you are installing the SmarTrunk II option board select SEriAL When the correct option is selected turn the radio off to save it to memory DTMF Decode Option Kit numbers PMLN 4063 Decode Board PMLN 4064 Decode Board 10 pack Overview The DTMF Decode Option Board is an accessory available with the GP68 portable radio This board requires the radio to be disassembled before it can be installed Pleas...

Page 37: ...D will appear on the screen Press the key and enter the Indi vidual ID code Press theYellow Light Enter button to store the code Rotate the selector knob clockwise and GrP ID will appear on the display Press the key and enter the Group ID code Press the Yellow Light Enter button to store the code Rotate the selector switch clockwise and ALL ID will appear on the display Press the but ton and enter...

Page 38: ...6 R703 R705 C705 C704 U701 VIEWED FROM SIDE 2 R702 J701 C703 CR701 C702 1 1 1 8 8 9 9 16 16 6 7 12 R704 U702 Y701 R701 ILLUSTRATOR DATE ENGINEER DATE ME LETTERING SIZE REQUIRES EDITOR DATE CHECKER DATE GP68 DTMF MAEPF 25975 O JP AM RG 1 9 97 TP2 TP1 TP4 TP5 TP6 TP3 VIEWED FROM SIDE 1 MAEPF 25974 O Circuit Board Details for DTMF Decoder Option Board PMLN4063 ...

Page 39: ...U702 5113806A09 Shift Register CRYSTAL Y701 4880915W01 Oscillator 3 58MHz PCB 8404750J01 DTMF Board 5V 5V 5V NET TP1 6 5 4 3 2 1 12 11 10 9 8 7 PTT DTMF_CLOCK OPT_TX_AUDIO TX_AUDIO GND 5V SR_DATA DTMF_DATA_IN UNMUTED_RX_AUDIO RX_AUDIO SR_CLOCK DTMF_DATA_OPT 63B81086C60 O TP2 J701 TP3 TP4 TP6 TP5 NET NET NET CR701 NET 2 3 1 NET 5V SERIAL CLOCK SERIAL DATA DATA READY R703 1000 C702 10nF 16 10 11 9 8...

Page 40: ...3 8 6881086C09 O March 1997 Accessory GP68 Portable Radios Service Manual DTMF Decoder Option Board PMLN4063 ...

Page 41: ...e Radio to Dealer Programming Mode To set the Dealer s radio to Dealer Programming Mode remove jumper R417 Figure 4 1 With this programming function enabled the dealer can program all the required channel parameters such as which channels should be on the scan list and the received and transmit frequencies for a particular channel clone the programmed settings over to a UserÕs radio NOTE If the ba...

Page 42: ... Turn the radio on while holding down and keep holding until the radio sounds a ringing Option Board Setup Mode start up tone takes about 3 seconds NOTE At power up all display segments light for about 2 seconds followed by a brief display of the software version which is installed in your radio If the battery voltage level is low the display indicates the BATT indicator flashes and the radio soun...

Page 43: ...ge Figure 4 4 5 6 7 Table 4 1Cloning Error Messages Error Message Problem Solution Err 01 Incompatible software options error Cloning from the master radio to the slave radio cannot be performed Err 02 Timeout error a The cloning cable connection is not properly connected or slave radio is not turned on b Communication between the two ra dios is disrupted during the cloning process a Check the clo...

Page 44: ...ive PL DPL Code the Transmit PL DPL Code and the default Squelch Mode Setting CSQ CTCSS and Signalling Squelch If required momentarily press to enter the MHz mode Select the desired frequency type of TX offset and off set frequency see page 4 5 onwards Press and hold the Enter Button for 3 seconds The LCD displays the following to prompt you to select the channel number Figure 4 6 The channel numb...

Page 45: ...ll hear all conversations on the selected receive channel When CTCSS is on continuously the radio operates in Coded PL DPL squelch mode In this mode you will hear only those conversations on the selected receive channel which have the same PL DPL code as your radio When CTCSS is flashing which requires that an option board is selected first via the Option Board Setup Mode the radio operates in Sig...

Page 46: ...ly selected fre quency With each number entry a valid keypress tone sounds When 6 digits are displayed the receiver is set to the entered frequency NOTE If an invalid number is pressed the valid number nearest the invalid keypress is entered such that the selected frequency will not be outside the allowed frequency band Valid frequencies entered via the keypad are dependent on the frequency step s...

Page 47: ...fill in trailing zeros press the Enter Button Once the frequency is fully entered press the Enter Button again to exit the user defined entry mode and commit the selected TX frequency NOTE The radio automatically exits the user defined entry mode after 5 seconds of inactiv ity and commits the selected TX frequency ONLY if you have completely keyed in the desired frequency a partially entered fre q...

Page 48: ...he Receive and Transmit PL DPL by pressing momentarily In the following example Figure 4 19 the Transmit PL DPL code is 020 Rotate the Channel Selector Knob clockwise to increase or counter clockwise to decrease the active Transmit PL DPL code NOTE If you reach the upper or lower limit of the PL DPL codes the displayed code wraps around to the opposite limit and starts to increment or decrement fr...

Page 49: ...If no Option Boards were Installed in the Dealer s Radio Table 4 3 Receive and Transmit PL DPL Codes rPL XXX tPL XXX PL FREQ Hz EQUIV PL CODE rPL XXX tPL XXX PL FREQ Hz EQUIV PL CODE rPL XXX tPL XXX EQUIV DPL CODE rPL XXX tPL XXX EQUIV DPL CODE rPL XXX tPL XXX EQUIV DPL CODE rPL XXX tPL XXX EQUIV DPL CODE 000 CSQ 022 136 5 4Z 043 23 065 152 087 343 109 606 001 67 0 XZ 023 141 3 4A 044 25 066 155 0...

Page 50: ...PTT ID Edit Acknowledgment ID Edit Indi vidual Call ID Edit Group Call ID and Edit All Call ID Only if DTMF Option Board is selected in Option Board Setup Mode The Special Programming mode also provides a Factory Reset feature which allows you to return certain user modifiable parameters in the radio to the factory default values IDs and access de access codes are unaffected by this programming fe...

Page 51: ...s tone and the keypress is ignored To exit this edit mode select another menu item by turn ing the Channel Selector Knob Edit Time Out Timer This menu item allows you to select the Time Out Timer length Rotate the Channel Selector Knob to select the Edit Time Out Timer menu item The menu will display the current setting where xxx represents one of The default display of shows the time out timer se...

Page 52: ... are valid in combination with all other digits Use or to scroll through the existing ID s digits To change the selected ID use to erase the unwanted digits and then enter the new digits The dis play shows the new digits as they are being entered When the flashing cursor is under a digit the maximum number of digits has been entered If you attempt to add more than 8 digits an invalid keypress tone...

Page 53: ... the reference oscillator crystal Y201 is defective the entire Radio Frequency RF board must be replaced When the new Radio Frequency board is installed the eight digit oscillator temperature compen sation code supplied with the new RF board must be programmed into the radio controller See the Radio Service Software RSS manual number 6881086C08 in English section 5 3 3 Simply enter the eight digit...

Page 54: ...U51 Check VCO Synth Inject on channel signal at C148 Check harmonic filter and antenna path Check external components connected to IFIC If OK replace U51 Check mixer U41 Is Q51 biased correctly Check XTAL filter Y51 Check 5vRX and IF amp components Is 12 dBS 116 dBm Check AFIC Is Q1 biased properly Check 2 pole and 3 pole filters components Check 5vRX and Q1 bias circuitry 1 Is 2nd LO on freq Chec...

Page 55: ...roubleshoot VCO Done Is Power OK 1 Check Pin Diodes 2 Check Harmonic Filter Inspect Repair TX Output Network NO NO LOW HIGH YES NO NO YES YES YES NOTE When using the 81 80377E77 housing elimi nator for Level III analysis the power level needs to be set at minimum on the power level setting to avoid any damage to the radio This can be performed by either the STS RVN 4159A transmit power tuning fiel...

Page 56: ...n Is Connection between U201 Pin 1 U251 Pin 5 OK Replace U201 Remove Shorts Is there a short between Pin 32 and Pins 9 10 of U201 If line between U201 Pin 18 U251 Pin 3 is OK then replace U201 Replace or resolder necessary components Is RF level at U201 Pin 20 between 10 5 dBm Are R202 R204 R205 C214 C215 C216 L201 OK Replace U201 If L203 C224 C226 C227 and runners between U201 Pin 20 U251 Pin 23 ...

Page 57: ...P AT U402 PIN 23 AUDIO PROBLEM TROUBLE SHOOT AUDIO CKT WITH POWER CONNECTED TO RADIO AND THE RADIO TURNED ON CHECK THE FOLLOWING 1 5V AT PIN 32 OF U401 IF NONE CHECK U411 2 WITH HIGH IMPEDANCE PROBE CHECK FOR 7 9488MHZ AT PIN 7 AND 10 OF U401 IF NO SIGNAL CHECK REPLACE L401 Q401 3 CHECK DC AT PIN 19 OF U401 IF 4 5VDC CHECK U402 PIN 25 FOR 2 1 MHZ SIGNAL 4 CHECK FOR TYPICAL VOLTAGES OF U401 AND U40...

Page 58: ...ixer VisualCheck of Board OK If all parts around Q251 are OK then replace Q251 Replace L269 Fix the Circuitry for 5VRX If all parts from U251 Pin 2 to Pin 3 of mixer are OK then replace U251 If all parts associated with those Pin s are OK then replace U251 If all parts from U251 Pin 4 to Input of PA are OK then replace U251 If C256 and R253 are OK then replace CR252 Replace R252 or L255 Replace C2...

Page 59: ...HT WORKING CONNECTION OK FIX J801 CONNECTION CHANGE LCD BOARD CONNECTION OK CLOCK WORKING R811 R812 R813 R816 R817 WORKING R814 R815 C801 WORKING COMPLETE DISPLAY CHANGE BAD COMPONENTS CHANGE BAD COMPONENTS LEDS WORKING R801 R802 R803 WORKING Q801 WORKING CHANGE U801 CHANGE BAD COMPONENTS CHANGE LEDS CHANGE Q801 CHANGE LCD BOARD YES NO YES YES YES YES YES YES YES YES YES NO NO NO NO NO NO NO NO YE...

Page 60: ...5 8 6881086C09 O March 1997 Troubleshooting GP68 Portable Radios Service Manual ...

Page 61: ...GP68 Portable Radios Service Manual Part II UHF 6881086C09 O March 1997 ...

Page 62: ...Motorola 8000 W Sunrise Blvd Ft Lauderdale FL 33322 6881086C09 O 6881086C09 ...

Page 63: ... copyrighted computer program Accordingly any copyrighted Motor ola 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 copy...

Page 64: ...C223 R104 R211 C215 R258 R117 C64 C282 R203 C61 R51 R204 R3 R105 C74 R62 C235 R216 MAEPF 25976 O Q53 Q152 R5 R111 R176 R63 R64 R159 R122 R115 R118 R120 R172 R259 Y53 3 4 2 1 1 1 1 1 CF51 3 4 2 CF52 F301 SL L7 L253 L256 L257 L261 E303 L106 L115 L111 L260 L52 L254 L1 L108 5 4 1 9 10 16 17 21 22 U251 30 23 5 12 U51 CR1 CR51 CR151 CR101 CR102 CR203 CR251 CR252 CR253 CR301 P401 2 20 19 J301 J401 C56 C1...

Page 65: ... 2113743K15 0 1uF C280 2113741F25 001uF C282 2113740F21 5 6 0 25pF C285 2113740F27 10 C286 2113740F27 10 C287 2113740F20 5 1 0 25pF C288 2113740F32 16 C289 2113741F25 001uF C291 2113741F25 001uF C309 2113741F25 001uF C310 2113741F25 001uF CERAMIC FILTER CF51 9104830J06 4 Pole 455kHz 20 25kHz REFERENCE SYMBOL MOTOROLA PART NO DESCRIPTION 9180453B03 4 Pole 455kHz 12 5 kHz CF52 9104830J06 4 Pole 455k...

Page 66: ...252 C236 R122 L54 NU C266 C286 R101 1200 390 R115 C60 680pF C127 C73 C14 C145 1 2uH L259 C243 C237 C85 NU C123 CR151 1 2uH L256 33nH 100nH L266 E303 BEAD C63 L106 39 R118 C141 1000 R102 C5 R60 100K R59 C108 C148 13K L55 C68 L112 R2 33 47nH CR202 7500 C151 10 R110 C54 C79 R120 15 62K R257 Q104 B C E1 E2 Q101 1 3 2 CR152 C143 1 3 2 C139 L5 Q106 30 51nH C69 C58 C131 C168 82nH L103 13 C251 C223 U51 IF...

Page 67: ... R211 R215 R216 R255 R256 R258 R259 R260 R261 R262 R263 R264 R265 SH101 SL1 TPB 25 24 17 16 9 8 1 U201 U252 MAEPF 25978 A C1 C2 C3 C13 C23 C24 C25 C26 C52 C53 C54 C56 C57 C58 C59 C60 C75 C77 C79 C84 C86 C88 C103 C122 C125 C126 C127 C128 C133 C137 C139 C141 C142 C143 C145 C148 C151 C156 C157 C158 C166 C168 C170 C172 C173 C204 C205 C206 C211 C212 C224 C226 C227 C233 C251 C252 C253 C254 C255 C256 C25...

Page 68: ...0 C282 2113740F27 10 C283 2113741F17 470 C284 2113740F41 39 C285 2113740F11 2 2 0 25pF C286 2113740F31 15 C287 2113740F31 15 C288 2113740F55 150 C289 2113740F51 100 C290 2113740F55 150 C291 2113740F31 15 C309 2113740F55 150 C310 2113740F55 150 CERAMIC FILTER CF51 9180453B06 4 Pole 455kHz 20 25 kHz REFERENCE SYMBOL MOTOROLA PART NO DESCRIPTION 9180453B03 4 Pole 455kHz 12 5 kHz CF52 9180453B06 4 Pol...

Page 69: ...TSQ 20 FREF 1 GND 2 IDAC 6 SQATIN 14 SQATOUT 18 SYNEN C253 12nH L1 680nH L54 CR251 CR151 27pF 1 1000 R161 Q155 1 3 2 2 3 Q153 1 3 2 L109 4 22nH R162 1000 R57 4300 150pF C273 82nH 390nH L257 C219 150pF L254 C277 C276 2 0pF 150pF C54 0 0 R150 51pF L264 C206 47pF 72 895MHz Y53 18nH 10nF 2200 R206 C59 C62 7 5pF L267 39nH C278 150pF C71 0 1uF 4 7 R103 CR101 R61 R111 620 B2 15 BI1 12 BI2 14 E1A 68K NC1 ...

Page 70: ...2 U302 64 49 48 33 32 17 16 1 U401 8 1 5 4 U452 6 1 4 3 U456 8 5 4 1 8 5 4 1 U457 VR401 VR402 VR403 VR405 MAEPF 25980 O C169 VIEWED FROM SIDE 1 C304 C410 C411 C412 C420 C449 C450 C451 C452 C453 C454 C455 C456 C465 C468 C469 C470 C471 C481 C482 C483 C484 C485 C486 C487 C488 C489 C490 CR403 2 20 19 J401 2 20 19 J402 12 7 6 J403 4 2 3 J405 2 3 J406 4 2 J407 Q101 8 5 4 1 1 1 1 R166 8 5 4 R167 8 5 4 R1...

Page 71: ...39uH L403 2462587N56 0 18uH TRANSISTOR Q101 4805128M67 PNP Q401 4880214G02 NPN Q402 5180159R03 PNP Q403 5180159R03 PNP Q404 4805128M67 PNP REFERENCE SYMBOL MOTOROLA PART NO DESCRIPTION RESISTOR Fixed ohm 5 0625W unless stated R166 5180682C03 100k array R167 5180682C02 51k array R168 5180682C03 100k array R169 5180682C02 51k array R170 0662057A97 100k R171 0662057A75 12k R172 0662057A93 68k R173 06...

Page 72: ...O_AMP U454 2 FC2 7 GND VCC 6 VIN 4 5 VO1 8 VO2 C481 100 R456 470K R482 2200 C308 TP410 R481 C484 U451 AFIC 14 4_BIT_ATTEN_IN 4_BIT_ATTEN_OUT 19 15 5_BIT_ATTEN_IN 5_BIT_ATTEN_OUT 20 33 CHIP_SELECT DPL_CAP 24 12 EXT_ALERT_TONE_IN GCB1 39 40 GCB3 GCB4 2 3 GCB5 GND 26 NC 37 PL_CLOCK_STROBE 32 PL_DPL_DECODER_OUT 27 8 PL_DPL_IN PRE_EMPHASIS_OUT 9 RESET 34 7 RX_IN RX_OUT 23 31 SERIAL_CLOCK_IN 6 AUX_RX_IN...

Page 73: ... 2 U302 64 49 48 33 32 17 16 1 U401 8 5 4 U452 6 1 1 4 3 U456 8 5 4 1 8 5 4 1 U457 VR401 VR402 VR403 VR405 MAEPF 25982 O C169 C304 C410 C411 C412 C420 C449 C450 C451 C452 C453 C454 C455 C456 C465 C468 C469 C470 C471 C481 C482 C483 C484 C485 C486 C487 C488 C489 C490 CR403 2 20 19 J401 2 20 19 J402 12 7 6 J403 4 2 J405 VIEWED FROM SIDE 1 2 3 J406 4 2 J407 L406 Q101 8 5 4 R166 8 5 4 R167 8 5 4 R168 8...

Page 74: ...7N56 0 18uH L406 2462587Q44 0 56uH L407 2462587Q44 0 56uH TRANSISTOR Q101 4805128M67 PNP Q401 4880214G02 NPN Q402 5180159R03 PNP Q403 5180159R03 PNP REFERENCE SYMBOL MOTOROLA PART NO DESCRIPTION Q404 4805128M67 PNP RESISTOR Fixed ohm 5 0625W unless stated R166 5180682C03 100k array R167 5180682C02 51k array R168 5180682C03 100k array R169 5180682C02 51k array R170 0662057A97 100k R171 0662057A75 1...

Page 75: ...Q 59 PA4 58 PA5 2 NC1 61 NC10 3 NC2 4 NC3 26 NC4 32 NC5 8 PB4 7 PB5 48 NC8 60 NC9 1 PA0 64 PA1 63 PA2 62 PA3 39 PC4 40 PC5 57 PA6 56 PA7 12 PB0 11 PB1 10 PB2 9 PB3 53 PD4 54 PD5 6 PB6 5 PB7 PC0 34 36 PC1 37 PC2 38 PC3 18 PE6 20 PE7 PC6 41 42 PC7 47 PD0 50 PD1 51 PD2 52 PD3 49 VSS1 24 VSS2 PE0 13 15 PE1 17 PE2 PE3 19 14 PE4 16 PE5 43 RESET STRA 28 30 STRB 55 VDD 22 VRH 21 VRL 23 VSS3 XIRQ 45 33 XTA...

Page 76: ... 13 MAEPF 25984 O C801 U801 DS801 DS802 DS803 14 1 8 7 J801 0 1 2 VIEWED FROM SIDE 1 3 4 5 6 7 8 9 Q801 R801 R802 43 56 1 14 15 28 42 29 R803 R811 R812 R813 R814 R815 R816 R817 Circuit Board Details for PMLN4061 Display Board ...

Page 77: ...1 0662057A81 22k R812 0662057A81 22k R815 0662057A89 47k R814 0662057B02 150k R813 0662057B47 0 JACK J801 0904655J01 Connector Header 14 position CAPACITOR Fixed pF 5 50V unless stated C801 2113741F41 0047uF LED DS801 4805729G90 LED DS802 4805729G90 LED DS803 4805729G90 LED TRANSISTOR Q801 4880214G02 NPN MODULE U801 5102463J14 LCD Driver 84 Segment LCD ASSEMBLY 1304695J01 Bezel 3904700J01 Zebra Co...

Page 78: ... BLANK COMB VLCM COMA VLCL GND VDD1 OSCIN CLK DATA LOAD OSCR OSCC SEG15 SEG9 SEG14 SEG13 SEG12 SEG11 SEG10 SEG8 SEG2 SEG7 SEG6 SEG5 SEG4 SEG3 42 36 41 40 39 38 37 35 29 34 33 32 31 30 1 7 2 3 4 5 6 8 14 9 10 11 12 13 33 27 32 31 30 29 28 26 20 25 24 23 22 21 19 13 18 17 16 15 14 12 9 11 10 8 2 7 6 5 4 3 1 A32_B32 A26_B26 A31_B31 A30_B30 A29_B29 A28_B28 A27_B27 A25_B25 A19_B19 A24_B24 A23_B23 A22_B...

Page 79: ... Speaker 15 5005256W01 Speaker 16 7504698J01 Keypad Top Control 17 1480577C01 Boot Microphone 18 5013920A04 Microphone Mini Electret 19 0104780J03 Mic Flex Assembly 20 7504697J01 Keypad Main 7509717J01 Pad No Keys 21 PMLN4059A GP68 Contr Board 22 PMLN4061A GP68 Display Board 23 4304711J01 Spacer Jack 24 0304726J01 Screw Torx T 6 25 PMLD4036A GP68 VHF RF Board 20 25 KHz 26 8404721J02 Board Flexible...

Page 80: ...March 1997 6881086C09 O 17 Exploded View from manual number 6804370J41 B Page 17 GP68 Exploded Mechanical View ...

Page 81: ...tandard charger 9 3980552D03 CONTACT battery position 3 10 3980552D02 CONTACT battery position 2 11 3980552D01 CONTACT battery position 1 12 6480951Z01 BASE charger 13 7580530C01 FEET charger 4 used 14 3380609D04 LABEL charger 230 V 15 3380609D01 LABEL charger 120 V 16 3380609D06 LABEL charger 240 V 20 6180996Z01 LIGHT PIPE Battery Charger Standard Rate 10 Hour Exploded View and Parts List Charger...

Page 82: ...R210 0660076A89 47k R211 0660076B01 100k R212 0660076A42 510 light emitting dlode DS201 4805729G44 red connector receptacle J201 0980422B01 power jack transistor Q201 4805128M16 PNP Q202 4813822A10 PNP Q203 4880214G02 NPN Q204 4813822A10 PNP Q205 4805128M16 PNP voltage regulator VR201 202 4880140L05 4 7 V VR203 4811058B05 30V Battery Charger Standard Rate 10 Hour Circuit Board Schematic Diagram an...

Page 83: ...20 6881086C09 O March 1997 ...

Page 84: ...d this Service manual provide you with the information necessary to service and maintain the specific equipment very much so generally yes to some extent no 4 How do you rate this particular Service Manual excellent very good good fair poor 5 We would appreciate any corrections or recommendations for improving this manual Please include the specific page number s of the diagram or procedure in que...

Page 85: ...rts List Page No __________ 6 General comments suggestions Name Company Customer COSC MSS FTR Other Address City State Zip Phone Number Please include Area Code PLEASE USE TAPE TO SEAL POSTAL REGULATIONS PROHIBIT USE OF STAPLES NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 9040 FT LAUDERDALE FL POSTAGE WILL BE PAID BY ADDRESSEE Attention Media a...

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