Motorola GM140, Basic Service Manual

Page 1: ...Professional Radio GM300 Series Basic Service Manual 68P64115B51 Issue July 2000 ...

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 products shall not be deemed to grant either directly or by implication estoppel or otherwise any license under the cop...

Page 3: ...ncy electromagnetic energy is within the guidelines in the above standards always adhere to the following procedures ELECTROMAGNETIC INTERFERENCE COMPATIBILITY To avoid electromagnetic interference and or compatibility conflicts turn off your radio in any facility where posted notices instruct you to do so Hospital or health facilities may be using equipment that is sensitive to external RF energy...

Page 4: ...TE Refer to Table 1 for rated power and minimum distance values for transmitting antennas WARNING Turn off your Two Way radio when you are in any area with a potentially explosive atmosphere unless it is a radio type especially qualified for use in such areas Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death WARNING To avoid possib...

Page 5: ...ations 2 4 Chapter 3 MAINTENANCE 1 0 Introduction 3 1 2 0 Preventive Maintenance 3 1 2 1 Inspection 3 1 2 2 Cleaning Procedures 3 1 3 0 Safe Handling of CMOS and LDMOS Devices 3 2 4 0 Repair Procedures and Techniques General 3 3 5 0 Disassembling and Reassembling the Radio General 3 3 6 0 Radio Disassembly Detailed 3 4 6 1 Control Head Removal 3 4 6 2 Top Cover Removal 3 5 6 3 Transceiver Board Re...

Page 6: ...M380 3 15 9 0 Service Aids 3 16 10 0 Test Equipment 3 17 11 0 Programming Test Cable RKN4083_ 3 18 Chapter 4 TRANSCEIVER PERFORMANCE TESTING 1 0 General 4 1 2 0 Setup 4 1 3 0 RF Test Mode 4 2 Chapter 5 RADIO TUNING AND PROGRAMMING 1 0 Introduction 5 1 2 0 CPS Programming Setup 5 1 3 0 Radio Tuning Setup 5 3 3 1 Initial Test Equipment Control Settings 5 3 Chapter 6 POWER UP SELF TEST 1 0 Error Code...

Page 7: ...e 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 approp...

Page 8: ...l Customer Care Centre Tel 49 6128 70 2164 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 from ...

Page 9: ...70 2342 Fax 49 0 6128 95 1096 Email TFG003 email mot com Northern Europe Bjorn Rambert Telephone 46 8 735 9282 Fax 46 8 735 9280 Email TCW275X email mot com Germany Telephone 49 0 6128 70 2266 Fax 49 0 6128 95 1685 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 0...

Page 10: ...tics Table 1 1 Radio Model Number Example MDM25KHC9AN1AE Type of Unit Model Series Freq Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package MD M 25 K VHF 136 174MHz H 1 25W C GM140 GM340 GM640 9 Program mable AA Conventional MDC 1 GM140 GM340 GM640 A E R UHF1 403 470MHz K 40 60W F GM160 GM360 GM660 AN 5 Tone 5 GM160 GM360 GM660 B LB1 29 7 36 0MHz ...

Page 11: ...scription X GCN6112_ Control Head GM340 X GCN6120_ Control Head GM360 X GCN6121_ Control Head GM380 X IMUE6015_ Tanapa GM340 X IMUE6015_ Tanapa GM360 X IMUE6038_ Tanapa GM380 X X X ENBN4056_ Packaging Waris Mobile X X X GLN7324_ Low Profile Mounting Trunion X X X HKN4137_ 12V Power Cable 1 25W X X X MDRMN4025_ Enhanced Compact Microphone X 6864110B80 User Guide GM340 X 6864110B81 User Guide GM360 ...

Page 12: ...iption X GCN6112_ Control Head GM340 X GCN6120_ Control Head GM360 X GCN6121_ Control Head GM380 X IMUD6013_ Tanapa GM340 X IMUD6013_ Tanapa GM360 X IMUD6024_ Tanapa GM380 X X X ENBN4056_ Packaging Waris Mobile X X X GLN7324_ Low Profile Mounting Trunion X X X HKN4137_ 12V Power Cable 1 25W X X X MDRMN4025_ Enhanced Compact Microphone X 6864110B80 User Guide GM340 X 6864110B81 User Guide GM360 X 6...

Page 13: ...0W 255 Ch MDM25DKF9AN5_E GM360 LB3 42 0 50 0 MHz 25 60W 255 Ch Item Description X X X GCN6120_ Control Head GM360 X IMUB6003_ Tanapa GM360 LB1 X IMUB6004_ Tanapa GM360 LB2 X IMUB6005_ Tanapa GM360 LB3 X X X ENBN4056_ Packaging Waris Mobile X X X HKN9402_ 12V Power Cable X X X MDRMN4025_ Enhanced Compact Microphone X X X RLN4774_ 3 Point Mount X X X 6864110B81_ User Guide GM360 X Indicates one of e...

Page 14: ...ow Band 40 60W GM360 177mm X 176mm X 56mm add 8mm for Volume Knob 6 97 X 6 93 X 2 2 add 0 3 for Volume Knob 186mm X 179mm X 59mm add 9mm for Volume Knob 7 32 X 7 05 X 2 34 add 0 35 for Volume Knob 188mm X 185mm X 72mm add 7mm for Volume Knob 7 4 X 7 28 X 2 83 add 0 27 for Volume Knob 250mm X 179mm X 59mm add 9mm for Volume Knob 9 8 X 7 05 X 2 34 add 0 35 for Volume Knob Weight Low power 1 25W High...

Page 15: ...1 LB2 LB3 Sensitivity 12dBSINAD ETS 0 30µV 0 22 µV Typical Intermodulation ETS 65 dB 70 dB in Base Mode 65 dB Adjacent Channel Selectivity ETS 80 dB 25 kHz 75 dB 20 kHz 65 dB 12 5 kHz 75 dB 25 kHz 70 dB 20 kHz 65 dB 12 5 kHz 80 dB 25 kHz 75 dB 20 kHz 65 dB 12 5 kHz Spurious Rejection ETS 80 dB 20 25 kHz 75 dB 12 5 kHz 75 dB 20 25 kHz 70 dB 12 5 kHz 80 dB 20 25 kHz 75 dB 12 5 kHz Rated Audio ETS 3W...

Page 16: ...2 6 MODEL CHART AND TEST SPECIFICATION ...

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: ... 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 tr...

Page 19: ... the plated circuit out of the hole When soldering near the 20 pin and 40 pin connectors Avoid accidentally getting solder in the connector Be careful not to form solder bridges between the connector pins Examine your work closely for shorts due to solder bridges 5 0 Disassembling and Reassembling the Radio General Since these radios may be disassembled and reassembled with the use of only four bo...

Page 20: ...o models without a display and radio models fitted with a display 6 1 Control Head Removal 1 Insert the dismantling tool in the groove between the control head and the radio assembly as shown in Figure 3 1 2 Press on the dismantling tool until the snap connectors on the side of the control head release from the radio assembly Figure 3 1 Typical Control Head Removal 3 Pull the control head away fro...

Page 21: ...ver Removal 1 Insert the dismantling tool in the middle of the radio assembly side groove as shown in Figure 3 3 2 Press on the dismantling tool until the snap connectors on the side of the cover release from the radio chassis 3 Lift the top cover from the chassis Figure 3 3 Top Cover Removal Flexible Connection ZWG0130210 O Dismantling Tool ZWG0130211 O ...

Page 22: ...mates with the control head and pull gently toward the front of the radio as shown in Figure 3 5 Take care to slide the antenna connector and power connector out of the chassis towards the front Figure 3 5 Transceiver Board Removal CAUTION The thermal grease or pads can act as an adhesive and cause the leads of the heat dis sipating devices to be over stressed if the board is lifted too quickly Di...

Page 23: ...e side of the back housing release from the control head 3 Disconnect the speaker socket Figure 3 7 Control Head Board Removal 4 Remove the board from the control head housing by stretching the control head housing and pulling up on the board as shown in Figure 3 7 and 3 8 5 Remove the keypad from the control head housing by lifting up the rubber keypad NOTE Care should be taken not to touch or co...

Page 24: ...nd 3 7 2 On the GM360 disconnect the speaker socket and pull out the speaker with speaker tube by stretching the control head housing Figure 3 9 Figure 3 9 Speaker and Speaker Tube Removal 3 Remove the board from the control head housing by stretching the control head housing and pulling up on the board 4 Remove the keypad from the control head housing by lifting up the rubber keypad NOTE The spea...

Page 25: ...astomeric connector strips into the spaces above and below the display respectively 2 Fit the rubber keypad onto the board ensuring that the on off control and microphone connector on the board locate correctly with the cut outs in the keypad 3 On the board rotate the on off control spindle fully counter clockwise 4 Also rotate the volume knob on the front housing fully counter clockwise 5 Align t...

Page 26: ...X driver Begin with the two screws located in the middle of the chassis followed by the four outer screws Since the screws usually take a set torque the screws a second time 1 9 NM in the same order 6 Refit the top cover over the assembled radio chassis Press the cover down until it snaps into place 7 4 Control Head Fitting 1 Align the 0 mark on the flex with the 0 mark on the chassis to the socke...

Page 27: ...10 included 4 Antenna Connector with Gasket BNC 0986166B01 5 Power Connector 0986165B01 6 Connector 20 PIN 0986105B01 7 Connector Assembly 2886122B02 8 Gasket Cover 3202607Y01 9 Connector 1580922V01 10 Gasket Accessory Connector 3202606Y01 11 Gasket Cover 25W 3286086B01 12 Cover 25W 1586084B01 13 Cover Plastic 25W 1586083B01 14 Screw T20 6x M4 0310911A30 15 Screw T8 Power Device Fastner some model...

Page 28: ...in PCB items 4 5 and 8 included 4 Antenna Connector Mini UHF 0986166B02 5 Power Connector 0986165B01 6 Connector 20 PIN 0986105B01 7 Connector Assembly 2886122B01 8 Gasket Cover Connector 3202607Y01 9 Connector 1580922V01 10 Gasket Accessory Connector 3202606Y01 11 Gasket Cover 60W 3286152B01 12 Cover 60W 1586150B01 13 Cover Plastic 60W 1586151B01 Screw T20 9x not shown 0310911A30 ZWG0130203 A 11 ...

Page 29: ...tguide 1586086B01 2 Knob Volume 3686098B02 3 Label 1364279B13 4 Speaker 5086126B01 5 Keypad including Keypad Button 7586089B01 3886133B 6 PCB Kit GLN7350_ 7 Potentiometer 1805911V02 8 10 PIN Microphone Jack 2864287B01 9 Flex 12 Position Connector Controlhead to Radio 8486127B01 10 Backhousing including Back Housing O ring Back Housing Grounding Clip 1586092B02 3286094B01 3286217B01 ZWG0130198 A 1 ...

Page 30: ... Gasket 3786107B01 6 Keypad including Keypad Button 7586091B02 3886134B 7 LCD Glass 7286104B01 8 Frame LCD 0786099B01 9 Conn Elastomeric Top and Bottom 2886130B01 2886130B02 10 Back Housing including 1586093B02 Back Housing O ring 3286094B01 Back Housing Grounding Clip 3986218B01 11 PCB Kit GLN7353_ 12 Potentiometer 1805911V02 13 10 PIN Micphone Jack 2864287B01 not shown Flex 12 Position Connector...

Page 31: ...98B02 3 Label 1364279B15 4 LCD Module 5164313B01 5 Keypad including Keypad Button 7564314B01 3886134B 6 PCB Kit GLN7361_ 7 Potentiometer 1805911V02 8 10 PIN Microphone Jack 2864287B01 9 Flex 24 Position connector 8464346B02 10 Backhousing including 1564305B01 Back housing O ring Grounding Clip left Grounding Clip right 3286094B01 3908450X02 3908451X02 not shown Flex 12 Position Connector Controlhe...

Page 32: ...ophone input RLN4008_ Radio Interface Box Enables communications between radio and computer s serial communications adapter HLN8027_ Mini UHF to BNC Adaptor Adapts radio antenna port to BNC cabling of test equipment GPN6133_ Power Supply Provides the radio with power when bench testing EPN4040_ Wall Mounted Power Supply Used to supply power to the RIB UK EPN4041_ Wall Mounted Power Supply Used to ...

Page 33: ...ncy 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_ 0180305F17 0180305F31 0180305F40 RLN4610_ T1013_ Wa...

Page 34: ...tor SPEAKER EXTERNAL MIC DIGITAL IN 1 EXT PTT DIGITAL OUT 2 EXT ALARM FLAT TX AUDIO SENSITIVITY DIGITAL IN 3 MPT MAP 27 RX GND DIGITAL IN OUT 4 MPT MAP 27 TX DIGITAL IN 5 w WAKEUP EMG IGNITION FLAT FILTERED RX AUDIO DIGITAL IN OUT 7 SWITCHED BATTERY VOLTAGE DIGITAL IN OUT 8 RSSI SPEAKER BUS FOR CPS AND FLASHING BOOT CONTROL N C N C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 AUDIO AUDIO AUD...

Page 35: ...ning Test Setup Diagram Chapter 5 Figure 5 4 Initial equipment control settings should be as indicated in Table 4 1 The remaining tables in this chapter contain the following related technical data Table Number Title 4 2 Test Environments 4 3 Test Channel Spacing 4 4 Test Frequencies 4 5 Transmitter Performance Checks 4 6 Receiver Performance Checks Table 4 1 Initial Equipment Control Settings Ser...

Page 36: ...play 7 Pressing P1 causes the radio to turn on all the dots of the first character Another P1 press turns on all the dots of the next character and so on until the last character 8 Pressing P1 at the end of the LCD test activates the Icon Test The next P1 press turns on the first icon 9 Pressing P1 at the end of the Icon test activates the button test Pressing any button except P1 or any keypad bu...

Page 37: ... TX selected DTMF tone pair 9 MPT 0 RX unsquelch if carrier detected TX 1200 baud with data 0 10 MPT 1 RX unsquelch if carrier detected TX 1200 baud with data 1 4 MPT 3 RX speaker muted high tone sounds when below sequence detected TX 1200 baud with bit pattern aa aa c4 d7 d2 90 49 f1 f1 bb f5 c7 6 Select 5 CCIR SV C RX speaker muted high tone sounds when below sequence detected TX CCIR sequence 1...

Page 38: ...47 650 33 025 40 225 47 525 RX 5 12 161 250 447 675 33 125 40 325 47 425 TX 6 13 167 525 458 825 34 225 41 025 48 125 RX 6 13 167 550 458 850 34 325 41 125 48 025 TX 7 14 173 950 469 950 35 950 41 950 49 950 RX 7 14 173 975 469 975 35 975 41 975 49 975 Table 4 5 Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comment Reference Frequency Mode PWR MON 4th channel test...

Page 39: ...st Channel 4 carrier squelch output at antenna Remove modulation input Deviation 2 5 kHz Max 12 5 kHz Ch Sp 4 kHz Max 20 kHz Ch Sp 5 kHz Max 25 kHz Ch Sp DTMF Modulation As above 4th channel test frequency TEST MODE Test Channel 4 DTMF output at antenna As above Deviation 1 4 1 9 kHz 12 5 kHz Ch Sp 2 3 3 0 kHz 20 kHz Ch Sp 2 9 3 8 kHz 25 kHz Ch Sp PL DPL Modulation As above 4th channel test freque...

Page 40: ...EST MODE Test Channel 4 carrier squelch PTT to OFF center meter selector to Audio PA Set volume control to 8 12Vrms Distortion As above except to distortion As above As above Distortion 5 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 3µV Noise Squelch Threshold only radios with conventional system need to be tested RF level ...

Page 41: ...Tuning Setup 2 0 CPS Programming Setup The CPS programming setups shown in Figures 5 1 through 5 3 are used to program the radio NOTE Refer to the appropriate program on line help files for the programming procedures Description Kit Number EMEA CD ENLN4115_ Software Installation Manual 68P64113B14_ NOTE Refer to appropriate program on line help files for the programming procedures Figure 5 1 CPS P...

Page 42: ... 5 3 CPS Programming Setup Cable with Internal RIB and Rear Adapter Cable Power Supply 13 2VDC Programming Cable RKN4081 Rx Data Gnd Tx Data DB25 Radio DC RF ACC ZWG0130339 0 Programming RKN4081 Cable Adapter RLN4853 Cable Rx Data Gnd Tx Data DB25 Radio DC RF ACC Power Supply 13 2VDC ZWG0130340 0 ...

Page 43: ...st Set Power Supply Monitor Mode Power Monitor Speaker set A Voltage 13 2Vdc RF Attenuation 70 Speaker load Speaker DC on standby Standby AM CW FM FM PTT OFF Volt Range 20V Oscilloscope Source Mod Oscilloscope Horizontal 10mSec Div Oscilloscope Vertical 2 5 kHz Div Oscilloscope Trigger Auto Monitor Image Hi Monitor BW Nar Monitor Squelch mid CW Monitor Volume 1 4 CW Current 20A Wattmeter Audio Gen...

Page 44: ...5 4 RADIO TUNING AND PROGRAMMING ...

Page 45: ...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 46: ...6 2 POWER UP SELF TEST ...