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Motorola Gm Series Detailed 6864115b62 A Manual

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    							vii
    OPERATIONAL WARNINGS
    For Vehicles With An Air Bag 
    Potentially Explosive Atmospheres
     Blasting Caps And Areas
    OPERATIONAL CAUTIONS
    Antennas
    Do not use any portable radio that has a damaged antenna. If a damaged antenna comes into contact with your 
    skin, a minor burn can result.
    Batteries
    All batteries can cause property damage and/or bodily injury such as burns if a conductive material such as 
    jewellery, keys, or beaded chains touch exposed terminals. The conductive material may complete an electrical 
    circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when 
    placing it inside a pocket, purse, or other container with metal objects.
    MOBILE RADIO OPERATION AND EME EXPOSURE
    To assure optimal radio performance and that human exposure to radio frequency electromagnetic energy is 
    within the guidelines referenced earlier in this document, transmit only when people outside the vehicle are at 
    least the minimum lateral distance away from a properly installed, externally-mounted antenna. Table 1 lists the 
    minimum distance for several different ranges of rated radio power.
    WARNING: Do not place a portable radio in the area over an air bag or in the air bag 
    deployment area. Air bags inflate with great force. If a portable radio  is placed in the air bag 
    deployment area and the air bag inflates, the radio product may be propelled with great force 
    and cause serious injury to occupants of vehicle.
    NOTEThe areas with potentially explosive atmospheres referred to above include fueling 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 poten-
    tially explosive atmospheres are often but not always posted.
    WARNING: Turn off your radio  prior to entering any area with a potentially explosive 
    atmosphere, unless it is a radio type especially qualified for use in such areas as 
    Intrinsically Safe (for example, Factory Mutual, CSA, UL or CENELEC Approved).  Do not 
    remove, install, or charge batteries 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 possible interference with blasting operations, turn off your radio when 
    you are near electrical blasting caps, in a “blasting area” or in areas posted 
    “Turn off two-way radio”. Obey all signs and instructions.
    Ta b l e  1 :  Ta b l e  1  Rated Power and Lateral Distance
    Radiated Power of 
    Vehicle-installed 
    Mobile Two-way Minimum Lateral 
    Distance From 
    Transmitting 
    Less than 7 Watts 20 cm (8 Inches)
    !
    !
    ! 
    						
    							viii
    ANTENNA INSTALLATION
    Mobile Antennas
    Recommended mobile antenna installations are limited to metal body vehicles at the centre of the roof and centre 
    of the trunk deck locations.
    The antenna installation must additionally be in accordance with: 
     a) The requirements of the antenna manufacturer/supplier
     b) Instructions in the Radio Installation Manual
    Fixed Site Antennas 
    Mobile radio equipment is sometimes installed at a fixed location and  operated as a control station or as a fixed 
    unit.   In such cases the antenna installation must comply with the following requirements in order to assure 
    optimal performance and make sure human exposure to radio frequency electromagnetic energy is within the 
    guidelines set forth in the above standards:
    The antenna must be mounted outside the building
    Mount the antenna on a tower if at all possible
    If the antenna is to be mounted on a building then it must be mounted on the roof.
    As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in accordance 
    with applicable regulatory requirements and may require additional compliance actions such as site survey 
    measurements, signage, and site access restrictions in order to insure that exposure limits are not exceeded.
    7 to 15 Watts 30 cm (1 Ft)
    16 to 50 Watts 60 cm (2 Ft)
    More than 50 Watts 90 cm (3 Ft)
    Table 1: Ta b l e  1  Rated Power and Lateral Distance
    Radiated Power of 
    Vehicle-installed 
    Mobile Two-way Minimum Lateral 
    Distance From 
    Transmitting  
    						
    							Chapter 1
    INTRODUCTION
    1.0 Scope of Manual
    This manual is intended for use by service technicians familiar with similar types of equipment. It 
    contains service information required for the equipment described and is current as of the printing 
    date. Changes which occur after the printing date may be incorporated by a complete Manual 
    revision or alternatively as additions.
    2.0 Warranty and Service Support
    Motorola offers long term support for its products. This support includes full exchange and/or repair 
    of the product during the warranty period, and service/ repair or spare parts support out of warranty. 
    Any return for exchange or return for repair by an authorised Motorola Dealer must be 
    accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an 
    Authorised Motorola Dealer.
    2.1 Warranty Period and Return Instructions
    The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or 
    Reseller contract. These conditions may change from time to time and the following notes are 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 appropriate Motorola warranty depot, please contact 
    Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be 
    accompanied by a Warranty Claim Form, available from your Customer Services representative. 
    Products should be shipped back in the original packaging, or correctly packaged to ensure no 
    damage occurs in transit. 
    2.2 After Warranty  Period
    After the Warranty period, Motorola continues to support its products in two ways. 
    1.Motorolas Radio Aftermarket and Accessory Division (AAD) offers a repair service to both 
    end users and dealers at competitive prices. 
    2.AAD supplies individual parts and modules that can be purchased by dealers who are techni-
    cally capable of performing fault analysis and repair.
    NOTEBefore operating or testing these units, please read the Safety Information Section in the
    front of this manual. 
    						
    							1-2INTRODUCTION
    2.3 European Radio Support Centre (ERSC)
    The ERSC Customer Information Desk is available through the following service numbers:
    Austria: 06 60 75 41 Italy:  16 78 77 387
    Belgium:  08 00 72 471 Luxemburg:  08 00 23 27
    Denmark:  80 01 55 72  Netherlands: 60 22 45 13
    Finland: 08 00 11 49 10 Norway:  80 01 11 15
    France: 05 90 30 90 Portugal:  05 05 49 35 70
    Germa ny:   0800  1875240    Spain:   90 09 84 902
    Greece: 00 80 04 91 29 020 Sweden:  02 07 94 307
    UK: 08 00 96 90 95 Switzerland: 1 55 30 82
    Ireland: 18 00 55 50 21 Iceland:  80 08 147
    Or dial Customer Care Centre: Tel: +49 6128 70 2618 
    Please use these n
    umbers 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 Motorola. If the part number is appended with an asterisk, the part is serviceable by 
    Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable 
    parts are available for that kit or assembly.
    All enquiries should be directed to your local  Technical Support Team.  
    						
    							Warranty and Service Support1-3
    2.5 Technical Support
    Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions 
    which may be encountered.
    2.6 Related Documents
    The following documents are directly related to the use and maintainability of th\
    is product.UK/Ireland
     - Richard Russell
    Telephone:  +44 (0) 1256 488 082
    Fax:  +44 01256 488 080
    Email:  BRR001@email.mot.com France -
     Armand Roy
    Telephone:  +33 1 6929 5715
    Fax:  +33 1 6929 5904
    Email:  armand.roy@motorola.com
    East Europe, Turkey and Central Asia
    Siggy Punzenberger
    Telephone:  +49 (0) 6128 70 2342
    Fax:  +49 (0) 6128 95 1096
    Email:  TFG003@email.mot.com Italy -
     Ugo Gentile
    Telephone:  +39 0 2822 0325
    Fax: +39 0 2822 0334
    Email:  C13864@email.mot.com
    Scandin avia
    Telephone:  +46 8 735 9282
    Fax:  +46 8 735 9280 Middle East & Africa -
     Ralph Schubert
    Telephone: +33 (0) 4 4230 5887
    Fax: +33 (0) 4 4230 4784
    Email: ralph.schubert@motorola.com
    Central Europe (Germany, Benelux, 
    Austria & Switzerland) -  Customer Connect
    Telephone:  +49 (0) 6128 70 2266
    Fax:  +49 (0) 6128 95 1685
    Email: cgiss.emea@europe.mot.com
    Title Language Part Number
    GM100 Series Product ManualEnglishENLN4147
    GM300 Series Product Manual English German
    French
    Italian
    Spanish
    RussianENLN4137
    ENLN4138
    ENLN4139
    ENLN4140
    ENLN4141
    ENLN4142
    GM600/GM1200 Series Product ManualEnglish
    German
    French
    RussianENLN4143
    ENLN4144
    ENLN4145
    ENLN4146 
    						
    							1-4INTRODUCTION
    3.0 Radio Model Information
    The model number and serial number are located on a label attached to the back of your radio. You 
    can determine the RF output power, frequency band, protocols, and physical packages. The 
    example below shows one mobile radio model number and its specific characteristics.
    Table 1-1   Radio Model Number (Example: MDM25KHC9AN1AE)
    Type of 
    UnitModel 
    SeriesFreq. 
    BandPower 
    LevelPhysical 
    PackagesChannel 
    SpacingProtocolFeature 
    LevelModel
    RevisionModel 
    Package
    MD M 25 K
    VHF
    (136-
    174MHz)H
    1-25WC
    GM140,
    GM340,
    GM6409
    Program-
    mableAN
    Conventional
    5 Tone1
    GM140 
    GM340
    GM640AE
    R
    UHF 1
    (403-
    470MHz)K
    25-40W
    40-60WN
    GM380,
    GM1280AA
    Conventional
    MDCO
    Databox
    (5Tone)
    S
    UHF 2
    (450-
    527MHz)F
    GM160
    GM360
    GM660CK
    MPT5
    GM160
    GM360
    GM660
    B
    LB1
    29-36MHzA 
    Databox8
    GM380
    GM1280
    C
    LB2
    36-42MHz7 
    Databox
    (MPT)
    D
    LB3
    42-50MHz
     MD = Motorola Internal Use
    M = Mobile 
    						
    							Chapter 2
    Internal sur faces should be cleaned only when the radio is disassem bled  for se rvicing or
    C AUTION : The effects of ce rtain chemicals and their  vapo rs can h ave harmful results on 
    ! 
    						
    							2-2  MAINTENANCE
    3.0  Safe Handling of CMOS and LDMOS
    Always use a fresh supply of alcohol and a clean container to pr event contamination  by 
    						
    							General Repair Procedures and Techniques2-3
    Chip Components
    Use either the RLN4062 Hot-Air Repair Station or the Motorola 0180381B45 Repair Station for 
    chip component replacement. When using the 0180381B45 Repair Station, select the TJ-65 mini-
    thermojet hand piece. On either unit, adjust the temperature control to 370 °C (700 °F), and 
    adjust the airflow to a minimum setting. Airflow can vary due to component density.
    n nTo remove a chip component: 
    1.Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm 
    (1/8) above the component to be removed. 
    2.Begin applying the hot air. Once the solder reflows, remove the component using a pair 
    of tweezers. 
    3.Using a solder wick and a soldering iron or a power desoldering station, remove the 
    excess solder from the pads.
    n nTo replace a chip component using a soldering iron: 
    1.Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the 
    solder pads. 
    2.Using a pair of tweezers, position the new chip component in place while heating the 
    fresh solder. 
    3.Once solder wicks onto the new component, remove the heat from the solder. 
    4.Heat the remaining pad with the soldering iron and apply solder until it wicks to the 
    component. If necessary, touch up the first side. All solder joints should be smooth and 
    shiny.
    n nTo replace a chip component using hot air:
    1.Use the hot-air hand piece and reflow the solder on the solder pads to smooth it. 
    2.Apply a drop of solder paste flux to each pad. 
    3.Using a pair of tweezers, position the new component in place. 
    4.Position the hot-air hand piece approximately 0.3 cm (1/8” ) above the component and 
    begin applying heat. 
    5.Once the solder wicks to the component, remove the heat and inspect the repair. All 
    joints should be smooth and shiny. 
    						
    							2-4MAINTENANCE
    Shields
    Removing and replacing shields will be done with the R1070 station with the temperature control 
    set to approximately 215°C (415°F) [230°C (445°F) maximum].
    n nTo remove the shield: 
    1.Place the circuit board in the R1070 circuit board holder. 
    2.Select the proper heat focus head and attach it to the heater chimney. 
    3.Add solder paste flux around the base of the shield. 
    4.Position the shield under the heat-focus head. 
    5.Lower the vacuum tip and attach it to the shield by turning on the vacuum pump. 
    6.Lower the focus head until it is approximately 0.3 cm (1/8”) above the shield. 
    7.Turn on the heater and wait until the shield lifts off the circuit board. 
    8.Once the shield is off, turn off the heat, grab the part with a pair of tweezers, and turn off 
    the vacuum pump. 
    9.Remove the circuit board from the R1070 circuit board holder.
    n nTo replace the shield: 
    1.Add solder to the shield if necessary, using a micro-tipped soldering iron. 
    2.Next, rub the soldering iron tip along the edge of the shield to smooth out any excess 
    solder. Use solder wick and a soldering iron to remove excess solder from the solder 
    pads on the circuit board. 
    3.Place the circuit board back in the R1070 circuit board holder. 
    4.Place the shield on the circuit board using a pair of tweezers. 
    5.Position the heat-focus head over the shield and lower it to approximately 0.3 cm (1/8”) 
    above the shield. 
    6.Turn on the heater and wait for the solder to reflow.
    7.Once complete, turn off the heat, raise the heat-focus head and wait approximately one 
    minute for the part to cool. 
    8.Remove the circuit board and inspect the repair. No cleaning should be necessary. 
    						
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