Motorola Gp328plus Gp338plus Gp338xls Detailed 6804112j28 G Manual

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Operational Cautions
Intrinsically Safe Radio Information
The Intrinsically safe approval unit refers to a product that has been approved as intrinsically safe by 
an approval agency (for example FM Approvals, CSA, UL, or Cenelec) and certifies that a particular 
product meets the Agencys applicable intrinsic safety standards for specific types of hazardous 
classified locations. A portable radio that has been approved for intrinsic safety will have Approval 
label attached to the radio to identify the unit as being Approved for specified hazardous 
atmospheres. This label specifies the hazardous Class/Division/Group along with the part number of 
the battery that must be used. The intrinsically safe approval label will be located on the portable 
radio unit.
Operational Cautions for Intrinsic Safe Equipment
Warnings for Radios Approved as Intrinsically Safe
Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability 
and the intrinsic safety approval labelling (FM, UL, CSA, CENELEC). Radios will not be upgraded to 
this capability and labeled once they have been shipped to the field.
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 jewelry, keys, or beaded chains touches 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. 
• Do not operate radio communications equipment in a hazardous atmosphere unless it is a type 
especially qualified (for example, FM, UL, CSA, or CENELEC 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 charge batteries in a hazardous atmosphere. Contact sparking may occur while 
installing or removing batteries and cause an explosion or fire. 
						

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A modification changes the units hardware from its original design configuration. Modifications can 
only be made by the original product manufacturer.
Repair
A repair constitutes something done internally to the unit that would bring it back to its original 
condition.
Items not considered as repairs are those in which an action is performed on a unit which does not 
require the outer casing of the unit to be opened in a manner that exposes the internal electrical 
circuits of the unit.
Do Not Substitute Options or Accessories
The Motorola communications equipment certified as intrinsically safe by the approving agency, 
(FM, UL, CSA, CENELEC) is tested as a complete system which consists of the listed agency 
Approved portable, Approved battery, and Approved accessories or options, or both. This Approved 
portable and battery combination must be strictly observed. 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 by the Approving Agency (FM, UL, CSA, 
CENELEC).
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 identifies the approved 
Accessories and or options that can be used with that portable radio unit.
Using a non Motorola intrinsically safe battery and or accessory with the Motorola approved radio 
unit will void the intrinsically safe approval of that radio unit.
• Do not replace or change accessories in a hazardous atmosphere. Contact sparking may 
occur while installing or removing accessories and cause an explosion or fire.
• Turn the radio off before removing or installing a battery or accessory.
• Do not disassemble an intrinsically safe product in any way that exposes the internal 
circuits of the unit.
• Failure to use an intrinsically safe approved battery or Approved accessories specifically 
approved for the radio unit may result in the dangerously unsafe condition of an 
unapproved radio combination being used in a hazardous location.
• Unauthorized or incorrect modification of the intrinsically safe approved Product will 
negate the approval rating of the product.
• Incorrect repair or relabeling of any intrinsically safe Agency approved radio could 
adversely affect the Approval rating of the unit.
• Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in 
serious injury or death.
REPAIRS FOR MOTOROLA PRODUCTS WITH INTRINSICALLY SAFE APPROVAL ARE THE 
RESPONSIBILITY OF THE USER.
• Repairs to a Motorola FM approved radio product should only be done at a location that 
has been FM audited under the FM 3605 repairs and service standard.
• Contact Motorola for assistance regarding repairs and service of Motorola intrinsically 
safe equipment. 
						

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Table of Contents
Document History  ............................................................................................. i
Safety Information  .......................................................................................... iii
Section 1Introduction
1.0 Scope of Manual .................................................................................................. 1-1
2.0 Warranty and Service Support............................................................................. 1-1
2.1 Warranty Period ............................................................................................. 1-1
2.2 After Warranty Period ..................................................................................... 1-1
2.3 Piece Parts ..................................................................................................... 1-2
2.4 Technical Support .......................................................................................... 1-2
2.5 Further Assistance From Motorola ................................................................. 1-2
Section 2Service Aids
1.0 Recommended Test Tools................................................................................... 2-1
Section 3Power Up Self-Test
1.0 Error Codes ......................................................................................................... 3-1
Section 4Controller Information
1.0 Overview .............................................................................................................. 4-1
2.0 Radio Power Distribution ..................................................................................... 4-1
3.0 Controller Board................................................................................................... 4-2
3.1 General........................................................................................................... 4-2
3.2 Digital Architecture ......................................................................................... 4-3
3.3 Keypad ........................................................................................................... 4-5
3.4 Troubleshooting Chart .................................................................................... 4-6
3.5 Controller Board Diagrams ............................................................................. 4-7
Controller Board Top View  (PCB No. 8404051G07/G08) ..................................... 4-7
Controller Board Top View  (PCB No. 8404051G07/G08) ..................................... 4-8
Controller Board Top View  (PCB No. 8404051G09) ............................................. 4-9
Controller Board Bottom View (PCB No.8404051G09) ........................................ 4-10
3.6 Controller Schematics .................................................................................. 4-11
Complete Controller Schematic Diagram ............................................................. 4-11
Controller ASFIC/ON_OFF Schematic Diagram .................................................. 4-12
Controller Micro Processor Schematic Diagram .................................................. 4-13
Controller Memory Schematic Diagram ............................................................... 4-14 
						

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Controller Audio Power Amplifier Schematic Diagram..........................................4-15
Controller Parts List for VHF (for 8404051G07/G08 and 8404051G09)...............4-16
Controller Parts List for UHF 1, UHF 2 and 330MHz (for 8404051G07/G08 and 
8404051G09) ................................................................................................4-17
3.7 Controller Board Diagrams ...........................................................................4-18
Controller Board Top View (PCB No. 8404056G01).............................................4-18
Controller Board Bottom View (PCB No.8404056G01) ........................................4-19
Controller Board Top View (PCB No. 8404056G02).............................................4-20
Controller Board Bottom View (PCB No. 8404056G02) .......................................4-21
3.8 Controller Schematics...................................................................................4-22
Complete Controller Schematic Diagram..............................................................4-22
Controller ASFIC/ON_OFF Schematic Diagram ...................................................4-23
Controller Micro Processor Schematic Diagram ...................................................4-24
Controller Memory Schematic Diagram ................................................................4-25
Controller Audio Power Amplifier Schematic Diagram..........................................4-26
Controller Interface Schematic Diagram (for 8404056G01)..................................4-27
Controller Interface Schematic Diagram (for 8404056G02)..................................4-28
Controller Parts List for VHF (for 8404056G01/G02) ............................................4-29
Controller Parts List for UHF 1, UHF 2 and 330MHz (for 8404056G01/G02) .......4-31
Section 5AModel Chart and Test Specifications (136-174 Mhz)
1.0 Model Chart....................................................................................................... 5A-1
2.0 Specifications (for GP328 Plus) ........................................................................ 5A-2
3.0 Specifications (for GP338 Plus/GP338 XLS) .................................................... 5A-3
4.0 Transmitter ........................................................................................................ 5A-4
4.1 General ........................................................................................................ 5A-4
5.0 Receiver ............................................................................................................ 5A-6
5.1 Receiver Front-End...................................................................................... 5A-6
5.2 Receiver Back-End ...................................................................................... 5A-7
5.3 Automatic Gain Control Circuit .................................................................... 5A-8
6.0 Frequency Generation Circuitry ........................................................................ 5A-9
6.1 Synthesizer ................................................................................................ 5A-10
6.2 VCO - Voltage Controlled Oscillator .......................................................... 5A-11
7.0 Notes For All Schematics and Circuit Boards ................................................. 5A-13
8.0 Circuit Board/Schematic Diagrams and Parts List .......................................... 5A-15
VHF (136-174MHz) Main Board Top Side PCB No. 8404055G05/G06/G07..... 5A-15
VHF (136-174MHz) Main Board Bottom Side  
PCB No. 8404055G05/G06/G07 ............................................................... 5A-16
VHF (136-174MHz) Main Board Top Side PCB No. 8404055G09 .................... 5A-17
VHF (136-174MHz) Main Board Bottom Side PCB No. 8404055G09 ............... 5A-18
VHF Controls And Switches Schematic Diagram (sheet 1 of 2) ........................ 5A-19
VHF Controls And Switches Schematic Diagram (sheet 2 of 2) ........................ 5A-20
VHF Controls And Switches Schematic Diagram  
(sheet 2 of 2 for 8404055G09 PCB) .......................................................... 5A-21 
						

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VHF Receiver Front End Schematic Diagram ....................................................5A-22
VHF Receiver Back End Schematic Diagram ....................................................5A-23
VHF Synthesizer Schematic Diagram................................................................5A-24
VHF Voltage Controlled Oscillator Schematic Diagram .....................................5A-25
VHF Transmitter Schematic Diagram.................................................................5A-26
VHF Radio Parts List (RF Board) .......................................................................5A-27
9.0 Troubleshooting Charts ...................................................................................5A-31
Troubleshooting Flow Chart for Controller .........................................................5A-31
Troubleshooting Flow Chart for Receiver (Sheet 1 of 2) ....................................5A-32
Troubleshooting Flow Chart for Receiver (Sheet 2 of 2) ....................................5A-33
Troubleshooting Flow Chart for Transmitter .......................................................5A-34
Troubleshooting Flow Chart for Synthesizer ......................................................5A-35
Troubleshooting Flow Chart for VCO .................................................................5A-36
Section 5BModel Chart and Test Specifications (403-470 Mhz)
1.0 Model Chart .......................................................................................................5B-1
2.0 Specifications (for GP328 Plus) .........................................................................5B-2
3.0 Specifications (for GP338 Plus/GP338 XLS) .....................................................5B-3
4.0 Transmitter.........................................................................................................5B-4
4.1 General.........................................................................................................5B-4
5.0 Receiver.............................................................................................................5B-6
5.1 Receiver Front-End ......................................................................................5B-6
5.2 Receiver Back-End.......................................................................................5B-7
5.3 Automatic Gain Control Circuit .....................................................................5B-8
6.0 Frequency Generation Circuitry .........................................................................5B-9
6.1 Synthesizer.................................................................................................5B-10
6.2 VCO - Voltage Controlled Oscillator ...........................................................5B-11
7.0 Notes For All Schematics and Circuit Boards ..................................................5B-13
8.0 Circuit Board/Schematic Diagrams and Parts List ...........................................5B-15
UHF (403-470MHz) Main Board Top Side PCB No. 8404077G05/G06/G07 .....5B-15
UHF (403-470MHz) Main Board Bottom Side  
PCB No. 8404077G05/G06/G07 ................................................................5B-16
UHF (403-470MHz) Main Board Top Side PCB No. 8404077G09 ....................5B-17
UHF (403-470MHz) Main Board Bottom Side PCB No. 8404077G09 ...............5B-18
UHF Controls And Switches Schematic Diagram (sheet 1 of 2) ........................5B-19
UHF Controls And Switches Schematic Diagram 
(sheet 2 of 2 for 8404077G09 PCB)...........................................................5B-20
UHF Receiver Front End Schematic Diagram ....................................................5B-21
UHF Receiver Back End Schematic Diagram ....................................................5B-22
UHF Synthesizer Schematic Diagram................................................................5B-23
UHF Voltage Controlled Oscillator Schematic Diagram .....................................5B-24
UHF Transmitter Schematic Diagram................................................................5B-25
UHF Band 1 Radio Parts List (RF Board) ..........................................................5B-26
9.0 Troubleshooting charts ....................................................................................5B-29 
						

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Troubleshooting Flow Chart for Controller ......................................................... 5B-29
Troubleshooting Flow Chart for Receiver (Sheet 1 of 2).................................... 5B-30
Troubleshooting Flow Chart for Receiver (Sheet 2 of 2).................................... 5B-31
Troubleshooting Flow Chart for Transmitter ...................................................... 5B-32
Troubleshooting Flow Chart for Synthesizer ...................................................... 5B-33
Troubleshooting Flow Chart for VCO................................................................. 5B-34
Section 5CModel Chart and Test Specifications (450-527 Mhz)
1.0 Model Chart....................................................................................................... 5C-1
2.0 Specifications (for GP328 Plus) ........................................................................ 5C-2
3.0 Specifications (for GP338 Plus/GP338 XLS) .................................................... 5C-3
4.0 Transmitter ........................................................................................................ 5C-4
4.1 General ........................................................................................................ 5C-4
5.0 Receiver ............................................................................................................ 5C-6
5.1 Receiver Front-End...................................................................................... 5C-6
5.2 Receiver Back-End ...................................................................................... 5C-7
5.3 Automatic Gain Control Circuit .................................................................... 5C-8
6.0 Frequency Generation Circuitry ........................................................................ 5C-9
6.1 Synthesizer ................................................................................................ 5C-10
6.2 VCO - Voltage Controlled Oscillator .......................................................... 5C-11
7.0 Notes For All Schematics and Circuit Boards ................................................. 5C-13
8.0 Circuit Board/Schematic Diagrams and Parts List .......................................... 5C-15
UHF Band 2 (450-527MHz) Main Board Top Side 
PCB No. 8404102G03/G04/G05 ............................................................... 5C-15
UHF Band 2 (450-527MHz) Main Board Bottom Side 
PCB No. 8404102G03/G04/G05 ............................................................... 5C-16
UHF Band 2 (450-527MHz) Main Board Top Side PCB No. 8404102G07........ 5C-17
UHF Band 2 (450-527MHz) Main Board Bottom Side PCB No. 8404102G07 .. 5C-18
UHF Band 2 Controls And Switches Schematic Diagram (sheet 1 of 2) 
UHF Band 2 Controls And Switches Schematic Diagram (sheet 2 of 2) ... 5C-19
UHF Band 2 Controls And Switches Schematic Diagram 
(sheet 2 of 2 for 8404102G07 PCB) .......................................................... 5C-21
UHF Band 2 Receiver Front End Schematic Diagram ....................................... 5C-22
UHF Band 2 Receiver Back End Schematic Diagram ....................................... 5C-23
UHF Band 2 Synthesizer Schematic Diagram ................................................... 5C-24
UHF Band 2 Voltage Controlled Oscillator Schematic Diagram........................ 5C-25
UHF Band 2 Transmitter Schematic Diagram.................................................... 5C-26
UHF Band 2 Radio Parts List (RF Board) .......................................................... 5C-27
9.0 Troubleshooting charts.................................................................................... 5C-31
Troubleshooting Flow Chart for Controller ......................................................... 5C-31
Troubleshooting Flow Chart for Receiver (Sheet 1 of 2).................................... 5C-32
Troubleshooting Flow Chart for Receiver (Sheet 2 of 2).................................... 5C-33
Troubleshooting Flow Chart for Transmitter ...................................................... 5C-34
Troubleshooting Flow Chart for Synthesizer ...................................................... 5C-35 
						

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 Troubleshooting Flow Chart for VCO ............................................................... 5C-36
Section 5DModel Chart and Test Specifications (330-400 Mhz)
1.0 Model Chart ...................................................................................................... 5D-1
2.0 Specifications (for GP328 Plus) ........................................................................ 5D-2
3.0 Specifications (for GP338 Plus) ........................................................................ 5D-3
4.0 Transmitter........................................................................................................ 5D-4
4.1 General........................................................................................................ 5D-4
5.0 Receiver............................................................................................................ 5D-6
5.1 Receiver Front-End ..................................................................................... 5D-6
5.2 Receiver Back-End...................................................................................... 5D-7
5.3 Automatic Gain Control Circuit .................................................................... 5D-8
6.0 Frequency Generation Circuitry ........................................................................ 5D-9
6.1 Synthesizer................................................................................................ 5D-10
6.2 VCO - Voltage Controlled Oscillator .......................................................... 5D-11
7.0 Notes For All Schematics and Circuit Boards ................................................. 5D-13
8.0 Circuit Board/Schematic Diagrams and Parts List .......................................... 5D-15
330-400MHz Main Board Top Side PCB No. 8404101G02/G03/G04............... 5D-15
330-400MHz Main Board Bottom Side PCB No. 8404101G02/G03/G04 ......... 5D-16
330-400MHz Main Board Top Side PCB No. 8404101G06 .............................. 5D-17
330-400MHz Main Board Bottom Side PCB No. 8404101G06 ......................... 5D-18
330-400MHz Controls And Switches Schematic Diagram (sheet 1 of 2) .......... 5D-19
330-400MHz Controls And Switches Schematic Diagram (sheet 2 of 2) .......... 5D-20
330-400MHz Controls And Switches Schematic Diagram 
(sheet 2 of 2 for 8404101G06 PCB).......................................................... 5D-21
330-400MHz Receiver Front End Schematic Diagram ..................................... 5D-22
330-400MHz Receiver Back End Schematic Diagram...................................... 5D-23
330-400MHz Synthesizer Schematic Diagram .................................................. 5D-24
330-400MHz Voltage Controlled Oscillator Schematic Diagram ....................... 5D-25
330-400MHz Transmitter Schematic Diagram .................................................. 5D-26
330-400MHz Radio Parts List (RF Board) ......................................................... 5D-27
9.0 Troubleshooting charts ................................................................................... 5D-31
Troubleshooting Flow Chart for Controller ........................................................ 5D-31
Troubleshooting Flow Chart for Receiver (Sheet 1 of 2) ................................... 5D-32
Troubleshooting Flow Chart for Receiver (Sheet 2 of 2) ................................... 5D-33
Troubleshooting Flow Chart for Transmitter ...................................................... 5D-34
Troubleshooting Flow Chart for Synthesizer ..................................................... 5D-35
Troubleshooting Flow Chart for VCO ................................................................ 5D-36
Section 6Flex Layout/Schematic Diagrams and Parts Lists
1.0 RF-Controller Interconnect Flex........................................................................... 6-1
1.1 Rev A.............................................................................................................. 6-1
1.2 Rev B ............................................................................................................. 6-1 
						

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2.0 Schematic for RF-Controller Interconnect Flex ....................................................6-2
3.0 Universal Connector Flex .....................................................................................6-3
3.1 GP328 Plus.....................................................................................................6-3
3.2 GP338 Plus/GP338 XLS.................................................................................6-4
4.0 Schematic for Universal Connector Flex ..............................................................6-5
4.1 GP328 Plus.....................................................................................................6-5
4.2 GP338 Plus/GP338 XLS.................................................................................6-5
5.0 Parts List for Universal Connector Flex................................................................6-6
5.1 GP328 Plus.....................................................................................................6-6
5.2 GP338 Plus/GP338 XLS.................................................................................6-6 
						

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Section 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
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 
Services. 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 Accessories and Aftermarket 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. 
						

							1-2Warranty and Service Support
2.3 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’s Accessories and 
Aftermarket 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 orders for parts/information should include the complete Motorola identification number. All part 
orders should be directed to your local AAD office. Please refer to your latest price pages.
2.4 Technical Support
Technical support is available to assist the dealer/distributor in resolving any malfunction which may 
be encountered. Initial contact should be by telephone wherever possible. When contacting Motorola 
Technical Support, be prepared to provide the product model number and the unit’s serial number.
2.5 Further Assistance From Motorola
You can also call the CGISS Indirect Business Customer Help Desk number, (604)-6302525 or send 
an email to [email protected].