Motorola Gp640 Gp680 Basic 68p64115b23a Manual
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Professional Radio GP600 Series Basic Service Manual 68P64115B23A Issue: June 2000
ii Computer Software Copyrights The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motor- ola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or repro- duce in any form, the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied or reproduced in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola prod- ucts shall not be deemed to grant, either directly or by implication, estoppel or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive royalty-free license to use that arises by operation of law in the sale of a product.
iii SAFETY INFORMATION Read this information before using your radio. SAFE AND EFFICIENT OPERATION OF MOTOROLA TWO-WAY RADIOS This document provides information and instructions for the safe and efficient operation of Motorola Portable and Mobile Two-Way Radios. The information provided in this document supersedes the general safety information contained in user guides published prior to 1 January 1998. For information regarding radio use in hazardous areas, please refer to the Factory Mutual (FM) approval manual supplement. EXPOSURE TO RADIO FREQUENCY ENERGY Your Motorola Two-Way Radio, which generates and radiates radio frequency (RF) electromagnetic energy (EME), is designed to comply with the following National and International Standards and Guidelines regarding exposure of human beings to radio frequency electromagnetic energy: Federal Communications Commission Report and Order No. FCC 96-326 (August 1996) American National Standards Institute (C95.1 - 1992) National Council on Radiation Protection and Measurements (NCRP-1986) International Commission on Non-Ionizing Radiation Protection (ICNRP- 1986) European Committee for Electrotechnical Standardization (CENELEC): To assure optimal radio performance and to ensure that your exposure to radio frequency electromagnetic energy is within the guidelines in the above standards, always adhere to the following procedures: PORTABLE RADIO OPERATION AND EME EXPOSURE When transmitting with a portable radio, hold radio in a vertical position with the microphone 2.5 to 5.0 centimeters (one to two inches) away from the mouth. Keep antenna at least 2.5 centimeters (one inch) from your head or body when transmit- ting. If you wear a portable two-way radio on your body, ensure that the antenna is at least 2.5 centimeters (one inch) from the body when transmitting. 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. When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in accor- dance with airline regulations or crew instructions.- ENV 50166-1 1995 E Human exposure to electromagnetic fields Low frequency(0Hzto10kHz) - ENV 50166-2 1995 E Human exposure to electromagnetic fields High frequency (10 kHz to 300 GHz) - Proceedings of SC211/B 1996 “Safety Considerations for Human Exposure to EMFs from Mobile Telecommunication Equipment (MTE) in the Fre- quency Range 30MHz - 6 GHz.” (EMF - Electro-Magnetic Fields) NOTE Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately shielded, designed, or alternately configured for electromagnetic compatibility. 2.5 to 5.0 cm (1 to 2 in.)
ivSAFETY INFORMATION OPERATIONAL WARNINGS Vehicles with an air bag Potentially explosive atmospheres Batteries Blasting caps and areas OPERATIONAL CAUTIONS Damaged antennas Batteries WARNING: Do not place a portable radio in the area over an air bag or in the air bag deploy- ment area. Air bags inflate with great force. If a portable radio is placed in the air bag deploy- ment area and the air bag inflates, the radio may be propelled with great force and cause serious injury to occupants of vehicle. 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 (e.g. FM or Cenelec approved). Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death. WARNING: Do not replace or recharge batteries in a potentially explosive atmosphere. Con- tact sparking may occur while installing or removing batteries and cause an explosion. 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. NOTEThe areas with potentially explosive atmospheres referred to above include fuelling areas such as: below decks on boats; fuel or chemical transfer or storage facilities; areas where the air contains chemicals or particles, such as grain, dust or metal powders; and any other area where you would normally be advised to turn off your vehicle engine. Areas with potentially explosive atmospheres are often but not always posted. CAUTION: Do not use any portable two-way radio that has a damaged antenna. If a damaged antenna comes into contact with your skin, a minor burn can result. CAUTION: All batteries can cause property damage and/or bodily injury such as burns if a conductive material such as jewellry, 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. ! ! ! ! ! !
v Ta b l e o f C o n t e n t s Chapter 1 INTRODUCTION 1.0 Scope of Manual .................................................................................................. 1-1 2.0 Warranty and Service Support ............................................................................. 1-1 2.1 Warranty Period and Return Instructions ....................................................... 1-1 2.2 After Warranty Period ..................................................................................... 1-1 2.3 European Radio Support Centre (ERSC) ....................................................... 1-2 2.4 Piece Parts ..................................................................................................... 1-2 2.5 Technical Support........................................................................................... 1-3 3.0 Radio Model Information ...................................................................................... 1-4 Chapter 2 INTRINSICALLY SAFE RADIO INFORMATION 1.0 FMRC Approved Equipment ................................................................................ 2-1 2.0 Repair of FMRC Approved Products ................................................................... 2-2 2.1 Repair ............................................................................................................. 2-2 2.2 Relabelling ...................................................................................................... 2-2 2.3 Do Not Substitute Options or Accessories ..................................................... 2-3 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 Front Cover from Chassis Disassembly ......................................................... 3-4 6.2 Chassis Assembly Disassembly ..................................................................... 3-6 6.3 Keypad, Display, and Keypad/Option Board Disassembly ............................. 3-7 6.4 Speaker, Microphone, and Universal Connector Flex Disassembly............... 3-8 6.5 PTT Disassembly ........................................................................................... 3-9 6.6 Control Top Disassembly ............................................................................. 3-10 7.0 Radio Reassembly—Detailed .......................................................................... 3-10 7.1 PTT Reassembly .......................................................................................... 3-10 7.2 Control Top Reassembly .............................................................................. 3-10 7.3 Speaker, Microphone, and Universal Connector Flex Reassembly ............. 3-10 7.4 Keypad, Display, and Keypad Option Board Reassembly ........................... 3-10 7.5 Chassis Assembly Reassembly ................................................................... 3-11 7.6 Chassis and Front Cover Reassembly ......................................................... 3-11
vi 8.0 Option Board Installation ................................................................................... 3-12 9.0 Mechanical View and Parts List ......................................................................... 3-14 9.1 GP640 Exploded View and Parts List .......................................................... 3-14 9.2 GP680 Exploded View and Parts List .......................................................... 3-16 10.0 Service Aids ....................................................................................................... 3-18 11.0 Test Equipment.................................................................................................. 3-19 12.0 Programming/Test Cable ................................................................................... 3-20 Chapter 4 PERFORMANCE TESTING 1.0 Introduction .......................................................................................................... 4-1 2.0 Receiver Performance Tests ............................................................................... 4-1 3.0 Transmitter Performance Tests ........................................................................... 4-2 Chapter 5 RADIO TUNING AND PROGRAMMING 1.0 Introduction .......................................................................................................... 5-1 2.0 Global Radio Tuning Setup.................................................................................. 5-1 2.1 Initial Test Equipment Setup .......................................................................... 5-2 3.0 CPS Programming Setup .................................................................................... 5-2 Chapter 6 MODEL CHART AND TEST SPECIFICATION 1.0 Model Chart (VHF)............................................................................................... 6-1 2.0 Model Chart (UHF) .............................................................................................. 6-1 3.0 Model Chart (UHF2) ............................................................................................ 6-2 4.0 Model Chart (300R1) ........................................................................................... 6-2 5.0 Specifications - Professional GP600 Series Radios ............................................ 6-3 Chapter 7 POWER UP SELF-TEST 1.0 Error Codes ......................................................................................................... 7-1
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 par ts 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 Germany: 01 30 18 75 24 Spain: 90 09 84 902 Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307 UK: 0800969095 Switzerland: 1553082 Ireland: 18 00 55 50 21 Iceland: 80 08 147 Or dial Customer Care Centre: Tel: +49 6128 70 2618 Please use these numbers for repair enquiries only 2.4 Piece Parts Some replacement parts, spare parts, and/or product information can be ordered directly. If a complete Motorola part number is assigned to the part, it is available from Motorola Radio Aftermarket and Accessory Division (AAD). If no part number is assigned, the part is not normally available from Motorola. If the par t number is appended with an asterisk, the par t 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: Motorola GmbH European Parts Department 65232 Taunusstein Germany.
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. UK/Ireland- Richard Russell Telephone: +44 (0) 1256 488 082 Fax: +44 01256 488 080 Email: [email protected] Central/East Europe- Siggy Punzenberger Telephone: +49 (0) 6128 70 2342 Fax: +49 (0) 6128 95 1096 Email: [email protected] Scandinavia-BjornRambert Telephone: +46 8 735 9282 Fax: +46 8 735 9280 Email: [email protected] Germany -Karin Struck Telephone: +49 (0) 6128 70 2248 Fax: +49 (0) 6128 95 1082 Email: [email protected] France -Lionel Lhermitte Telephone: +33 1 6929 5722 Fax: +33169295904 Email: [email protected] Italy -Ugo Gentile Telephone: +39 0 2822 0325 Fax: +39 0 2822 0334 Email: [email protected] Africa & Middle East -Ralph Schubert Telephone: +33 (0)4 4230 5887 Fax: +33 (0)4 4230 4784 Email: [email protected]
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 portable radio model number and its specific characteristics. Ta b l e 1 - 1Radio Model Number (Example: MDH25KDC9AA3AE) Type of UnitModel SeriesFreq. BandPower LevelPhysical PackagesChannel SpacingProtocolFeature LevelModel RevisionModel Package MD H 25 K VHF (136- 174MHz)D 4-5WC GP140, GP320, GP340, GP640.9 Program- mableAA Conventional MDCO GP320AE R UHF1 (403- 470MHz)E 5-6WH GP380, GP680AN Conventional 5 Tone3 GP140, GP340, GP640. S UHF2 (450-527 MHz)N GP1280CK MPT5 GP360 B LB1 29-42MHzF GP360PW MPT/5T6 GP380, GP680 C LB2 35-50MHz8 GP1280 E 300R1 (300- 350MHz) MD= Motorola Internal Use H=Portable