Table of Contents
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Table of Contents
Related Manuals for Motorola GP200 Series
Summary of Contents for Motorola GP200 Series
- Page 1 Professional Radio GP200/500 Series Basic Service Manual 68P64115B64...
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Page 2: Computer Software Copyrights
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-... -
Page 3: Safety Information
Use of non-Motorola-approved body worn accessories may exceed ICNIRP RF exposure guidelines. If you do not use a Motorola approved body-worn accessory and are not using the radio in the intended use positions along side of the head in the phone mode or in front of... -
Page 4: Approved Accessories
DO NOT hold the antenna when the radio is "IN USE". Holding the antenna affects call quality and may cause the radio to operate at a higher power level than needed. Approved Accessories For a list of approved Motorola accessories please contact your dealer, or local Motorola representative. ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY... -
Page 5: Operational Warnings
SAFETY INFORMATION OPERATIONAL WARNINGS Vehicles with an air bag 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. - Page 6 SAFETY INFORMATION...
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Page 7: Table Of Contents
Table of Contents 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 Parts Identification and Ordering..............1-2 2.5 EMEA Test Equipment Support .............. - Page 8 viii 7.6 Chassis and Front Cover Reassembly ............3-13 8.0 Mechanical Views and Parts Lists..............3-14 8.1 GP240/GP540 ....................3-14 8.2 GP280/GP580 ....................3-16 9.0 Service Aids .......................3-18 10.0 Test Equipment ....................3-19 11.0 Programming/Test Cable ...................3-20 Chapter 4 PERFORMANCE TESTING 1.0 Introduction ......................4-1 2.0 Setup........................4-1 3.0 Test Mode ......................4-2 3.1 RF Test Mode ....................4-2 4.0 Receiver Performance Tests................4-5...
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Page 9: Chapter 1 Introduction
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. -
Page 10: European Radio Support Centre (Ersc)
Online (Extranet). EMEA Test Equipment Support Information related to support and service of Motorola Test Equipment is available via Motorola Online (Extranet), through the Customer Care Organisation of Motorola’s local area representation or by calling the Motorola switchboard in Germany on telephone number: +49 6128 700. -
Page 11: Technical Support
Warranty and Service Support 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: BRR001@email.mot.com... -
Page 12: Radio Model Information
INTRODUCTION 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. Table 1-1 Radio Model Number (Example: MDH25RDC9GB3AE) Type of Model... -
Page 13: Intrinsically Safe Radio Information
WARNING: Do not disassemble the FMRC Approved Product unit in any way that exposes the internal electrical circuits of the unit. Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the field. -
Page 14: Repair Of Fmrc Approved Products
REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF THE USER You should not repair or relabel any Motorola manufactured communication equipment bearing the FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC Approval standard for repairs and service (“Class Number 3605”). -
Page 15: Do Not Substitute Options Or Accessories
Repair of FMRC Approved Products Do Not Substitute Options or Accessories The Motorola communications equipment certified by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM 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. - Page 16 INTRINSICALLY SAFE RADIO INFORMATION...
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Page 17: Chapter 3 Maintenance
Chapter 3 MAINTENANCE Introduction This chapter provides details about the following: Preventive maintenance (inspection and cleaning) Safe handling of CMOS and LDMOS devices Disassembly and reassembly of the radio Repair procedures and techniques Installation of Option Boards Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. -
Page 18: Safe Handling Of Cmos And Ldmos Devices
0180386A82), which includes a wrist strap, two ground cords, a table mat, and a floor mat. Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX4015.) Do not wear nylon clothing while handling CMOS devices. -
Page 19: Repair Procedures And Techniques - General
When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number and order the part from the nearest Motorola Communications parts centre listed in the “Piece Parts” section of this manual. -
Page 20: Disassembling And Reassembling The Radio - General
TORX™ T6 screwdriver Chassis opener (6680702Z01) If a unit requires more complete testing or service than is customarily performed at the basic level, send this unit to a Motorola Authorized Service Centre. (See Chapter 1 for a list of authorized service centres.) -
Page 21: Radio Disassembly - Detailed
Radio Disassembly — Detailed The following disassembly procedures should be performed only if necessary: Chassis Assembly Disassembly (Paragraph 6.2) Keypad, Display, and Keypad/Option Board Disassembly (Paragraph 6.3) Speaker, Microphone, and Universal Connector Flex Disassembly (Paragraph 6.4) PTT Disassembly (Paragraph 6.5) Control Top Disassembly (Paragraph 6.6) Radio Disassembly —... - Page 22 MAINTENANCE Pull the volume and channel selector knobs off of their shafts. Knobs Figure 3-2 Knob Removal NOTE Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts. Separate the chassis from the internal electronics front cover assembly as follows: Insert the small, flat-blade screwdriver, or chassis opener (6680702Z01), in between the thin retaining wall and the chassis at the bottom of the radio.
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Page 23: Chassis Assembly Disassembly
Radio Disassembly — Detailed Lift the latches on the main circuit board to release the flexes from their connectors. Latches Flex Connectors Figure 3-4 Unlatch Flex Connectors Chassis Assembly Disassembly Use a TORX™ screwdriver with a T6 head to remove the four screws holding the main board to the chassis. -
Page 24: Keypad, Display, And Keypad/Option Board Disassembly
MAINTENANCE Keypad, Display, and Keypad/Option Board Disassembly If the disassembly of the keypad, the keypad printed circuit board, or the display is required, lift the microphone flex circuit up, and carefully remove the microphone and its boot from the front cover pocket. (See Figure 3-6.) Lay this flex circuit to one side. -
Page 25: Speaker, Microphone, And Universal Connector Flex Disassembly
Radio Disassembly — Detailed Retainer Display Module Keypad Board Assembly Keypad/Option Board Keypad Radio Body Figure 3-7 Removing the Keypad Retainer and Other Boards from the Radio Body Speaker, Microphone, and Universal Connector Flex Disassembly Turn the screw at the bottom of the dustcover counterclockwise with your fingers. Lift the dustcover out of its pocket. -
Page 26: Ptt Disassembly
3-10 MAINTENANCE Notch In Speaker @ 12:00 Speaker Orientation Tab @ 12:00 Speaker Universal Connector Tail Microphone Boot Microphone Speaker Microphone Flex Circuit Assembly Figure 3-8 Removal Speaker-Microphone Assembly After the universal connector tail of the speaker-microphone assembly is removed, the assembly can be completely removed. -
Page 27: Control Top Disassembly
Radio Reassembly — Detailed 3-11 Control Top Disassembly To remove the control top assembly, place a screwdriver next to the antenna boss, and pry it against the control top escutcheon. This will lift the control top escutcheon away from its double-sided adhesive. -
Page 28: Chassis Assembly Reassembly
3-12 MAINTENANCE Insert the “top hooks” of the keypad retainer into the slots below the speaker (above the display) in the front cover. Snap all of the retainer arm tabs in place in the front cover. NOTE Pull the speaker-microphone flex circuit out of harm’s way during reassembly. Re-insert the microphone and boot into the pocket in the front cover. -
Page 29: Chassis And Front Cover Reassembly
Radio Reassembly — Detailed 3-13 Chassis and Front Cover Reassembly Align the chassis assembly end-to-end with the front cover assembly. Insert the tails of the flex circuits into their respective connectors at the bottom of the front cover. Push down the latches on the connectors to hold the flex circuits to the main board. Slide the volume potentiometer and frequency switch shafts into their respective holes in the front cover. -
Page 30: Mechanical Views And Parts Lists
3-14 MAINTENANCE Mechanical Views and Parts Lists GP240/GP540 Figure 3-12 Radio Exploded Mechanical View (GP240/GP540) - Page 31 Mechanical Views and Parts Lists 3-15 Motorola Motorola Item Part Description Item Part Description Number Number See Chapter 6 Antenna 3280534Z01 Seal, Contact 3680529Z01 Knob, Volume 3280536Z01 Gasket, O-Ring 3680530Z02 Knob, Frequency 3980698Z01 Contact, Ground, Compliant, 1380525Z01 Escutcheon, Top 2780518Z01...
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Page 32: Gp280/Gp580
3-16 MAINTENANCE GP280/GP580 Figure 3-13 Radio Exploded Mechanical View (GP280/GP580) - Page 33 NOTE: When intending to replace a front housing, keypad Replaceable or keypad front cover, check your radio to determine if the Motorola logo is printed on the housing, or printed on a 7580532Z01 Keypad, Side Control label/escutcheon above the speaker grille. If the logo is...
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Page 34: Service Aids
Table 3-1 lists service aids recommended for working on the GP200/500 Series Radios. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. -
Page 35: 10.0 Test Equipment
Test Equipment 3-19 10.0 Test Equipment Table 3-2 lists test equipment required to service the GP200/500 Series and other two-way radios. Table 3-2 Recommended Test Equipment Motorola Part Description Characteristics Application Number R2670_ Comms System Analyzer This monitor will Frequency/deviation meter and... - Page 36 3-20 MAINTENANCE Table 3-3 lists the recommended tools used for maintaining this family of radios. These tools are also available from Motorola Table 3-3 Recommended Test Tools Motorola Part Description Application Number 6680702Z01 Chassis opener and knob removal Disassembly tool.
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Page 37: Programming/Test Cable
Programming/Test Cable RKN4074_ 3-21 11.0 Programming/Test Cable RKN4074_ TO RADIO TO RIB TEST SET RLN4008 36" Cable 36" Cable TO RADIO UNIVERSAL CONNECTOR Figure 3-14 Programming Test/Cable Internal Pin Outs Connections External Speaker + Brown External Speaker - Dark Blue Option B + External Mic Grey... - Page 38 3-22 MAINTENANCE TO RADIO TO RADIO UNIVERSAL TEST SET CONNECTOR RLN4460 EXT SPKR + AUDIO - EXT SPKR - OPTION B+ AUDIO + EXT MIC MIC AUDIO OPT SEL 2 OPT SEL 1 RX DATA VOL CTRL TX DATA DISC RSSI XMIT/RX AUDIO OPT SEL INT/EXT...
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Page 39: Performance Testing
Chapter 4 PERFORMANCE TESTING Introduction The radios have been prepared to meet published specifications through their manufacturing process with the use of laboratory-quality test equipment of the highest accuracy. The recommended field service equipment approaches the accuracy of the manufacturing equipment with a few exceptions. -
Page 40: Test Mode
PERFORMANCE TESTING Test Mode RF Test Mode When the radio is operating in its normal environment, the microcontroller controls the RF channel selection, the transmitter key-up, and receiver muting. When the unit is on the bench for testing, alignment or repair, it is removed from the normal environment and it cannot receive commands from the system. - Page 41 Test Mode 3.1.3 Keypad Test the keypad as follows: Press 0, view “48/1”; release, view “48/0”. Press 1, view “49/1”; release, view “49/0”. Press 2, view “50/1”; release, view “50/0”. Press 3, view “51/1”; release, view “51/0”. Press 4, view “52/1”; release, view “52/0”. Press 5, view “53/1”;...
- Page 42 PERFORMANCE TESTING Table 4-3 Test Channel Spacing No. of BKC Channel Spacing 1 BKC -25 kHz 2 BKC - 12.5 kHz 3 BKC - 20 kHz Table 4-4 Test Frequencies Channel Selector Test Channel 330-400 UHF1 UHF2 Switch Position 1 Low Power TX#1 or #8 330.020 403.025...
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Page 43: Receiver Performance Tests
Receiver Performance Tests Receiver Performance Tests The receiver performance tests are described in Table 4-5 below. Table 4-5 Receiver Performance Checks Communications Test Name Radio Test Set Comments Analyzer Reference Mode: PWR MON TEST MODE, PTT to Frequency error to be ±200Hz VHF Frequency Monitor: Frequency error... -
Page 44: Transmitter Performance Tests
PERFORMANCE TESTING Transmitter Performance Tests The transmitter performance tests are described in Table 4-2 below. Table 4-6 Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference Mode: PWR MON TEST MODE, PTT to continu- Frequency error to be ±200Hz VHF Frequency Monitor: Frequency error... -
Page 45: Radio Tuning And Programming
Chapter 5 RADIO TUNING AND PROGRAMMING Introduction This chapter provides an overview of the Customer Programming Software (CPS) and tuner program which are designed for use in a Windows 95/98 environment. These programs are available in separate kits as listed in the Table 5-1. An Installation instruction manual is also included with each kit. -
Page 46: Initial Test Equipment Setup
RADIO TUNING AND PROGRAMMING Initial Test Equipment Setup The supply voltage is connected to the radio using a Motorola battery eliminator, P/N 0180305G54. The initial test equipment control settings are listed in Chapter 4. NOTE Refer to appropriate program on-line help files for the tuning procedures. -
Page 47: Model Chart And Test Specification
Chapter 6 MODEL CHART AND TEST SPECIFICATION Model Chart (800 MHz) Professional GP200/500 Series Model Description MDH25UCC6FB3_E GP240 806-870 MHz 2.5W MDH25UCH6FB6_E GP280 806-870 MHz 2.5W MDH25UCC6FC3_E GP540 806-870 MHz 2.5W MDH25UCH6FC6_E GP580 806-870 MHz 2.5W Item Description * PMLF4020_ GP240/GP540 Back Cover Kit * PMLF4021_ GP280/GP580 Back Cover Kit... -
Page 48: Model Chart (Uhf 403-470 Mhz)
MODEL CHART AND TEST SPECIFICATION Model Chart (UHF 403-470 MHz) Professional GP200/500 Series Model Description MDH25RDC9GB3_E GP240 403-470 MHz 4W MDH25RDH9GB6_E GP280 403-470 MHz 4W MDH25RDC9GC3_E GP540 403-470 MHz 4W MDH25RDH9GC6_E GP580 403-470 MHz 4W Item Description * PMLE4192_ GP240/GP540 Back Cover Kit * PMLE4193_ GP280/GP580 Back Cover Kit * PMLN4216_... -
Page 49: Model Chart (Vhf 136-174 Mhz)
Model Chart (VHF 136-174 MHz) Model Chart (VHF 136-174 MHz) Professional GP200/500 Series Model Description MDH25KDC9GB3_E GP240 136-174 MHz 5W MDH25KDH9GB6_E GP280 136-174 MHz 5W MDH25KDC9GC3_E GP540 136-174 MHz 5W MDH25KDH9GC6_E GP580 136-174 MHz 5W Item Description * PMLD4170_ GP240/GP540 Back Cover Kit * PMLD4171_ GP280/GP580 Back Cover Kit * PMLD4216_... -
Page 50: Specifications - Professional Gp200/500 Series Radios
MODEL CHART AND TEST SPECIFICATION Specifications - Professional GP200/500 Series Radios General Data is specified for +25°C unless otherwise stated. General Specifications Channel Capacity 128 in conventional Mode Power Supply Rechargeable battery 7.5v Dimensions: H x W x D (mm) Height excluding knobs With standard high capacity NiMH battery 137 x 57.5 x 37.5... -
Page 51: Transmitter
Specifications - Professional GP200/500 Series Radios Transmitter Transmitter UHF/800 UHF: 403-470 MHz *Frequencies - Full Bandsplit 800: 806-825 MHz VHF: 136-174 MHz 851-870 MHz Channel Spacing 403-470 MHz:12.5/20/25 kHz 12.5/20/25 kHz 800 MHz: 20/25 kHz Frequency Stability ±1.5 ppm ±2.5 ppm (-30°C to +60°C, +25°... -
Page 52: Receiver
MODEL CHART AND TEST SPECIFICATION Receiver Receiver UHF/800 UHF: 403-470 MHz 136-174 MHz *Frequencies - Full Bandsplit 800MHz: 851-870 MHz Channel Spacing UHF: 12.5/20/25 kHz 12.5/20/25 kHz 800MHz: 20/25kHz Sensitivity (12 dB SINAD) EIA 0.35 µV Intermodulation EIA - 65dB Adjacent Channel Selectivity -70dB Frequency Stability... -
Page 53: Error Codes
Chapter 7 POWER UP SELF-TEST Error Codes At power-up, the radio performs a self-test routine that checks the radio functionality. If the checks are successful, the radio generates a high-pitched self-test pass tone. If the self-test is not successful, one low-pitched (300Hz) error tone is heard to indicate there is a failure (see Table 7-1 below). - Page 54 POWER UP SELF-TEST...