Motorola GP300 Series Basic Service Manual
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Motorola GP300 Series Basic Service Manual

Professional radio
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Professional Radio
GP300 Series
Basic Service Manual
68P64115B18C
Issue: Nov 2001
Table of Contents
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Summary of Contents for Motorola GP300 Series

  • Page 1 Professional Radio GP300 Series Basic Service Manual 68P64115B18C Issue: Nov 2001...
  • Page 2 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 To maintain compliance with ICNIRP RF exposure guidelines, if you wear a radio on your body when transmitting, always place the radio in a Motorola approved clip, holder, holster, case, or body harness for this product. Use of non-Motorola-approved body worn accessories may exceed ICNIRP RF exposure guidelines. If you do not use a...
  • Page 4 SAFETY INFORMATION Approved Accessories For a list of approved Motorola accessories please contact your dealer, or local Motorola representative. ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY NOTE Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inade- quately shielded, designed, or alternately configured for electromagnetic compatibility.
  • Page 5 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...

  • 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 Piece Parts..................... 1-2 2.5 Technical Support ..................
  • Page 8 MODEL CHART AND TEST SPECIFICATION 1.0 Model Chart (UHF)....................6-1 2.0 Model Chart (VHF) ....................6-3 3.0 Model Chart (LB)....................6-4 4.0 Model Chart (300R1)....................6-5 5.0 Specifications - Professional GP300 Series Radios ..........6-6 5.1 GP320/340/360/380..................6-6 5.2 GP344/388......................6-8 Chapter 7 POWER UP SELF-TEST 1.0 Error Codes......................7-1...

  • 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)

    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.

  • 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: [email protected]...

  • 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: MDH25KDC9AA3AE) 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...

  • 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 ❏...

  • Page 18: Safe Handling Of Cmos And Ldmos Devices

    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: Radio Disassembly - Detailed

    MAINTENANCE 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.) The following disassembly procedures should be performed only if necessary: Chassis Assembly Disassembly (Paragraph 6.2)
  • Page 21 Radio Disassembly — Detailed Pull the volume and channel selector knobs off of their shafts. Knobs GP344/388 Knobs GP320/340/360/380 Figure 3-2 Knob Removal Both knobs slide on and off. However, they are supposed to fit very tightly on their shafts. NOTE Separate the chassis from the internal electronics front cover assembly as follows: Insert a small, flat-blade screwdriver, or similar instrument, in between the thin retaining...

  • Page 22: Chassis Assembly Disassembly

    MAINTENANCE Lift the latches on the main circuit board to release the flexes from their connectors. Flex Connector Latches Latch Flex Connectors GP344/388 GP320/340/360/380 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 23: Keypad, Display, And Keypad/Option Board Disassembly

    Radio Disassembly — Detailed 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.

  • Page 24: Speaker, Microphone, And Universal Connector Flex Disassembly

    MAINTENANCE The keypad/option board, and the keypad, can be removed without the use of tools. Retainer Retainer Display Module Controller Board Keypad/Option Board Keypad Display Module Keypad Radio Body GP360/380 GP388 Figure 3-7 Removing the Keypad Retainer and Other Boards from the Radio Body At this point, the Option Board Installation Procedure should be performed, if necessary.

  • Page 25: Ptt Disassembly

    Radio Disassembly — Detailed Speaker Notch In Speaker @ 12:00 Speaker Orientation Microphone Tab @ 12:00 Speaker Flex Circuit Universal Connector Assembly Tail Slot for Top Notch (Speaker) Microphone Boot Microphone Speaker Microphone Speaker Catches Flex Circuit Assembly GP344/388 GP320/340/360/380 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 26: Controller Board Disassembly (Gp344/Gp388)

    3-10 MAINTENANCE Controller Board Disassembly (GP344/GP388) Use a Philips screwdriver to remove the screw from its position. Insert a flat blade screwdriver in-between the controller board and front cover. Pull up the screwdriver to disassemble the controller board from the front cover. Philips Screw Controller Board Front Cover...

  • Page 27: Ptt Reassembly

    Radio Reassembly — Detailed 3-11 PTT Reassembly Place the bezel top tab in the top slot inside the front cover PTT opening. Slightly bow the bezel so that the bottom tab can fall inside the bottom slot. Press the PTT assembly against the front cover opening. Look inside the front cover to make sure the T-tab is fully engaged with the front cover.

  • Page 28: Chassis Assembly Reassembly

    3-12 MAINTENANCE Lay the speaker-microphone flex on top of keypad/option board retainer. Catches Catches Retainer Retainer GP360/380 GP388 Figure 3-11 Lock retainer catches to the radio’s body Chassis Assembly Reassembly Slide on the ground contact (if necessary) on the top corner boss of the chassis. Replace the O-ring.

  • 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: Option Board Installation

    3-14 MAINTENANCE Option Board Installation With the keypad retainer removed, the keypad backer board can be removed without the use of tools. Remove the jumper flex from the connector on the keypad board. Notice the orientation of the flex to the connector. Arrows on the jumper flex point to the correct way of inserting the flex into the connector.
  • Page 31 Option Board Installation 3-15 Replace the retainer by placing the two top hooks into the slots below the speaker in the front cover; then, pivot the retainer into the front cover. Ensure that all four tab arms snap correctly into the front cover. 10.

  • Page 32: Mechanical Views And Parts Lists

    3-16 MAINTENANCE Mechanical Views and Parts Lists GP320/GP340 Figure 3-14 Radio Exploded Mechanical View (GP320/GP340)
  • Page 33 Mechanical Views and Parts Lists 3-17 Motorola Motorola Item Part Description Item Part Description Number Number See Chapter Antenna 3586057A01 Felt Speaker 1480577C01 Boot, Microphone 3680529Z01 Knob, Volume 5085962A02 Speaker 3680530Z01 Knob, Frequency 5013920A04 Microphone 1380525Z01 Escutcheon, Top - GP340...

  • Page 34: Gp360/Gp380

    3-18 MAINTENANCE GP360/GP380 Figure 3-15 Radio Exploded Mechanical View (GP360/GP380)
  • Page 35 Mechanical Views and Parts Lists 3-19 Motorola Motorola Item Part Description Item Part Description Number Number See Chapter Antenna 4280504Z01 Retainer, Speaker 1480503Z01 Boot, Backup Battery 3680529Z01 Knob, Volume 6062884G01 Backup Battery 3680530Z01 Knob, Frequency 0304726J04 Screw 1380525Z03 Escutcheon, Top...

  • Page 36: Gp344

    3-20 MAINTENANCE GP344 Figure 3-16 Radio Exploded Mechanical View (GP344)
  • Page 37 Mechanical Views and Parts Lists 3-21 Motorola Item Part Description Number See Chapter Antenna JMLN4638_ Dust Cover 1385905Z01 Universal Connector Seal 0302020P03 Screw for Dust Cover 3385959Z07 Front, label GP344 6102001P10 Light Pipe 0104031G98 Front Cover Assembly 3680530Z02 Frequency Knob...

  • Page 38: Gp388

    3-22 MAINTENANCE GP388 Figure 3-17 Radio Exploded Mechanical View (GP388)
  • Page 39 Mechanical Views and Parts Lists 3-23 Motorola Motorola Item Part Description Item Part Description Number Number See Chapter 6 Antenna 8404055G05 RF Board (VHF) 3680529Z01 Volume Knob 8404077G01 RF Board (UHF) 3680530Z02 Frequency Knob 7580556Z01 Thermal Pad 1386160Z01 Top Escutcheon...

  • Page 40: Service Aids

    10.0 Service Aids Table 3-1 lists service aids recommended for working on the GP300 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 41: 11.0 Test Equipment

    Test Equipment 3-25 11.0 Test Equipment Table 3-2 lists test equipment required to service the GP300 Series Radios and other two-way radios. Table 3-2 Recommended Test Equipment Motorola Part Description Characteristics Application R2600_NT Comms System This monitor will Frequency/deviation meter...

  • Page 42: 12.0 Programming/Test Cable

    3-26 MAINTENANCE 12.0 Programming/Test Cable 1 metre Cable 1 metre Cable Side Connector GP320/340/360/380 - RKN4074_ GP344/388 - JMKN4123_ Figure 3-18 Programming Test/Cable Internal Pin Outs Connections External Speaker + Brown External Speaker - Dark Blue Option B + External Mic Grey Option Select 2 Light Blue...
  • Page 43 Programming/Test Cable 3-27 25 Pos Male D Connector Side Connector 25 Pos Female D Connector GP320/340/360/380 TO RADIO TO RADIO UNIVERSAL TEST SET CONNECTOR RLN4460 EXT SPKR + AUDIO - EXT SPKR - AUDIO + OPTION B+ EXT MIC MIC AUDIO OPT SEL 2 OPT SEL 1 RX DATA...
  • Page 44 3-28 MAINTENANCE...

  • Page 45: Performance Testing

    Chapter 4 PERFORMANCE TESTING Introduction The receiver and transmitter performance tests are contained in Tables 4-1 and 4-2 respectively. Refer to Chapter 5 for the test equipment set up. Note that all test measurements are taken at 25°C. Receiver Performance Tests The receiver performance tests are described in Table 4-1 below.

  • Page 46: Transmitter Performance Tests

    PERFORMANCE TESTING Transmitter Performance Tests The transmitter performance tests are described in Table 4-2 below. Table 4-2 Transmitter Performance Checks Communications Test Name Radio Test Set Comments Analyzer Reference Mode: PWR MON TEST MODE, PTT to continu- Frequency error to be ±200Hz VHF Frequency Monitor: Frequency error...

  • Page 47: 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. Refer to the appropriate program on-line help files for the programming procedures.

  • Page 48: 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 (Figure 5-1) control settings are listed in Table 5-2. Refer to appropriate program on-line help files for the tuning procedures.

  • Page 49: Model Chart And Test Specification

    Chapter 6 MODEL CHART AND TEST SPECIFICATION Model Chart (UHF) Professional GP300 Series (UHF) Model Description MDH25RDC9AN0_E GP320 UHF 403-470MHz 4W 1-Ch MDH25RDC9AN3_E GP340 UHF 403-470MHz 4W 16-Ch MDH38RDC9AN3_E GP344 UHF 403-470MHz 4W 16-Ch MDH38SDC9AN3_E GP344 UHF2 450-527MHz 4W 16-Ch...
  • Page 50 MODEL CHART AND TEST SPECIFICATION Professional GP300 Series (UHF) Model Description NAE6483_ UHF Whip (403-470 MHz) Antenna PMAE4008_ UHF2 Whip (450-527 MHz) Antenna JMNN4023__ Battery, Li-Ion Standard HNN9008_ Battery, NiMH Standard x = Indicates one of each is required.

  • Page 51: Model Chart (Vhf)

    Model Chart (VHF) Model Chart (VHF) Professional GP300 Series (VHF) Model Description MDH25KDC9AN0_E GP320 VHF 136-174MHz 5W 1-Ch MDH25KDC9AN3_E GP340 VHF 136-174MHz 5W 16-Ch MDH38KDC9AN3_E GP344 VHF 136-174MHz 5W 16-Ch MDH25KDF9AN5_E GP360 VHF 136-174MHz 5W 255-Ch MDH25KDH9AN6_E GP380 VHF 136-174MHz 5W 255-Ch...

  • Page 52: Model Chart (Lb)

    MODEL CHART AND TEST SPECIFICATION Model Chart (LB) Professional GP300 Series (LB) Model Description MDH25BEC9AN3_E GP340 LB1 29.7-42 MHz 6W 16-Ch MDH25BEH9AN6_E GP380 LB1 29.7-42 MHz 6W 255-Ch MDH25CEC9AN3_E GP340 LB2 35-50 MHz 6W 16-Ch MDH25CEH9AN6_E GP380 LB2 35-50 MHz 6W 255-Ch...

  • Page 53: Model Chart (300R1)

    Model Chart (300R1) Model Chart (300R1) Professional GP300 Series (300R1) Model Description MDH25EDC9AN3_E GP340 300R1 300-350 MHz 4W Item Description PMLD4141_ GP340 300R1 Back Cover Kit PMLN4216_ GP340 300R1 Front Cover Kit 6864110B13_ GP340 Basic User Guide PMAD4022_ VHF 9cm (300-344 MHz) Antenna...

  • Page 54: Specifications - Professional Gp300 Series Radios

    MODEL CHART AND TEST SPECIFICATION Specifications - Professional GP300 Series Radios GP320/340/360/380 Data is specified for +25°C unless otherwise stated. General Specifications Channel Capacity GP320 GP340 GP360 GP380 Power Supply Rechargeable battery 7.5v Dimensions: H x W x D (mm)
  • Page 55 Specifications - Professional GP300 Series Radios Transmitter UHF/VHF/300R1 VHF 136-174 MHz LB1 29.7-42 MHz *Frequencies - Full Bandsplit UHF 403-470 MHz LB2 35-50 MHz 300R1 300-350MHz Channel Spacing 12.5/20/25 kHz ±2.5 ppm @ 12.5kHz Frequency Stability ±5.0 ppm @ 25 kHz ±10ppm...
  • Page 56 MODEL CHART AND TEST SPECIFICATION GP344/388 Data is specified for +25°C unless otherwise stated. General Specifications Channel Capacity GP344 GP388 Power Supply Rechargeable battery 7.5v Dimensions: H x W x D (mm) Height excluding knobs GP344 GP388 With standard Lilon battery 101.5 x 55.5 x 30.5 101.5 x 55.5 x 33.0 With high capacity Lilon battery...
  • Page 57 Specifications - Professional GP300 Series Radios Transmitter UHF1/UHF2 UHF1 403-470 MHz *Frequencies - Full Bandsplit VHF 136-174 MHz UHF2 450-527 MHz Channel Spacing 12.5/20/25 kHz Frequency Stability 0.00025% (-30°C to +60°C, +25° Ref.) Low: 1W Low: 1W Power High: 5W High: 4W -36 dBm <1 GHz...
  • Page 58 6-10 MODEL CHART AND TEST SPECIFICATION...

  • Page 59: Power Up Self-Test

    Once Hardware codeplug error, Reprogram codeplug. If message possibly codeplug structure re-occurs, replace main board or mismatch or non-existant return it to the nearest Motorola codeplug. depot. “Test 2 Failed” Twice Select 5 Application Vector Reprogram codeplug and retest the corrupted.
  • Page 60 POWER UP SELF-TEST...

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