GM338/GM398
Mobile Radios
Basic Service Manual
6804112J17-D
June, 2002
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
Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or
reproduce 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 products 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.
i
SAFETY INFORMATION
SAFETY AND GENERAL INFORMATION
Information and Instructions on RF Energy Exposure and Product Safety
READ THIS IMPORTANT INFORMATION ON SAFE AND EFFICIENT OPERATION BEFORE
INSTALLING AND USING YOUR MOTOROLA MOBILE TWO-WAY RADIO IN A VEHICLE OR AS
A CONTROL STATION.
Compliance with RF Energy Exposure Standards
Your Motorola two-way radio is designed and tested to comply with a number of national and
international standards and guidelines (listed below) regarding human exposure to radio frequency
electromagnetic energy. This radio complies with the IEEE (FCC) and ICNIRP exposure limits at duty
cycles of up to 50% talk-50% listen and should be used for occupational use only. In terms of
measuring RF energy for compliance with the FCC exposure guidelines, your radio radiates
measurable RF energy only while it is transmitting (during talking), not when it is receiving (listening)
or in standby mode.
Your Motorola two-way radio complies with the following RF energy exposure standards and
guidelines:
•
•
•
•
•
•
•
United States Federal Communications Commission, Code of Federal Regulations; 47CFR part
2 sub-part J
American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers
(IEEE) C95. 1-1992
Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999 Edition
International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998
Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radio frequency Electromagnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999
Australian Communications Authority Radiocommunications (Electromagnetic Radiation Human Exposure) Standard 2001
ANATEL, Brazil Regulatory Authority, Resolution 256 (April 11, 2001) "additional requirements
for SMR, cellular and PCS product certification."
Operational Instructions and Training Guidelines
To ensure optimal performance and compliance with the RF energy exposure limits in the above
standards and guidelines, users should transmit no more than 50% of the time and always adhere to
the following procedures:
Transmit and Receive
•
•
To transmit (talk), push the Push-To-Talk (PTT) button; to receive, release the PTT button.
Transmit only when people outside the vehicle are at least the minimum lateral distance away,
as shown in Table 1, from a properly installed, externally-mounted antenna.
ii
SAFETY INFORMATION
Table 1 lists the minimum lateral distance for bystanders in an uncontrolled environment from the
transmitting antenna at several different ranges of rated radio power for mobile radios installed in a
vehicle.
Table 1: Rated Power and Lateral Distance
Rated Power of Vehicle-Installed
Mobile Two-way Radio
Minimum Lateral Distance
from Transmitting
Antenna
Less than 7 watts
8 inches (20 centimeters)
7 to 15 watts
1 foot (30 centimeters)
16 to 50 watts
2 feet (60 centimeters)
51 to 110 watts
3 feet (90 centimeters)
Mobile Antennas
•
•
Install antennas at the center of the roof or the center of the trunk deck. These mobile antenna
installation guidelines are limited to metal body vehicles.
The antenna installation must additionally be in accordance with:
a. The requirements of the antenna manufacturer/supplier
b. Instructions in the Radio Installation Manual
•
Use only Motorola approved supplied antenna or Motorola approved replacement
antenna. Unauthorized antennas, modifications, or attachments could damage the radio and
may violate FCC regulations.
Approved Accessories
For a list of approved Motorola accessories please contact your dealer, or local Motorola
representative.
Fixed Site Antennas
If mobile radio equipment is installed at a fixed location and operated as a control station or as a fixed
unit, the antenna installation must comply with the following requirements in order to ensure optimal
performance and compliance with the RF energy exposure limits in the above standards and
guidelines.
•
•
The antenna should be mounted outside the building on the roof or a tower if at all possible.
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.
ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY
NOTE Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately
shielded, designed, or otherwise configured for electromagnetic compatibility. It may be necessary
to conduct compatibility testing to determine if any electronic equipment used in or around vehicles
or near fixed antenna sites is sensitive to external RF energy and if any procedures need to be followed to eliminate or mitigate the potential for interaction between the radio transmitter and the
equipment or device.
SAFETY INFORMATION
iii
Facilities
To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any facility
where posted notices instruct you to do so. Hospitals or health care facilities may be using equipment
that is sensitive to external RF energy.
Vehicles
To avoid possible interaction between the radio transmitter and any vehicle electronic control
modules, for example, ABS, engine, or transmission controls, we recommend that the radio be
installed by an experienced installer and that the following precautions be used when installing the
radio:
1. Refer to any manufacturer’s instructions or other technical bulletins or recommendations on radio installation.
2. Before installing the radio, determine the location of the electronic control modules and their harnesses in
the vehicle.
3. Route all radio wiring, including the antenna transmission line, as far away as possible from the electronic
control units and associated wiring.
Driver Safety
Check the laws and regulations on the use of radios in the area where you drive. Always obey them.
When using your radio while driving, please:
•
•
Give full attention to driving and to the road.
Pull off the road and park before making or answering a call if driving conditions so require.
OPERATIONAL WARNINGS
For Vehicles With an Air Bag
Do not place a mobile radio in the area over an air bag or in the air bag deployment
area. Air bags inflate with great force. If a radio is placed in the air bag deployment
area and the air bag inflates, the radio may be propelled with great force and cause
serious injury to occupants of the vehicle.
!
WARNING
Potentially Explosive Atmospheres
Turn off your radio prior to entering any area with a potentially explosive atmosphere. Sparks in a
potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even
death.
NOTE The areas with potentially explosive atmospheres referred to above include fueling areas
such as below decks on boats, fuel or chemical transfer or storage facilities, and areas
where the air contains chemicals or particles, such as grain, dust or metal powders. Areas
with potentially explosive atmospheres are often but not always posted.
Blasting Caps and Areas
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.
For radios installed in vehicles fuelled by liquefied petroleum gas in the U.S., refer to the (U.S.) National Fire
Protection Association standard, NFPA 58, for storage, handling, and/or container information. For a copy of the
LP-gas standard, NFPA 58, contact the National Fire Protection Association, One Battery Park, Quincy, MA.
iv
SAFETY INFORMATION
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v
Table of Contents
Section 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 Piece Parts Availability ...................................................................................1-2
2.4 Technical Support...........................................................................................1-2
3.0 Radio Model Information......................................................................................1-3
Section 2
Maintenance
1.0 Introduction ..........................................................................................................2-1
2.0 Preventive Maintenance ......................................................................................2-1
2.1 Inspection .......................................................................................................2-1
2.2 Cleaning Procedures ......................................................................................2-1
3.0 Safe Handling of CMOS and LDMOS Devices ....................................................2-2
4.0 Repair Procedures and Techniques — General ..................................................2-3
5.0 Disassembling and Reassembling the Radio — General ....................................2-3
6.0 Radio Disassembly - Detailed..............................................................................2-4
6.1 Control Head Removal ...................................................................................2-4
6.2 Top Cover Removal........................................................................................2-5
6.3 Transceiver Board Removal ...........................................................................2-6
6.4 Disassembly of Control Heads .......................................................................2-7
7.0 Radio Assembly ...................................................................................................2-9
7.1 Control Heads - GM338 and GM398..............................................................2-9
7.2 Radio Chassis And Transceiver Board...........................................................2-9
7.3 Control Head Fitting........................................................................................2-9
8.0 Radio Exploded Mechanical Views and Parts Lists ...........................................2-10
8.1 Radio Assembly............................................................................................2-10
8.2 Control Head - GM338 .................................................................................2-11
8.3 Control Head - GM398 .................................................................................2-12
9.0 Service Aids .......................................................................................................2-13
10.0 Test Equipment..................................................................................................2-14
11.0 Programming/Test Cable - RKN4083_ .............................................................2-15
Section 3
Transceiver Performance Testing
1.0 General ................................................................................................................3-1
2.0 Setup....................................................................................................................3-1
3.0 RF Test Mode ......................................................................................................3-2
vi
Section 4
Radio Tuning and Programming
1.0 Introduction .......................................................................................................... 4-1
2.0 CPS Programming Setup .................................................................................... 4-1
3.0 Radio Tuning Setup ............................................................................................. 4-3
3.1 Initial Test Equipment Control Settings .......................................................... 4-3
Section 5
Power Up Self-Test
1.0 Error Codes ......................................................................................................... 5-1
Section 6
Model Chart and Test Specification
1.0 Low Power Radios............................................................................................... 6-1
1.1 Model Chart (VHF 136-174 MHz)................................................................... 6-1
1.2 Model Chart (UHF Band 1, 403-470 MHz) ..................................................... 6-2
1.3 Model Chart (UHF Band 2, 450-527 MHz) ..................................................... 6-3
1.4 Model Chart (Low Band, 29.7-50.0 MHz)....................................................... 6-3
1.5 Specifications ................................................................................................ 6-4
2.0 High Power Radios .............................................................................................. 6-6
2.1 Model Chart (VHF 136-174 MHz)................................................................... 6-6
2.2 Model Chart (UHF Band 1, 403-470 MHz) ..................................................... 6-6
2.3 Model Chart (UHF Band 2, 450-520 MHz) ..................................................... 6-7
2.4 Model Chart (UHF Band 1, LDMOS, 403-470 MHz) ...................................... 6-7
2.5 Model Chart (UHF Band 2, LDMOS, 450-520 MHz) ...................................... 6-8
2.6 Specifications ................................................................................................ 6-9
Glossary of Terms .................................................................................... G-1
1-1
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.
NOTE Before operating or testing these units, please read the Safety Information section in the
front of this manual.
2.0
Warranty and Service Support
Motorola offers support which 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” to an authorized Motorola Dealer must be accompanied by a
Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized 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 subsections
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. All returns must be accompanied by a Warranty Claim Form, available from
your Customer Resources representative. Products should be shipped back in the original
packaging, or correctly packaged to ensure that no damage occurs in transit.
2.2
After Warranty Period
After the Warranty period, Motorola continues to support its products in two ways:
1.
Motorola's 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 technically capable of performing fault analysis and repair.
1-2
2.3
Warranty and Service Support
Piece Parts Availability
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.
Toll-Free
Country or Territory
Number
China
800-810-0976
Indonesia
0800-1-686868
Malaysia
1800-801687
Philippines
1800-16510271
Singapore
1800-4855333
Thailand
1800-225412
Non-Toll-Free
Country or Territory
Number
China
(86-10) 6843-8231
Hong Kong SAR
(852) 2966-4188
India
(91) 80-658-7677-7678
Indonesia
(62-21) 251-3050
Korea
(822) 3466-5401
Malaysia
(603) 7803-9922
Philippines
(63-2) 810-0762
Singapore
(65) 486-7171
Taiwan
(886) 2-27058000 ext. 6308
Thailand
(66) 2254-8388
Vietnam
(84) 8-8294091
All Other Countries
IDD code + (65) 4855333
1-3
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: AZM25KHF9AA5)
Type of Model
Unit
Series
M
25
Freq.
Band
Power
Level
Physical
Packages
Channel
Spacing
K
VHF
(136174MHz)
H
1-25W
F
GM338
9
Programmable
K
R
UHF1 25-60W
(403470MHz)
N
GM398
Protocol
Feature
Level
AA
Conventional
5
GM338
M = Mobile
AZ
AZ = Country Code
3.0
Radio Model Information
S
UHF2
(450527MHz)
B
LB, R1
(29.736MHz)
C
LB, R2
(3640MHz)
D
LB, R3
(4250MHz)
8
GM398
1-4
Radio Model Information
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2-1
Section 2
MAINTENANCE
1.0
Introduction
This chapter provides details about the following:
2.0
•
Preventive maintenance (inspection and cleaning).
•
Safe handling of CMOS and LDMOS devices.
•
Disassembly and reassembly of the radio.
•
Repair procedures and techniques.
Preventive Maintenance
The radios do not require a scheduled preventive maintenance program; however, periodic visual
inspection and cleaning is recommended.
2.1
Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. It is not recommended to inspect the interior electronic circuitry.
2.2
Cleaning Procedures
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the front
cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic
visual inspection reveals the presence of smudges, grease, and/or grime.
NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or
repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (70% by volume).
!
CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.
Cleaning External Plastic Surfaces
Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to
work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the
solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks,
or crevices.
2-2
Safe Handling of CMOS and LDMOS Devices
Cleaning Internal Circuit Boards and Components
Isopropyl alcohol (70%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge
embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the
dislodged material out and away from the inside of the radio. Make sure that controls or tunable
components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process
since this could cause the liquid to collect in unwanted places. After completing of the cleaning
process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl
alcohol to the frame, front cover, or back cover.
NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
3.0
Safe Handling of CMOS and LDMOS Devices
Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and
are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting
in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent
device damage during disassembly, troubleshooting, and repair.
Handling precautions are mandatory for CMOS circuits and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without first referring to the following
CAUTION statement.
!
CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are properly
grounded. Take the following precautions when working on this unit:
•
Store and transport all CMOS devices in conductive material so that all exposed
leads are shorted together. Do not insert CMOS devices into conventional plastic
“snow” trays used for storage and transportation of other semiconductor devices.
•
Ground the working surface of the service bench to protect the CMOS device. We
recommend using the Motorola Static Protection Assembly (part number
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.
•
Do not insert or remove CMOS devices with power applied. Check all power
supplies used for testing CMOS devices to be certain that there are no voltage
transients present.
•
When straightening CMOS pins, provide ground straps for the apparatus used.
•
When soldering, use a grounded soldering iron.
•
If at all possible, handle CMOS devices by the package and not by the leads. Prior
to touching the unit, touch an electrical ground to remove any static charge that you
may have accumulated. The package and substrate may be electrically common. If
so, the reaction of a discharge to the case would cause the same damage as
touching the leads.
Repair Procedures and Techniques — General
4.0
2-3
Repair Procedures and Techniques — General
Parts Replacement and Substitution
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 center listed in the “Piece Parts” section of this
manual.
Rigid Circuit Boards
This family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise
care to avoid pulling the plated circuit out of the hole.
When soldering near the 20-pin and 40-pin connectors:
5.0
•
Avoid accidentally getting solder in the connector.
•
Be careful not to form solder bridges between the connector pins.
•
Examine your work closely for shorts due to solder bridges.
Disassembling and Reassembling the Radio — General
Since these radios may be disassembled and reassembled with the use of only four (board to
casting) screws, it is important to pay particular attention to the snaps and tabs, and how parts align
with each other.
The following tools are required for disassembling the radio:
•
Small flat blade screwdriver
•
Dismantling Tool (Motorola Part No. 6686119B01)
•
TORX™ T20 screwdriver
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 Center. (See Chapter 1 for a list of authorized
service centers.)
The following disassembly procedures should be performed only if necessary:
2-4
6.0
Radio Disassembly - Detailed
Radio Disassembly - Detailed
The procedure to remove and replace a Control Head, Top Cover or Transceiver Board is similar for
all models of radio. A typical procedure is therefore shown followed by specific disassembly
procedures for Control Heads on radio models.
6.1
Control Head Removal
1.
Insert the dismantling tool in the groove between the control head and the radio assembly as
shown in Figure 2-1.
2.
Press on the dismantling tool until the snap connectors on the side of the control head release
from the radio assembly.
Dismantling
Tool
ZWG0130209-O
Figure 2-1 Typical Control Head Removal.
3.
Pull the control head away from the radio assembly as shown in Figure 2-2.
Radio Disassembly - Detailed
2-5
Flexible
Connection
ZWG0130210-O
Figure 2-2 Flexible Connection Removal
4.
6.2
Remove the flexible connection from the socket on the control head board.
Top Cover Removal
1.
Insert the dismantling tool in the middle of the radio assembly side groove as shown in
Figure 2-3.
2.
Press on the dismantling tool until the snap connectors on the side of the cover release from
the radio chassis.
3.
Lift the top cover from the chassis.
Dismantling
Tool
ZWG0130211-O
Figure 2-3 Top Cover Removal.
2-6
6.3
Radio Disassembly - Detailed
Transceiver Board Removal
1.
Remove six screws from the diecast cover using the T20 TORX™ driver as shown in
Figure 2-4.
2.
Lift the cover from the chassis.
Screws (6)
Diecast
Cover
Radio
Chassis
ZWG0130212-O
Figure 2-4 Diecast Cover Removal.
3.
!
Slowly lift the transceiver board on the edge at the front of the radio (the edge that mates with
the control head) and pull gently toward the front of the radio as shown in Figure 2-5. Take
care to slide the antenna connector and power connector out of the chassis towards the front.
CAUTION: The thermal grease or pads can act as an adhesive and cause the leads of the heat
dissipating devices to be over stressed if the board is lifted too quickly.
Lift
Antenna
Connector
ZWG0130213-O
Figure 2-5 Transceiver Board Removal
Radio Disassembly - Detailed
6.4
2-7
Disassembly of Control Heads
1.
To dismount the control head housing from the back housing, insert the dismantling tool in the
groove between the two housings as shown in Figure 2-6.
ZWG0130214-O
Figure 2-6 Control Head Back Housing Removal
2.
Press the dismantling tool until the snap connectors on the side of the back housing release
from the control head.
3.
Disconnect the speaker socket and pull out the speaker (with speaker tube) by stretching the
control head housing, Figure 2-7 (GM338 only).
NOTE The speaker and speaker tube are glued together to form one unit.
ZWG0130218-O
Figure 2-7 Speaker and Speaker Tube Removal
2-8
Radio Disassembly - Detailed
4.
Remove the board from the control head housing by stretching the control head housing and
pulling up on the board as shown in Figure 2-8 and Figure 2-9.
ZWG0130215-O
Figure 2-8 Control Head Board Removal
5.
Remove the keypad from the control head housing by lifting up the rubber keypad.
6.
Remove the display and the top and bottom elastomeric connectors from the control head
housing.
NOTE Care should be taken not to touch or contaminate the conductive pads on the under
side of the keypad, the elastomeric connectors or the conductive contacts on the
printed circuit board .
ZWG0130216-O
Figure 2-9 Board, Keypad and Speaker Removal
Radio Assembly
2-9
7.0
Radio Assembly
7.1
Control Heads - GM338 and GM398
1.
On the GM338 only, locate the display in the control head ensuring that the two cut-outs in the
display are aligned with their corresponding indentations, then press the display into place.
Insert the top and bottom elastomeric connector strips into the spaces above and below the
display respectively.
NOTE Care should be taken not to touch or contaminate the conductive pads on the underside of the display and the elastomeric connectors (GM338 only).
7.2
7.3
2.
Fit the rubber keypad onto the board ensuring that the ON/OFF control and microphone on
the board locate correctly with the cut-outs in the keypad.
3.
On the board, rotate the ON/OFF control spindle fully counter-clockwise.
4.
Also, rotate the volume knob on the front housing fully counter-clockwise.
5.
Align the board with the control head, inserting the ON/OFF control spindle and microphone
connector through the holes in the control head.
6.
Ensure that the keypad, ON/OFF control spindle and microphone connector are aligned with
the control head then press the board into place until it clicks.
7.
On the GM338, insert the speaker tube and speaker into the control head and press it in until
it clicks. Connect the speaker connector to the board.
Radio Chassis And Transceiver Board
1.
Inspect the transceiver board chassis and if required reapply thermal grease to the heatsink
area on the chassis and heat dissipating devices. You may have to remove damaged thermal
pads from the chassis and devices prior to applying the grease.
2.
Insert the transceiver board at an angle (approximately 30°) into the chassis taking care to
slide the antenna connector and accessory connector into their cut-outs in the chassis.
3.
Lower the transceiver board onto the chassis and align the two locating holes in the board
with the locating pins in the chassis.
4.
Secure the cover to the chassis with the six screws previously removed.
5.
Torque the six screws to 1.9 NM (17 in lbs) using the T20 TORX™ driver. Begin with the two
screws located in the middle of the chassis followed by the four outer screws. Since the
screws usually take a set, torque the screws a second time (1.9 NM) in the same order.
6.
Refit the top cover over the assembled radio chassis. Press the cover down until it snaps into
place.
Control Head Fitting
1.
Align the “0” mark on the flex with the “0” mark on the chassis to the socket on the radio
assembly as shown in Figure 2-2.
2.
Check that the back housing o-ring seal is undamaged and fitted in the groove. Replace the
seal if it is damaged (refer to the exploded view diagrams and parts list).
3.
Fit the back housing to the control head. Ensure that the tags on the back housing align with
the snap catch grooves on the control head. Press the back housing into place until it snaps
into place.
4.
Check that the radio chassis o-ring seal is undamaged and fitted in the groove on the chassis
assembly. Replace the seal if it is damaged.
2-10
Radio Exploded Mechanical Views and Parts Lists
8.0
Radio Exploded Mechanical Views and Parts Lists
8.1
Radio Assembly
10
9
8
7
6
5
4
15
13
3
14
16
12
1
11
2
Figure 2-10 Radio Assembly
Item No.
Description
Part Number
1
Chassis 25W
2786082B02
2
Gasket, Controlhead
3202620Y01
3
Main PCB (items 4, 5 and 6 included)
4
Antenna Connector with Gasket, BNC
0986166B01
5
Power Connector
0986165B01
6
Connector 20 PIN
0986105B01
7
Connector Assembly
2886122B02
8
Gasket Cover
3202607Y01
9
Connector Housing (Optional extra)
1580922V01
10
Gasket Accessory Connector (Optional extra)
3202606Y01
11
Gasket Cover 25W
3286085B01
12
Cover 25W
1586084B01
13
Cover, Plastic 25W
1586083B01
14
Screw T20, 6x (M4)
0310911A30
15
Screw T8 Power Device Fastner (some models only)
0310911A12
16
Silicon Pressure pad, Power devices (25W cover only)
7586187B01
ZWG0130202-A
Radio Exploded Mechanical Views and Parts Lists
8.2
2-11
Control Head - GM338
10
11
4
12
2
9
13
7
8
5
6
1
3
ZWG0130200-A
Figure 2-11 Control Head - GM338
Item no
Description
Part No.
1
Housing Front
Gasket, Lens, Lightguide
1586088B01
2
Knob, Volume
3686098B02
3
Label
1364279B17
4
Speaker
5086126B01
5
Tube, Speaker with Gasket
3786107B01
6
Keypad, including:
Keypad Button
7586091B02
3886134B--
7
LCD Glass
7286104B01
8
Frame LCD
0786099B01
9
Conn. Elastomeric (Top and Bottom)
2886130B01
10
Back Housing, including:
Back Housing, O-ring
Back Housing, Grounding Clip
1586093B02
3286094B01
3986218B01
11
PCB Kit
GLN7353_
12
Potentiometer
1805911V02
13
10 PIN Microphone Jack
2864287B01
Flex, 12 Position Connector
(Controlhead to Radio)
8486127B01
2886130B02
(not shown)
2-12
8.3
Radio Exploded Mechanical Views and Parts Lists
Control Head - GM398
10
9
4
7
6
2
8
5
1
ZWG0130201-O
3
Figure 2-12 Control Head - GM398
Item No
Description
Part No
1
Housing Front, including:
Gasket, Lens, Lightguide
1564304B01
2
Knob, Volume
3686098B02
3
Label
1364279B18
4
LCD Module
5164313B01
5
Keypad, including:
Keypad Button
7564314B01
3886134B--
6
PCB Kit
GLN7361_
7
Potentiometer
1805911V02
8
10 PIN Microphone Jack
2864287B01
9
Flex, 24 Position connector
8464346B02
10
Backhousing, including:
Back housing O-ring
Grounding Clip, left
Grounding Clip, right
1564305B01
3286094B01
3908450X02
3908451X02
Flex, 12 Position Connector
(Controlhead to Radio)
8486127B01
(not shown)
Service Aids
9.0
2-13
Service Aids
Table 2-1 lists the service aids recommended for working on the radio. While all of these items are
available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-1 Service Aids
Motorola Part
No.
Description
Application
RLN4460_
Portable Test Set
Enables connection to audio/accessory jack.
Allows switching for radio testing.
RKN4081_
Programming Cable with Internal RIB
Includes radio interface box (RIB) capability.
RLN4853_
10 to 20 Pin Adapter
Connects RKN4081 to radio accessory conn.
RKN4083_
Mobile Programming/Test Cable
Connects radio to RIB (RLN4008_).
GTF374_
Program Cable
Connects RIB to Radio microphone input
RLN4008_
Radio Interface Box
Enables communications between radio and
computer’s serial communications adapter.
HLN8027_
Mini UHF to BNC Adaptor
Adapts radio antenna port to BNC cabling of
test equipment.
GPN6133_
Power Supply
Provides the radio with power when bench
testing.
EPN4040_
Wall-Mounted Power Supply
Used to supply power to the RIB (UK).
EPN4041_
Wall-Mounted Power Supply
Used to supply power to the RIB (Euro)
8180384J59
Housing Eliminator (short)
Test Fixture used to bench test the radio PCB
8180384J60
Housing Eliminator (medium)
Test Fixture used to bench test the radio PCB
8180384J61
Housing Eliminator (long)
Test Fixture used to bench test the radio PCB
3080369B71
Computer Interface Cable
Connects the RIB to the Computer (25-pin)
3080369B72
Computer Interface Cable
Connects the RIB to the Computer (9-pin)
(Use for IBM PC AT - other IBM models use
the B71 cable above)
6686119B01
Removal Tool
Assists in the removal of radio control head.
2-14
10.0
Test Equipment
Test Equipment
Table 2-2 lists test equipment required to service the radio and other two-way radios.
Table 2-2 Recommended Test Equipment
Motorola Part
No.
Description
Characteristics
Application
R2600_NT
Comms System
Analyzer (non MPT)
This monitor will
substitute for items with
an asterisk *
Frequency/deviation meter
and signal generator for widerange troubleshooting and
alignment
R2680_NT
Comms System
Analyzer
(MPT1327) to be
ordered with
RLN1022_ (H/W)
RLN1023_ (S/W)
This monitor will
substitute for items with
an asterisk *
Frequency/deviation meter
and signal generator for widerange troubleshooting and
alignment
*R1072_
Digital Multimeter
*R1377_
AC Voltmeter
100 µV to 300 V,
5Hz-1MHz,
10 Mega Ohm input
impedance
Audio voltage
measurements
WADN4133_
Delay
Oscilloscope
2 Channel 40 MHz bandwidth,
5 mV/cm - 20 V/cm
Waveform measurements
R1440_
Wattmeter,
Transmitter power output
measurements
0180305F17
0180305F31
0180305F40
RLN4610_
Plug-in Elements
Plug-in Elements
Plug-in Elements
Carry case
Thruline 50-Ohm,
±5% accuracy
10W, 25 - 60 MHz
10W, 100 - 250 MHz
10W, 200 - 500 MHz Wattmeter and
6 elements
T1013_
RF Dummy Load
S1339_
RF Millivolt Meter
100mV to 3 VRF,
10 kHz to 1.2 GHz
RF level measurements
R1011_/220V
220V Power
Supply
0-40V, 0-40A
Programmable
AC/DC voltage and current
measurements
Programming/Test Cable - RKN4083_
2-15
11.0 Programming/Test Cable - RKN4083_
P1 (Male)
To Radio
Test Set
1
13
13
14
J1 (Female)
To RIB
RLN4008
25
25
1
14
1000 +_ 50mm
Cable
1000 +_ 50mm
Cable
J2 (Female)
To Mobile Radio
Accessory
Connector
1
19
17
20
18
Viewed from
Front (pin end)
of Connector
2
FLO830308-0
FL0830308O
Figure 2-13 Programming/Test Cable
J2 Mobile
Radio
Accessory
Connector
SPEAKER EXTERNAL MIC
DIGITAL IN 1 (EXT. PTT)
DIGITAL OUT 2 (EXT. ALARM)
1
2
3
4
FLAT TX AUDIO SENSITIVITY
5
6
DIGITAL IN 3/MPT MAP 27 RX
GND
DIGITAL IN/OUT 4/MPT MAP 27 TX
DIGITAL IN 5 w WAKEUP (EMG)
7
8
9
IGNITION 10
FLAT/FILTERED RX AUDIO
DIGITAL IN/OUT 7
SWITCHED BATTERY VOLTAGE
DIGITAL IN/OUT 8
11
12
13
14
RSSI 15
SPEAKER +
BUS + (FOR CPS AND FLASHING)
BOOT CONTROL
N/C
16
17
18
19
N/C 20
P1
To Radio
Test Set
RLN4460
1
2
AUDIO +
AUDIO -
5
AUDIO +
7
10
15
AUDIO MIC AUDIO
MIC AUDIO
16
18
GND
VOL CTRL
19
20
25
DISC
PTT
BOOT CTRL
J1
To RIB
RLN4008
1
GND
4 BIAS
11 BUS 12 SW B +
15 BUS +
25 BOOT CTRL
FL0830307O
FLO830307-0
Figure 2-14 Pin Configuration of the Side Connector
2-16
Programming/Test Cable - RKN4083_
THIS PAGE INTENTIONALLY LEFT BLANK
3-1
Section 3
TRANSCEIVER PERFORMANCE TESTING
1.0
General
These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment. The recommended field service equipment approaches
the accuracy of the manufacturing equipment with few exceptions. This accuracy must be
maintained in compliance with the manufacturer’s recommended calibration schedule.
2.0
Setup
Supply voltage is provided using a 13.2Vdc power supply. The equipment required for alignment
procedures is connected as shown in the Radio Tuning Test Setup Diagram, Figure 4-4.
Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this
chapter contain the following related technical data:
Table Number
Title
3-2
Test Environments
3-3
Test Channel Spacing
3-4
Test Frequencies
3-5
Transmitter Performance Checks
3-6
Receiver Performance Checks
Table 3-1 Initial Equipment Control Settings
Service Monitor
Test Set
Power Supply
Monitor Mode: Power Monitor
Spkr set: A
Voltage: 13.2Vdc
RF Attn: -70
Spkr/load:
Speaker
DC On/Standby:
Standby
AM, CW, FM: FM
PTT: OFF
Volt Range: 20V
Oscilloscope Source: Mod
Oscilloscope Horiz: 10mSec/Div
Oscilloscope Vert: 2.5kHz/Div
Oscilloscope Trig: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: mid CW
Monitor Vol: 1/4 CW
Current: 20A
3-2
3.0
RF Test Mode
RF Test Mode
When the radio is operating in its normal environment, the radio’s microcontroller controls the RF
channel selection, transmitter key-up, and receiver muting. However, when the unit is on the bench
for testing, alignment, or repair, it is removed from its normal environment and cannot receive
commands from its system. Therefore, the internal microcontroller does not key the transmitter or
unmute the receiver. This prevents the use of a normal tuning procedure. To solve this problem, a
special “test mode” is incorporated into the radio.
To enter test mode (display radios):
1.
Turn the radio on.
2.
Within ten seconds after the self test is complete, press button P2, five times in succession.
3.
After “CSQ CHXX SP25” appears in the display, the radio is on channel XX, carrier squelch
mode, 25 kHz channel spacing.
4.
Each additional press of P2 scrolls through to the next channel spacing and a corresponding
set of tones are sounded.
5.
Pressing P1 scrolls through and accesses test environments as shown in 3-2.
6.
Pressing P2 for three seconds switches the radio to the control head test mode. ‘LCD Test’
appears on the display.
7.
Pressing P1 causes the radio to turn on all the dots of the first character. Another P1 press
turns on all the dots of the next character and so on until the last character.
8.
Pressing P1 at the end of the LCD test activates the ‘Icon Test’. The next P1 press turns on
the first icon.
9.
Pressing P1 at the end of the Icon test activates the “Button Test” mode. Pressing any button
(except P1) or any keypad button during the LCD test or Icon test immediately activates this
test.
10. Pressing P2 for 3 seconds in the control head test mode causes the radio to return to the RF
test mode.
RF Test Mode
3-3
Table 3-2 Test Environments
No. of
Beeps
Description
1
(high
pitch)
Function
Carrier Squelch
(CSQ)
RX: unsquelch if carrier detected
TX: mic audio
1
Tone
Private-Line (TPL)
RX: unsquelch if carrier and tone (192.8Hz) detected
TX: mic audio + tone (192.8Hz)
2
Digital
Private-Line (DPL)
RX: unsquelch if carrier and digital code (131) detected
TX: mic audio + digital code (131)
3
Dual-Tone multiple frequency
(DTMF)
RX: unsquelch if carrier detected
TX: selected DTMF tone pair
5
Unsquelch
(Open)
RX: constant unsquelch
TX: mic audio
9
MDC1200
(HSS)
RX: unsquelch if carrier detected
TX: 1500 Hz tone
11
CMP
RX: unsquelch if carrier detected
TX: mic audio
12
LLE
RX: unsquelch if carrier detected
TX: mic audio
Table 3-3 Test Channel Spacing
Number of Beeps
Channel Spacing
1
25 kHz
2
12.5 kHz
3
20 kHz
3-4
RF Test Mode
Table 3-4 Test Frequencies
Low
Band
Range 1
29.7-36
MHz
Low
Band
Range 2
36-42
MHz
Low
Band
Range 3
42-50
MHz
8
29.725
30.025
1
8
29.750
TX
2
9
RX
2
TX
Test
Channel
Low
Power
Test
Channel
High
Power
TX
1
RX
Test
Mode
VHF
UHF1
UHF2
42.025
136.025
403.025
450.025
36.050
42.050
136.050
403.050
450.050
30.225
37.125
43.225
142.325
414.150
462.825
9
30.325
37.225
43.125
142.350
414.175
462.850
3
10
31.025
38.225
44.525
148.625
425.325
475.650
RX
3
10
31.125
38.325
44.425
148.650
425.350
475.675
TX
4
11
32.125
39.125
46.125
154.975
436.475
488.475
RX
4
11
32.225
39.225
46.025
155.025
436.525
488.525
TX
5
12
33.025
40.225
47.525
161.225
447.650
501.325
RX
5
12
33.125
40.325
47.425
161.250
447.675
501.350
TX
6
13
34.225
41.025
48.125
167.525
458.825
514.125
RX
6
13
34.325
41.125
48.025
167.550
458.850
514.150
TX
7
14
35.950
41.950
49.950
173.950
469.950
526.950
RX
7
14
35.975
41.975
49.975
173.975
469.975
526.975
RF Test Mode
3-5
Table 3-5 Transmitter Performance Checks
Communications
Analyzer
Radio
Reference
Frequency
Mode: PWR MON
4th channel test frequency*
Monitor: Frequency error
Input at RF In/Out
TEST MODE,
Test Channel 4 carrier
squelch
PTT to
continuous
(during the
performance
check)
Frequency error:
±150 Hz VHF,
±150 Hz UHF
Power RF
As above
As above
As above
Low Power:
0.8-1.4 W.
High Power:
25-30W
Voice
Modulation
Mode: PWR MON
4th channel test frequency*
atten to -70, input to RF
In/ Out
Monitor: DVM, AC Volts
Set 1kHz Mod Out level
for 800mVrms at test set,
800mVrms at AC/DC test
set jack
As above
As above,
meter selector to mic
Deviation:
2.5 kHz Max.
(12.5 kHz Ch. Sp.).
4 kHz Max.
(20 kHz Ch. Sp.).
5 kHz Max.
(25 kHz Ch. Sp.).
Voice
Modulation
(internal)
Mode: PWR MON
4th channel test frequency*
atten to -70, input to RF
In/ Out
TEST MODE,
Test Channel 4 carrier
squelch output at
antenna
Remove
modulation
input
Deviation:
2.5 kHz Max.
(12.5 kHz Ch. Sp.).
4 kHz Max.
(20 kHz Ch. Sp.).
5 kHz Max.
(25 kHz Ch. Sp.).
High-Speed
Data
Modulation**
As above
TEST MODE,
Test
Channel 4
high speed
output at
antenna
PTT to
continuous
(during the
performance
check).
Deviation:
1.3-1.7 kHz
(12.5 kHz Ch. Sp.).
2.1-2.7 kHz
(20 kHz Ch. Sp.).
2.6-3.4 kHz
(25 kHz Ch. Sp.).
DTMF
Modulation
As above,
4th channel test
frequency*
TEST MODE,
Test
Channel 4
DTMF output
at antenna
As above
Deviation:
1.4-1.9 kHz
(12.5 kHz Ch. Sp.).
2.3-3.0 kHz
(20 kHz Ch. Sp.).
2.9-3.8 kHz
(25 kHz Ch. Sp.).
PL/DPL
Modulation
As above
4th channel test
frequency*
BW to narrow
TEST MODE,
Test
Channel 4
TPL
DPL
As above
Deviation:
0.25-0.5 kHz
(12.5 kHz Ch. Sp.).
0.4-0.8 kHz
(20 kHz Ch. Sp.).
0.5-1.0 kHz
(25 kHz Ch. Sp.).
Test Name
* See 3-4
** MPT
Test Set
Comment
3-6
RF Test Mode
Table 3-6 Receiver Performance Checks
Test Name
Communications
Analyzer
Radio
Test Set
Comment
Reference
Frequency
Mode: PWR MON
4th channel test frequency*
Monitor: Frequency error
Input at RF In/Out
TEST
MODE,
Test Channel 4 carrier
squelch output at
antenna
PTT to
continuous
(during the
performance
check)
Frequency error
to be
±150 Hz VHF
±150 Hz UHF
Rated Audio
Mode: GEN
Output level: 1.0mV RF
4th channel test frequency*
Mod: 1kHz tone at
3kHz deviation
Monitor: DVM: AC Volts
TEST MODE
Test Channel 4 carrier
squelch
PTT to OFF
(center),
meter selector to Audio
PA
Set volume control to 8.12Vrms
Distortion
As above, except to
distortion
As above
As above
Distortion <5.0%
Sensitivity
(SINAD)
As above, except SINAD,
lower the RF level for
12dB SINAD.
As above
PTT to OFF
(center)
RF input to be
<0.3µV
RF level set to 1mV RF
As above
PTT to OFF
(center),
meter selection to Audio
PA, spkr/
load to
speaker
Set volume control to 3.16Vrms
As above, except change
frequency to a conventional system. Raise RF
level from zero until radio
unsquelches.
out of TEST
MODE;
select a
conventional
system
As above
Unsquelch to
occur at <0.25µV.
Preferred SINAD
= 9-10dB
Noise
Squelch
Threshold
(only radios
with conventional system need to
be tested)
* See 3-4
4-1
Section 4
RADIO TUNING AND PROGRAMMING
1.0
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 4-1. An Installation instruction manual is also
included with each kit.
NOTE
Refer to the appropriate program on-line help files for the programming procedures.
Table 4-1 Software Installation Kits Radio Tuning Setup
Description
Customer Programming Software (CPS) CD
PMVN4043D
Customer Programming Software (CPS) Disk
PMVN4031D
CPS Programming Setup
The CPS programming setups, shown in Figure 4-1 through Figure 4-3, are used to program the
radio.
NOTE
Refer to appropriate program on-line help files for the programming procedures.
ACC
Radio
2.0
Kit Number
DC
RF
+13,2VDC
Power
Supply
Programming
Cable
RKN4081
DB15
RIB
RLN-4008
DB25
Tx Data
Rx Data
Gnd
Cable 3080369B72 (9 PIN)
Cable 3080369B71 (25 PIN)
ZWG0130338-0
Figure 4-1 CPS Programming Setup with RIB
4-2
CPS Programming Setup
Radio
ACC
DC
RF
+13,2VDC
Power
Supply
Programming Cable RKN4081
Tx Data
Rx Data
Gnd
DB25
ZWG0130339-0
Figure 4-2 CPS Programming Setup Cable with Internal RIB
Radio
ACC
Adapter
Cable
RLN4853
Programming
Cable
RKN4081
DC
RF
Tx Data
Rx Data
Gnd
DB25
+13,2VDC
Power
Supply
ZWG0130340-0
Figure 4-3 CPS Programming Setup Cable with Internal RIB and Rear Adapter Cable
Radio Tuning Setup
3.0
4-3
Radio Tuning Setup
A personal computer (PC), Windows 95/98 and a tuner program are required to tune the radio. To
perform the tuning procedures, the radio must be connected to the PC, radio interface box (RIB),
and test equipment setup as shown in Figure 4-4.
Audio In
Test Box
RLN4460
Tx
Audio Generator
Rx
Sinad Meter
Program/Test Cable
RKN4083
AC Voltmeter
DB15
Tx Data
Rx Data
Gnd
RIB
RLN-4008
Radio
ACC
DC
+13,2VDC
Power
Supply
RF
30 dB Pad
Cable 3080369B72 (9 PIN)
Cable 3080369B71 (25 PIN)
Mini UHF
to BNC
HLN8027
Service Monitor
or Counter
Transmit
Wattmeter
Receive
RF Generator
ZWG0130336-0
Figure 4-4 Radio Tuning Test Equipment Setup with External RIB
3.1
Initial Test Equipment Control Settings
The initial test equipment control settings are listed in Table 4-2.
Table 4-2 Initial Test Equipment Control Settings
Service Monitor
Test Set
Power Supply
Monitor Mode: Power Monitor
Speaker set: A
Voltage: 13.2Vdc
RF Attenuation: -70
Speaker/load:
Speaker
DC On/Standby:
Standby
AM, CW, FM: FM
PTT: OFF
Volt Range: 20V
Oscilloscope Source: Mod
Oscilloscope Horizontal: 10mSec/Div
Oscilloscope Vertical: 2.5 kHz/Div
Oscilloscope Trigger: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: mid CW
Monitor Volume: 1/4 CW
Current: 20A
4-4
Radio Tuning Setup
THIS PAGE INTENTIONALLY LEFT BLANK
5-1
Section 5
POWER UP SELF-TEST
1.0
Error Codes
Turning on the radio starts a self-test routine that checks the radio functionality. If the checks are
successful, the radio generates two high-pitched self-test pass tones, or a musical tone (selected in
CPS). If the self-test is not successful, one low-pitched tone is heard. Radios with displays are able
to display the error codes. The displayed error codes and related corrections are listed in Table 5-1.
NOTE
A radio without a display emits only the 300Hz tone if it fails the test.
Table 5-1 Power Up Error Codes
If the error code
displayed is...
then, there is a...
To correct the problem...
“RAM Test”
RAM test failure
Turn radio off-on.
If message reoccurs replace main board or
return it to the nearest Motorola depot.
“EEPRM HW
ERROR”
Codeplug structure mismatch or
non existence of codeplug.
Reprogram codeplug with correct version
and retest radio.
If message reoccurs, replace main board or
return to the nearest Motorola depot.
“EEPRM CS
ERROR”
Wrong codeplug checksum.
Reprogram the codeplug and retest the
radio.
No Display
Display module is not connected.
Check connection between main board and
the display module.
Display module faulty.
Replace display module.
300Hz Tone
(Radio Without Display)
Radio failure or invalid codeplug as
described above.
Turn radio off then on again.
Confirm that there is a 300Hz fail tone. Make
the relevant correction as described above.
5-2
Error Codes
THIS PAGE INTENTIONALLY LEFT BLANK
6-1
Section 6
MODEL CHART AND TEST SPECIFICATION
1.0
Low Power Radios
1.1
Model Chart (VHF 136-174 MHz)
GM Series, VHF 136-174 MHz
Model
AZM25KHF9AA5
AZM25KHN9AA8
Description
GM338 136-174 MHz 1-25W
GM398 136-174 MHz 1-25W
Item
X
Description
GCN6114_
GM338 Control Head Direct Mount
GCN6115_
GM398 Control Head Direct Mount
IMUD6010_
Tanapa WM 136-174 MHz 1-25W
X
IMUD6023_
Tanapa WM 136-174 MHz 1-25W
X
X
RAD4198_
BNC 136-144 MHz, 1/4 Wave Roof Mount
X
X
RAD4199_
BNC 146-150.8 MHz, 1/4 Wave Roof Mount
X
X
RAD4200_
BNC 150.8-162 MHz, 1/4 Wave Roof Mount
X
X
RAD4201_
BNC 162-174 MHz, 1/4 Wave Roof Mount
X
X
RAD4202_
BNC 146-172 MHz, 3dB Gain Roof Mount
6804112J06
GM338 User Guide
6804112J07
GM398 User Guide
X
X
X
X
x = Indicates one of each is required.
6-2
1.2
Low Power Radios
Model Chart (UHF Band 1, 403-470 MHz)
GM Series, UHF Band 1, 403-470 MHz
Model
AZM25RHF9AA5
AZM25RHN9AA8
Description
GM338 403-470 MHz 1-25W
GM398 403-470 MHz 1-25W
Item
X
Description
GCN6114_
GM338 Control Head Direct Mount
GCN6115_
GM398 Control Head Direct Mount
IMUE6021_
Tanapa WM 403-470 MHz 1-25W
X
IMUE6039_
Tanapa WM 403-470 MHz 1-25W
X
X
RAE4151_
BNC 403-430 MHz, 1/4 Wave Roof Mount
X
X
RAE4158_
BNC 406-420 MHz, 3.5dB Gain Roof Mount
X
X
RAE4152_
BNC 450-470 MHz, 1/4 Wave Roof Mount
X
X
RAE4153_
BNC 450-470 MHz, 3.5dB Gain Roof Mount
X
X
RAE4154_
BNC 450-470 MHz, 5dB Gain Roof Mount
6804112J06
GM338 User Guide
6804112J07
GM398 User Guide
X
X
X
X
x = Indicates one of each is required.
Low Power Radios
1.3
6-3
Model Chart (UHF Band 2, 450-527 MHz)
GM Series, UHF Band 2, 450-527 MHz
Model
AZM25SHF9AA5
Description
GM338 450-527 MHz 1-25W
AZM25SHN9AA8
GM398 450-527 MHz 1-25W
Item
X
Description
GCN6114_
GM338 Control Head Direct Mount
GCN6115_
GM398 Control Head Direct Mount
IMUE6022_
Tanapa WM 450-527 MHz 1-25W
X
IMUE6043
Tanapa WM 450-527 MHz 1-25W
X
X
RAE4155_
BNC 470-512 MHz, 1/4 Wave Roof Mount
X
X
RAE4156_
BNC 470-494 MHz, 3.5 Gain Roof Mount
X
X
RAE4157_
BNC 494-512 MHz, 5dB Gain Roof Mount
6804112J06
GM338 User Guide
6804112J07
GM398 User Guide
X
X
X
X
x = Indicates one of each is required.
1.4
Model Chart (Low Band, 29.7-50.0 MHz)
GM Series, Low Band, 29.7-50.0 MHz
Model
AZM25BKF9AA5
Description
GM338 29.7-36.0 MHz 40-60W
AZM25CKF9AA5
AZM25DKF9AA5
GM338 36.0-42.0 MHz 40-60W
GM338 42.0-50.0 MHz 40-60W
Item
X
X
X
X
X
X
X
X
X GCN6114_
Description
Preferred Control Head Direct Mount
IMUB6000_
Tanapa WM 29.7-36.0 MHz 40-60W
IMUB6001_
Tanapa WM 36.0-42.0 MHz 40-60W
X IMUB6002_
Tanapa WM 42.0-50.0 MHz 40-60W
RAB4002
Low Band 29.7-36.0 MHz, 1/4 Wave Base Loaded
RAB4003
Low Band 36.0-42.0 MHz, 1/4 Wave Base Loaded
X RAB4004
Low Band 42.0-50.0 MHz, 1/4 Wave Base Loaded
X 6804112J06
GM338 User Guide
x = Indicates one of each is required.
6-4
1.5
Low Power Radios
Specifications
General
Specification
Frequency Range:
VHF
136-174 MHz
UHF1
403-470 MHz
Frequency Stability
±2.5 PPM
(-30°C to +60°C, 25°C
Ref.)
Channel Spacing:
Power Output:
Power Supply:
UHF2
450-527 MHz
LOW BAND
Low Band 1 (29.7-36.0 MHz)
Low Band 2 (36.0-42.0 MHz)
Low Band 3 (42.0-50.0 MHz)
±2 PPM
±5 PPM
12.5/20/25 kHz
12.5/20/30 kHz
1-25W
40-60W
13.2Vdc (10.8 - 15.6 Vdc) negative vehicle ground
Dimensions
(L X W X H)
GM338:
GM398:
Weight:
Operating
Temperature:
186mm X 179mm X 59mm
(add 9mm for Volume Knob)
(7.32” X 7.05” X 2.34” - add 0.35”
for Volume Knob)
60mm X 179mm X 250mm
(add 9mm for Volume
Knob)
188mm X 185mm X 72mm (add 7mm for Volume 56mm X 176mm X 241mm
Knob)
(add 8mm for Volume
(7.4” X 7.28” X 2.83” - add 0.27” for Volume Knob)
Knob)
1400 g (3.15 lbs)
-30 to 60 o C
Sealing:
Passes rain testing to IP54
Shock and Vibration:
Meets MIL-STD 810-C,D&E
Dust:
Meets MIL-STD 810-C,D&E
Humidity:
50 o C 95% RH @ 8 hrs
2040 g (4.5 Ibs)
Low Power Radios
6-5
Transmitter
Specification
VHF
UHF1
UHF2
LOW BAND
Modulation Limiting:
±2.5 kHz @ 12.5 kHz
±4.0 kHz @ 20 kHz
±5.0 kHz @ 25 kHz
±2.5 kHz @ 12.5 kHz
±5.0 kHz @ 20/30 kHz
FM Hum and Noise:
-40 dB@12.5 kHz
-45 dB@ 20/25 kHz
-40 dB @ 12.5 kHz
-45 dB @ 20/30 kHz
Conducted/Radiated
Emissions:
-36 dBm < 1 GHz
-30 dBm > 1 GHz
-26 dBm < 1 GHz
-60dB @12.5,
-70dB @ 25kHz
-60dB @ 12.5kHz
-70dB @ 20/30kHz
Adjacent Channel Power
Audio Response:
( 300 to 3000Hz)
+1, -3dB
Audio Distortion
@ 1000 Hz, 60%
Rated Maximum Deviation:
3% Typical
Receiver
Specification
VHF
UHF1
LOW BAND
0.30 µV (0.22 µV Typical)
Sensitivity (12 dB SINAD) :
(ETS)
Intermodulation: (ETS)
UHF2
>65 dB, >70 dB in Base Mode
>80 dB, >70 dB in
Base Mode
Adjacent Channel
Selectivity: (ETS)
80 dB @ 25 kHz
75 dB @ 20 kHz
65 dB @ 12.5 kHz
75 dB @ 25 kHz
70 dB @ 20 kHz
65 dB @ 12.5 kHz
80 dB @ 20/30 kHz
65 dB @ 12.5 kHz
Spurious Rejection: (ETS)
80 dB @ 20/25 kHz
75 dB @ 12.5 kHz
75 dB @ 20/25 kHz
70 dB @ 12.5 kHz
80 dB @ 20/30 kHz
70 dB @ 12.5 kHz
Rated Audio:
Audio Distortion @ Rated
Audio:
Hum and Noise:
Audio Response:
( 300 to 3000Hz)
Conducted Spurious
Emission per FCC Part 15:
3W Internal
7.5W External
13W External
3W Internal
13W External
3% Typical
-40 dB @ 12.5 kHz
-45 dB @ 20/25 kHz
-45 dB @ 20/30 kHz
-40 dB @ 12.5 kHz
+1, -3dB
-57 dBm <1 GHz
-47 dBm >1 GHz
-26 dBm <1 GHz
6-6
High Power Radios
2.0
High Power Radios
2.1
Model Chart (VHF 136-174 MHz)
GM Series, VHF 136-174 MHz
Model
AZM25KKF9AA5
Description
GM338 136-174 MHz 25-45W
Item
Description
X
GCN6114_
GM338 Control Head Direct Mount
X
IMUD6011_
Tanapa WM 136-174 MHz 25-45W
X
RAD4198_
BNC 136-144 MHz, 1/4 Wave Roof Mount
X
RAD4199_
BNC 146-150.8 MHz, 1/4 Wave Roof Mount
X
RAD4200_
BNC 150.8-162 MHz, 1/4 Wave Roof Mount
X
RAD4201_
BNC 162-174 MHz, 1/4 Wave Roof Mount
X
RAD4202_
BNC 146-172 MHz, 3dB Gain Roof Mount
X
6804112J06
GM338 User Guide
x = Indicates one of each is required.
2.2
Model Chart (UHF Band 1, 403-470 MHz)
GM Series, UHF Band 1, 403-470 MHz
Model
AZM25RKF9AA5
Description
GM338 403-470 MHz 25-40W Conv Pref (Bipolar)
Item
Description
X
GCN6114_
GM338 Control Head Direct Mount
X
IMUE6012_
Tanapa WM 403-470 MHz 25-40W
X
RAE4151_
BNC 403-430 MHz, 1/4 Wave Roof Mount
X
RAE4152_
BNC 450-470 MHz, 1/4 Wave Roof Mount
X
RAE4153_
BNC 450-470 MHz, 3.5dB Gain Roof Mount
X
RAE4154_
BNC 450-470 MHz, 5dB Gain Roof Mount
X
RAE4158_
BNC 406-420 MHz, 3.5dB Gain Roof Mount
X
6804112J06
GM338 User Guide
x = Indicates one of each is required.
High Power Radios
2.3
6-7
Model Chart (UHF Band 2, 450-520 MHz)
GM Series, UHF Band 2, 450-520 MHz
Model
AZM25SKF9AA5
Description
GM338 450-520 MHz 25-40W (Bipolar)
Item
Description
X
GCN6114_
GM338 Control Head Direct Mount
X
IMUE6019_
Tanapa WM 450-520 MHz 25-40W
X
RAE4155_
BNC 470-512 MHz, 1/4 Wave Roof Mount
X
RAE4156_
BNC 470-494 MHz, 3.5 Gain Roof Mount
X
RAE4157_
BNC 494-512 MHz, 5dB Gain Roof Mount
X
6804112J06
GM338 User Guide
x = Indicates one of each is required.
2.4
Model Chart (UHF Band 1, LDMOS, 403-470 MHz)
GM Series, UHF Band 1, 403-470 MHz
Mode
AZM25RKF9AA5
Description
GM338 403-470 MHz 25-40W Conv Pref (LDMOS)
Item
Description
X
GCN6114_
GM338 Control Head Direct Mount
X
IMUE6024_
Tanapa WM 403-470 MHz 25-40W
X
RAE4151_
BNC 403-430 MHz, 1/4 Wave Roof Mount
X
RAE4152_
BNC 450-470 MHz, 1/4 Wave Roof Mount
X
RAE4153_
BNC 450-470 MHz, 3.5dB Gain Roof Mount
X
RAE4154_
BNC 450-470 MHz, 5dB Gain Roof Mount
X
RAE4158_
BNC 406-420 MHz, 3.5dB Gain Roof Mount
X
6804112J06
GM338 User Guide
x = Indicates one of each is required.
6-8
2.5
High Power Radios
Model Chart (UHF Band 2, LDMOS, 450-520 MHz)
GM Series, UHF Band 2, 450-520 MHz
Model
AZM25SKF9AA5
Description
GM338 450-520 MHz 25-40W (LDMOS)
Item
Description
X
GCN6114_
GM338 Control Head Direct Mount
X
IMUE6019_
Tanapa WM 450-520 MHz 25-40W
X
RAE4155_
BNC 470-512 MHz, 1/4 Wave Roof Mount
X
RAE4156_
BNC 470-494 MHz, 3.5 Gain Roof Mount
X
RAE4157_
BNC 494-512 MHz, 5dB Gain Roof Mount
X
6804112J06
GM338 User Guide
x = Indicates one of each is required.
High Power Radios
2.6
6-9
Specifications
General
Specification
Frequency Range:
VHF
UHF1
136-174 MHz
Frequency Stability
±2.5 PPM
(-30°C to +60°C, 25°C
Ref.)
Power Supply:
403-470 MHz
450-520 MHz
±2 PPM
Channel Spacing:
Power Output:
UHF2
12.5/20/25 kHz
25-45W
25-40W
13.2Vdc (10.8 - 15.6 Vdc) negative vehicle ground
Dimensions
(L X W X H)
GM338:
Weight:
Operating
Temperature:
186mm X 179mm X 59mm
(add 9mm for Volume Knob)
(7.32” X 7.05” X 2.34” - add 0.35”
for Volume Knob)
1400 g (3.15 lbs)
-30 to 60 o C
Sealing:
Passes rain testing to IP54
Shock and Vibration:
Meets MIL-STD 810-C,D&E
Dust:
Meets MIL-STD 810-C,D&E
Humidity:
50 o C 95% RH @ 8 hrs
6-10
High Power Radios
Transmitter
Specification
VHF
UHF1
UHF2
Modulation Limiting:
±2.5 kHz @ 12.5 kHz
±4.0 kHz @ 20 kHz
±5.0 kHz @ 25 kHz
FM Hum and Noise:
-40 dB@12.5 kHz
-45 dB@ 20/25 kHz
Conducted/Radiated
Emissions:
-36 dBm < 1 GHz
-30 dBm > 1 GHz
Adjacent Channel Power
-60dB @12.5,
-70dB @ 25kHz
Audio Response:
( 300 to 3000Hz)
+1, -3dB
Audio Distortion
@ 1000 Hz, 60%
Rated Maximum Deviation:
3% Typical
Receiver
Specification
Sensitivity (12 dB SINAD) :
(ETS)
VHF
UHF1
UHF2
0.30 µV (0.22 µV Typical)
Intermodulation: (ETS)
>65 dB
Adjacent Channel
Selectivity: (ETS)
80 dB @ 25 kHz
75 dB @ 20 kHz
65 dB @ 12.5 kHz
75 dB @ 25 kHz
70 dB @ 20 kHz
65 dB @ 12.5 kHz
Spurious Rejection: (ETS)
80 dB @ 20/25 kHz
75 dB @ 12.5 kHz
75 dB @ 20/25 kHz
70 dB @ 12.5 kHz
Rated Audio:
Audio Distortion @ Rated
Audio:
3W Internal
7.5W External
13W External
3% Typical
Hum and Noise:
-40 dB @ 12.5 kHz
-45 dB @ 20/25 kHz
Audio Response:
( 300 to 3000Hz)
+1, -3dB
Conducted Spurious
Emission per FCC Part 15:
-57 dBm <1 GHz
-47 dBm >1 GHz
G-1
GLOSSARY OF TERMS
Term
Definition
ALC
Automatic Level Control: a circuit in the transmit RF path that controls RF
power amplifier output, provides leveling over frequency and voltage, and
protects against high VSWR (Voltage Standing Wave Ratio).
ASFIC
Audio Signalling Filter Integrated Circuit with voice compander.
CD
Compact Disk.
CMP
Compression.
CPS
Customer Programming Software.
CSQ
Carrier Squelch.
DTMF
Dual-Tone Multifrequency.
DPL
Digital Private-Line™.
EEPROM
Electronically Erasable/Programmable Read-Only Memory: used by the radio
to store its personality.
Firmware
Software, or a software/hardware combination of computer programs and data,
with a fixed logic configuration stored in a read-only memory. Information
cannot be altered or reprogrammed.
FGU
Frequency Generation Unit.
GaAs
Gallium Arsenide: a type of crystalline material used in some semiconductors.
ISW
Inbound Signalling Word: data transmitted on the control channel from a
subscriber unit to the central control unit.
LCD
Liquid Crystal Display: a module used to display the radio’s current operating
channel or system and scan status.
LDMOS
Lateral Difussion MOS.
LH DATA
Longhorn Data: a bidirectional 0-5V, RS-232 line that uses the microcontroller’s
integrated RS-232 asynchronous serial communications interface (SCI)
peripheral.
LLE
Low Level Expander: slight amount of volume expansion; used to improve the
signal to noise ratio.
LSH
Low-Speed Handshake: 150 baud digital data sent to the radio during trunked
operation while receiving audio.
MDC
Motorola Data Communication.
MRTI
Motorola Radio-Telephone Interconnect: a system that provides a repeater
connection to the Public Switched Telephone Network (PSTN). The MRTI
allows the radio to access the telephone network when the proper access code
is received.
MSK
Minimum-Shift Keying.
G-2
Glossary
OMPAC
Over-Molded Pad-Array Carrier: a Motorola custom package, distinguished by
the presence of solder balls on the bottom pads.
OSW
Outbound Signalling Word: data transmitted on the control channel from the
central controller to the subscriber unit.
PC Board
Printed Circuit Board.
PL
Private-Line® tone squelch: a continuous sub-audible tone that is transmitted
along with the carrier.
PLL
Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a
reference, usually after passing through a frequency divider.
PTT
Push-To-Talk: the switch located on the left side of the radio which, when
pressed, causes the radio to transmit.
RAM
Random Access Memory: the radio’s RAM is loaded with a copy of the
EEPROM data.
Registers
Short-term data-storage circuits within the microcontroller.
Repeater
Remote transmit/receive facility that retransmits received signals to improve
communications coverage.
RESET
Reset line: an input to the microcontroller that restarts execution.
RF PA
Radio Frequency Power Amplifier.
RIB
Radio Interface Box.
ROM
Read Only Memory.
RSSI
Received Signal-Strength Indicator: a dc voltage proportional to the received
RF signal strength.
RPT/TA
Repeater/Talk-Around.
Softpot
Software Potentiometer: a computer-adjustable electronic attenuator.
Software
Computer programs, procedures, rules, documentation, and data pertaining to
the operation of a system.
SPI (clock and data
lines)
Serial Peripheral Interface: how the microcontroller communicates to modules
and ICs through the CLOCK and DATA lines.
Squelch
Muting of audio circuits when received signal levels fall below a pre-determined
value.
Standby Mode
An operating mode whereby the radio is muted but still continues to receive
data.
System Central
Controller
Main control unit of the trunked dispatch system; handles ISW and OSW
messages to and from subscriber units (see ISW and OSW).
System Select
The act of selecting the desired operating system with the system-select switch
(also, the name given to this switch).
TOT
Time-Out Timer: a timer that limits the length of a transmission.
TPL
Tone Private-line.
Glossary
G-3
µC
Microcontroller.
UHF
Ultra High Frequency.
µP
Microprocessor.
VCO
Voltage-Controlled Oscillator: an oscillator whereby the frequency of oscillation
can be varied by changing a control voltage.
VCOBIC
Voltage-Controlled Oscillator Buffer Integrated Circuit.
VHF
Very High Frequency.
VSWR
Voltage Standing Wave Ratio.
G-4
Glossary
Notes
Technical Information Updates
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Manual No.: 6804112J17