Motorola GP series User manual

Professional Radio
GP Series
Detailed Service Manual
6866558D03-O

ii

KTT EMEA Publications Department, Jays Close, Viables Industrial Estate, Basingstoke, Hampshire, RG22 4PD, UK.
Issue :November 2004 iii
Professional Radio
GP Series
Detailed Service Manual
6866558D03-O
Contents
Section 1 Service Maintainability
Section 2 Keypad Service Information
Section 3 Power Distribution and Controller Information
Section 4 UHF1 Service Information
Section 5 UHF2 Service Information
Section 6 800MHz Service Information

iv

v
SAFETY INFORMATION
Read this information before using the radio.
PRODUCT SAFETY AND RF EXPOSURE FOR PORTABLE TWO-WAY RADIOS.
This document provides information and instructions for the safe and efficient operation of Motorola
Portable Two-Way Radios. The information provided in this document supersedes information
contained in user guides published prior to February 2002.
RF Energy Exposure Awareness and Control Information and Operational
Instructions for Occupational Use
Note:This Radio is intended for use in occupational/controlled applications, where users have been
made aware of the potential for exposure and can exercise control over their exposure. This radio
device is NOT authorized for general population, consumer or similar use.
This two-way radio uses electromagnetic energy in the radio frequency (RF) spectrum to provide
communications between two or more users over a distance. It uses radio frequency (RF) energy or
radio waves to send and receive calls. RF energy is one form of electromagnetic energy. Other forms
include, but are not limited to, sunlight and x-rays. RF energy, however, should not be confused with
these other forms of electromagnetic energy, which when used improperly, can cause biological
damage. Very high levels of x-rays, for example, can damage tissues and genetic material.
Experts in science, engineering, medicine, health, and industry work with organizations to develop
standards for safe exposure to RF energy. These standards provide recommended levels of RF
exposure for both workers and the general public. These recommended RF exposure levels include
substantial margins of protection.
All Motorola two-way radios are designed, manufactured, and tested to ensure they meet
government-established RF exposure levels. In addition, manufacturers also recommend specific
operating instructions to users of two-way radios. These instructions are important because they
inform users about RF energy exposure and provide simple procedures on how to control it.
Please refer to the following websites for more information on what RF energy exposure is and how to
control your exposure to assure compliance with established RF exposure limits:
http://www.fcc.gov/oet/rfsafety/rf-faqs.html
http://www.osha.gov/SLTC/radiofrequencyradiation/index.html
Federal Communication Commission (FCC) Regulations (US markets only)
The FCC rules require manufacturers to comply with the FCC RF energy exposure limits for portable
two-way radios before they can be marketed in the U.S. When two-way radios are used as a
consequence of employment, the FCC requires users to be fully aware of and able to control their
exposure to meet occupational requirements. Exposure awareness can be facilitated by the use of a
product label directing users to specific user awareness information. Your Motorola two-way radio has
a RF Exposure Product Label. Do not remove this RF Exposure Label from the device. Also, your
Motorola user manual, or separate safety booklet includes information and operating instructions
required to control your RF exposure and to satisfy compliance requirements.

vi
Compliance with RF 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) for human exposure to radio frequency
electromagnetic energy. This radio complies with the IEEE (FCC) and ICNIRP exposure limits for
occupational/controlled RF exposure environments at operating duty factors of up to 50% talk-
50% listen and is authorized by the IEEE/ICNIRP for occupational use only.
In terms of measuring RF energy for compliance with these exposure guidelines, your radio
generates measurable RF energy only while it is transmitting (during talking), not when it is
receiving (listening) or in standby mode.
Note: The approved batteries, supplied with this radio, are rated for a 5-5-90 duty cycle (5% talk–5%
listen–90% standby), even though this radio complies with IEEE/ICNIRP occupational exposure limits
at usage factors of up to 50% talk.
Your Motorola two-way radio complies with the following RF energy exposure standards and
guidelines:
●United States Federal Communications Commission, Code of Federal Regulations; 47 CFR 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 Radiofrequency
Electromagnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999
●Australian Communications Authority Radiocommunications (Electromagnetic Radiation - Human
Exposure) Standard 2003
●ANATEL ANNEX to Resolution No. 303 of July 2, 2002 "Regulation of limitation of exposure to
electrical, magnetic and electromagnetic fields in the radio frequency range between 9 KHz and
300 GHz" and "Attachment to resolution # 303 from July 2, 2002"
RF Exposure Compliance and Control Guidelines and Operating Instructions
To control your exposure and ensure compliance with the occupational/controlled environment expo-
sure limits, always adhere to the following procedures:
Guidelines:
●User awareness instructions should accompany device when transferred to other users.
●Do not use this device if the operational requirements described herein are not met.
Operating Instructions
●Transmit no more than the rated duty factor of 50% of the time. To transmit (talk), push the Push-To-
Talk (PTT) button. To receive calls, release the PTT button.
Transmitting 50% of the time, or less, is important because this radio generates measurable RF
energy exposure only when transmitting (in terms of measuring for standards compliance).
●When worn on the body, always place the radio in a Motorola-approved clip, holder, holster, case,
or body harness for this product. Using approved body-worn accessories is important because the
use of non-Motorola-approved accessories may result in exposure levels, which exceed the IEEE/
ICNIRP occupational/controlled environment RF exposure limits.
●If you are not using a body-worn accessory and are not using the radio in the intended use position,
along side the head in the phone mode (TETRA only), in front of the face in the hand held mode,
then ensure the antenna and the radio are kept 2.5 cm (one inch) from the body when transmitting.
Keeping the radio at a proper distance is important because RF exposures decrease with
increasing distance from the antenna.

vii
Hand-held Mode - Operating Instructions
●Hold the radio in a vertical position in front of the face with the microphone (and other
parts of the radio including the antenna) at least 2.5 cm (one inch) away from the nose or
lips. Antenna should be kept away from the eye. Keeping the radio at a proper distance is
important since RF exposures decrease with increasing distance from the antenna.
Phone Mode (TETRA only) - Operating Instructions
●When placing or receiving a phone call, hold your radio product as you would a wireless telephone.
Speak directly into the microphone.
Approved Accessories
●Use only Motorola-approved supplied or replacement antennas, batteries, and accessories. Use of
non–
Motorola - approved antennas, batteries and accessories may exceed IEEE/ICNIRP RF exposure
guidelines.
For a list of Motorola-approved antennas, batteries, and other accessories please see your dealer
or local Motorola contact. Your nearest dealer can be found at the following web site:
http://www.motorola.com/cgiss/emea/dealerlocator.html
Additional Information
For additional information on exposure requirements or other training information, visit
http://www.motorola.com/rfhealth.

viii
ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY
NOTE: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if
inadequately shielded, designed or otherwise configured for electromagnetic compatibility.
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.
Aircraft
When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in
accordance with applicable regulations per airline crew instructions.
Medical Devices
Pacemakers
The Advanced Medical Technology Association (AdvaMed) recommends that a minimum separation
of 15 cms (6 inches) be maintained between a handheld wireless radio and a pacemaker.These
recommendations are consistent with those of the U.S. Food and Drug Administration.
Persons with pacemakers should:
●ALWAYS keep the radio more than 15 cms from their pacemaker when the radio is turned ON.
●Not carry the radio in the breast pocket.
●Use the ear opposite the pacemaker to minimize the potential for interference.
●Turn the radio OFF immediately if you have any reason to suspect that interference is taking place.
Hearing Aids
Some digital wireless radios may interfere with some hearing aids. In the event of such interference,
you may want to consult your hearing aid manufacturer to discuss alternatives.
Other Medical Devices
If you use any other personal medical device, consult the manufacturer of your device to determine if
it is adequately shielded from RF energy. Your physician may be able to assist you in obtaining this
information.
Use of Communication Devices While Driving
Always check the laws and regulations on the use of radios in the areas where you drive.
●Give full attention to driving and to the road.
●Use hands-free operation, if available.
●Pull off the road and park before making or answering a call, if driving conditions or regulations so
require.

ix
OPERATIONAL WARNINGS
Vehicles with an air bag
Refer to vehicle manufacturer's manual prior to installation of electronic equipment to avoid
interference with air bag wiring.
Potentially explosive atmospheres
Blasting caps and areas
OPERATIONAL CAUTIONS
Antennas
Batteries
WARNING: Do not place a portable radio in the area over an air bag or in the air bag
deployment area. Air bags inflate with great force. If a portable 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: Turn off your radio prior to entering any area with a potentially explosive
atmosphere, unless it is a radio type especially qualified for use in such areas as
"Intrinsically Safe" (for example, Factory Mutual, CSA, UL, CENELEC or ATEX Approved). Do
not remove, install, or charge batteries in such areas. 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 fuelling areas such as
below decks on boats, fuel or chemical transfer or storage facilities, areas where the air contains
chemicals or particles, such as grain, dust or metal powders. Areas with potentially explosive
atmospheres are often but not always posted.
WARNING: To avoid possible interference with blasting operations, turn off your radio when
you are near electrical blasting caps, in a blasting area, or in areas posted:
"Turn off two-way radio". Obey all signs and instructions.
CAUTION: Do not use any portable radio that has a damaged antenna. If a damaged antenna
comes into contact with your skin, a minor burn can result.
CAUTION: All batteries can cause property damage and/or bodily injury such as burns if a
conductive material such as jewellery, keys, or beaded chains touch exposed terminals. The
conductive material may complete an electrical circuit (short circuit) and become quite hot.
Exercise care in handling any charged battery, particularly when placing it inside a pocket,
purse, or other container with metal objects.
!
!
!
!
!

x
INTRINSICALLY SAFE RADIO INFORMATION
The Intrinsically safe approval unit refers to a product that has been approved as intrinsically safe by
an approval agency (for example FM Approvals, CSA, UL, CENELEC or ATEX) and certifies that a
particular product meets the Agency's applicable intrinsic safety standards for specific types of
hazardous classified locations. A portable radio that has been approved for intrinsic safety will have
Approval label attached to the radio to identify the unit as being Approved for specified hazardous
atmospheres. This label specifies the hazardous Class/Division/Group along with the part number of
the battery that must be used. The Intrinsically Safe Approval Label will be located on the portable
radio unit.
Operational Cautions for Intrinsic Safe Equipment
Warnings for Radios Approved as Intrinsically Safe
Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability
and the intrinsic safety approval labelling (FM, UL, CSA, CENELEC or ATEX). Radios will not be
upgraded to this capability and labeled once they have been shipped to the field.
A modification changes the unit’s hardware from its original design configuration. Modifications can
only be made by the original product manufacturer.
●Do not operate radio communications equipment in a hazardous atmosphere unless it is a
type especially qualified (for example, FM, UL, CSA, or CENELEC or ATEX approved). An
explosion or fire may result.
●Do not operate a radio unit that has been approved as intrinsically safe product in a
hazardous atmosphere if it has been physically damaged (for example, cracked housing).
An explosion or fire may result.
●Do not replace or charge batteries in a hazardous atmosphere. Contact sparking may
occur while installing or removing batteries and cause an explosion or fire.
●Do not replace or changeaccessories in a hazardous atmosphere. Contact sparking
may occur while installing or removing accessories and cause an explosion or fire.
●Turn the radio off before removing or installing a battery or accessory.
●Do not disassemble an intrinsically safe product in any way that exposes the
internal circuits of the unit.
●Failure to use an intrinsically safe approved battery or Approved accessories
specifically approved for the radio unit may result in the dangerously unsafe
condition of an unapproved radio combination being used in a hazardous location.
●Unauthorized or incorrect modification of the intrinsically safe approved Product
will negate the approval rating of the product.
●Incorrect repair or relabeling of any intrinsically safe Agency-approved radio could
adversely affect the Approval rating of the unit.
●Use of a radio that is not intrinsically safe in a hazardous atmosphere could result
in serious injury or death.
!
!

xi
Repair
A repair constitutes something done internally to the unit that would bring it back to its original
condition.
Items not considered as repairs are those in which an action is performed on a unit which does not
require the outer casing of the unit to be opened in a manner which exposes the internal electrical
circuits of the unit.
Do Not Substitute Options or Accessories
The Motorola communications equipment certified as intrinsically safe by the approving agency, (FM,
UL, CSA, CENELEC or ATEX) is tested as a complete system which consists of the listed agency
Approved portable, Approved battery, and Approved accessories or options, or both. This Approved
portable and battery combination must be strictly observed. There must be no substitution of items,
even if the substitute has been previously Approved with a different Motorola communications
equipment unit. Approved configurations are listed by the Approving Agency (FM, UL, CSA,
CENELEC or ATEX).
The Intrinsically Safe Approval Label affixed to radio refers to the intrinsically safe classification of that
radio product, and the approved batteries that can be used with that system.
The manual PN referenced on the Intrinsically Safe Approval Label identifies the approved
Accessories and or options that can be used with that portable radio unit.
Using a non Motorola intrinsically safe battery and or accessory with the Motorola approved radio unit
will void the intrinsically safe approval of that radio unit.
REPAIRS FOR MOTOROLA PRODUCTS WITH INTRINSICALLY SAFE APPROVAL ARE
THE RESPONSIBILITY OF THE USER.
●Repairs to a Motorola FM approved radio product should only be done at a location
that has been FM audited under the FM 3605 repairs and service standard.
●Contact Motorola for assistance regarding repairs and service of Motorola
intrinsically safe equipment.
!

xii

Professional Radio
GP Series
UHF2 (450 - 527MHz)
Service Information
Issue: November 2004

ii
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored
in semiconductor memories or other media. Laws in the United States and other countries preserve for
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.

iii
Table of Contents
Chapter 1 MODEL CHART AND TECHNICAL SPECIFICATIONS
1.0 GP640/GP680 Model Chart .................................................................................1-1
2.0 GP1280 Model Chart ...........................................................................................1-1
3.0 Technical Specifications ......................................................................................1-2
Chapter 2 THEORY OF OPERATION
1.0 Introduction ..........................................................................................................2-1
2.0 UHF2 Transmitter ................................................................................................2-1
2.1 Power Amplifier ..............................................................................................2-1
2.2 Antenna Switch...............................................................................................2-2
2.3 Harmonic Filter ...............................................................................................2-2
2.4 Antenna Matching Network ............................................................................2-2
2.5 Power Control Integrated Circuit (PCIC) ........................................................2-2
3.0 UHF2 Receiver (All models except those with PCB 8486686Z02)......................2-3
3.1 Receiver Front-End ........................................................................................2-3
3.2 Receiver Back-End.........................................................................................2-4
3.3 Automatic Gain Control (AGC) .......................................................................2-5
4.0 UHF2 Receiver (Models with PCB 8486686Z02) ................................................2-6
4.1 Receiver Front-End ........................................................................................2-6
4.2 Receiver Back-End.........................................................................................2-7
5.0 Frequency Generation Circuit ..............................................................................2-8
5.1 Synthesizer.....................................................................................................2-9
5.2 Voltage Controlled Oscillator (VCO).............................................................2-10
6.0 Voice Storage (GP1280 Only) ...........................................................................2-12
Chapter 3 TROUBLESHOOTING CHARTS
1.0 Troubleshooting Flow Chart for Receiver (All models except those with PCB
8486686Z02) (Sheet 1 of 2).................................................................................3-1
2.0 Troubleshooting Flow Chart for Receiver (All models except those with PCB
8486686Z02)(Sheet 2 of 2)..................................................................................3-2
3.0 Troubleshooting Flow Chart for Receiver (Models with PCB 8486686Z02)
(Sheet 1 of 2) .......................................................................................................3-3
4.0 Troubleshooting Flow Chart for Receiver (Models with PCB 8486686Z02)
(Sheet 2 of 2) .......................................................................................................3-4
5.0 Troubleshooting Flow Chart for Transmitter ........................................................3-5
6.0 Troubleshooting Flow Chart for Synthesizer........................................................3-6
7.0 Troubleshooting Flow Chart for VCO...................................................................3-7
8.0 Troubleshooting Flow Chart for Receive Message/Personal Memo Recording ..3-8
9.0 Troubleshooting Flow Chart for Message Playback ............................................3-9

iv
Chapter 4 UHF2 PCB/SCHEMATICS/PARTS LISTS
1.0 Allocation of Schematics and Circuit Boards .......................................................4-1
1.1 Controller Circuits...........................................................................................4-1
1.2 Voice Storage Facility..................................................................................... 4-1
2.0 UHF2 PCB 8485641Z02 Schematics ..................................................................4-3
3.0 UHF2 PCB 8485641Z02 / PCB 8485677Z02 Parts List ....................................4-11
4.0 UHF2 PCB 8485641Z06 Schematics ................................................................4-15
5.0 UHF2 PCB 8485641Z06 Parts List...................................................................4-23
6.0 UHF2 PCB 8485677Z02....................................................................................4-27
7.0 UHF2 PCB 8485677Z02 Voice Storage Parts List (GP1280)............................ 4-30
8.0 UHF2 PCB 8485677Z03....................................................................................4-31
9.0 UHF2 PCB 8485677Z03 Parts List ...................................................................4-33
10.0 UHF2 PCB 8486686Z02 Schematics ................................................................4-39
11.0 UHF2 PCB 8486686Z02 Parts List.................................................................... 4-48

Chapter 1
MODEL CHART AND TECHNICAL SPECIFICATIONS
1.0 GP640/GP680 Model Chart
2.0 GP1280 Model Chart
Professional GP600 Series (UHF2)
Model Description
MDH25SDC9CK3_E GP640 UHF2 450-527 MHz 4W
MDH25SDH9CK6_E GP680 UHF2 450-527 MHz 4W
Item Description
XPMLE4122_ GP640 UHF2 Back Cover Kit
X PMLE4123_ GP680 UHF2 Back Cover Kit
X6864110B14 GP640 Basic User Guide
X 6864110B19 GP680 Basic User Guide
X X PMAE4008_ UHF 14cm (465-527 MHz) Antenna
X X HNN9008_ Battery, NiMH Standard
x = Indicates one of each is required.
Professional GP1280 (UHF2)
Model Description
MDH25SDN9CK8_E GP1280 UHF 450-527 MHz 4W
Item Description
XPMLE4142_ GP1280 UHF2 Back Cover Kit
X 6864110B20 GP1280 Basic User Guide
XPMAE4008_ UHF 14cm (465-527MHz) Antenna
X HNN9008_ Battery, NiMH Standard
x = Indicates one of each is required.

1-2 MODEL CHART AND TECHNICAL SPECIFICATIONS
3.0 Technical Specifications
Data is specified for +25°C unless otherwise stated.
General Specifications
Channel Capacity
GP640
GP680
GP1280
16 (Conventional)
16 (Conventional)
16 (Conventional)
Power Supply Rechargeable battery 7.5v
Dimensions: H x W x D (mm) Height excluding knobs
With standard high capacity NiMH battery
With ultra high capacity NiMH battery
With NiCD battery
With Lilon battery
GP640/680
137 x 57.5 x 37.5
137 x 57.5 x 40.0
137 x 57.5 x 40.0
137 x 57.5 x 33.0
With standard high capacity NiMH battery
With ultra high capacity NiMH battery
With NiCD battery
With Lilon battery
GP1280
152 x 57.5 x 37.5
152 x 57.5 x 37.5
152 x 57.5 x 37.5
152 x 57.5 x 37.5
Weight: (gm)
With Standard high capacity NiMH battery
With Ultra high capacity NiMH battery
With NiCD battery
With Lilon battery
GP640 GP680
420 428
500 508
450 458
350 358
With Standard high capacity NiMH battery
With Ultra high capacity NiMH battery
With NiCD battery
With Lilon battery
GP1280
460
535
485
390
Average Battery Life @5/5/90 Cycle:
With Standard high capacity NiMH battery
With Ultra high capacity NiMH battery
With NiCD battery
With Lilon battery
Low Power High Power
11 hours 8 hours
14 hours 11 hours
12 hours 9 hours
11 hours 8 hours
Sealing: Withstands rain testing per
MIL STD 810 C/D /E and IP54
Shock and Vibration: Protection provided via impact
resistant housing exceeding MIL STD
810-C/D /E and TIA/EIA 603
Dust and Humidity: Protection provided via environment
resistant housing exceeding MIL STD
810 C/D /E and TIA/EIA 603

Technical Specifications 1-3
*Availability subject to the laws and regulations of individual countries.
Transmitter UHF2
*Frequencies - Full Bandsplit 450-527 MHz
Channel Spacing 12.5/20/25 kHz
Frequency Stability
(-25°C to +55°C, +25° Ref.) ±2.5 ppm
Power 450 - 527 MHz: 1-4W
Modulation Limiting
±2.5 @ 12.5 kHz
±4.0 @ 20 kHz
±5.0 @ 25 kHz
FM Hum & Noise -40 dB typical
Conducted/Radiated Emission -36 dBm <1 GHz
-30 dBm >1 GHz
Adjacent Channel Power -60 dB @ 12.5 kHz
-70 dB @ 25 kHz
Audio Response (300 - 3000 Hz) +1 to -3 dB
Audio Distortion <5% typical
Receiver UHF2
*Frequencies - Full Bandsplit 450-527 MHz
Channel Spacing 12.5/20/25 kHz
Sensitivity (12 dB SINAD) EIA
Sensitivity (20 dB SINAD) ETS
0.25 µV typical
0.50 µV typical
Intermodulation EIA -65 dB
Adjacent Channel Selectivity -60 dB @ 12.5 kHz
-70 dB @ 25 kHz
Spurious Rejection >70 dB
Rated Audio 0.5W
Audio Distortion @ Rated Audio <3% typical
Hum & Noise -45 dB @ 12.5 kHz
-50 dB @ 20/25 kHz
Audio Response (300 - 3000 Hz) +1 to -3 dB
Conducted Spurious Emission
-57 dBm <1 GHz
-47 dBm >1 GHz
ETS 300 086

1-4 MODEL CHART AND TECHNICAL SPECIFICATIONS