Motorola GM338 Service Manual
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Motorola GM338 Service Manual

Mobile radios
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GM338/GM398
Mobile Radios
Basic Service Manual
6804112J17-D
June, 2002

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Summary of Contents for Motorola GM338

  • Page 1 GM338/GM398 Mobile Radios Basic Service Manual 6804112J17-D June, 2002...

  • Page 2: Computer Software Copyrights

    Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied or reproduced in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola prod-...

  • Page 3: Safety Information

    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.

  • Page 4: Mobile Antennas

    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...

  • Page 5: Operational Warnings

    SAFETY INFORMATION 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...
  • Page 6 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 7: Table Of Contents

    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...
  • Page 8 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....................

  • Page 9: Scope Of Manual

    In instances where the product is covered under a “return for replacement” or “return for repair” warranty, a check of the product should be performed prior to shipping the unit back to Motorola. This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty.

  • Page 10: Piece Parts Availability

    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.

  • Page 11: Radio Model Information

    Table 1-1 Radio Model Number (Example: AZM25KHF9AA5) Type of Model Freq. Power Physical Channel Feature Protocol Unit Series Band Level Packages Spacing Level 1-25W GM338 Program- Conventional GM338 (136- mable 174MHz) UHF1 25-60W GM398 GM398 (403- 470MHz) UHF2 (450- 527MHz) LB, R1 (29.7-...
  • Page 12 Radio Model Information THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 13: Maintenance

    Section 2 MAINTENANCE Introduction This chapter provides details about the following: Preventive maintenance (inspection and cleaning). • Safe handling of CMOS and LDMOS devices. • Disassembly and reassembly of the radio. • Repair procedures and techniques. • Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended.

  • Page 14: Safe Handling Of Cmos And Ldmos Devices

    Wear a conductive wrist strap in series with a 100k resistor to ground. • (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX4015_). Do not wear nylon clothing while handling CMOS devices.

  • Page 15: Repair Procedures And Techniques - General

    When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number and order the part from the nearest Motorola Communications parts center listed in the “Piece Parts” section of this manual.

  • Page 16: Radio Disassembly - Detailed

    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. Control Head Removal Insert the dismantling tool in the groove between the control head and the radio assembly as shown in Figure 2-1.

  • Page 17: Top Cover Removal

    Radio Disassembly - Detailed Flexible Connection ZWG0130210-O Figure 2-2 Flexible Connection Removal Remove the flexible connection from the socket on the control head board. Top Cover Removal Insert the dismantling tool in the middle of the radio assembly side groove as shown in Figure 2-3.

  • Page 18: Transceiver Board Removal

    Radio Disassembly - Detailed Transceiver Board Removal Remove six screws from the diecast cover using the T20 TORX™ driver as shown in Figure 2-4. Lift the cover from the chassis. Screws (6) Diecast Cover Radio Chassis ZWG0130212-O Figure 2-4 Diecast Cover Removal. 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.

  • Page 19: Disassembly Of Control Heads

    Press the dismantling tool until the snap connectors on the side of the back housing release from the control head. Disconnect the speaker socket and pull out the speaker (with speaker tube) by stretching the control head housing, Figure 2-7 (GM338 only). The speaker and speaker tube are glued together to form one unit. NOTE...
  • Page 20 Radio Disassembly - Detailed 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 Remove the keypad from the control head housing by lifting up the rubber keypad. Remove the display and the top and bottom elastomeric connectors from the control head housing.

  • Page 21: Radio Assembly

    Radio Assembly Control Heads - GM338 and GM398 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.

  • Page 22: Radio Exploded Mechanical Views And Parts Lists

    2-10 Radio Exploded Mechanical Views and Parts Lists Radio Exploded Mechanical Views and Parts Lists Radio Assembly ZWG0130202-A Figure 2-10 Radio Assembly Item No. Description Part Number Chassis 25W 2786082B02 Gasket, Controlhead 3202620Y01 Main PCB (items 4, 5 and 6 included) Antenna Connector with Gasket, BNC 0986166B01 Power Connector...

  • Page 23: Control Head - Gm338

    Radio Exploded Mechanical Views and Parts Lists 2-11 Control Head - GM338 ZWG0130200-A Figure 2-11 Control Head - GM338 Item no Description Part No. Housing Front 1586088B01 Gasket, Lens, Lightguide Knob, Volume 3686098B02 Label 1364279B17 Speaker 5086126B01 Tube, Speaker with Gasket...

  • Page 24: Control Head - Gm398

    2-12 Radio Exploded Mechanical Views and Parts Lists Control Head - GM398 ZWG0130201-O Figure 2-12 Control Head - GM398 Item No Description Part No Housing Front, including: 1564304B01 Gasket, Lens, Lightguide Knob, Volume 3686098B02 Label 1364279B18 LCD Module 5164313B01 Keypad, including: 7564314B01 Keypad Button 3886134B--...

  • Page 25: 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.

  • Page 26: Test Equipment

    2-14 Test Equipment 10.0 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 Description Characteristics Application R2600_NT Comms System This monitor will Frequency/deviation meter Analyzer (non MPT)

  • Page 27: 11.0 Programming/Test Cable - Rkn4083

    Programming/Test Cable - RKN4083_ 2-15 11.0 Programming/Test Cable - RKN4083_ P1 (Male) J1 (Female) To Radio To RIB Test Set RLN4008 1000 50mm Cable 1000 50mm Cable J2 (Female) To Mobile Radio Accessory Connector Viewed from Front (pin end) of Connector FLO830308-0 FL0830308O Figure 2-13 Programming/Test Cable...
  • Page 28 2-16 Programming/Test Cable - RKN4083_ THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 29: Transceiver Performance Testing

    Section 3 TRANSCEIVER PERFORMANCE TESTING General These radios meet published specifications through their manufacturing process by utilizing high- accuracy 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.

  • Page 30: Rf Test Mode

    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.
  • Page 31 RF Test Mode Table 3-2 Test Environments No. of Description Function Beeps Carrier Squelch RX: unsquelch if carrier detected (high (CSQ) TX: mic audio pitch) Tone RX: unsquelch if carrier and tone (192.8Hz) detected Private-Line (TPL) TX: mic audio + tone (192.8Hz) Digital RX: unsquelch if carrier and digital code (131) detected Private-Line (DPL)
  • Page 32 RF Test Mode Table 3-4 Test Frequencies Test Test Band Band Band Test Channel Channel Range 1 Range 2 Range 3 UHF1 UHF2 Mode High 29.7-36 36-42 42-50 Power Power 29.725 30.025 42.025 136.025 403.025 450.025 29.750 36.050 42.050 136.050 403.050 450.050 30.225...
  • Page 33 RF Test Mode Table 3-5 Transmitter Performance Checks Communications Test Name Radio Test Set Comment Analyzer Reference Mode: PWR MON TEST MODE, PTT to Frequency error: 4th channel test fre- Frequency Test Chan- continuous ±150 Hz VHF, quency* nel 4 carrier (during the ±150 Hz UHF Monitor: Frequency error...
  • Page 34 RF Test Mode Table 3-6 Receiver Performance Checks Communications Test Name Radio Test Set Comment Analyzer Reference Mode: PWR MON TEST PTT to Frequency error Frequency 4th channel test fre- MODE, continuous to be quency* Test Chan- (during the ±150 Hz VHF Monitor: Frequency error nel 4 carrier performance...

  • Page 35: Radio Tuning And Programming

    Section 4 RADIO TUNING AND PROGRAMMING Introduction This chapter provides an overview of the Customer Programming Software (CPS) and tuner program which are designed for use in a Windows 95/98 environment. These programs are available in separate kits as listed in the Table 4-1. An Installation instruction manual is also included with each kit.
  • Page 36 CPS Programming Setup +13,2VDC Power Supply Programming Cable RKN4081 Tx Data Rx Data DB25 ZWG0130339-0 Figure 4-2 CPS Programming Setup Cable with Internal RIB Adapter Programming Cable Cable RLN4853 RKN4081 Tx Data Rx Data DB25 +13,2VDC Power Supply ZWG0130340-0 Figure 4-3 CPS Programming Setup Cable with Internal RIB and Rear Adapter Cable...

  • Page 37: Radio Tuning Setup

    Radio Tuning Setup 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 Audio Generator Test Box...
  • Page 38 Radio Tuning Setup THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 39: Power Up Self-Test

    “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 Codeplug structure mismatch or Reprogram codeplug with correct version ERROR” non existence of codeplug.
  • Page 40 Error Codes THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 41: Model Chart And Test Specification

    Description AZM25KHF9AA5 GM338 136-174 MHz 1-25W AZM25KHN9AA8 GM398 136-174 MHz 1-25W Item Description GCN6114_ GM338 Control Head Direct Mount GCN6115_ GM398 Control Head Direct Mount IMUD6010_ Tanapa WM 136-174 MHz 1-25W IMUD6023_ Tanapa WM 136-174 MHz 1-25W RAD4198_ BNC 136-144 MHz, 1/4 Wave Roof Mount RAD4199_ BNC 146-150.8 MHz, 1/4 Wave Roof Mount...

  • Page 42: Model Chart (Uhf Band 1, 403-470 Mhz)

    Description AZM25RHF9AA5 GM338 403-470 MHz 1-25W AZM25RHN9AA8 GM398 403-470 MHz 1-25W Item Description GCN6114_ GM338 Control Head Direct Mount GCN6115_ GM398 Control Head Direct Mount IMUE6021_ Tanapa WM 403-470 MHz 1-25W IMUE6039_ Tanapa WM 403-470 MHz 1-25W RAE4151_ BNC 403-430 MHz, 1/4 Wave Roof Mount RAE4158_ BNC 406-420 MHz, 3.5dB Gain Roof Mount...

  • Page 43: Model Chart (Uhf Band 2, 450-527 Mhz)

    Description AZM25SHF9AA5 GM338 450-527 MHz 1-25W AZM25SHN9AA8 GM398 450-527 MHz 1-25W Item Description GCN6114_ GM338 Control Head Direct Mount GCN6115_ GM398 Control Head Direct Mount IMUE6022_ Tanapa WM 450-527 MHz 1-25W IMUE6043 Tanapa WM 450-527 MHz 1-25W RAE4155_ BNC 470-512 MHz, 1/4 Wave Roof Mount RAE4156_ BNC 470-494 MHz, 3.5 Gain Roof Mount...

  • Page 44: Specifications

    13.2Vdc (10.8 - 15.6 Vdc) negative vehicle ground Dimensions (L X W X H) 186mm X 179mm X 59mm 60mm X 179mm X 250mm GM338: (add 9mm for Volume Knob) (add 9mm for Volume (7.32” X 7.05” X 2.34” - add 0.35” Knob)
  • Page 45 Low Power Radios Transmitter Specification UHF1 UHF2 LOW BAND Modulation Limiting: ±2.5 kHz @ 12.5 kHz ±2.5 kHz @ 12.5 kHz ±4.0 kHz @ 20 kHz ±5.0 kHz @ 20/30 kHz ±5.0 kHz @ 25 kHz FM Hum and Noise: -40 dB@12.5 kHz -40 dB @ 12.5 kHz -45 dB @ 20/30 kHz...

  • Page 46: High Power Radios

    = Indicates one of each is required. Model Chart (UHF Band 1, 403-470 MHz) GM Series, UHF Band 1, 403-470 MHz Model Description AZM25RKF9AA5 GM338 403-470 MHz 25-40W Conv Pref (Bipolar) Item Description GCN6114_ GM338 Control Head Direct Mount IMUE6012_...

  • Page 47: Model Chart (Uhf Band 2, 450-520 Mhz)

    = Indicates one of each is required. Model Chart (UHF Band 1, LDMOS, 403-470 MHz) GM Series, UHF Band 1, 403-470 MHz Mode Description AZM25RKF9AA5 GM338 403-470 MHz 25-40W Conv Pref (LDMOS) Item Description GCN6114_ GM338 Control Head Direct Mount IMUE6024_...

  • Page 48: Model Chart (Uhf Band 2, Ldmos, 450-520 Mhz)

    High Power Radios Model Chart (UHF Band 2, LDMOS, 450-520 MHz) GM Series, UHF Band 2, 450-520 MHz Model Description AZM25SKF9AA5 GM338 450-520 MHz 25-40W (LDMOS) Item Description GCN6114_ GM338 Control Head Direct Mount IMUE6019_ Tanapa WM 450-520 MHz 25-40W...

  • Page 49: Specifications

    Power Supply: 13.2Vdc (10.8 - 15.6 Vdc) negative vehicle ground Dimensions (L X W X H) 186mm X 179mm X 59mm GM338: (add 9mm for Volume Knob) (7.32” X 7.05” X 2.34” - add 0.35” for Volume Knob) Weight: 1400 g (3.15 lbs)
  • Page 50 6-10 High Power Radios Transmitter Specification 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 -36 dBm < 1 GHz Emissions: -30 dBm >...

  • Page 51: Glossary Of Terms

    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.
  • Page 52 Glossary OMPAC Over-Molded Pad-Array Carrier: a Motorola custom package, distinguished by the presence of solder balls on the bottom pads. Outbound Signalling Word: data transmitted on the control channel from the central controller to the subscriber unit. PC Board Printed Circuit Board.
  • Page 53 Glossary µC Microcontroller. Ultra High Frequency. µP Microprocessor. 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. Very High Frequency. VSWR Voltage Standing Wave Ratio.
  • Page 54 Glossary Notes...
  • Page 55 Service Manuals need to be updated accordingly. If you wish to be informed of these updates, kindly fill in and fax us your details. Fax to: 6-04-6124944 The Technical Publications Coordinator, Media and Communications, R&D Department, Motorola Penang. Your Details Name/Contact Person: Company Name: Address: Telephone No.: Fax No.:...
  • Page 56 Kindly take a few moments to provide feedback on this manual. Thank you for your cooperation. Fax to: 6-04-6124944 The Technical Publications Coordinator, Media and Communications, R&D Department, Motorola Penang. 1. Please check all the appropriate boxes: Disassembly Pro- cedures Alignment...

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