Motorola GM338 User manual

GM328/GM338/GM398

Mobile Radios

Detailed Service Manual

6804112J18-E

December, 2003

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 prod-

ucts 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.

DOCUMENT HISTORY

The following major changes have been implemented in this manual since the previous edition:

Edition Description Date

6804112J18-O Initial edition

6804112J18-E Added Document History section. Dec. 2003

Changed to latest Safety Information (Feb. 2002)

Added GM328 model information to VHF, UHF1

and UHF2 bands.

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December, 2003

GM328/GM338/GM398

Mobile Radios

Detailed Service Manual

Contents

Section 1 Service Maintainability

Section 2 Controlhead Service Information

Section 3 Controller Service Information

Section 4 VHF Service Information

Section 5 UHF Band 1 Service Information

Section 6 UHF Band 2 Service Information

Section 7 Low Band Service Information

Section 8 VHF 45W Bipolar Service Information

Section 9 UHF Band 1 40W Bipolar Service Information

Section 10 UHF Band 2 40W Bipolar Service Information

Section 11 UHF Band 1 40W LDMOS Service Information

Section 12 UHF Band 2 40W LDMOS Service Information

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GM328/GM338/GM398

Mobile Radios

Service Maintainability

Issue: December, 2003

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

Product Safety and RF Exposure for Mobile Two-Way Radios Installed in

Vehicles or as Fixed Site Control Stations

The information provided in this document supersedes the general safety information contained in

user guides published prior to February 2002.

RF Energy Exposure Awareness and Control Information, and

Operational Instructions for FCC Occupational Use Requirements

NOTICE: This radio is intended for use in occupational/controlled conditions, where users

have full knowledge of their exposure and can exercise control over their exposure

to meet FCC limits. This radio device is NOT authorized for general population,

consumer or any other use.

This 2-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 from 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 2-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 2-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 Web sites 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-fags.html

http://www.osha.gov/SLTC/radiofrequencyradiation/index.html

BEFORE USING THIS RADIO, READ THIS BOOKLET WHICH CONTAINS IMPORTANT OPERAT-

ING INSTRUCTIONS FOR SAFE USAGE AND RF ENERGY AWARENESS AND CONTROL

INFORMATION FOR COMPLIANCE WITH RF ENERGY EXPOSURE LIMITS IN APPLICABLE

NATIONAL AND INTERNATIONAL STANDARDS.

ii

Federal Communication Commission (FCC) Regulations

The FCC rules require manufacturers to comply with the FCC RF energy exposure limits for mobile

2-way radios before they can be marketed in the U.S. When 2-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

label directing users to specific user awareness information. Your Motorola 2-way radio has a RF

exposure product label. 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.

Compliance with RF Exposure Standard

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 and ICNIRP exposure limits for

occupational/controlled RF exposure environment at duty factors of up to 50% talk–50% listen and

is authorized by the FCC for occupational use. In terms of measuring RF energy for compliance with

the FCC exposure guidelines, your radio antenna 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; 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 Elec-

tromagnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999

• Australian Communications Authority Radiocommunications (Electromagnetic Radiation -

Human Exposure) Standard, 2003

• ANATEL, Brasil Regulatory Authority, Resolution 256 (April 11, 2001) “additional requirements

for SMR, cellular and PCS product certification.”

RF Exposure Compliance and Control Guidelines and Operating Instructions

To control exposure to yourself and others and to ensure compliance with the RF exposure 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.

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).

• Transmit only when people outside the vehicle are at least the recommended minimum

laterial distance away, as shown in Table 1, from the body of a vehicle with a properly

installed antenna. This separation distance will ensure that there is sufficient distance from a

iii

properly installed (according to installation instructions) externally-mounted antenna to satisfy

the RF exposure requirements in the standards listed above.

NOTE: Table 1 below lists the recommended lateral distance for bystanders in an uncontrolled

environment from the body of a vehicle with an approved, properly installed transmitting

antenna (i.e., monopoles overa a ground plane, or dipoles) at several different ranges of

rated radio power for mobile radios installed in a vehicle.

NOTE:If you are not sure of the rated power of your radio, contact your Motorola representative or

dealer and supply the radio model number found on the radio model label. If you cannot

determine the rated power out, then assure 3-feet separation from the body of the vehicle.

Mobile Antenna Installation Guidelines

• These mobile antenna installation guidelines are limited to metal body motor vehicles or vehicles

with appropriate ground planes.

• Antennas should be installed in the center area of the roof or the trunk lid taking into account the

bystander exposure conditions of backseat passengers and according to the specific instructions

and restrictions in the Radio Installation Manual along with the requirements of the antenna sup-

plier.

• Trunk lid installations are limited to vehicles with clearly defined flat trunk lide, and in some

cases, to specific radio models and antennas. See the Radio Installation Manual for specific

information on how and where to install specific types of approved antennas to facilitate recom-

mended operating distances to all potentially exposed persons.

• Use only the Motorola-approved, supplied antenna or a Motorola-approved replacement

antenna. Unauthorized antennas, modifications, or attachments could damage the radio and

may result in non-compliance with RF Safety Standards.

Approved Accessories

• This radio has been tested and meets RF Safety Standards when used with the Motorola acces-

sories supplied or designated for this product. Use of other accessories may result in non-compli-

ance with RF Safety Standards.

• For a list of Motorola-approved antennas, visit the following Web site, which lists approved

accessories for your radio model: http://ap.cgiss.motorola.com/AAD/index.html

Additional Information

For additional information on exposure requirements or other training information,

visit http://www.motorola.com/rfhealth.

Table 1: Rated Power of Vehicle-Installed Mobile Two-Way Radio and

Recommended Minimum Lateral Distance from Vehicle Body

Mobile Radio Rated

Power (see Note)

Minimum Lateral Distance

from Vehicle Body

Less than 7 watts 8 inches (20 centimeters)

7 to 15 watts 1 foot (30 centimeters)

16 to 39 watts 2 feet (60 centimeters)

40 to 110 watts 3 feet (90 centimeters)

iv

Compliance and Control Guidelines and Operating Instructions for

Mobile Two-Way Radios Installed as Fixed Site Stations

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 standards and

guidelines listed on page ii:

• 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 compli-

ance actions such as site survey measurements, signage, and site access restrictions in order to

ensure 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 site antenna is sensitive to external RF energy or if

any procedures need to be followed to eliminate or mitigate the potential for interaction

between the radio transmitter and the equipment or device.

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, such as ABS, engine, or transmission controls, the radio should be installed only by an

experienced installer and the following precautions should be used when installing the radio:

1. Refer to the manufacturer’s instructions or other technical bulletins for 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.

v

Operational Warnings

For Vehicles With An Air Bag

Do not mount or 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.

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.

The areas with potentially explosive atmospheres 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 Blasting 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 fueled by liquefied petroleum gas, 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.

vi

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vii

Table of Contents

SAFETY INFORMATION.........................................................................................i

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

2.5 Further Assistance From Motorola.................................................................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 .........................................................................................................2-1

3.0 Safe Handling of CMOS and LDMOS..................................................................2-2

4.0 General Repair Procedures and Techniques.......................................................2-2

5.0 Notes For All Schematics and Circuit Boards......................................................2-5

Section 3 Service Aids

1.0 Recommended Test Tools...................................................................................3-1

2.0 Test Equipment....................................................................................................3-2

viii

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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.

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 techni-

cally capable of performing fault analysis and repair.

NOTE

Before operating or testing these units, please read the Safety Information section in the

front of this manual.

1-2 Warranty and Service Support

2.3 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.

2.5 Further Assistance From Motorola

You can also call the CGISS Indirect Business Customer Help Desk number, (604)-6302525 or

send an email to customercare.asia@motorola.com.

1-3 Radio Model Information

3.0 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

Unit

Model

Series

Freq.

Band

Power

Level

Physical

Packages

Channel

Spacing

Protocol

Feature

Level

AZ M 25 K

VHF

(136-

174MHz)

H

1-25W

C

GM328

9

Program-

mable

AA

Conventional

1

GM328

R

UHF1

(403-

470MHz)

K

25-60W

F

GM338

5

GM338

S

UHF2

(450-

527MHz)

N

GM398

8

GM398

B

LB, R1

(29.7-

36MHz)

C

LB, R2

(36-

40MHz)

D

LB, R3

(42-

50MHz)

AZ = Country Code

M = Mobile

1-4 Radio Model Information

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