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Motorola GM1200E Service Manual

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See also: Service Manual , User Manual
GM1200E
Mobile Radio
Basic Service Manual
68P64115B12
European Publications Department (RPG) Fleet, Hampshire, England
Issue: May 1998

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Summary of Contents for Motorola GM1200E

  • Page 1 GM1200E Mobile Radio Basic Service Manual 68P64115B12 European Publications Department (RPG) Fleet, Hampshire, England Issue: May 1998...
  • Page 3 Cautions and Warnings CAUTION ELECTROSTATIC SENSITIVE DEVICES PRECAUTIONS SHOULD BE TAKEN TO MINIMIZE THE RISK OF DAMAGE BY ELECTROSTATIC DISCHARGE TO ELECTROSTATIC SENSITIVE DEVICES (ESDs). ANY DEVICES EMPLOYING METAL OXIDE SILICON (MOS) TECHNOLOGY ARE PARTICULARLY SUSCEPTIBLE. CIRCUIT DIAGRAMS MARKED WITH THE ABOVE SYMBOL INDICATE ELECTRONIC CIRCUITS (PECs) FOR WHICH ESD HANDLING PRECAUTIONS ARE NECESSARY.
  • Page 4 Cautions and Warnings...
  • Page 5 Cautions and Warnings WARNING SAFETY WARNINGS THE ELECTRICAL POWER USED IN THIS EQUIPMENT IS AT A VOLTAGE HIGH ENOUGH TO ENDANGER LIFE. BEFORE CARRYING OUT MAINTENANCE OR REPAIR, PERSONS CONCERNED MUST ENSURE THAT THIS EQUIPMENT IS ISOLATED FROM THE ELECTRICAL SUPPLY AND TESTS ARE MADE TO ENSURE THAT ISOLATION IS COMPLETE.
  • Page 6 Cautions and Warnings...
  • Page 7 Contents Basic Service Manual Contents Chapter General Gives a brief introduction into the manual; the service policy, models and technical specifications. Maintenance Describes how to disassemble/assemble the radio for maintenance purposes and provides lists of test equipment. Accessories Gives service details and provides a list of accessories available for the radio. Radio Tuning Procedure Provides detailed radio tuning procedure for all bands available.
  • Page 8 Contents viii Basic Service Manual...

  • Page 9: Table Of Contents

    Table of Contents Chapter 1 General Table of Contents Paragraph Page Introduction ....................1 Scope of Manual ..................1 How to Use This Manual ................1 Warranty and Service Support ..............1 Warranty Period................... 1 After Warranty Period .................. 2 Piece Parts ....................
  • Page 10 Table of Contents 1-ii General...

  • Page 11: Introduction

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

  • Page 12: After Warranty Period

    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 Radio Parts and Service Group (RPSG). If a generic part is listed or only a part description is listed, the part is not normally available from Motorola.

  • Page 13: Model Chart

    Low Profile Trunnion Kit GUE1124_ RF & HSG UHF 12.5kHz 5-25W GUE1125_ RF & HSG UHF 25kHz 5-25W GUD1326_ RF & HSG VHF 12.5kHz 5-25W GUD1327_ RF & HSG VHF 25kHz 5-25W GKN6270_ Power Cable 68P64110B08 GM1200E User Guide M/L General...

  • Page 14: Service Options

    Service Options GM1200E 403-470 MHz UHF 136-174 MHz VHF X = Indicates one of each required Item Description ENUD1061AS GM1200E UHF 12.5kHz MD534AD ENUD1062AS GM1200E UHF 25kHz MD514AD ENUD1063AS GM1200E UHF 12.5kHz MD534AE ENUD1064AS GM1200E UHF 25kHz MD514AE ENUE1071AS GM1200E VHF 12.5kHz MD334AD...

  • Page 15: Technical Specifications

    Technical Specifications Technical Specifications General SPECIFICATION ITEM TYPICAL VALUE UHF: 403-470 MHz Frequency Range VHF: 136-174 MHz Channel Spacing 12.5 kHz or 20/25kHz ± 2ppm (UHF) / ± 5ppm (VHF) Frequency Stability Power Supply 10.8 to 15.6V dc, negative earth K5 Model - 44x168x160 mm (HxWxD) Dimensions K6 Model - 55x185x167 mm (HxWxD)

  • Page 16: Receiver

    Technical Specifications Receiver SPECIFICATION ITEM TYPICAL VALUE Channel Spacing 12.5kHz or 20/25kHz < 0.35 µ V (12dB SINAD) Sensitivity @ 12.5kHz or 20/25kHz Intermodulation >65dB ETS; >70dB with Base Option Adjacent Channel Selectivity >60dB (12.5kHz); >70dB (20/25kHz) ETS Spurious Rejection >70dB ETS Audio Distortion @ Rated Audio <5%...
  • Page 17 Table of Contents Chapter 2 Maintenance Table of Contents Paragraph Page Overview ..................... 1 Disassemble the Radio ................1 Remove the Control Head ................1 Remove the Top Cover................1 Remove the Transceiver Board ..............2 Disassemble the Control Head ..............3 Assemble Radio ..................
  • Page 18 Table of Contents 2-ii Maintenance...

  • Page 19: Overview

    Overview Overview This chapter explains, step by step, how to disassemble and assemble the radio, to transceiver board level. The chapter also contains a list of test equipment required to service the radio. Disassemble the Radio Remove the Control Head Recess Figure 2-1 Control Head Removal.

  • Page 20: Remove The Transceiver Board

    Disassemble the Radio Remove the Transceiver Board Protruding Tabs Clip Flex Recess Clip Recess Chassis Transceiver Board Top Cover Figure 2-3 Transceiver Board Removal. Remove the power and antenna connector retaining clips by inserting a small flat blade screw driver between the clip and the top of the chassis wall and gently prying the clip upwards. Remove 13 screws from the transceiver board using a T8 TORX driver.

  • Page 21: Assemble Radio

    Assemble Radio Control Head Housing LCD Module Recess Keypad Recess Protruding Tabs Printed Circuit Board Control Head Housing Back LAPD0014 Figure 2-4 Control Head Assembly. Assemble Radio Assemble the Control Head Ensure that the LCD module and frame are correctly positioned on the PCB. Place the keypad onto the board assembly, making sure the keypad is flush with the board.

  • Page 22: Exploded View Diagrams And Parts

    Exploded View Diagrams and Parts Press the control head onto the radio chassis until the protruding tabs on the chassis snap into the recesses inside the control housing, see Figure 2-5. Recess Figure 2-5 Control Head Replacement. Exploded View Diagrams and Parts Cover Chassis 1502609Y01 incl.
  • Page 23 Exploded View Diagrams and Parts Housing, back 1586001B01 Gasket 3286006B01 8486015B04 Keypad 7586002B01 LCD Frame 0786004B01 LCD Module 7286003B01 LCD Gasket 3286005B01 Housing, front Control head 1586000B01 Figure 2-7 Control Head for Display/Keypad Radio Model. Maintenance...

  • Page 24: Service Aids

    Service Aids Service Aids The list in table 2-1 includes service aids recommended for working on the GM1200E radio. Table 2-1 Service Aids. PART No. DESCRIPTION APPLICATION GTF376 Test Box Cable Connects radio to GTF180 test box. GTF374 Combined Interface Connects radio to RLN4008 RIB.

  • Page 25: Test Equipment

    Battery-operated test equipment is recommended when available. The “Characteristics” column is included so that equivalent equipment may be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended.
  • Page 26 Test Equipment Maintenance...
  • Page 27 Table of Contents Chapter 3 Accessories Table of Contents Paragraph Page GM1200E Accessory Connector Plan............1 GM1200E Accessory Diagrams ..............2 Speaker GSN6059 5.5ins/130mm, 13 Watts..........2 Handset HMN9416 (P/O HMN3141) Mechanical Exploded View................3 Enhanced Compact Microphone GMN6146 Mechanical Exploded View................5 DTMF Microphone GMN6148 Mechanical Exploded View................
  • Page 28 Table of Contents 3-ii Accessories...

  • Page 29: Gm1200E Accessory Connector Plan

    GM1200E Accessory Connector Plan GM1200E Accessory Connector Plan CAUTION: The accessory connections shown are not compatible to some other models of Motorola radios. Check the appropriate accessory or technical manual for further information. +12V Alarm Alternative Relay +12V +12V Alarm...

  • Page 30: Gm1200E Accessory Diagrams

    GM1200E Accessory Diagrams GM1200E Accessory Diagrams Speaker GSN6059 5.5ins/130mm, 13 Watts 130.0 130.0 100.0 55.0 1 + 16 connected Cable Length 2540 mm 135.0 30.0 80.0 Accessories...

  • Page 31: Handset Hmn9416 (P/O Hmn3141) Mechanical Exploded View

    GM1200E Accessory Diagrams Handset HMN9416 (P/O HMN3141) Mechanical Exploded View Mechanical Parts List Motorola Motorola Part No. Description Part No. Description 13-80928W01 Escutcheon 38-84658P01 PTT Button 15-82281R01 Top Housing Speaker (LS10) 75-80927W01 Top Housing Pad 32-80272F16 Microphone Gasket 30-06418T01 Coil Cord Cable...
  • Page 32 GM1200E Accessory Diagrams 2.2.1 Description The HMN3141 Handset and hang-up cup is a slimline telephone handset with push to talk (PTT) button. It is used in place of, and operates similar to, the standard mobile microphone. 2.2.2 Installation General When planning the installation of your handset, it is important that it does not interfere with the operation of the vehicle or its accessories, nor disturb passenger seating or leg space.

  • Page 33: Enhanced Compact Microphone Gmn6146 Mechanical Exploded View

    GM1200E Accessory Diagrams Enhanced Compact Microphone GMN6146 Mechanical Exploded View Mechanical Parts List Motorola Motorola Part No. Description Part No. Description 0180704Y99 Rear Housing assembly 3880568B01 PTT Button 0311994A23 Screw (3 used) 7580983Z03 Rubber Spacer 5480104R12 Model Label (GMN6146C) 4180150R01...

  • Page 34: Schematic Diagram

    GM1200E Accessory Diagrams Schematic Diagram Electrical Parts Lists Circuit Motorola Circuit Motorola Description Description Part No. Part No. R1300 1805500L04 RES VAR 2.2k (not C1306 2113741A21 CAP CHIP CL2 X7R 1n used) C1307 2113741A21 CAP CHIP CL2 X7R 1n R1301 0660076A57 RES CHIP 2.2k 5 1/8...

  • Page 35: Dtmf Microphone Gmn6148 Mechanical Exploded View

    GM1200E Accessory Diagrams DTMF Microphone GMN6148 Mechanical Exploded View Mechanical Parts List Motorola Part No. Description 15-80652D02 Microphone front housing 32-80565B01 Microphone gasket 75-80983Z03 Rubber Spacer, Switch j kl 38-80654D01 Button, push to talk 41-80658D01 Spring, PTT 35-80089D02 Felt baffle...
  • Page 36 GM1200E Accessory Diagrams Schematic Diagram Accessories...
  • Page 37 GM1200E Accessory Diagrams PCB Layout Accessories...

  • Page 38: Electrical Parts List

    GM1200E Accessory Diagrams Electrical Parts List GMN6148_ Circuit Motorola Circuit Motorola Description Description Part No. Part No. 23-11049A07 1uF; 16V, 10%, TANT CR12 48-83636N18 LED; GREEN, SMD 21-13740A73 560pF CR13 48-83636N18 LED; GREEN, SMD 23-11049A59 10uF; 6V,10%, TANT CR1301 48-13833C04...

  • Page 39: Base Tray Gln7318/Gln7326

    GM1200E Accessory Diagrams GMN6148_ continued, Circuit Motorola Circuit Motorola Description Description Part No. Part No. R1302 06-60076A57 2.2K; 5%, 1/8W 48-80140L05 4.7V; 5%, ZENER R1303 06-60076A49 1K; 5%, 1/8W VR1301 48-80140L17 12V; 5%, ZENER R1305 06-60076B05 150K; 5%, 1/8W VR1302 48-80140L17 12V;...

  • Page 40: Remote Mount Front / Rear Housing Kits Gln7331 / Gln7332 Mechanical Exploded View

    GM1200E Accessory Diagrams Remote Mount Front / Rear Housing Kits GLN7331 / GLN7332 Mechanical Exploded View GLN7331_ Remote Remote Front Housing mount radio Front housing PCB GLN7333 External spe 7586011B01 connector Remote mount Radio front housing 1586010B01 Gasket for Flex connector...

  • Page 41: Power Supply Gpn6133 (Emc/Ce Approved)

    GM1200E Accessory Diagrams Power Supply GPN6133 (EMC/CE Approved) Accessories 3-13...

  • Page 42: Power Supply Hpn8393 (Not Emc Approved)

    GM1200E Accessory Diagrams Power Supply HPN8393 (Not EMC Approved) Electrical Characteristics Input Voltages: 105-125VAC; 210-250VAC, 47-63Hz 13.8VDC ±0.1 volts Output Voltage: (internally adjustable 11-15VDC) Ripple: less than 5mV peak to peak (full load and low line) Provides 8 amps continuous duty and 14 amps intermittent duty over an ambient temperature range of -30 to +60°C .
  • Page 43 GM1200E Accessory Diagrams Schematic Diagram Accessories 3-15...

  • Page 44: List Of Accessories

    List of Accessories List of Accessories Mechanical Hardware Kits: GLN7324 Low Profile Trunnion Kit (Standard) GLN7317 High Profile Trunnion Kit GLN7320 In-Dash Mount, DIN install. Kit GLN7325 IP54 seal, accessory connector HLN9457 Accessory Connector Facility Kit Microphones: GMN6146 Enhanced Compact Microphone (Standard) GMN6148 DTMF Microphone HMN3141...
  • Page 45 Table of Contents Chapter 4 Radio Tuning Procedure Table of Contents Paragraph Page GM1200E Tuning Procedure..............1 General ......................1 PA Bias Voltage................... 2 Battery Threshold ..................3 Transmitter Power ..................3 Reference Oscillator ..................4 Front-End Pre-Selector................4 Rated Volume ....................5 Squelch......................
  • Page 46 Table of Contents 4-ii Radio Tuning Procedure...

  • Page 47: Gm1200E Tuning Procedure

    GM1200E Tuning Procedure GM1200E Tuning Procedure General The recommended hardware platform is a 386 or 486 DX 33 PC (personal computer) with 8 Mbytes RAM, MS DOS 5.0™, Windows 3.1™, and DPS (Dealer Programming Software). These are required to align the radio. Refer to your DPS Installation Manual for installation and setup procedures for the required software;...

  • Page 48: Pa Bias Voltage

    GM1200E Tuning Procedure The Service windows introduce the concept of the “Softpot”, an analog SOFTware controlled POTentiometer used for adjusting all transceiver alignment controls. A softpot can be selected by clicking with the mouse at the value or the slider or by hitting the TAB key until the value or the slider is highlighted.

  • Page 49: Battery Threshold

    GM1200E Tuning Procedure Table 4-1 Quiescent Current Alignment RF-Band Target 440mA±10% VHF / 300-390MHz 150mA±15% Battery Threshold The radio uses 2 battery threshold levels Tx High and Tx Low to determine the battery condition. The Program buttons must only be activated when the power supply is set to the indicated voltage. If...

  • Page 50: Reference Oscillator

    GM1200E Tuning Procedure From the Service menu, select Transmitter Alignment. Select RF Power Tuning to open the RF power tuning window. The window will indicate the transmit test frequencies to be used. Select Point 1 value of the first frequency.

  • Page 51: Rated Volume

    GM1200E Tuning Procedure Select the first test frequency shown, and set the corresponding value to the start value shown in table 4-4. Set the RF test generator to the receive test frequency, and set the RF level to 10µV modulated with a 1 kHz tone at the normal test deviation shown in table 4-3.

  • Page 52: Squelch

    GM1200E Tuning Procedure Squelch The squelch softpots set the signal to noise ratio at which the squelch opens. The squelch value needs to be set at 7 frequencies across the frequency range. Set the test box (GTF180) meter selection switch to the "Audio PA" position and connect a SINAD meter to the "METER"...

  • Page 53: Transmit Deviation Limit

    GM1200E Tuning Procedure Change the input tone to 3 kHz, 200 mVrms. Adjust the deviation to within ±2% of the value recorded in step 6. Check the deviation at 80 Hz again and repeat step 7-8, if it has changed since step 6.
  • Page 54 GM1200E Tuning Procedure CAUTION: Inadvertant use of the program buttons may result in radio failure. Set test box (GTF180) meter selection switch to the “AUDIO PA” position and the speaker load switch to the "MAXAR" position. From the Service menu, select Receiver Alignment.
  • Page 55 Table of Contents Appendix A PL/DPL Codes Table of Contents Paragraph Page PL Codes and Digital PL (DPL) Codes ......1 PL Codes.
  • Page 56 Table of Contents A-ii PL (CTCSS) Codes...
  • Page 57 PL Codes and Digital PL (DPL) Codes PL Codes and Digital PL (DPL) Codes The following have been tested and are acceptable for programming into any transmit or receive frequency. PL Codes GROUP A GROUP B GROUP C Code Freq Code Freq Code...
  • Page 58 PL Codes and Digital PL (DPL) Codes PL (CTCSS) Codes...
  • Page 59 Table of Contents Appendix B NPD Application Notes Table of Contents Paragraph Page Non Prescribed Data (NPD) Calls............. 1 Calls with DTE connected to External Data Connector (Radio Accessory Connector) ..............1 DTE Initiated Call (Outgoing Calls).............. 1 Calls Initiated by another Radio Unit (Incoming Calls) ........ 1 Calls with DTE connected to Internal Data Connector (Radio Option Connector).................
  • Page 60 Table of Contents B-ii NPD Application Notes...

  • Page 61: Non Prescribed Data (Npd) Calls

    Non Prescribed Data (NPD) Calls Non Prescribed Data calls utilising external Data Terminal Equipment (DTE) can be made using the GM1200E Databox radio as the carrier. Call protocol is by a combination of control line handshakes, the complexity of which depends on the intelligence of the DTE.

  • Page 62: Other Calls

    Other Calls Calls Initiated by another Radio Unit (Incoming Calls) Incoming calls will be indicated by a signal on the CTS. The call will be “answered” by the DTE signalling on ‘Call 3’ (i.e.Call 1 and Call 2 lines both enabled).

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