Motorola 92FT3808 User Manual

TM

®

ASTRO

Digital Mobile Radio

XTL

5000

Installation Manual

zTitle Page

®

XTL™ 5000

Digital Mobile Radio

Installation Manual

Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322

i

6881096C72-B

Foreword

This manual covers all models of the ASTRO® XTL™ 5000 digital mobile radios (models W3, W4, W5, W7, and W9),
unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum
working time, using le vels 1 and 2 main tenance pro cedures. Th is level of service goes do wn to the boa rd replacemen t level
and is typical of some local service centers, self-maintained customers, and distributors.

For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A
list of related publication s is provid ed in t he secti on “Related Publications,” on page vii.

Product Safety and RF Exposure Compliance

See “Insta llatio n Require ment s for Com pliance with Ra dio Freq uency (RF) Ene rgy Expo sure Safe ty Standards ,” on p age ii i.

Manual Revisions

Changes which occur af te r this man ual is pri nte d are de sc ribe d in FM R s (Fl orid a Ma nua l Revi sions). These FMRs provide
complete replacement pages for all added, changed, and deleted items.
To obtain FMRs, go to https://businessonline.motorola.com.

Parts Ordering

See Appendix A: Replacement Parts Ordering for information on how to obtain replacement parts. For part numbers, refer
to the ASTRO XTL 5000 Digital Mobile Radio Basic Service Manual (Motorola publication part number 6881096C73).

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 copyrighte d compu ter program s, includi ng, but not limited to, the exclus ive rig ht to copy or reprodu ce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may no t b e co pie d, reproduced, modified, rev ers e-e ngi nee red , or distributed 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 license to use that arises by operation of law in the
sale of a product.

Document Copyrights

No duplication or distrib ution of this document or any portion thereof sha ll take pl ace witho ut the express w ritten permis sion
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.

Disclaimer

The information in thi s d ocu ment is carefully exa mi ned , an d is believed to be entirely reliable. How e ve r, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.

Trademarks

MOTOROLA, the Stylized M logo, FLASHport, and ASTRO are registered in the US Patent & Trademark Office. All other
product or service names are the property of their respective owners.

© Motorola, Inc. 2003.

ii

Installation Requirements for Compliance with

Radio Frequency (RF) Energy Exposure Safety

Standards

ATTENTION!

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.

To ensure compliance to RF Energy Safety Standards:

• Install only Motorola approved antennas and accessories

• Be sure that antenna installation is per

• Be sure that Product Safety and RF Safety Booklet enclosed with this radio is available to the end user
upon completion of the installation of this radio

Before using this product, the operator must be familiar with the RF energy awareness information and
operating instructions in the Product Safety and RF Exposure booklet enclosed with each radio (Motorola
Publication part number 68P81095C99) to ensure compliance with Radio Frequency (RF) energy exposure
limits.

“Antenna Installation,” on page 2-14 of this manual

For a list of Motorola-approved antennas and other accessories, visit the following web site which lists
approved accessories for your radio model: http://www.motorola.com/cgiss/index.shtml

.

iii

This Page Intentionally Left Blank

iv

Table of Contents v

Table of Contents

Foreword.........................................................................................................ii

Product Safety and RF Exposure Compliance............................................................................................ii

Manual Revisions ............................ ................................................................................... .........................ii

Parts Ordering .............................................................................................................................................ii

Computer Software Copyrights ...................................................................................................................ii

Document Copyrights..................................................................................................................................ii

Disclaimer....................................................................................................................................................ii

Trademarks .................................................................................................................................................ii

Installation Requirements for Compliance with

Radio Frequenc y ( RF) Ene r gy Expos ure Safety Standard s........ .. .. ..........iii

Mobile Radio Model Numbering Scheme.....................................................x

Commercial Warranty ...................................................................................xi

Limited Warranty ........................................................................................................................................xi

MOTOROLA COMMUNICATION PRODUCTS................................................................................xi

I. What This Warranty Covers And For How Long .....................................................................xi

II. General Provisions.................................................................................................................xi

III. State Law Rights ..................................................................................................................xii

IV. How To Get Warranty Service.............................................................................................xii

V. What This Warranty Does Not Cover....................................................................................xii

VI. Patent And Software Provisions .........................................................................................xiii

VII. Governing Law....................... ....... ...... ....... ...... ...... ............................................................ xiii

Chapter 1 Introduction ......................................................................... 1-1

1.1 Mobile Radio Description............................................................................................................... 1-1

1.1.1 Dimensions....................................................................................................................... 1-1

1.2 Standard Configurations................................................................................................................ 1-1

1.2.1 Dash Mount Configuration................................................................................................1-1

1.2.2 Remote Mount Configuration............................................................................................1-2

1.2.3 Dual Control Configuration ...............................................................................................1-2

1.3 Motorcycle Configurations .............................................................................................................1-2

1.4 Base/Control Stations....................................................................................................................1-2

1.5 Tools Required for XTL 5000 Installations..................................................................................... 1-3

Chapter 2 Standard Configurations.................................................... 2-1

2.1 Planning the Installation...................... ....... ...... ....... ...... ....................................... ...... ....................2-1

2.1.1 Installation Example s.................................................... ...... ....... ...... ....... ...... ....... ...... ....... 2-1

2.1.2 Wiring Diagrams...............................................................................................................2-2

2.2 Radio Mounting.............................................................................................................................. 2-4

2.2.1 Dash Mount with Trunnion................................................................................................ 2-5

2.2.2 Remote Mount with Trunnion............................................................................................2-6

6881096C72-B September 9, 2003

vi Table of Contents

2.2.2.1 Transceiver..............................................................................................................2-6

2.2.2.2 Control Head and Remote Mount Cabling............................................................... 2-6

2.2.3 Locking Kit (Optional) .....................................................................................................2-13

2.3 Power Cable ................................................................................................................................ 2-13

2.4 Ignition Cable.................. ....... ...... ....... ......................................................................................... 2-14

2.5 Antenna Installation..................................................................................................................... 2-14

2.5.1 Selecting an Antenna Site/Location on a Metal Body Vehicle........................................ 2-15

2.5.2 Mini-UHF Connection ..................................................................................................... 2-15

2.6 Speaker ...................................................................................................................................... 2-17

2.7 Microphone Hang-Up Clip ........................................................................................................... 2-17

2.7.1 Standard Hang-Up Clip................................................................................................... 2-17

2.7.2 Handheld Hang-Up Box (W3 Mode l) ..................... ...... ....... ...... ....... ............................... 2-18

2.8 Completing the Installation .......................................................................................................... 2-18

Chapter 3 Options and Accessories Installation...............................3-1

3.1 VIP Overview................................................................................................................................. 3-1

3.1.1 VIP Output Connections................................................................................................... 3-1

3.1.2 VIP Input Connections......................................................................................................3-2

3.2 Remote-Mount Accessory Installations for W4/5/7/9 Models ........................................................ 3-2

3.2.1 Emergency Pushbutton, Footswitch, Horn Relay, and Light Relay Installation ............... 3-3

3.2.1.1 Emergency Pushbutton or Footswitch Installation................................................... 3-3

3.2.1.2 Horn (External Alarm) Relay Installation ................................................................. 3-4

3.2.1.3 Lights (External Alarm) Relay Installation................................................................ 3-4

3.3 Dash-Mount Accessory Installations for W4/5/7/9 Models ............................................................ 3-4

3.3.1 MDC Emergency Pushbutton or Footswitch Installation................................................... 3-4

3.3.2 Horn and Lights (External Alarms) Relays........................................................................ 3-5

3.4 Remote-Mount Accessory Installations for W3 Model................................................................... 3-5

3.4.1 MDC Emergency Pushbutton or Footswitch Installation for W3 with Remote Cable Assembly
3-6

3.4.2 Horn and Lights (External Alarms) Relays Installation for W3 with Remote Cable Assembly
3-6

3.5 Accessory Connector Assembly Details (P2)................................................................................ 3-7

3.5.1 Installation into the Vehicle................................................. ...... ........................................ 3-7

3.5.2 Installation onto the Radio................................................................................................3-7

3.5.3 Disassembly and Assembly.............................................................................................. 3-8

3.5.3.1 Disassembly ............................................................................................................ 3-8

3.5.3.2 Assembly.................................................................................................................3-8

3.5.4 Adapter Cable................................................................................................................... 3-9

3.5.5 Rear Accessory Jack Connection................................................................................... 3-10

Chapter 4 Motorcycle Radio Installation ............................................4-1

4.1 Motorcycle Radio Description........................................................................................................ 4-1

4.1.1 Transceiver Enclosure......................................................................................................4-1

4.1.2 Control/Display Unit.......................................................................................................... 4-1

4.1.3 Control Head Cable.................................. ....... ................................................................. 4-1

4.1.4 Microphone....................................................................................................................... 4-1

4.1.5 External Speaker ......................... ....... ...... ....... ...... ...... ....... ...... ....... ................................. 4-1

4.1.6 Headset Capability............................................................................................................ 4-2

4.1.7 Antenna ............................................................................................................................ 4-2

4.1.8 Ignition Wire.................... ....... ............................................. .............................................. 4-2

4.2 Installation Overview ..................................................................................................................... 4-2

September 9, 2003 6881096C72-B

Table of Contents vii

4.2.1 General.............................................................................................................................4-2

4.2.2 Important Installation Hints ...............................................................................................4-3

4.2.3 Parts Identification ............................................................................................................ 4-3

4.2.4 Order of Installation ..........................................................................................................4-3

4.3 Installing the Universal Mounting Plate..........................................................................................4-4

4.4 Installing the Speaker and Control Head....................................................................................... 4-5

4.4.1 Handlebar Installation with Speaker and Control Head Mounted Together......................4-6

4.4.2 Fuel Tank Console Installation with Speaker and Control Head Mounted Together........4-7

4.4.3 Handlebar Installation with Speaker and Control Head Mounted Separately...................4-9

4.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted Separately ...4-10

4.5 Installing the Speaker .................................................................................................................. 4-10

4.6 Installing the Microphone Hang-Up Clip...................................................................................... 4-11

4.6.1 Extension Bracket Mounting...........................................................................................4-11

4.6.2 Speaker/Control Head Bracket Side Mounting ...............................................................4-11

4.6.3 Other Hang-Up Clip Mounting ........................................................................................4-11

4.7 Installing Cables ..........................................................................................................................4-12

4.8 Installing the Weather-Resistant Enclosure................................................................................. 4-13

4.9 Transceive r and Cablin g Insta ll ation....................... ...... ...... ....... ..................................................4-14

4.9.1 Installing Cabling in the Enclosure.................................................................................. 4-14

4.9.2 Installing the Transceiver................................................................................................4-15

4.10 Installing the Antenna .................................................................................................................. 4-18

4.11 Installing the Emergency Switch Option ......................................................................................4-18

4.12 Installing the External Alarm Relay Option ..................................................................................4-18

4.13 Installing the Headset Accessory.................................................................................................4-18

4.14 Horn/Lights Wiring ....................................................................................................................... 4-18

4.15 Emergency Switch Wiring............................................................................................................ 4-19

Chapter 5 Finishing the Installation: Cable Connection................... 5-1

Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information............................................................................................................A-1

A.2 Motorola Online .............................................................................................................................A-1

A.3 Mail Orders ....................................................................................................................................A-1

A.5 Fax Orders.....................................................................................................................................A-2

A.6 Parts Identification .........................................................................................................................A-2

A.7 Product Customer Service............................................................... ....... ...... ....... ...... ....................A-2

Glossary.........................................................................................Glossary-1

Index.....................................................................................................Index-1

Related Publications

ASTRO XTL 5000 Digital Mobile Radio Model W3 User’s Guide................................................6881096C67

ASTRO XTL 5000 Digital Mobile Radio Models W4, W5, W7, and W9 User’s Guide ................6881096C68

ASTRO XTL 5000 Digital Mobile Radio Basic Service Manual ...................................................6881096C73

CPS Programming Installation Guide ..........................................................................................6881095C44

ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual.........6881091C78

Spectra Control Station Installation Manual................................................................................6880101W87

6881096C72-B September 9, 2003

viii List of Figures

List of Figures

Figure 1-1. Front View of Dash Mount Radio.......................................................................................... 1-1

Figure 1-2. Side View of Dash Mount Radio ........................................................................................... 1-1

Figure 1-3. Dash Mount Configuration.................................................................................................... 1-1

Figure 1-4. Remote Mount Configuration................................................................................................ 1-2

Figure 2-1. Mounting Flexibility in Middle Console.................................................................................. 2-1

Figure 2-2. On Top or Under Dash Mounting.......................................................................................... 2-1

Figure 2-3. Remote Mount–Control Head in Console............................................................................. 2-1

Figure 2-4. In Dash Mounting.................................................................................................................. 2-1

Figure 2-5. Remote Mount–Control Head in Dash.................................................................................. 2-1

Figure 2-6. Remote Mount–Control Head on Top or Under Dash........................................................... 2-1

Figure 2-7. Radio Installation (Dash Mount) Using W4, W5, or W7 Control Heads................................ 2-2

Figure 2-8. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads ............................... 2-3

Figure 2-9. Radio Installation (Dash Mount) Using W3 Control Heads................................................... 2-3

Figure 2-10. Radio Installation (Remote) Using W3 Control Heads.......................................................... 2-4

Figure 2-11. Trunnion Orientation............................................................................................................. 2-5

Figure 2-12. Transmission Hump Trunnion Mounting ............................................................................... 2-5

Figure 2-13. Below Dash Trunnion Mounting............................................................................................ 2-6

Figure 2-14. W4, W5, W7, and W9 Control Heads ................................................................................... 2-7

Figure 2-15. W4, W5, and W7 Control Head Installation Exploded View ................................................. 2-8

Figure 2-16. W9 Control Head Installation Exploded View ....................................................................... 2-9

Figure 2-17. W4, W5, and W7 Control Head Rear View........................................................................... 2-9

Figure 2-18. W3 Control Head ................................................................................................................ 2-10

Figure 2-19. Fuseholder Assembly for Orange and Green Control Cables .............................................2-11

Figure 2-20. Locking Kit (Optional) ......................................................................................................... 2-13

Figure 2-21. Cabling Interconnect Diagram for Remote Mount .............................................................. 2-13

Figure 2-22. Cabling Interconnect Diagram for Dash Mount................................................................... 2-14

Figure 2-23. Mini-UHF Connection ......................................................................................................... 2-16

Figure 2-24. Mini-UHF Connector Tool................................................................................................... 2-16

Figure 2-25. Speaker Mounting............................................................................................................... 2-17

Figure 3-1. VIP Connector Detail ............................................................................................................ 3-3

Figure 3-2. Emergency Switch Wiring Diagram for W4/5/7/9.................................................................. 3-4

Figure 3-3. Horn/Light Wiring Diagram for W4/5/7/9...............................................................................3-5

Figure 3-4. Emergency Switch Wiring Diagram for W3........................................................................... 3-6

Figure 3-5. Horn/Light Wiring Diagram for W3........................................................................................ 3-6

Figure 3-6. Exploded View of Accessory Connector Assembly (P2) ...................................................... 3-8

Figure 3-7. Rear Accessory Connector Audio Configuration .................................................................. 3-9

Figure 3-8. Rear Accessory Connector Data Configuration.................................................................... 3-9

Figure 3-9. Rear Accessory Jack Pin Configuration (J2) (Radio Side) ................................................. 3-10

Figure 4-1. Universal Mounting Plate Installation (Part of Radio Enclosure Kit)..................................... 4-4

Figure 4-2. Handlebar Installation with Speaker and Control Head Mounted Together.......................... 4-6

Figure 4-3. Fuel Tank Console Installation with Speaker and Control Head Mounted Together............. 4-8

Figure 4-4. Handlebar Installation with Speaker and Control Head Mounted Separately ....................... 4-9

Figure 4-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately........ 4-10

Figure 4-6. Cable Routing..................................................................................................................... 4-12

Figure 4-7. Weather-Resistant Enclosure Installation........................................................................... 4-13

Figure 4-8. Installing Cables ................................................................................................................. 4-15

Figure 4-9. Installing the Transceiver.................................................................................................... 4-17

Figure 4-10. Horn/Lights Wiring Diagram................................................................................................ 4-18

Figure 4-11. Emergency Switch Wiring Diagram .................................................................................... 4-19

September 9, 2003 6881096C72-B

List of Tables ix

List of Tables

Table 2-1. Radio Functions Connections...................................................................................2-11

Table 2-2. Fuse Assembly for Orange and Green Leads Parts List ..........................................2-12

Table 3-1. VIP Output Connections .............................................................................................3-1

Table 3-2. VIP Input Connections................................................................................................3-2

Table 3-3. Rear Accessory Jack Pin Functions .........................................................................3-11

Table 3-4. Rear Connector and Front Connector Naming Schemes.........................................3-12

Table 3-5. How to Connect to a Computer

Table 4-1. Transceiver Installation Parts List.............................................................................4-16

1

(DTE Device) ........................................................3-12

6881096C72-B September 9, 2003

x Mobile Radio Model Numbering Scheme

Mobile Radio Model Numbering Scheme

Typical Model Number:

Position:

Position 1 - Type of Unit

M = Mobile
L = Table Top Station

Positions 2 & 3 - Model Series

20 = XTL 5000

Position 4 - Frequency Band

Less than 29.7MHz

A

=

29.7 to 35.99MHz

B

=

36 to 41MHz

C

=

42 to 50MHz

D

=

300 to 345MHz

E

=

66 to 80MHz

F

=

74 to 90MHz

G

=

Product Specific

H

=

VHF Range
136 to 162MHz

J

=

146 to 178MHz

K

=

174 to 210MHz

L

=

190 to 235MHz

M

=

* For XTL 5000 "U" in Position 4 represents
764-870MHz.

Note: Values represented are not absolute,
and are given to indicate range only.

Position 5 - Power Level

0 to 0.7 Watts

A

=

0.7 to 0.9 Watts

B

=

1.0 to 3.9 Watts

C

=

4.0 to 5.0 Watts

D

=

5.1 to 6.0 Watts

E

=

6.1 to 10 Watts

F

=

10.1 to 15 Watts

G

=

16 to 25 Watts

H

=

Note: Values represented are not absolute,
and are given to indicate range only.

Position 6 - Physical Packages

RF Modem Operation

A

=

Receiver Only

B

=

Standard Control; No Display

C

=

Standard Control; With Display

D

=

Limited Keypad; No Display

E

=

Limited Keypad; With Display

F

=

Full Keypad; No Display

G

=

Full Keypad; With Display

H

=

Limited Controls; No Display

J

=

Limited Controls; Basic Display

K

=

Limited Controls; Limited Display

L

=

Rotary Controls; Standard Display

M

=

Enhanced Controls; Enhanced Display

N

=

Low Profile; No Display

P

=

Low Profile; Basic Display

Q

=

Low Profile; Basic Display, Full Keypad

R

=

Tranceiver with Selectable Control Head

S

=

T

=

U

=

VDV Control Head

V

=

Control Head #2

W

=

Position 7 - Channel Spacing

0 =
1 = 5KHz
2 = 6.25KHz
3 = 10KHz
4 = 12.5KHz

M20U RS 9 P W 1 A N S P 0 1

123 4 5 6 7 8 9 1011 1213141516

330 to 370MHz

N

=

366 to 410MHz

P

=

403 to 437MHz

Q

=

438 to 482MHz

R

=

470 to 620MHz

S

=

Product Specific

T

=

UHF Range
806 to 870MHz*

U

=

825 to 870MHz

V

=

896 to 941MHz

W

=

403-470MHz

X

=

1.0 to 1.6GHz

Y

=

1.5 to 2.0GHz

Z

=

26 to 35 Watts

J

=

36 to 60 Watts

K

=

61 to 110 Watts

L

=

Up to 125 Watts

M

=

1-25 Watts

N

=

25-40 Watt

P

=

25-45 Watt

Q

=

10-35 Watt

R

=

5 = 15KHz
6 = 20/25KHz
7 = 30KHz
8 = 12.5/25KHz
9 = Variable/Programmable

Positions 13 - 16

SP Model Suffix

Position 12 -

Unique Model Variations

C = Cenelec
N = Standard Package

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 10 - Feature Level

1 = Basic
2 = Limited Package
3 = Limited Plus
4 = Intermediate
5 = Standard Package

Position 9 - Primary System Type

A

=

Conventional

B

=

Privacy Plus

C

=

Clear SMARTNET

D

=

Advanced Conventional Stat-Alert

E

=

Enhanced Privacy Plus

F

=

Nauganet 888 Series

G

=

Japan Specialized Mobile Radio (JSMR)

H

=

Multi-Channel Access (MCA)

J

=

CoveragePLUS

K

=

MPT1327* - Public

L

=

MPT1327* - Private

M

=

Radiocom

N

=

Tone Signalling

P

=

Binary Signalling

Q

=

Phonenet

R

=

IDEN Basic

S

=

IDEN Advanced Feature

T

=

JSMR Digital

U

=

LTR Protocol

V

=

Single Sideband

W

=

Programmable

X

=

Secure Conventional

Y

=

Secure SMARTNET

Z

=

TETRA

2

=

SmartZone

* MPT = Ministry of Posts and Telecommunications

Position 8 - Primary Operation

=

A

Conventional/Simplex

=

B

Conventional/Duplex

=

C

Trunked Twin Type

=

D

Dual Mode Trunked

=

E

Dual Mode Trunked/Duplex

=

F

Trunked Type I

=

G

Trunked Type II

=

H

FDMA* Digital Dual Mode

=

J

TDMA** Digital Dual Mode

=

K

Single Sideband

=

L

Global Positioning Satellite Capable

=

M

Amplitude Companded Sideband (ACSB)

=

N

Digital Dispatch

=

P

Programmable

=

Q

Digital Interconnect

=

R

Digital Multi-Service

=

S

9600 Capable

=

T

TDMA

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

6 = Standard Plus
7 = Expanded Package
8 = Expanded Plus
9 = Full Feature/
Programmable

MAEPF-27634-O

September 9, 2003 6881096C72-B

Commercial Warranty xi

Commercial Warranty

Limited Warranty

MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication
Products listed below (“Product”) against defects in material and workmanship under normal use and
service for a period of time from the date of purchase as scheduled below:

ASTRO XTL 5000 Digital Mobile Radio One (1) Year
Product Accessories One (1) Year

Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.

This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.

MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.

II. General Provisions

This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product.
Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive
remedy. THIS W ARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR
DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE
DISCLAIMED BY LAW.

6881096C72-B September 9, 2003

xii Commercial Warranty

III. St a te Law Rig hts

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.

This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.

IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also call
Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary

manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,

modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs (includ-

ing, without limitation, the addition to the Product of non-Motorola supplied equipment) which

adversely affect performance of the Product or interfere with Motorola’s normal warranty

inspection and testing of the Product to verify any warranty claim.
F. Product which has had the serial number removed or made illegible.
G. Rechargeable batteries if:

- any of the seals on the battery enclosure of cells are broken or show evidence of tamper­ing.

- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.

H. Freight costs to the repair depot.
I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the Prod-

uct, does not function in accordance with MOTOROLA’s published specifications or the FCC
type acceptance labeling in effect for the Product at the time the Product was initially distrib­uted from MOTOROLA.

J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of

the Product.

K. Normal and customary wear and tear.

September 9, 2003 6881096C72-B

Commercial Warranty xiii

VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:

A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such

claim;

B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its

settlement or compromise; and

C. should the Product or parts become, or in MOTOROLA’s opinion be likely to become, the

subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to con­tinue using the Product or parts or to replace or modify the same so that it becomes nonin­fringing or to grant such purchaser a credit for the Product or parts as depreciated and accept
its return. The depreciation will be an equal amount per year over the lifetime of the Product
or parts as established by MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.

Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.

VII. Governing Law

This Warranty is governed by the laws of the State of Illinois, USA.

6881096C72-B September 9, 2003

xiv Commercial Warranty

Notes

September 9, 2003 6881096C72-B

Chapter 1 Introduction

This manual covers the installation procedures for ASTRO XTL 5000 mobile and motorcycle radios
and accessories required to complete the radio system. The radio system consists of a control head,
radio, antenna, microphone, speaker, cabling, and accessories.

1.1 Mobile Radio Description

1.1.1 Dimensions

Figure 1-2 and Figure 1-1 show the basic dimensions of a dash mount XTL 5000 radio. The

transceiver portion of a remote mount XTL 5000 is sized similarly.
When installing the radio, make sure to plan the installation carefully and leave additional room in the

rear of the radio for cabling and accessory connections; in the front of the radio for access, controls,
and cabling (if remote mount); and to the sides of the radio so that you may access and install the
trunnion wing screws.

8.5"

7.1"

Figure 1-1. Front View of Dash Mount Radio Figure 1-2. Side View of Dash Mount Radio

NOTE: The rear accessory connector adds 0.75 in. to the overall length.

9.1"

1.2 Standard Configurations

1.2.1 Dash Mount Configuration

In the dash mounting version of the XTL 5000, the control head is mounted on the front of the
transceiver housing. Electrical connection between the two takes place within the radio via a flexible
circuit board between the connectors on the front of the transceiver and at the back of the control
head.

2"

3.5"

Figure 1-3. Dash Mount Configuration

For details on this configuration, see Section 2.2.1 on p age 2-5.

1-2 Introduction: Motorcycle Configurations

1.2.2 Remote Mount Configuration

In the remote control version, the transceiver and the control head are mounted separately in the
vehicle. The control head is mounted in a remote trunnion near the operator. The transceiver is
mounted by means of a trunnion or other mounting hardware. If the transceiver is located in a car
trunk, be sure that secure mounting and sufficient cooling are provided. Do not cover the transceiver
with baggage, blankets, etc.

PWR

Mode

0

Phon

Vol

Scan

Call

DIM

HOME

Figure 1-4. Remote Mount Configuration

For details on this configuration, see Section 2.2.2 on page 2-6.

Sel

1

2

3

XMIT

4

S

ts

5

6

BUSY

M

s

g

7

H

/L

8

M

o

n

9

D

ir

R

c

l

0

D

e

l

MAEPF-27638-O

1.2.3 Dual Control Configuration

The dual control head option allows two, separate, remotely operated control heads to operate and
control the radio. For example, a fire truck could have a control head located in the cab and on the
rear of the truck so that the radio could be operated from outside the vehicle.

For details on this configuration, see the ASTRO Digital Spectra Mobile Radios Dual Control Head
Radio System Service Manual (Motorola publication part number 6881091C78).

1.3 Motorcycle Configurations

The ASTRO XTL 5000 motorcycle radio models provide most of the equipment needed for installing
a standard ASTRO XTL 5000 radio on a motorcycle. Most of this radio system is standard
equipment. See Chapter 4: Motorcycle Radio Installation for further information.

1.4 Base/Control Stat ions

The base/control station option provides the radio with a desk microphone and power supply for use
at a fixed location. All operations are the same as the mobile, except for the desk microphone.

Choose a location for your base/control station as close as possible to where the antenna cable
enters the building. Be sure an electric outlet is available. Make sure sufficient air can flow around
the radio to permit adequate cooling.

The antenna should be installed outside of the building, but never within two feet (for radios with less
than 50 watts power output) or within three feet (for radios with 50 watts or higher power output) of
station operators or bystanders.

For more information, refer to the Spectra Control Station Installation Manual (Motorola publication
part number 6880101W87).

September 9, 2003 6881096C72-B

Introduction: Tools Required for XTL 5000 Installations 1-3

1.5 Tools Required for XTL 5000 Installations

Tool Part Number

11/32 hex driver —
RF cable tool HLN6695_
Regular slot screwdriver of

Phillips #2
Pin removal tool 6680163F01
1/4 hex driver —

—

6881096C72-B September 9, 2003

1-4 Introduction

Notes

September 9, 2003 6881096C72-B

Chapter 2 Standard Configurations

2.1 Planning the Installation

The XTL 5000 radio operates only in negative ground electrical systems. Before starting the radio
installation, make sure that the ground polarity of the vehicle is correct. Accidentally reversing the
polarity will not damage the radio, but will cause the cable fuses to blow.

Planning is the key to fast, easy radio installation. Before starting the installation, inspect the vehicle
and determine how and where you intend to mount the antenna, radio, and accessories. Plan wire
and cable runs to provide maximum protection from inching, crushing, and overheating.

CAUTION Before installing any electrical equipment, check the vehicle manufacturer’s user manual.

The installation of this device should be completed by an authorized servicer or installer.

2.1.1 Installation Examples

Your mobile two-way radio offers various methods of installation, including dash or remote mount
(see Figure 2-1 through Figure 2-6).

Speaker

Battery

Radio

Antenna
1/4-Wavelength

Radio

Speaker

Radio

Battery

Antenna
1/4-Wavelength

Figure 2-1. Mounting Flexibility in Middle Console Figure 2-2. On Top or Under Dash Mounting

Antenna

Speaker

Control Head

Battery

1/4-Wavelength

Radio

Figure 2-3. Remote Mount–Control Head in Console

Antenna

Speaker

1/4-Wavelength

Speaker

Radio

Battery

Figure 2-4. In Dash Mounting

Control Head

Speaker

Antenna
1/4-Wavelength

Antenna
1/4-Wavelength

Battery

Control Head

Radio

Battery

Control Head

Radio

Figure 2-5. Remote Mount–Control Head in Dash Figure 2-6. Remote Mount–Control Head on Top or

Under Dash

2-2 Standard Configurations: Planning the Installation

2.1.2 Wiring Diagrams

Figure 2-7 through Figure 2-10 show the wiring diagrams for all the possible configurations. The title

under each figure identifies which model control head is being shown. Identify which of these figures
shows the configuration that you are installing, and use the diagram when planning the installation.

HORN
RELAY

SPEAKER

MIC

(-)

LIGHT
RELAY

MIC

CLIP

EMERGENCY

SWITCH

BATTERY

(+)

FUSE

FUSE

FUSE

BLOCK

IGNITION CABLE

P2

(SEE J2

PINOUT)

PWR

Mode

Phon Sel

Vol

MIC

Scan

DIM

HOME

CONTROL HEAD*

* MODEL W7 SHOWN

RED LEAD

ANTENNA

FIREWALL

HOLE

DC

POWER

CABLE

ANTENNA

CONNECTION

TRUNNION

123

Call

45

Sts Msg

6

XMIT

BUSY

78 9

H/L Mon Dir

Rcl Del

0

MOUNTING

SCREW

REAR ACCESSORY CONNECTOR

26

SPKR-

IGNITION

EMERGENCY

21

20

SPKR+

VIP OUT 2

12V

(RELAY)

VIP OUT 1

12V

(RELAY)

GROUND

14

J2

7

13

8

1

MAEPF-27612-O

Figure 2-7. Radio Installation (Dash Mount) Using W4, W5, or W7 Control Heads

(For complete pin configurat ion , see Figure 3-9.)

September 9, 2003 6881096C72-B

Standard Configurations: Planning the Installation 2-3

SPEAKER

FUSE

GRN LEAD

FUSE

BLOCK

Mode

Phon Sel

Vol

DIM

HOME

MIC

CONTROL HEAD*

FUSE

REMOTE

MOUNT

CONTROL

CABLE

123

Scan

Call

45

Sts Msg

XMIT

H/L Mon Dir

78 9

BUSY

Rcl Del

0

DC POWER

CABLE

6

FIREWALL

HOLE

ANTENNA

CONNECTION

PORT ON BACK OF CONTROL HEAD

VIP MIC RADIO

12

3457810111213 14 151617

20 212324

1918

35

34

37 38

36

VIP SECTION PIN OUT

1 VIP OUT - 2
2 VIP OUT - 1
3 VIP IN - 2 *
4 VIP IN - 1
5 DEK DATA OUT

EMERGENCY WITH JUMPER CHANGES TO CONTROL HEADS

*

18 SWB +
19 SWB +
20 GROUND
21 GROUND

ANTENNA

HORN
RELAY

MIC

MIC

CLIP

(-)

LIGHT
RELAY

BATTERY

(+)

ORG LEAD

FUSE

PWR

RADIO

EMERGENCY

SWITCH

P506

J5

J6

* MODEL W7 SHOWN

Figure 2-8. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads

J0103

28 29

26 27

44 45 46 47 48 49 50

40 41 43

34 VIP OUT - 3 / DEK STROBE
35 SWB +
36 GROUND
37 VIP IN - 3 / DEK DATA IN
38 DEK CLOCK

30 313233

MAEPF-27613-O

LIGHT OR

HORN

RELAY

SPEAKER

HANDHELD

CONTROL

HEAD

(-)

HANG-UP

BOX

EMERGENCY

SWITCH

Figure 2-9. Radio Installation (Dash Mount) Using W3 Control Heads

BATTERY

(+)

FUSE

FUSE

ANTENNA

FUSE

BLOCK

FIREWALL

HOLE

IGNITION CABLE

P2

(SEE J2

PINOUT)

DC

POWER

CABLE

ANTENNA

CONNECTION

TRUNNION

P506

J6

J5

MOUNTING

SCREW

CONTROL HEAD

(For complete pin configuration, see Figure 3-9.)

REAR ACCESSORY CONNECTOR

J2

26

SPKR-

IGNITION

21

20

SPKR+

VIP OUT 2

12V

(RELAY)

VIP OUT 1

12V

(RELAY)

EMERGENCY

GROUND

14

7

13

8

1

MAEPF-27614-O

6881096C72-B September 9, 2003

2-4 Standard Configurations: Radio Mou ntin g

LIGHT OR

HORN

RELAY

SPEAKER

HANDHELD

CONTROL

HEAD

(-)

HANG-UP

BOX

EMERGENCY

SWITCH

BATTERY

(+)

FUSE

FUSE

FUSE

BLOCK

IGNITION CABLE

PINOUT

MOUNT CONTROL

P506

J5

J3

REMOTE

CABLE

RADIO

FIREWALL

HOLE

DC POWER

CABLE

J6

ANTENNA

CONNECTION

REMOTE MOUNT

ACCESSORY CONNECTOR

SPKR

LO

DIG

SPKR

GND

NOTES:

1. TX AUDIO IN SP CUSTOMER APPLICATIONS.

2. DET AUDIO IN SP CUSTOMER APPLICATIONS.

7

8

15 14 13

NC

BUS+

HI

Figure 2-10. Radio Installation (Remote) Using W3 Control Heads

J3

IGNITION

SWB+

6

12 11 10 9

NC

NOTE 2

VIP OUT 1 BUS-

VIP

OUT 2

EMER

MAEPF-27615-O

NOTE 1

12345

BUSY

2.2 Radio Mounting

CAUTION: DO NOT mount the radio on a plastic dashboard

!

C a u t i o n

The mounting location must be accessible and visible. Select a location that will permit routing the
RF antenna cable as directly as possible.

NOTE: For optimum radio performance, orient the mounting trunnion as shown in Figure 2-11. For

new or existing installations, use only the XTL 5000 trunnion (kit number: HLN6861_).

without first reinforcing the dashboard; the weight of the radio may
crack or break the dashboard.
CAUTION: DO NOT mount the radio on a flat or concave surface
where the radio could be partially submersed in water. This is
especially important if the cab area of the vehicle is cleaned by
spraying with water. If the radio sits in water for a length of time,
moisture may seep inside the radio and damage the electronic
components.
CAUTION: DO NOT allow water to stand in recessed areas of
vertically mounted radios. Remove any moisture immediately to
prevent it from seeping down into the radio.

September 9, 2003 6881096C72-B

Standard Configurations: Radio Moun tin g 2-5

RADIO

FRONT

APPLIES TO RADIOS WITH INTEGRAL

OR REMOTE MOUNT CONTROL UNITS

Figure 2-11. Trunnion Orientation

2.2.1 Dash Mount with Trunnion

1. Select the location to mount your radio on the transmission hump (see Figure 2-12) or under
the dash (see Figure 2-13). When mounting the trunnion on the transmission hump take care
the transmission housing is not affected.

2. Using the trunnion mounting bracket as a template, mark the positions of the holes on the
mounting surface. Use the innermost four holes for a curved mounting surface such as the
transmission hump, and the four outmost holes for a flat surface such as under the dash.

3. Center punch the spots you have marked and realign the trunnion in position.

4. Secure the trunnion mounting bracket with the four self-drilling screws provided (see

Figure 2-12 and Figure 2-13).

5. Ensure that the plastic guides are aligned (horizontal) to the grooves of the trunnion. Slide the
radio into t he gr ooves un til it snap s in to plac e (see Figure 2-12). Secure the radio with the two
wing screws provided.

Wing Screw

Trunnion

Plastic Guides

Tabs

Wing Screw

Groove

Threaded Hole
for Wing Screw

Figure 2-12. Transmission Hump Trunnion Mounting

6881096C72-B September 9, 2003

2-6 Standard Configurations: Radio Mou ntin g

Trunnion

Wing Screw

Figure 2-13. Below Dash Trunnion Mounting

2.2.2 Remote Mount with Trunnion

2.2.2.1 Transceiver

CAUTION Before installing any electrical equipment, check the vehicle manufacturer’s user

manual.
The installation of this device should be completed by an authorized servicer or

installer.

Holes for

Microphone

S-Hook

Wing Screw

For a remote mount installation, the transceiver may be mounted anywhere in the vehicle, provided
that the installation location is safe, follows the cautions mentioned at the beginning of this section,
and is accessible for servicing/maintenance as well as cabling. A typical mounting location
recommended by Motorola is in the vehicle’s trunk. The trunnion provided may still be used to mount
the transceiver, and the mounting process is the same as for the dash mount installation (Section

2.2.1 on page 2-5). See Figure 2-8 for a remote W4, W5, W7, and W9 installation, and Figure 2-10

for a remote W3 installation.

2.2.2.2 Control Head and Remote Mount Cabling

For radios equipped with optional remote mount control heads, see Figure 2-8. For radios equipped
with remote handheld control heads, see Figure 2-10. Choose a mounting location for the radio,
considering accessibility, and control and antenna cable lengths.

2.2.2.2.1 Remote W4, W5, W7, and W9 Model Control Head Installation

Figure 2-14 shows each of the control head models.

If you are required to insert any of the replaceable buttons available with these radios, refer to the
XTL 5000 Basic Service Manual (Motorola publication part number 6881096C73) for further
information.

September 9, 2003 6881096C72-B

Standard Configurations: Radio Moun tin g 2-7

W4

W7

W7

W5

W5

W9

W9

Figure 2-14. W4, W5, W7, and W9 Control Heads

The recommended mounting surfaces for the control unit are under the dashboard, on the
transmission hump, or on the center console. Figure 2-15 shows how the trunnion, control head, and
cables should be installed for the W4, W5, and W7 control heads. Figure 2-16 shows the installati on
for the W9 model control head.

NOTE: For control head models W4, W5, and W7 only: To seal the control head and meet

U. S. MIL-STD-810D environmental specifications, covers are supplied for protection of the
control head’s rear connector pins. These covers are in the bag that is fastened to the remote
control head’s mounting trunnion.

If the VIP connector is not being used to connect options, the VIP protective cover should be
installed as shown in Figure 2-17. If the microphone is connected to the front of the control
head, the MIC protective cover should be installed as shown in Figure 2-17. Alternately, the
microphone can be connected to the rear connector in place of the cover, and the control head
will still be environmentally sealed.

An adjustable trunnion, which allows a number of mounting positions, is supplied for mounting the
control unit. The installation must not interfere with the operation of the vehicle or its accessories, nor
disturb passenger seating or leg room. The control head must be within convenient reach and
viewing of the user.

If the trunnion is mounted on a plastic dashboard, all four mounting screws should penetrate the
dashboard’s supporting metal frame. If that is not possible, use a metal backing plate (not supplied)
to strengthen the installation. Install the control unit as follows:

1. Use the control unit trunnion as a template to mark the mounting holes; drill 5/32" holes. If
mounting on a plastic surface, use a metal backing plate.

2. Attach the trunnion bracket using all four 10-16" x 5/8" self-tapping screws provided.

3. Temporarily install the control head (adjusting for proper viewing angle) and fasten it to the
trunnion with two wing screws. T est the installation to be sure the unit does not wobble or feel
“spongy” when you press the buttons.

NOTE: Use all four mounting screws and be sure they are tightly screwed into metal — either a

dashboard support bracket or a backing plate.

6881096C72-B September 9, 2003