Page 1
TM
®
ASTRO
700–800 MHz
Digital Mobile Radio
XTL
5000
Basic Service Manual
Page 2
Page 3
Title P a ge
ASTRO® XTL™ 5000
700–800 MHz
Digital Mobile Radio
Basic Service Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322
6881096C73-O
Page 4
Foreword
This manual covers all models of the ASTRO® XTL™ 5000 700–800 MHz Digital Mobile Radio (control head models W3,
W4, W5, W7, and W9), unless otherwise specified. It includes all the information necessary to maintain peak product
performance and m axim um work ing ti me, us ing le vels 1 and 2 main tenanc e proc edures . This level of serv ice g oes d own t o
the board replacement 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 sect i on, “Related Publications,” on page xii.
Product Safety and RF Exposure Compliance
Before using this product, read the operating instructions
for safe usage contained in the Product Safety and RF
!
C a u t i o n
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
Before using this product, read the RF energy awa reness information a nd operating instruction s in the
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number
6881095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site
which lists approved accessories: http://www.motorola.com/cgiss/index.shtml
Exposure booklet enclosed with your radio.
ATTENTION!
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
.
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, ASTRO, and FLASHport are registered in the US Patent & Trademark Office. All other
product or service names are the property of their respective owners.
© Motorola, Inc. 2003.
Page 5
Table of Contents iii
Table of Contents
Foreword.........................................................................................................ii
Product Safety and RF Exposure Compliance............................................................................................ii
Manual Revisions .. ....... ...... ....... ...... ....... ...... ....... ...... ............................................. ....... ..............................ii
Computer Software Copyrights ...................................................................................................................ii
Document Copyrights..................................................................................................................................ii
Disclaimer....................................................................................................................................................ii
Trademarks .................................................................................................................................................ii
Commercial Warranty .................................................................................xiii
Limited Warranty ...................................................................................................................................... xiii
MOTOROLA COMMUNICATION PRODUCTS..............................................................................xiii
I. What This Warranty Covers And For How Long ................................................................... xiii
II. General Provisions............................................................................................................... xiii
III. State Law Rights .................................................................................................................xiv
IV. How To Get Warranty Service............................................................................................xiv
V. What This Warranty Does Not Cover...................................................................................xiv
VI. Patent And Software Provisions ..........................................................................................xv
VII. Governing Law.................................................................... ....... ...... ....... ...... ....... ...............xv
Model Numbering, Cha rts, and Specificat ions............ .. ... .. ................... ..xvii
Mobile Radio Model Numbering Scheme................................................................................................ xvii
ASTRO XTL 5000 Motorcycle 3.5–35 Watt Model Chart ....................................................................... xviii
ASTRO XTL 5000 3.5–35 Watt Model Chart............................................................................................xix
700–800 MHz Radio Specifications..........................................................................................................xxi
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual...................................................................................................... 1-1
1.2 Radio Description .......................................................................................................................... 1-1
1.3 FLASHport
1.4 Control Head Descriptions............................................................................................................. 1-2
1.4.1 W3 Control Head .............................................................................................................. 1-3
1.4.2 W3 Controls......................................................................................................................1-3
1.4.3 W4, W5, W7, and W9 Controls Heads ............................................................................. 1-4
1.4.4 W4, W5, W7, and W9 Controls......................................................................................... 1-5
®
...................................................................................................................................1-2
Chapter 2 Basic Maintenance.............................................................. 2-1
2.1 Introduction....................................................................................................................................2-1
2.2 Preventive Maintenance................................................................................................................2-1
2.2.1 Inspection ......................................................................................................................... 2-1
2.2.2 Cleaning............................................................................................................................2-1
2.2.2.1 Cleaning External Plastic Surfaces..........................................................................2-1
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2.2.2.2 Cleaning Internal Circuit Boards and Components..................................................2-2
2.2.3 General Radio Care and Handling Precautions................................................................2-2
2.2.4 RF Power Amplifier (RF PA) Heatsinking .........................................................................2-2
2.3 Handling Precautions.....................................................................................................................2-2
Chapter 3 Basic Theory of Operation ................................................. 3-1
3.1 Introduction ....................................................................................................................................3-1
3.2 General Overview ..........................................................................................................................3-1
3.3 Controller Section ......... ....... ...... ....... ...... ....... ...... ............................................. ....... ...... ................3-2
3.3.1 Introduction .......................................................................................................................3-2
3.3.2 Location ............................................................................................................................3-2
3.4 Daughtercard Module ....................................................................................................................3-2
3.4.1 Microprocessor .................................................................................................................3-3
3.4.2 FLASH IC..........................................................................................................................3-3
3.4.3 SRAM IC...........................................................................................................................3-3
3.5 Surrounding Controller Region ......................................................................................................3-3
3.5.1 Introduction .......................................................................................................................3-3
3.5.2 Voltage Regulation............................................................................................................3-4
3.5.3 Emergency........................................................................................................................3-4
3.5.4 Front and Rear Connectors ..............................................................................................3-4
3.5.4.1 Audio........................................................................................................................3-5
3.5.4.2 Program Cable.........................................................................................................3-5
3.5.4.3 SB9600....................................................................................................................3-5
3.5.4.4 VIP...........................................................................................................................3-5
3.5.4.5 RS232......................................................................................................................3-5
3.5.4.6 One-Wire..................................................................................................................3-5
3.6 Analog Mode of Operation.............................................................................................................3-6
3.6.1 Receive Operation .................................. ....... ............................................. ...... ....... ...... ...3-6
3.6.2 Transmit Operation ........................... ...... ....... ...... ...... ....... ...... ....... ...... ....... ......................3-6
3.7 ASTRO Mode of Operation............................................................................................................3-6
3.8 Control Head Assembly .................................................................................................................3-6
3.8.1 Display (W4, W5, and W7 Control Heads)........................................................................3-6
3.8.2 Display (W9 Control Head) ...............................................................................................3-7
3.8.3 Vacuum Fluorescent (VF) Display Driver..........................................................................3-7
3.8.4 Vacuum Fluorescent (VF) Voltage Source (W9)...............................................................3-7
3.8.5 Controls and Indicators.....................................................................................................3-7
3.8.6 Status LEDs......................................................................................................................3-7
3.8.7 Backlight LEDs . ....... ...... ....... ...... ....... ............................................. ...... ....... ...... ....... ... ......3-7
3.8.8 Vehicle Interface Port (VIP) ..............................................................................................3-8
3.8.8.1 Remote-Mount.........................................................................................................3-8
3.8.8.2 Dash-Mount .............................................................................................................3-8
3.8.9 Control-Head Power Supplies...........................................................................................3-8
3.8.9.1 W3 Control Head .................................. ...... ...... ....... ...... ....... ...... ....... ...... ....... .........3-8
3.8.9.2 W4 Control Head .................................. ...... ...... ....... ...... ....... ...... ....... ...... ....... .........3-8
3.8.9.3 W5, W7, W9 Control Heads.....................................................................................3-8
3.8.10 Ignition Sense Circuits ......................................................................................................3-8
3.9 Radio-Frequency Power Amplifier (RF PA) and Output Network (ON) .........................................3-9
3.9.1 Gain Stages ............................................ ....... ............................................. ...... ....... .........3-9
3.9.2 Power Control ...................................................................................................................3-9
3.9.3 Circuit Protection..................................... ....... ............................................. ...... ....... .. .......3-9
3.9.4 DC Interconnect................................................................................................................3-9
3.10 700–800 Receiver Overview........................................................................................................3-10
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3.10.1 Receiver Front-End......................................................................................................... 3-10
3.10.2 Mixer............................................................................................................................... 3-10
3.10.3 IF Circuitry ... ....... ...... ....... ...... ............................................. ....... ...... ....... ...... ....... ...........3-10
3.10.4 Abacus III Back-End .......................................................................................................3-10
3.11 Frequency Generation Unit (FGU)............................................................................................... 3-11
Chapter 4 Test Equipment, Ser v ic e Aids , a nd Tools......................... 4 - 1
4.1 Recommended Test Equipment....................................................................................................4-1
4.2 Service Aids and Recommended Tools......................................................................................... 4-2
4.3 Field Programming Equipment......................................................................................................4-3
4.3.1 XTL 5000 Field Programming...........................................................................................4-3
4.3.1.1 Dash-Mounted Radios.............................................................................................4-3
4.3.1.2 Remote-Mounted Radios......................................................................................... 4-4
4.3.1.3 Field-Programming Items ................. ...... ...... .............................................. ...... ....... 4-4
4.3.1.4 W3 Control-Head Error Message ............................................................................ 4-4
Chapter 5 Per formance Checks ................. .................................... ..... 5-1
5.1 Introduction....................................................................................................................................5-1
5.2 Test Setup ..................................................................................................................................... 5-1
5.3 Test Mode...................................................................................................................................... 5-1
5.3.1 Entering Test Mode .......................................................................................................... 5-1
5.3.2 RF Test Mode............................... ...... ....... ...... ...... ....... ...... ....... ...... ....... ...... ....... ...... ....... 5-3
5.3.3 Control Head Test Mode................................................................................................... 5-4
5.4 Receiver Performance Checks...................................................................................................... 5-5
5.5 Transmitter Performance Check s....... ....... ............................................. ...... ....... ...... ....... ...... ... .... 5-6
Chapter 6 Radio Alignment Procedures............................................. 6-1
6.1 Introduction....................................................................................................................................6-1
6.2 ASTRO XTL 5000 Tuner Software ................................................................................................ 6-1
6.3 Radio Information .......................................................................................................................... 6-3
6.4 Transmitter Alignments........................................... ...... ............................................. ....... .............6-3
6.4.1 PA Bias 1 Alignment .........................................................................................................6-3
6.4.2 PA Bias 2 Alignment ......................................................................................................... 6-4
6.4.3 PA Bias 3 Alignment ......................................................................................................... 6-5
6.4.4 Reference Oscillator Alignment ........................................................................................6-6
6.4.5 Power Detector Calibration.................................... ....... ...... ....... ...... ....... ...... ....... .............6-8
6.4.6 Tx Power Characterization ............................................................................................... 6-9
6.4.7 Tx Current Limit .............................................................................................................. 6-10
6.4.8 Tx Deviation Balance (Compensation) ...........................................................................6-12
6.4.9 Tx Deviation Limit ........................................................................................................... 6-14
6.5 Performance Testing ................................................................................................................... 6-16
6.5.1 Bit Error Rate (BER) Test............................................................................................... 6-16
6.5.2 Transmitter Test Pattern............... ...... ....... ...... ...... ....... ...... ............................................ 6-17
6.6 Mic Sensitivity Calibration............................................................................................................6-18
Chapter 7 Encryption ........................................................................... 7-1
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7.1 Universal Crypto Module Kits.........................................................................................................7-1
7.1.1 Secure Interface Boards ................................ ............................................. ...... ....... ...... ...7-1
7.1.2 Secure Dispatch Operation.. ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................................7-1
7.1.3 Secure Emergency Operation.............................. ............................................. ....... ...... ...7-2
7.2 Load an Encryption Key.................................................................................................................7-2
7.2.1 W3 Control Head .......... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................................7-2
7.2.2 W4, W5, W7, and W9 Control Heads ...............................................................................7-3
7.3 Advanced Secure Operation..........................................................................................................7-3
7.3.1 Multikey Operation............................................................................................................7-3
7.4 Erase a Key ...................................................................................................................................7-3
7.4.1 W3 Control Head .......... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................................7-4
7.4.2 W4, W5, W7, and W9 Control Heads ...............................................................................7-5
7.5 Erase a Single Key (W3 Control Head) .........................................................................................7-6
7.6 Erase All Keys................................................................................................................................7-6
7.6.1 W3 Control Head .......... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................................7-6
7.6.2 W4, W5, W7, and W9 Control Heads ...............................................................................7-7
7.7 Over-the-Air Rekeying ...................................................................................................................7-7
7.7.1 W3 Control Head .......... ....... ...... ....... ...... ....... ...... ...... ....... ...... ....... ...................................7-8
7.7.2 W4, W5, W7, and W9 Control Heads ...............................................................................7-9
Chapter 8 Disassembly/Reassembly Procedures.............................8-1
8.1 Introduction ....................................................................................................................................8-1
8.2 Replacement Procedures ..............................................................................................................8-1
8.2.1 Required Tools and Supplies............................................................................................8-1
8.2.2 Control Head Boards Disassembly/Reassembly ..............................................................8-2
8.2.2.1 W3 Disassembly............................ ....... ...... ...... .............................................. ...... ...8-2
8.2.2.2 W3 Reassembly... ....... ............................................. ...... ....... ...... ....... ...... ................8 -3
8.2.2.3 W4, W5, and W7 Disassembly ................................................................................8-4
8.2.2.4 W4, W5, and W7 Reassembly.................................................................................8-5
8.2.2.5 W9 Disassembly............................ ....... ...... ...... .............................................. ...... ...8-6
8.2.2.6 W9 Reassembly... ....... ............................................. ...... ....... ...... ....... ...... ................8 -6
8.2.3 Remote Back Housing Interface Board Disassembly/Reassembly ..................................8-7
8.2.3.1 W4, W5, and W7 Disassembly ................................................................................8-7
8.2.3.2 W4, W5, and W7 Reassembly.................................................................................8-7
8.2.4 Remote Interconnect Board Assembly/Reassembly.........................................................8-7
8.2.4.1 Assembly .................................................................................................................8-7
8.2.4.2 Reassembly.............................................................................................................8-8
8.2.5 Radio Disassembly ...........................................................................................................8-8
8.2.6 Radio Reassembly..........................................................................................................8-19
8.3 Chassis Thermal Pad Replacement Procedure...........................................................................8-30
8.4 Fastener Torque Chart.................................................................................................................8-32
Chapter 9 Basic Troubleshooting....................................................... 9-1
9.1 Introduction ....................................................................................................................................9-1
9.1.1 J2 Accessory Connector................... ...... ....... ...... ...... ....... ...... ....... ...... .............................9-1
9.1.2 I/O Disclaimer ...................................................................................................................9-3
9.1.3 Microphone Bias ...............................................................................................................9-4
9.1.4 Audio PA Out Bias ............................................................................................................9-5
9.1.5 High Power RF Precaution ...............................................................................................9-5
9.2 Replacement Board Procedures....................................................................................................9-5
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9.3 Power-Up Error Codes .................................................................................................................. 9-5
9.4 Operational Error Codes................................................................................................................ 9-7
9.5 Transmitter Troubleshootin g.. ....... ...... ....... ...... ....... ...... ............................................. ....... .............9-7
9.6 Receiver Troubleshooting.............................................................................................................. 9-8
Chapter 10 Functional Block Diagrams and Connectors ................. 10-1
10.1 XTL 5000 Functional Block Diagram ...........................................................................................10-2
10.2 Radio Connectors........................................................................................................................ 10-3
10.3 Radio Connector Locations .........................................................................................................10-4
10.4 Radio Connector Locations (cont.) .............................................................................................. 10-4
10.5 Control Head Cabling Diagram....................................................................................................10-5
10.6 Control Head Connector.............................................................................................................. 10-6
10.7 Connector Naming Schemes....................................................................................................... 10-7
Chapter 11 Exploded Views and Parts Lists...................................... 11-1
11.1 W3 Hand-Held Control Head Exploded View .............................................................................. 11-2
11.2 W4 Rotary Control Head Exploded View.....................................................................................11-3
11.3 W5 and W7 Pushbutton Control Head Exploded View................................................................11-4
11.4 W9 Pushbutton Control Head Exploded View ............................................................................. 11-5
11.5 XTL 5000 (3.5-35 W) Radio Exploded View................................................................................11-6
11.6 Motorcycle Interconnect Board and Assembly ............................................................................ 11-7
11.7 Interconnect Board and Assembly............................................................................................... 11-7
11.8 Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone ......................... 11-8
11.9 Handlebar Installation (Control Head and Speaker Mounted Together....................................... 11-9
11.10 Handlebar Installation (Control Head and Speaker Mounted Separately)................................... 11-9
11.11 Fuel-Tank Console Installation (Control Head and Speaker Mounted Together)...................... 11-10
11.12 Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately)................... 11-10
11.13 HMN1062_ Motorcycle Microphone .......................................................................................... 11-11
11.14 HSN6003_ Motorcycle Weather-Resistant Speaker.................................................................. 11-11
11.15 Motorcycle Weather-Resistant Radio Enclosure .......................................................................11-12
11.16 Motorcycle Universal Mounting Plate ........................................................................................11-13
11.17 Small Pushbutton Parts .............................................................................................................11-13
11.18 Large Pushbutton Parts.............................................................................................................11-13
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.4 Telephone Orders..........................................................................................................................A-1
A.5 Fax Orders.....................................................................................................................................A-2
A.6 Parts Identification .........................................................................................................................A-2
A.7 Product Customer Service............ ...... ....... ...... ....... ...... ...... ....... ........................................... .........A-2
Appendix B Environmental Information ................................................B-1
Glossary.........................................................................................Glossary-1
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Index......................................................................................................Index-i
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List of Figures ix
List of Figures
Figure 1-1. Mobile Radio Model Numbering Scheme ............................................................................. xvii
Figure 1-1. W3 Hand-Held Control Head................................................................................................ 1-3
Figure 1-2. Typical W4 Rotary Control Head...........................................................................................1-4
Figure 1-3. Typical W5 Limited Keypad Control Head ............................................................................ 1-4
Figure 1-4. Typical W7 Full Keypad Control Head ..................................................................................1-4
Figure 1-5. Typical W9 Full Keypad Control Head ..................................................................................1-5
Figure 3-1. Controller Sections................................................................................................................ 3-2
Figure 3-2. Frequency Generation Unit Diagram .................................................................................. 3-11
Figure 5-1. Performance Checks Test Setup ..........................................................................................5-1
Figure 5-2. W4 Control-Head Key-Closure Displays............................................................................... 5-4
Figure 5-3. W5 and W7 Control-Head Key-Closure Displays ................................................................. 5-5
Figure 5-4. W9 Control-Head Key-Closure Displays............................................................................... 5-5
Figure 6-1. Radio Alignment Test Setup.................................................................................................. 6-1
Figure 6-2. Tuner Main Menu.................................................................................................................. 6-2
Figure 6-3. Radio Information Screen.....................................................................................................6-3
Figure 6-4. PA Bias 1 Alignment Screen................................................................................................. 6-4
Figure 6-5. PA Bias 2 Alignment Screen................................................................................................. 6-5
Figure 6-6. PA Bias 3 Alignment Screen................................................................................................. 6-6
Figure 6-7. Reference Oscillator Window................................................................................................ 6-7
Figure 6-8. Power Detection Calibration Alignment Screen....................................................................6-8
Figure 6-9. Tx Power Characterization Alignment Screen...................................................................... 6-9
Figure 6-10. Tx Current Limit Alignment Screen..................................................................................... 6-11
Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen.................................................. 6-13
Figure 6-12. Tx Deviation Limit Alignment Screen.................................................................................. 6-15
Figure 6-13. Bit Error Rate Screen..........................................................................................................6-16
Figure 6-14. Transmitter Test Pattern Screen .......................... ............................................. ....... ...........6-17
Figure 6-15. Mic Sensitivity Calibration Screen....................................................................................... 6-18
Figure 8-1. W4 Rotary Control-Head Assembly Screw and Snap Sequence ......................................... 8-4
Figure 8-2. W5 and W7 Pushbutton Control-Head Assembly Screw Sequence..................................... 8-5
Figure 8-3. Removing the Front Panel Screws ....................................................................................... 8-8
Figure 8-4. Removing the Control Head.................................................................................................. 8-9
Figure 8-5. Removing the Flex (Control-Head Connector)...................................................................... 8-9
Figure 8-6. Removing the Headbridge.................................................................................................. 8-10
Figure 8-7. Removing the Flex (Main-Board Connector) ...................................................................... 8-10
Figure 8-8. Control-Head Flex (Removed)............................................................................................ 8-11
Figure 8-9. Headbridge Seal (Removed) .............................................................................................. 8-11
Figure 8-10. Removing the Secure Interface Board................................................................................8-12
Figure 8-11. Removing the Top Cover Screws........................................................................................ 8-13
Figure 8-12. Lifting the Top Cover...........................................................................................................8-13
Figure 8-13. Removing the Top Cover.................................................................................................... 8-14
Figure 8-14. Removing the J2 Rear Accessory Flex from the Main Board............................................. 8-14
Figure 8-15. Removing the PA Screws ................................................................................................... 8-15
Figure 8-16. Removing the RF/DC Retention Clip (J2 Connector Side)................................................. 8-16
Figure 8-17. Removing the RF/DC Retention Clip (Antenna Connector Side)........................................ 8-16
Figure 8-18. Pushing Up the Main Board................................................................................................8-17
Figure 8-19. Lifting Out the Main Board.................................................................................................. 8-17
Figure 8-20. Removing the J2 Rear Accessory Connector..................................................................... 8-18
Figure 8-21. Inspecting the Chassis Shield Gasketing and Thermal Pads............................................. 8-19
Figure 8-22. Inserting the J2 Rear Accessory Connector .......................................................................8-20
Figure 8-23. Inserting the Main Board into the Chassis .......................................................................... 8-21
6881096C73-O June 11, 2003
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x List of Figures
Figure 8-24. Inserting the RF/DC Retention Clip (DC Side)....................................................................8-22
Figure 8-25. Inserting the RF/DC Retention Clip (RF Side) ....................................................................8-22
Figure 8-26. Connecting the J2 Rear Accessory Connector Flex to the Main Board..............................8-23
Figure 8-27. Installing the PA Screws......................................................................................................8-24
Figure 8-28. Inspecting the Thermal Pad and Installing the Cover Main Seal ........................................8-24
Figure 8-29. Preparing to Place the T op Cover on the Chassis ..............................................................8-25
Figure 8-30. Securing the Top Cover to the Chassis...............................................................................8-25
Figure 8-31. Installing the Secure Interface Board..................................................................................8-26
Figure 8-32. Installing the Headbridge Seal............................................................................................8-27
Figure 8-33. Installing the Control-Head Flex in the Transceiver ............................................................8-27
Figure 8-34. Installing the Headbridge on the Transceiver......................................................................8-28
Figure 8-35. Installing the Control-Head Flex on the Control Head.........................................................8-28
Figure 8-36. Inserting the Control Head Into the Transceiver .................................................................8-29
Figure 8-37. Installing the Control-Head Screws.....................................................................................8-29
Figure 8-38. Chassis Thermal Pad Locations .........................................................................................8-30
Figure 9-1. J2 Accessory Connector Pin-Out Arrangement ....................................................................9-1
Figure 10-1. ASTRO XTL 5000 Functional Block Diagram .....................................................................10-2
Figure 10-2. J0103 Remote-Mount Control Head Connector..................................................................10-3
Figure 10-3. J5 Control Cable for Remote-Mount Control Head .............................................................10-3
Figure 10-4. J6 Radio Operations Connector..........................................................................................10-3
Figure 10-5. J3 Remote-Control Cable Accessory Connector ................................................................10-3
Figure 10-6. J2 Rear Accessory Connector ............................................................................................10-3
Figure 10-7. P104 Microphone Jack .......................................................................................................10-3
Figure 10-8. Dash-Mount Radio Connector Locations ............................................................................10-4
Figure 10-9. Remote-Mount Radio Connector Locations.......................................................................10-4
Figure 10-10.Main Board Connector Locations - Side 1..........................................................................10-4
Figure 10-11.Main Board Connector Locations - Side 2 .........................................................................10-4
Figure 10-12.Control Head Cabling Diagram ..........................................................................................10-5
Figure 10-13.Control Head 50-pin Connector .........................................................................................10-6
Figure 10-14.XTL 5000 Radio Connector Naming Scheme....................................................................10-7
Figure 11-1. W3 Hand-Held Control Head Exploded View...................................................................... 11-2
Figure 11-2. W4 Rotary Control Head Exploded View............................................................................ 11-3
Figure 11-3. W5 and W7 Pushbutton Control Head Exploded View....................................................... 11-4
Figure 11-4. W9 Pushbutton Control Head Exploded View..................................................................... 11-5
Figure 11-5. XTL 5000 (3.5-35 W) Radio Exploded View .......................................................................11-6
Figure 11-6. Motorcycle Interconnect Board and Assembly Exploded View........................................... 11-7
Figure 11-7. Interconnect Board and Assembly Exploded View ............................................................. 11-7
Figure 11-8. Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone................. 11-8
Figure 11-9. Handlebar Installation (Control Head and Speaker Mounted Together) Exploded View..... 11-9
Figure 11-10.Handlebar Installation (Control Head and Speaker Mounted Separately) Exploded View. 11-9
Figure 11-11.Fuel-Tank Console Installation (Control Head and Speaker Mounted Together) Exploded
View ..................................................................................................................................11-10
Figure 11-12.Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately) Exploded
View ..................................................................................................................................11-10
Figure 11-13.HMN1062_ Motorcycle Microphone..................................................................................11-11
Figure 11-14.HSN6003_ Motorcycle Weather-Resistant Speaker .........................................................11-11
Figure 11-15.Motorcycle Weather-Resistant Radio Enclosure.............................................................. 11-12
Figure 11-16.Motorcycle Universal Mounting Plate Exploded View ...................................................... 11-13
June 11, 2003 6881096C73-O
Page 13
List of Tables xi
List of Tables
Table 1-1. Control Head Basic Features................................................................................................ 1-2
Table 4-1. Recommended Motorola Test Equipment.............................................................................4-1
Table 4-2. Wattmeter Plug-In Elements................................................................................................. 4-1
Table 4-3. Recommended Non-Motorola Test Equipment..................................................................... 4-2
Table 4-4. Service Aids for XTL 5000 Board-Level Troubleshooting.....................................................4-2
Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting......................................... 4-3
Table 4-6. Recommended Non-Motorola Tools for Board-Level Troubleshooting.................................4-3
Table 4-7. XTL 5000 Radio Field-Programming Items...........................................................................4-4
Table 5-1. T est-Mode Displays ..............................................................................................................5-2
Table 5-2. T est Frequencies .................................................................................................................. 5-3
Table 5-3. Signaling Types .................................................................................................................... 5-4
Table 5-4. Receiver Performance Checks.............................................................................................5-5
Table 5-5. Transmitter Performance Checks .........................................................................................5-6
Table 6-1. PA Bias 1 Alignment RF Power Amplifier Devices................................................................6-3
Table 6-2. Power Supply Voltage Settings.............................................................................................6-3
Table 6-3. PA Bias 1 Alignment Device Bias Current ............................................................................6-4
Table 6-4. PA Bias 2 Alignment Amplifier Devices.................................................................................6-4
Table 6-5. Power Supply Voltage Settings.............................................................................................6-4
Table 6-6. PA Bias 2 Alignment Device Bias Current ............................................................................6-5
Table 6-7. PA Bias 3 Alignment Amplifier Devices.................................................................................6-5
Table 6-8. Power Supply Voltage Settings.............................................................................................6-5
Table 6-9. PA Bias 3 Alignment Device Bias Current ............................................................................6-6
Table 6-10. Reference Oscillator Alignment ............................................................................................6-8
Table 6-11. Power Supply Voltage Settings.............................................................................................6-8
Table 6-12. Power Supply Voltage Settings............................................................................................. 6-9
Table 6-13. Power Supply Voltage Settings........................................................................................... 6-10
Table 6-14. Transmit Current Limit Offset.............................................................................................. 6-11
Table 6-15. Transmit Current Limit Devices........................................................................................... 6-12
Table 6-16. Bit Error Rate Test Fields....................................................................................................6-16
Table 6-17. Transmitter Test Pattern Fields........................................................................................... 6-17
Table 7-1. UCM Kit Listing.....................................................................................................................7-1
Table 7-2. Secure Interface Board Kits..................................................................................................7-1
Table 8-1. Required Tools and Supplies................................................................................................ 8-1
Table 8-2. Chassis Thermal Pad Parts................................................................................................8-30
Table 8-3. Fastener Torque Chart........................................................................................................ 8-32
Table 9-1. J2 Accessory Connector Signal and Voltage Descriptions................................................... 9-1
Table 9-2. Normal Operation Range and ESD Clamping Voltages........................................................9-3
Table 9-3. Power-Up Error Codes..........................................................................................................9-5
Table 9-4. Operational Error Codes....................................................................................................... 9-7
Table 9-5. Transmitter Troubleshooting Chart .......................................................................................9-7
Table 9-6. Receiver Troubleshooting Chart ...........................................................................................9-8
Table 10-1. Table of Functional Block Diagrams and Connectors......................................................... 10-1
Table 11-1. Table of Exploded Views ....................................................................................................11-1
Table 11-2. W3 Hand-Held Control Head Exploded View Parts List ..................................................... 11-2
Table 11-3. W4 Rotary Control Head Parts List..................................................................................... 11-3
Table 11-4. W5 and W7 Pushbutton Control Head Parts List................................................................ 11-4
Table 11-5. W9 Pushbutton Control Head Parts List ............................................................................ 1 1-5
Table 11-6. XTL 5000 (3.5-35W) Radio Parts List................................................................................. 11-6
Table 11-7. Motorcycle Interconnect Board and Assembly Parts List.................................................... 11-7
Table 11-8. Interconnect Board and Assembly Parts List...................................................................... 11-7
Table 11-9. Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone Parts List. 11-8
Table 11-10. Handlebar Installation (Control Head and Speaker Mounted Together) Parts List ............. 11-9
Table 11-11. Handlebar Installation (Control Head and Speaker Mounted Separately) Parts List .......... 11-9
Table 11-12. Fuel-T ank Console Installation (Control Head and Speaker Mounted Together)
Parts List........................................................................................................................... 11-10
6881096C73-O June 11, 2003
Page 14
xii Related Publications
Table 11-13. Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately)
Parts List........................................................................................................................... 11-10
Table 11-14. HMN1062_ Motorcycle Microphone Parts List...................................................................11-11
Table 11-15. HSN6003_ Motorcycle Weather-Resistant Speaker Parts List ..........................................11-11
Table 11-16. Motorcycle Weather-Resistant Radio Enclosure Parts List (Enclosure Parts).................. 11-12
Table 11-17. Motorcycle Weather-Resistant Radio Enclosure Parts List (Mounting Parts) ................... 11-12
Table 11-18. Motorcycle Universal Mounting Plate Parts List................................................................ 11-13
Table 11-19. Small Pushbutton Parts List.............................................................................................. 11-13
Table 11-20. Large Pushbutton Parts List.............................................................................................. 11 -13
Related Publications
ASTRO XTL 5000 Digital Mobile Radio with W3 Control Head User’s Guide .............................6881096C67
ASTRO XTL 5000 Digital Mobile Radio with W4, W5, W7,and W9 Control Heads User’s
Guide ...........................................................................................................................................6881096C68
ASTRO XTL 5000 Digital Mobile Radio Installation Manual........................................................6881096C72
ASTRO XTL 5000 Digital Mobile Radio Detailed Service Manual...............................................6818096C74
CPS Programming Installation Guide ..........................................................................................6881095C44
KVL 3000 User’s Manual............................................................................................................. 6881131E16
June 11, 2003 6881096C73-O
Page 15
Commercial Warranty xiii
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 5 000 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 WARRANTY 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.
6881096C73-O June 11, 2003
Page 16
xiv Commercial Warranty
III. St a te Law Rig hts
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENT AL 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
Product, 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.
June 11, 2003 6881096C73-O
Page 17
Commercial Warranty xv
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.
6881096C73-O June 11, 2003
Page 18
xvi Commercial Warranty
Notes
June 11, 2003 6881096C73-O
Page 19
Model Numbering, Charts, and Specifications xvii
Model Numbering, Charts, and Specifications
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
J
136 to 162MHz
=
K
146 to 178MHz
=
L
174 to 210MHz
=
M
190 to 235MHz
=
* 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
Figure 1-1. Mobile Radio Model Numbering Scheme
6881096C73-O June 11, 2003
Page 20
June 12, 2003 6881096C73-O
xviii Model Numbering, Charts, and Specifications
ASTRO XTL 5000 Motorcycle 3.5–35 Watt Model Chart
M20URS9PW1AN 764–870 MHz
Option Description
G67AD ADD: Remote Control Microphone W4, W5, W7
G67AF ADD: Remote Mount No Control Head Needed
G82AA ADD: Motorcycle W4 Control Head
G83AA ADD: Motorcycle W5 Control Head
G84AA ADD: Motorcycle W7 Control Head
B977DV ADD: Control Hdw7 G48AN and G806AF
B977EB INT: Control Head W4 Std Button
B977EC INT: Control Head W5 Std Button
B977ED INT: Control Head W7 Std Button
G239AR INT: Secure Button W7
G239AM INT: Secure Button W4
G239AN INT: Secure Button W5
G239AP INT: Secure Button W7 G50/51
G159AC ADD: Encryption UCM Hardware
G159AD ADD: Encryption UCM HW 30-Sec Key Ret
W22AT ADD: Motorcycle Palm Microphone
W15AG ADD: Black Weather Resistant Enclosure
G151AA ADD: White Weather Resistant Enclosure
B18CM ADD: Auxiliary Speaker Spec Motorcycle
G335AU ADD: Ant 3 dB Motorcycle 764-870 MHz
Item No. Description
XXX HLN6863_ Accessory Connector
X
HUF4017_ 700-800 MHz Main Board
X
HHN4045_ 700-800 MHz Transceiver Hardware
XX
HLN6861_ Hardware Standard Install
XX
HLN6884_ Motorcycle Interconnect Board
X
HKN6062_ Motorcycle Control Head Cable 8’
XX HLN6865_ Remote-Mount Control Head Hardware
XX
HLN6125_ Hardware Housing Front Remote
X HKN6032_ Power Cable
X
HLN6216_ Motorcycle Hdw Spare Control Head
X PMLN4019_ W4 Motorcycle Control Head
XX HLN6105_ Spare Button Kit
XX HLN6688_ Spare Button Kit
X HLN6444_ W5 Motorcycle Control Head
X HLN6445_ W7 Motorcycle Control Head
X HLN6549_ W4 Standard Button Map
X X HLN6548_ W5 Standard Button Map
X X X HLN6523_ W7 Standard Button Map
X X HLN6524_ W7 Secure Button Map
X HLN6249_ W4 Secure Button Map
X HLN6208_ W5 Secure Button Map
X HLN6876_ Secure Interface Board 30-Day Key Ret
X HLN6877_ Secure Interface Board 30-Sec Key Ret
X HMN1079_ Motorcycle Palm Microphone
X HSN6003_ Motorcycle Water Resistant Speaker
X HAF4015_ Antenna 3 dB Motorcycle 764-870 MHz
X HAF4018_ Antenna 3 dB Low-Profile 764-870 MHz
X HHN6001_ W hite Enclosure
X HHN6002_ Black Enclosure
X X HLN6889_ Motorcycle Hardware
XXX HLN6179_ Control Head/Speaker Adapter Kit
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
Page 21
Model Numbering, Charts, and Specifications xix
ASTRO XTL 5000 3.5–35 Watt Model Chart
M20URS9PW1AN 764–870 MHz
Option Description
G66AA ADD: Dash Mount W4, W5, W7
G66AB ADD: Dash Mount W3
G66AC ADD: Dash Mount No Control Head Needed
G67AA ADD: Remote Mount W4, W5, W7
G67AB ADD: Remote Mount W9
G67AC ADD: Remote Mount W3
G67AE ADD: Remote Mount No Control Head
G72AA ADD: W3 Handheld Control Head
G73AA ADD: W4 Control Head
G79AA ADD: W5 Control Head
G80AA ADD: W7 Control Head
G81AA ADD: W9 Control Head
B977DU ADD: Control Head W9 Hdw
B977DV ADD: Control Head W7 G48AN and G806AF
B977DZ ADD: Control Head W9 G48AN and G806AF
B977EB INT: Control Head W4 Std Button
B977EC INT: Control Head W5 Std Button
B977ED INT: Control Head W7 Std Button
G239AR INT: Secure Button W7
G239AD INT: Secure Button W9
Item No. Description
X HUF4017_ 700-800 MHz Main Board
X
XXXXXXX HLN6861_ Hardware Standard Install
XX
XXXXX HLN6863_ Accessory Connector
X HLN6864_ Control Head Dash Interconnect
X
XXX HKN4191_ Mobile Power Cable
XXXX HLN6185_ Hardware Remote CH
X
XXXX HLN6865_ Remote-Mount Control Head Hardware
X
X
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
X HLN6885_ Handheld CH Interconnect Board
XX X HLN6883_ Remote Interconnect Board
X HLN6813_ Control Head Trunnion Kit
X HLN6432_ Back Housing Kit
XXXX HKN4192_ Mobile Power Cable 20 ft.
X HLN4921_ Trunnion
X HMN4044_ Handheld Control Head
X AAMN4045_ W4 Control Head
XXX HLN6105_ Spare Button Kit
XXX HLN6688_ Spare Button Kit
X HLN6440_ W5 Control Head
XX HLN6396_ CH DEK Compatible
X HLN6441_ W7 Control Head
X HCN1078_ W9 Control Head (Black)
X HLN6481_ W9 Clear Button Kit
X HLN6476_ W9 Secure Button Kit
X HLN6549_ W4 Standard Button Map
X HLN6548_ W5 Standard Button Map
X HLN6523_ W7 Standard Button Map (Also see next page)
X X HLN6524_ W7 Secure Button Map
HHN4045_ 700-800 MHz Transceiver Hardware
X HLN6800_ W9 Secure Button Kit
6881096C73-O June 11, 2003
Page 22
xx Model Numbering, Charts, a nd Specifications
ASTRO XTL 5000 3.5–35 Watt Model Chart (cont.)
M20URS9PW1AN 764–870 MHz
Option Description
G239AM INT: Secure Button W4
G239AN INT: Secure Button W5
G239AP INT: Secure Button W7 G50/51
G239AQ INT: Secure Button W9 G50/51
G159AC ADD: Encryption UCM Hardware
G159AD ADD: Encryption UCM Hdw 30 Sec Key Ret
W382AG ALT: Control Station Palm Microphone
W665BE ADD: Control Station Operation
G91AA ADD: Control Station Power Supply
W22AR ADD: W9 Palm Microphone
W22AS ADD: Hand Microphone
W109CS ALT: Microphone Handset with Hangup Cup
G110AB INT: 17 ft Control Head Cable W4, W5, W7, W9
G110AC INT: W3 Remote Y Cable
B18CL ADD: Auxiliary Spkr Spectra 5 Watt
W432AE ENH: 10 Watt Audio (Standard on High Power)
W484AD ADD: Antenna 3 dB Gain (764-870 MHz)
G335AT ADD: Antenna 1/4 Wave 764-870 MHz
G174AA ADD: Antenna 3 dB Low-Profile 764-870 MHz
G175AA ADD: Antenna 3 dB Elevat Feed 764-870 MHz
Item No. Description
X HLN6249_ W4 Secure Button Map
X
X HLN6523_ W7 Standard Button Map (Also see prev. pg)
X HLN6675_ W9 Secure Button Map
X HMN1050_ Control Station Microphone
X HLN6876_ Secure Interface Board 3 Day Key Retention
X HLN6877_ Secure Interface Board 30 Sec Key Retention
X HLN6042_ Base Tray
X HLN6047_ BDW Installation Base Tray
X HPN4001_ Control Station Power Supply
X HMN1061_ W9 Palm Microphone
X HMN1080_ Standard Palm Microphone W4, W5, W7
X HLN1220_ Microphone Handset with Hangup Clip
X HKN4356_ Standard 17 ft Control Head Remote Cable
X HKN6096_ Handheld Control Head Y Cable
X HSN4018_ Speaker 5 Watt
X HSN6001_ Speaker 10 Watt
X HAF4017_ Antenna 3 dB Gain 762-870 MHz
X HAF4016_ Antenna 1/4 Wave 762-870 MHz
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
HLN6208_ W5 Secure Button Map
X HAF4013_ Antenna 3 dB Low Profile 762-870 MHz
X HAF4014_ Antenna 3 dB Elevated Feed 762-870 MHz
June 11, 2003 6881096C73-O
Page 23
Model Numbering, Charts, and Specifications xxi
700–800 MHz Radio Specifications
GENERAL RECEIVER TRANSMITTER
FCC Designations: AZ492FT5823 Frequency Range: Frequency Range:
Temperature Range: 800 MHz Band: 851–870 MHz Repeater Mode: 794–806 MHz
Operating: –30° C to +60° C Talkaround Mode: 764–776 MHz
Storage: –40° C to +85° C Channel Spacing: 12.5 kHz/20 kHz/25 kHz 800 MHz Band:
Power Supply: 12 Vdc Negative Ground Only Input Impedance: 50 ohm Talkaround Mode: 851–870 MHz
Battery Drain: (Maximum) Frequency Separation: Full Bandsplit Rated Output Powe r:
35 W: 764–806 MHz Band: 2***/30 W
Standby @ 13.8V: 0.7 A Sensitivity: 806–870 MHz Band : 35 W
Receive at Rated Audio @ 13.8 V: 3.0 A 20 dB Quieting:
Transmit @ Rated Power: 25 kHz Channel Spacing: 0.30 µV Channel Spacing: 12.5 kHz/20 kHz/25 kHz
35 W 12.0 A 12 dB SINAD:
Dimensions (H x W x D)
W4, W5, and W7 Models: Digital Sensitivity**: Frequency Separation: Full Bandsplit
Remote-Mount Control Head: 2.0" x 7.1"x 2.2" 1% BER (12.5 kHz channel): 0.30 µV
(50.8 mm x 180.3 mm x 55.9 mm) 5% BER (12.5 kHz channel): 0.25 µV Frequency Stability*:
Dash-Mount Radio: 2.0" x 7.1"x 9.1" (–30° to +60°C; 25°C Ref.): ±0.00015%
(50.8 mm x 180.3 mm x 231.1 mm) Adjacent Channel Selectivity*:
W9 Model: 25 kHz Channel: 80 dB Modulation Limiting*:
Remote-Mount Control Head: 3.4" x 6.5"x 1.7" 12.5 kHz Channel: 65 dB 25 kHz Channel Spacing: ±5.0 kHz
(86.4 mm x 165.0 mm x 43.2 mm) 12.5 kHz Channel Spacing: ±2.5 kHz
Speaker: (excluding mounting bracket) Intermodulation*: 80 dB
5.5" x 5.5"x 2.5" Modulation Fidelity (C4FM)**:
(139.7 mm x 139.7 mm x 63.5 mm) Spurious Rejection*: 90 dB 12.5 kHz Digital Channel: ±2.8 kHz
Weight: Frequency Stability*: FM Hum and Noise*:
Radio: 6.1 lbs (2.8 kg) (–30° to +60° C; 25° C Ref.): ±0.00015% 20/25 kHz Channel: –40 dB
Speaker: 1.5 lbs (0.7 kg) 12.5kHz Channel: –34 dB
700 MHz Band: 764–776 MHz 700 MHz Band:
Repeater Mode: 806–825 MHz
25 kHz Channel Spacing: 0.25 µV Output Impeda nc e: 50 ohm
Audio Output a t 3% Distortion*:
7.5 Watts into 8 Ohms Emission (Conducted and Radiated):
13 Watts into 3.2 Ohms –70 dBc/–85 dBc (GNSS)
Audio Sensitivity*:
(For 60% Max. Deviation at 1 kHz):
Audio Respon se*:
(6 dB/Octave Pre-Emphasis 300 to 3000 Hz):
Audio Distortion*: 2%
Emissions Designators:
8K10F1D, 8K10F1E, 11K0F3E, 16K0F3E, and
20K0F1E
0.08 V ±3 dB
+1,–3 dB
Specifications subject to change without notice.
* Measured in analog mode per TIA/EIA 603 under nominal conditions.
** Measured in digital mode per TIA/EIA IS 102.CAAB.
*** 2 W. itinerant frequencies.
6881096C73-O June 11, 2003
Page 24
xxii Model Numbering, Charts, and Specifications
Notes
June 11, 2003 6881096C73-O
Page 25
Chapter 1 Introduction
1.1 Notati o ns Used in This Manual
Throughout the text in this publication, you will notice the use of note, caution, warning, and danger
notations. These notations are used to emphasize that safety hazards exist, and due care must be
taken and observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.
!
C a u t i o n
!
!
W A R N I N G
!
D A N G E R
CAUTION indicates a potentially hazardous situation which, if
not avoided, might
WARNING indicates a potentially hazardous situation
which, if not avoided, could
DANGER indicates an imminently hazardous
situation which, if not avoided, wi ll
injury.
1.2 Radio Description
The ASTRO XTL 5000 digital mobile radio is Motorola’s newest two-way mobile radio designed for
your organization’s most demanding needs. The XTL 5000 Mobile is available in the 764–870 MHz
frequency band with 3.5–35 W variable power (2 W itinerant).
result in equipment damage.
result in death or injury.
result in death or
The ASTRO XTL 5000 radios are among the most sophisticated two-way radios available. They
have a new robust design for radio users who need high performance, quality, and reliability in their
daily communications. This new architecture provides the capability of supporting a multitude of
legacy and advanced features resulting in a more cost-effective two-way radio communications
solution.
Page 26
1-2 Introduction: FLASHport
The ASTRO XTL 5000 radios are available with five control heads. Table 1-1 provides a description
of basic features for these control heads.
Table 1-1. Control Head Basic Features
Feature W3 W4 W5 W7 W9
®
Display 2 line/14
characters
Liquid-Crystal
Display (LCD)
with 8 Status
Annunciators
Control Type Rocker Switches Rotary Mode and
Numeric
Keypad
Channel
Capability
Remote Mount Available Available Available Available Available
Dash Mount Available Available Available Available Not Available
Dual Control
Head
Motorcycle Not Available Available Available Available Not Available
1.3 FLASHport
YesNoNoYesYes
512 512 512 512 512
Not Available Available Available Available Available
®
1 line/8
characters
Vacuum
Fluorescent
Display
Volume Controls
1 line/8
characters
Vacuum
Fluorescent
Display
Rocker Switch
Mode and
Volume Controls
1 line/8
characters
Vacuum
Fluorescent
Display
Rocker Switch
Mode and
Volume Controls
1 line/11
characters
Vacuum
Fluorescent
Display
Rocker Switch
Mode and
Volume Controls
All ASTRO XTL 5000 digital mobile radios are part of the FLASHport program and ship standard with
a FLASH EE Prom, which allows for feature and system upgrades. FLASHPort Aftermarket Software
is used to upgrade to the latest version of your System Enhancement Software Package, to upgrade
to a different System Enhancement Software Package, or to order enhancements for existing
ASTRO XTL 5000 digital radios in the field.
1.4 Control Head Descriptions
The control heads used with XTL 5000 radios have microprocessor circuitry that operates the
standard and optional features built into the system.
The following illustrations show some typical ASTRO XTL 5000 control heads.
June 11, 2003 6881096C73-O
Page 27
Introduction: Control Head Descriptions 1-3
1.4.1 W3 Control Head
On/Off
Button
(T1)
Push-To-Talk
(PTT) Button
Volume
Control
Orange Programmable
Button
(T2)
HOME
MODE
VOL
2
ABC
1
QZ
4
GHI
7
PRS
3
DEF
5
JKL
6
MNO
8
TUV
9
WXY
0
Figure 1-1. W3 Hand-Held Control Head
Programmable
Button
(T3)
LED
Indicator
Display
Side Button 1 (S1)
Side Button 2 (S2)
Side Button 3 (S3)
Mode Control
Alphanumeric
Keypad
MAEPF-27650-O
1.4.2 W3 Controls
• On/Off Button (T1) — Turns the radio on and off.
• Orange Programmable Button (T2) — Programmed at the factory for emergency. Fieldprogrammable by a qualified radio technician.
• Programmab le Bu tton (T3 ) — Field-programmable by a qualified radio technician.
• LED Indicator — Gree n/r ed li ght-emitting diode indicates ope ratin g status.
•Display — Two-line x 14-character display provides visual information about many radio
features.
•Keypad — Provides control of, and data interface with, many features.
• Programmable Side Button 1 (S1) — Field-programmable by a qualified radio technician.
• Programmable Side Button 2 (S2) — Field-programmable by a qualified radio technician.
• Programmable Side Button 3 (S3) — Field-programmable by a qualified radio technician.
• Mode Control — Is used for selecting modes and programming menus.
• Volume Control — Is used for selecting the volume level, editing names, and making certain
radio adjustments.
• Push-To-Talk (PTT) Button — Engages the transmitter.
6881096C73-O June 11, 2003
Page 28
1-4 Introduction: Control Head Descriptions
1.4.3 W4, W5, W7, and W9 Controls Heads
HOME
HORN/
LIGHTS
PAGE
Page
or
SECURE
or
Home
H/L
Dim
Mic
PRIORITY/
NON-PRIORITY
INDICATORS
Emer
SCAN SELECT MONITOR
PHONE
Phon
CALL DIRECT
Call SelScan
Mode
XMIT
BUSY
MODE
POWER ON/OFF/
DIRECT
INDICATOR
KNOB
Dir Mon
Volume
Pwr
VOLUME KNOB
EMERGENCY
MAEPF-27651-O
Figure 1-2. Typical W4 Rotary Control Head
PAGE
Page
or
SECURE
or
Emer
SCAN
PHONE
Phon
Scan
Vol
DIM
HOME
POWER
ON/OFF
PWR
Mic
EMERGENCY
MODE
Mode
CALL
Call Sel
SELECT
XMIT
BUSY
NOTE:Typical as stated in the
figure titles refers to the ability to
customize the features accessed
by certain pushbuttons on the
control heads.
H/L Mon Dir
HOME
VOLUME
PRIORITY/
NON-PRIORITY
INDICATORS
DIRECT
INDICATOR
HORN/
LIGHTS
DIRECT
MONITOR
MAEPF-27652-O
Figure 1-3. Typical W5 Limited Keypad Control Head
POWER
ON/OFF
PWR
EMERGENCY
SECURE
MODE
Mode
Vol
Mic
VOLUME
or
DIM
HOME
HOME
Emer
PHONE
Phon
PRIORITY/
NON-PRIORITY
INDICATORS
SCAN
Scan
INDICATOR
CALL
SELECT
Call Sel
DIRECT
SITE
XMIT
BUSY
RECALL
STATUS
1Ste 2
4Sts
7
Figure 1-4. Typical W7 Full Keypad Control Head
2
or
2Pge
PAGE
LOCK
Lck
3
5Rpg
6Msg
H/L
9
Dir
8
Mon
O #Del Rcl
DELETE
MONITOR
MAEPF-27653-O
REPROGRAM
MESSAGE
HORN/LIGHTS
DIRECT
June 11, 2003 6881096C73-O
Page 29
Introduction: Control Head Descriptions 1-5
FUNCTION
BUTTON
XMIT BUSY
Dir
Mode
ScanEmer
Vol Sel
VOLUME
ROCKER
FUNCTION
ON/OFF
INDICATORS
MODE
ROCKER
* Optional buttons (included but not installed or programmed)
Figure 1-5. Typical W9 Full Keypad Control Head
1.4.4 W 4, W5, W7, and W9 Controls
• Power Switch — The power (PWR) switch turns the radio and its accessories on or off. The
power switch is part of the rotary volume knob on the W4 model, a push-type switch on the W5
and W7 models, and a slide switch on the right-hand bottom surface of the W9 model.
• Mode Switch — The Mode switch is used for selecting modes and programming menus. The
Mode switch is a rotary switch on the W4 model and a rocker switch on the W5, W7, and W9
models. Pressing the right side of this rocker switch increases the mode number. Pressing the
left side decreases the mode number. If you press and hold the switch, it scrolls the mode
number up or down. The mode names appear in the display window.
• Volume Switch — The Volume switch is used for selecting the volume level, editing names, and
making certain radio adjustments. The Volume switch is a rotary switch on the W4 model and a
rocker switch on the W5, W7, and W9 models. On the pushbutton models, pressing and
releasing the volume switch checks the volume setting. Your display will show “VOLUME_ _”
and a number value (0-15). Press and hold the left side to decrease the volume. The number
value scrolls up or down to your desired level. The Volume rocker switch also controls the
volume level of the public address (PA) and external radio speaker (Ex Rd) options when they
are enabled. The display window shows “PA VOL _ _” when public address is on and the
Volume rocker switch is pressed.
• Dim Button — The DIM button is used to control the brightness of the display and button
backlighting. When you turn on the system, the display comes on at the brightness level it was
on before the system was last turned off. Press the DIM button once to reduce the brightness of
the display to medium level and twice for low brightness level. Press the DIM button a third time
to turn the display and button backlighting off. This is called the “surveillance” mode.
• Home Button — The Home button is used for restoring preprogrammed mode, establishing
programmed mode, selecting programming entries, etc. Press the Home button to go to the
radio’s preprogrammed “home” mode. On the W7 models, you may use the Home button
instead of Mode switch to change modes. Hold the Home button until a beep sounds to enter
the configuration state. The display shows an entry prompt. Use the keypad to enter your new
mode choice and press the Home button again. Your mode is now changed without scrolling.
• Select Button — The Sel button is used to configure radio options.
• Option Buttons — The option buttons are used for turning options on and off, such as Phone,
Scan, Emergency Call, and Secure.
PRIORITY
INDICATOR
Call
Non
Home
SELECT HOME
NON-PRIORITY
INDICATOR
DIMMER
CONTROL
STATUS*
0
POWER
SWITCH
DIM
KEYPAD
MESSAGE*
RECALL
DELETE
MAEPF-27654-O
123
456
Phon H/L
Pri
Pri
789
Sts Msg
Rcl Sql Del
6881096C73-O June 11, 2003
Page 30
1-6 Introduction: Control Head Descriptions
• Display — The vacuum fluorescent (VF) display’s primary function is to display mode numbers,
mode names, volume level, and the status of options. It also functions as an on-off indicator for
the entire system and plays an integral role in the operator’s reconfiguration of options. The
display is 8 characters on W4, W5, and W7 models; 11 characters on the W9 model.
• XMIT and BUSY Indicators — The XMIT indicator lights when the radio is transmitting. The
BUSY indicator lights when the selected channel is busy.
• Scan Indicators — When scan operation detects activity on a non-priority (NON-PRI) channel,
the NON-PRI indicator light comes on. Activity on a second priority channel causes the priority
(PRI) indicator to light. First priority channel activity causes PRI to flash.
• 12-Button Keypad (W7 and W9) — The keypad is used to change the status of options and for
entering numbers. Several keys serve multiple functions. See the ASTRO XTL 5000 Digital
User’s Guide for a complete description of keypad operation.
-Site (Ste - #1 key) — Forces the radio to scan for a new site when the automatic multiple-
site select (AMSS) feature for wide-area coverage is in use.
- Page (2 or 2Pge - #2 Key) — Initiates a Call Alert page/enters Call ID list programming.
-Lock (Lck - #3 key) — Locks the radio onto the current site when the AMSS feature is in
use.
-Status (Sts - #4 key) — Used alone or in conjunction with other keypad buttons and the Sel
button to send a status transmission, indicating a predetermined condition change.
- Regroup (Rpg - #5 key) — Requests a change in the radio’s talkgroup assignment when
the dynamic regrouping feature is used.
- Message (Msg - #6 key) — Used alone or in conjunction with other keypad buttons and the
Sel button to transmit a message, indicating a response or temporary condition.
- Horn/Lights (H/L - #7 key) — Selects/enables radio external alarms.
- Monitor (Mon - #8 key) — Monitors the radio for channel traffic.
- Direct/Simplex (Dir - #9 key) — Used for talkaround (mobile-to-mobile) conversations.
- Recall (Rcl - * key) — Reviews mo des in scan and phone lists.
- Delete (Del - # key) — Used when editing stored lists.
June 11, 2003 6881096C73-O
Page 31
Chapter 2 Basic Maintenance
2.1 Introduction
This section of the manual describes preventive maintenance, handling precautions, and some basic
repair procedures and techniques. Each of these topics provides information vital to the successful
operation and maintenance of your rad io.
NOTE: For board- and component-level repair of the radio, refer to the Detailed Service Manual (see
”Related Publications” on page xii).
2.2 Preventive Maintenance
Radios are shipped from the factory with a worst-case frequency error of ±500 Hz for 700–800 MHz.
These specifications are tighter than the more stringent FCC requirements of ±1.5 ppm for the 700–
800 MHz bands. For radios that have been in storage for over six months from the factory ship date,
the reference oscillator should be checked when the radio is initially deployed to the field. It is
strongly recommended that the reference oscillator be checked every time the radio is serviced or at
least once a year, whichever comes first. The crystal contained in the reference oscillator naturally
drifts over time due to its aging characteristic. Periodic (annual) adjustment of the reference oscillator
is important for proper radio operation. Improper adjustment can result in both poor performance and
interference with other users operating on adjacent channels.
2.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. A detailed inspection of the interior electronic circuitry is not needed.
2.2.2 Cleaning
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the control
head and radio chassis. These surfaces should be cleaned whenever a periodic visual inspection
reveals the presence of smudges, grease, and/or grime. Internal surfaces should be cleaned only
when the radio is disassembled for servicing or repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. T he only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (70% by volume).
The effects of certain chemicals and their vapors can have harmful results on
!
C a u t i o n
certain plastics. Aerosol sprays, tuner cleaners, and other chemicals should
be avoided.
2.2.2.1 Cleaning External Plastic Surfaces
The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled
brush to work all loose dirt away from the radio. A soft, absorbent, lint-free cloth or tissue should be
used to remove the solution and dry the radio. Make sure that no water remains entrapped near the
connectors, cracks, or crevices.
Page 32
2-2 Basic Maintenance: Handling Precautions
2.2.2.2 Cleaning Internal Circuit Boards and Components
Isopropyl alcohol may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded
or caked materials located in hard-to-reach areas. The brush stroke should direct the dislodged
material out and away from the inside of the radio. Be careful not to break off electrical components.
Alcohol is a high-wetting liquid and can carry contamination into unwanted places if an excessive
quantity is used. Make sure that controls or tunable components are not soaked with the liquid. Do
not use high-pressure air to hasten the drying process, since this could cause the liquid to puddle
and collect in unwanted places.
Upon completion of the cleaning process, use a soft, absorbent, lint-free cloth to dry the area. Do not
brush or apply any isopropyl alcohol to any plastic parts.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
2.2.3 General Radio Care and Handling Precautions
• Avoid physical abuse: do not pound, drop, or throw the radio. It may damage exposed parts
such as controls and connectors.
• Do not connect accessories other than Motorola compatible equipment as they may damage
the radio.
• The use of any mini-UHF adaptor not listed in this manual can damage the RF antenna
connector and lead to radio failure and may void the warranty.
• Operating the radio without an antenna cable attached may lead to radio failure and may void
the warranty.
2.2.4 RF Power Amplifier (RF PA) Heatsinking
You should never transmit unless the printed-circuit board (PCB) DC/RF clips and internal screws
are installed in the chassis. Doing so can result in immediate failure of RF PA devices or greatly
reduced RF PA device life. You also can transmit for short periods with the chassis eliminator if it is
used properly.
2.3 Handling Precautions
Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices,
are used in this family of radios. While the attributes of these devices are many, their characteristics
make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges.
Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special
precautions must be taken to prevent device damage during disassembly, troubleshooting, and
repair. Handling precautions are mandatory for this radio, and are especially important in lowhumidity conditions. DO NOT attempt to disassemble the radio without observing the following
handling precautions:
• Eliminate static generators (plastics, Styrofoam, etc.) in the work area.
• Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back
loose-hanging neckties.
• Store and transport all static-sensitive devices in ESD-protective containers.
• Disconnect all power from the unit before ESD-sensitive components are removed or inserted
unless otherwise noted.
• Use a static-safeguarded workstation, through the use of an anti-static kit (Motorola part
number 01-80386A82). This kit includes a wrist strap, two ground cords, a static-control table
mat and a static-control floor mat.
June 11, 2003 6881096C73-O
Page 33
Basic Maintenance: Handling Precautions 2-3
NOTE:Be sure that the table and floor mats are properly grounded.
When these items are not readily available, observing the following techniques will minimize the
chance of damage:
• If a static-sensitive device is to be temporarily set down, use a conductive surface for
placement of the device.
• Make skin contact with a conductive work surface first and maintain this contact when the
device is set down or picked up.
• Always wear a conductive wrist strap when servicing this equipment. The Motorola part number
for a replacement wrist strap that connects to the table mat is 42-80385A59.
• For additional information, refer to Service and Repair Note SRN-F1052, Static Control
Equipment for Servicing ESD Sensitive Products, available from the Literature Distribution
Center.
Motorola
Literature Distribution Center
2200 Galvin Drive, Suite 2218
Elgin, IL 60123
(847) 783-2522
(847) 783-2523/2524 (Fax)
6881096C73-O June 11, 2003
Page 34
2-4 Basic Maintenance: Handling Precautions
Notes
June 11, 2003 6881096C73-O
Page 35
Chapter 3 Basic Theory of Operation
3.1 Introduction
The ASTRO XTL 5000 radio combines the controller and RF sections into a single board and
contains three modules: a daughtercard, RX VCO module, and TX VCO module. It is important to
correctly identify the malfunctioning region before replacing expensive modules. To assist with radio
repair, descriptions of the sections contained on the XTL 5000 uniboard are listed below.
3.2 General Overview
The XTL 5000 radios are wideband, synthesized, fixed-tuned radios and are available with 700 and
800 MHz bands. All XTL 5000 radios are capable of both analog operation (12.5 kHz, 20 kHz, and
25 kHz bandwidths) and ASTRO mode operation (12.5 kHz bandwidth).
The XTL 5000 radios contain the following assemblies and sections:
• Control-Head Assembly (Dash- or Remote-Mount)—is connected directly to the front of the
transceiver or remotely by the interconnect board and control cable. This assembly contains a
vacuum fluorescent (VF) display, VF driver, microprocessor and serial bus interface.
• Power Amplifier (PA) section—contains the antenna switch, directional coupler/ detector, and
amplifier(s).
• Front-End Receiver section—contains the preselector, low-noise amplifier (LNA), and mixer.
• IF section—contains the receiver intermediate-frequency (IF) amplifier/filter and the digital
receiver back-end integrated circuit (IC).
• Frequency Generation section—contains the synthesizer, voltage controlled oscillators (VCOs),
reference oscillator, and receive and transmit buffers.
• Controller section—combines a VOCON board and a Command board, into a single section,
and contains the following elements:
- Voltage regulators, data communication circuitry (RS232, USB, and SB9600)
- Daughtercard module (Microprocessor, FLASH IC, SRAM IC)
- Modulation D/A conversion circuitry
- CODEC audio circuitry
- TX power-control circuitry
- Emergency circuitry
- V.I.P input/output paths
- Secure interconnect board interface
- Front connector interface for control heads and remote-mount interconnect boards (I.B)
- Rear connector for additional accessories
- DC power-in plug
Page 36
3-2 Basic Theory of Operation: Controller Section
3.3 Controller Section
3.3.1 Introduction
The XTL 5000 radio is primarily a uniboard design, consisting of isolated topside and bottomside
controller sections and various RF sections. The controller section will be discussed here in basic
terms, to assist in the overall understanding of what is contained in the controller section, and a
simplified purpose of its elemental parts. Some limited warnings and recommendations are offered
for prevention of common repair-induced damage.
The controller section combines the elements of a VOCON board, with the elements of a command
board. The controller section also contains a daughtercard module. We distinguish the entire
controller section into 2 parts: the "daughtercard module" and the "surrounding controller region".
3.3.2 Location
The controller section is located on the far side of the board, with critical parts arranged on the top
and bottom sides of the uniboard. (see
controller section).
Figure 3-1 below, with component-filled areas denoting
SIDE1 SIDE2
Figure 3-1. Controller Sections
Troubleshooting of the controller section usually requires the removal of the
!
C a u t i o n
uniboard from the chassis. Whenever this board is removed, any
transmitting of the RF section, whether intentional or accidental (trunking
affiliation), can cause permanent destruction or degradation of various RF
components. Such damage may not be visually noticeable, but can impact
the radios performance and reliabil ity.
3.4 Daughtercard Module
This module contains primarily three parts: microprocessor, FLASH IC, and SRAM IC.
NOTE: The three parts on the daughtercard module are highly susceptible to ESD and moisture
damage. Extreme care is advised.
DAUGHTERCARD
MODULE
June 11, 2003 6881096C73-O
Page 37
Basic Theory of Operation: Surrounding Controller Region 3-3
3.4.1 Microprocessor
The microprocessor consists of an MCORE-based controller and a DSP that communicates with the
memory ICs via a 16-bit data bus. It also communicates to peripheral ICs on the main board via an
SSI and SPI bus. This microprocessor contains a fixed amount of one-time programmable ROM and
a small section of RAM. However, the microprocessor does not contain the radio software setting as
programmed in the Customer Programming Software (CPS) or the firmware as installed at the
factory. The only purpose of this IC is for interpretation and processing of the content inside the
FLASH IC. Therefore, this part may be replaced as is without the need to reflash the radio.
There are six clocks supplied to the daughtercard, a 16.8 MHz master clock (CKIH), a 32 kHz realtime clock (CK IL), a 20 kHz RX frame-sync clock, a 48 kHz TX frame -sync clo ck, a 1 .2 MHz RX data
clock, and a 2.4 MHz TX data clock. The microprocessor also generates the digital audio bus clocks:
a 512 kHz data clock and an 8 kHz frame-sync clock.
3.4.2 FLASH IC
The FLASH IC is the firmware storage IC. Programming this IC is accomplished using one of three
input paths:
• 2-wire RS232 directly from a computer's serial port to the radio’s rear connector data cable,
HKN6160
• 2-wire RS232 through an HKN6155 programming cable at the control head’s 10-pin
microphone port
• 2-wire RS232 through an HKN6155 programming cable at the Remote Mount Interconnect
board’s 10-pin flash port.
if you choose to reflash the radio (reflash the IC), DO NOT interrupt the
!
C a u t i o n
NOTE: In remote-mount configurations, the control head 10-pin microphone port is disabled for any
NOTE: It is recommended thatFLASH IC replacement is not supported as a field repair option. If this
process; otherwise, you might corrupt the FLASH IC and need advanced
technical support to revive your radio.
kind of programming.
part is removed, the radio must be reflashed and retuned. This is because the FLASH IC must
be hard-boot loaded at the factory to allow the programming of a unique file.
3.4.3 SRAM IC
The SRAM IC is only used by the microprocessor to perform its memory operations and is not
upgradeable to a larger SRAM IC.
3.5 Surrounding Controller Region
3.5.1 Introduction
The surrounding controller region contains the regulated power, audio, and data translation
hardware.
This hardware allows a computer to program the radio's features, maintain an active control of the
RF sections, and make necessary mode and audio adjustments as related to feedback from a
control head device.
6881096C73-O June 11, 2003
Page 38
June 13, 2003 6881096C73-O
3-4 Basic Theory of Operation: Surrounding Controller Region
NOTE: A control head is not necessary for the function of the radio (in special application
configurations), but the controller section is critical for the RF sections to function. This is an
important point since repairs and troubleshooting of the RF sections usually requires that the
controller section is operating correctly.
3.5.2 Voltage Regulation
The uniboard contains the following voltage regulators: 9 V, 5 V , 3V, 2.85 V, 1.85 V, and 1.55 V.
The radio’s A+ supply is regulated down to additional supplies for various blocks (frequency
generation unit (FGU), receiver, transmitter power amplifier, and controller). Specifically, A+ is used
to regulate three separate 9.3-volt supplies, one for the FGU and receiver circuitry, one for the
transmitter power amplifier circuitry, and one for the controller sections.
• The FGU and receiver circuitry use the 9.3-volt supply to further regulate a common 5-volt
supply and two separate 3-volt supplies, one for the FGU and one for the Abacus III IC.
• The transmitter power amplifier uses its 9.3-volt supply directly for its pre-amplifier and to a 3volt supply for most of the ALC (automatic level control).
• The controller uses the 9.3-volt supply to power the microphone, part of a RS232 translator,
and to provide voltage to the 5-volt regulator, which supplies the 2.85 V, 1.85 V, and 1.55 V
supplies.
- The 2.85-volt regulator supplies most of the digital logic circuitry on the controller, as well as
the I/O of the microprocessor.
- The 1.85-volt regulator supplies the FLASH and SRAM circuitry.
- The 1.55-volt regulator supplies the core of the microprocessor.
3.5.3 Emergency
Circuity exists to support emegency switch operation. While the radio is ON, emergency can be
activated to alert dispatch.
NOTE: This feature is either visual or can be set to covert, and is programmable through the CPS
(customer programming software). This functionality is dependent on CPS version and
customer demand for feature availability.
3.5.4 Front and Rear Connectors
The surrounding controller section contains the front and rear connections to allow interfacing with
existing and future accessories.
These custom connectors are optimized to meet voltage and current requirements for existing
accessories and for the compatible flexes that are used with the XTL 5000 radio.
NOTE: It is not recommended to insert non-Motorola parts or flexes into these connectors.
Page 39
Basic Theory of Operation: Surrounding Controller Region 3-5
3.5.4.1 Audio
The audio circuitry of the controller section contains the following:
•Audio PA
• Codec
• MIC Audio
• DSP controlled EEPOTS
• AUX RX, AUX TX, and external speaker paths
• FILT audio.
This allows interfacing to the existing accessories made by Motorola, such as VRS, SIREN, and
Consolette. It also allows for select compatibility with aftermarket modems.
3.5.4.2 Program Cable
If the programming cable is used with a standard legacy control head, circuitry found in the controller
section provides the voltage-translated boot RX and boot TX communication paths, as well as the
cable-detection circuit.
3.5.4.3 SB9600
Just as on many Motorola products, an SB9600 communication bus exists on the XTL 5000 radio.
Hence, many Motorola SB9600 accessories are compatible with the radio. These lines include
BUS+, BUS-, Busy, and RESET. These lines are available at connectors J5 and J6.
3.5.4.4 VIP
VIP-IN and VIP-OUT lines are available at the front and two VIP-out lines are located at the rear.
Their purpose is to drive relays to control external logical devices, or to logically communicate
directly to the XTL 5000 microprocessor. Their most versatile usage is in conjunction with a DEK, but
this is not mandatory.
NOTE: Please see the VIP section of the ASTRO XTL 5000 700–800 MHz Digital Portable Radio
Detailed Service Manual for configurations and voltage level requirements.
3.5.4.5 RS232
UART_A can be selected as a standard 4-wire RS232 or 4-wire USB slave device. The UART_B is
defaulted to use SB9600 lines so that all legacy control heads and SB9600 accessories are
compatible with the radio.
3.5.4.6 One-Wire
One-wire technology is embedded in the radio for future compatibility with upcoming smart
accessories.
6881096C73-O June 11, 2003
Page 40
3-6 Basic Theory of Operation: Analog Mode of Operation
3.6 An alog Mode of Operation
3.6.1 Receive Operation
When the radio is receiving, the signal comes from the antenna through the RF PA output network
located in the power amplifier section to the front-end receiver assembly. The signal is then filtered,
amplified, and mixed with the first local oscillator signal generated by the receiver voltage controlled
oscillator (VCO). The resulting intermediate-frequency (IF) signal is fed to the IF circuitry where it is
again filtered and amplified. This amplified signal is passed to the Abacus III IC where it is mixed with
the second local oscillator to create the second IF at 2.25 MHz. The analog IF is processed by an
analog-to-digital (A/D) converter located within the digital back-end IC, where it is converted to a
digital bit stream and decimated down to an I/Q digital sample. This digital signal is then passed on
to the DSP, where filtering and discrimination are performed in the software. For a voice signal, the
DSP routes the digital voice data to the Codec for conversion to an analog signal. The signal passes
through a Log Pot to the audio power amplifier, which drives the speaker. For signaling information,
the DSP decodes the message and passes it to the microcom put er.
3.6.2 Transmit Operation
When the radio is transmitting, microphone audio is passed to the gain control, and then to the
Codec, where the signal is digitized. The Codec passes digital data to the DSP, where pre-emphasis
and low-pass (splatter) filtering is done. The DSP returns this signal to the Codec and the signal is
then passed to a digital-to-analog (DAC) converter where it is reconverted into an analog signal. The
signal is then passed through a switched capacitor filter IC and then to the synthesizer IC as a
modulation signal for the transmitter voltage controlled oscillators. Also, transmitted signaling
information is accepted by the DSP from the microcomputer, coded appropriately, and passed to the
Codec, which handles it the same as a voice signal. Modulation information is passed to the
synthesizer along the modulation line. A modulated carrier is provided to the RF power amplifier,
which transmits the signal under dynamic power control.
3.7 ASTRO Mode of Operation
In the ASTRO mode (digital mode) of operation, the transmitted or received signal is limited to a
discrete set of deviation levels, instead of continuously varying. The receiver handles an ASTROmode signal identically to an analog-mode signal up to the point where the DSP decodes the
received data.
In the ASTRO receive mode, the DSP uses a specifically defined algorithm to recover information.
In the ASTRO transmit mode, microphone audio is processed the same as an analog mode with the
exception of the algorithm the DSP uses to encode the information. This algorithm will result in
deviation levels that are limited to discrete levels.
3.8 Control Head Assembly
3.8.1 Dis play (W4, W5, and W7 Control Heads)
The W4, W5, and W7 control-head assemblies have an 8-character, alphanumeric, vacuum
fluorescent display. The anodes and the grids operate at approximately 34 Vdc when on and 0 Vdc
when off. The filament operates at approximately 24 Vrms. The voltage for the display is generated
by a fixed-frequency, variable duty-cycle controlled “flyback” voltage converter. The switching
frequency is approximately 210 kHz. The internal microprocessor controls the voltage converter,
which provides approximately 3.7 Vdc to the vacuum fluorescent (VF) driver and approximately
2.4 Vrms to the VF display.
June 11, 2003 6881096C73-O
Page 41
Basic Theory of Operation: Control Head Assembly 3-7
3.8.2 Display (W9 Control Head)
The W9 control-head assembly has an 11-character, alphanumeric, vacuum fluorescent display. It
needs three separate voltages to operate: the cathode needs 35 V to accelerate electrons to the
anode; the grid needs 40 V to totally shut off current flow; the filament needs 3.8 Vrms at 80 mA.
These voltages are obtained from the transformer on the display controller board.
3.8.3 Vacuum Fluorescent (VF) Display Driver
This VF display driver receives ASCII data from the controller section of the main board, decodes it
into display data, and then scans the display with the data. Once properly loaded into the display,
data is refreshed without any further processor action. The display driver is periodically reset by the
actions of transistors that watch the clock line from the microprocessor to the display driver. When
the clock line is held low for more than 600 ms, the display driver resets and new display data
follows.
3.8.4 Vacuum Fluorescent (VF) Voltage Source (W9)
Voltage for the VF display is generated by a fixed frequency, variable-duty cycle-driven, flyback
voltage converter. An emitter-coupled astable multivibrator runs at approximately 150 kHz. The
square-wave output from this circuit is integrated to form a triangle that is applied to the non-inverting
input of half an IC.
During start up, the inverting input is biased at 3.7 V. A transistor is on while the non-inverting input
voltage is below 3.7 V. This allows current to flow in a transformer, building a magnetic field. When
the triangle wave exceeds 3.7 V, the transistor turns off and the magnetic field collapses, inducing
negative current in the transformer.
This current flow charges two capacitors. As the voltage on one of the capacitors increases beyond
35 V, a diode begins to conduct, pulling the integrated circuit’s inverting input below 3.7 V. This
decreases the cycle time to produce the 35 V. The 41-volt supply is not regulated, but it tracks the
35-volt supply.
Similarly, the AC supply for VF filament is not regulated, but is controlled to within one volt by an
inductor on the display board.
3.8.5 Controls and Indicators
The control head assembly processes all the keypad (button) inputs and visual indicators through
the microprocessor. Some of the buttons double as function keys for radio options. All buttons are
backlit to allow operation in low light. Refer to
Descriptions” on page 1-2
) for functional descriptions of each control switch, button, or indicator.
3.8.6 Status LEDs
These LEDs are driven by the display driver as though they were decimal points on the VF display.
Level shifting transistors are required for this since the display driver uses 39 Vdc for control signals.
3.8.7 Backlight LEDs
The microprocessor operates the backlight LEDs. A transistor supplies base current to the individual
LED driver transistors. The driver transistors act as constant current sources to the LEDs. Some
backlight LEDs are connected to a thermistor. This circuit allows more current to flow through these
LEDs at room temperature and reduces current as the temperature rises.
Chapter 1. Introduction (“1.4 Control Head
6881096C73-O June 11, 2003
Page 42
3-8 Basic Theory of Operation: Control Head Assembly
3.8.8 Vehicle Interface Port (VIP)
3.8.8.1 Remote-Mount
The VIPs allow the control head to operate outside circuits and to receive inputs from outside the
control head. There are three VIP outputs that are used for the W9 control head and two VIP outputs
for the W3, W4, W%, and W7 control heads. There are also three VIP inputs that accept inputs from
switches. See the cable kit section for typical connections of VIP input switches and VIP output
relays.
The VIP output pins are located on the back of the control head below the area labeled “VIP.” These
connections are used to control relays. One end of the relay should be connected to switched B+,
while the other side is connected to a software-controlled on/off switch inside the control head. The
relay can be normally on or normally off depending on how the VIP outputs are configured. The
function of these VIP outputs can be defined by field programming the radio. Typical applications for
VIP outputs are external horn/lights alarm and horn ring transfer relay control.
3.8.8.2 Dash-Mount
The VIP outputs are driven by a serial-to-parallel shift register. The output transistors are capable of
sourcing 300mA current. Primarily, these transistors control external relays. The relay is connected
between the collector and switched B+.
Each VIP input transistor is connected to a dedicated input port through transistors used for input
protection. These VIP inputs are connected to ground with either normally open or normally closed
switches.
3.8.9 Control-Head Power Supplies
This section describes the control-head power supply operation.
3.8.9.1 W3 Control Head
W3 control heads supply power to the switched B (SWB+) line through a P-channel power MOSFET
from the HLN6885 interface board only.
3.8.9.2 W4 Control Head
For W4 control heads, power to SWB+ is supplied by a mechanical switch on the volume control
knob. If the ignition line option is used, power to the switch comes directly from the ignition wire
instead of A+.
3.8.9.3 W5, W7, W9 Control Heads
SWB+ is supplied from A+ through an N-channel power MOSFET driven by the Serial Input/Output
(SIO) IC in the legacy control heads. SWB+ supplies power to the accessories, the VF display, the 5volt regulator, and the power-control line for the main board for all other voltage regulators on the
main board. The SIO IC monitors the condition of the power switch and the ignition switch to
determine the on/off stat e of the radio.
3.8.10 Ignition Sense Circuits
A transistor senses the vehicle ignition’s state, disabling the radio when the ignition is off. For
negative-ground systems, the orange lead for remote-mount radios and the red lead for dash-mount
radios is typically connected to the fuse box (+12 V).
June 11, 2003 6881096C73-O
Page 43
Basic Theory of Operation: Radio-Frequency Power Amplifier (RF PA) and Output Network (ON ) 3-9
3.9 Radio-Frequency Power Amplifier (RF PA) and Output Network
(ON)
The RF PA is a three-stage power amplifier consisting of discrete LDMOS transistors:
• Controlled stage
• Drive r stag e
• Final stage
The RF PA is followed by the ON section consisting of discrete circuitry with the following functions:
• Antenna switch
• Harmonic Filter
• Power Detector
3.9.1 G ain Stages
The controlled stage consists of a two-stage, integrated amplifier with external matching which
amplifies the input signal from the VCO buffer and provides drive to the driver stage. Power is
controlled via gate bias to both internal stages and drain bias is supplied via K9.1V. The drive stage
has a fixed gate bias and drain bias is supplied by the A+ (battery) voltage. The driver stage drives
the final stage consisting of two transistors operating in parallel. Both devices have separate, fixed
gate biases and their drain biases are supplied by the A+ voltage. The output of the final stage feeds
the antenna switch which routes the RF PA to the harmonic filter/power detector/antenna and
isolates the RX front-end in transmit mode. Antenna switch routes antenna/power detector/harmonic
filter to RX and isolates TX in RX mode. Mode is determined via K9.1V. The harmonic filter is a lowpass filter that attenuates harmonics generated by the RF PA in transmit mode and provides
additional receive selectivity in receive mode.
3.9.2 Power Control
Power is regulated by an automatic-level control (ALC) circuit. The transmitter ALC consists of a
distributed power detector with a detection diode, buffer/amplifier, digital-to-analog converter (DAC),
and loop integrator. During transmission, the RF PA gain and output power is adjusted by a control
voltage. The power detector senses incident power transferred to the antenna via a directional
coupler whose signal is converted to a DC voltage by the detection diode. This DC voltage is
buffered/amplified and then added to the DAC voltage which is then compared to a fixed voltage
reference. The carrier power level is set tby adjusting the DAC voltage while monitoring the output
power, which is saved tin radio memory.
3.9.3 Circuit Protection
RF PA final-stage drain current, RF PA final-stage temeperature, RF PA control voltage, and battery
voltage are sensed by the power-control circuitry. If a fault condition is detected, the control voltage
is reduced, which cuts back the output power to a level that is safe for the particular conditions.
3.9.4 DC Interconnect
The DC connector at the edge of the board carries the A+ supply for the entire board. This supply is
routed directly to the controller and transmitter circuitry for both direct supply and regulating
additional supplies. The radio chassis is grounded through the PCB screws and also via direct
contact to the board. The control head receives the A+ supply through the 50-pin flex connector.
6881096C73-O June 11, 2003
Page 44
3-10 Basic Theory of Operation: 700–800 Receiver Overview
3.10 700–800 Receiver Overview
The receiver circuits primary duties are to detect, filter, amplify, and demodulate RF signals in the
presence of strong interfering noise and unintended signals. The receiver is broken down into the
following blocks:
• Front-end (preselector and LNA)
•Mixer
•IF
• Back-end IC
3.10.1 Receiver Front-End
The 700–800 MHz receiver front-end operates in two bands. The primary function of the front-end is
to optimize image rejection and selectivity while providing the first conversion. The front-end uses
ceramic filter technology and includes a wideband, monolithic amplifier. The first filter is a dual
switched filter that reduces the image frequency response and limits some of the out-of-band
interference. The second filter following the monolithic Low Noise Amplifier (LNA) provides additional
image rejection.
3.10.2 Mixer
The signal is then fed to the monolithic Mixer IC where it is down converted to an IF of 73.35 MHz.
The mixer is designed to provide low conversion loss and high intermodulation performance. The
mixer is driven by the receiver injection buffer, a two-stage discrete IC design used with the receiver
VCO to efficiently drive the mixer over a wide temperature range with minimum power variation. The
injection buffer provides 15 dBm to the mixer. The VCO performs low-side injection for the 800 MHz
band and high-side Injection for the 700 MHz band. The design maintains temperature stability, low
insertion loss, and high out-of-band rejection.
3.10.3 IF Circuitry
The crystal filters provide IF selectivity and out-of-band signal protection to the back-end IC. Two 2pole crystal filters centered at 73.35 MHz that are isolated from one another by a stable, moderate
gain amplifier are used to meet the receiver specifications for gain, close-in intermodulation
rejection, adjacent-channel selectivity, and second-image rejection.
3.10.4 Abacus III Back-End
The output of the IF circuit is fed directly to the Abacus III digital back-end IC. The ABACUS III is an
IC with a variable-bandwidth bandpass Sigma-Delta architecture. It is capable of down-converting
analog as well as digital RF protocols into a baseband signal transmitted on the Synchronous Serial
Interface (SSI) bus. The Abacus III IC converts the 73.35 MHz signal from the IF section down to
2.25 MHz using a second LO frequency of 71.1 MHz or 75.6 MHz. The second LO VCO is tuned to
71.1 MHz (low side) or 75.6 MHz (high side injection). The choice of frequency depends on known
spurious interference related to the programmed received frequency.
June 11, 2003 6881096C73-O
Page 45
Basic Theory of Operation: Frequency Generation Unit (FGU) 3-11
3.11 Frequency Generation Unit (FGU)
-
+
9.3V
-
+
3V
RxFE
RFPA
-
9.3V
-
9.1V
8.2VOut
Adapt
LoopFilter
Steering
LineVoltage
+
Rx
Buffer
+
Tx
Buffer
DualRxVCO
DualTxVCO
SuperFilter
Dual
Charge
Pump
Transmit
Modulation
AUX-
Tx/RxSelect
Synthesizer
PreScaler
IN
LVFrac-N
SPI
MAEPF-27588-A
TCXO
16.8MHz
Buffer
Controller
RxBE
Figure 3-2. Frequency Generation Unit Diagram
The frequency generation unit (FGU) (
Figure 3-2) is comprised of a fractional-N synthesizer IC, a
16.8 MHz reference oscillator IC, two voltage-controlled oscillator (VCO) modules (receive and
transmit, containing two VCOs each), VCO buffer/amplifier circuits, and associated circuitry.
The reference oscillator IC provides a frequency standard to the fractional-N synthesizer IC, the
Abacus III digital back-end IC and to the controller section. The synthesizer turns on one of the four
VCOs (determined by mode and band of operation) and tunes it to the receiver (RX) local oscillator
(LO) or transmitter (TX) carrier frequency.
The voltage-controlled oscillator (VCO) module employs a Colpitts configuration with two bipolar
stages in a common-base, common-collector configuration. The LC tank circuit’s capacitive portion
consists of a varactor diode, coupling capacitor and a laser-trimmed capacitor for frequency
adjustment. The inductive portion consists of microstrip transmission line resonators for TX VCO and
coaxial resonators for RX VCO. Tuning is performed by the module manufacturer and is not field
adjustable. The varactor changes the oscillator frequency when the DC voltage of the steering line
changes. The output of the common base is coupled to the second transistor for impedance
buffering, and its output is coupled to respective TX/RX buffer amplifiers.
In TX mode, the transmitter VCO output is coupled to a three-stage buffer before being injected into
the power amplifier (see
on page 3-9
). In RX mode, the receiver VCO output is buffered and amplified with a two-stage
“3.9 Radio-Frequency Power Amplifier (RF PA) and Output Network (ON)”
transistor/microwave monolithic IC (MMIC) circuit. The output of the first-stage transistor is split into
two paths. One path feeds back to the synthesizer prescaler; the other path is injected into the
second-stage MMIC. The output of the MMIC provides the proper signal level for the LO port of the
RX front-end mixer (see
“3.10 700–800 Receiver Overview” on page 3-10).
The super filter supplies the voltage to the first two stages of the TX buffer and to the first-stage
transistor of the RX buffer/amplifier. The voltage for the third stage of the TX buffer is supplied by a
keyed 9.1 V source to conserve current drain while the radio is receiving. The second stage MMIC of
the RX buffer/amplifier is supplied by a 9.3 V regulator.
6881096C73-O June 11, 2003
Page 46
3-12 Basic Theory of Operation: Frequency Generation Unit (FGU)
Notes
June 11, 2003 6881096C73-O
Page 47
Chapter 4 Test Equipment, Service Aids, and Tools
4.1 Recommended Test Equipme nt
The list of equipment contained in T able 4-1 includes most of the standard test equipment required
for servicing Motorola mobile radios, as well as several unique items designed specifically for
servicing this family of radios. The Characteristics column is included so that equivalent equipment
can 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.
Table 4-1. Recommended Motorola T est Equipment
Motorola
Model Number
R-1439 or
R-1440
(See Table 4-2 for
plug-in elements)
R-1611 Dual-Channel 100 MHz
R-2670
(with options, as
applicable)
Description Characteristics Application
BIRD Wattmeter
BIRD Wattmeter
Oscilloscope (Agilent)
System Analyzer This item will substitute for items
Power range: 100 mW to 100W,
2 MHz to 1GHz,
UHF-F connector
Power range: 100 mW to 100W,
2 MHz to 1GHz,
N-female connector
Two-channel, 100MHz
bandwidth, 200 Msample rate/
sec., 2MB memory/channel
with an asterisk (*).
Transmitter power
measurements
Waveform measurements
Frequency/deviation meter and
signal generator for wide-range
troubleshooting and alignment
Table 4-2 contains a listing of the plug-in elements that are available for the BIRD wattmeters listed
in the Table 4-1.
Table 4-2. Wattmeter Plug-In Elements
Power 25-60 MHz 50-125 MHz 100-250 MHz 200-500 MHz 400-1000 MHz
5W --- 0180305F29 0180305F38 0180305F46
10W --- 0180305F22 0180305F30 0180305F47
25W 0180305F15 0180305F23 0180305F31 0180305F40 0180305F48
50W 0180305F16 0180305F24 0180305F32 0180305F41 0180305F49
100W 0180305F17 0180305F25 0180305F33 0180305F42 0180305F50
250W 0180305F18 0180305F26 0180305F34 0180305F43 0180305F51
500W 0180305F19 0180305F27 0180305F35 0180305F44 0180305F52
1000W 0180305F20 0180305F28 0180305F36 0180305F45 0180305F53
Page 48
4-2 Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools
Table 4- 3 contains a listing of non-Motorola test equipment recommended for servicing mobile
radios.
Table 4-3. Recommended Non-Motorola Test Equipment
Model Number Description Application
1:1 Audio Transformer Audio measurement (audio PA must NOT be grounded)
Agilent 6552 Power Supply (0-20 V, 0-25 A) Mobile radio power supply
Agilent 8901 Modulation Analyzer Frequency, reference oscillator deviation and
compensation measur em ents
Agilent 8903 Audio Analyzer Audio signal-level, SINAD, and distortion
measurements
Fluke 45 Bench-Top Digital Multimeter AC/DC voltage and current measurements
Fluke 187 or 189 Handheld Digital Multimeter
(True RMS, AC, AC+DC, dB)
Fluke 190 Series Handheld Oscilloscope
(60-200 MHz Bandwidth, 2.5GS/
sec, Built-in 500-Count True
RMS Multimeter)
HP E4430 Digital I/Q Modulation Signal
Source
Weinschel 49 30 43 30 dB RF Attenuator For tests that require a modulation analyzer or
AC/DC voltage and current measurements
Waveform measurements
Signal source for transmit and receive digital tests
wattmeter
4.2 Servi ce Aids and Recommended Tools
Refer to the tables in this section for a listing and description of the service aids and tools designed
specifically for servicing this family of radios, as well as the more common tools required to
disassemble and properly maintain the radio. These kits and/or parts are available from the Motorola
parts di vision offices listed in Appendix A. Replacement Parts Ordering.
Table 4-4. Service Aids for XTL 5000 Board-Level Troubleshooting
Motorola
Part Number
Description Application
HKN6155 Programming Flash Cable Used with Tuner Software, CPS, and FLASHport
RVN4185 C ustomer Programming
Software and Tuner Software
June 11, 2003 6881096C73-O
Programming and radio alignment software on CD
Page 49
Test Equipment, Service Aids, and Tools: Field Programming Equipment 4-3
Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting
Motorola
Part Number
0180386A82 Anti-static grounding kit
8180384N71 Chassis eliminator
Control-head interconnect service cable
1185984D01 Electromagnetic Interference (EMI) metallic shielding tape, or
equivalent
0180320B16 Magnetic screwdriver set with bits
3085651A01 Mini-UHF to N-type adapter cable
6686119B01 Plastic scraping tool
6680163F01 Removal and insertion tool
RSX4043 Roto-Torq adjustable torque driver
Tools and Supplies
Table 4-6. Recommended Non-Motorola Tools for Board-Level Troubleshooting
Part Number Tools and S upplies
2.5 mm hex-key bit
Flat-blade screwdriver
Small, flat-blade screwdr ive r
MA-800G Solder aid, (black stick), Hexacon Electric Co.
Torx® T10 and T20 drivers
4.3 Field Programming Equipment
The ASTRO family of radios can be aligned and programmed in the field. This requires specific
equipment and special instructions. Refer to the online help in the Customer Programming Software
(RVN4185).
4.3.1 X TL 5000 Field P rogramming
The XTL 5000 radios use a flash memory device to store information on frequencies, squelch codes,
signaling codes, time-out timer durations, and other parameters.
The XTL 5000 radios can be programmed in the field any number of times without removing the flash
memory from the radio.
4.3.1.1 Dash-Mounted Radios
To program and tune a dash-mounted XTL 5000 radio, the HKN6155 cable is connected to the radio
via the microphone connector. The opposite end of the cable is connected to an IBM or IBM PCcompatible computer. Another programming option is to connect a direct adapter cable to the radio’s
rear accessory connector, J2, and connect the other end to the computer. (Please refer to the CPS
Programming Installation Guide
procedures for the software.)
—Motorola part number 6881095C44—for installation and setup
6881096C73-O June 11, 2003
Page 50
4-4 Test Equipment, Service Aids, and Tools: Field Programming Equipment
4.3.1.2 Remote-Mounted Ra dios
For remote-mounted radios, the cable is connected to the radio at the FLASHport connector, which
is located on the remote faceplate of the transceiver. Another programming option is to use a direct
adapter cable to connect the radio’s rear accessory connector, J2, to the computer. A third option is
to use an ASTRO Packet Data cable to directly connect J6 on the remote faceplate to the computer.
(Please ref er to the CPS Prog ramming Inst allatio n Guide
—Motorola part number 6881095C44—for
installation and setup procedures for the software.)
Do not attempt to program via the remote control head. Be sure to disconnect any accessories that
are connected to the radio’s microphone ports (including the microphones). Bias to these
accessories could impair programming/tuning capability.
4.3.1.3 Field-Programming Items
Once the computer is connected to the radio, the prompts provided by the programming software
can be followed. The following items, available through the Radio Products Services Division (except
the computer), are required when programming XTL 5000 radios.
Table 4-7. XTL 5000 Radio Field-Programming Items
Type or Part Number Description
HKN6155 Programming Cable Used to connect radio directly to the computer.
Computer, IBM or IBM PC-
compatible
RVN4185 Customer
Programming Software and
Tuner Software
This software enables you to program the radio’s features and
align its paramete r s.
4.3.1.4 W3 Contro l-Head Error Message
For a radio equipped with a W3 control head, it is possible for the message FL01/90 to display while
using the HKN6155 programming cable for tuner, CPS, or flash programming. Upon completion of
the operation, a reset will clear the message. Powering on the radio before attaching the
programming cable will decrease the occurrence of the
FL01/90 message.
June 11, 2003 6881096C73-O
Page 51
Chapter 5 Performance Checks
5.1 Introduction
This section covers performance checks used to verify that the radio meets published specifications.
The recommended test equipment listed in the
manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in
compliance with the manufacturer’s recommended calibration schedule.
5.2 Test Setup
The equipment required for XTL 5000 radio performance checks is connected as shown in the
following diagram.
Chapter 4 approaches the accuracy of the
COMMUNICATIONS
ANALYZER
RF PORT
RADIO
5.3 Test Mode
!
C a u t i o n
RF
ATTENUATOR
MATCHING
TRANSFORMER
TEST
SPEAKER
RX
OR
Figure 5-1. Performance Checks Test Setup
Be sure to transmit into a load when keying a radio under test.
WATTMETER
AGILENT 8901
MODULATION
ANALYZER
SINAD METER
AC VOLTMETER
COMMUNICATIONS
ANALYZER
Vert/SINAD Dist/
DVM Counter
MAEPF-27656-O
5.3.1 Entering Test Mode
1. To enter test mode, turn the radio on.
2. Within 10 seconds after Self Test is complete, press the Home button five times in
succession.
3. The radio will show a series of displays that will give information regarding various version
numbers and subscriber-specific information. The displays are described in
page 5-2
.
Table 5-1 on
Page 52
5-2 Performance Checks: Test Mode
Table 5-1. Test-Mode Displays
Display Name Description Appears
SERVICE Indicates the radio has entered test mode Always
Radio Host Software
Version
DSP Software Version The version of firmware be ing us ed by the
EMC Secure Version Version of the encryption hardware When the
Encryption Firmware Firmware version for encryption When the
Encryption Type 1 Type of encryption being used When the
Encryption Type 2 Type of encryption being used When the
Control Head Version Control head firmware version number Always
Auxiliary Control Head Firmware version for the auxiliary control
The version of radio firmware Always
Always
DSP
radio is secure
equipped
radio is secure
equipped
radio is secure
equipped
radio is secure
equipped
When an
head
auxiliary
control head is
present
Siren Version Firmware version for the siren When a siren
is present
VRS Version Number Firmware version for the VRS When VRS is
present
Model Number The radio’s model number, as
programmed in the codeplug
Serial Number The radio’s seri al number , as program med
in the codeplug
ROM Size Memory capacity of the flash port Always
FLASHcode The FLASHcodes, programmed as a part
of the radio’s codeplug
Always
Always
Always
Note: All displays are temporary and will expire without any user
intervention. If the information is longer than the physical length
of the control head display, it will wrap around to the next display .
After the last display,
RF TEST will be displayed.
4. Pressing the Mode rocker will cause the displays to stop. The test mode menu, CH TEST, will
be displayed.
June 11, 2003 6881096C73-O
Page 53
Performance Checks: Test Mode 5-3
5. Pressing the Home button will cause the displays to stop. The RF test mode will be entered.
The display will show
1 CSQ, indicating test frequency 1, Carrier SQuelch mode.
6. G o to the RF Test Mode section.
5.3.2 RF Test Mode
A special routine, called RF TEST MODE or air test, has been incorporated in the radio.
1. Enter the RF test mode by pressing the Home button when the test mode menu
is displayed. Use the Mode rocker to cause the radio to display the test mode
TEST
menu, RF TEST, if the display reads CH TEST.
2. Press the Home button to move the cursor back and forth between the frequency and
signaling type (See
Table 5-2 on this page and Table 5-3 on page 5-4). The first digit will
flash to indicate which type is currently selected. Press the Mode button to scroll through the
available selections.
Table 5-2. Test Frequencies
Test Channel 700/800 MHz
TX #1 762.0125
RX #1 762.0625
TX #2 769.0125
RX #2 769.0625
TX #3 775.9875
RX #3 775.9375
TX #4 794.0125
RF
RX #4 851.0625
TX #5 805.9875
RX #5 860.0625
TX #6 806.0125
RX #6 860.0625
TX #7 823.9875
RX #7 869.9375
TX #8 851.0125
RX #8 851.0625
TX #9 860.0125
RX #9 860.0625
TX #10 869.8875
RX #10 869.9375
6881096C73-O June 11, 2003
Page 54
5-4 Performance Checks: Test Mode
PR
12/1/93
EH
12/1/93
Table 5-3. Signaling Types
Display Modulation Demodulation Type
CSQ None None Carrier Squelch
TPL 192 Hz 192 Hz Private-Line
AST 1200 Hz N/A ASTRO (digital)
USQ None None Open Squelch
When in the transmit test mode, DTMF modulation produces a sidetone in the speaker. All signaling
types will continually modulate the transmitted signal for detection/measurement by external
instruments.
5.3.3 Control Head Test Mode
The control head test mode is part of the diagnostics built into the radio and is entered through the
front panel programming sequence. This test mode allows you to perform button and display tests to
verify proper operation.
1. Enter the control he ad te st mode by pr essing the Home butt on when the t est mod e men u,
, is display ed. Use t he Mode rocker to cause the radio to display the test mode menu, CH
TEST
, if the display reads RF TEST.
TEST
CH
2. Press the Mode switch to change the test mode from the RF test mode to the control head
test mode (
CH TEST).
NOTE:Once the CH Test has been selected by pressing Home, pressing the Mode switch
will not change the control head test mode back to the RF test mode. You must turn
the radio off and reenter the RF test mode as described earlier.
3. When the control hea d te st m ode i s s el e ct ed (
CH TEST), press the Home button. The display
will show the interpreted key number. Status of the key press is indicated to the right of the
key number.
KEY 103
XMIT
BUSY
KEY 104
Mode
KEY 04
KEY 105
KEY 106
Dir Mon
Volume
Pwr
KEY 02
KEY 107
KEY 96
KEY 97
KEY 98
Home
Dim
Mic
KEY 99
H/L
Emer
KEY 100
Phon
KEY 102
KEY 101
Call SelScan
Figure 5-2. W4 Control-Head Key-Closure Displays
June 11, 2003 6881096C73-O
Page 55
Performance Checks: Receiver Performance Checks 5-5
PR
12/1/93
EH
12/1/93
PR
5/9/94
JP
5/9/94
KEY 103
KEY 52
XMIT
BUSY
KEY 55
KEY 49
KEY 50
12
Sts
4
7
H/L
KEY 58
3
5
Msg
6
9
Dir
8
Mon
O#Del Rcl
KEY 82
KEY 83
KEY 81
KEY 80
PWR
Mode
Vol
DIM
HOME
Mic
KEY 97
KEY 96
MIC PTT: KEY 01
MIC HUB*: KEY 06
IGN SENSE: KEY 07
* TAKE MIC OFF HOOK
KEY 100
KEY 99
VIP IN 1: KEY 16
VIP IN 2: KEY 17
VIP IN 3: KEY 18
Phon
KEY 101
Scan
KEY 102
Call Sel
Figure 5-3. W5 and W7 Control-Head Key-Closure Displays
KEY 100
KEY 99
KEY 101
XMIT BUSY
Emer Dir
Scan
Mode Vol Sel
KEY 102
KEY 103
Srch
KEY 104
Call
Non
Home
KEY 52
Pri
Pri
KEY 49
KEY 50
123
Page Rpgm
456
Phon H/L Lock
789
Sts Msg
0
Rcl Sql
KEY 51
DIM
Site
Del
KEY 53
KEY 54
KEY 57
KEY 56
KEY 51
KEY 53
KEY 54
KEY 56
KEY 57
KEY 48
KEY 59
MAEPF-24120-A
KEY 58
KEY 59
KEY 48KEY 55
KEY 80
KEY 81
KEY 82
KEY 97KEY 83
KEY 96
Figure 5-4. W9 Control-Head Key-Closure Displays
4. Switch the radio power off temporarily to exit the test mode and return to normal radio
operation.
5.4 Receiver Performance Checks
Table 5-4. Receiver Performance Checks
Test Name System Analyzer Radio Test Condition Comments
Reference
Frequency
Rated Audio Mode: GEN
Mode: PWR MON
1st channel test frequency*
Monitor: Frequency error
Input at RF In/Out
Output level: 1.0 mV RF
1st channel test frequency*
Mod: 1 kHz tone at 3 kHz
deviation
Monitor: DVM: AC V ol t s
TEST MODE,
1 CSQ output
at antenna
TEST MODE,
1 CSQ
Press and hold
PTT switch.
Release PTT
switch.
Frequency error to be
± 150 Hz (800 MHz)
Set volume control to
6.3 Vrms across the
3.2 ohm speaker
Distortion As above, except to distortion TEST MODE,
6881096C73-O June 11, 2003
1 CSQ
Release PTT
switch.
Distortion < 3.0%
Page 56
5-6 Performance Checks: Transmitter Performance Checks
Table 5-4. Receiver Performance Checks (Continued)
Test Name System Analyzer Radio Test Condition Comments
Sensitivity
(SINAD)
Noise Squelch
Threshold
(only radios with
conventional
system need to
be tested)
As above, except SINAD, lower
the RF level for 12 dB SINAD
RF level set to 1 mV RF TEST MODE,
As above, except change
frequency to a conventional
system. Raise RF level fro m zero
until radio unsquelches.
TEST MODE,
1 CSQ
1 CSQ
Out of TEST
MODE;
select a
conventional
system
* Test frequencies are listed in Table 5-2.
5.5 Transmitter Performance Checks
Table 5-5. Transmitter Performance Checks
Test Name System Analyzer Radio
Reference
Frequency
Mode: PWR MON
1st channel test frequency**
Monitor: Frequency error
Input at RF In/Out
TEST MODE,
1 CSQ
Release PTT
switch.
Release PTT
switch.
Release PTT
switch.
T est
Condition
Press and hold
PTT switch.
RF input to be
< 0.25 µV
Set volume control to
3.16 Vrms across the
speaker.
Unsquelch to occur at
< 0.25 µV
Comments
Frequency error to be
± 150 Hz (800 MHz)
Power RF As above TEST MODE,
1 CSQ
Voice Modulation Mode: PWR MON
1st channel test frequency** atten
to –70,
input to RF In/Out,
Monitor: DVM, AC Volts
Set 1 kHz Mod Out level for
0.025 Vrms at test set,
80 mVrms at dummy microphone
or load box input
Voice Modulation
(internal)
Mode: PWR MON
1st channel test frequency** atten
to –70, input to RF In/Out
TEST MODE,
1 CSQ
TEST MODE,
1 CSQ, output
at antenna
Press and hold
PTT switch.
Press and hold
PTT switch.
Remove
modulation input
from dummy
microphone or
load box.
Press and hold
PTT switch.
Refer to the Radio
Specifications in the
front of the manual.
Deviation:
800 MHz:
>= 3.6 kHz but <= 5.0
kHz
See the Detailed
Service Manual for test
equipment
descriptions.
Press PTT switch on
microphone and say
“four” loudly into the
radio mic.
Measure deviation:
800 MHz:
>= 3.8 kHz but <= 5.0
kHz
See the Detailed
Service Manual for test
equipment
descriptions.
June 11, 2003 6881096C73-O
Page 57
Performance Checks: Transmitter Performance Checks 5-7
Table 5-5. Transmitter Performance Checks (Continued)
Test Name System Analyzer Radio
PL Modulation
(radios with
conventional, cl ear
mode, coded
squelch operation
only)
Talkaround
Modulation (radios
with conventional,
clear mode,
talkaround
operation only)
Talkaround
Modulation (radios
with conventional,
secure mode,
talkaround
operation only) *
Change frequency to 1st channel
test frequency**;
B/W to narrow
Change frequency to conventional
talkaround frequency.
Mode: PWR MON
deviation, attenuation to –70,
input to RF In/Out
Monitor: DVM, AC V ol t s
Set 1 kHz Mod Out level for
8 mVrms at dummy m icrophone or
load box.
Change frequency to conventional
talkaround frequency.
Mode: PWR MON
deviation, attenuation to –70,
input to RF In/Out
Monitor: DVM, AC V ol t s
Mod: 1 kHz out level for 80 mVrms
at dummy microphone or load box.
TEST MODE,
1 TPL
Conventional
talkaround
personality
(clear mode
operation)
1 CSQ
Conventional
talkaround
personality
(secure mode
operation).
Load key into
radio 1 sec.
Test
Condition
Remove
modulation input
from dummy
microphone or
load box.
Press and hold
PTT switch.
Press and hold
PTT switch.
Press and hold
PTT switch.
Comments
Deviation:
800 MHz:
>= 500 Hz but <= 1000
Hz
See the Detailed
Service Manual for test
equipment
descriptions.
Deviation:
800 MHz:
>= 3.8 kHz but <= 5.0
kHz
See the Detailed
Service Manual for test
equipment
descriptions.
Deviation:
800 MHz:
>= 3.6 kHz but <= 4.4
kHz
See the Detailed
Service Manual for test
equipment
descriptions.
* The secure mode, talkaround modulation test is only required for radios that do not have clear mode
talkaround capability.
** Test frequencies are listed in
Table 5-2.
6881096C73-O June 11, 2003
Page 58
5-8 Performance Checks: Transmitter Performance Checks
Notes
June 11, 2003 6881096C73-O
Page 59
Chapter 6 Radio Alignment Procedures
6.1 Introduction
This section describes both receiver and transmitter radio alignment procedures.
6.2 ASTRO XTL 5000 Tuner Software
A personal computer (PC) and Tuner Software are required to align the radio. Please refer to the
CPS Programming Installation Gu ide (Motorola part number 6881095C44) for installation and setup
procedures for the software. To perform the alignment procedures, the radio must be connected to
the computer and to a universal test set, as shown in the following figure.
COMMUNICATIONS
ANALYZER
RADIO
RF PORT
MATCHING
TEST
SPEAKER
CONTROL
HEAD
For dash-mount applications, the program/flash cable (HKN6155)
*
is connected to the microphone port on the control head.
For remote-mount applications, the program/flash cable is connected
to the FLASHport connector on the front face of the radio (P506).
Do not attempt to use a microphone while the cable is connected.
TRANSFORMER
HKN6155
*
Figure 6-1. Radio Al ignment Test Setup
RF
ATTENUATOR
OR
RX
TX
GND
RX
WATTMETER
AGILENT 8901
MODULATION
ANALYZER
SINAD METER
AC VOLTMETER
COMMUNICATIONS
ANALYZER
Vert/SINAD Dist/
DVM Counter
COMPUTER
MAEPF-27657-O
These procedures should only be attempted by qualified
!
C a u t i o n
service personnel. Failure to perform alignment procedures
properly may result in seriously degraded radio or system
performance.
Select Tuner from the Start menu. To read the radio, use the File
. Figure 6-2 on page 6-2 illustrates how the alignment screens are organized. To access a
screen, double-click on the desired screen name in the Tuner menu.
➝ Read Device menu or click on
Page 60
6-2 Radio Alignment Procedures: ASTRO XTL 5000 Tuner Software
Figure 6-2. Tuner Main Menu
The alignment screens utilize the “softpot,” an analog SOFTware-controlled POTentiomet e r us ed f o r
adjusting all transceiver alignment controls.
Do NOT switch radios in the middle of any alignment
!
C a u t i o n
Each alignment screen provides the ability to increase or decrease the softpot value by using the
slider or the spin buttons (
scale on the display indicates the minimum, maximum, and proposed value of the softpot.
procedure. Always left-click the Close button on t he screen to
return to the Tuner Main Menu screen before disconnecting
the radio. Improper exits from the Alignment screens may
leave the radio in an improperly configured state and result in
seriously degraded radio or system performance.
▲ and ▼), or by entering the new value from the keyboard. A graphical
June 11, 2003 6881096C73-O
Page 61
Radio Alignment Procedures: Radio Inform ati on 6-3
6.3 Radio Information
Figure 6-3 shows a typical Radio Information screen. All of the data appearing here is informational
and cannot be changed.
Figure 6-3. Radio Information Screen
6.4 Transmitter Alignments
6.4.1 PA Bias 1 Alignment
NOTE: This alignment is required after replacing (or servicing) the transceiver board.
The PA Bias 1 alignment procedure adjusts the drain bias current in one of the RF power amplifier
devices:
Table 6-1. PA Bias 1 Alignment RF Power Amplifier Devices
Band/Power Level Device
700–800 MHz 35 W/15 W Motorcycle Final1
NOTE: The antenna port should be terminated with a 50-ohm load while tuning.
1. Set the power supply voltage as indicated in Table 6-2. Set power supply current limit to 3 A.
Table 6-2. Power Supply Voltage Settings
Band/Power Level Supply Voltage (V) Supply Current Limit (A)
700–800 MHz 35 W/15 W Motorcycle 13.6 15
2. Select PA Bia s 1 from the Tuner Main Menu. When the screen is opened, the radio enters a
special bias tune mode and radio current increases by approximately 100 mA.
6881096C73-O June 11, 2003
Page 62
6-4 Radio Alignment Procedures: Transmitter Alignments
Figure 6-4. PA Bias 1 Alignment Screen
3. Read baseline current from current meter on power supply.
4. Add baseline current to device bias current to calculate target current.
Table 6-3. PA Bias 1 Alignment Device Bias Current
Band/Power Level Device bias current (mA)
700–800 MHz 35 W/15 W Motorcycle 250
5. Left-click the Bias Toggle button to apply bias to gate of device.
6. Adjust softpot value until target current is achieved within
7. Left-click the Bias Toggle button to remove bias from gate of device.
8. Left-click the Program All button to save tuned value.
9. Left-click Close button to close the screen and return to the Tuner Main Menu.
6.4.2 PA Bias 2 Alignment
NOTE: This alignment is required after replacing (or servicing) the transceiver board.
The PA Bias 2 alignment procedure adjusts the drain bias current in one of the RF power amplifier
devices:
Table 6-4. PA Bias 2 Alignment Amplifier Devices
700–800 MHz 35 W/15 W Motorcycle Final2
NOTE: The antenna port should be terminated with a 50-ohm load while tuning.
1. Set the power supply voltage as indicated in Table 6-5. Set power supply current limit to 3 A.
Table 6-5. Power Supply Voltage Settings
±10%
Band/Power Level Device
Band/Power Level Supply Voltage (V) Supply Current Limit (A)
700–800 MHz 35 W/15 W Motorcycle 13.6 15
June 11, 2003 6881096C73-O
Page 63
Radio Alignment Procedures: Transm itt er Align me nts 6-5
2. Select PA Bia s 2 from the Tuner Main Menu. When the screen is opened, the radio enters a
special bias tune mode and radio current increases by approximately 100 mA.
Figure 6-5. PA Bias 2 Alignment Screen
3. Read baseline current from current meter on power supply.
4. Add baseline current to device bias current to calculate target current.
Table 6-6. PA Bias 2 Alignment Device Bias Current
Band/Power Level Device bias current (mA)
700–800 MHz 35W/15W Motorcycle 250
5. Left-click the Bias Toggle button to apply bias to gate of device.
6. Adjust softpot value until target current is achieved within
7. Left-click the Bias Toggle button to remove bias from gate of device.
8. Left-click the Program All button to save tuned value.
9. Left-click Close button to close the screen and return to the Tuner Main Menu.
6.4.3 PA Bias 3 Alignment
NOTE: This alignment is required after replacing (or servicing) the transceiver board.
The PA Bias 3 alignment procedure adjusts the drain bias current in one of the RF power amplifier
devices:
Tab le 6- 7. PA Bias 3 Alignment Amplifier Devices
700–800 MHz 35 W/15 W Motorcycle Driver
NOTE: The antenna port should be terminated with a 50-ohm load while tuning.
±10%
Band/Power Level Device
1. Set the power supply voltage as indicated in Table 6-8. Set power supply current limit to 3 A.
Band/Power Level Supply Voltage (V) Supply Current Limit (A)
700–800 MHz 35 W/15 W Motorcycle 13.6 15
6881096C73-O June 11, 2003
Table 6-8. Power Supply Voltage Settings
Page 64
6-6 Radio Alignment Procedures: Transmitter Alignments
2. Select PA Bias 3 from the Tuner Main Menu. When the screen is opened, the radio enters a
special bias tune mode and radio current increases by approximately 100 mA.
Figure 6-6. PA Bias 3 Alignment Screen
3. Read baseline current from current meter on power supply.
4. Add baseline current to device bias current to calculate target current.
Table 6-9. PA Bias 3 Alignment Device Bias Current
Band/Power Level Device bias current (mA)
700–800 MHz 35 W/15 W Motorcycle 100
5. Left-click the Bias Toggle button to apply bias to gate of device.
6. Adjust softpot value until target current is achieved within
7. Left-click the Bias Toggle button to remove bias from gate of device.
8. Left-click the Program All button to save tuned value.
9. Left-click Close button to close the screen and return to the Tuner Main Menu.
6.4.4 Reference Oscillator Alignment
Radios are shipped from the factory with a worst-case frequency error of ±500 Hz for 700–800 MHz.
These specifications are tighter than the more stringent FCC requirements of ±1.5 ppm for the 700–
800 MHz bands.
For radios that have been in storage for over six months from the factory ship date, the reference
oscillator should be checked when the radio is initially deployed to the field. It is strongly
recommended that the reference oscillator be checked every time the radio is serviced or at least
once a year, whichever comes first.
The crystal contained in the reference oscillator naturally drifts over time due to its aging
characteristic. Periodic (annual) adjustment of the reference oscillator is important for proper radio
operation.
Improper adjustment can result in both poor performance and interference with other users operating
on adjacent channels.
±10%
June 11, 2003 6881096C73-O
Page 65
Radio Alignment Procedures: Transm itt er Align me nts 6-7
This test can be done with either the R-2670 Communication Analyzer or the Agilent 8901
Modulation Analyzer.
• Initial set up using the R-2670 Communication Analyzer:
- RF Control: MON ITOR
- B/W: WB
- Freq: RSS frequency under test
- Attenuation: 20dB
- Mon RF in: RF I/O
- Meter: RF Display
- Mode: STD
- Input Level: uV or W
- Display: Bar Graphs
- Squelch: Mid-range or adjust as necessary
• Initial set up using the Agilent 8901 Modulation Analyzer:
- Press the green Automatic Operation button on the analyzer.
- Press the FREQ key.
- Type 7.1 followed by the SPCL button to set the 8901 Modulation Analyzer for maximum
accuracy.
1. Select Reference Oscillator from the Tuner Main Menu (Figure 6-7).
2. If you are using the R-2670 analyzer, enter the frequency displayed on the Tuner screen in
the "RF control" section of the R-2670. Under the "Meter" section of the display, choose
RF DISPLAY.
3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen
indicates whether the radio is transmitting.
4. Wait five seconds until the analyzer reading stabilizes, and then record the transmitter
frequency.
6881096C73-O June 11, 2003
Figure 6-7. Reference Oscillator Window
Page 66
6-8 Radio Alignment Procedures: Transmitter Alignments
5. Adjust the reference oscillator’s softpot value until the measured value is as close as possible
to the frequency shown on the screen. Allow approximately five seconds for the analyzer
frequency reading to stabilize after each change. See Table 6-10.
Table 6-10. Reference Oscillator Alignment
Band Target
800 MHz ±100 Hz
6. Left-click the Pr ogra m All button on the screen to dekey the radio and save the tuned values.
7. Left-click the Close button on the screen to return to the Tuner Main Menu.
6.4.5 Power Detector Calibration
NOTE: This alignment is required after replacing (or servicing) the transceiver board.
The power detector calibration alignment procedure adjusts the buffer gain for the forward power
detector to minimize radio power variation from radio to radio.
NOTE: Antenna port should be terminated with calibrated power meter through a 30 db RF pad.
1. Set the power supply voltage and current limit as indicated in Table 6-11.
Table 6-11. Power Supply Voltage Settings
Band/Power Level Supply Voltage (V) Supply Current Limit (A)
700–800 MHz 35 W/15 W Motorcycle 13.6 15
2. Select Power Detection Calibration from the Tuner Main Menu.
Figure 6-8. Power Detection Calibration Alignment Screen
3. Left-click the PTT Toggle button to transmit at indicated frequency.
4. Adjust softpot value until target power is achieved.
5. Left-click the PTT Toggle button to disable transmit mode.
June 11, 2003 6881096C73-O
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Radio Alignment Procedures: Transm itt er Align me nts 6-9
6. Left-click the Program All button to save tuned value.
7. Left-click Close button to close screen and return to the Tuner Main Menu.
6.4.6 Tx Power Characterization
NOTE: This alignment is required after replacing (or servicing) the transceiver board.
The Tx Power Characterization alignment procedure characterizes power tuning so that Tx power
can be adjusted with CPS software. You will transmit at two power levels for each test frequency and
record the measured power level with 0.1 W resolution.
NOTE: The antenna port should be terminated with a calibrated power meter through a 30 db RF
pad.
1. Set the power supply voltage and current limit as indicated in Table 6-12.
Table 6-12. Power Supply Voltage Settings
Band/Power Level Supply Voltage (V) Supply Current Limit (A)
700–800 MHz 35 W/15 W Motorcycle 13.6 15
2. Select Tx Power Characterization from the Tuner Main Menu.
Figure 6-9. Tx Power Characterization Alignment Screen
3. Left-click in the first box of the Measured Power 1 column. A green circle will appear to the
left of box indicating active characterization point.
6881096C73-O June 11, 2003
Page 68
6-10 Radio Alignment Procedures: Transmitter Alignments
4. Left-click the PTT Toggle button to transmit at indicated frequency and record power
measurement with 0.1 W resolution. The green circle will turn red indicating that the radio is
transmitting.
5. Left-click the PTT Toggle button to disable transmit mode.
6. Enter the power meas u rem e nt w it h 0.1W resolution overwrit i ng an y va lu e th a t m ay resi d e in
the box from previous tuning.
7. Left-click in the first box of the Measured Power 2 column. The green circle will move to the
left of this box indicating it has become active characterization point.
8. Repeat steps 4-6.
9. Repeat steps 3-8 for the remaining frequencies.
10. Left-click the Program All button to save tuned value.
11. Left-click Close button to close screen and return to the Tuner Main Menu.
6.4.7 Tx Current Limit
NOTE: This alignment is required after replacing (or servicing) the transceiver board or after there
has been a change in the CPS-adjustable power level.
The Tx Current Limit alignment procedure tunes the Tx current-limiting protection. If you increase the
CPS-adjustable power level, then the current limit must be retuned so the radio can achieve the
desired power level. If you decrease the CPS-adjustable power level, the current limit can be retuned
to increase protection. You must first determine the test frequency at which maximum transmit
current occurs and then tune on that test frequency.
NOTE: The antenna port should be terminated with a calibrated power meter through a 30 dB RF
pad.
1. Set the power supply voltage and current limit as per Table 6-13.
Table 6-13. Power Supply Voltage Settings
Band/Power Level Supply Voltage (V) Supply Current Limit (A)
700–800 MHz 35 W/15 W Motorcycle 13.6 15
June 11, 2003 6881096C73-O
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Radio Alignment Procedures: Transmitter Alignments 6-11
2. Select Tx Current Limit from the Tuner Main Menu.
Figure 6-10. Tx Current Limit Alignment Screen
3. Use a slider or the spin buttons to change any one softpot value to 255.
4. Left-click the Program All button to save the tuned value. All softpots will change to 255, and
transmit-current limiting will be disabled.
5. Left-click in upper softpot box.
6. Left-click the PTT Toggle button to transmit and record radio the transmit current drain. The
tuner software uses a high CPS-adjustable power-level setting when transmitting.
7. Left-click the PTT Toggle button to disable transmit mode.
8. Repeat steps 6-8 for each test frequency to determine the frequency at which maximum
transmit current drain occurs.
9. Once the proper test frequency is determined, left-click the PTT Toggle button to transmit
and record transmit power on that test frequency.
10. Decrease the softpot value until transmit power degrades by 5%, and then left-click the PTT
Toggle button to disable transmit.
11. Increase the softpot value to set the proper operating head room.
Tab le 6- 14. Transmit Current Limit Offset
Band/Power Level Current Limit Offset
700–800 MHz 35 W/15 W Motorcycle 8
6881096C73-O June 11, 2003
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6-12 Radio Alignment Procedures: Transmitter Alignments
12. Left-click the Program All button to save tuned value.
13. Left-click the Close button to close screen and return to the Tuner Main Menu.
Table 6-15. Transmit Current Limit Devices
Band/Power Level Devices
700–800 MHz 35 W/15 W Motorcycle Final1 Final2 Driver
6.4.8 Tx Deviation Balance (Compe nsation)
NOTE: This alignment is required after replacing (or servicing) components on the transceiver board.
The Tx Deviation Balance (Compensation) alignment procedure balances the modulation
contributions of the low- and high-frequency portions of a baseband signal. Proper alignment is
critical to the operation of signaling schemes that have very low frequency components (for example,
DPL) and could result in distorted waveforms if improperly adjusted. This procedure needs to be
performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF
band is divided into frequency zones with a calibration point (value) in each zone. When performing
this tuning procedure the PTT Tone Low generates an 80 Hz modulation frequency. The deviation
level of this 80 Hz tone is used as the reference level for adjusting the deviation level of the PTT
Tone High, which is a 3 kHz modulation frequency.
This test can be done with either the R-2670 Communication Analyzer or the Agilent 8901
Modulation Analyzer. The method of choice is the R-2670 Analyzer.
• Initial set up using the R-2670 Communication Analyzer:
- Connect a BNC cable between the "DEMOD OUT" port and the "VERT/SINAD DIST/DMM
COUNTER IN" port on the R-2670.
- Press the SPF key on the R-2670 to display the "SPECIAL FUNCTIONS MENU." Move the
cursor to "High Pass," and select 5 Hz on the soft key menu. Select 20 kHz for the "Low
Pass" setting.
- In the "RF Control" section of the R-2670, enter the frequency displayed on the Tuner
screen. Move the cursor to the "B/W" setting and select "WIDE
menu.
- Place the R-2670 cursor in the "Display" zone. Select "AC VOLTS" on the soft key menu.
Move the cursor to the "Range" setting and select "AUTO."
• Initial set up using the 8901 Modulation Analyzer:
- Press the FM MEASUREMENT button. (The "Error 03-input level too low" indication is
normal until an input signal is applied.)
- Simultaneously press the Peak - and Peak + buttons. Both LEDs on the buttons should
light.
- Press the 15 kHz LP filter key.
±100 kHz" on the soft key
June 11, 2003 6881096C73-O
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Radio Alignment Procedures: Transmitter Alignments 6-13
1. Select TX Deviation Balance (Compensation) from the Tuner Main Menu. The screen will
indicate the transmit frequencies to be used.
Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen
2. Left-click the highest frequency field first.
3. Left-click the PTT Tone Low button.
4. Left-click the PTT Toggle button on the screen to enable transmission. The screen indicates
whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on R2670, or the deviation shown on the 8901 Analyzer, stabilizes.
5. Measure and record the AC voltage value from the R-2670 Analyzer or the deviation value
from the 8901 Analyzer.
6. Left-click the PTT Tone High button.
7. Adjust the softpot value until the measured deviation/voltage, when using the high tone, is
within
±1.5% of the value observed when using the low tone.
8. Repeat steps 3-7 for the remaining frequencies.
9. Left-click the Program All button on the screen to dekey the radio and save the tuned values.
10. Left-click the Close button on the screen to return to the Tuner Main Menu.
6881096C73-O June 11, 2003
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6-14 Radio Alignment Procedures: Transmitter Alignments
6.4.9 Tx Deviation Limit
NOTE: This alignment is required after replacing (or servicing) components on the transceiver board.
The Tx Deviation Limit alignment procedure limits the modulation of a baseband signal. It is used for
primary modulation limiting. This procedure needs to be performed at multiple frequencies to allow
for proper alignment across the entire RF band. The RF band is divided into frequency zones with a
calibration point (value) in each zone.
This test can be done with either the R-2670 Communication Analyzer or the Agilent 8901
Modulation Analyzer. The method of choice is the R-2670 Analyzer.
• Initial set up using the R-2670 Communication Analyzer:
- Connect a BNC cable between the "DEMOD OUT" port and the "VERT/SINAD DIST/DMM
COUNTER IN" port on the R-2670.
- Press the SPF key on the R-2670 to display the "SPECIAL FUNCTIONS MENU." Move the
cursor to "High Pass," and select 5 Hz on the soft key menu. Select 20 kHz for the "Low
Pass" setting.
- In the "RF Control" section of the R-2670, enter the frequency displayed on the tuner
screen. Move the cursor to the "B/W" setting and select "WIDE
menu.
- Place the R-2670 cursor in the "Display" zone. Select "AC VOLTS" on the soft key menu.
- Move the cursor to the "Range" setting and select "AUTO."
• Initial set up using the 8901 Modulation Analyzer:
- Press the FM MEASUREMENT button. (The "Error 03-input level too low" indication is
normal until an input signal is applied.)
- Simultaneously press the Peak - and Peak + buttons. Both LEDs on the buttons should
light.
- Press the 15 kHz LP filter key.
1. Select TX Deviation Limit from the Tuner Main Menu. The screen will indicate the transmit
frequencies to be used. See Figure 6-12 on page 6-15.
±100 kHz" on the soft key
June 11, 2003 6881096C73-O
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Radio Alignment Procedures: Transmitter Alignments 6-15
Figure 6-12. Tx Deviation Limit Alignment Screen
2. Left-click the highest frequency field first.
3. Left-click the PTT Toggle button on the screen to make the radio transmit. Wait
approximately 5 seconds until the deviation/voltage displayed on the analyzer stabilizes. The
screen indicates whether the radio is transmitting.
4. Adjust the deviation limit between 0.158 and 0.163 Vac on the R-2670 (2.785 to 2.885 kHz).
The optimum setting is 0.160 Vac (2.83 kHz).
5. Repeat steps 3-5 for the remaining frequencies.
6. Left-click the Program All button on the screen to dekey the radio and save the tuned values.
7. Left-click the Close button on the screen to return to the Tuner Main Menu.
6881096C73-O June 11, 2003
Page 74
6-16 Radio Alignment Procedures: Performance Testing
6.5 Performance Testing
6.5.1 Bit Error Rate (BER) Test
This procedure tests the Bit Error Rate (BER) of the radio’s receiver at a desired frequency and
contains the fields described in Table 6-16.
Figure 6-13. Bit Error Rate Screen
Table 6-16. Bit Error Rate Test Fields
Field Description
Rx Frequency Selects the Receive Frequency in MHz.
Test Pattern Selects the Digital test pattern - TIA. Choices are: Standard Tone
Test Pattern (framed 1011) and Standard Interface Test Pattern
(CCITT V.52).
Modulation Type Selects the digital modulation type of the incoming signal on which
BER is to be calculated.
Continuous Operation Allows the user to adjust the number of test repetitions. A sele cti on of
Yes will cause the radio to calculate BER on a continuous basis
indefinitely and update the results on this screen after each
integration time. A selection of No will cause the BER test to execute
only one sample and then update the display.
NOTE: When Continuous Operation = Yes, all fields will be grayed
out while the test is in progress. They will be enabled when
the test is complete, or if the STOP button is pressed.
When Continuous Operation = No, a wait cursor will be
displayed while the test is in progress and return to normal
when the test is done.
June 11, 2003 6881096C73-O
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Radio Alignment Procedures: Performance Testing 6-17
Table 6-16. Bit Error Rate Test Fields (Continued)
Field Description
Audio Allows the user to select the audio output during a test.
Selecting External will route the same sign al to the radio’s accessory
connector audio output.
Selecting Internal is not supported.
Selecting Mute will disable the audio output.
BER Integration Time Represents the amount of tim e during which the Bit Error Rate is to be
calculated. Remember that integration over a longer time period
results in a more precise measurement, at the expense of more time
per measurement.
NOTE: This is especially useful in fading measurements.
The range is from 0.360 to 91.8 seconds in increments of 0.360
seconds.
6.5.2 Transmitter Test Pattern
This procedure allows you to generate test patterns at selectable frequencies and channel spacing
to check the transmitter. The procedure contains the fields described in Table 6-17:
Table 6-17. Transmitter Test Pattern Fields
Field Description
Tx Frequency This field selects the Transmit Frequency directly in MHz.
Channel Spacing This field allows the user to select the desired transmit deviation in kHz.
Test Pattern Type This field represents the type of test pattern which will be transmitted by
the radio when the PTT Toggle button is pressed.
NOTE: Channel Spacing and Test Pattern Type fields will be grayed out while radio is transmitting.
6881096C73-O June 11, 2003
Figure 6-14. Transmitter Test Pattern Screen
Page 76
6-18 Radio Alignment Procedures: Mic Sensitivity Calibration
6.6 Mic Sensitivity Calibration
This procedure allows you to calibrate the microphone sensitivity level at each CPS setting
(-12, -9, .... +9, +12), eliminating tolerances and deviations in the microphone hardware lineup
circuitry. By tuning each CPS setting, the microphone sensitivity will be adjusted to exactly 3 dB
difference between every 2 consecutive settings throughout the programmable range of the circuit.
The Autotune All button will calibrate all nine settings in one adjustment.
Figure 6-15. Mic Sensitivity Calibration Screen
June 11, 2003 6881096C73-O
Page 77
Chapter 7 Encryption
7.1 Universal Crypto Module Kits
NOTE: This information applies to both conventional and trunked systems.
The encryption modules use a custom encryption IC and an encryption key variable to perform their
encode/decode functions. The encryption key variable is loaded into the encryption module using a
key variable loader (KVL). The encryption IC corresponds to the particular encryption algorithm
purchased.
Table 7-1 contains the Universal Crypto Module (UCM) kits and their corresponding algorithms for
secure-equipped XTL 5000 radios.
Table 7-1. UCM Kit Listing
Kit Number Description
NNTN4006 DES, DES-XL, DES-OFB ENCRYPTION KIT–UCM
NTN9837 DES, DES-XL, DES-OFB WITH DVP-XL ENCRYPTION KIT–UCM
NTN9838 DVI-XL ENCRYPTI ON KIT–UCM
NTN9839 DVP-XL ENCRYPTION KIT–UCM
7.1.1 Secure Interface Boards
Table 7-2 contains the secure interface board kits, which are used in conjunction with the UCM kits.
Every secure-equipped radio must contain one of the two secure interface board kits, which is paired
with one of the UCM kits.
Table 7-2. Secure Interface Board Kits
Kit Number Description
HLN6876 Secure Interface Board, 3-day key retention
HLN6877 Secure Interface Board, 30-second key retention
7.1.2 Secure Dispatch Operation
For personalities or talkgroups that are programmed to be secure-selectable, press and release the
Secure button to toggle between Secure and Clear.
• An illuminated secure status annunciator indicates that the transmitted signal will be encrypted
when the PTT button is pressed.
• The absence of the secure status annunciator indicates that the transmitted signal will not be
encrypted.
Page 78
7-2 Encryption: Load an Encryption Key
Whether the current personality is strapped for secure or clear, the secure status annunciator
correctly displays the transmit operation as being either secure (encrypted) or clear (non-encrypted).
NOTE: You cannot change from secure to clear while the PTT button is pressed. The radio will
generate an illegal tone and the transmission will be terminated.
Secure-equipped radios automatically determine whether a secure or clear voice message is being
received. This allows you to receive either type of message without having to reset the
programmable secure button.
7.1.3 Secure Emergency Operation
Clear or Secure emergency-call operation is determined by the programming of the selected mode
(or talkgroup) or the default emergency mode, if set up. Otherwise, transmit operation is controlled
by the setting of the secure, programmable button. You will not be able to change from Secure to
Clear, or from Clear to Secure, operation during an emergency call.
7.2 Load an Encryption Key
7.2.1 W3 Control Head
To load an encryption key into a W3 control-head equipped radio:
1. Ensure that an encryption module is installed in the radio.
2. Load an encryption key into the radio’s memory from a key-variable loader (KVL)
using the correct loader for the radio’s encryption type.
To load the key, attach the keyloader cable to the front of the radio. (Refer to the
KVL instruction manual for loading.)
3.
KEYLOADING is displayed on your radio while the key
transfer is in progress.
For single-key radios, a short tone sounds when a key is successfully loaded.
For multikey radios, an alternating tone sounds for a few seconds after keys are
successfully loaded.
NOTE: An invalid encryption key aborts a secure transmission.
displayed and a keyfail tone (consecutive medium-pitched beeps) sounds
until you release the PTT button.
4. If a mode is not programmed for either secure or clear-only operation, use th e
secure programmable button to select secure or clear transmission.
NOTE: You cannot change from secure to clear, or from clear to secure, while
pressing the PTT button.
KEYFAIL is
June 11, 2003 6881096C73-O
Page 79
Encryption: Advanced Secure Operation 7-3
7.2.2 W 4, W5, W7, and W9 Control Heads
To load an encryption key into a W4, W5, W7, or W9 control-head equipped radio:
1. Turn on the radio and set the volume level.
The position of the
2. Connect the cable from the key-variable loader (KVL) to the microphone connector
on the radio.
3. Load an encryption key into the radio’s memory from a KVL using the correct loader
for the radio’s encryption type.
Refer to your KVL user’s manual for more information on keyloading.
D button is not important.
7.3 Advanced Secure Operation
NOTE: The Advanced Secure feature is available only on radios that have been equipped by the
factory to support it. The radio must also be equipped with an encryption module.
Advanced Secure incorporates the Multikey feature and a dual-encryption feature into the existing
secure system. Multikey allows a radio to be equipped with multiple encryption keys. A default key is
included and is associated with the current mode. The keys are strapped to a given mode or are
operator-selectable and can be indexed into groups of keys called keysets. The keys are loaded
using a manual keyloader.
In addition, your radio can support up to eight different encryption algorithms simultaneously.
7.3.1 Multikey Operation
The multikey feature can be used in both conventional and trunked applications.
• Conventional Multikey - The encryption keys can be selectively strapped, one per each
channel. In addition, the programmable radio features include operator-selectable keys,
operator-selectable indices, and operator-selectable key erasure. Encryption keys are loaded
into the radio through a KVL.
• Trunked Multikey - If the radio is used for both conventional and trunked applications, the
encryption keys have to be strapped for trunking on a talkgroup, or announcement group, basis.
In addition, a different encryption key can be strapped to other features, such as Private Call,
Dynamic Regrouping, Failsoft, Interconnect, System Wide, or Emergency Talkgroup.
7.4 Erase a Key
This feature allows you to select any one, or all, of the encryption keys to erase.
6881096C73-O June 11, 2003
Page 80
7-4 Encryption: Erase a Key
7.4.1 W3 Control Head
1. Press > to scroll to ERAS.
2. Press the
m button below ERAS.
The last selected and stored key is displayed.
3. Do one of the foll owing:
NOTE:
ERASED alternates with the key name if you go to a key that has been
erased.
> to scroll forward in the list; press < to scroll backward.
Press
OR
With Direct Entry, press the numeric keys to jump to the desired encryption key.
4. Go to
Section 7.5: “Erase a Single Key (W3 Control Head)” on page 7-6.
June 11, 2003 6881096C73-O
Page 81
Encryption: Erase a Key 7-5
7.4.2 W 4, W5, W7, and W9 Control Heads
The Select Key t o Er as e feature allows you to manually select any one, or all, of the encryption keys
to erase.
1. To enter the Advanced Secure menu,
press and hold the
D button until a tone
sounds.
HOME SECURE
Home
H/L
Dim
Mic
INDICATOR
MODE
PWR
Mode
Vol
Mic
HOME
MODE
PWR
Mode
Vol
Mic
HOME
SECURE
DIM
HOME
DIM
HOME
INDICATOR
Phon
SECURE
SECURE
INDICATOR
SECURE
SECURE
SECURENET
Call SelScan
Phon
Scan
Phon
Scan
Model W4
Mode
XMIT
BUSY
MODE
KNOB
Model W5
Call Sel
XMIT
H/L Mon Dir
BUSY
Model W7
1
Ste
Call Sel
5
4
Sts
XMIT
7
H/L
8
BUSY
Model W9
Dir Mon
Volume
Pwr
2
Rpg
Mon
O#Del Rcl
3
Lck
6
Msg
9
Dir
XMIT BUSY
Scan
Emer Dir
Mode Vol Sel
MODE SELECT
Srch
Call
Pri
Non
Pri
Home
HOME
123
Page
Rpgm
456
Phon H/L Lock
789
Sts Msg
0
Rcl Sql
DIM
Site
Del
2. Turn the Mode knob (W4) or press t he Mode rocker switch (W5, W7, W9) to scroll to
the
ERASE KEY option.
3. Press the Sel button to enter the Key Erase menu.
The display changes to show the last key that was selected and stored after the Key
Erase menu was entered.
4. Turn the Mode knob (W4) or press t he Mode rocker switch (W5, W7, W9) to scroll to
the desired key.
5. To delete the selected key, press the Sel Button.
The radio deletes the key, and the display alternates between the key name and
ERASED.
NOTE: When you scroll to an erased key, the display alternates between the key
name and
ERASED.
6881096C73-O June 11, 2003
Page 82
7-6 Encryption: Erase a Single Key (W3 Control Head)
7.5 Erase a Single Key (W3 Control Head)
To erase a single key:
1. Press the
of the selected key.
ERASE SNGL KEY, YES and NO are displayed.
2. Press the button below
The internal selected key is set to zero.
ERASED is alternately displayed with the key name
confirming the erasure.
3. To exit the menu without erasing a key, press the
PTT button, or the mode button, or
The home mode is displayed.
m button below SNGL to request erasure
7.6 Erase All Keys
YES.
m button below ABRT, or the
O.
7.6.1 W3 Control Head
To erase all keys at the same time:
1. Press the
all keys.
ERASE ALL KEYS, YES and NO are displa ye d.
2. Press the button below
ERASED is alternately displayed with the key name
confirming the erasure.
m button below ALL to request erasure of
YES. All keys are erased.
June 11, 2003 6881096C73-O
Page 83
Encryption: Over-the-Air Rekeying 7-7
7.6.2 W 4, W5, W7, and W9 Control Heads
1. To enter the Advanced Secure
menu, press and hold the
D
button until a tone sounds.
HOME SECURE
Home
H/L
Dim
Mic
MODE
PWR
Mode
Vol
Mic
HOME
MODE
PWR
Mode
Vol
Mic
HOME
SECURE
INDICATOR
SECURE
DIM
HOME
SECURE
INDICATOR
SECURE
DIM
HOME
SECURE
INDICATOR
Phon
SECURENET
Call SelScan
Phon
Scan
Phon
Scan
Model W4
Mode
XMIT
BUSY
MODE
KNOB
Model W5
Call Sel
XMIT
H/L Mon Dir
BUSY
Model W7
1
Ste
Call Sel
4
Sts
XMIT
7
H/L
BUSY
Model W9
Dir Mon
Volume
Pwr
2
5
Rpg
8
Mon
O#Del Rcl
3
Lck
6
Msg
9
Dir
2. Turn the Mode knob (W4) or press the Mode rocker switch (W5, W7, W9) to
scroll to the
ALL option.
3. Press the Sel button to erase all the keys in the radio.
The display shows
seconds, followed by
PLS WAIT (W4, W5, W7) or PLEASE WAIT (W9) for two
ERASED being shown for about two seconds, then the
display reverts back to
4. To abort from the key-erase menu, press the HOME button or the PTT
button.
Pressing the PTT button causes the radio to transmit.
7.7 Over-the-Air Rekeying
The over-the-air rekeying (OTAR) feature allows the dispatcher to reprogram the encryption keys in
the radio remotely.
ALL.
XMIT BUSY
Scan
Emer Dir
Mode Vol Sel
MODE SELECT
DIM
Home
HOME
123
Call
Page
Rpgm
Site
456
Phon H/L Lock
Pri
Non
Pri
789
Sts Msg
0
Rcl Sql
Del
Srch
6881096C73-O June 11, 2003
Page 84
7-8 Encryption: Over-the-Air Rekeying
7.7.1 W3 Control Head
1. Press > until REKY appears.
2. Press
m below REKY.
REQUEST REKY is displayed.
3. Press the PTT button to send the rekey request.
PLEASE WAIT is displayed.
One of the following occu rs:
The radio sounds five tones when the dispatcher has
received the request.
NOTE: Any subsequent pressing of the PTT button will exit the feature and allow
you to transmit in the normal manner. Pressing
O or the emergency button
also exits the feature.
If the display momentarily shows
REKEY FAIL and a
bad-key tone sounds, the rekey operation failed
because the radio does not contain the Unique
Shadow Key (USK) or Unique Key Encryption Key
(UKEK).
You have to load the USK into the radio using the
KVL before the radio can be reprogrammed over the
air.
NOTE: If you exit at this point, but stay on the current channel in the dispatch mode,
the radio momentarily shows
REKEYED or DENIED and sounds a tone
indicating the status of the rekey request.
If the display shows
NO ACK and a bad-key tone
sounds, then the dispatcher has not acknowledged
your request after the radio has tried five times to
send it.
The radio then returns to the display message in step
2, allowing you to retry the request.
If the request is accepted and the radio is
successfully rekeyed, the display momentarily shows
REKEYED.
If the display momentarily shows
DENIED and a bad-
key tone sounds, the request has been denied by the
dispatcher, and the radio returns to the home display.
June 11, 2003 6881096C73-O
Page 85
Encryption: Over-the-Air Rekeying 7-9
7.7.2 W4, W5, W7, and W9 Control Heads
1. To enter the Advanced Secure
menu, press and hold the
D
button until a tone sounds.
HOME SECURE
Home
H/L
Dim
Mic
INDICATOR
MODE
PWR
Mode
Vol
HOME
Mic
HOME
MODE
PWR
Mode
Vol
Mic
HOME
SECURE
SECURE
DIM
SECURE
INDICATOR
DIM
HOME
INDICATOR
Phon
SECURE
SECURE
SECURENET
Phon
Phon
SECURE
Model W4
Call SelScan
XMIT
BUSY
Model W5
Scan
Call Sel
XMIT
BUSY
Model W7
Scan
Call Sel
XMIT
BUSY
Model W9
Mode
MODE
KNOB
Dir Mon
Volume
Pwr
H/L Mon Dir
1
Ste
2
5
Rpg
4
Sts
7
H/L
8
Mon
O#Del Rcl
Lck
3
6
Msg
9
Dir
XMIT BUSY
Scan
Emer Dir
Mode Vol Sel
MODE SELECT
Srch
Call
Pri
Non
Pri
Home
HOME
DIM
123
Page Rpgm
Site
456
Phon H/L Lock
789
Sts Msg
0
Rcl Sql
Del
2. Do one of the foll owing:
W4: Using the Mode knob, scroll to the
REKY option.
OR
W5, W7, or W9: Using the Mode rocker switch, scroll to the
REKY REQ
option.
3. To enter the rekey request menu, press and release the
SEL button.
4. To initiate a rekey request, press and release either the Sel button or the
PTT button.
The radio displays
PLS WAIT (W4, W5, W7) or PLEASE WAIT (W9).
6881096C73-O June 11, 2003
Page 86
7-10 Encryption: Over-the-Air Rekeying
5. One of the following occurs:
If the radio receives an acknowledgment from the dispatcher, five tones
sound.
If the radio does not receive an acknowledgment from the dispatcher, the
display shows
NO ACK.
After the radio is rekeyed, it displays
REKEYED and returns to dispatch mode.
If the dispatcher does not allow it to be rekeyed, the radio displays
and returns to dispatch mode after three seconds.
6. Press
O to exit and return to normal operation.
DENIED
June 11, 2003 6881096C73-O
Page 87
Chapter 8 Disassembly/Reassembly Procedures
8.1 Introduction
This section details the procedures necessary to remove and replace the printed circuit board in the
ASTRO XTL 5000 radio. After troubleshooting and determining what needs to be replaced,
disconnect the test equipment, the antenna cable, and the power cable.
Disconnect the power cable from the radio before
!
!
W A R N I N G
Locate the exploded view of the radio in Chapter 11. Exploded Views and Parts Lists. Keep it handy
for reference as you disassemble and reassemble the radio.
When installing a new circuit board, all mounting screws should be started before any are torqued.
This will help ensure proper alignment.
After installing a new board, perform a complete alignment procedure as outlined in Chapter 6.
Radio Alignment Procedures.
opening and removing the PCB. Failure to remove power
can result in unit damage caused by transients or
accidental shorts, as well as presenting a shock hazard.
8.2 Replacement Procedures
After performing alignment procedures, always exit the SERVICE menu
!
C a u t i o n
8.2.1 Required Tools and Supplies
entirely (to the MAIN MENU) to properly save all changes. Failure to do so can
result in an alignment, or other, failure.
Table 8-1. Required Tools and Supplies
Tools and Supplies
2.5 mm hex-key bit
Anti-static grounding kit 0180386A82
Chassis eliminator 8180384N71
Control-head button extraction tool 6685629A01
Control-head interconnect service cable
Dismantling tool 6686119B01
Electromagnetic Interference (EMI) metallic shielding
tape, or equivalent
Motorola
Part Number
1185984D01
Flat-blade screwdriver
Page 88
June 13, 2003 6881096C73-O
8-2 Disassembly/Reassembly Procedures: Replacement Procedures
8.2.2 Control Head Boards Disassembly/Reassembly
8.2.2.1 W3 Disassembly
NOTE: Bracketed numbers are identical to item numbers shown in Figure 11-1. “W3 Hand-Held
Control Head Exploded View” on page 11-2.
1. Remove the strain-relief boot covering the control-head cable connector [15] from the
housing assembly [7] by pulling it away from the control head until they are completely
separated.
2. Carefully remove the rubber seal (part of cable assembly [15]) from the housing assembly [7]
opening.
NOTE:Take care to avoid damaging this seal.
3. Using a small screwdriver, remove the seal support wedge [14] from the control head.
4. Using a small screwdriver to depress the telco lever, remove the telco connector at the end of
the cable assembly [15] from the control head, and pull the cable assembly away from the
housing (like a telephone jack).
5. Remove the rear cover assembly [2] from the control head.
Locate the recesses in the lower portion of the housing on both sides of the rear cover’s snap
features and, prying the snaps until the two parts separate, remove the rear cover from the
unit.
6. Remove the two snap retainers [4] from between the SB9600 circuit board [5] and the
housing assembly [7].
7. Disconnect the microphone assembly [8] connector from the SB9600 circuit board [5].
8. Carefully remove the microphone assembly [8] from the keypad [6].
NOTE:Be careful to avoid damaging circuit-board components in the next step.
9. There are seven snaps locking the circuit board to the housing. Carefully pry the housing’s
snap features from the SB9600 circuit board [5]. As the snap features are deflected, push the
circuit board upward, using the keypad, to release the circuit board from the snap features.
10. Remove the circuit board assembly from the housing assembly [7].
11. Remove the keypad [6] from the housing assembly [7].
Magnetic screwdriver set with bits 0180320B16
Mini-UHF to N-type adapter cable 3085651A01
Plastic scraping tool 6686119B01
Removal and insertion tool 6680163F01
Roto-Torq adjustable driver RSX4043
Small, flat-blade screwdriver
Solder aid (black stick), Hexacon Electric Co. MA-800G
Torx® T10 and T20 drivers
Table 8-1. Required Tools and Supplies (Continued)
Tools and Supplies
Motorola
Part Number
Page 89
6881096C73-O June 13, 2003
Disassembly/Reass em bly Proced ur es: Replacement Procedures 8-3
12. Remove the PTT boot [12] and the PTT lever [10] from the housing assembly [7].
13. Remove the PTT actuator [9] from the housing assembly [7].
14. If damaged, remove the nameplate label [13] from the front of the housing assembly [7].
15. Remove the transmit indicator [11] from the housing assembly [7].
8.2.2.2 W3 Reassembly
NOTE: Bracketed numbers are identical to item numbers in Figure 11-1. “W3 Hand-Held Control
Head Exploded View” on page 11-2.
1. Insert the transmit indicator [11] into the housing assembly [7]. Ensure that the top surface of
the lightpipe is below the label rece ss of the housi ng.
2. Attach the nameplate label [13] to the front of the housing assembly [7]. Ensure that the label
is securely attach ed.
3. Install the PTT actuator [9] into the housing assembly [7]. Ensure that its lip is seated in the
grove in the housing.
4. Install the PTT lever [10] and the PTT boot [12] into the housing assembly [7]. Ensure that the
lever is seated in its nest and the boot is located properly in the recesses in the housing.
5. Install the keypad [6] into the housing assembly [7]. Ensure that all of the keys are located in
the correct openings in the housing.
6. Install the microphone assembly [8] into the keypad. Ensure that the front surface of the
cartridge is located up against the keypad membrane.
NOTE:The membrane is the rain seal and is very sensitive to puncture by sharp objects.
7. Connect the microphone assembly [8] connector to the mating location on the SB9600 circuit
board [5].
8. Install the circuit board [5] into the housing assembly [7] as follows:
a. Hold the housing assembly so that its key openings face downward and its top faces away
from you.
b. Insert the circuit board’s display down under the housing retention features, and rotate the
board downward, ensuring that the board is positioned between the snap features. Ensure
that the microphone assembly’s [8] wire passes through the opening in the circuit board.
c. Press downward firmly on the board until the seven snap features lock the board into
place.
9. Install the two snap retainers [4] between the circuit board and the side wall of the housing
assembly [7], one on each side.
10. Install the main seal [3] onto the rear cover assembly [2], placing the seal under the retainer
features around the perimeter of the cover.
11. Install the rear cover assembly [2] onto the housing assembly [7].
Starting at the top of the cover, pivot the cover toward the housing and squeeze the two
halves together until the snap features at the lower end of the rear cover engage the
housing’s features and snap closed.
12. Insert the cable assembly’s [15] telco connector into the opening in the bottom of the housing,
ensuring that it correctly is oriented.
13. Press the telco connector in place until it snaps in (like a phone plug).
14. Place the seal support wedge [14] into the housing’s opening, orientating it so that its long
portion is under the telco connector lever, and then push until it is properly seated.
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8-4 Disassembly/Reassembly Procedures: Replacement Procedures
15. Push the rubber seal (part of the cable assembly [15]) into the housing’s opening and ensure
that it is properly seated.
NOTE:This seal must be inserted completely into the housing to ensure the rain seal.
16. Push the strain relief boot (part of the cable assembly [15]) into the housing, and ensure that
it is properly seated.
17. Insert the kit label [1] into the recess on the rear cover, ensuring that it is securely attached.
8.2.2.3 W4, W5, and W7 Disassembly
NOTE: For the following procedure, refer to Chapter 11. Exploded Views and Parts Lists, beginning
on page 11-1, for the exploded view and associated parts list applicable to the model being
disassembled.
1. Unplug the microphone.
2. Remove the two front panel screws using a 2.5 mm hex-key driver.
3. Disconnect the control cable on remot e mo dels.
4. Grasp the front panel firmly, and carefully unplug the control head assembly from the radio or
remote control head back housing. For dash-mount models, unplug the interconnect flex
cable from the control head.
5. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar
the display.
6. Using a Torx T10 driver, remove the control head screws:
- W4 control head: four screws [callouts 5-8], as shown in Figure 8-1 on page 8-4.
The W4 control head has, in addition to the screws, four snap features [callouts 1-4], which are
shown in Figure 8-1 on page 8-4.
- W5 and W7 control heads: seven screws, as shown in F igur e 8-2 on page 8-5.
58
4
3
7 1
2 6
Figure 8-1. W4 Rotary Control-Head Assembly Screw and Snap Sequence
June 11, 2003 6881096C73-O
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Disassembly/Reassembly Procedures: Replacement Procedures 8-5
416
3
Figure 8-2. W5 and W7 Pushbutton Control-Head Assembly Screw Sequence
7. Carefully separate the printed circuit board, internal spacer, and elastomer keypad assembly
from the front panel.
On rotary control-head models, care must be taken not to damage the flex circuit when
separating the printed circuit board from the front housing. Do not disturb the buttons in the
front panel.
On rotary control-head models, the flex circuit must also be unplugged.
8. On rotary control-head models, desolder the XMIT and BUSY LED before removing the
elastomer keypad.
9. Re mov e the ela sto mer key pad from the print ed circui t boar d.
5
7
2
NOTE:Before you unsnap the PC board, notice that the board slips under a hook on the
right and snaps on the left. This will facilitate assembly.
10. Remove the PC board from the internal spacer. The PC board snaps into and out of the
spacer.
8.2.2.4 W4, W5, and W7 Reassembly
NOTE: For the following procedure, refer to Chapter 11. Exploded Views and Parts Lists, beginning
on page 11-1, for the exploded view and associated parts list applicable to the model being
reassembled.
1. To reassemble, snap the PC board into the internal spacer. Before you press the elastomer
keypad into the board, make sure that the conductive pads in the board and the elastomer
keypad are clean and free of any foreign material.
2. On rotary control-head models, solder the XMIT and Busy LEDs onto the PC board.
NOTE:On rotary control-head models, the flex circuit must be connected to the PC board
prior to attaching the PC board to the spacer.
3. Install the PC board internal spacer and elastomer keypad assembly into the front panel.
Replace the screws and torque them to 6-8 in.-lbs.
When reassembling the control head, make sure the
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microphone pins are properly inserted through the elastomeric
keypad. Also make sure the elastomeric keypad inserts are
secured to the PC board.
6881096C73-O June 11, 2003
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June 13, 2003 6881096C73-O
8-6 Disassembly/Reassembly Procedures: Replacement Procedures
4. For dash-mounted radios, plug the interconnect flex from the radio into the control head, slide
the control head into the headbridge, and fasten the control head with the two front panel
screws (torqued to 6-8 in.-lbs).
OR
For remote-mount control heads, replace the front panel into the remote control head back
housing, make sure the gasket is in place, then torque the screws to 6-8 in.-lbs. Replace any
plugs and cables on the rear of the control head.
8.2.2.5 W9 Disassembly
NOTE: Bracketed numbers are identical to item numbers in Figure 11-4. “W9 Pushbutton Control
Head Exploded View” on page 11-5.
NOTE: Before disassembling the W9 control head, note the location of the labeled bottom.
1. Using a Torx T15 driver, remove the two 30mm machine screws [29] from the back housing
[31] of the control head.
2. Fold the front housing [41] over so that the front housing is face down and the back housing is
on your working surface with the flex cable [18] attached.
3. Using a Torx T10 driver, remove the five 8mm tapping screws [17] from the Display Board Kit
[37], the two 10mm captive screws [12] with the leaf assembly spring [11], and the two 16mm
tapping screws [38] from the control PC board.
4. Remove the Command Board Kit [36] from the back housing and the Display Board Kit [37]
from the front housing.
5. Remove the elastomer keypad [7], ON/OFF switch gasket [34], the “D” Connector Gasket
[33], the solder side shield [16], and the component side shield [19] from the PC boards.
NOTE:Be careful to not bend the tabs on the shields when removing them and align them
carefully when replacing the shields. When working with chips and SOT (small
outline transistor) parts, use extreme caution when heating. Never reuse a chip or
SOT part; always replace with the correct Motorola part.
8.2.2.6 W9 Reassembly
NOTE: Bracketed numbers are identical to item numbers in Figure 11-4. “W9 Pushbutton Control
Head Exploded View” on page 11-5.
1. Install the new PC board with the elastomer keypad, the ON/OFF switch gasket, the “D”
Connector Gasket, the “D” Connector O-ring, the solder-side shield, and the component-side
shield in the appropriate locations.
2. Reassemble the Command Board Kit [36] into the back housing [31], making sure that the
power switch is in the proper location and replace the two tapping screws [38], torquing them
to 6-8 in.-lbs.
3. Reassemble the Display Board Kit [37] into the front housing [41], making sure that the
elastomer keypad [7] is in the proper location.
Take care to avoid misalignment of connector pins. On dash
mount radios, remove the radio top cover to allow visual
inspection during connector alignment.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-7
4. Replace the captive screws [12] and the leaf assembly spring [11] in the front housing, and
torque them to 6-8 in.-lbs.
NOTE:Before assembling the leaf assembly spring, check that the insulator [10] on the
board is present. Ensure that the leaf assembly spring and captive screws are
aligned properly to prevent stripping the front housing screw bosses.
5. Close the assembly by replacing the front housing [41] and the two screws in the back
housing [31]. Torque the screws to 6-8 in.-lbs.
8.2.3 Remote Back Housing Interface Board Disassembly/Reassembly
8.2.3.1 W4, W5, and W7 Disassembly
1. Unplug the microphone.
2. Disconnect the control cable from the control head on remote models.
3. Remove the two front panel screws using a 2.5 mm hex-key driver.
4. Grasp the front panel firmly, and carefully unplug the control head assembly from the radio or
remote control head back housing.
5. Remove the two remote back housing interface attachme nt screw s.
6. Remove the remote control head interface board from the remote control head back housing.
8.2.3.2 W4, W5, and W7 Reassembly
1. Attach the new interface PC board to the back housing with two screws torqued to 6-8 in.-lbs.
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C a u t i o n
2. Reassemble the back housing to the front housing with two screws torqued to 4-6 in.-lbs.
Take care to avoid misalignment of connector pins.
8.2.4 Remote Interconnect Board Assembly/Reassembly
8.2.4.1 Assembly
1. Remove the two front panel screws using a 2.5 mm hex key driver.
2. Grasp the front panel firmly, and carefully unplug it from the radio.
3. Remove the three screws that hold the remote interconnect board to the front panel using a
Torx T10 driver.
4. Install the new remote interconnect board onto the front panel, and replace the screws.
Torque the screws to 6-8 in.-lbs.
Take care to avoid misalignment of connector pins. Remove
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6881096C73-O June 11, 2003
the radio top cover to allow visual inspection during connector
alignment.
Page 94
8-8 Disassembly/Reassembly Procedures: Replacement Procedures
8.2.4.2 Reassembly
1. Reconnect the interconnect flex to the radio, noting proper alignment of the mating
connections.
2. Reassemble the front panel into the radio and replace the screws.
3. Torque the screws to 6-8 in.-lbs.
8.2.5 Radio Disassembly
Use the following procedure to disassemble your radio:
1. Ensure all accessory connections, power, antenna, and microphone are unplugged.
If the radio is a remote-mount radio, disconnect the remote-mount control cable from the front
of the transceiver.
2. Remove the two front control-head screws using a 2.5 mm hex-key bit. Save them for later
use.
Figure 8-3. Removing the Front Panel Screws
June 11, 2003 6881096C73-O
Page 95
Disassembly/Reassembly Procedures: Replacement Procedures 8-9
3. Firmly grasp the front panel of the control head, and carefully remove the control-head
assembly from the radio. Be careful not to pull on the attached flex.
Figure 8-4. Removing the Control Head
4. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar
the face of the display.
5. Carefully disconnect the control-head flex from the control head or remote interconnect
panel, and set the control head aside.
Figure 8-5. Removing the Flex (Control-Head Connector)
6881096C73-O June 11, 2003
Page 96
8-10 Disassembly/Reassembly Procedures: Replacement Procedures
6. Remove the plastic headbridge by squeezing in the center of the top and bottom sides of the
part and pulling away from the transceiver.
NOTE:Be careful to avoid pulling on the flex.
Figure 8-6. Removing the Headbridge
7. Carefully remove the control-head flex from the transceiver by grasping the provided handle
and separating it from the connector.
Figure 8-7. Removing the Flex (Main-Board Connector)
June 11, 2003 6881096C73-O
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Disassembly/Reassembly Procedures: Replacement Procedures 8-11
Figure 8-8. Control-Head Flex (Removed)
8. Remove the headbridge seal from the transceiver.
Figure 8-9. Headbridge Seal (Removed)
The following steps MUST be performed for secure-equipped
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C a u t i o n
6881096C73-O June 11, 2003
radios prior to removal of the cover or damage to the radio
could occur.
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8-12 Disassembly/Reassembly Procedures: Replacement Procedures
9. For secure option-equipped radios, do the following prior to disassembly of the transceiver:
a. Remove the two screws holding the secure (UCM) shield in place.
b. Pull the UCM shield away from the assembly and remove it.
c. Insert a flathead screwdriver into the space in the upper-left corner of the secure pocket,
and gently pry the secure interface board (universal encryption module) away from the
chassis.
Flat
Blade
Screwdriver
Secure
Interface
Board
Screws
Secure
Shield
Universal
Encryption
Module
Figure 8-10. Removing the Secure Interface Board
MAEPF-27658-O
June 11, 2003 6881096C73-O
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Disassembly/Reassembly Procedures: Replacement Procedures 8-13
10. Remove the 10 top-cover screws using a T20 Torx bit. These screws have sealing washers
that should be kept with the screw.
Figure 8-11. Removing the Top Cover Screws
1 1. Remove the top cover by lifting up simultaneously on both side edges. It may be necessary to
gently pry the cover off using a plastic tool.
6881096C73-O June 11, 2003
Figure 8-12. Lifting the Top Cover
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8-14 Disassembly/Reassembly Procedures: Replacement Procedures
Figure 8-13. Removing the Top Cover
12. Disconnect the rear accessory jack’s flex from the main board.
Figure 8-14. Removing the J2 Rear Accessory Flex from the Main Board
June 11, 2003 6881096C73-O
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