Motorola ASTRO XTS 5000 I, ASTRO XTS 5000 II, ASTRO XTS 5000 III Basic Service Manual

Download

Page 1

ASTRO®XTS 5000

™

Digital Portable Radios Basic Service Manual

Model I

Model II

Model III

Page 2

Foreword This manual covers all models of the ASTRO

Portable Radio, unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level, and is typical of some local service centers, self-maintained customers, and distributors.

Included in this manual are: radio specifications for the 700/800 MHz frequency band; a general description of ASTRO Digital XTS 5000 models; recommended test equipment, service aids, and tools; radio alignment procedures; disassembly/reassembly procedures; exploded views and parts lists, and general maintenance recommendations.

For details on the operation of the radio, or component-level troubleshooting, refer to the applicable manuals, available separately. To help you with your selection, a list is provided under “Related Publications” at the front of this manual.

Digital XTS 5000™

Safety Before operating an ASTRO XTS 5000 Radio, please read the “User

Safety, Training, and General Information” section in the front of this manual.

Manual Revisions Changes which occur after this manual is printed are described in

“FMRs.” These FMRs provide complete information on changes, including pertinent parts list data.

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, 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.

Page 3

Table of Contents ➠

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside front cover

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover

Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside front cover

Computer Software Copyrights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside front cover

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

Commercial Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Motorola Communication Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Portable Radio Model Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

ASTRO Digital XTS 5000 Model Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

ASTRO Digital XTS 5000 R (Ruggedized) Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Specifications for 700/800 MHz Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

User Safety, Training, and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

Compliance with RF Energy Exposure Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Operational Instructions and Training Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Electromagnetic Interference/Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Medical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Driver Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Operational Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Operational Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Intrinsically Safe Radio Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xix

FMRC Approved Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xix

Repair of FMRC Approved Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notations Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Radio Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FLASHport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

, Motorola, ASTRO, and Private-Line are registered trademarks of Motorola, Inc.

XTS 5000, FLASHport, and Digital Private-Line are trademarks of Motorola, Inc.

All other product or service names are the property of their respective owners.

Basic Service Manual

68P81094C28-O

Page 4

Table of Contents

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

XTS 5000 R Radios Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 - Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Analog Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transmitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ASTRO Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Transceiver (XCVR) Board Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VOCON Board Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 - Recommended Test Equipment and Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Field Programming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 - Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Display Radio Test Mode (Models II/III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Entering Display Radio Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

RF Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Control Top and Keypad Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Non-Display Radio Test Mode (Model I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Entering Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

RF Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Top and Keypad Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6 - Radio Alignment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Softpot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Radio Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transmit Power Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Transmit Deviation Balance Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Transmit Deviation Limit Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Front End Filter Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure for 700 MHz Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure for 800 MHz Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure for UHF/VHF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Bit Error Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Bit Error Rate Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Transmitter Test Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Transmitter Test Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7 - Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Loading an Encryption Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Multikey Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Selecting a Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Page 5

Table of Contents

Using the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Using the Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Selecting an Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Using the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Using the Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Erasing a Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Method 1 — Key Zeroization (Multikey Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Method 2 — All Keys Erased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8 - Disassembly/Reassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Attach the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Remove the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Attach the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Attach the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Remove the Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remove the Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Attach the Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Remove the Frequency Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install the Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remove the Volume Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Install the Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Radio Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Ensuring Radio Submergibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Specialized Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Troubleshooting Leak Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

9 - Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Power-Up Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Operational Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10 - Exploded Views and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

11 - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Audio Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Carry Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Belt Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Belt Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Carry Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

iii

Page 6

Table of Contents

Enhanced and Multi-Unit Line Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Commport Integrated Microphone/Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Headset / Surveillance Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Earpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Headset Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Ear Microphones (Require Radio Interface Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Radio Interface Modules for Ear Microphones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Remote Speaker and Public Safety Microphones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Vehicular Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Allied Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

12 - Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Page 7

List of Figures

Figure 1. XTS 5000 Overall Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2. Receiver Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 3. Transceiver Block Diagram (Power and Control Omitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 4. Radio Alignment Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 5. Tuner Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 6. Typical Softpot Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 7. Radio Information Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 8. Reference Oscillator Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 9. Transmit Power Alignment Screen (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 10. Transmit Deviation Balance Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Figure 11. Transmit Deviation Limit Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 12. Front End Filter Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 13. Bit Error Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 14. Transmitter Test Pattern Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 15. Attach the antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 16. Remove the antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 17. Insert the top edge of the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 18. Press the battery into place. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 19. Press the release button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 20. Remove the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 21. Align the belt clip with the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 22. Press the belt clip into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 23. Press the belt clip tab away from the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 24. Remove the belt clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 25. Insert a screwdriver below the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 26. Remove the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 27. Hook the end into the slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 28. Press the cover into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 29. Partial Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Page 8

List of Tables

Table 1. ASTRO XTS 5000 Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table 2. Local Oscillator and First IF Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 3. Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table 4. Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Table 5. Initial Equipment Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 6. Front-Panel Access Test-Mode Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 7. Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 8. Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 9. Receiver Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 10. Receiver Tests for ASTRO Conventional Channels*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table 11. Transmitter Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 12. Transmitter Tests for ASTRO Conventional Channels*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 13. Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 14. Transmit Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 15. Partial Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Table 16. Submersible Radio Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Table 17. Power-Up Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Table 18. Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Table 19. Receiver Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Table 20. Transmitter Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Table 21. Encryption Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Page 9

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 XTS 5000 Portable Units 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.

II.General Provisions

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.

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

vii

Page 10

Commercial Warranty

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.

III.State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.

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

IV.How To Get Warranty Service

V.What This Warranty Does Not Cover

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.

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 (including, 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.

viii

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.

Page 11

Commercial Warranty

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.

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 beco me, t he sub ject of a cl aim o f infringeme nt of a U nited State s pat ent, 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.

Page 12

Portable Radio Model Numbering System

Typical Model Number:

Position:

Position 1 - Type of Unit

D = Dash-Mounted Mobile Radio

H = Hand-Held Portable

M = Motorcycle Mobile Radio T =Trunk-Mounted Mobile Radio

Positions 2 & 3 - Model Series

18 = XTS 5000

Position 4 - Frequency Band

A B C D F G H J K L M

04 = ASTRO

Less than 29.7MHz

29.7 to 35.99MHz

36 to 41.99MHz

42 to 50MHz

66 to 80MHz

74 to 90MHz

Product Specific

136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

H18 U CF 9 P W 7 A N S P 0 1

T04S LF 9 PW 7 A N S P 0 1 123 4 5 6 7 8 91011 1213141516

336 to 410MHz

403 to 437MHz

438 to 482MHz

470 to 520MHz

Product Specific

U = 764 to 870 MHz

806 to 870MHz

825 to 870MHz

896 to 941MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

Values given represent range only; they are

not absolute.

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Position 7 - Channel Spacing

1 = 5kHz 2 = 6.25kHz 3 = 10kHz 4 = 12.5kHz

5 = 15kHz 6 = 20/25kHz 7 = 30kHz 9 = Variable/Programmable

10.1 to 15 Watts

16 to 25 Watts

26 to 35 Watts

36 to 60 Watts

= 61 to 110 Watts

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

Conventional

Privacy Plus¤

Clear SMARTNET“

Advanced Conventional Stat-Alert“

Enhanced Privacy Plus¤

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS“

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet

Phonenet¤

Programmable

Secure Conventional

Secure SMARTNET“

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

* MPT = Ministry of Posts and Telecommunications

Position 8 - Primary Operation

Conventinal/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Programmable

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

Page 13

ASTRO Digital XTS 5000 Model Chart

MODEL NUMBER DESCRIPTION

H18UCC9PW5AN 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model I

H18UCF9PW6AN 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model II

H18UCH9PW7AN 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model III

ITEM NUMBER DESCRIPTION

X X X NUF3577_ Board, Transceiver (700/800MHz) X X X NTN9564_ Board, VOCON * X X X NTN8266_ Belt Clip Kit X X X HNN9031_ Battery, Nickel-Cadmium, Ultra-High Capacity X NTN9682_ Kit, Front Cover, Model I

X NTN9681_ Kit, Front Cover, Model II

X NTN9680_ Kit, Front Cover, Model III X X X NAF5080_ Antenna, 700/800 MHz X X X 0985973B01 Assembly, B+ Connector X X X 1505579Z01 Cover, Accessory Connector X 2685567D01 Assembly, VOCON Shield, Model I

X 2685567D02 Assembly, VOCON Shield-Keypad, Model II

X 2685567D03 Assembly, VOCON Shield-Keypad, Model III X X X 2685220D02 Shield, RF Board X X X 2785219D01 Assembly, Casting X X X 2885866A01 Connector, Compression, 26-Pin X X X 3205082E96 Gasket, Antenna O-Ring X X X 3205349Z03 Seal, Main X X X 3205351Z02 Seal, B+ X X X 3285877B02 Seal, Port X X X 3385873B01 Label, Port

X X 7285726C01 Module, LCD Display X X 7585189D01 Pad, Display Locator X 7585104D02 Keypad, Model II

X 7585104D01 Keypad, Model III

Notes: X =Item Included * = The radio’s model number, FLASHcode, Host code, and DSP code are required when placing an order for the VOCON Board.

• The model number and (sometimes) the FLASHcode, can be found on the FCC label on the back of the radio.

• The model number, Host code, DSP code, and (sometimes) the FLASHcode, can be found by putting a Model II or III

radio into the Test Mode.

• The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (RKN4105_ or

RKN4106_) and the CPS to read a Model I, II, or III radio.

Page 14

ASTRO Digital XTS 5000 R (Ruggedized) Model Chart

MODEL NUMBER DESCRIPTION

H18UCC9PW5AN w/Q155FP Opt Ruggedized 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model I

H18UCF9PW6AN w/Q155FQ Opt Ruggedized 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model II

H18UCH9PW7AN w/Q155FR Opt Ruggedized 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model III

H18UCC9PW5AN w/Q155GB Opt Ruggedized Yellow 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model I

H18UCF9PW6AN w/Q155GC Opt Ruggedized Yellow 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model II

H18UCH9PW7AN w/Q155GD Opt Ruggedized Yellow 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model III

ITEM NUMBER DESCRIPTION

X X X X X X NUF3577_ Board, Transceiver (700/800 MHz) X X X X X X NTN9564_ Board, VOCON * X X X X X X NTN8266_ Belt Clip Kit X X X X X X NTN8297_ Battery, Nickel-Cadmium (1525mAh) X NNTN4059_ Kit, Front Cover, Model I, Ruggedized

X NNTN4060_ Kit, Front Cover, Model II, Ruggedized

X NNTN4061_ Kit, Front Cover, Model III, Ruggedized

X NTN9685_ Kit, Yellow Front Cover, Model I, Ruggedized

X NTN9684_ Kit, Yellow Front Cover, Model II, Ruggedized

X NTN9683_ Kit, Yellow Front Cover, Model III, Ruggedized X X X X X X NAF5080_ Antenna, 700/800 MHz X X X X X X 0985973B02 Assembly, B+ Connector X X X X X X 1505579Z01 Cover, Accessory Connector X X 2685567D01 Assembly, VoCon Shield, Model I

X X 2685567D02 Assembly, VoCon Shield-Keypad, Model II

X X 2685567D03 Assembly, VoCon Shield-Keypad, Model III X X X X X X 2685220D02 Shield, RF Board X X X X X X 2785219D04 Assembly, Ruggedized Casting X X X X X X 2885866A01 Connector, Compression, 26-Pin X X X X X X 3205082E96 Gasket, Antenna O-Ring X X X X X X 3205349Z03 Seal, Main X X X X X X 3205351Z02 Seal, B+ Ruggedized X X X X X X 3285877B02 Seal, Port X X X X X X 3385873B01 Label, Port

X X X X 7285726C01 Module, LCD Display X X X X 7585189D01 Pad, Display Locator X X 7585104D02 Keypad, Model II

X X 7585104D01 Keypad, Model III

Notes: X =Item Included * = The radio’s model number, FLASHcode, Host code, and DSP code are required when placing an order for the VOCON Board.

• The model number and (sometimes) the FLASHcode, can be found on the FCC label on the back of the radio.

• The model number, Host code, DSP code, and (sometimes) the FLASHcode, can be found by putting a Model II or III

radio into the Test Mode.

• The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (RKN4105_ or

RKN4106_) and the CPS to read a Model I, II, or III radio.

xii

Page 15

SPECIFICATIONS FOR 700/800 MHZ RADIOS

All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted

GENERAL RECEIVER TRANSMITTER

FCC Designation: AZ489FT5806 Temperature Range:

Operating: –30°C to +60°C Storage: –40°C to +85°C

Power Supply: Nickel-Cadmium Battery (NiCd)

or Nickel-Metal-Hydride Battery (NiMH)

or Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal: 7.5 Vdc Range: 6 to 9 Vdc

Transmit Current Drain (Typical): 1400mA Receive Current Drain (Rated Audio): 240mA Standby Current Drain: 80mA

Recommended Battery:

Ultra-HIgh-Capacity Smart NiCd: HNN9031_

or Ultra-HIgh-Capacity NiCd: NTN8294_ or Extended-Capacity NiMH: NTN8293_ or Li-Ion: NTN8610_ or Ultra–High-Capacity NiCd FM: NTN8295_* or Ultra–High-Capacity NiMH FM: NTN8299_* Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1,

Groups C, D,E, F, and G. FM Non-incendive: Class 1, Division 2, Groups A, B, C, and D.

Frequency Range: 764-870MHz

Bandwidth: 106MHz

Usable Sensitivity (typical)

(12dB SINAD): 0.20µV

Intermodulation (typical): –75dB

Selectivity (typical)

(25/30kHz Channel): –72dB (12.5kHz Channel): –63dB

Spurious Rejection (typical): –75dB

Frequency Stability

(–30+60°C; 25°C reference): ±.00015%

Rated Audio: 500mW

FM Hum and Noise (typical):

25kHz –48dB

12.5kHz –40dB

Distortion (typical): 1.5%

Channel Spacing: 12.5/25 kHz

Frequency Range: 764-870MHz

RF Power:

764-806MHz: 2.5 Watts 806-870MHz: 3 Watts

Frequency Stability (typical)

(–30 to +60°C; 25°C ref.): ±.00015%

Emission (typical conducted): –75dBc

FM Hum and Noise (typical)

(Companion Receiver): 25kHz –45dB

12.5kHz –40dB

Distortion (typical): 1.5% (typical)

Modulation Limiting: 25kHz chnls ±5.0kHz

12.5kHz chnls ±2.5kHz

Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E,

8K10F1D, and 8K10F1E

Dimensions (H x W x D)

Note: 2.44" = width at PTT; 2.34" = width at

bottom; 1.83" = depth at speaker; 0.97" = depth at keypad

Without Battery (Radio Only):

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97" (167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm)

With Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 1.65" (167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

Weight: (w/ Antenna)

Less Battery: 14.10oz. (383gm) With Ultra-High Cap. NiCd: 25.19oz. (693gm) With Li-Ion: 20.41oz. (583gm) With Ultra-High Cap. NiMH:23.45oz. (644gm) With Extended- Cap. NiMH: 24.04oz. (682gm)

Specifications subject to change without notice

xiii

Page 16

(This page has been intentionally left blank.)

xiv

Page 17

User Safety, Training,

and General Information ➠

READ THIS IMPORTANT INFORMATION ON SAFE AND EFFICIENT OPERATION BEFORE USING YOUR MOTOROLA HANDHELD PORTABLE TWO-WAY RADIO

The information provided in this document supersedes the general safety information contained in user guides published prior to June 2001. For information regarding radio use in a hazardous atmosphere please refer to the Factory Mutual (FM) Approval Manual Supplement or Instruction Card, which is included with radio models that offer this capability.

Compliance with RF Energy Exposure Standards

Your Motorola two-way radio is designed and tested to comply with a number of national and international standards and guidelines (listed below) regarding human exposure to radio frequency electromagnetic energy. This radio complies with the IEEE (FCC) and ICNIRP exposure limits for occupational/controlled RF exposure environment at duty cycles of up to 50% talk-50% listen and should be used for occupational use only. In terms of measuring RF energy for compliance with the FCC exposure guidelines, your radio radiates measurable RF energy only while it is transmitting (during talking), not when it is receiving (listening) or in standby mode. Note that the approved, supplied batteries for this radio are rated for a 5-5-90 duty cycle (5% talk-5% listen - 90% standby), even though this radio complies with the FCC occupational exposure limits at duty cycles of up to 50% talk.

Your Motorola two-way radio complies with the following RF energy exposure standards and guidelines:

• United States Federal Communications Commission, Code of Federal Regulations; 47CFR part 2 sub-part J

• American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers (IEEE) C95. 1-1992

• Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999 Edition

• International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998

• Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radiofrequency Electromagnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999

• Australian Communications Authority Radiocommunications (Electromagnetic Radiation - Human Exposure) Standard 1999 (applicable to wireless phones only)

Page 18

User Safety, Training, and General Information

• ANATEL, Brasil Regulatory Authority, Resolution 256 (April 11, 2001) "additional requirements for SMR, cellular and PCS product certification."

Operational Instructions and Training Guidelines

Transmit and Receive

Hand-held radio operation

Body-worn operation

Antennas & Batteries

To ensure optimal performance and compliance with the occupational/controlled environment RF energy exposure limits in the above standards and guidelines, users should transmit no more than 50% of the time and always adhere to the following procedures:

• To transmit (talk), push the Push-To-Talk (PTT) button; to receive, release the PTT button.

• Hold the radio in a vertical position with the microphone one to two inches (2.5 to 5 cm) away from the lips.

• Always place the radio in a Motorola approved clip, holder, holster, case, or body harness for this product. Use of non-Motorola-approved

accessories may exceed FCC RF exposure guidelines.

• If you do not use a Motorola approved body-worn accessory and are not using the radio in the intended use position in front of the face, then ensure the antenna and the radio are kept 2.5 cm (one inch) from the body when transmitting.

• Use only Motorola approved supplied antenna or Motorola approved replacement antenna. Unauthorized antennas,

modifications, or attachments could damage the radio and may violate FCC regulations.

• Use only Motorola approved, supplied batteries or Motorola approved replacement batteries. Use of non-Motorola-approved

antennas or batteries may exceed FCC RF exposure guidelines.

Approved Accessories

Electromagnetic Interference/ Compatibility

• For a list of Motorola approved accessories see the appendix of this user manual or visit the following website which lists approved accessories:

http://www.motorola.com/cgiss/portables/xts5000.shtml

NOTE: Nearly every electronic device is susceptible to

electromagnetic interference (EMI) if inadequately shielded, designed, or otherwise configured for electromagnetic compatibility.

Facilities To avoid electromagnetic interference and/or compatibility conflicts, turn off

your radio in any facility where posted notices instruct you to do so. Hospitals or health care facilities may be using equipment that is sensitive to external RF energy.

Aircraft When instructed to do so, turn off your radio when on board an aircraft. Any

use of a radio must be in accordance with applicable regulations per airline crew instructions.

xvi

Page 19

User Safety, Training, and General Information

Medical Devices

Pacemakers The Advanced Medical Technology Association (AdvaMed) recommends that

a minimum separation of 6 inches (15 centimeters) be maintained between a handheld wireless radio and a pacemaker. These recommendations are consistent with those of the U.S. Food and Drug Administration.

Persons with pacemakers should:

• ALWAYS keep the radio more than 6 inches (15 centimeters) from their pacemaker when the radio is turned ON.

• not carry the radio in the breast pocket.

• use the ear opposite the pacemaker to minimize the potential for

interference.

• turn the radio OFF immediately if you have any reason to suspect that interference is taking place.

Hearing Aids Some digital wireless radios may interfere with some hearing aids. In the event

of such interference, you may want to consult your hearing aid manufacturer to discuss alternatives.

Other Medical Devices

If you use any other personal medical device, consult the manufacturer of your device to determine if it is adequately shielded from RF energy. Your physician may be able to assist you in obtaining this information.

Driver Safety Check the laws and regulations on the use of radios in the area where you

drive. Always obey them.

When using your radio while driving, please:

• Give full attention to driving and to the road.

• Use hands-free operation, if available.

• Pull off the road and park before making or answering a call if driving

conditions so require.

xvii

Page 20

User Safety, Training, and General Information

Operational Warnings

For Vehicles With an Air Bag

W A R N I N G

Do not place a portable radio in the area over an air bag or in the air bag deployment area. Air bags inflate with great force. If a portable radio is placed in the air bag deployment area and the air bag inflates, the radio may be propelled with great force and cause serious injury to occupants of the vehicle.

Potentially Explosive Atmospheres

Turn off your radio prior to entering any area with a potentially explosive atmosphere, unless it is a radio type especially qualified for use in such areas as “Intrinsically Safe” (for example, Factory Mutual, CSA, UL, or CENELEC). Do not remove, install, or charge batteries in such areas. Sparks in a potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death.

NOTE: The areas with potentially explosive atmospheres referred to above

include fueling areas such as below decks on boats, fuel or chemical transfer or storage facilities, areas where the air contains chemicals or particles, such as grain, dust or metal powders, and any other area where you would normally be advised to turn off your vehicle engine. Areas with potentially explosive atmospheres are often but not always posted.

Blasting Caps and Blasting Areas

To avoid possible interference with blasting operations, turn off your radio when you are near electrical blasting caps, in a blasting area, or in areas posted: “Turn off twoway radio.” Obey all signs and instructions.

Operational Cautions

Antennas

C a u t i o n

Do not use any portable radio that has a damaged antenna. If a damaged antenna comes into contact with your skin, a minor burn can result.

Batteries

All batteries can cause property damage and/or bodily injury such as burns if a conductive material such as jewelry, keys, or beaded chains touches exposed terminals. The conductive material may complete an electrical circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when placing it inside a pocket, purse, or other container with metal objects.

xviii

Page 21

Intrinsically Safe Radio Information

User Safety, Training, and General Information

FMRC Approved Equipment

• Do not operate radio communications equipment in a hazardous atmosphere

W A R N I N G

unless it is a type especially qualified (for example, FMRC Approved) for such use. An explosion or fire may result.

• Do not operate an FMRC Approved Product in a hazardous atmosphere if it has been physically damaged (for example, cracked housing). An explosion or fire may result.

Anyone intending to use a radio in a location where hazardous concentrations of flammable materials exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500 (hazardous [classified] locations).

An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers and the products approved by FMRC for use in such locations. FMRC has also issued a voluntary approval standard for repair service (“Class Number 3605”).

FMRC Approval labels are attached to the radio to identify the unit as being FM Approved for specified hazardous atmospheres. This label specifies the hazardous Class/Division/Group along with the part number of the battery that must be used. Depending on the design of the portable unit, this FM label can be found on the back or the bottom of the radio housing. The FM Approval mark is shown below:

APPROVED

• Do not replace or charge batteries in a hazardous atmosphere. Contact sparking may occur while installing or removing batteries and cause an explosion or fire.

• Do not replace or change accessories in a hazardous atmosphere. Contact sparking may occur while installing or removing accessories and cause an explosion or fire.

• Do not operate an FMRC Approved Product unit in a hazardous location with the accessory contacts exposed. Keep the connector cover in place when accessories are not used.

• Turn a radio off before removing or installing a battery or accessory.

• Do not disassemble an FMRC Approved Product unit in any way that exposes the

internal electrical circuits of the unit.

Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the field.

xix

Page 22

User Safety, Training, and General Information

A modification changes the unit’s hardware from its original design configuration. Modifications can only be made by the original product manufacturer at one of its FMRC-audited manufacturing facilities.

• Failure to use an FMRC Approved Product unit with an FMRC Approved battery or

W A R N I N G

FMRC Approved accessories specifically approved for that product may result in the dangerously unsafe condition of an unapproved radio combination being used in a hazardous location.

• Unauthorized or incorrect modification of an FMRC Approved Product unit will negate the Approval rating of the product.

Repair of FMRC Approved Products

• Incorrect repair or relabeling of any FMRC Approved Product unit could

W A R N I N G

Repair A repair constitutes something done internally to the unit that would bring it

adversely affect the Approval rating of the unit.

• Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in serious injury or death.

REPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL ARE THE RESPONSIBILITY OF THE USER.

You should not repair or relabel any Motorola-manufactured communication equipment bearing the FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC Approval standard for repairs and service (“Class Number 3605”).

You may want to consider using a repair facility that operates under 3605 repair service approval.

FMRC’s Approval Standard Class Number 3605 is subject to change at any time without notice to you, so you may want to obtain a current copy of 3605 from FMRC. Per the December 1994 publication of 3605, some key definitions and service requirements are as follows:

back to its original condition—Approved by FMRC. A repair should be done in an FMRC Approved facility.

Items not considered as repairs are those in which an action is performed on a unit which does not require the outer casing of the unit to be opened in a manner which exposes the internal electrical circuits of the unit. You do not have to be an FMRC Approved Repair Facility to perform these actions.

Relabeling The repair facility shall have a method by which the replacement of FMRC

Approval labels are controlled to ensure that any relabeling is limited to units that were originally shipped from the Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the repair facility. An FMRC Approval label shall be ordered from the original manufacturer, as needed, to repair a specific unit. Replacement labels may be obtained and applied by the repair facility, provided there is satisfactory evidence that the unit being relabeled was originally an FMRC Approved unit. Verification may include, but is not limited to: a unit with a damaged Approval label, a unit with a defective housing displaying an Approval label, or a customer invoice indicating the serial number of the unit and purchase of an FMRC Approved model.

Page 23

User Safety, Training, and General Information

Do Not Substitute Options or Accessories

The Motorola communications equipment certified by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or options, or both. This FM Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit. Approved configurations are listed in the FM Approval Guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped from the manufacturer with the FM Approved radio and battery combination. The Approval Guide, or the Approval Standard Class Number 3605 document for repairs and service, can be ordered directly from Factory Mutual Research Corporation located in Norwood, Massachusetts.

xxi

Page 24

User Safety, Training, and General Information

(This page has been intentionally left blank.)

xxii

Page 25

Introduction

C a u t i o n

W A R N I N G

General This manual covers information needed for levels one and two

troubleshooting. Level one troubleshooting consists of radio programming, radio alignment, knobs replacement, and installation and removal of antenna, belt clip, battery, and universal connector cover. Level two troubleshooting covers disassembly and reassembly of the radio to replace circuit boards.

Included in this manual are radio specifications for the 764-870 MHz frequency band, a general description of XTS 5000 models, recommended test equipment, service aids, radio alignment procedures, general maintenance recommendations, procedures for assembly and disassembly, and exploded views and parts lists.

Notations Used in This Manual

Throughout the text in this publication, you will notice the use of warnings, cautions, and notes. These notations are used to emphasize that safety hazards exist, and care must be taken and observed.

NOTE: An operational procedure, practice, or condition,

etc., which is essential to emphasize.

CAUTION indicates a potentially hazardous situation

result in equipment damage.

result in death or injury.

result in death

DANGER indicates an imminently hazardous

D A N G E R

situation which, if not avoided, will or injury.

which, if not avoided, may

WARNING indicates a potentially hazardous situation which, if not avoided, could

Page 26

Introduction

Radio Description The ASTRO Digital XTS 5000 radios are among the most sophisticated

two-way radios available. The radios are available in the 764-870 MHz band.

The ASTRO Digital XTS 5000 radio provides improved voice quality across more coverage area. The digital process, called “embedded signaling,” intermixes system signaling information with digital voice, resulting in improved system reliability, and the capability of supporting a multitude of advanced features.

ASTRO Digital XTS 5000 radios are available in three basic models. Table 1 describes their basic features.

Table 1. ASTRO XTS 5000 Basic Features

Feature Model I Model II Model III

Display None LCD

Fully bit-mapped.

• Normal operation = 4 lines/12 characters per line

• WAP (Wireless Application Protocol) mode =

6 lines/16 characters per line

Keypad None 3 x 2 Menu Buttons

(with 4-way Navigation button)

Channel Capability 48 512 512

Dialing from Prestored List No Yes Yes

Programmable Softkeys No Yes Yes

3 x 2 Menu Buttons (with 4-way

Navigation button), and 3 x 4

Alphanumeric Keypad

FLASHport The ASTRO Digital XTS 5000 radio utilizes Motorola’s FLASHport

technology. FLASHport makes it possible to add software that drives the radio’s capabilities both at the time of purchase and later on. Previously, changing a radio’s features and capabilities meant significant modifications, or buying a new radio. But now, similar to how a computer can be loaded with different software, the radio’s features and capabilities can be upgraded with FLASHport software.

Page 27

Basic Maintenance

C a u t i o n

Introduction This section of the manual describes preventive maintenance and handling

precautions. Each of these topics provides information vital to the successful operation and maintenance of your radio.

General Maintenance

Inspection Check that the external surfaces of the radio are clean, and that all external

Cleaning The following procedures describe the recommended cleaning agents and the

In order to avoid operating outside the limits set by the FCC, it is recommended that the ASTRO Digital XTS 5000 radio’s reference oscillator be aligned every time the radio is taken apart, or once per year, whichever comes first. Periodic visual inspection and cleaning is also recommended.

For XTS 5000R Radios - It is recommended that radio submergibility be checked annually by qualified service personnel.

controls and switches are functional. A detailed inspection of the interior electronic circuitry is not needed.

methods to be used when cleaning the external surfaces of the radio. External surfaces include the housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime.

The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water.

The effects of certain chemicals and their vapors can have harmful results on certain plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided.

Cleaning External Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff, nonmetallic, short-bristled brush to work all loose dirt away from the radio. A soft, absorbent, lintless 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 28

Basic Maintenance

C a u t i o n

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 highvoltage 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 low-humidity conditions.

• The XTS 5000 radio casting has two vent ports that allow for pressure equalization in the radio. Never poke these vents with any objects, such as needles, tweezers, or screwdrivers. This could create a leak path into the radio and, in the case of XTS 5000 R radios, the radio’s submergibility will be lost.

• The pressure equalization vent is located on the chassis, just below the battery contact. Never obstruct or cover the two slots with any object, including a label. Ensure that no oily substances come in contact with this vent.

•(XTS 5000 R Radios Only) The XTS 5000 R radio is designed to be submerged to a maximum depth of 6 feet, with a maximum submersion time of 4 hours. Exceeding either maximum limit may result in damage to the radio.

XTS 5000 R Radios Only 1. If the radio battery contact area has been submerged in water, dry

and clean the radio battery contacts before attaching a battery to the radio. Otherwise, the water could short-circuit the radio.

2. If the radio has been submerged in water, shake the radio well so that any water that may be trapped inside the speaker grille and microphone port can be removed. Otherwise, the water will decrease the audio quality of the radio.

Page 29

Basic Theory of

Operation 3

General Overview

The ASTRO Digital XTS 5000 radio is a wideband, synthesized radio available in the 764 to 870 MHz band. All ASTRO Digital XTS 5000 radios are capable of both analog operation (12.5 kHz or 25 kHz bandwidths) and ASTRO mode (digital) operation (12.5 kHz only).

The ASTRO Digital XTS 5000 radio includes the following major assemblies (see Figure 1.):

• VOCON Board — contains a dual-core processor which includes both the microcontroller unit (MCU) and a digital signal processor (DSP) core, the processor’s memory devices, an audio and power supply support integrated circuit (IC), a digital support IC, and the audio power amplifier.

• Transceiver (XCVR) Board — contains all transmit, receive, and frequency generation circuitry, including the digital receiver back-end IC and the reference oscillator.

• Controls/Universal Flex — contains volume/on/off switch, frequency selector switch, push-to-talk (PTT) switch, monitor button, several function-selectable switches, universal connector, speaker, and microphone.

• Display (Models II and III Only) — 96 pixels x 64 pixels bit-mapped, liquid-crystal display (LCD).

• Keypad (Models II and III Only) — Model II - a 3 x 2 Menu keypad with 4way navigation button; Model III - a 3 x 2 Menu keypad with 4-way navigation button, and a 3 x 4 alphanumeric keypad.

Page 30

Basic Theory of Operation

External Accessory Connector

Note: indicates 26 wires

Universal

Flex

J1 P101

(Side Connector,

Controls, LEDs,

Speaker,

Microphone)

Keypad

Display

P201 J2

J101

Transceiver

Board

VOCON

Board

J107

Encryption

J701

J301

Module

(Optional)

Figure 1. XTS 5000 Overall Block Diagram

Antenna

Battery

7.5V

Analog Mode of Operation

Receiving When the radio is receiving (see Figure 2.), the signal comes from the

antenna connector to the Transceiver board, passing through the antenna switch and the receiver front end. The signal is then filtered, amplified, and mixed with the first local-oscillator signal, generated by the voltage-controlled oscillator (VCO).

RF Input

Harmonic

XTAL Filter

Filter

Antenna

Switch

Tuneable

Preslector

ABACUS III - RX Back End

RX Front End

LNA

Amp

Tuneable

Preselector

Filter

ADC

1st LO

1st

Mixer

to VOCON Board

RX_SSI_ DATA

CKO

Figure 2. Receiver Block Diagram

Page 31

Basic Theory of Operation

The resulting intermediate frequency (IF) signal is fed to the IF circuitry, where it is again filtered and passed to the Abacus III digital back-end IC. In the digital back-end IC, the IF signal is mixed with the second local oscillator to create the second IF at 2.25 MHz. In the backend IC, a bandpass, sigma-delta, analog-to-digital converter then decodes the second IF signal, and outputs, on the radio’s serial synchronous interface (SSI) bus, digital audio to the VOCON board.

On the VOCON board, the dual-core processor’s digital-signal processor (DSP) digitally filters the PCM audio. The DSP decodes the information in the signal and identifies the appropriate destination for it.

• For a voice signal, the DSP will route the digital voice data to the CODEC inside the audio and power supply support IC, for conversion to an analog signal. The CODEC will then present the signal to the receive audio pre-amplifier, then to the audio power amplifier, which drives the speaker.

• For signaling information, the DSP will decode the message and pass it internally to the microcontrol unit of the dual-core processor.

Transmitting When the radio is transmitting (see Figure 3.), microphone audio is

passed through gain stages to the CODEC, where the signal is digitized. The CODEC passes digital data to the DSP, where preemphasis and low-pass (splatter) filtering are done. The DSP passes this signal to a digital/analog converter (DAC), where it is reconverted into an analog signal and scaled for application to the voltage-controlled oscillator as a modulation signal.

TX Buffer Q304

Mixer

U401

TX Driver

Amplifier

U102

Preselector

Filter

FL401

Power

Module

PCIC U104

RF Power

Detector

D103

RX LNA

Q401

Directional

Coupler

U101

Preselector

Filter

FL402

Antenna Switch

Harmonic

Filter

Antenna

TX_SSI from

VOCON Board

RX_SSI to

VOCON Board

Reference

Oscillator

EPIC Y200

DAC

U203

LPF

FL200

Serial EE

PROM

FracN

U203

MOD

ABACUS III U500

Loop Filter

VCO

VCOBIC

U202

Crystal

Filter

FL403

Sample

Clk

2ND

Figure 3. Transceiver Block Diagram (Power and Control Omitted)

Transmitted signaling information is applied to the DSP from the microcontrol unit, where it is coded, and passed to the DAC, which handles it the same as a voice signal. The DAC output connects to the synthesizer modulation input. A modulated carrier is provided to the

Page 32

Basic Theory of Operation

transmitter power amplifier, which transmits the signal under dynamic power control.

ASTRO Mode of Operation

Transceiver (XCVR) Board Basic Theory of Operation

In the ASTRO (digital) mode of operation, the transmitted or received signal is limited to a discrete set of frequency deviation levels. The receiver handles an ASTRO-mode 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 different algorithm to recover data.

In the ASTRO transmit mode, microphone audio is processed identically to an analog mode, with the exception of the algorithm the DSP uses to encode the information. Using this algorithm, transmitter FM deviation is limited to discrete levels.

The receiver front end consists of a preselector filter, low-noise amplifier, a second preselector, and a mixer. Both preselectors are varactor-tuned band pass filters, controlled by the microcontroller. See Table 2 for local oscillator (LO) and first IF information.

Table 2. Local Oscillator and First IF Frequencies

700/800 MHz

LO Frequency Range 741.35-885.65 MHz First IF Frequency 109.65 MHz

The frequency generation function is performed by three ICs, three VCOs, and associated circuitry. The reference oscillator IC provides a frequency standard to the synthesizer. The fractional-N synthesizer turns on one of three external VCOs, and tunes it to the RX LO or TX carrier frequency. The VCO buffer and a transistor amplify the signal to the required power level. The synthesizer is controlled by the microcontrol unit through a serial peripheral interface (SPI) bus. Most of the synthesizer circuitry is enclosed in rigid metal cans on the XCVR board to reduce interference and microphonic effects.

The receiver back end consists of a bandpass crystal filter, input and output impedance matching networks, and the digital back-end IC. Final filtering is done digitally in the DSP.

The Abacus III digital back-end IC contains a low-noise amplifier, a mixer, a variable gain amplifier with integral anti-alias filter, a bandpass, sigma delta, analog-to-digital converter, and a decimation filter with a programmable decimation factor. The Abacus III also contains an automatic gain control (AGC) circuit to provide 25 dB of continuous gain adjustments. For the second LO, the Abacus III has an internal, integer-N frequency synthesizer, and an external, discrete loop filter and voltage-controlled oscillator (VCO). The output of the Abacus III is digital data on the RX_SSI bus.

The transmitter power amplifier (PA) consists of a driver amplifier IC and a discrete final-stage. Transmit power is controlled by a power control IC (PCIC) that monitors the output of a directional coupler

Page 33

Basic Theory of Operation

and adjusts PA control voltages. The transmitter RF signal then passes through a PIN diode antenna switch and a low-pass harmonic filter, which connects to the antenna connector.

VOCON Board Basic Theory of Operation

The vocoder and controller (VOCON) board comprises the dual-core processor, which contains the radio’s microcontrol unit and digital signal processor (DSP) in a single integrated circuit (IC) package, its memory ICs, an audio and power supply IC, a digital support IC, and the audio power amplifier. Connected to the VOCON board are the liquid-crystal display (LCD) board, XCVR board, keypad flex, controls/ universal flex, and (optional) encryption module.

The microcontrol unit portion of the dual-core processor controls receive/transmit frequencies, power levels, display, and other radio functions, using either direct logic control or serial communications paths to the devices. The microcontrol unit executes a stored program located in the FLASH memory device. Data is transferred to and from memory by the microcontrol unit data bus. The memory location from which data is read, or to which data is written, is selected by the address lines. The microcontrol unit of the dual-core processor requires a 16.8MHz clock on its CKIH pin and a 32kHz clock on its CKIL pin.

The DSP portion of the dual-core processor performs signaling and voice encoding and decoding, as well as audio filtering and volume control. The DSP performs Private-Line®/Digital Private Line™ (PL/ DPL) encode and alert-tone generation. The DSP transmits preemphasis on analog signals, and applies a low-pass (splatter) filter to all transmitted signals. The DSP controls squelch, deviation, and executes receiver and transmitter filtering. The DSP executes a stored program located in the FLASH memory device.

The DSP of the dual-core processor requires a 16.8MHz clock on the CKIH pin. Additionally, it requires the 520kHz clock and 8kHz interrupt signal from the digital support IC, as well as clocks from the Abacus III digital back-end IC on the XCVR board.

The digital support IC is supplied with a 16.8MHz clock from the XCVR board. Using this clock, the digital support IC generates a 13MHz clock for the analog and power supply IC, and a 520kHz clock and an 8kHz interrupt signal for both the DSP and the analog and power supply IC. Additionally, the digital support IC uses a crystal to generate the 32kHz clock used by the dual-core processor and audio and power supply IC. It monitors the position of the on/off switch and controls the shutdown of the regulators on the audio and power supply IC. Finally, the digital support IC interfaces to the radio’s 13-pin universal (accessory) connector. This IC is programmed by the dualcore processor.

The analog and power supply IC has many functions. This IC supplies most of the voltages used on the VOCON board, while an external linear regulator supplies 5 volts. It also has microphone audio amplifiers, switching between internal and accessory microphones, and the audio CODEC. The audio CODEC performs analog-to-digital and digital-to-analog conversions on audio signals. It also has an

Page 34

Basic Theory of Operation

analog/digital converter (ADC), which is used to monitor volume setting and battery voltage. This IC is programmed by the dual-core processor.

The audio power amplifier (PA) drives the speakers with the received audio from the analog output of the CODEC from the audio and power supply IC. The audio PA is sourced from the battery (nominal value of 7.5 volts). It is programmed by the dual-core processor.

Page 35

Recommended Test

Equipment and Service Aids 4

Recommended Test Equipment

Motorola

Model Number

R2600 Series with applicable options

Agilent 8901B Modulation Analyzer Transmitter parameter testing.

Fluke 8012 Digital Multimeter Recommended for ac/dc voltage

R1150_* Code Synthesizer Injection of audio and digital

Communications System Analyzer

The list of equipment contained in Table 3 includes all of the standard test equipment required for servicing two-way portable radios, as well as several unique items designed specifically for servicing this family of radios. The “Characteristics” column is included so that equivalent equipment may be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended.

Table 3. Recommended Test Equipment

Description Characteristics Application

This monitor will substitute for items with an asterisk (*).

Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment.

Deviation balance and limit for <2% accuracy.

and current measurements

signaling codes

R1377_* AC Voltmeter 1mV to 300V, 10-Megohm

input impedance

R1094_ Dual-Trace

Oscilloscope

R1443_* Wattmeter Fixed-Element, Broadband Transmitter power output

S1339_ RF Millivolt Meter 100µV to 3V RF RF-level measurements

R1013_* SINAD Meter Receiver sensitivity measurements

S1348_ (programmable)

DC Power Supply 0-20Vdc, 0-5 Amps

20MHz bandwidth 5mV to 5V/division

current limited

Audio voltage measurements

Waveform measurements

measurements

Bench supply for 7.5Vdc

Service Aids Refer to Table 4, “Service Aids,” for a listing and description of the service aids

designed specifically for servicing this family of radios. These kits and/or parts are available from the Accessories and Aftermarkets Division offices listed in the “Replacement Parts Ordering” section located on the inside back cover of this manual. While all of these items are available from Motorola, most are

Page 36

Recommended Test Equipment and Service Aids

standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.

Table 4. Service Aids

Motorola Part

Number

81-80384M64 Housing Eliminator Fixture Special fixture that allows radio’s internal board to be

58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test

66-85833D01 Housing/Casting Separation

Tool

NLN9839_ Vacuum Pump Kit Submersible radios only. Vacuum pump with gauge and

NTN4265_ Pressure Pump Kit Submersible radios only. Pressure pump with gauge and

NTN9279_ Vacuum Adapter with Gasket

Kit

REX4424_ Battery Eliminator Used in place of battery to connect radio to external power

RKN4105_ USB Cable Kit Connects radio to RLN-4460_ Portable Test Set for radio

Description Application

mounted externally. Provides easy access to electronic circuits, required for board-level troubleshooting.

equipment.

Special tool used to separate housing and casting near battery latch area for access to inside of radio.

vacuum hose. Requires NTN9279_ Adapter Kit.

pressure hose. Requires NTN9279_ Adapter Kit.

Submersible radios only. Connects the vacuum/pressure hose to the radio’s casting.

supply.

performance checks, and to Universal Serial Bus (USB) port on personal computer for CPS programming and tuner alignments.

RKN4106_ RS232 Cable Kit Connects radio to RLN-4460_ Portable Test Set for radio

performance checks, and to serial port on personal computer for CPS programming and tuner alignments.

RLN4460_ Portable Test Set Used for radio performance checks. Connects to radio’s

universal connector and allows remote switching and signal injection/outputs for test equipment measurements.

RVN4181_ Customer Programming

Software (CPS) and Tuner Software

Field Programming Equipment

This family of radios can be aligned and programmed in the field. This requires specific equipment and special instructions. Refer to the on-

CPS allows customer-specific programming of modes and features. Tuner software required to perform alignment of radio parameters. Can be used for both XTS 5000 and XTS 2500 products.

line help in the Customer Programming Software (CPS) for complete field programming information.

Page 37

Performance Checks

Introduction This section covers performance checks used to ensure that the radio meets

published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the test equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule. Checks should be performed if radio performance degradation is suspected.

Setup Supply voltage can be connected from the battery eliminator. The equipment

required for alignment procedures is connected as shown in Figure 4.

BATTERY

ELIMINATOR

REX-4424

COMPUTER

30 dB PAD

TRANSMIT

30 dB PAD

SMA-BNC

58-80348B33

RADIO

PROGRAM/TEST CABLE

RKN4105_ OR RKN4106_

Initial equipment control settings should be as indicated in Table 5 on page 14, and should hold for all alignment procedures, except as noted.

BNC

RF GENERATOR

RECEIVE

SET TO APPROX. 450mV FOR Tx

AUDIO IN

TEST SET

RLN-4460_

MEASURE 80mV FOR Tx

Figure 4. Radio Alignment Test Setup

SYSTEM ANALYZER

OR COUNTER

WATTMETER

AUDIO GENERATOR

SINAD METER

AC VOLTMETER

Page 38

Performance Checks

Table 5. Initial Equipment Control Settings

System Analyzer Test Set Power Supply

Monitor Mode: Standard* Spkr/Load: Speaker Voltage: 7.5Vdc

Receiver Checks RF Control: GEN Output Level: -47 dBm Modulation: 1kHz tone

@3kHz deviation Frequency: Set to selected

radio RX frequency

Meter: AC Volts

Transmitter Checks RF Control: MONITOR Frequency: Set to selected

radio TX frequency

Meter: RF Display Modulation Type: FM Attenuation: 20 dB

* Use “PROJ 25 STD” if testing ASTRO Conventional channels.

Display Radio Test Mode (Models II/III)

PTT: OFF (center) DC On/Standby: Standby

Meter Out: RX Volt Range: 10Vdc

Opt Sel: ON Current: 2.5 Amps

Entering Display Radio Test Mode

1. Turn the radio on.

2. Within 10 seconds after “SELF TEST” is complete, press Side Button 2 five times in succession.

3. The radio will show a series of displays that give information regarding various version numbers and subscriber specific information. The displays are described in Table 6.

Table 6. Front-Panel Access Test-Mode Displays

Name of Display Description Appears

“SERVICE” The literal string indicates the radio has entered test

mode.

Host Software Version The version of host firmware is displayed. Always

DSP Software Version The version of DSP firmware is displayed. Always

EMC Secure Version Version of the encryption hardware When the radio is secure equipped

Encryption Type 1 Type of encryption being used When the radio is secure equipped

Encryption Type 2 Type of encryption being used When the radio is secure equipped

Model Number The radio’s model number, as programmed in the

codeplug

Always

Page 39

Performance Checks

Table 6. Front-Panel Access Test-Mode Displays (Continued)

Name of Display Description Appears

Serial Number The radio’s serial number, as programmed in the

codeplug

ROM Size The memory capacity of the host FLASH part Always

FLASHcode The FLASH codes as programmed in the codeplug Always

Always

NOTE: All displays are temporary and will expire without any

user intervention. If information is longer than the physical length of the radio’s display, the information will wrap around to the next display. After the last display, “RF TEST” is displayed.

4a. Press the Top Side Button to stop the displays and put the radio

into the Control Top and Keypad test mode. The test mode menu “CH TEST” will be displayed. Go to “Control Top and Keypad Test Mode” on page 16.

NOTE: Each press of the Top Side Button will toggle

between “CH TEST” and “RF TEST.”

4b. Press the Top Button (Orange button) to stop the displays and

put the radio into the RF test mode. The test mode menu, “1 CSQ”, will be displayed, indicating test frequency 1

uelch mode. Go to “RF Test Mode”, below.

, Carrier

RF Test Mode When the ASTRO Digital XTS 5000 radio is operating in its normal

environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment via a special routine, called TEST MODE or “air test.”

1. Each additional press of Side Button 2 will advance to the next

test channel. (Refer to Table 7.)

2. Pressing Side Button 1 will scroll through and access test

environments as shown in Table 8.

NOTE: Transmit into a load when keying a radio under test.

Table 7. Test Frequencies

Tes t

Channel

F1 764.0625 764.0125 F2 769.0625 769.0125 F3 775.9375 775.9875 F4 851.0625 794.0125 F5 860.0625 809.0125

700/800 MHz RX

(MHz)

700/800 MHz TX

(MHz)

Page 40

Performance Checks

Table 7. Test Frequencies (Continued)

No. of

Ton es

Tes t

Channel

F6 869.9375 823.9875 F7 851.0625 851.0125 F8 860.0625 860.0125 F9 869.9375 869.8875

700/800 MHz RX

(MHz)

700/800 MHz TX

(MHz)

Table 8. Test Environments

Display Description Function

CSQ

TPL

SEC

AST

USQ

Carrier Squelch RX: unsquelch if carrier detected

TX: mic audio

Tone Private-Line

Secure*** RX: auto-coded clear

ASTRO RX: none

Carrier Unsquelch

RX: unsquelch if carrier and tone (192.8 Hz) detected

TX: mic audio + tone (192.8 Hz)

TX: with key present—encrypted audio

with key absent—constant unsquelch

TX: 1200Hz tone ** RX: unsquelch always

TX: mic audio

Control Top and

Keypad Test Mode

** All deviation values are based on deviation tuning of this mode *** On radios equipped with secure option

This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected.

1. Press and hold the Top Button (Orange button); all segments on the display will light, and the LED lights red.

2. Release the Top Button; “3/0” appears, which indicates that the Top Button is in the open condition.

3. Press the Top Button again; “3/1” appears, which indicates that the Top Button is in the closed condition.

4. Rotate the 16-Position Select Switch; “4/0” through “4/15” appears, which indicates that the selector switch is in mode/zone position 1 through 16.

5. Rotate the Two-Position Concentric Switch; “65/0” and “65/1” appear.

6. Cycle through the Three-Position A/B/C Switch; “67/0,” “67/1,” and “67/2” appear.

7. Rotate the Volume Control; “2/0” through “2/255” appear.

8. Press the Top Side Button; “96/1” appears; release, “96/0” appears.

9. Press Side Button 1; “97/1”appears; release, “97/0” appears.

10. Press Side Button 2; “98/1”appears; release, “98/0” appears.

Page 41

Performance Checks

11. Press the PTT Button; “1/1” appears; release, “1/0” appears.

12. Keypad Checks:

Model III Only—

- Press 0, “48/1” appears; release, “48/0” appears.

- Press 1, “49/1” appears; release, “49/0” appears.

- Press 2, “50/1” appears; release, “50/0” appears.

- Press 3, “51/1” appears; release, “51/0” appears.

- Press 4, “52/1” appears; release, “52/0” appears.

- Press 5, “53/1” appears; release, “53/0” appears.

- Press 6, “54/1” appears; release, “54/0” appears.

- Press 7, “55/1” appears; release, “55/0” appears.

- Press 8, “56/1” appears; release, “56/0” appears.

- Press 9, “57/1” appears; release, “57/0” appears.

- Press *, “58/1” appears; release, “58/0” appears.

- Press #, “59/1” appears; release, “59/0” appears.

Non-Display Radio Test Mode (Model I)

Entering NonDisplay Radio Test Mode

Models II and III—

- Press V, “128/1” appears; release, “128/0” appears.

- Press h, “129/1” appears; release, “129/0” appears.

- Press U, “130/1” appears; release, “130/0” appears.

- Press D, “131/1” appears; release, “131/0” appears.

- Press E, “132/1” appears; release, “132/0” appears.

- Press F, “133/1” appears; release, “133/0” appears.

- Press @, “134/1” appears; release, “134/0” appears.

- Press X, “135/1” appears; release, “135/0” appears.

- Press Y, “136/1” appears; release, “136/0” appears.

1. Turn the radio on.

2. Within 10 seconds after the top green LED turns off, press Side button 2

five times in succession.

3a. Press the Top Side Button to put the radio into the Control Top and

Keypad test mode. Go to “Control Top and Keypad Test Mode” on page 18.

NOTE: Each press of the Top Side Button will toggle between

Control Top and Keypad test mode (non-display radio) and RF test mode (non-display radio).

Page 42

Performance Checks

3b. Press the Top Button (Orange button) to stop the displays and

put the radio into the RF test mode. Go to “RF Test Mode”, below.

RF Test Mode When the ASTRO Digital XTS 5000 radio is operating in its normal

1. Each additional press of Side Button 2 will advance to the next test channel. (Refer to Table 7 on page 15) The channel number is represented by the number of tones emitted by the radio after the button press (for example, five tones indicates channel 5).

2. Pressing Side Button 1 will scroll through and access test environments as shown in Table 8 on page 16. The test environment is represented by the number of tones emitted by the radio after the button press (for example, 11 tones indicate AST).

Control Top and Keypad Test Mode

NOTE: Transmit into a load when keying a radio under test.

This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected.

1. Press and hold the Top Button (Orange button); the LED lights red, and the radio beeps.

2. Release the Top Button; the radio beeps again.

3. Press the Top Button again; the radio beeps, indicating that the Top Button is in the closed condition.

4. Rotate the Two-Position Concentric Switch; the radio beeps in each switch position.

5. Rotate the 16-Position Select Switch; the radio beeps in each switch position.

6. Cycle through the Three-Position A/B/C Switch; the radio beeps in each switch position.

7. Rotate the Volume Control; the radio beeps at each new volume setting.

8. Press the Top Side Button; the radio beeps.

9. Press Side Button 1; the radio beeps.

10. Press Side Button 2; the radio beeps.

Page 43

Performance Checks

Table 9. Receiver Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference Frequency

Rated Audio RF Control: Gen

Distortion As above, except

Sensitivity (SINAD)

Noise Squelch Threshold (only radios with conventional system need to be tested)

RF Control: Monitor Meter: RF Display Display: Bar Graphs Freq: Selected radio TX freq.

Output Level: -47 dBm Freq: Selected radio RX freq. Mod: 1kHz tone @ 3kHz dev. Meter: AC Volts

Meter: Ext Dist.

As above, except Meter: SINAD

Set as for rated audio check Out of TEST

TEST MODE CSQ channel* or programmed conventional channel

As above PTT to OFF (center) Set volume

As above As above Distortion < 3.0%

As above As above RF input to be <

MODE; select a conventional system

PTT to continuous (during the performance check)

As above Set volume

Frequency error to be ≤ ±1.2kHz

control to

3.74Vrms

0.35µV

control to

3.74Vrms. Set RF level to -

130 dBm and raise until radio unsquelches.

Unsquelch to occur at < 0.25µV. Preferred SINAD = 6-8dB

* See Table 8 on page 16.

Page 44

Performance Checks

Table 10. Receiver Tests for ASTRO Conventional Channels*

Test Name System Analyzer

Bit Error rate (BER) Floor

Reference Sensitivity

Audio Output Distortion

Residual Audio Noise Ratio

Mode: Proj 25 Std RF Control: Gen Output Level: -47 dBm Proj 25 Dev: 2.83 kHz Code: 1011 Hz PAT

As above; lower the output level until 5% BER is obtained

Mode: Proj 25 Std RF Control: Gen Output Level: -47 dBm Proj 25 Dev: 2.83 kHz Code: 1011 Hz PAT Meter: Ext. Distortion

Mode: Proj 25 Std RF Control: Gen Output Level: -47 dBm Proj 25 Dev: 2.83 kHz Code:

A) 1011 Hz PAT B) Silence PAT

Meter: AC Volts

Radio/Tuner

Software

Radio Tuner Software is required; Bit Error Rate Screen

As above As above Output level

Radio Tuner Software not used;

Radio: Out of TEST MODE; Select a conventional ASTRO channel

As above As above Residual Audio

Test Set Comments

PTT to OFF (center) BER <0.01%

<0.35 µV (-116 dBm)

PTT to OFF (center) Meter selector to

Audio PA

Spkr/Load to

Speaker

Distortion < 3.0%

Noise Ratio >45dB

* These tests require a communications system analyzer with the ASTRO 25 test options.

Some tests require the use of the Radio Tuner Software.

Page 45

Performance Checks

Table 11. Transmitter Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference Frequency

Power RF As above As above As above Refer to Maintenance

Voice Modulation

(External)

Voice Modulation (internal)

PL Modulation (radios with conventional, clear mode, coded squelch operation only)

RF Control: Monitor Meter: RF Display Display: Bar Graphs Freq: Selected radio TX

freq.

As above. Set fixed 1kHz audio level to 400 mV.

RF Control: Monitor Meter: RF Display Display: Bar Graphs Freq: Selected radio TX

freq.

As above Conventional

TEST MODE CSQ channel* or programmed conventional channel

As above As above Deviation:

As above Remove modulation

coded squelch personality (clear mode operation) or TPL channel (test mode*)

PTT to continuous (during the performance check).

input. PTT to OFF (center)

PTT to continuous (during the performance check)

Frequency error to be ≥ ±1.2kHz.

Specifications page in front of manual.

(12.5kHz) ≥ 2.1kHz but ≤

2.5kHz (25kHz) ≥ 4.1kHz but ≤

5.0kHz

Press PTT button on radio. Say “four” loudly into the radio mic. Measure deviation:

(12.5kHz) ≥ 2.1kHz but ≤

2.5kHz (25kHz) ≥ 4.1kHz but ≤

5.0kHz

Deviation: (12.5kHz) ≥ 375Hz but ≤

500Hz (25kHz) ≥ 500Hz but ≤

1000Hz

Secure Modulation (radios with conventional, secure mode, talkaround operation only)

As above Programmed

* See Table 8 on page 16

conventional channel (secure mode operation) Load key into radio.

As above Deviation:

≥ 3.7kHz but ≤ 4.3kHz

Page 46

Performance Checks

Table 12. Transmitter Tests for ASTRO Conventional Channels*

Test Name System Analyzer Radio Test Set Comments

RF Output Power

Frequency Error

Frequency Deviation

Mode: Proj 25 Std RF Control: Monitor Meter: RF Display

As above As above As above Error ≤ ±1.0 kHz

As above Radio Tuner

Radio Tuner Software not used.

Radio: Out of TEST MODE; Select a conventional ASTRO channel

Software is required;

Transmitter Bit Patterns screen.

High use:

Symbol Rate PAT

Low use: Low Symbol Rate P

PTT to continuous (during measurement).

PTT to OFF (center) D

* These tests require a communications system analyzer with the ASTRO 25 test options.

Some tests require the use of the Radio Tuner Software.

Refer to Maintenance Specifications page in front of manual.

HIGH

≥ 2.543 kHz but ≤ 3.110 kHz

LOW

≥ 0.841 kHz but ≤ 1.037 kHz

Page 47

Radio Alignment

C a u t i o n

Procedures 6

Introduction This section describes both receiver and transmitter radio alignment

procedures.

General A personal computer (PC) and tuner software are required to align the radio.

Refer to the applicable manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC and to a universal test set as shown in Table 4 on page 13.

These procedures should only be attempted by qualified 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 ➝ Read

Device menu or click on

are organized. To access a screen, double-click on the desired screen name in the Tuner menu.

123ABC1234

Radio Information (page 25)

Transmitter Alignments

Receiver Alignments

Performance Testing

. Figure 5 illustrates how the alignment screens

Reference Oscillator (page 25)

Tx Power High (page 27)

Tx Power Mid (page 27)

Tx Power Low (page 27)

Tx Deviation Balance (page 28)

Tx Deviation Limit (page 29)

Front End Filter (page 31)

Bit Error Rate (page 32)

Transmitter Test Pattern (page 33)

Figure 5. Tuner Menu Layout

Page 48

Radio Alignment Procedures

C a u t i o n

Softpot The alignment screens introduce the concept of the “softpot,” an

analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls.

Do NOT switch radios in the middle of any Alignment procedure. Always left-click the Close button on the screen to return to the 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.

Each alignment screen provides the ability to increase or decrease the softpot value by using a slider or the screen’s UP/DOWN arrow keys (▲ ▼), or by entering the new value from the keyboard. A graphical scale on the display indicates the minimum, maximum, and proposed value of the softpot; see Figure 6

Figure 6. Typical Softpot Screen

Adjusting the softpot value sends information to the radio to increase (or decrease) the voltage in the corresponding circuit. For example, left-clicking the UP arrow ▲ on the Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage across a varactor in the reference oscillator, which increases the frequency.

In ALL cases, the softpot value is just a relative number corresponding to a digital-to-analog (D/A) generated voltage in the radio.

Perform the following procedures in the sequence indicated.

NOTE: Some of the following screens may vary depending

upon the radio under test and the version of tuner software you are using. Refer to the software’s on-line help.

Page 49

Radio Alignment Procedures

Radio Information Figure 7 shows a typical Radio Information screen.

Figure 7. Radio Information Screen

Reference Oscillator Alignment

Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will result not only in poor operation, but also in a misaligned radio that will interfere with other users operating on adjacent channels. For this reason, the reference oscillator should be checked every time the radio is serviced, or once a year, whichever comes first. The frequency counter used for this procedure must have a stability of 0.1 ppm (or better).

NOTE: Reference oscillator alignment is required after

replacing (or servicing) the transceiver board.

1. Select the Reference Oscillator alignment screen. See Figure 8.

Figure 8. Reference Oscillator Alignment Screen

Page 50

Radio Alignment Procedures

2. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting.

3. Measure the transmit RF frequency with your service monitor.

4. Adjust the reference oscillator’s softpot value until the measured value is as close as possible to the frequency shown on the screen. See Table 13.

Table 13. Reference Oscillator Alignment

Band Target

700/800 MHz ±100 Hz

5. Left-click the Program All button on the screen to dekey the radio and save the tuned values.

6. Left-click the Close button on the screen to return to the Transmitter Alignments menu.

Transmit Power Alignment

This alignment procedure adjusts the transmit power of the radio and must be performed for three different power levels (Low, Mid, and High), at multiple frequencies for each power level, 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.

NOTES:

• The same softpot attenuation value will result in DIFFERENT

radio output power levels at different frequencies.

• All power measurements are to be made at the antenna port.

• Transmit Power alignment is required after replacing (or

servicing) the transceiver board.

1. Select the TX Power alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 9.

2. Left-click the desired frequency field (starting with the highest frequency shown).

3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting.

4. Measure the transmit power of the radio with a service monitor.

5. Adjust the softpot value until the required power, as shown in Table 14, is indicated on the service monitor.

Table 14. Transmit Power Settings

Test Frequencies

Power Level

700/800 MHz

Low (1 Watt) 1.2W - 1.4W Mid (2 Watts) 2.5W - 2.7W High (3 Watts) 3.2W - 3.4W

6. Repeat the above process for all frequencies and all power levels.

Page 51

Radio Alignment Procedures

7. Left-click the Program All button on the screen to dekey the

radio and save the tuned values.

8. Left-click the Close button on the screen to return to the

Transmitter Alignments menu.

Transmit Deviation Balance Alignment

Figure 9. Transmit Power Alignment Screen (Typical)

This 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 signalling 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.

NOTE: This alignment is required after replacing (or servicing)

the VOCON board or the transceiver board.

1. Select the TX Deviation Balance alignment screen. The screen

will indicate the transmit frequencies to be used. See Figure 10.

2. Left-click the desired frequency field (starting with the highest

frequency shown).

Page 52

Radio Alignment Procedures

3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting.

Transmit Deviation Limit Alignment

Figure 10. Transmit Deviation Balance Alignment Screen

4. Left-click the PTT Tone: Low button.

5. Measure the transmitted signal deviation of the radio with a service monitor.

6. Left-click the PTT Tone: High button.

7. Adjust the softpot value until the measured deviation, when using the high tone, is a close as possible to that observed when using the low tone.

8. Repeat the above process for all 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 Transmitter Alignments menu.

This alignment procedure limits the modulation of a baseband signal. It is used for primary modulation limiting.

Page 53

Radio Alignment Procedures

NOTE: This alignment is required after replacing (or servicing)

the VOCON board or the transceiver board.

1. Select the TX Deviation Limit alignment screen. The screen will

indicate the transmit frequencies to be used. See Figure 11.

Figure 11. Transmit Deviation Limit Alignment Screen

2. Left-click the desired frequency field (starting with the highest

frequency shown).

3. Left-click the PTT Toggle button on the screen to make the radio

transmit. The screen indicates whether the radio is transmitting.

4. Measure the transmitted signal deviation of the radio with a

service monitor.

5. Adjust softpot value until the measured deviation is as close as

possible to 2.83 kHz.

6. Repeat the above process for all frequencies.

7. Left-click the Program All button on the screen to dekey the

radio and save the tuned values.

8. Left-click the Close button on the screen to return to the

Transmitter Alignments menu.

Page 54

Radio Alignment Procedures

C a u t i o n

Front End Filter Alignment

This procedure should only be attempted by qualified service personnel.

Definition This alignment procedure adjusts the front end receiver bandpass filters for

best receiver sensitivity and selectivity. It should be performed for all test frequencies to allow for proper software interpolation for frequencies in between the test frequencies in the band (see Figure 12).

NOTE: Rx Front End Filter Alignment is required after

replacing (or servicing) the transceiver board.

Procedure for 700 MHz Frequencies

Procedure for 800 MHz Frequencies

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency.

3. Start with a softpot value (approximately 10 or 20), increase softpot in ascending order, and note the RSSI values. The RSSI will reach a peak value and remain stable and then decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3. Choose the middle of the peak range and program the corresponding softpot value as the tuned softpot value.

4. Repeat the above process for all 700MHz frequencies.

5. Click on the “Program All” button to save the tuned values in the radio.

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency.

3. Start with a softpot value of 50, increase softpot in ascending order, and note the RSSI values. The RSSI will reach a peak value and remain stable and then decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3. Note the upper end of the peak range and program the corresponding softpot value as the tuned softpot value.

Procedure for UHF/VHF 1. Left-click the desired frequency field.

4. Repeat the above process for all 800MHz frequencies.

5. Click on the “Program All” button to save the tuned values in the radio.

2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency.

3. Adjust the softpot value until the maximum RSSI value is found.

4. Repeat the above process for all frequencies.

5. Click on the “Program All” button to save the tuned values in the radio.

Page 55

Radio Alignment Procedures

Figure 12. Front End Filter Alignment Screen

Bit Error Rate

Definition This screen is used to test the Bit Error Rate (BER) of the radio’s receiver at a

desired frequency (see Figure 13).

Bit Error Rate Fields

This screen contains the following fields:

Rx Frequency:

This field selects the Receive Frequency directly in MHz.

Test Pattern:

This field selects the Digital test pattern — TIA. Choices are: Standard Tone Test Pattern (framed 1011) and Standard Interface Test Pattern (CCITT V.52).

Modulation Type:

This field represents the digital modulation type of the incoming signal on which BER is to be calculated.

Page 56

Radio Alignment Procedures

Continuous Operation:

This field allows the user the option to repeat the BER test indefinitely. A selection of Yes will cause the radio to calculate BER on a continuous basis and update the results on this screen after each integration time. A selection of No will cause the BER test to execute for only one sample of the integration time and then update the display.

Audio:

This field allows the user to select the audio output during a test. Selecting Internal will cause the radio’s built-in speaker to unmute to any signals at the desired frequency which are present during the test. Selecting External will route the same signal to the radio’s accessory connector audio output. Selecting Mute will disable the audio output.

Integration Time:

This field represents the amount of time over which the Bit Error Rate is to be calculated. The range is from 0.360 to 91.8 seconds in increments of 0.360 seconds.

NOTE: When Continuous Operation = Yes, all

fields will be grayed out while test is in progress. They will be enabled when 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.

Figure 13. Bit Error Rate Screen

Page 57

Radio Alignment Procedures

Transmitter Test Pattern

Definition This screen is used to transmit specific test patterns at a desired frequency so

that the user can perform tests on the radio’s transmitter (see Figure 14).

Transmitter Test Fields

This screen contains the following fields:

Tx Frequency:

This field selects the Transmit Frequency directly in MHz.

Channel Spacing:

This field allows the user to select the desired transmit deviation.

Test Pattern Type:

This field represents the type of test pattern which will be transmitted by the radio when “PTT TOGGLE” button is pressed.

NOTE: Channel Spacing and Test Pattern Type fields will

be grayed out while radio is transmitting.

Figure 14. Transmitter Test Pattern Screen

Page 58

Radio Alignment Procedures

Notes

Page 59

Encryption

Loading an Encryption Key

Multikey Feature

1. Refer to the key-variable loader (KVL) manual for equipment connections and setup.

2. Attach the KVL to the radio. The display shows “KEYLOADING.” All other

radio functions, except for power down, backlight, and volume, are locked out.

3. Refer to the KVL manual for how to load the encryption keys into the

radio.

4. When the key is loaded successfully, you will hear:

- On single-key radios — a short tone.

- On multikey radios — an alternating tone.

This feature allows the radio to be equipped with multiple encryption keys. It can support up to two different encryption algorithms simultaneously (e.g., DVP-XL and DES-XL).

• Conventional Multikey — The encryption keys can be tied (strapped), on

a one-per-channel basis. In addition, the radio can have operatorselectable keys, operator-selectable indices, and operator-selectable key erasure. If talkgroups are enabled in conventional, then the encryption keys are strapped to the talkgroups.

• Trunked Multikey — If the radio is used for both conventional and

trunked applications, strap the encryption keys for trunking on a pertalkgroup or announcement group basis. In addition, a different key can be strapped to other features; for example, dynamic regrouping, failsoft, or emergency talkgroup. The radio can have operator-selectable key erasure.

Selecting a Key

Using the Menu 1. Press U until the display shows “KEY.”

2. Press D, E, or F directly below “KEY.” The display shows the last

user selected and stored encryption key, and the available menu selections.

3. Press V or U to scroll through the list of encryption keys. NOTE: If you select an erased key, the display shows the key and

“ERASED KEY.”

4. Press D, E, or F directly below the desired menu.

- PSET = selects the preset or default encryption key.

Page 60

Encryption

- SEL = saves the newly selected key and returns to the home

display.

5. Press h, the PTT button, or D, E, or F directly below the

ABRT menu, or turn the 16-Position Select knob to exit this menu.

- If the selected key is erased, the display shows “KEY FAIL” and the radio sounds a momentary keyfail tone.

- If the selected key is not allowed, the display shows “ILLEGAL KEY” and the radio sounds a momentary illegal key tone.

Using the Keypad 1. Press U until the display shows “KEY.”

2. Press D, E, or F directly below “KEY.” The display shows

the last user selected and stored encryption key, and the available menu selections.

3. Enter the number of the desired key, using the keypad. NOTE: If you select an erased key, the display shows the key

and “ERASED KEY.”

4. Press V or U to select from the menu.

- PSET = selects the preset or default encryption key.

- SEL = saves the newly selected key and returns to the home

display.

5. Press h, the PTT button, or D, E, or F directly below the ABRT menu, or turn the 16-Position Select knob to exit this menu.

- If the selected key is erased, the display shows “KEY FAIL” and

the radio sounds a momentary keyfail tone.

- If the selected key is not allowed, the display shows “ILLEGAL

KEY” and the radio sounds a momentary illegal key tone.

Selecting an Index This feature lets the user select one or more groups of several

encryption keys from among the available keys stored in the radio. For example, the radio could have a group of three keys structured to one index, and another group of three different keys structured to another index. Changing indices makes the radio automatically switch from one set of keys to the other. Every channel to which one of the original keys was tied to will now have the equivalent new key instead.

Using the Menu 1. Press U until the display shows “INDX.”

2. Press D, E, or F directly below “INDX.” The display shows the last user selected and stored index, and the available index menu selections.

3. Press D, E, or F directly below the desired index. The display shows the last user selected and stored index, and the available index menu selections.

Page 61

4. To save the index, press D, E, or F directly below “SEL.”

To exit this menu without changing the index selection, press h

or the PTT button, or turn the 16-Position Select knob.

Using the Keypad 1. Press U until the display shows “INDX.”

2. Press D, E, or F directly below “INDX.” The display shows

the last user selected and stored index, and the available index menu selections.

3. Enter the number of the desired index, using the keypad.

4. To save the index, press D, E, or F directly below “SEL.”

To exit this menu without changing the index selection, press h

or the PTT button, or turn the 16-Position Select knob.

Erasing a Key

Encryption

Method 1 — Key Zeroization (Multikey Only)

1. Press U until the display shows “ERAS.”

2. Press D, E, or F directly below “ERAS.” The display shows

the last user selected and stored encryption key, and the available menu selections:

- ALL = erases all the encryption keys in the radio. The display shows “ERS ALL KEYS” and “YES” and “NO.”

- SNGL = selects the displayed encryption key to be erased.The display shows “ERS SNGL KEY” and “YES” and “NO.”

- ABRT = exits this menu and returns to the home display.

NOTE: To exit this menu at any time without changing the

index selection, press h or the PTT button, or turn the 16-Position Select knob.

3. Press D, E, or F directly below the desired menu.

Press V or U to find the desired encryption key. The display

shows the selected key, and the available menu selections shown in step 2. Press D, E, or F directly below the desired menu.

Enter the location number of the desired key, using the keypad.

The display shows the selected key, and the available menu selections shown in step 2. Press D, E, or F directly below the desired menu.

4. Press h, the PTT button, or turn the 16-Position Select knob to

exit this menu.

Page 62

Encryption

Method 2 — All Keys Erased

NOTE: This is the method used for erasing the key in radios

with the “single key” option.

1. With the radio on, press and hold the Top Side button; while holding this button down, press the Top button.

NOTE: DO NOT press the Top button before pressing the Top

Side button, unless you are in an emergency situation;

this would send an emergency alarm.

Before the keys are erased, the display shows “PLEASE WAIT.”

When all the encryption keys have been erased, the display shows “ERASED.”

Page 63

Disassembly/Reassembly

Procedures 8

Introduction This section gives detailed procedures for disassembling/reassembling

XTS 5000 radios, and ensuring the submergibility of ruggedized radios. When performing these procedures, refer to “Exploded Views and Parts Lists” on page 67 and the diagrams that accompany the text. Items in parentheses ( ) refer to item numbers in the exploded view diagrams.

This section also has procedures for removing and installing the XTS 5000 radio’s standard accessories and changing the Volume and Frequency Knobs.

Antenna

Attach the Antenna

Remove the Antenna

With the radio turned off, turn the antenna clockwise to attach it to the radio.

Figure 15. Attach the antenna

With the radio turned off, turn the antenna counter-clockwise to remove it from the radio.

Figure 16. Remove the antenna

Page 64

Disassembly/Reassembly Procedures

W A R N I N G

C a u t i o n

Battery

To avoid a possible explosion:

• DO NOT replace the battery in an area labeled “hazardous atmosphere.”

Attach the Battery 1. With the radio turned off, insert the top edge of the battery into

the radio’s frame as shown.

• DO NOT discard batteries in a fire.

If the radio is programmed with volatile-key retention, encryption keys will be retained for approximately 30 seconds after battery removal.

NOTE: The Motorola-approved battery shipped with the

XTS 5000 radio is uncharged. Prior to using a new battery, charge it for a minimum of 16 hours to ensure optimum capacity and performance.

Figure 17. Insert the top edge of the battery

2. Rotate the battery toward the radio and press down until the battery clicks into place.

Figure 18. Press the battery into place

Remove the Battery 1. With the radio turned off, press the release button on the bottom

of the battery until the battery releases from the radio.

Figure 19. Press the release button

Page 65

Disassembly/Reassembly Procedures

2. Remove the battery from the radio.

Figure 20. Remove the battery

Belt Clip NOTE: The battery must be removed from the radio before

the belt clip can be installed or removed.

Attach the Belt Clip 1. Align the grooves of the belt clip with those of the battery.

Grooves

Slots

Battery

Figure 21. Align the belt clip with the battery

2. Press the belt clip downward until you clear a click.

Slots

Battery

Figure 22. Press the belt clip into place

Remove the Belt Clip 1. Use a flat-bladed object to press the belt clip tab away from the

battery.

Metal

Tab

Figure 23. Press the belt clip tab away from the battery

Page 66

Disassembly/Reassembly Procedures

Metal

C a u t i o n

2. Slide the belt clip upward to remove it.

Tab

Figure 24. Remove the belt clip

Universal Connector Cover

Remove the Universal Connector Cover

When the universal connector is not in use, keep it covered

1. Insert a flat-blade screwdriver into the area between the bottom of the cover and the slot below the connector.

2. Hold the top of the cover with your thumb while you pry the bottom of the cover away from the radio with the screwdriver.

with the universal connector cover.

Figure 25. Insert a screwdriver below the cover

Figure 26. Remove the cover

Page 67

Disassembly/Reassembly Procedures

Attach the Universal Connector Cover

1. Insert the hooked end of the cover into the slot above the

connector. Press downward on the cover’s top to seat it in the slot.

Top

Hooked End

Top Slot

Figure 27. Hook the end into the slot

2. Press the cover’s lower tab into the slot below the connector until

it snaps in place.

Tab

Bottom

Hooked End

Bottom

Slot

Figure 28. Press the cover into place

Page 68

Disassembly/Reassembly Procedures

Frequency Knob NOTES:

• Refer to Figure 29, the Partial Exploded View, and Table 15, the

Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 29 and Table 15.

• The battery (56) should be removed from the radio before

installing or removing the frequency knob (13).

• In cases where the frequency knob retainer insert (11) and

frequency dial escutcheon (12) must be removed, a new insert and new escutcheon must be used for reassembly.

11 10

Alignment Tabs Alignment Notch

Figure 29. Partial Exploded View

Page 69

Disassembly/Reassembly Procedures

Table 15. Partial Exploded View Parts List

ITEM

NO.

1 3305630Z01 LABEL, Motorola Bottom

3 3285757D01 MEMBRANE, Microphone Front

4 3385221D01 LABEL, Motorola, Front

5 1505579Z01 COVER, Universal Connector

6 3605371Z01 KNOB, Volume

7 4305372Z01 INSERT, Volume Knob Retainer

8 3205379W01 O-RING, Volume Torque

9 6105376Z01 LIGHTPIPE, Indicator

10 4505375Z01 LEVER, Secure

11 4305373Z02 INSERT, Frequency Knob Retainer

12 1305374Z03 ESCUTCHEON, Frequency Dial

13 3605370Z01 KNOB, Frequency

14 NAF5037_

MOTOROLA

PART NO.

or NAF5042_ or NAF5080_

DESCRIPTION

ANTENNA, Whip, Halfwave (806-870 MHz) ANTENNA, Stubby, 1/4 Wave (806-870 MHz) ANTENNA, Whip (764-870 MHz)

17 3305574Z01 LABEL, Motorola Back

56 NTN8294_ BATTERY, NiCd

57 NTN8266_ CLIP, Belt

65 3585741D01 MESH, Microphone

66 3385658D01 ESCUTCHEON, Concentric Switch

67 3385657D01 ESCUTCHEON, Toggle

68 - - - - - - - - - - LABEL, Flashport

69 - - - - - - - - - - LABEL, Radio Serial Number

70 - - - - - - - - - - LABEL, Approval Agency

Page 70

Disassembly/Reassembly Procedures

Remove the Frequency Knob

Install the Frequency Knob

1. Hold the radio in one hand so that the top of the radio faces upward, and the front of the radio faces you.

2. With the other hand, grasp the frequency knob (13) and pull it upward, while rocking the knob back and forth, until it is free from the frequency knob retainer insert (11), or the insert is free from the shaft.

3. If necessary, while pressing the insert’s (11) two snap tabs away from the frequency control shaft so that the insert disengages from the shaft, use needle-nosed pliers to lift the insert up and off of the frequency control shaft. Discard the removed insert.

4. Remove the secure lever (10) and the indicator lightpipe (9).

1. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.

2. Align the lightpipe indicator (9) so that its straight tab is over the slot for the illuminated pointer. Push the tab down into the slot so that it is securely seated.

3. Place the secure lever (10) on the frequency control shaft, aligning it so that its pointer is at the front of the radio and its two inner slots line up with the two keys on the shaft. Slide the secure lever down to the bottom of the shaft.

4. If you are replacing the frequency dial escutcheon (12):

a. Remove the backing paper from the escutcheon. b. Align the number “1” on the escutcheon with the alignment

notch on the frequency knob retainer insert (11).

c. Slide the escutcheon down over the insert, ensuring that the

alignment tab on the escutcheon fits inside the tab recess on the insert.

d. Press the escutcheon firmly onto the insert to ensure proper

adhesion.

5. Place a new frequency knob retainer insert (11) and new frequency dial escutcheon (12) on the frequency control shaft, aligning the insert’s D-shaped hole with the D-shaped shaft. Press downward firmly on the insert until it snaps in place on the shaft.

6. Place the frequency knob (13) on the insert (11), aligning it’s pointer with the number “1” on the escutcheon (12). Press firmly downward on the knob until it seats securely in place.

Page 71

Volume Knob NOTES:

• Refer to Figure 29. on page 44, the Partial Exploded View,

• The battery (56) should be removed from the radio before

• In cases where the volume insert (7) must be removed, a

Disassembly/Reassembly Procedures

and Table 15 on page 45, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 29 and Table 15.

installing or removing the volume knob (6).

new volume insert must be used for reassembly.

Remove the Volume Knob

1. Turn the volume knob (6) to the off position.

2. Hold the radio in one hand so that the top of the radio faces

upward, and the front of the radio faces you.

3. With the other hand, grasp the volume knob (6) and pull it

upward, while pushing it toward the back of the radio, until it is free from the volume knob retainer insert (7).

4. Bend the volume knob retainer insert’s (7) two snap tabs away

from the volume control shaft so that the insert disengages from the shaft, then use needle-nosed pliers to pull the insert up and off of the volume control shaft. Discard the removed volume insert.

5. Using needle-nosed pliers or some other pointed instrument,

remove the volume torque o-ring (8).

Install the Volume Knob 1. Place the volume torque o-ring (8) inside a new volume knob

retainer insert (7), and press it downward until it seats securely at the bottom of the insert.

2. Hold the radio so that the top of the radio faces upward, and the

front of the radio faces you.

3. Place a new volume knob retainer insert (7) on the volume

control shaft, aligning the insert’s D-shaped hole with the Dshaped shaft. Press downward firmly on the insert until it snaps in place on the shaft.

4. Place the volume knob (6) on the volume knob retainer insert (7),

aligning the two lugs on the inside of the knob with the insert’s two snap tabs. Press firmly downward on the knob until it seats securely in place.

Page 72

Disassembly/Reassembly Procedures

Radio Disassembly and Reassembly

Disassembly 1. Turn off the radio by rotating the On/Off/Volume control fully

counterclockwise until you hear a click.

2. Remove the antenna, the battery, and the universal connector cover or any accessory connected to the radio.

NOTE: It is not necessary to remove the volume knob (6)

and insert (7) or frequency knob (13) and insert (11) to service the casting assembly. However, if any top control is suspected, then the knobs and inserts should be removed prior to removing the casting assembly (51) from the housing assembly (2). Refer to “Frequency Knob” on page 44 and “Volume Knob” on page 47.

3. With the back of the radio facing upward, insert the 6685833D01 special tool at the bottom of the radio between the housing assembly (2) and the two housing tabs on the casting assembly (51) until the special tool’s latch engages the two battery tabs on the casting assembly. With the latch engaged, gently pull the casting away to remove it from the housing (do not use a prying motion). Making sure that the antenna bushing has cleared the hole in the control top, carefully lift the casting assembly clear of the housing assembly.

4. While holding the casting assembly (51) in one hand and the housing assembly (2) in the other, unplug the 40-pin connector, on the controls flex assembly (18), from the VOCON board (44).

NOTE: This can easily be done using the thumb of the

hand holding the housing assembly.

Put the housing assembly aside.

5. Remove the main seal (55) from around the casting assembly (51).

6685833D01 Tool

Battery Tabs

6. If you are disassembling a model I radio, skip to step 9; if you are disassembling a model II or III radio, continue this procedure.

With the front of the radio facing upward, unplug the 22-pin connector for the LCD module (38) (located to the right and above the LCD module). Lift the LCD module (38), with display locator pad (39), up and off of the two locator posts on the casting (51).

7. Remove the LCD module (38) and put it aside.

8. Unplug the 22-pin connector for the keypad flex (37) (located to the left and above the LCD module area).

9. Pry upward on all four control locking clips (40) for the VOCON

Page 73

Disassembly/Reassembly Procedures

C a u t i o n

board shield assembly (41), alternating diagonally across the shield. Remove the VOCON board shield assembly, with keypad flex assembly (37) (models II and III only) and clips still attached, from the casting.

10. Lift the VOCON board (44) up and away from the casting.

NOTE: If the radio is equipped with hardware encryption,

the encryption board (45) is attached to the back side of the VOCON board via a 40-pin connector. When the VOCON board is lifted out of the casting, the encryption board is removed with it.

11. Lift out the 26-pin compression connector (46).

12. Using needle-nosed pliers, carefully unplug the coaxial cable’s

connector (52) from the transceiver board’s (48) surface-mount connector.

13. With the front of the radio facing upward, disengage the clip (63)

that secures the upper left portion of the RF shield (47) by inserting a thin, flat-bladed screwdriver between the clip and the casting assembly (51) and prying the clip free. Then, release the snap on the bottom left side and the two snaps on the right side of the RF shield. Lift the shield out, with the clip still attached, rotating it around its top edge.

14. Remove the rubber pad (71).

15. Lift the transceiver board (48) out of the casting assembly. Inspect

the casting to make sure that the thermal pad (58) is attached to the casting. If the pad is attached to the transceiver board, remove it from the board and discard it. Attach a new thermal pad to the casting as shown in the exploded view.

16. Lift the B+ assembly (49) and B+ seal (50) out of the casting

assembly.

Housing Assembly 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. To begin housing disassembly, remove the speaker retainer screw

(23).

3. Remove the speaker retainer (36).

4. Install the universal connector cover (5) (see page 43). This will

hold the universal connector in place when the controls flex is removed.

Removing the controls flex without installing the universal connector cover may compromise the universal connector.

5. Disconnect the controls flex (18) from the universal connector by

disengaging the spring tab on the backer from the catch features on the housing.

6. Disconnect the controls flex’s (18) 22-pin connector from PTT

area of the housing assembly (2).

7. Referring to “Frequency Knob” on page 44 and “Volume Knob”

Page 74

Disassembly/Reassembly Procedures

on page 47, remove the frequency knob, frequency insert, secure lever, lightpipe, volume knob, volume insert, and o-ring.

8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the controls bracket assembly (34) first, then unsnap the right snap.

9. Remove the controls bracket assembly (34).

10. Remove the controls seal (35).

Battery Contact and Battery Contact Seal

1. Referring to “Radio Disassembly and Reassembly” on page 48, remove the housing assembly (2) from the radio.

2. Completely disassemble the casting assembly (51).

3. Remove the battery contact (49) and battery contact seal (50).

Reassembly 1. Reinstall the B+ assembly (49) and B+ seal (50), making sure that

the seal seats properly in the casting assembly (51). Inspect the B+ assembly from the back of the casting to ensure that the seal shows evenly around the B+ assembly.

2. Make sure that a thermal pad (58) is attached to the casting. If it is not, attach a new thermal pad to the casting as indicated in the exploded view.

3. With the front of the radio facing upward, place the transceiver board (48) in position, tucking the right side of the board in first — in the casting slot.

4. Put the rubber pad (71) in place on top of the transceiver board (48).

5. Reinstall the RF shield (47). Insert the shield’s top edge in first, aligning the two tabs on the shield’s top edge with the two slots in the casting, then pivot the shield down into position. Engage the two snaps on the right side and the snap on the bottom left side first, then snap down the single left side clip (63).

6. Plug the coaxial cable’s connector (52) into the transceiver board’s (48) surface-mount connector, making sure to lead the coax’s connector straight into the surface-mount connector. An angled lead-in can damage the surface-mount connector or the center of the coax.

7. Reinstall the 26-pin compression connector (46). It can only be inserted in one way—with the two-peg edge pointing downward on the left side.

8. If the radio is equipped with an encryption board (45), connect it to the back of the VOCON board (44) through the 40-pin connector. Ensure that these connectors are properly engaged.

9. Reinstall the VOCON board (44). Tuck the tab at the top of the VOCON board into the retention slot on the casting, rotate the board into position, and engage the 26-pin connector.

10. Reinstall the VOCON board shield assembly (41), with keypad (models II and III only) and four clips (40) attached, onto the casting. Snap the shield’s clips down, alternating diagonally across the shield.

11. If you are reassembling a model I radio, skip to step 14; if you are reassembling a model II or III radio, complete the remainder of

Page 75

Disassembly/Reassembly Procedures

C a u t i o n

step 10. Plug the 22-pin connector at the end of the keypad flex’s (43) tail into the connector on the VOCON board (44).

12. Reinstall the LCD module (38) and display locator pad (39).

Position the LCD module, with the display locator pad facing upward, so that the connector on the flex points toward the bottom of the radio. Press the display locator pad (39) down over the two locator posts on the casting, making sure that the locator pad’s loops are fully captured by the casting posts.

13. Plug the 22-pin connector at the end of the display module (38)

flex into the mating connector on the VOCON board (44).

14. Reinstall the main seal (55) around the casting assembly (51).

Start at the top of the casting and work the seal around the perimeter of the casting until it is completely in place.

15. While holding the casting assembly (51) in one hand and the

housing assembly (2) in the other, plug the 40-pin connector on the controls flex assembly (18) into the connector on the VOCON board (44).

NOTE: This can easily be done using the thumb of the

hand holding the casting.

16. With the fronts of both the casting assembly (51) and housing

assembly (2) facing downward, carefully insert the top of the casting into the top of the housing assembly. Making sure that the antenna bushing is inside the antenna hole in the control top, pivot the bottom of the casting downward toward the bottom of the housing until they meet. Snap the housing assembly and casting assembly together.

The main seal o-ring should not be visible when looking at the back side of the radio. If the seal is visible, it is improperly installed.

17. Referring to the appropriate section in this manual, reinstall: the

universal connector cover or any accessory connected to the radio, the antenna, and the battery.

NOTE: If the volume knob (6) or frequency knob (13) were

removed prior to servicing the main casting, reinstall them.

Housing Assembly 1. Inspect the housing seal surfaces for debris. Remove any debris.

2. Install the controls seal (35).

3. Reassemble the controls bracket assembly (34) into the housing

(2) by snapping in the right side of the bracket first, then snapping in the left side.

4. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, install the frequency knob, new frequency escutcheon, new frequency insert, secure lever, lightpipe, volume knob, new volume insert, and o-ring.

5. Reconnect the controls flex (18) to the universal connector and

the PTT area of the housing assembly (2). Make sure the spring tabs on the backer fully engage the catch features on the housing.

Page 76

Disassembly/Reassembly Procedures

C a u t i o n

6. Install the main seal o-ring (55) around the casting assembly (51).

7. Reassemble the housing assembly (2) to the radio.

8. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Battery Contact and Battery Contact Seal

1. Inspect the casting seal surface for debris or damage. Remove any debris and replace casting if damaged.

2. Install the battery contact (49) and battery contact seal (50).

When installing the battery contact seal, make sure that the ledge around the outside of the seal completely protrudes through the opening in the casting and sits flush with the outside surface of the casting. Also, make sure that the seal’s shape is not distorted.

3. Reassemble the casting assembly (51).

4. Install the main seal o-ring (55) around the casting assembly (51).

5. Reassemble the housing assembly (2) to the radio.

6. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Seal Ledge

Casting

Page 77

Disassembly/Reassembly Procedures

C a u t i o n

Ensuring Radio Submergibility

Introduction ASTRO XTS 5000 R radio models meet the stringent requirements of

U. S. MIL-STD-810C, Method 512.1, Procedure I; MIL-STD-810D, Method 512.2, Procedure I; MIL-STD-810E, Method 512.3, Procedure I; and MIL-STD-810F, Method 512.4, Procedure I, which require the radio to maintain watertight integrity when immersed in three feet of water for two hours. XTS 5000R radios shipped from the Motorola factory have passed vacuum testing and should not be disassembled. If disassembly is necessary, refer to qualified service personnel and service shops capable of restoring the watertight integrity of the radio.

It is strongly recommended that maintenance of the radio be deferred to qualified service personnel and service shops. This is of paramount importance as irreparable damage to the radio can result from service by unauthorized persons. If disassembly is necessary, unauthorized attempts to repair the radio may void any existing warranties or extended performance agreements with Motorola. It is also recommended that submergibility be checked annually by qualified service personnel.

If the radio is accidentally dropped in water, shake the radio to remove the excess water from the speaker grille and microphone port area before operating; otherwise, the sound may be distorted until the water has evaporated, or is dislodged from these areas.

General Information To ensure that the radio is truly a watertight unit, special testing, test

procedures, and specialized test equipment are required. The special testing involves a vacuum check of the radio and pressure testing (troubleshooting) for water leaks if the vacuum check fails. The specialized test equipment is needed to perform the vacuum check and pressure testing, if required.

Specialized Test Equipment

Vacuum Pump Kit NLN9839

Pressure Pump Kit NTN4265

The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. An adapter with gasket (NTN9279A), which must be ordered separately, connects the vacuum hose to the radio’s casting. The vacuum pump kit is also used on Motorola ASTRO SABER R radios. The adapter with gasket is the same as that for the ASTRO XTS 3000R and XTS 3500 R.

The pressure pump kit includes a pressure pump with gauge, and a pressure hose; the pressure pump kit is also used on Motorola ASTRO SABER R radios. As with the vacuum pump kit above, the NTN9279A adapter connects the pressure hose to the radio’s casting.

Page 78

Disassembly/Reassembly Procedures

C a u t i o n

Miscellaneous Hardware

Disassembly and Reassembly

Disassembly Disassemble the radio according to “Disassembly” on page 48.

Reassembly Reassemble the radio according to “Reassembly” on page 50. Tighten

Other items needed for testing the submersible radio include:

• Large water container.

• Deionized (DI) water

• A supply of replacement seals, o-rings, and gaskets (refer to the

ASTRO XTS 5000 R exploded view parts list).

If disassembly and reassembly of the radio is required, refer to“Radio Disassembly and Reassembly” on page 48.

all hardware that was loosened or removed.

Do not reassemble the radio without first performing the following preliminary inspection procedure.

1. Remove the main seal o-ring from the casting.

2. Inspect the seal area around the casting for foreign material that might prevent the main seal o-ring from sealing properly.

3. Install a new main seal o-ring; discard the old o-ring.

4. Reassemble the housing.

The main seal o-ring should not be visible when looking at the back side of the radio. If the seal is visible, it is improperly installed.

Vacuum Test Refer to the exploded view diagrams and parts lists in this manual.

General The vacuum test uses a vacuum pump and gauge. The pump creates a

vacuum condition inside the radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly sealed, watertight unit. Before starting the vacuum test:

• Remove the battery.

• Remove the universal connector cover to expose the universal

connector.

Conducting the Test 1. Attach the vacuum hose to the vacuum pump. Check the pump

and hose for leaks by blocking off the open end of the hose and operating the pump a few times. The actual reading of the gauge at this point is not important; it is important that the gauge pointer remains steady, indicating no vacuum leaks in the pump.

2. Remove the vacuum test port using a pair of needle-nosed pliers and pulling upward.

3. Ensure that a rubber gasket is attached to the hose-to-casting adapter. Screw the adapter into the tapped hole in the casting.

Page 79

Disassembly/Reassembly Procedures

4. Attach the open end of the hose to the adapter.

5. Place the radio on a flat surface with the casting facing upward.

Place two or three drops of water on each slot of the label (62) that protects the vent port seal (61) on the casting. This will ensure that no air goes through the seal.

6. Operate the pump a few times until the gauge indicates 5 in. Hg;

do not pull more than 7 in. Hg of vacuum on the radio.

Operate the pump again until the gauge indicates 6 in. Hg.

7. Observe the gauge for approximately 1 minute.

• If the needle falls 1 in. Hg or less (for example, from 6 in. Hg to 5 in. Hg), then the radio has passed the vacuum test and is approved for submergibility. No additional testing will be required.

• If the needle falls more than 1 in. Hg (for example, from 6 in. Hg to less than 5 in. Hg), then the radio has failed the vacuum test and the radio might leak if submerged. Additional troubleshooting of the radio will be required; complete this procedure, then go to the “Pressure Test” section of this manual.

8. Dry the water from the slots on the label (62) that protects the vent port seal to allow the radio to equalize. The pressure should drop slowly to “0.”

9. Remove the vacuum hose and adapter from the radio.

10. Install the vacuum test port plug by pressing it in, ensuring that the plug sits flat all around the edges and it is flush with the casting.

Pressure Test Refer to the exploded view diagrams and parts lists in this manual.

General Pressure testing the radio is necessary only if the radio has failed the

vacuum test. Do not perform the pressure test until the vacuum test has been completed. Pressure testing involves creating a positive pressure condition inside the radio, submerging the radio in water, and observing the radio for a stream of bubbles (leak). Since all areas of the radio are being checked, observe the entire unit carefully for the possibility of multiple leaks before completing this test.

Conducting the Test 1. Remove the vacuum test port using a pair of needle-nosed pliers

and pulling upward.

2. Screw the adapter (with gasket) into the tapped hole in the casting.

3. Attach one end of the pressure hose to the adapter and the other end to the pressure pump.

4. Cover the vent port seal (61) and label (62) on the back of the casting with your thumb. This will prevent air from going through the seal. Keep the vent port covered with your thumb until the test is complete (through step 8).

5. Operate the pump until the gauge reads approximately 1 psig.

Page 80

Disassembly/Reassembly Procedures

C a u t i o n

Pressure any greater than 1 psig may push air around the main seal.

6. Maintain the pressure at 1 psig and submerge the radio into a water-filled container. Keep the vent port covered with your thumb while the radio is submerged.

7. Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.

NOTE: Some air entrapment may cause the accumulation

of bubbles, especially in the grille area, but the bubbles should not be continuous.

8. Note all of the seal areas that show signs of leakage. Pinpoint the problem(s) to one (or more) of the following areas:

• Housing

• Antenna bushing seal

• Controls seal

• Frequency switch, toggle, and on/off/volume control switch

• Main seal

• Battery contact and battery contact seal

• Keypad

9. Remove the radio from the water container, remove your thumb from the vent port seal, and dry the radio thoroughly. Be especially careful to dry the area around the main seal to prevent contamination of the internal electronics while the unit is open.

To avoid equipment damage, keep the area around the port seal dry by ensuring that there is no water around the casting’s vacuum port.

10. Remove the adapter and pressure hose added in steps 1 and 2, above.

11. Install the vacuum test port plug by pressing it in, ensuring that the plug sits flat all around the edges and it is flush with the casting.

12. Inspect the vent port seal (61) to ensure that the seal behind the label’s (62) two slots has not been punctured. If it has been punctured, the seal and the label must be replaced.

Troubleshooting Leak Areas

Before repairing any leak, read all applicable area repair paragraphs. This will help to eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot only the faulty seal areas listed in “Pressure Test” on page 55, and, when multiple leaks exist, in the order listed.

NOTE: Before reassembling the radio, always install a new

main seal o-ring, and new seals in the defective area.

Page 81

Disassembly/Reassembly Procedures

C a u t i o n

Housing 1. If a leak occurs at the lens, universal connector, casting/housing

interface, or PTT/Ratt button area of the housing, replace the

housing. Referring to “Disassembly” on page 48: a. Remove the housing assembly (2) from the radio. b. Discard the housing assembly (2) and main seal o-ring (55). c. Install a new main seal o-ring (55) around the casting

assembly (51). d. Install a new housing assembly (2) to the radio. e. Inspect the main seal (55) for proper seating. f. Observe carefully to ensure that the main seal o-ring (55) is

not pinched between the housing (2) and the casting (51).

2. If the leak occurs at the control top area, remove the knobs, knob inserts and antenna in order to determine the leak location:

a. Conduct the Pressure Test. b. Identify the leak location.

Antenna Bushing Seal 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove and discard the antenna bushing gasket (54).

3. Inspect the housing seal surface for debris or damage. Remove any debris and replace housing if damaged.

4. Install new antenna bushing gasket (54).

5. Install a new main seal o-ring (55) around the casting assembly (51).

6. Reassemble the housing assembly (2) to the radio.

7. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Controls Seal 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove the speaker retainer screw (23).

3. Remove the speaker retainer (36).

4. Install the universal connector cover (5) (see page 43). This will hold the universal connector in place when the controls flex is removed.

Removing the controls flex without installing the universal connector cover may compromise the universal connector.

5. Disconnect the controls flex (18) from the universal connector by disengaging the spring tab on the backer from the catch features on the housing.

6. Disconnect the controls flex’s (18) 22-pin connector from PTT area of the housing assembly (2).

Page 82

Disassembly/Reassembly Procedures

C a u t i o n

7. Referring to “Frequency Knob” on page 44 and “Volume Knob” on page 47, remove the frequency knob, frequency insert, secure lever, lightpipe, volume knob, volume insert, and o-ring.

8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the controls bracket assembly (34) first, then unsnap the right snap.

9. Remove the controls bracket assembly (34).

10. Remove and discard the controls seal (35).

11. Inspect the housing seal surfaces for debris. Remove any debris.

12. Install a new controls seal (35).

13. Reassemble the controls bracket assembly (34) into the housing (2) by snapping in the right side of the bracket first, then snapping in the left side.

14. Referring to “Frequency Knob” on page 44 and “Volume Knob” on page 47, install the frequency knob, new frequency escutcheon, new frequency insert, secure lever, lightpipe, volume knob, new volume insert, and o-ring.

15. Reconnect the controls flex (18) to the universal connector and the PTT area of the housing assembly (2). Make sure the spring tabs on the backer fully engage the catch features on the housing.

Frequency Switch, Toggle, and On/Off/ Volume Control Switch

16. Install a new main seal o-ring (55) around the casting assembly (51).

17. Reassemble the housing assembly (2) to the radio.

18. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

1. Referring to “Radio Disassembly and Reassembly” on page 48, remove the housing assembly (2) from the radio.

2. Remove the speaker retainer screw (23).

3. Remove the speaker retainer (36).

4. Install the universal connector cover (5) (see page 43). This will hold the universal connector in place when the controls flex is removed.

Removing the controls flex without installing the universal connector cover may compromise the universal connector.

5. Disconnect the controls flex (18) from the universal connector by disengaging the spring tab on the backer from the catch features on the housing.

6. Disconnect the controls flex (18) 22-pin connector from PTT area of the housing assembly (2).

7. Referring to “Frequency Knob” on page 44 and “Volume Knob” on page 47, remove the frequency knob, frequency insert, secure lever, lightpipe, volume knob, volume insert, and o-ring.

8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the

Page 83

Disassembly/Reassembly Procedures

controls bracket assembly (34) first, then unsnap the right snap.

9. Remove the controls bracket assembly (34).

10. Remove the controls seal (35).

11. Disassemble the controls bracket assembly (34) by disengaging

the snaps to remove the bottom bracket (33)

12. Replace the switch that leaks by following the unsoldering and

replacement instructions contained in the new switch’s instruction sheet.

13. Reassemble the controls bracket assembly (34) by snapping the

two brackets together.

14. Install the controls seal (35).

15. Reassemble the controls bracket assembly (34) into the housing

(2) by snapping in the right side of the bracket first, then snapping in the left side.

16. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, install the frequency knob, new frequency escutcheon, new frequency insert, secure lever, lightpipe, volume knob, new volume insert, and o-ring.

17. Reconnect the controls flex (18) to the universal connector and

the PTT area of the housing assembly (2). Make sure the spring tabs on the backer fully engage the catch features on the housing.

18. Install a new main seal o-ring (55) around the casting assembly

(51).

19. Reassemble the housing assembly (2) to the radio.

20. Inspect the main seal (55) for proper seating. Observe carefully to

ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Main Seal 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove and discard the main seal (55).

3. Inspect the housing and casting seal surfaces for debris or

damage. Remove any debris and replace the housing (2) or casting (51) if damaged.

4. Install a new main seal o-ring (55) around the casting assembly

(51).

5. Reassemble the housing assembly (2) to the radio.

6. Inspect the main seal (55) for proper seating. Observe carefully to

ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Battery Contact and Battery Contact Seal

1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Completely disassemble the casting assembly (51).

3. Remove and discard the leaking component.

4. Inspect the casting seal surface for debris or damage. Remove any

debris and replace casting if damaged.

Page 84

Disassembly/Reassembly Procedures

C a u t i o n

5. Install a new battery contact (49) and a new battery contact seal (50), if necessary.

6. Reassemble the casting assembly (51).

7. Install a new main seal o-ring (55) around the casting assembly (51).

8. Reassemble the housing assembly (2) to the radio.

9. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Seal Ledge

Casting

Keypad 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove and discard the keypad (15).

3. Inspect the housing seal surface for debris or damage. Remove any debris and replace housing if damaged.

4. Install new keypad (15).

5. Install a new main seal o-ring (55) around the casting assembly (51).

6. Reassemble the housing assembly (2) to the radio.

7. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal o-ring is not pinched between the housing (2) and the casting (51).

Vacuum Port Seal 1. Remove the vacuum port plug (59), using a pair of needle-nosed

pliers and pulling upward.

2. Inspect the casting seal surface for debris or damage. Remove any debris and replace the casting if damaged.

3. Install a new vacuum port plug (59) by pressing it in, ensuring that the plug sits flat all around the edges and it is flush with the casting.

Table 16. Submersible Radio Torque Specifications

Application

Speaker Bracket Screw 2 0.23 66-80321B79

Tor que

(in.-lbs)

Tor que

(N•m)

Torque Bit Part

No.

Vent Port Seal 1. Remove the seal label (62) that covers the vent port seal (61).

2. Remove the vent port seal (61).

3. Ensure that the casting’s surfaces are clean and free from any adhesive or other foreign materials.

Page 85

Disassembly/Reassembly Procedures

4. Install a new vent port seal (61), covering the two vent port holes,

in the small recessed area in the casting. Ensure that no oily substances come in contact with the seal.

5. Install a new seal label (62) over the vent port seal (61) in the

larger recessed area in the casting. Press down evenly over the label’s surface to ensure good adhesion.

Page 86

Disassembly/Reassembly Procedures

Notes

Page 87

Basic Troubleshooting

Introduction to This Section

Power-Up Error Codes

This section of the manual contains troubleshooting charts and error codes that will help you to isolate a problem. Level one and two troubleshooting will support only radio alignment, programming, battery replacement, and knob replacement, and circuit board replacement.

Component-level service information can be found in the “ASTRO Digital XTS 5000 Portable Radios Detailed Service Manual,” Motorola publication number 68P81094C31.

When the radio is turned on (power-up), the radio performs self-tests to determine if its basic electronics and software are in working order. Problems detected during these tests are presented as error codes on the radio’s display. For non-display radios, the problem will be presented at power-up by a single, low-frequency tone. The radio should be sent to the depot if cycling power and reprogramming the code plug do not solve the problem. The presence of an error should prompt the user that a problem exists and that a service technician should be contacted.

Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user operation; non-fatal errors will not. Use Table 17 on page 64 to aid in understanding particular power-up error code displays.

Page 88

Basic Troubleshooting

Table 17. Power-Up Error Code Displays

Error

Code

01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug 01/12 Security Partition Checksum Non-Fatal Error Send radio to depot 01/20 ABACUS Tune Failure Non-Fatal Error Turn the radio off, then on 01/22 Tuning Codeplug Checksum Non-Fatal Error Send radio to depot 01/81 Host ROM Checksum Fatal Error Send radio to depot 01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug 01/88 External RAM Fatal Error — Note: not a checksum failure Send radio to depot 01/90 General Hardware Failure Fatal Error Turn the radio off, then on 01/92 Security Partition Checksum Fatal Error Send radio to depot 01/93 FLASHport Authentication Code Failure Send radio to depot 01/98 Internal RAM Fail Fatal Error Send radio to depot 01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot 02/81 DSP ROM Checksum Fatal Error Send radio to depot 02/88 DSP RAM Fatal Error — Note: not a checksum failure Turn the radio off, then on 02/90 General DSP Hardware Failure (DSP startup message not

received correctly) 09/10 Secure Hardware Error Turn the radio off, then on 09/90 Secure Hardware Fatal Error Turn the radio off, then on

Note: If the corrective action does not fix the failure, send the radio to the depot.

Description Corrective Action

Turn the radio off, then on

Operational Error Codes

Error Code Description Corrective Action

FAIL 001 Synthesizer Out-of-Lock a. Reprogram external codeplug

FAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram external codeplug

During radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as error codes on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 18 to aid in understanding particular operational error codes.

Table 18. Operational Error Code Displays

b. Send radio to depot

Page 89

Table 19. Receiver Troubleshooting Chart

Basic Troubleshooting

Symptom Possible Cause

Radio Dead; Display Does Not Tur n On

Radio Dead; Display Tur ns Off

No Receive Audio or Receiver Does Not Unmute

Audio Distorted or Not Loud Enough

RF Sensitivity Poor 1. Synthesizer Not

1. Dead Battery Replace with charged battery.

2. Blown Fuse Send radio to depot.

3. On/Off Switch

4. Regulators

1. VOCON Board Send radio to depot.

2. RF Board

Programming a. Does the transmitted signal match the receiver

Synthesizer Not On Frequency

On Frequency

2. Antenna Switch/ Connector

3. Receiver Front End Tuning

Correction or Test (Measurements

Taken at Room Temperature)

configuration (PL, DPL, etc.)? b. With the monitor function enabled, can the radio

be unmuted? Check synthesizer frequency by measuring the transmitter

frequency; if off by more than ±1000Hz, realign.

Check synthesizer frequency by measuring the transmitter frequency; if off by more than ≤ ±1000Hz, realign.

Send radio to depot.

Check RF front-end tuning for optimum sensitivity using the tuner.

Radio Will Not Turn Off VOCON Board Send radio to depot.

Table 20. Transmitter Troubleshooting Chart

Symptom Possible Cause

No RF Power Out 1. TX Power Level or Frequency Check TX power level and frequency

2. No Injection To Power Amplifier Send radio to depot.

3. Antenna Switch/Connector

No Modulation; Distorted Modulation

Bad Microphone Sensitivity 1. Check Deviation and Compensation Realign if necessary.

No/Low signaling (PL, DPL, MDC)

Cannot Set Deviation Balance

1. Programming Check deviation and compensation

2. VOCON Board Send radio to depot.

2. Microphone Send radio to depot.

1. Programming Check programming

2. VOCON Board Send radio to depot.

RF Board Send radio to depot.

Correction or Test (Measurements

Taken at Room Temperature)

programming (from tuner).

settings using the tuner.

Page 90

Basic Troubleshooting

Table 21. Encryption Troubleshooting Chart

Symptom Possible Cause Corrective Action

No “KEYLOAD” on Radio Display When Keyloading Cable is Attached to the Radio Side Connector

Keyloader Displays “FAIL.” 1. Wrong Keyloader Type Use correct keyloader

1. Defective Keyload Cable Send radio to depot.

2. Defective Radio

type. Refer to Keyloader User Guide for more information.

2. Bad Keyloader Try another keyloader

3. Defective Radio Send radio to depot.

Page 91

Model I Exploded View Parts List

NO.

ITEM

MOTOROLA

PART NUMBER

DESCRIPTION

Exploded Views

ITEM

NO.

MOTOROLA

PART NUMBER

1 3305630Z02

3305630Z04

2 1585468D07

or 1585468D10 or 1585468D13

3 3285757D01 MEMBRANE, Microphone (part of item 2) 4 3385221D01

or 3385221D02 or 3385221D03

5 1505579Z01 COVER, Universal Connector (part of item 2) 6 3605371Z01 KNOB, Volume 7 4305372Z01 INSERT, Volume Knob Retainer 8 3205379W01 O-RING, Volume Torque

9 6105376Z01 LIGHTPIPE, Indicator 10 4505375Z01 LEVER, Secure 11 4305373Z02 INSERT, Frequency Knob Retainer 12 1305374Z03 ESCUTCHEON, Frequency Dial 13 3605370Z01 KNOB, Frequency 14 NAF5037_ ANTENNA, 800MHz Whip (80 6-8 70M H z)

or NAF5042_ ANTENNA, 800MHz Stubby1/4 Wave (806-870MHz) or NAF5080_ ANTENNA, 700/800MHz Whip (764-870MHz)

16 3585340D01 MESH, Speaker (part of item 2) 17 3305574Z01

or 3305574Z02

18 0105956T85 ASSEMBLY, Controls Universal Flex (includes items 19, 21, 19 5085272D01 SPEAKER (part of item 18)

21 - - - - - - - - - - MICROPHONE, Electret (part of item 18) 22 - - - - - - - - - - CAPACITOR, 56pF (part of item 18)

23 0300140332 SCREW, Tapping - 28 x 3/16 24 0660076A93 RESISTOR, 68kΩ (part of item 18) 25 0660076A96 RESISTOR, 91kΩ (part of item 18) 26 0660076B05 RESISTOR, 150kΩ (part of item 18) 27 4805729G 99 LED, Green/Red (5 req’d) (part of item 18)

LABEL, Motorola Bottom (non-intrinsic) (part of item 2) LABEL, Motorola Bottom (intrinsic) (part of item 2) ASSEMBLY, Model I Housing (Standard Models) (includes items 1, 3, 4, 5, 16, 17, and 65 thru 67) ASSEMBLY, Model I Housing (R Models) (includes items 1, 3, 4, 5, 16, 17, and 65 th ru 67) ASSEMBLY, Model I Housing (Yellow R Model) (includes items 1, 3, 4, 5, 16, 17, and 65 thru 67)

LABEL, Motorola Front (part of item 2) LABEL, Motorola Front (R Model) (part of item 2) LABEL, Motorola Front (Yellow R Model) (part of item 2)

LABEL, Motorola Back (part of item 2) LABEL, Motorola Back (Yellow R Model) (part of item 2)

22, 24 thru 28, and 30 thru 34)

(Not Field Replaceable) (Not Field Replaceable)

DESCRIPTION

28 1805629V04 POTENTIOMETER, Volume (part of item 18) 30 1486164A02 BOOT, Microphone Boot (part of item 18) 31 4005572W04 SWITCH, Toggle, 3 Pos. A/B/C (part of item 18) 32 4002622J04 SWITCH, Frequency (part of item 18) 33 0705357Z01 BRACKET, Controls Bottom (part of item 18) 34 0705352Z01 BRACKET, Controls (part of item 18) 35 3205354Z02 SEAL, Controls 36 4285400D01 RETAINER, Speaker 40 4205631Z01 CLIP, Control Locking (Part of item 41) (4 req’d) 41 2685567D01 SHIELD, Controller Front (Includes items 40 and 42) 42 4285288D01 RETAINER (Part of item 41) 44 NTN9564_ KIT, VOCON Board 45 NTN9837A

46 2885866A01 CONNECTOR, Compression, 26-Pin 47 2685220D02 SHIELD, RF with Insulator and Clip (Includes item 63) 48 NUF3577_ KIT, T r ansceiver Board, 700/800MHz 49 0985973B01 ASSEMBLY, B+

50 3205351Z02 SEAL, B+ 51 2785219D01 ASSEMBLY, Casting

52 3005664Z01 ASSEMBLY, Coaxial Cable 53 7505487Z01 PAD, Coaxial 54 3205082E96 GASKET, O-Ring Bushing 55 3205349Z03 SEAL, Main 56 HNN9031_ BATTERY, NiCd, Ultra-High Capacity 57 NTN8266_ KIT, Belt Clip 58 326 273 7D 0 1 PAD, Thermal 59 3285688D01 PLUG, Vacuum Test Port 61 3285877B02 SEAL, Port 62 3385873B01 LABEL, Seal 63 4285704D01 CLIP, RF Locking (Part of item 47) 65 3585741D01 MESH, Microphone (part of item 2) 66 3385658D01 ESCUTCHEON, Concentric Switch (part of item 2) 67 3385657D01 ESCUTCHEON, Toggle (part of item 2) 71 7585936D01 PAD

NTN9838A NTN9839A

NNTN4006A

or 0985973B02 ASSEMBLY, B+ (R Models)

or 2785219D04 ASSEMBLY, Casting (R Models)

DES, DES-XL, DES-OFB with DVP-XL Encryption Kit - UCM DVI-XL Encryption Kit - UCM DVP-XL Encryption Kit - UCM DES, DES-XL, DES-OFB Encryption Kit - UCM

and Parts Lists 10

Model I Exploded View Parts List

Page 92

Exploded Views and Parts Lists

66 67

25 21

26 22

MAEPF-27209-O

Model I Exploded View

Page 93

Exploded Views and Parts Lists

Models II and III Exploded View Parts List

ITEM

NO.

MOTOROLA

PART NUMBER

1 3305630Z02

3305630Z04

2 1585468D08

or 1585468D11 or 1585468D14

1585468D09

or 1585468D12 or 1585468D15

3 3285757D01 MEMBRANE, Microphone (part of item 2) 4 3385221D01

or 3385221D02 or 3385221D03

5 1505579Z01 COVER, Universal Connect or (part of item 2) 6 3605371Z01 KNOB, Volume 7 4305372Z01 INSERT, Volume Knob Retainer 8 3205379W01 O-RING, Volume Torque

9 6105376Z01 LIGHTPIPE, Indicator 10 4505 375 Z0 1 L EVE R, Se cur e 11 4305373Z02 INSERT , Frequency Knob Retainer 12 1305374Z03 ESCUTCHEON, Frequency Dial 13 3605 370 Z0 1 K NOB , Fr equ en cy 14 NAF5037_ ANTENNA, 800MHz Whip (806-870MHz)

or NAF5039_ ANTENNA, 800MHz Dipole (806-870MHz) or NAF5042_ ANTENNA, 800MHz Stubby1/4 Wave (806-870MHz) or NAF5080_ ANTENNA, 700/800MHz Whip (764-870MHz)

15 7585104D01 KEYPAD, Model III

or 7585104D02 KEYPAD, Model II 16 3585340D01 MESH, Speaker (part of item 2) 17 3305574Z01 LABEL, Motorola Back (part of item 2)

or 3305574Z02 LABEL, Motorola Back (Yellow R Models) (part of item 2) 18 0105956T85 ASSEMBLY, Controls Universal Flex (includes items 19, 21, 22,

19 5085272D01 SPEAKER (part of item 18) 21 - - - - - - - - - - MICROPHONE, Electret (part of item 18)

22 - - - - - - - - - - CAPACITOR, 56pF (part of item 18) 23 0300140332 SCREW, Tapping - 28 x 3/16

24 0660076A93 RESISTOR, 68kΩ (part of item 18) 25 0660076A96 RESISTOR, 91kΩ (part of item 18) 26 0660076B05 RESISTOR, 150kΩ (part of item 18) 27 4805729G99 LED, Green/Red (5 req’d) (part of item 18)

LABEL, Motorola Bottom (non-intrinsic) (part of item 2) LABEL, Motorola Bottom (intrinsic) (part of item 2)

ASSEMBLY, Model II Housing (Standard Models) (includes items 1, 3, 4, 5, 16, 17, and 64 thru 67) ASSEMBLY, Model II Housing (R Models) (includes items 1, 3, 4, 5, 16, 17, and 64 thru 67) ASSEMBLY, Model II Housing (Yellow R Model) (includes items 1, 3, 4, 5, 16, 17, and 64 thru 67) ASSEMBLY, Model III Housing (Standard Models) (includes items 1, 3, 4, 16, 17, and 64 thru 67) ASSEMBLY, Model III Housing (R Models) (includes items 1, 3, 4, 16, 17, and 64 thru 67) ASSEMBLY, Model III Housing (Yellow R Model) (includes items 1, 3, 4, 5, 16, 17, and 64 thru 67)

LABEL, Motorola Front (part of item 2) LABEL, Motorola Front (R Models) (part of item 2) LABEL, Motorola Front (Yellow R Models) (part of item 2)

24 thru 28, and 30 thru 34)

(Not Field Replaceable) (Not Field Replaceable)

DESCRIPTION

ITEM

NO.

MOTORO LA

PA RT NUMBER

28 1805629V04 POTENTIOMETER, Volume (part of item 18) 30 1486164A02 BOOT, Microphone Boot (part of item 18) 31 4005572W04 SWITCH, Toggle, 3 Pos. A/B/C (part of item 18) 32 4002622J04 SWITCH, Frequency (part of item 18) 33 0705357Z01 BRACKET, Controls Bottom (part of item 18) 34 0705352Z01 BRACKET, Controls (part of item 18) 35 3205354Z02 SEAL, Controls 36 4285400D01 RETAINER, Speaker 37 2685567D03 ASSEMBLY, Keypad Flex, Model III (Includes items 41 and 43)

or 2685567D02 ASSEMBLY, Keypad Flex, Model II (Includes item 41 and 43) 38 7285726C01 MODULE, LCD 39 7585189D01 PAD, Display Locator 40 4205631Z01 CLIP, Control Locking (part of item 41) (4 req’d) 41 2685567D01 SHIELD, Controller Front (Includes items 40 and 42) 42 - - - - - - - - - - RETAINER (Part of item 41) 43 8485188D01 FLEX, Keypad, Model III (part of item 37)

or 8485187D01 FLEX, Keypad, Model III (part of item 37) 44 NTN9564_ KIT, VOCON Board 45 NTN9837A

46 2885866A01 CONN ECTOR, Com pre ssion , 26-P in 47 2685220D02 SHIELD, RF with Insulator and Clip (Includes item 63) 48 NUF3577_ KIT, Transceiver Board, 700/800MHz 49 0985973B01 ASSEMBLY, B+

50 3205351Z02 SEAL, B+ 51 2785219D01 ASSEMBLY, Casting

52 3005664Z01 ASSEMBLY, Coaxial Cable 53 7505487Z01 PAD, Coax 54 3205082E96 GASKET, O-Ring Bushing 55 3205349Z03 SEAL, Main 56 HNN9031_ BATTERY, NiCd, Ultra-High Capacity 57 NTN8266_ KIT, Belt Clip 58 3262737D01 PAD, Thermal 59 3285688D01 PLUG, Vacuum Test Port 61 3285877B02 SEAL, Port 62 3385873B01 LABEL, Seal 63 4285704D01 CLIP, RF Locking (Part of item 47) 64 3385419C01

65 3585741D01 MESH, Microphone (part of item 2) 66 3385658D01 ESCUTCHEON, Concentric Switch (part of item 2) 67 3385657D01 ESCUTCHEON, Toggle (part of item 2) 71 7585936D01 PAD

NTN9838A NTN9839A

NNTN4006A

or 0985973B02 ASSEMBLY, B+ (R Models)

or 2785219D04 ASSEMBLY, Casting (R Models)

3385419C07

or NNTN4071_ Bezel Display Kit

DES, DES-XL, DES-OFB with DVP-XL Encryption Kit - UCM DVI-XL Encryption Kit - UCM DVP-XL Encryption Kit - UCM DES, DES-XL, DES-OFB Encryption Kit - UCM

BEZEL, Display - Titanium Silver (part of item 2) BEZEL, Display - Black (part of item 2)

DESCRIPTION

Models II and III Exploded View Parts List

Page 94

Exploded Views and Parts Lists

43 42

25 21

26 22

66 67

Models II and III Exploded View

MAEPF-27210-O

Page 95

ASTRO® XTS 5000™ Digital Portable Radios Accessory Section Changes

This FMR applies to the accessory section of the following publications and CDs:

• 68P81094C25-O ASTRO XTS 5000 Digital Portable Radio Model I User Guide

• 68P81094C26-O ASTRO XTS 5000 Digital Portable Radio Model II User Guide

• 68P81094C27-O ASTRO XTS 5000 Digital Portable Radio Model III User Guide

• 68P81094C28-O ASTRO XTS 5000 Digital Portable Radio Basic Service Manual

• 9985901D01 ASTRO XTS 5000 Digital Portable Radio Models I, II, and III User Guides CD

• 9985902D01 ASTRO XTS 5000 Digital Portable Radio Basic Service Manual CD

The accessories listed below are not compatible with the XTS 5000 at this time. Please refer to the following web site for a complete list of approved accessories: http://www.motorola.com/cgiss/portables/xts5000.shtml

Motorola Kit Numbers

BDN6664 BDN6669 BDN6728 BDN6780 NMN6246 BDN6665 BDN6670 BDN6729 BDN6781 NTN1624 BDN6666 BDN6676 BDN6730 BDN6782 NTN1625 BDN6667 BDN6726 BDN6731 NMN1020 NTN1663 BDN6668 BDN6727 BDN6732 NMN6245 NTN1736

A, Motorola, ASTRO, and XTS 5000 are trademarks of Motorola, Inc.

*FMR-2014-1*

FMR-2014-1

Page 96

Accessories

Antennas

Audio Adapters

Motorola provides the following approved optional accessories to improve the productivity of the XTS 5000 portable two-way radio.

NAF5037 800 MHz Whip, Halfwave (806-870 MHz) NAF5042 800 MHz Stubby, Quarterwave (806-870 MHz) NAF5080 700/800 MHz Whip (764-870 MHz)

BDN6676 Adapter, 3.5mm w/PTT Switch

Batteries

Carry Accessories

Belt Clips

Belt Loops

Carry Cases

NTN8294 NiCd, Ultra-High Capacity

NTN8266 Belt Clip Kit (Compatible with Clamshell Batteries)

NTN8040 Belt Loop, Swivel, Leather, 3.0”, High-Activity (For use

only with the high-activity leather swivel snap carry cases.)

NTN8381 Leather High Activity, 3.0”, Swivel Belt Loop, Model II and

III Radios

Page 97

Accessories

Chargers

NTN1873 Single-Unit, Dual Rate, Rapid, Tri-Chemistry; 110 V NTN1874 Single-Unit, Dual Rate, Rapid, Tri-Chemistry; 220 V (2-

prong Euro plug)

NTN1875 Single-Unit, Dual Rate, Rapid, Tri-Chemistry 240 V (3-

prong UK plug) NTN1177 Multi-Unit, Dual Rate, Rapid: 110 V NTN1178 Multi-Unit, Dual Rate, Rapid: 220 V (2-prong Euro plug) NTN1179 Multi-Unit, Dual Rate, Rapid: 240V (UK 13 MAP Plug) NTN1667 Single-Unit, Tri-Chemistry, Rapid Rate,110 V NTN1668 Single-Unit, Tri-Chemistry, Rapid Rate, 230 V (2-prong

Euro Plug) NTN1669 Single-Unit, Tri-Chemistry, Rapid Rate, 230 V (3-prong

UK Plug) NTN4796 Multi-Unit, Tri-Chemistry, Rapid Rate,110 V NTN9176 Vehicular, Tri-Chemistry and compatible with PAC•R T

Enhanced and Multi-Unit Line Cords

Commport Integrated Microphone/Receiver

WPLN4111 Impres™ Single-Unit, Tri-Chemistry,110 V

NTN7373 110 V Interchangeable Line NTN7374 220 V Interchangeable Line (2 prong Euro plug) NTN7375 240 V Interchangeable Line (3 prong UK plug)

NTN1624 MTS/XTS/HT w/ Palm PTT

Page 98

Accessories

Headset / Surveillance Accessories

Earpieces

(May require BDN6 67 6D — 3. 5 mm ad ap t er ja ck th at att ach es to the rad io )

BDN6645 Noise-Canceling Boom Mic Headset with PTT on earcup BDN6780 Earbud, Single with Mic and PTT Combined NMN6246 Ult ra lite Heads et w/Bo om Mic roph one NMN6258 Over the Head Headset w/ In Line PTT

BDN6641 Ear mic, high noise level up to 105dB GREY (must order Inter-

face module) BDN6664 Earpiece with standard earpiece BEIGE BDN6665 Earpiece with Extra-Loud Earphone (exceeds OSHA limits)

BEIGE BDN6666 Earpiece with Volume Control BEIGE BDN6667 Earpiece, Mic and PTT Combined BEIGE BDN6668 Earpiece, Mic and PTT Separate BEIGE BDN6669 Earpiece, Mic and PTT combined with extra loud earpiece BEIGE BDN6670 Earpiece, Mic and PTT separate with extra loud earpiece BEIGE BDN6677 Ear mic, standard, noise up to 95dB BLACK (must order Interface

module) BDN6726 Earpiece with standard earpiece BLACK BDN6727 Earpiece with extra loud earphone BLACK BDN6728 Earpiece with volume control BLACK BDN6729 Earpiece, Mic and PTT combined BLACK BDN6730 Earpiece, Mic and PTT separate BLACK BDN6731 Earpiece, Mic and PTT com bined with extra loud earpiece

BLACK BDN6732 Earpiece, Mic and PTT separate with extra loud earpiece BLACK BDN6781 Earbud, dual, receive only BLACK BDN6782 Earbud single receive only BLACK NTN1625 Commport ear mic, with PTT for noise levels up to 100 db (ship w/

BDN6676 adapter) NTN1663 Commport ear mic, with Ring PTT for noise levels up to 100 db

(ship w/ BDN6676 adapter) NTN1736 Commport ear mic, with Snap-On Side PTT for noise levels up to

100 db (ship w/ BDN6676 adapter)

Headset Accessories

BDN6635 Heavy-Duty VOX Headset with Noise-Cancelling Boom Mic

(Requires BDN6673_)

Page 99

Accessories

Ear Microphones (Require Radio Interface Module)

Radio Interface Modules for Ear Microphones

BDN6636 Heavy-Duty VOX Headset with Throat Microphone (Requires

BDN6673_) BDN6673 Cable, Headset Adapter NMN1020 Lightweight with Boom Mic to be Worn on Helmet or Safety

Glasses NMN6245 Lightweight with Single-Sided Headset and In-Line PTT Switch NMN6259 M edi um Weight, Behind-the-Head with In-Line PTT Switch RMN4049 Temple Transducer

BDN6677 Ear Mic, Standard — 95 dB (Black) BDN6678 Ear Mic, Standard — 95 dB (Beige)

BDN6671 Voice-activated Interface Module BDN6708 Push-to-Talk Interface Module

Remote Speaker and Public Safety Microphones

NMN6191 RSM Noise Canceling Includes: 6.0' coiled cord assembly ,

3.5mm earjack, swivel clip, quick disconnect

NMN6193 Remote Speaker Mic

Page 100

Vehicular Adapters

Accessories

HMN4069 Next-Generation Mobile Mic HSN1006 Speaker, 6-Watt NKN6455 Cable, 6-Watt Speaker NTN1606 Vehicular Adapter, BNC, Open Face NTN1607 Vehicular Adapter, BNC, Closed Face NTN8270 Tool Wrench NTN8480 Vehicular Adapter Trunnion Kit NTN8560 Vehicular Adapter, Mini-U, Open Faced NTN8561 Vehicular Adapter, Mini-U, Closed Faced NTN9176 Vehicular Ch arger, XTS PLN7737 Handheld Contro l Head

Allied Models

N1799 Vehicular Adapter, Mini-U, Closed Faced N2001 Vehicular Adapter, Mini-U, Open Face N2002 Vehicular Adapter, BNC, Open Face N2003 Vehicular Adapter, BNC, Closed Face

Motorola ASTRO XTS 5000 I, ASTRO XTS 5000 II, ASTRO XTS 5000 III Basic Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword This manual covers all models of the ASTRO

Safety Before operating an ASTRO XTS 5000 Radio, please read the “User

Manual Revisions Changes which occur after this manual is printed are described in

Computer Software Copyrights

Table of Contents ➠

List of Figures

List of Tables

Commercial Warranty

Limited Warranty

Motorola Communication Products

I.What This Warranty Covers And For How Long

II.General Provisions

III.State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF

IV.How To Get Warranty Service

V.What This Warranty Does Not Cover

VI.Patent And Software Provisions

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

Portable Radio Model Numbering System

ASTRO Digital XTS 5000 Model Chart

ASTRO Digital XTS 5000 R (Ruggedized) Model Chart

SPECIFICATIONS FOR 700/800 MHZ RADIOS

Compliance with RF Energy Exposure Standards

Operational Instructions and Training Guidelines

Transmit and Receive

Hand-held radio operation

Body-worn operation

Antennas & Batteries

Approved Accessories

Electromagnetic Interference/ Compatibility

Facilities To avoid electromagnetic interference and/or compatibility conflicts, turn off

Aircraft When instructed to do so, turn off your radio when on board an aircraft. Any

Medical Devices

Pacemakers The Advanced Medical Technology Association (AdvaMed) recommends that

Hearing Aids Some digital wireless radios may interfere with some hearing aids. In the event

Other Medical Devices

Driver Safety Check the laws and regulations on the use of radios in the area where you

Operational Warnings

For Vehicles With an Air Bag

Potentially Explosive Atmospheres

Blasting Caps and Blasting Areas

Operational Cautions

Antennas

Batteries

Intrinsically Safe Radio Information

FMRC Approved Equipment

Repair of FMRC Approved Products

Repair A repair constitutes something done internally to the unit that would bring it

Relabeling The repair facility shall have a method by which the replacement of FMRC

Do Not Substitute Options or Accessories

Introduction

General This manual covers information needed for levels one and two

Notations Used in This Manual

Radio Description The ASTRO Digital XTS 5000 radios are among the most sophisticated

FLASHport The ASTRO Digital XTS 5000 radio utilizes Motorola’s FLASHport

Basic Maintenance

Introduction This section of the manual describes preventive maintenance and handling

General Maintenance

Inspection Check that the external surfaces of the radio are clean, and that all external

Cleaning The following procedures describe the recommended cleaning agents and the

Cleaning External Plastic Surfaces

Handling Precautions

XTS 5000 R Radios Only 1. If the radio battery contact area has been submerged in water, dry

General Overview

Analog Mode of Operation

Receiving When the radio is receiving (see Figure 2.), the signal comes from the

Transmitting When the radio is transmitting (see Figure 3.), microphone audio is

ASTRO Mode of Operation

Transceiver (XCVR) Board Basic Theory of Operation

VOCON Board Basic Theory of Operation

Recommended Test Equipment

Service Aids Refer to Table 4, “Service Aids,” for a listing and description of the service aids

Field Programming Equipment

Performance Checks

Introduction This section covers performance checks used to ensure that the radio meets

Setup Supply voltage can be connected from the battery eliminator. The equipment

Display Radio Test Mode (Models II/III)