Motorola ASTRO XTL 5000 Basic Service Manual
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Motorola ASTRO XTL 5000 Basic Service Manual

700–800 mhz digital mobile radio
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ASTRO
XTL
5000
®
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700–800 MHz
Digital Mobile Radio
Basic Service Manual
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Summary of Contents for Motorola ASTRO XTL 5000

  • Page 1 ASTRO 5000 ® 700–800 MHz Digital Mobile Radio Basic Service Manual...
  • Page 3 ® ASTRO XTL™ 5000 Title Page 700–800 MHz Digital Mobile Radio Basic Service Manual Motorola, Inc. 8000 West Sunrise Boulevard 6881096C73-O Fort Lauderdale, Florida 33322...

  • Page 4: Foreword

    No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

  • Page 5: Table Of Contents

    VII. Governing Law........................xv Model Numbering, Charts, and Specifications........xvii Mobile Radio Model Numbering Scheme ....................xvii ASTRO XTL 5000 Motorcycle 3.5–35 Watt Model Chart ............... xviii ASTRO XTL 5000 3.5–35 Watt Model Chart.................... xix 700–800 MHz Radio Specifications......................xxi Chapter 1 Introduction .................
  • Page 6 Table of Contents 2.2.2.2 Cleaning Internal Circuit Boards and Components..........2-2 2.2.3 General Radio Care and Handling Precautions..............2-2 2.2.4 RF Power Amplifier (RF PA) Heatsinking ................. 2-2 Handling Precautions........................2-2 Chapter 3 Basic Theory of Operation ..........3-1 Introduction ............................ 3-1 General Overview ..........................
  • Page 7 Receiver Performance Checks ...................... 5-5 Transmitter Performance Checks ....................5-6 Chapter 6 Radio Alignment Procedures..........6-1 Introduction ............................ 6-1 ASTRO XTL 5000 Tuner Software ....................6-1 Radio Information .......................... 6-3 Transmitter Alignments........................6-3 6.4.1 PA Bias 1 Alignment ......................6-3 6.4.2...
  • Page 8 Table of Contents Universal Crypto Module Kits......................7-1 7.1.1 Secure Interface Boards ....................7-1 7.1.2 Secure Dispatch Operation....................7-1 7.1.3 Secure Emergency Operation................... 7-2 Load an Encryption Key......................... 7-2 7.2.1 W3 Control Head ......................7-2 7.2.2 W4, W5, W7, and W9 Control Heads ................7-3 Advanced Secure Operation......................
  • Page 9 11.16 Motorcycle Universal Mounting Plate ..................11-13 11.17 Small Pushbutton Parts ......................11-13 11.18 Large Pushbutton Parts ......................11-13 Appendix A Replacement Parts Ordering..........A-1 Basic Ordering Information ......................A-1 Motorola Online ..........................A-1 Mail Orders ............................A-1 Telephone Orders..........................A-1 Fax Orders.............................A-2 Parts Identification .........................A-2 Product Customer Service......................A-2...
  • Page 10 viii Table of Contents Index...................... Index-i June 11, 2003 6881096C73-O...
  • Page 11 List of Figures List of Figures Figure 1-1. Mobile Radio Model Numbering Scheme ................xvii Figure 1-1. W3 Hand-Held Control Head ....................1-3 Figure 1-2. Typical W4 Rotary Control Head................... 1-4 Figure 1-3. Typical W5 Limited Keypad Control Head ................1-4 Figure 1-4.
  • Page 12 Figure 8-38. Chassis Thermal Pad Locations ..................8-30 Figure 9-1. J2 Accessory Connector Pin-Out Arrangement ..............9-1 Figure 10-1. ASTRO XTL 5000 Functional Block Diagram ..............10-2 Figure 10-2. J0103 Remote-Mount Control Head Connector..............10-3 Figure 10-3. J5 Control Cable for Remote-Mount Control Head ............. 10-3 Figure 10-4.
  • Page 13 Service Aids for XTL 5000 Board-Level Troubleshooting ............. 4-2 Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting......... 4-3 Table 4-6. Recommended Non-Motorola Tools for Board-Level Troubleshooting ......... 4-3 Table 4-7. XTL 5000 Radio Field-Programming Items................4-4 Table 5-1. Test-Mode Displays ......................5-2 Table 5-2.
  • Page 14 Related Publications ASTRO XTL 5000 Digital Mobile Radio with W3 Control Head User’s Guide ......6881096C67 ASTRO XTL 5000 Digital Mobile Radio with W4, W5, W7,and W9 Control Heads User’s Guide ............................6881096C68 ASTRO XTL 5000 Digital Mobile Radio Installation Manual ............6881096C72 ASTRO XTL 5000 Digital Mobile Radio Detailed Service Manual ..........6818096C74...

  • Page 15: Commercial Warranty

    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.

  • Page 16: State Law Rights

    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.

  • Page 17: Patent And Software Provisions

    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.
  • Page 18 Commercial Warranty Notes June 11, 2003 6881096C73-O...

  • Page 19: Model Numbering, Charts, And Specifications

    Model Numbering, Charts, and Specifications xvii Model Numbering, Charts, and Specifications Mobile Radio Model Numbering Scheme Typical Model Number: Position: 12 13 Position 1 - Type of Unit Positions 13 - 16 M = Mobile SP Model Suffix L = Table Top Station Position 12 - Positions 2 &...

  • Page 20: Astro Xtl 5000 Motorcycle 3.5-35 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 Motorcycle 3.5 35 Watt Model Chart – – M20URS9PW1AN 764 870 MHz Option Description G67AD ADD: Remote Control Microphone W4, W5, W7 G67AF ADD: Remote Mount No Control Head Needed G82AA...

  • Page 21: Astro Xtl 5000 3.5-35 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 3.5 35 Watt Model Chart – – M20URS9PW1AN 764 870 MHz Option Description G66AA ADD: Dash Mount W4, W5, W7 G66AB ADD: Dash Mount W3 G66AC ADD: Dash Mount No Control Head Needed...
  • Page 22 Model Numbering, Charts, and Specifications ASTRO XTL 5000 3.5 35 Watt Model Chart (cont.) – – M20URS9PW1AN 764 870 MHz Option Description G239AM INT: Secure Button W4 G239AN INT: Secure Button W5 G239AP INT: Secure Button W7 G50/51 G239AQ INT: Secure Button W9 G50/51...

  • Page 23: Mhz Radio Specifications

    Model Numbering, Charts, and Specifications 700–800 MHz Radio Specifications GENERAL RECEIVER TRANSMITTER FCC Designations: AZ492FT5823 Frequency Range: Frequency Range: 700 MHz Band: 764–776 MHz 700 MHz Band: Temperature Range: 800 MHz Band: 851–870 MHz Repeater Mode: 794–806 MHz Operating: –30° C to +60° C Talkaround Mode: 764–776 MHz Storage:...
  • Page 24 xxii Model Numbering, Charts, and Specifications Notes June 11, 2003 6881096C73-O...

  • Page 25: Chapter 1 Introduction

    Radio Description The ASTRO XTL 5000 digital mobile radio is Motorola’s newest two-way mobile radio designed for your organization’s most demanding needs. The XTL 5000 Mobile is available in the 764–870 MHz frequency band with 3.5–35 W variable power (2 W itinerant).

  • Page 26: Flashport

    ® FLASHport All ASTRO XTL 5000 digital mobile radios are part of the FLASHport program and ship standard with a FLASH EE Prom, which allows for feature and system upgrades. FLASHPort Aftermarket Software is used to upgrade to the latest version of your System Enhancement Software Package, to upgrade to a different System Enhancement Software Package, or to order enhancements for existing ASTRO XTL 5000 digital radios in the field.

  • Page 27: W3 Control Head

    Introduction: Control Head Descriptions 1.4.1 W3 Control Head On/Off Orange Programmable Programmable Button Button Button (T1) (T2) (T3) Indicator Display Push-To-Talk (PTT) Button Side Button 1 (S1) H O M E Side Button 2 (S2) Side Button 3 (S3) Volume V O L MODE Mode Control...

  • Page 28: W4, W5, W7, And W9 Controls Heads

    Introduction: Control Head Descriptions 1.4.3 W4, W5, W7, and W9 Controls Heads NOTE: Typical as stated in the PAGE Page figure titles refers to the ability to SECURE customize the features accessed Emer EMERGENCY SCAN SELECT MONITOR by certain pushbuttons on the PHONE CALL DIRECT...

  • Page 29: W4, W5, W7, And W9 Controls

    Introduction: Control Head Descriptions FUNCTION PRIORITY DIMMER BUTTON INDICATOR STATUS* CONTROL XMIT BUSY Emer Scan Call FUNCTION ON/OFF INDICATORS Phon KEYPAD MESSAGE* RECALL DELETE Mode Home MODE VOLUME SELECT HOME ROCKER ROCKER POWER NON-PRIORITY SWITCH INDICATOR * Optional buttons (included but not installed or programmed) MAEPF-27654-O Figure 1-5.
  • Page 30 • 12-Button Keypad (W7 and W9) — The keypad is used to change the status of options and for entering numbers. Several keys serve multiple functions. See the ASTRO XTL 5000 Digital User’s Guide for a complete description of keypad operation.

  • Page 31: Chapter 2 Basic Maintenance

    Chapter 2 Basic Maintenance Introduction This section of the manual describes preventive maintenance, handling precautions, and some basic repair procedures and techniques. Each of these topics provides information vital to the successful operation and maintenance of your radio. NOTE: For board- and component-level repair of the radio, refer to the Detailed Service Manual (see ”Related Publications”...

  • Page 32: Cleaning Internal Circuit Boards And Components

    • Avoid physical abuse: do not pound, drop, or throw the radio. It may damage exposed parts such as controls and connectors. • Do not connect accessories other than Motorola compatible equipment as they may damage the radio. • The use of any mini-UHF adaptor not listed in this manual can damage the RF antenna connector and lead to radio failure and may void the warranty.
  • Page 33 • Make skin contact with a conductive work surface first and maintain this contact when the device is set down or picked up. • Always wear a conductive wrist strap when servicing this equipment. The Motorola part number for a replacement wrist strap that connects to the table mat is 42-80385A59.
  • Page 34 Basic Maintenance: Handling Precautions Notes June 11, 2003 6881096C73-O...

  • Page 35: Chapter 3 Basic Theory Of Operation

    Chapter 3 Basic Theory of Operation Introduction The ASTRO XTL 5000 radio combines the controller and RF sections into a single board and contains three modules: a daughtercard, RX VCO module, and TX VCO module. It is important to correctly identify the malfunctioning region before replacing expensive modules. To assist with radio repair, descriptions of the sections contained on the XTL 5000 uniboard are listed below.

  • Page 36: Controller Section

    Basic Theory of Operation: Controller Section Controller Section 3.3.1 Introduction The XTL 5000 radio is primarily a uniboard design, consisting of isolated topside and bottomside controller sections and various RF sections. The controller section will be discussed here in basic terms, to assist in the overall understanding of what is contained in the controller section, and a simplified purpose of its elemental parts.

  • Page 37: Microprocessor

    Basic Theory of Operation: Surrounding Controller Region 3.4.1 Microprocessor The microprocessor consists of an MCORE-based controller and a DSP that communicates with the memory ICs via a 16-bit data bus. It also communicates to peripheral ICs on the main board via an SSI and SPI bus.

  • Page 38: Voltage Regulation

    These custom connectors are optimized to meet voltage and current requirements for existing accessories and for the compatible flexes that are used with the XTL 5000 radio. NOTE: It is not recommended to insert non-Motorola parts or flexes into these connectors. June 13, 2003...

  • Page 39: Audio

    XTL 5000 microprocessor. Their most versatile usage is in conjunction with a DEK, but this is not mandatory. NOTE: Please see the VIP section of the ASTRO XTL 5000 700–800 MHz Digital Portable Radio Detailed Service Manual for configurations and voltage level requirements.

  • Page 40: Analog Mode Of Operation

    Basic Theory of Operation: Analog Mode of Operation Analog Mode of Operation 3.6.1 Receive Operation When the radio is receiving, the signal comes from the antenna through the RF PA output network located in the power amplifier section to the front-end receiver assembly. The signal is then filtered, amplified, and mixed with the first local oscillator signal generated by the receiver voltage controlled oscillator (VCO).

  • Page 41: Display (W9 Control Head)

    Basic Theory of Operation: Control Head Assembly 3.8.2 Display (W9 Control Head) The W9 control-head assembly has an 11-character, alphanumeric, vacuum fluorescent display. It needs three separate voltages to operate: the cathode needs 35 V to accelerate electrons to the anode;...

  • Page 42: Vehicle Interface Port (Vip)

    Basic Theory of Operation: Control Head Assembly 3.8.8 Vehicle Interface Port (VIP) 3.8.8.1 Remote-Mount The VIPs allow the control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs that are used for the W9 control head and two VIP outputs for the W3, W4, W%, and W7 control heads.

  • Page 43: Radio-Frequency Power Amplifier (Rf Pa) And Output Network (On)

    Basic Theory of Operation: Radio-Frequency Power Amplifier (RF PA) and Output Network (ON) Radio-Frequency Power Amplifier (RF PA) and Output Network (ON) The RF PA is a three-stage power amplifier consisting of discrete LDMOS transistors: • Controlled stage • Driver stage •...

  • Page 44: Receiver Overview

    3-10 Basic Theory of Operation: 700–800 Receiver Overview 3.10 700 800 Receiver Overview – The receiver circuits primary duties are to detect, filter, amplify, and demodulate RF signals in the presence of strong interfering noise and unintended signals. The receiver is broken down into the following blocks: •...

  • Page 45: Frequency Generation Unit (Fgu)

    Basic Theory of Operation: Frequency Generation Unit (FGU) 3-11 3.11 Frequency Generation Unit (FGU) 9.3 V 3 V 8.2 V Out Super Filter Adapt LV Frac-N Dual Synthesizer Charge Pump Loop Filter Steering Transmit Line Voltage Modulation AUX- PreScaler Tx/Rx Select 9.3 V TCXO Rx FE Buffer 16.8 MHz Dual Rx VCO Buffer 9.1 V RFPA Buffer Dual Tx VCO...
  • Page 46 3-12 Basic Theory of Operation: Frequency Generation Unit (FGU) Notes June 11, 2003 6881096C73-O...

  • Page 47: Chapter 4 Test Equipment, Service Aids, And Tools

    The Characteristics column is included so that equivalent equipment can be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended.

  • Page 48: Service Aids And Recommended Tools

    Refer to the tables in this section for a listing and description of the service aids and tools designed specifically for servicing this family of radios, as well as the more common tools required to disassemble and properly maintain the radio. These kits and/or parts are available from the Motorola parts division offices listed in Appendix A.

  • Page 49: Field Programming Equipment

    Test Equipment, Service Aids, and Tools: Field Programming Equipment Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting Motorola Tools and Supplies Part Number 0180386A82 Anti-static grounding kit 8180384N71 Chassis eliminator Control-head interconnect service cable 1185984D01 Electromagnetic Interference (EMI) metallic shielding tape, or...

  • Page 50: Remote-Mounted Radios

    — — (Please refer to the CPS Programming Installation Guide Motorola part number 6881095C44 installation and setup procedures for the software.) Do not attempt to program via the remote control head. Be sure to disconnect any accessories that are connected to the radio’s microphone ports (including the microphones). Bias to these accessories could impair programming/tuning capability.

  • Page 51: Chapter 5 Performance Checks

    Chapter 5 Performance Checks Introduction This section covers performance checks used to verify that the radio meets published specifications. The recommended test equipment listed in the approaches the accuracy of the Chapter 4 manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 52: Table 5-1. Test-Mode Displays

    Performance Checks: Test Mode Table 5-1. Test-Mode Displays Display Name Description Appears SERVICE Indicates the radio has entered test mode Always Radio Host Software The version of radio firmware Always Version DSP Software Version The version of firmware being used by the Always EMC Secure Version Version of the encryption hardware...

  • Page 53: Rf Test Mode

    Performance Checks: Test Mode 5. Pressing the Home button will cause the displays to stop. The RF test mode will be entered. The display will show 1 CSQ , indicating test frequency 1, Carrier SQuelch mode. 6. Go to the RF Test Mode section. 5.3.2 RF Test Mode A special routine, called RF TEST MODE or air test, has been incorporated in the radio.

  • Page 54: Control Head Test Mode

    Performance Checks: Test Mode Table 5-3. Signaling Types Display Modulation Demodulation Type None None Carrier Squelch 192 Hz 192 Hz Private-Line 1200 Hz ASTRO (digital) None None Open Squelch When in the transmit test mode, DTMF modulation produces a sidetone in the speaker. All signaling types will continually modulate the transmitted signal for detection/measurement by external instruments.

  • Page 55: Receiver Performance Checks

    5/9/94 5/9/94 Performance Checks: Receiver Performance Checks KEY 81 KEY 100 KEY 102 KEY 49 KEY 80 KEY 99 KEY 101 KEY 103 KEY 50 Phon KEY 51 Mode Scan Call KEY 53 KEY 54 KEY 82 KEY 56 XMIT KEY 83 KEY 57 BUSY...

  • Page 56: Transmitter Performance Checks

    Performance Checks: Transmitter Performance Checks Table 5-4. Receiver Performance Checks (Continued) Test Name System Analyzer Radio Test Condition Comments Sensitivity As above, except SINAD, lower TEST MODE, Release PTT RF input to be (SINAD) the RF level for 12 dB SINAD 1 CSQ switch.
  • Page 57 Performance Checks: Transmitter Performance Checks Table 5-5. Transmitter Performance Checks (Continued) Test Test Name System Analyzer Radio Comments Condition PL Modulation Change frequency to 1st channel TEST MODE, Remove Deviation: (radios with test frequency**; 1 TPL modulation input 800 MHz: conventional, clear B/W to narrow from dummy...
  • Page 58 Performance Checks: Transmitter Performance Checks Notes June 11, 2003 6881096C73-O...

  • Page 59: Chapter 6 Radio Alignment Procedures

    A personal computer (PC) and Tuner Software are required to align the radio. Please refer to the CPS Programming Installation Guide (Motorola part number 6881095C44) for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the computer and to a universal test set, as shown in the following figure.

  • Page 60: Figure 6-2. Tuner Main Menu

    Radio Alignment Procedures: ASTRO XTL 5000 Tuner Software Figure 6-2. Tuner Main Menu The alignment screens utilize 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.

  • Page 61: Radio Information

    Radio Alignment Procedures: Radio Information Radio Information Figure 6-3 shows a typical Radio Information screen. All of the data appearing here is informational and cannot be changed. Figure 6-3. Radio Information Screen Transmitter Alignments 6.4.1 PA Bias 1 Alignment NOTE: This alignment is required after replacing (or servicing) the transceiver board. The PA Bias 1 alignment procedure adjusts the drain bias current in one of the RF power amplifier devices: Table 6-1.

  • Page 62: Pa Bias 2 Alignment

    Radio Alignment Procedures: Transmitter Alignments Figure 6-4. PA Bias 1 Alignment Screen 3. Read baseline current from current meter on power supply. 4. Add baseline current to device bias current to calculate target current. Table 6-3. PA Bias 1 Alignment Device Bias Current Band/Power Level Device bias current (mA) 700–800 MHz 35 W/15 W Motorcycle...

  • Page 63: Pa Bias 3 Alignment

    Radio Alignment Procedures: Transmitter Alignments 2. Select PA Bias 2 from the Tuner Main Menu. When the screen is opened, the radio enters a special bias tune mode and radio current increases by approximately 100 mA. Figure 6-5. PA Bias 2 Alignment Screen 3.

  • Page 64: Reference Oscillator Alignment

    Radio Alignment Procedures: Transmitter Alignments 2. Select PA Bias 3 from the Tuner Main Menu. When the screen is opened, the radio enters a special bias tune mode and radio current increases by approximately 100 mA. Figure 6-6. PA Bias 3 Alignment Screen 3.

  • Page 65: Figure 6-7. Reference Oscillator Window

    Radio Alignment Procedures: Transmitter Alignments This test can be done with either the R-2670 Communication Analyzer or the Agilent 8901 Modulation Analyzer. • Initial set up using the R-2670 Communication Analyzer: - RF Control: MONITOR - B/W: WB - Freq: RSS frequency under test - Attenuation: 20dB - Mon RF in: RF I/O - Meter: RF Display...

  • Page 66: Power Detector Calibration

    Radio Alignment Procedures: Transmitter Alignments 5. Adjust the reference oscillator’s softpot value until the measured value is as close as possible to the frequency shown on the screen. Allow approximately five seconds for the analyzer frequency reading to stabilize after each change. See Table 6-10.

  • Page 67: Tx Power Characterization

    Radio Alignment Procedures: Transmitter Alignments 6. Left-click the Program All button to save tuned value. 7. Left-click Close button to close screen and return to the Tuner Main Menu. 6.4.6 Tx Power Characterization NOTE: This alignment is required after replacing (or servicing) the transceiver board. The Tx Power Characterization alignment procedure characterizes power tuning so that Tx power can be adjusted with CPS software.

  • Page 68: Tx Current Limit

    6-10 Radio Alignment Procedures: Transmitter Alignments 4. Left-click the PTT Toggle button to transmit at indicated frequency and record power measurement with 0.1 W resolution. The green circle will turn red indicating that the radio is transmitting. 5. Left-click the PTT Toggle button to disable transmit mode. 6.

  • Page 69: Figure 6-10. Tx Current Limit Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments 6-11 2. Select Tx Current Limit from the Tuner Main Menu. Figure 6-10. Tx Current Limit Alignment Screen 3. Use a slider or the spin buttons to change any one softpot value to 255. 4. Left-click the Program All button to save the tuned value. All softpots will change to 255, and transmit-current limiting will be disabled.

  • Page 70: Tx Deviation Balance (Compensation)

    6-12 Radio Alignment Procedures: Transmitter Alignments 12. Left-click the Program All button to save tuned value. 13. Left-click the Close button to close screen and return to the Tuner Main Menu. Table 6-15. Transmit Current Limit Devices Band/Power Level Devices 700–800 MHz 35 W/15 W Motorcycle Final1 Final2...

  • Page 71: Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments 6-13 1. Select TX Deviation Balance (Compensation) from the Tuner Main Menu. The screen will indicate the transmit frequencies to be used. Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen 2. Left-click the highest frequency field first. 3.

  • Page 72: Tx Deviation Limit

    6-14 Radio Alignment Procedures: Transmitter Alignments 6.4.9 Tx Deviation Limit NOTE: This alignment is required after replacing (or servicing) components on the transceiver board. The Tx Deviation Limit alignment procedure limits the modulation of a baseband signal. It is used for primary modulation limiting.

  • Page 73: Figure 6-12. Tx Deviation Limit Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments 6-15 Figure 6-12. Tx Deviation Limit Alignment Screen 2. Left-click the highest frequency field first. 3. Left-click the PTT Toggle button on the screen to make the radio transmit. Wait approximately 5 seconds until the deviation/voltage displayed on the analyzer stabilizes. The screen indicates whether the radio is transmitting.

  • Page 74: Performance Testing

    6-16 Radio Alignment Procedures: Performance Testing Performance Testing 6.5.1 Bit Error Rate (BER) Test This procedure tests the Bit Error Rate (BER) of the radio’s receiver at a desired frequency and contains the fields described in Table 6-16. Figure 6-13. Bit Error Rate Screen Table 6-16.

  • Page 75: Transmitter Test Pattern

    Radio Alignment Procedures: Performance Testing 6-17 Table 6-16. Bit Error Rate Test Fields (Continued) Field Description Audio Allows the user to select the audio output during a test. Selecting External will route the same signal to the radio’s accessory connector audio output. Selecting Internal is not supported.

  • Page 76: Mic Sensitivity Calibration

    6-18 Radio Alignment Procedures: Mic Sensitivity Calibration Mic Sensitivity Calibration This procedure allows you to calibrate the microphone sensitivity level at each CPS setting (-12, -9, ..+9, +12), eliminating tolerances and deviations in the microphone hardware lineup circuitry. By tuning each CPS setting, the microphone sensitivity will be adjusted to exactly 3 dB difference between every 2 consecutive settings throughout the programmable range of the circuit.

  • Page 77: Chapter 7 Encryption

    Chapter 7 Encryption Universal Crypto Module Kits NOTE: This information applies to both conventional and trunked systems. The encryption modules use a custom encryption IC and an encryption key variable to perform their encode/decode functions. The encryption key variable is loaded into the encryption module using a key variable loader (KVL).

  • Page 78: Secure Emergency Operation

    Encryption: Load an Encryption Key Whether the current personality is strapped for secure or clear, the secure status annunciator correctly displays the transmit operation as being either secure (encrypted) or clear (non-encrypted). NOTE: You cannot change from secure to clear while the PTT button is pressed. The radio will generate an illegal tone and the transmission will be terminated.

  • Page 79: W4, W5, W7, And W9 Control Heads

    Encryption: Advanced Secure Operation 7.2.2 W4, W5, W7, and W9 Control Heads To load an encryption key into a W4, W5, W7, or W9 control-head equipped radio: 1. Turn on the radio and set the volume level. The position of the D button is not important. 2.

  • Page 80: W3 Control Head

    Encryption: Erase a Key 7.4.1 W3 Control Head 1. Press > to scroll to ERAS . 2. Press the m button below ERAS . The last selected and stored key is displayed. 3. Do one of the following: NOTE: ERASED alternates with the key name if you go to a key that has been erased.

  • Page 81: W4, W5, W7, And W9 Control Heads

    Encryption: Erase a Key 7.4.2 W4, W5, W7, and W9 Control Heads The Select Key to Erase feature allows you to manually select any one, or all, of the encryption keys to erase. 1. To enter the Advanced Secure menu, Model W4 press and hold the D button until a tone HOME...

  • Page 82: Erase A Single Key (W3 Control Head)

    Encryption: Erase a Single Key (W3 Control Head) Erase a Single Key (W3 Control Head) To erase a single key: 1. Press the m button below SNGL to request erasure of the selected key. ERASE SNGL KEY , YES and NO are displayed. 2.

  • Page 83: W4, W5, W7, And W9 Control Heads

    Encryption: Over-the-Air Rekeying 7.6.2 W4, W5, W7, and W9 Control Heads 1. To enter the Advanced Secure Model W4 menu, press and hold the D HOME SECURE button until a tone sounds. Home Phon Scan Call Mode Volume XMIT BUSY SECURE MODE INDICATOR...

  • Page 84: W3 Control Head

    Encryption: Over-the-Air Rekeying 7.7.1 W3 Control Head 1. Press > until REKY appears. 2. Press m below REKY . REQUEST REKY is displayed. 3. Press the PTT button to send the rekey request. PLEASE WAIT is displayed. One of the following occurs: The radio sounds five tones when the dispatcher has received the request.

  • Page 85: W4, W5, W7, And W9 Control Heads

    Encryption: Over-the-Air Rekeying 7.7.2 W4, W5, W7, and W9 Control Heads 1. To enter the Advanced Secure Model W4 menu, press and hold the D HOME SECURE button until a tone sounds. Home Phon Scan Call Mode Volume XMIT BUSY SECURE MODE INDICATOR...
  • Page 86 7-10 Encryption: Over-the-Air Rekeying 5. One of the following occurs: If the radio receives an acknowledgment from the dispatcher, five tones sound. If the radio does not receive an acknowledgment from the dispatcher, the display shows NO ACK . After the radio is rekeyed, it displays REKEYED and returns to dispatch mode. If the dispatcher does not allow it to be rekeyed, the radio displays DENIED and returns to dispatch mode after three seconds.

  • Page 87: Chapter 8 Disassembly/Reassembly Procedures

    This section details the procedures necessary to remove and replace the printed circuit board in the ASTRO XTL 5000 radio. After troubleshooting and determining what needs to be replaced, disconnect the test equipment, the antenna cable, and the power cable.

  • Page 88: Control Head Boards Disassembly/Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures Table 8-1. Required Tools and Supplies (Continued) Motorola Tools and Supplies Part Number Magnetic screwdriver set with bits 0180320B16 Mini-UHF to N-type adapter cable 3085651A01 Plastic scraping tool 6686119B01 Removal and insertion tool 6680163F01 Roto-Torq adjustable driver...

  • Page 89: W3 Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 12. Remove the PTT boot [12] and the PTT lever [10] from the housing assembly [7]. 13. Remove the PTT actuator [9] from the housing assembly [7]. 14. If damaged, remove the nameplate label [13] from the front of the housing assembly [7]. 15.

  • Page 90: W4, W5, And W7 Disassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 15. Push the rubber seal (part of the cable assembly [15]) into the housing’s opening and ensure that it is properly seated. NOTE: This seal must be inserted completely into the housing to ensure the rain seal. 16.

  • Page 91: W4, W5, And W7 Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures Figure 8-2. W5 and W7 Pushbutton Control-Head Assembly Screw Sequence 7. Carefully separate the printed circuit board, internal spacer, and elastomer keypad assembly from the front panel. On rotary control-head models, care must be taken not to damage the flex circuit when separating the printed circuit board from the front housing.

  • Page 92: W9 Disassembly

    When working with chips and SOT (small outline transistor) parts, use extreme caution when heating. Never reuse a chip or SOT part; always replace with the correct Motorola part. 8.2.2.6 W9 Reassembly NOTE: Bracketed numbers are identical to item numbers in Figure 11-4.

  • Page 93: Remote Back Housing Interface Board Disassembly/Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 4. Replace the captive screws [12] and the leaf assembly spring [11] in the front housing, and torque them to 6-8 in.-lbs. NOTE: Before assembling the leaf assembly spring, check that the insulator [10] on the board is present.

  • Page 94: Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 8.2.4.2 Reassembly 1. Reconnect the interconnect flex to the radio, noting proper alignment of the mating connections. 2. Reassemble the front panel into the radio and replace the screws. 3. Torque the screws to 6-8 in.-lbs. 8.2.5 Radio Disassembly Use the following procedure to disassemble your radio:...

  • Page 95: Figure 8-4. Removing The Control Head

    Disassembly/Reassembly Procedures: Replacement Procedures 3. Firmly grasp the front panel of the control head, and carefully remove the control-head assembly from the radio. Be careful not to pull on the attached flex. Figure 8-4. Removing the Control Head 4. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar the face of the display.

  • Page 96: Figure 8-6. Removing The Headbridge

    8-10 Disassembly/Reassembly Procedures: Replacement Procedures 6. Remove the plastic headbridge by squeezing in the center of the top and bottom sides of the part and pulling away from the transceiver. NOTE: Be careful to avoid pulling on the flex. Figure 8-6. Removing the Headbridge 7.

  • Page 97: Figure 8-8. Control-Head Flex (Removed)

    Disassembly/Reassembly Procedures: Replacement Procedures 8-11 Figure 8-8. Control-Head Flex (Removed) 8. Remove the headbridge seal from the transceiver. Figure 8-9. Headbridge Seal (Removed) The following steps MUST be performed for secure-equipped radios prior to removal of the cover or damage to the radio could occur.

  • Page 98: Figure 8-10. Removing The Secure Interface Board

    8-12 Disassembly/Reassembly Procedures: Replacement Procedures 9. For secure option-equipped radios, do the following prior to disassembly of the transceiver: a. Remove the two screws holding the secure (UCM) shield in place. b. Pull the UCM shield away from the assembly and remove it. c.

  • Page 99: Figure 8-11. Removing The Top Cover Screws

    Disassembly/Reassembly Procedures: Replacement Procedures 8-13 10. Remove the 10 top-cover screws using a T20 Torx bit. These screws have sealing washers that should be kept with the screw. Figure 8-11. Removing the Top Cover Screws 11. Remove the top cover by lifting up simultaneously on both side edges. It may be necessary to gently pry the cover off using a plastic tool.

  • Page 100: Figure 8-13. Removing The Top Cover

    8-14 Disassembly/Reassembly Procedures: Replacement Procedures Figure 8-13. Removing the Top Cover 12. Disconnect the rear accessory jack’s flex from the main board. Figure 8-14. Removing the J2 Rear Accessory Flex from the Main Board June 11, 2003 6881096C73-O...

  • Page 101: Figure 8-15. Removing The Pa Screws

    Disassembly/Reassembly Procedures: Replacement Procedures 8-15 The PA screws must be removed BEFORE the RF/DC retention clips or damage may occur to the PCB. C a u t i o n 13. : Remove the three PA screws using a T10 Torx bit. Figure 8-15.

  • Page 102: Figure 8-16. Removing The Rf/Dc Retention Clip (J2 Connector Side)

    8-16 Disassembly/Reassembly Procedures: Replacement Procedures 14. Remove the RF/DC retention clips by gently prying them out with a flathead screwdriver. For leverage, use only the slots provided immediately adjacent to the clips. Figure 8-16. Removing the RF/DC Retention Clip (J2 Connector Side) Figure 8-17.

  • Page 103: Figure 8-18. Pushing Up The Main Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-17 15. Remove the main board by sliding a finger into the provided opening at the front of the chassis and gently pressing up on the 50-pin connector, lifting up the front of the PCB. Figure 8-18. Pushing Up the Main Board 16.

  • Page 104: Figure 8-20. Removing The J2 Rear Accessory Connector

    8-18 Disassembly/Reassembly Procedures: Replacement Procedures 17. Remove the J2 rear accessory connector by sliding it out of the chassis wall. Do not attempt to remove the J2 accessory connector by pulling on the flex. Doing so might damage the flex. C a u t i o n Figure 8-20.

  • Page 105: Radio Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 8-19 8.2.6 Radio Reassembly Use the procedure that follows to reassemble your radio. 1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks, cuts, etc.) or dirt. Refer to the exploded view bill of materials for the correct part numbers, and replace parts, as necessary.

  • Page 106: Figure 8-22. Inserting The J2 Rear Accessory Connector

    8-20 Disassembly/Reassembly Procedures: Replacement Procedures 2. After inspecting and seating the seal properly on the connector, insert the J2 rear accessory connector into the chassis and slide it into place. Do not attempt to insert the J2 accessory connector by holding onto the flex.

  • Page 107: Figure 8-23. Inserting The Main Board Into The Chassis

    Disassembly/Reassembly Procedures: Replacement Procedures 8-21 3. Tilt the main board and slide it into place, taking care to line up the RF and DC connectors with the holes in the back of the chassis. Push back and down on the front of the main board to fully seat it.

  • Page 108: Figure 8-24. Inserting The Rf/Dc Retention Clip (Dc Side)

    8-22 Disassembly/Reassembly Procedures: Replacement Procedures 4. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to properly locate the main board. Figure 8-24. Inserting the RF/DC Retention Clip (DC Side) Figure 8-25. Inserting the RF/DC Retention Clip (RF Side) June 11, 2003 6881096C73-O...

  • Page 109: Figure 8-26. Connecting The J2 Rear Accessory Connector Flex To The Main Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-23 5. Connect the J2 rear accessory connector flex to the PCB. Figure 8-26. Connecting the J2 Rear Accessory Connector Flex to the Main Board 6881096C73-O June 11, 2003...

  • Page 110: Figure 8-27. Installing The Pa Screws

    8-24 Disassembly/Reassembly Procedures: Replacement Procedures 6. Insert and torque the three PA screws to 6-8 in.-lbs. Start all three screws prior to torquing them down. Figure 8-27. Installing the PA Screws 7. Inspect the reverse polarity thermal pad located on the top cover, and then inspect and seat the main seal properly on the cover.

  • Page 111: Figure 8-29. Preparing To Place The Top Cover On The Chassis

    Disassembly/Reassembly Procedures: Replacement Procedures 8-25 8. Place the cover on the chassis and seat it properly. You can compress the cover and chassis together to squeeze the seal into place and make torquing the screws easier. Figure 8-29. Preparing to Place the Top Cover on the Chassis 9.

  • Page 112: Figure 8-31. Installing The Secure Interface Board

    8-26 Disassembly/Reassembly Procedures: Replacement Procedures 10. For secure option-equipped radios, do the following: a. Inspect the kapton tape on the back of the secure interface board for damage and replace if necessary. b. Ensure the universal encryption module (UCM) is securely plugged into the secure inter- face board.

  • Page 113: Figure 8-32. Installing The Headbridge Seal

    Disassembly/Reassembly Procedures: Replacement Procedures 8-27 Figure 8-32. Installing the Headbridge Seal 13. Grasp the handle on the transceiver end of the control-head flex (dash or remote), and plug the flex into the 50-pin connector on the side of the main board. Figure 8-33.

  • Page 114: Figure 8-34. Installing The Headbridge On The Transceiver

    8-28 Disassembly/Reassembly Procedures: Replacement Procedures 14. Hold the headbridge with one hand, and squeeze the center of the long span. 15. Align the headbridge with the transceiver, thread the control-head flex through the headbridge, and push the headbridge into place. You might hear a small snap as the alignment tabs engage.

  • Page 115: Figure 8-36. Inserting The Control Head Into The Transceiver

    Disassembly/Reassembly Procedures: Replacement Procedures 8-29 18. Insert the control head to the transceiver. Figure 8-36. Inserting the Control Head Into the Transceiver 19. Secure the control head to the transceiver with the two screws using the 2.5 mm hex-key bit. Apply 6-8 in.-lbs.

  • Page 116: Chassis Thermal Pad Replacement Procedure

    8-30 Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure Chassis Thermal Pad Replacement Procedure Use the following procedures for replacing the chassis thermal pads. MAEPF-27649-O Figure 8-38. Chassis Thermal Pad Locations Table 8-2. Chassis Thermal Pad Parts Item No. Part No. Description 7585366E01 Pad, Thermal, Audio PA...
  • Page 117 The pad is an elastomer-coated sheet of foil. The foil sheet will lift off in pieces. The black elastomer residue will remain on the chassis. 2. Scrape the residue off using a plastic flat-edge tool, such as a dismantling tool (Motorola P/N 6686119B01).

  • Page 118: Fastener Torque Chart

    8-32 Disassembly/Reassembly Procedures: Fastener Torque Chart Fastener Torque Chart Table 8-3 lists the various fasteners by part number and description, followed by the torque values and the location where used. Torque all fasteners to the recommended value when assembling the radio.

  • Page 119: Chapter 9 Basic Troubleshooting

    This section can help you isolate a problem to the board level. Board-level troubleshooting does not attempt to isolate problems to the component level. Component-level service information can be found in the ASTRO XTL 5000 Digital Mobile Radio Detailed Service Manual. (Refer to the "Related Publications"...
  • Page 120 USB + Data This is part of the 2-wire USB differential data bus for future USB accessories. RESET SB9600 RESET This is part of the Motorola SB9600 communications bus to connect external devices. BUSY SB9600 BUSY This is part of the Motorola SB9600 communications bus to connect external devices.

  • Page 121: I/O Disclaimer

    Basic Troubleshooting: Introduction Table 9-1. J2 Accessory Connector Signal and Voltage Descriptions (Continued) Function Description RX FILT AUDIO Receive Filtered Audio This is a fixed level (independent of volume level) received audio signal, including alert tones. Flat or de-emphasis are programmed by CPS.

  • Page 122: Microphone Bias

    Basic Troubleshooting: Introduction Table 9-2. Normal Operation Range and ESD Clamping Voltages (Continued) 5HYHUVH %LDV '% 9ROWDJH DW 3RUW -** )HPDOH VROWDJH DW 3RUW -* 3LQV 5.5 K 0.00 UARTA_RxD USB - 0.50 0.09 0.51 0.07 USB + RESET 0.51 0.00 BUSY 0.50...

  • Page 123: Audio Pa Out Bias

    • Order a replacement board from Radio Products Services Division at 1-800-422-4210. Refer to “Appendix A Replacement Parts Ordering” on page A-1 for further information. • Troubleshoot the defective board using the ASTRO XTL 5000 Digital Mobile Radios Detailed Service Manual. (Refer to the "Related Publications"...
  • Page 124 Basic Troubleshooting: Power-Up Error Codes Table 9-3. Power-Up Error Codes (Continued) Error Code Description Error Type Corrective Action ERROR 01/22 Tuning Codeplug NON-FATAL Reprogram the tuning partition. Checksum FAIL 01/81 FLASH ROM Checksum FATAL Reprogram the radio firmware. FAIL 01/82 FLASH ROM Codeplug FATAL Reprogram the codeplug.

  • Page 125: Operational Error Codes

    Basic Troubleshooting: Operational Error Codes Operational Error Codes 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.

  • Page 126: Receiver Troubleshooting

    Basic Troubleshooting: Receiver Troubleshooting Table 9-5. Transmitter Troubleshooting Chart (Continued) Correction or Test (Measurements Taken at Symptom Possible Cause Room Temperature) Radio Damaged Flex Replace flex to control head. transmiits when programming cable is inserted into control head NOTE: “AC-coupled” is adding a 10 µf capacitor externally to prevent biasing on the MIC-HI line from being grounded.
  • Page 127 Basic Troubleshooting: Receiver Troubleshooting Table 9-6. Receiver Troubleshooting Chart (Continued) Correction or Test (Measurements Taken Symptom Possible Cause at Room Temperature) Radio Will Not Codeplug Check the offending channel for spurious activity Squelch by monitoring with a known-good radio or service monitor.
  • Page 128 9-10 Basic Troubleshooting: Receiver Troubleshooting Notes June 12, 2003 6881096C73-O...

  • Page 129: Chapter 10 Functional Block Diagrams And Connectors

    Chapter 10 Functional Block Diagrams and Connectors This chapter contains the ASTRO XTL 5000 digital mobile radio functional block diagrams and connector locations. Table 10-1. Table of Functional Block Diagrams and Connectors Page Figure Name 10-2 Figure 10-1. ASTRO XTL 5000 Functional Block Diagram 10-3 Figure 10-2.

  • Page 130: Xtl 5000 Functional Block Diagram

    CONTROL HEAD (REMOTE MOUNT) CONTROL HEAD (REMOTE MOUNT) W3 HANDHELD CONTROL HEAD (W5/W7 PUSHBUTTON AND W4 ROTARY MODELS) (W5/W7 PUSHBUTTON AND W4 ROTARY MODELS) (W9 PUSHBUTTON MODEL) MAEPF-27633-O Figure 10-1. ASTRO XTL 5000 Functional Block Diagram June 12, 2003 6881096C73-O...

  • Page 131: Radio Connectors

    Functional Block Diagrams and Connectors: Radio Connectors 10-3 10.2 Radio Connectors FIL AUD REMOTE MOUNT SHLD BATT - ACCESSORY CONNECTOR PTT/ VIP 1 DATA BATT + ANALOG SENSE EMER BUS + VIP IN 1 EMGCY (A+) SPKR NOTE 1 IGNITION OUT 2 VIP 2 SPKR...

  • Page 132: Radio Connector Locations

    Functional Block Diagrams and Connectors: Radio Connector Locations 10-4 10.3 Radio Connector Locations 10.4 Radio Connector Locations (cont.) J0950 J6700 Antenna J0402 REAR VIEW Power P104 MAEPF-27645-A Figure 10-8. Dash-Mount Radio Connector Locations FRONT EDGE OF BOARD MAEPF-27663-O Figure 10-10. Main Board Connector Locations - Side 1 J0950 J6700 Antenna...

  • Page 133: Control Head Cabling Diagram

    10-5 Functional Block Diagrams and Connectors: Control Head Cabling Diagram 10.5 Control Head Cabling Diagram CONTROL HEAD RADIO P1001 IGN+ IGN- BATT+ BATT+ BATT- SPARE 2 SPARE 2 BATT- EMERGENCY EMERGENCY SPARE 1 SPARE 1 DIG GRD DIG GND SWB+ SWB+ BUS + BUS +...

  • Page 134: Control Head Connector

    Functional Block Diagrams and Connectors: Control Head Connector 10-6 10.6 Control Head Connector Figure 10-13 illustrates the pin arrangement and associated signals and voltages for the 50-pin control-head connector. BOTTOM ROW = touching PC board TOP ROW = farthest away from PC board <...

  • Page 135: Connector Naming Schemes

    Functional Block Diagrams and Connectors: Connector Naming Schemes 10-7 10.7 Connector Naming Schemes Figure 10-14 illustrates the differences between the XTL 5000 radio connector computer data and control signal names as these signals pass from one connector to another. REAR CONNECTOR naming schemes Connecting to a computer = DTE device: P2 rear accessory DB9 (Male) serial...
  • Page 136 10-8 Functional Block Diagrams and Connectors: Connector Naming Schemes Notes June 12, 2003 6881096C73-O...

  • Page 137: Chapter 11 Exploded Views And Parts Lists

    Chapter 11 Exploded Views and Parts Lists This chapter contains the exploded views and associated parts lists for the ASTRO XTL 5000 digital mobile radio and accessories. Tables containing pushbutton parts lists are also included at the end of this chapter.

  • Page 138: W3 Hand-Held Control Head Exploded View

    11-2 Exploded Views and Parts Lists: W3 Hand-Held Control Head Exploded View 11.1 W3 Hand-Held Control Head Exploded View Table 11-2. W3 Hand-Held Control Head Exploded View Parts List Item No. Motorola Part No. Description Not available LABEL 0105955T26 ASSEMBLY, Rear Cover...

  • Page 139: W4 Rotary Control Head Exploded View

    Exploded Views and Parts Lists: W4 Rotary Control Head Exploded View 11-3 11.2 W4 Rotary Control Head Exploded View Table 11-3. W4 Rotary Control Head Parts List Item No. Motorola Part No. Description 0380077M07 SCREW, Control Head Mounting (Qty 2) 3602113Z05...

  • Page 140: W5 And W7 Pushbutton Control Head Exploded View

    Exploded Views and Parts Lists: W5 and W7 Pushbutton Control Head Exploded View 11.3 W5 and W7 Pushbutton Control Head Exploded View Table 11-4. W5 and W7 Pushbutton Control Head Parts List Item No. Motorola Part No. Description 3880227M04 SWITCH, On/Off Cap...

  • Page 141: W9 Pushbutton Control Head Exploded View

    Exploded Views and Parts Lists: W9 Pushbutton Control Head Exploded View 11-5 11.4 W9 Pushbutton Control Head Exploded View Table 11-5. W9 Pushbutton Control Head Parts List (Continued) Item No. Motorola Part No. Description 7505127X01 KEYPAD 7280242J01 DISPLAY, VF 7580094M05...

  • Page 142: Xtl 5000 (3.5-35 W) Radio Exploded View

    Exploded Views and Parts Lists: XTL 5000 (3.5-35 W) Radio Exploded View 11.5 XTL 5000 (3.5-35 W) Radio Exploded View Table 11-6. XTL 5000 (3.5-35W) Radio Parts List Item No. Motorola Part No. Description 0385870E01 SCREW ASSEMBLY, TOP COVER 1585860C02...

  • Page 143: Motorcycle Interconnect Board And Assembly

    Figure 11-6. Motorcycle Interconnect Board and Assembly Exploded View Figure 11-7. Interconnect Board and Assembly Exploded View Table 11-7. Motorcycle Interconnect Board and Assembly Parts List Table 11-8. Interconnect Board and Assembly Parts List Item No. Motorola Part No. Description Item No. Motorola Part No. Description...

  • Page 144: Motorcycle Radio Remote-Mount Control Head With Speaker And Microphone

    Exploded Views and Parts Lists: Interconnect Board and Assembly 11.8 Motorcycle Radio Remote-Mount Control Head with Speaker and Table 11-9. Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone Parts List Microphone Item Motorola Description Part No. – See Model Chart Motorcycle hardware kit SECURENET –...

  • Page 145: Handlebar Installation

    Figure 11-10. Handlebar Installation (Control Head and Speaker Mounted Separately) Exploded View Table 11-10. Handlebar Installation (Control Head and Speaker Mounted Together) Parts List Table 11-11. Handlebar Installation (Control Head and Speaker Mounted Separately) Parts List Item Motorola Part Item Motorola Part Item...

  • Page 146: Fuel-Tank Console Installation (Control Head And Speaker Mounted Together)

    Figure 11-11. Fuel-Tank Console Installation (Control Head and Speaker Mounted Together) Exploded View Table 11-13. Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately) Parts List Table 11-12. Fuel-Tank Console Installation (Control Head and Speaker Mounted Together) Parts List Item Motorola Part Item Motorola Part Item...

  • Page 147: Hmn1062_ Motorcycle Microphone

    11-11 11.13 HMN1062_ Motorcycle Microphone 11.14 HSN6003_ Motorcycle Weather-Resistant Speaker Figure 11-14. HSN6003_ Motorcycle Weather-Resistant Speaker Table 11-15. HSN6003_ Motorcycle Weather-Resistant Speaker Parts List Item No. Motorola Part No. Description 35-06850K01 Cloth grille Figure 11-13. HMN1062_ Motorcycle Microphone 40-83477E03 Switch, toggle, SPST...

  • Page 148: Motorcycle Weather-Resistant Radio Enclosure

    11-12 Exploded Views and Parts Lists: Motorcycle Weather-Resistant Radio Enclosure 11.15 Motorcycle Weather-Resistant Radio Enclosure Table 11-16. Motorcycle Weather-Resistant Radio Enclosure Parts List (Enclosure Parts) Item Motorola Description Part No. 04-84336M02 Lockwasher (4 used) 04-84338M01 Washer, flat (8 used) 03-84208M16...

  • Page 149: Motorcycle Universal Mounting Plate

    Exploded Views and Parts Lists: Small Pushbutton Parts 11-13 11.16 Motorcycle Universal Mounting Plate Table 11-18. Motorcycle Universal Mounting Plate Parts List Motorola Part No. Description 0200009644 0300001908 Screw 0400139951 Lockwasher 6483673F02 Mounting plate, universal Figure 11-16. Motorcycle Universal Mounting Plate Exploded View 11.17 Small Pushbutton Parts...
  • Page 150 11-14 Exploded Views and Parts Lists: Large Pushbutton Parts Notes June 11, 2003 6881096C73-O...

  • Page 151: Appendix A Replacement Parts Ordering

    Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model number in which the part is used. Motorola Online Motorola Online users can access our online catalog at https://www.motorola.com/businessonline To register for online access, please call 800-814-0601 (for U.S. and Canada Service Centers only).

  • Page 152: Fax Orders

    Replacement Parts Ordering: Fax Orders Fax Orders Radio Products Services Division* (United States and Canada) 1-800-622-6210 847-576-3023 (International) USFGMD (Federal Government Orders) 1-800-526-8641 (For Parts and Equipment Purchase Orders) Parts Identification Radio Products Services Division* (United States and Canada) 1-800-422-4210, menu 3 Product Customer Service Customer Response Center (Non-technical Issues)
  • Page 153 Steel There are no embedded batteries in this product. Do not dispose of this product in a landfill. Motorola, Inc. encourages reuse or recycling of the material used to manufacture this product. Please contact the Motorola, Inc. Commercial, Government, and Industrial Solutions Sector (CGISS) at 1-888-567-7347 or your local sales...

  • Page 154: Appendix B Environmental Information

    Environmental Information: Notes June 11, 2003 6881096C73-O...

  • Page 155: Glossary

    Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and some terms are merely generic in nature. Term Definition See analog-to-digital conversion.
  • Page 156 Glossary-2 Term Definition See baseband interface port. baseband interface Synchronous serial interface to the transceiver board used to transfer port transmit and receive audio data. See ball grid array. ball grid array A type of IC package characterized by solder balls arranged in a grid that are located on the underside of the package.
  • Page 157 FLASHcodes are only applicable for radios which are upgradeable through the FLASHport process. FLASHport A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again.
  • Page 158 Glossary-4 Term Definition Florida Manual A publication that provides supplemental information for its parent Revision publication before it is revised and reissued. frequency Number of times a complete electromagnetic-wave cycle occurs in a fixed unit of time (usually one second). frequency This unit generates ultra-stable, low-phase noise master clock and other generation unit...
  • Page 159 Data transmitted on the control channel from the central controller to the word subscriber unit. over-molded pad- A Motorola custom IC package, distinguished by the presence of solder array carrier balls on the bottom pads. 6881096C73-O June 11, 2003...
  • Page 160 Glossary-6 Term Definition over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the radio. Power amplifier. paging One-way communication that alerts the receiver to retrieve a message. Patriot IC A dual-core processor that contains an MCU and a DSP in one IC package.
  • Page 161 Glossary-7 Term Definition read-only memory A type of computer memory on which data has been prerecorded. Once data has been written onto a ROM chip, it cannot be removed and can only be read. real-time clock A module that keeps track of elapsed time even when a computer is turned off.
  • Page 162 Glossary-8 Term Definition Serial Input/Output An integrated circuit that provides SB9600 serial and power-control functions. SCI IN See Serial Communication Interface Input Line. Serial Peripheral How the microcontroller communicates to modules and ICs through the Interface CLOCK and DATA lines. signal An electrically transmitted electromagnetic wave.
  • Page 163 Glossary-9 Term Definition time-out timer A timer that limits the length of a transmission. See time-out timer. transceiver Transmitter-receiver. A device that both transmits and receives analog or digital signals. Also abbreviated as XCVR. transmitter Electronic equipment that generates and amplifies an RF carrier signal, modulates the signal, and then radiates it into space.
  • Page 164 Glossary-10 Notes June 11, 2003 6881096C73-O...
  • Page 165 Index Index theory of operation ..........3-6 controller section, radio ..........3-2 controls, control head .........1-5, 3-7 copyrights computer software .............ii Numerics document ..............ii 700-800 MHz radio specifications ......xxi dash-mount vehicle interface port ......3-8 daughtercard module ..........3-2 accessory connector, J2 ..........9-1 descriptions advanced secure operation ........7-3 control heads ............
  • Page 166 Index-ii exploded view interconnect board ..........11-7 motorcycle loading encryption keys ..........7-2 fuel-tank console installation ......11-10 handlebar installation ........11-9 interconnect board ........... 11-7 microphone .............11-11 maintenance radio enclosure ..........11-12 cleaning remote-mount control head ......11-8 external plastic surfaces ........2-1 speaker ............11-11 general ..............

  • Page 167: Parts List

    Index-iii control head ............3-6 specifications, 700-800 MHz ........xxi conventional multikey ..........7-3 upgrading with FLASHport ........1-2 multikey ..............7-3 radio care and handling instructions, general ... 2-2 trunked multikey ............ 7-3 receiver operational error codes ..........9-7 Abacus III back-end ..........
  • Page 168 Index-iv ASTRO mode ............3-6 transmit current limit alignment ......6-11 control head Tx current limit alignment ........6-10 backlight LEDs ........... 3-7 Tx deviation balance (compensation) alignment ..6-12 controls and indicators ........3-7 Tx deviation limit alignment ........6-14 ignition sense circuits .........
  • Page 170 Motorola, Inc. 8000 West Sunrise Boulevard Ft. Lauderdale, FL 33322 MOTOROLA, the Stylized M Logo, and ASTRO are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. © Motorola, Inc. 2003.

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