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Motorola Astro XTL 5000 Basic Service Manual
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6881096C
73-O
Ju
ne 11,
2003
Disass
embly/Re
assembly Pro
cedures
: R
eplacement Proc
edures
8-27
Figure 8-
32. Installing
the Headbr
idge Seal
13.
Gr
asp the handl
e on the tr
ansceive
r end of th
e contro
l-head flex
(dash or
remote), an
d plug
the flex
into the 5
0-pin conn
ector on the
side of th
e main boa
rd.
Figure 8-
33. Installing t
he Control
-Head Fle
x in the T
ransceiv
er
112
114
Table of Contents
Foreword
4
Manual Revisions
4
Computer Software Copyrights
4
Document Copyrights
4
Disclaimer
4
Trademarks
4
Table of Contents
5
Commercial Warranty
15
Limited Warranty
15
Motorola Communication Products
15
What this Warranty Covers and for How Long
15
General Provisions
15
Motorola, Inc
15
State Law Rights
16
How to Get Warranty Service
16
What this Warranty Does Not Cover
16
Patent and Software Provisions
17
Governing Law
17
Model Numbering, Charts, and Specifications
19
Mobile Radio Model Numbering Scheme
19
Figure 1-1. Mobile Radio Model Numbering Scheme
19
ASTRO XTL 5000 Motorcycle 3.5-35 Watt Model Chart
20
ASTRO XTL 5000 3.5-35 Watt Model Chart
21
Mhz Radio Specifications
23
Chapter 1 Introduction
25
Notations Used in this Manual
25
Radio Description
25
Flashport
26
Control Head Descriptions
26
Table 1-1. Control Head Basic Features
26
Figure 1-1. W3 Hand-Held Control Head
27
W3 Control Head
27
W3 Controls
27
Figure 1-2. Typical W4 Rotary Control Head
28
Figure 1-3. Typical W5 Limited Keypad Control Head
28
Figure 1-4. Typical W7 Full Keypad Control Head
28
W4, W5, W7, and W9 Controls Heads
28
Figure 1-5. Typical W9 Full Keypad Control Head
29
W4, W5, W7, and W9 Controls
29
Chapter 2 Basic Maintenance
31
Introduction
31
Preventive Maintenance
31
Inspection
31
Cleaning
31
Cleaning External Plastic Surfaces
31
Cleaning Internal Circuit Boards and Components
32
General Radio Care and Handling Precautions
32
RF Power Amplifier (RF PA) Heatsinking
32
Handling Precautions
32
Chapter 3 Basic Theory of Operation
35
Introduction
35
General Overview
35
Controller Section
36
Introduction
36
Location
36
Daughtercard Module
36
Figure 3-1. Controller Sections
36
Flash IC
37
Microprocessor
37
Sram IC
37
Surrounding Controller Region
37
Introduction
37
Voltage Regulation
38
Emergency
38
Front and Rear Connectors
38
Audio
39
Program Cable
39
Sb9600
39
Vip
39
Rs232
39
One-Wire
39
Analog Mode of Operation
40
Receive Operation
40
Transmit Operation
40
ASTRO Mode of Operation
40
Control Head Assembly
40
Display (W4, W5, and W7 Control Heads)
40
Display (W9 Control Head)
41
Vacuum Fluorescent (VF) Display Driver
41
Vacuum Fluorescent (VF) Voltage Source (W9)
41
Controls and Indicators
41
Status Leds
41
Backlight Leds
41
Vehicle Interface Port (VIP)
42
Remote-Mount
42
Dash-Mount
42
Control-Head Power Supplies
42
W3 Control Head
42
W4 Control Head
42
W5, W7, W9 Control Heads
42
Ignition Sense Circuits
42
Radio-Frequency Power Amplifier (RF PA) and Output Network (ON)
43
Gain Stages
43
Power Control
43
Circuit Protection
43
DC Interconnect
43
Receiver Overview
44
Receiver Front-End
44
Mixer
44
IF Circuitry
44
Abacus III Back-End
44
Frequency Generation Unit (FGU)
45
Figure 3-2. Frequency Generation Unit Diagram
45
Chapter 4 Test Equipment, Service Aids, and Tools
47
Recommended Test Equipment
47
Table 4-1. Recommended Motorola Test Equipment
47
Table 4-2. Wattmeter Plug-In Elements
47
Service Aids and Recommended Tools
48
Table 4-3. Recommended Non-Motorola Test Equipment
48
Table 4-4. Service Aids for XTL 5000 Board-Level Troubleshooting
48
Field Programming Equipment
49
XTL 5000 Field Programming
49
Dash-Mounted Radios
49
Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting
49
Table 4-6. Recommended Non-Motorola Tools for Board-Level Troubleshooting
49
Remote-Mounted Radios
50
Field-Programming Items
50
W3 Control-Head Error Message
50
Table 4-7. XTL 5000 Radio Field-Programming Items
50
Chapter 5 Performance Checks
51
Introduction
51
Test Setup
51
Test Mode
51
Entering Test Mode
51
Figure 5-1. Performance Checks Test Setup
51
Table 5-1. Test-Mode Displays
52
RF Test Mode
53
Table 5-2. Test Frequencies
53
Control Head Test Mode
54
Figure 5-2. W4 Control-Head Key-Closure Displays
54
Table 5-3. Signaling Types
54
Receiver Performance Checks
55
Figure 5-3. W5 and W7 Control-Head Key-Closure Displays
55
Figure 5-4. W9 Control-Head Key-Closure Displays
55
Table 5-4. Receiver Performance Checks
55
Transmitter Performance Checks
56
Table 5-5. Transmitter Performance Checks
56
Chapter 6 Radio Alignment Procedures
59
Introduction
59
ASTRO XTL 5000 Tuner Software
59
Figure 6-1. Radio Alignment Test Setup
59
Figure 6-2. Tuner Main Menu
60
Radio Information
61
Transmitter Alignments
61
PA Bias 1 Alignment
61
Figure 6-3. Radio Information Screen
61
Table 6-1. PA Bias 1 Alignment RF Power Amplifier Devices
61
Table 6-2. Power Supply Voltage Settings
61
PA Bias 2 Alignment
62
Figure 6-4. PA Bias 1 Alignment Screen
62
Table 6-3. PA Bias 1 Alignment Device Bias Current
62
Table 6-4. PA Bias 2 Alignment Amplifier Devices
62
Table 6-5. Power Supply Voltage Settings
62
PA Bias 3 Alignment
63
Figure 6-5. PA Bias 2 Alignment Screen
63
Table 6-6. PA Bias 2 Alignment Device Bias Current
63
Table 6-7. PA Bias 3 Alignment Amplifier Devices
63
Table 6-8. Power Supply Voltage Settings
63
Reference Oscillator Alignment
64
Figure 6-6. PA Bias 3 Alignment Screen
64
Table 6-9. PA Bias 3 Alignment Device Bias Current
64
Figure 6-7. Reference Oscillator Window
65
Power Detector Calibration
66
Figure 6-8. Power Detection Calibration Alignment Screen
66
Table 6-10. Reference Oscillator Alignment
66
Table 6-11. Power Supply Voltage Settings
66
Tx Power Characterization
67
Figure 6-9. Tx Power Characterization Alignment Screen
67
Table 6-12. Power Supply Voltage Settings
67
Tx Current Limit
68
Table 6-13. Power Supply Voltage Settings
68
Figure 6-10. Tx Current Limit Alignment Screen
69
Table 6-14. Transmit Current Limit Offset
69
Tx Deviation Balance (Compensation)
70
Table 6-15. Transmit Current Limit Devices
70
Figure 6-11. Tx Deviation Balance (Compensation) Alignment Screen
71
Tx Deviation Limit
72
Figure 6-12. Tx Deviation Limit Alignment Screen
73
Performance Testing
74
Bit Error Rate (BER) Test
74
Figure 6-13. Bit Error Rate Screen
74
Table 6-16. Bit Error Rate Test Fields
74
Transmitter Test Pattern
75
Figure 6-14. Transmitter Test Pattern Screen
75
Table 6-17. Transmitter Test Pattern Fields
75
MIC Sensitivity Calibration
76
Figure 6-15. MIC Sensitivity Calibration Screen
76
Chapter 7 Encryption
77
Universal Crypto Module Kits
77
Secure Interface Boards
77
Secure Dispatch Operation
77
Table 7-1. UCM Kit Listing
77
Table 7-2. Secure Interface Board Kits
77
Secure Emergency Operation
78
Load an Encryption Key
78
W3 Control Head
78
W4, W5, W7, and W9 Control Heads
79
Advanced Secure Operation
79
Multikey Operation
79
Erase a Key
79
W3 Control Head
80
W4, W5, W7, and W9 Control Heads
81
Erase a Single Key (W3 Control Head)
82
Erase All Keys
82
W3 Control Head
82
W4, W5, W7, and W9 Control Heads
83
Over-The-Air Rekeying
83
W3 Control Head
84
W4, W5, W7, and W9 Control Heads
85
Chapter 8 Disassembly/Reassembly Procedures
87
Introduction
87
Replacement Procedures
87
Required Tools and Supplies
87
Table 8-1. Required Tools and Supplies
87
Control Head Boards Disassembly/Reassembly
88
W3 Disassembly
88
W3 Reassembly
89
W4, W5, and W7 Disassembly
90
Figure 8-1. W4 Rotary Control-Head Assembly Screw and Snap Sequence
90
W4, W5, and W7 Reassembly
91
Figure 8-2. W5 and W7 Pushbutton Control-Head Assembly Screw Sequence
91
W9 Disassembly
92
W9 Reassembly
92
Remote Back Housing Interface Board Disassembly/Reassembly
93
W4, W5, and W7 Disassembly
93
W4, W5, and W7 Reassembly
93
Remote Interconnect Board Assembly/Reassembly
93
Assembly
93
Reassembly
94
Radio Disassembly
94
Figure 8-3. Removing the Front Panel Screws
94
Figure 8-4. Removing the Control Head
95
Figure 8-5. Removing the Flex (Control-Head Connector)
95
Figure 8-6. Removing the Headbridge
96
Figure 8-7. Removing the Flex (Main-Board Connector)
96
Figure 8-8. Control-Head Flex (Removed)
97
Figure 8-9. Headbridge Seal (Removed)
97
Figure 8-10. Removing the Secure Interface Board
98
Figure 8-11. Removing the Top Cover Screws
99
Figure 8-12. Lifting the Top Cover
99
Figure 8-13. Removing the Top Cover
100
Figure 8-14. Removing the J2 Rear Accessory Flex from the Main Board
100
Figure 8-15. Removing the PA Screws
101
Figure 8-16. Removing the RF/DC Retention Clip (J2 Connector Side)
102
Figure 8-17. Removing the RF/DC Retention Clip (Antenna Connector Side)
102
Figure 8-18. Pushing up the Main Board
103
Figure 8-19. Lifting out the Main Board
103
Figure 8-20. Removing the J2 Rear Accessory Connector
104
Radio Reassembly
105
Figure 8-21. Inspecting the Chassis Shield Gasketing and Thermal Pads
105
Figure 8-22. Inserting the J2 Rear Accessory Connector
106
Figure 8-23. Inserting the Main Board into the Chassis
107
Figure 8-24. Inserting the RF/DC Retention Clip (DC Side)
108
Figure 8-25. Inserting the RF/DC Retention Clip (RF Side)
108
Figure 8-26. Connecting the J2 Rear Accessory Connector Flex to the Main Board
109
Figure 8-27. Installing the PA Screws
110
Figure 8-28. Inspecting the Thermal Pad and Installing the Cover Main Seal
110
Figure 8-29. Preparing to Place the Top Cover on the Chassis
111
Figure 8-30. Securing the Top Cover to the Chassis
111
Figure 8-31. Installing the Secure Interface Board
112
Figure 8-32. Installing the Headbridge Seal
113
Figure 8-33. Installing the Control-Head Flex in the Transceiver
113
Figure 8-34. Installing the Headbridge on the Transceiver
114
Figure 8-35. Installing the Control-Head Flex on the Control Head
114
Figure 8-36. Inserting the Control Head into the Transceiver
115
Figure 8-37. Installing the Control-Head Screws
115
Chassis Thermal Pad Replacement Procedure
116
Figure 8-38. Chassis Thermal Pad Locations
116
Table 8-2. Chassis Thermal Pad Parts
116
Fastener Torque Chart
118
Table 8-3. Fastener Torque Chart
118
Chapter 9 Basic Troubleshooting
119
Introduction
119
J2 Accessory Connector
119
Figure 9-1. J2 Accessory Connector Pin-Out Arrangement
119
Table 9-1. J2 Accessory Connector Signal and Voltage Descriptions
119
I/O Disclaimer
121
Table 9-2. Normal Operation Range and ESD Clamping Voltages
121
Microphone Bias
122
Audio PA out Bias
123
High Power RF Precaution
123
Replacement Board Procedures
123
Power-Up Error Codes
123
Table 9-3. Power-Up Error Codes
123
Operational Error Codes
125
Transmitter Troubleshooting
125
Table 9-4. Operational Error Codes
125
Table 9-5. Transmitter Troubleshooting Chart
125
Receiver Troubleshooting
126
Table 9-6. Receiver Troubleshooting Chart
126
Chapter 10 Functional Block Diagrams and Connectors
129
Table 10-1. Table of Functional Block Diagrams and Connectors
129
Figure 10-1. ASTRO XTL 5000 Functional Block Diagram
130
XTL 5000 Functional Block Diagram
130
Figure 10-2. J0103 Remote-Mount Control Head Connector
131
Figure 10-3. J5 Control Cable for Remote-Mount Control Head
131
Figure 10-4. J6 Radio Operations Connector
131
Figure 10-5. J3 Remote-Control Cable Accessory Connector
131
Figure 10-6. J2 Rear Accessory Connector
131
Figure 10-7. P104 Microphone Jack
131
Radio Connectors
131
Figure 10-8. Dash-Mount Radio Connector Locations
132
Figure 10-9. Remote-Mount Radio Connector Locations
132
Radio Connector Locations
132
Radio Connector Locations (Cont.)
132
Control Head Cabling Diagram
133
Figure 10-12.Control Head Cabling Diagram
133
Control Head Connector
134
Figure 10-13.Control Head 50-Pin Connector
134
Connector Naming Schemes
135
Figure 10-14.XTL 5000 Radio Connector Naming Scheme
135
Chapter 11 Exploded Views and Parts Lists
137
Table 11-1. Table of Exploded Views
137
Figure 11-1. W3 Hand-Held Control Head Exploded View
138
Table 11-2. W3 Hand-Held Control Head Exploded View Parts List
138
W3 Hand-Held Control Head Exploded View
138
Figure 11-2. W4 Rotary Control Head Exploded View
139
Table 11-3. W4 Rotary Control Head Parts List
139
W4 Rotary Control Head Exploded View
139
Figure 11-3. W5 and W7 Pushbutton Control Head Exploded View
140
Table 11-4. W5 and W7 Pushbutton Control Head Parts List
140
W5 and W7 Pushbutton Control Head Exploded View
140
Figure 11-4. W9 Pushbutton Control Head Exploded View
141
Table 11-5. W9 Pushbutton Control Head Parts List
141
W9 Pushbutton Control Head Exploded View
141
Figure 11-5. XTL 5000 (3.5-35 W) Radio Exploded View
142
Table 11-6. XTL 5000 (3.5-35W) Radio Parts List
142
XTL 5000 (3.5-35 W) Radio Exploded View
142
Figure 11-6. Motorcycle Interconnect Board and Assembly Exploded View
143
Figure 11-7. Interconnect Board and Assembly Exploded View
143
Interconnect Board and Assembly
143
Motorcycle Interconnect Board and Assembly
143
Table 11-7. Motorcycle Interconnect Board and Assembly Parts List
143
Table 11-8. Interconnect Board and Assembly Parts List
143
Figure 11-8. Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone
144
Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone
144
Table 11-9. Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone Parts List
144
Figure 11-10.Handlebar Installation (Control Head and Speaker Mounted Separately) Exploded View
145
Figure 11-9. Handlebar Installation (Control Head and Speaker Mounted Together) Exploded View
145
Handlebar Installation
145
Handlebar Installation (Control Head and Speaker Mounted Separately)
145
Table 11-10. Handlebar Installation (Control Head and Speaker Mounted Together) Parts List
145
Table 11-11. Handlebar Installation (Control Head and Speaker Mounted Separately) Parts List
145
Figure 11-11.Fuel-Tank Console Installation (Control Head and Speaker Mounted Together) Exploded View
146
Figure 11-12.Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately) Exploded View
146
Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately)
146
Fuel-Tank Console Installation (Control Head and Speaker Mounted Together)
146
Table 11-12. Fuel-Tank Console Installation (Control Head and Speaker Mounted Together)
146
Table 11-13. Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately) Parts List
146
Figure 11-13.HMN1062_ Motorcycle Microphone
147
Figure 11-14.HSN6003_ Motorcycle Weather-Resistant Speaker
147
HMN1062_ Motorcycle Microphone
147
HSN6003_ Motorcycle Weather-Resistant Speaker
147
Table 11-14. HMN1062_ Motorcycle Microphone Parts List
147
Table 11-15. HSN6003_ Motorcycle Weather-Resistant Speaker Parts List
147
Figure 11-15.Motorcycle Weather-Resistant Radio Enclosure
148
Motorcycle Weather-Resistant Radio Enclosure
148
Table 11-16. Motorcycle Weather-Resistant Radio Enclosure Parts List (Enclosure Parts)
148
Table 11-17. Motorcycle Weather-Resistant Radio Enclosure Parts List (Mounting Parts)
148
Figure 11-16.Motorcycle Universal Mounting Plate Exploded View
149
Large Pushbutton Parts
149
Motorcycle Universal Mounting Plate
149
Small Pushbutton Parts
149
Table 11-18. Motorcycle Universal Mounting Plate Parts List
149
Table 11-19. Small Pushbutton Parts List
149
Table 11-20. Large Pushbutton Parts List
149
Appendix A Replacement Parts Ordering
151
Basic Ordering Information
151
Motorola Online
151
Mail Orders
151
Telephone Orders
151
Fax Orders
152
Parts Identification
152
Product Customer Service
152
A.5 Fax Orders
152
Appendix B Environmental Information
154
Glossary
155
Parts List
167
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Motorola Astro XTL 5000 Specifications
General
Brand
Motorola
Model
Astro XTL 5000
Category
Radio
Language
English
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