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

Digital mobile radio hf/uhf range 1/uhf range 2/ 700–800 mhz
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  • Page 2 ® ASTRO Digital XTL™ 5000 Title Page1301 VHF/UHF Range 1/UHF Range 2/ 700–800 MHz Mobile Radio Basic Service Manual Motorola, Inc. 1301 E. Algonquin Rd, 6871769L01-A Schaumburg, IL 60196-1078 USA...

  • Page 3: 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 4: Document History

    Document History The following major changes have been implemented in this manual since the previous edition: Edition Description Date 6871769L01-A Initial Release Oct. 2006 6871769L01-A October 30, 2006...
  • Page 5 Notes October 30, 2006 6871769L01-A...

  • Page 6: Table Of Contents

    ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart (Cont.) ..........xxxix ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt (Reband) Model Chart ...........xl ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt (Reband) Model Chart (Cont.) ........xli ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart ................xlii ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart (Cont.) ..............
  • Page 7 Table of Contents Fax Orders ...........................A-2 Parts Identification ........................A-2 Product Customer Service ......................A-2 Appendix B Environmental Information ..........B-1 Glossary ..................Glossary-1 Index ...................... Index-i 6871769L01-A October 30, 2006...
  • Page 8 List of Figures List of Figures Figure 1-1. XTL 5000 O3 Control Head....................1-4 Figure 1-2. XTL 5000 Control Head ....................... 1-5 Figure 3-1. Controller Sections (Mid Power) ..................3-3 Figure 3-2. Controller Sections (High Power) ..................3-3 Figure 3-3. Audio Receive Path in XTL 5000 Transceiver..............
  • Page 9 List of Figures xiii Figure 8-9. Front Panel Reassembly...................... 8-9 Figure 8-10. Removing the Control Head Screws .................. 8-10 Figure 8-11. Removing the Control Head....................8-10 Figure 8-12. Removing the Flex (Control Head Connector) ..............8-11 Figure 8-13. Removing the Headbridge ....................8-11 Figure 8-14.
  • Page 10 List of Figures Figure 9-1. GCAI Connector ........................9-1 Figure 9-2. J2 Rear Accessory Connector ..................... 9-3 Figure 9-3. J100 Mobile Accessory Port (MAP) Connector ..............9-5 Figure 9-4. J200 Power and Audio Connector ..................9-7 Figure 9-5. J300 Controller Area Network (CAN) Connector on CHIB ........... 9-8 Figure 9-6.
  • Page 11 Recommended Non-Motorola Test Equipment ..............4-2 Table 4-4. Service Aids for XTL 5000 Board-Level Troubleshooting ............ 4-3 Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting ........4-3 Table 4-6. Recommended Non-Motorola Tools for Board-Level Troubleshooting ........ 4-4 Table 4-7. XTL 5000 Radio Field-Programming Items................4-4 Table 5-1.
  • Page 12 Related Publications Table 11-5. Transceiver Interface Board (TIB) Parts List ..............11-5 Table 11-6. XTL 5000 Dash Mount Radio Parts List ................11-6 Table 11-7. XTL 5000 Dash Mount Radio Parts List ................11-7 Table 11-8. XTL 5000 Mid Power Remote Mount Radio Parts List............11-8 Table 11-9.

  • Page 13: 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 14: Iii. 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 15: Vi. 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 16 Commercial Warranty Notes October 30, 2006 6871769L01-A...

  • Page 17: Model Numbering, Charts, And Specifications

    Model Numbering, Charts, and Specifications Model Numbering, Charts, and Specifications Mobile Radio Model Numbering Scheme Typical Model Number: Position: 12 13 14 15 16 Position 1 - Type of Unit Positions 13 - 16 M = Mobile SP Model Suffix L = Table Top Station Position 12 - Positions 2 &...

  • Page 18: Astro Xtl 5000 O3 Vhf 10-50 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart M20KSS9PW1AN Option Description G66AH ADD: Dash Mount Mid Power O3 G67AZ ADD: Remote Mount Mid Power O3 G67AY ADD: Remote Mount High Power O3 G655AH...

  • Page 19: Astro Xtl 5000 O3 Vhf 10-50 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications xxiii ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart (Cont.) M20KSS9PW1AN Option Description G927AA INT: Connector Remote Mount W874AA ADD: Handset/Hangup Armored Cable (GCAI) G874AA ADD: Handset/Hangup (GCAI) G876AA ADD: Hangup/Cradle w/Coiled CBL, GCAI...
  • Page 20 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart (Cont.) M20KSS9PW1AN Option Description W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt W432AE ADD: External 13 Watt Speaker G296AA ADD: Antenna 1/4 Wave Whip Roof Top 136-144 MHz G297AA ADD: Antenna 1/4 Wave Roof Top VHF 144-150.8 MHz...

  • Page 21: Astro Xtl 5000 O3 Vhf 100 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 VHF 100 Watt Model Chart M20KTS9PW1AN Option Description G66AH ADD: Dash Mount Mid Power O3 G67AZ ADD: Remote Mount Mid Power O3 G67AY ADD: Remote Mount High Power O3 G655AH ADD: Quick Release Remote Mount O3 High Power...

  • Page 22: Astro Xtl 5000 O3 Vhf 100 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 VHF 100 Watt Model Chart (Cont.) M20KTS9PW1AN Option Description G159AH ADD: XTL Encryption UCM HW 30 Sec Key G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret G927AA...
  • Page 23 Model Numbering, Charts, and Specifications xxvii ASTRO XTL 5000 O3 VHF 100 Watt Model Chart (Cont.) M20KTS9PW1AN Option Description W81AL ADD: Key Lock Mount W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt...

  • Page 24: Astro Xtl 5000 O3 Uhf Range 1 10-40 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 UHF Range 1 10-40 Watt Model Chart M20QSS9PW1AN Option Description G66AH ADD: Dash Mount Mid Power O3 G67AZ ADD: Remote Mount Mid Power O3 G67AY ADD: Remote Mount High Power O3...

  • Page 25: Astro Xtl 5000 O3 Uhf Range 1 10-40 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications xxix ASTRO XTL 5000 O3 UHF Range 1 10-40 Watt Model Chart (Cont.) M20QSS9PW1AN Option Description G159AH ADD: XTL Encryption UCM HW 30 Sec Key G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret...
  • Page 26 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 UHF Range 1 10-40 Watt Model Chart (Cont.) M20QSS9PW1AN Option Description W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt W432AE...

  • Page 27: Astro Xtl 5000 O3 Uhf Range 1 100 Watt Model Chart

    Model Numbering, Charts, and Specifications xxxi ASTRO XTL 5000 O3 UHF Range 1 100 Watt Model Chart M20QTS9PW1AN Option Description G66AH ADD: Dash Mount Mid Power O3 G67AZ ADD: Remote Mount Mid Power O3 G67AY ADD: Remote Mount High Power O3...

  • Page 28: Astro Xtl 5000 O3 Uhf Range 1 100 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 UHF Range 1 100 Watt Model Chart (Cont.) M20QTS9PW1AN Option Description G927AA INT: Connector Remote Mount G442AA ADD:XTL 5000 Control Head G159AH ADD: XTL Encryption UCM HW 30 Sec Key...
  • Page 29 Model Numbering, Charts, and Specifications xxxiii ASTRO XTL 5000 O3 UHF Range 1 100 Watt Model Chart (Cont.) M20QTS9PW1AN Option Description W688AP ADD: External Emergency Pushbutton W81AL ADD: Key Lock Mount W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel...

  • Page 30: Astro Xtl 5000 O3 Uhf Range 2 10-40 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 UHF Range 2 10-40 Watt Model Chart M20SSS9PW1AN Option Description G66AH ADD: Dash Mount Mid Power O3 G67AZ ADD: Remote Mount Mid Power O3 G67AY ADD: Remote Mount High Power O3...

  • Page 31: Astro Xtl 5000 O3 Uhf Range 2 10-40 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications xxxv ASTRO XTL 5000 O3 UHF Range 2 10-40 Watt Model Chart (Cont.) M20SSS9PW1AN Option Description G159AH ADD: XTL Encryption UCM HW 30 Sec Key G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret...
  • Page 32 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 UHF Range 2 10-40 Watt Model Chart (Cont.) M20SSS9PW1AN Option Description W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt...

  • Page 33: Astro Xtl 5000 O3 700-800 Mhz 10-35 Watt Model Chart

    Model Numbering, Charts, and Specifications xxxvii ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart M20URS9PW1AN Option Description G66AH ADD: Dash Mount Mid Power O3 G67AZ ADD: Remote Mount Mid Power O3 G67AY ADD: Remote Mount High Power O3...

  • Page 34: Astro Xtl 5000 O3 700-800 Mhz 10-35 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart (Cont.) M20URS9PW1AN Option Description G159AH ADD: XTL Encryption UCM HW 30 Sec Key G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret...
  • Page 35 Model Numbering, Charts, and Specifications xxxix ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart (Cont.) M20URSM9PW1AN Option Description W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt W432AE...

  • Page 36: Astro Xtl 5000 O3 700-800 Mhz 10-35 Watt (Reband) Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt (Reband) Model Chart M20URS9PW1AN Option Description G927AA INT: Connector Remote Mount G442AC ADD: XTL 5000 Control Head RB G442AE ADD: XTL 5000 Control Head Dash UCM RB...

  • Page 37: Astro Xtl 5000 O3 700-800 Mhz 10-35 Watt (Reband) Model Chart (Cont.)

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt (Reband) Model Chart (Cont.) M20URS9PW1AN Option Description G91AB ADD: Control Station Power Supply W688AP ADD: External Emergency Pushbutton W81AL ADD: Key Lock Mount W116AN ADD: External Alarm and Relay Cable...

  • Page 38: Astro Xtl 5000 O5 Vhf 10-50 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart M20KSM9PW1AN Option Description G66AF ADD: Dash Mount, No Control Head G66AD ADD: Dash Mount G67AP ADD: Mid Remote Mount G67AR ADD: Remote Mount, No Control Head...

  • Page 39: Astro Xtl 5000 O5 Vhf 10-50 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications xliii ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart (Cont.) M20KSM9PW1AN Option Description G927AA INT: Connector Remote Mount W874AA ADD: Handset/Hangup Armoured Cable (GCAI) G874AA ADD: Handset/Hangup (GCAI) G876AA ADD: Hangup/Cradle w/Coiled CBL, GCAI...
  • Page 40 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart (Cont.) M20KSM9PW1AN Option Description W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt W432AE ADD: External 13 Watt Speaker G296AA ADD: Antenna 1/4 Wave Whip Roof Top 136-144 MHz G297AA ADD: Antenna 1/4 Wave Roof Top VHF 144-150.8 MHz...
  • Page 41 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O5 VHF 100 Watt Model Chart M20KTM9PW1AN Option Description G67AQ ADD: Remote Mount, No Control Head G67AK ADD: Thumb Screw, Remote Mount G655AF ADD: Quick, HP Remote Mount No Control Head G655AE...
  • Page 42 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O5 VHF 100 Watt Model Chart (Cont.) M20KTM9PW1AN Option Description G159AH ADD: XTL Encryption UCM HW 30 Sec Key G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret G927AA...
  • Page 43 Model Numbering, Charts, and Specifications xlvii ASTRO XTL 5000 O5 VHF 100 Watt Model Chart (Cont.) M20KTM9PW1AN Option Description W81AL ADD: Key Lock Mount W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt...
  • Page 44 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O5 UHF Range 1 10-40 Watt Model Chart M20QSM9PW1AN Option Description G66AD ADD: Dash Mount G67AP ADD: Mid Remote Mount G67AR ADD: Remote Mount, No Control Head G582AA ADD: Remote Mount Cable 40 meters (131 ft)
  • Page 45 Model Numbering, Charts, and Specifications xlix ASTRO XTL 5000 O5 UHF Range 1 10-40 Watt Model Chart (Cont.) M20QSM9PW1AN Option Description G159AH ADD: XTL Encryption UCM HW 30 Sec Key G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret...
  • Page 46 Model Numbering, Charts, and Specifications ASTRO XTL 5000 O5 UHF Range 1 10-40 Watt Model Chart (Cont.) M20QSM9PW1AN Option Description W116AN ADD: External Alarm and Relay Cable W591AP ADD: Auxiliary Switch Panel B18CL ADD: Auxiliary Spkr Spectra 5 Watt W432AE...
  • Page 47 Basic Theory of Operation: VHF Receiver Overview 3-25 3.11 VHF Receiver Overview The primary duties of the receiver circuits are to detect, filter, amplify, and demodulate RF signals in the presence of strong interfering noise and unintended signals. The receiver contains the following blocks: •...
  • Page 48 3-26 Basic Theory of Operation: UHF Receiver Overview 3.12 UHF Receiver Overview The primary duties of the UHF receiver circuits are to detect, filter, amplify, and demodulate RF signals in the presence of strong interfering noise and unintended signals. The receiver contains the following blocks: •...
  • Page 49 Basic Theory of Operation: 700–800 MHz Receiver Overview 3-27 3.13 700 800 MHz 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 50: Figure 3-19. Vhf Frequency Generation Unit Diagram

    3-28 Basic Theory of Operation: VHF Frequency Generation Unit (FGU) 3.14 VHF Frequency Generation Unit (FGU) 9.3 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...

  • Page 51: Figure 3-20. Uhf Frequency Generation Unit Diagram

    Basic Theory of Operation: UHF Frequency Generation Unit (FGU) 3-29 3.15 UHF Frequency Generation Unit (FGU) 9.3 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...

  • Page 52: Figure 3-21. 700-800 Mhz Frequency Generation Unit Diagram

    3-30 Basic Theory of Operation: 700–800 MHz Frequency Generation Unit (FGU) 3.16 700 800 MHz Frequency Generation Unit (FGU) – 9.3 V 8.2 V Out Super Filter Adapt LV Frac-N Dual Synthesizer Charge Pump Loop Filter Steering Transmit Line Voltage Modulation AUX- PreScaler...
  • Page 53 Basic Theory of Operation: 700–800 MHz Frequency Generation Unit (FGU) 3-31 In TX mode, the transmitter VCO output is coupled to a three-stage buffer before being injected into the power amplifier (see “3.10 Radio-Frequency Power Amplifier (RF PA) & Output Network (ON)” on page 3-24).
  • Page 54 3-32 Basic Theory of Operation: 700–800 MHz Frequency Generation Unit (FGU) Notes October 30, 2006 6871769L01-A...

  • Page 55: Table 4-1. Recommended Motorola Test Equipment

    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 56: Table 4-3. Recommended Non-Motorola Test Equipment

    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 57: Table 4-4. Service Aids For Xtl 5000 Board-Level Troubleshooting

    This cable will not work correctly in a dash mount radio configuration (attaching cable at J2) unless an emergency jumper wire is installed inside the 26pin connector of this cable. Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting Motorola Tools and Supplies Part Number...

  • Page 58: Table 4-6. Recommended Non-Motorola Tools For Board-Level Troubleshooting

    Global Core Accessory Interface (GCAI) connector. This is the 10-pin connector to which the microphone is commonly attached. The GCAI connector is below the volume knob and to the left of the LCD display. Refer to the CPS Programming Installation Guide (Motorola part number 6881095C44) for installation and setup procedures for the software.

  • Page 59: Figure 5-1. Performance Checks Test Setup

    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 Chapter 4 approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 60: Table 5-1. Test-Mode Displays

    Performance Checks: Test Mode Table 5-1. Test-Mode Displays Display Name Description Appears Indicates the radio has entered test Always SERVICE mode HOST VERSION The version of the transceiver firmware Always DSP VERSION The version of the transceiver DSP Always firmware EMC Secure Version Version of the encryption hardware When the radio is...

  • Page 61: Table 5-2. Test Frequencies

    Performance Checks: Test Mode 4. Turn the Mode Rotary Knob for O5 Control Head. The test mode menu, CH TEST, is displayed. 5. Pressing the Home button enters the RF test mode. The display shows 1 CSQ, indicating test frequency 1, Carrier SQuelch mode. 6.

  • Page 62: Table 5-3. Signaling Types

    Performance Checks: Test Mode Table 5-2. Test Frequencies (Continued) – Test Channel UHF R1 UHF R2 800 MHz RX #7 159.8125 455.825 490.875 869.9375 TX #8 164.5125 469.9375 496.625 851.0125 RX #8 164.5625 469.9875 496.675 851.0625 Table 5-3. Signaling Types Display Modulation Demodulation...

  • Page 63: Figure 5-2. Xtl 5000 O3 Control Head

    Performance Checks: Test Mode Orange Button Programmable Button 14-Character Display Navigation Keys Data Button Figure 5-2. XTL 5000 O3 Control Head 3. Turn the radio off and back on to exit test mode and return to normal radio operation. 5.3.4 O5 Control Head Test Mode The control head test mode is part of the diagnostics built into the radio and is entered through the front-panel programming sequence.

  • Page 64: Figure 5-3. Xtl 5000 Control Head

    Performance Checks: Receiver Performance Checks VOLUME MODE EMERGENCY KNOB BUTTON KNOB HOME POWER INDICATORS ON/OFF GCAI NAVIGATION SOFT MENU CONNECTOR KEYS KEYS Figure 5-3. XTL 5000 Control Head 3. Turn the radio off and back on to exit test mode and return to normal radio operation. Receiver Performance Checks Table 5-4.

  • Page 65: Table 5-5. Transmitter Performance Checks

    Performance Checks: Transmitter Performance Checks Transmitter Performance Checks Table 5-5. Transmitter Performance Checks Test Test Name System Analyzer Radio Comments Condition Reference Mode: PWR MON TEST MODE, Press and hold Maximum Frequency Frequency 1st channel test frequency** 1 CSQ PTT switch. error is Monitor: Frequency error ±...
  • Page 66 Performance Checks: Transmitter Performance Checks Table 5-5. Transmitter Performance Checks (Continued) Test Test Name System Analyzer Radio Comments Condition Talkaround Change frequency to conventional Conventional Press and hold Deviation: Modulation (radios talkaround frequency. talkaround PTT switch. VHF, UHF, 700- with conventional, Mode: PWR MON personality 800 MHz:...

  • Page 67: Figure 6-1. Radio Alignment Test Setup

    A personal computer (PC) and Tuner Software are required to align the radio. 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 68: Figure 6-2. Vhf/700-800 Mhz Tuner Main Menu

    Radio Alignment Procedures: ASTRO XTL 5000 Tuner Software Figure 6-2 shows the tuner main menu screen for VHF and 700–800 MHz radios. Figure 6-2. VHF/700-800 MHz Tuner Main Menu Figure 6-3 shows the tuner main menu screen for UHF radios. For UHF radios, the receiver front-end filter alignment is added.

  • Page 69: Figure 6-4. Radio Information Screen

    Radio Alignment Procedures: Radio Information The alignment screens utilize the “softpot,” an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls. Each alignment screen provides the ability to increase or decrease the softpot value by using the slider or the spin buttons ( ), or by entering the new value from the keyboard.

  • Page 70: Figure 6-5. Pa Bias 1 Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments NOTE: The antenna port should be terminated with a 50-ohm load while tuning. 1. Set the power supply voltage as indicated in Table 6-2. Set power supply current limit to 3 A. Table 6-2. Power Supply Voltage Settings Band/Power Level Supply Voltage (V) Supply Current Limit (A)

  • Page 71: Table 6-4. Pa Bias 2 Alignment Amplifier Devices

    Radio Alignment Procedures: Transmitter Alignments 7. Left-click the Bias Toggle button to remove bias from gate of device. 8. Left-click the Program All button to save tuned value. 9. Left-click Close button to close the screen and return to the Tuner Main Menu. 6.4.2 PA Bias 2 Alignment NOTE: This alignment is required after replacing (or servicing) the transceiver board.

  • Page 72: Figure 6-6. Pa Bias 2 Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments Figure 6-6. PA Bias 2 Alignment Screen 3. Read baseline current from current meter on power supply. 4. Add baseline current to device bias current to calculate target current. Table 6-6. PA Bias 2 Alignment Device Bias Current Band/Power Level Device Bias Current (mA) VHF 50 W/25 W...

  • Page 73: Figure 6-7. Pa Bias 3 Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments 6.4.3 PA Bias 3 Alignment NOTE: This alignment is required after replacing (or servicing) the transceiver board. The PA Bias 3 alignment procedure adjusts the drain bias current in one of the RF power amplifier devices.

  • Page 74: Table 6-9. Pa Bias 3 Alignment Device Bias Current

    Radio Alignment Procedures: Transmitter Alignments 4. Add baseline current to device bias current to calculate target current. Table 6-9. PA Bias 3 Alignment Device Bias Current Band/Power Level Device Bias Current (mA) VHF 50 W/25 W VHF 100 W UHF R1 40 W UHF R1 100 W UHF R2 45 W 700–800 MHz 35 W...

  • Page 75: Figure 6-8. Reference Oscillator Window

    Radio Alignment Procedures: Transmitter Alignments - Display: Bar Graphs - Squelch: Mid-range or adjust as necessary • Initial setup using the Agilent 8901 Modulation Analyzer: - Press the green Automatic Operation button on the analyzer. - Press the FREQ key. - Type 7.1, followed by the SPCL button, to set the 8901 Modulation Analyzer for maximum accuracy.

  • Page 76: Table 6-5. Power Supply Voltage Settings

    6-10 Radio Alignment Procedures: Transmitter Alignments 6.4.5 Power Detector Calibration NOTE: This alignment is required after replacing (or servicing) the transceiver board. The power detector calibration alignment procedure adjusts the buffer gain for the forward power detector to minimize radio power variation from radio to radio. NOTE: Antenna port should be terminated with calibrated power meter through a 30 db RF pad.

  • Page 77: Figure 6-9. Power Detection Calibration Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments 6-11 2. Select Power Detection Calibration from the Tuner Main Menu. Figure 6-9. Power Detection Calibration Alignment Screen 3. Left-click the PTT Toggle button to transmit at indicated frequency. 4. Adjust softpot value until target power is achieved. 5.

  • Page 78: Figure 6-10. Tx Power Characterization Alignment Screen

    6-12 Radio Alignment Procedures: Transmitter Alignments 2. Select Tx Power Characterization from the Tuner Main Menu. Figure 6-10. Tx Power Characterization Alignment Screen 3. Left-click in the first box of the Measured Power 1 column. A green circle will appear to the left of the box indicating active characterization point.

  • Page 79: Table 6-8. Power Supply Voltage Settings

    Radio Alignment Procedures: Transmitter Alignments 6-13 6.4.7 Tx Current Limit NOTE: This alignment is required after replacing (or servicing) the transceiver board or after there has been a change in the CPS-adjustable power level. The Tx Current Limit alignment procedure tunes the Tx current-limiting protection. If you increase the CPS-adjustable power level, then the current limit must be retuned so the radio can achieve the desired power level.

  • Page 80: Figure 6-11. Tx Current Limit Alignment Screen

    6-14 Radio Alignment Procedures: Transmitter Alignments 2. Select Tx Current Limit from the Tuner Main Menu. Figure 6-11. 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 81: Table 6-14. Transmit Current Limit Offset

    Radio Alignment Procedures: Transmitter Alignments 6-15 Table 6-14. Transmit Current Limit Offset Band/Power Level Current Limit Offset VHF 50 W/25 W VHF 100 W UHF R1 40 W UHF R1 100 W UHF R2 45 W 700–800 MHz 35 W 12.

  • Page 82: Figure 6-12. Tx Deviation Balance (Compensation) Alignment Screen

    6-16 Radio Alignment Procedures: Transmitter Alignments - Press the SPF key on the R-2670 to display the "SPECIAL FUNCTIONS MENU." Move the cursor to "High Pass," and select 5 Hz on the soft key menu. Select 20 kHz for the "Low Pass"...
  • Page 83 Radio Alignment Procedures: Transmitter Alignments 6-17 4. Left-click the PTT Toggle button on the screen to enable transmission. The screen indicates whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on R- 2670, or the deviation shown on the 8901 Analyzer, stabilizes. 5.

  • Page 84: Figure 6-13. Tx Deviation Limit Alignment Screen

    6-18 Radio Alignment Procedures: Transmitter Alignments Figure 6-13. 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 85: Figure 6-14. Rx Front-End Filter Alignment Screen

    Radio Alignment Procedures: Transmitter Alignments 6-19 2. To find the RSSI Peak: a. Start with a softpot value of at least 10, and adjust the softpot value either by clicking the up arrow and incrementing the New Softpot Value spin box or by directly entering the desired value into the New Softpot Value spin box.

  • Page 86: Figure 6-15. Bit Error Rate Screen

    6-20 Radio Alignment Procedures: Performance Testing 6. Repeat steps 1 through 5 for all the remaining tuning frequencies. 7. Click the Program All button to save the tuned values in the radio. 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...

  • Page 87: Figure 6-16. Transmitter Test Pattern Screen

    Radio Alignment Procedures: Performance Testing 6-21 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 88 6-22 Radio Alignment Procedures: Performance Testing Notes October 30, 2006 6871769L01-A...

  • Page 89: Table 7-1. Ucm Kit Listing

    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 90: Table 7-2. Secure Interface Board Kits

    Encryption: Universal Crypto Module Kits 7.1.1 Secure Interface Boards Table 7-2 contains the secure interface board kits, which are used in conjunction with the UCM kits. Every secure-equipped radio must contain one of the two secure interface board kits, which is paired with one of the UCM kits.
  • Page 91 Encryption: Load an Encryption Key Load an Encryption Key To load an encryption key into an XTL 5000 radio: 1. Ensure that an encryption module is installed in the radio. 2. Ensure the secure shield is installed and screwed into chassis prior to radio power-up. This is necessary for proper radio operation.
  • Page 92 Encryption: Erase a Single Key Erase a Single Key 1. Press the menu button labeled ERAS. Alternatively, press and hold the menu button labeled SEC until a tone sounds. Then press ERAS on the second menu that is displayed. If ERAS or SEC is not on the current menu, use the NAV key to scroll through the available menus.
  • Page 93 Encryption: Over-the-Air Rekeying Over-the-Air Rekeying The over-the-air rekeying (OTAR) feature allows the dispatcher to reprogram the encryption keys in the radio remotely. The following steps describe how to use this feature. 1. Press the menu button labeled REKY. Alternatively, press and hold the menu button labeled SEC until a tone sounds.
  • Page 94 Encryption: Over-the-Air Rekeying Notes October 30, 2006 6871769L01-A...

  • Page 95: Table 8-1. Required Tools And Supplies

    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 96: Figure 8-1. Cable Lock Detachment

    Disassembly/Reassembly Procedures: Replacement Procedures 8.2.2 XTL 5000 O3 Control Head Disassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 11-1. “XTL 5000 O3 Control Head Exploded View” on page 11-2. 1. Hold the control head straight up, and twist the cable lock as shown in the figure. “Marking”...

  • Page 97: Figure 8-2. Front Housing And Back Housing Detachment

    Disassembly/Reassembly Procedures: Replacement Procedures Figure 8-2. Front Housing and Back Housing Detachment 3. Disconnect the 40-pin connector and separate the front housing. Figure 8-3. Separate Front Housing and Back Housing 6871769L01-A October 30, 2006...

  • Page 98: Figure 8-4. Pcb Detachment

    Disassembly/Reassembly Procedures: Replacement Procedures 4. Using a Torx T-8 screwdriver, remove the 5 printed circuit board (PCB) screws. T-8 screw Main PCB Assembly T-8 screw Back Housing Hang-up stud connector wire Figure 8-4. PCB Detachment 5. Gently pull out the 2-pin connector which connect the back housing to the PCB. 2-PINS Connector Hang-up stud connector wire...

  • Page 99: Figure 8-6. Control Head Screw Sequence

    Disassembly/Reassembly Procedures: Replacement Procedures 8.2.3 XTL 5000 O3 Control Head Reassembly NOTE:Bracketed numbers are identical to item numbers shown in Figure 11-1. “XTL 5000 O3 Control Head Exploded View” on page 11-2. 1. To reassemble, ensure that the wire from the back housing is connected to the PCB and the o-ring seal is installed properly.
  • Page 100 Disassembly/Reassembly Procedures: Replacement Procedures 1. To reassemble, ensure that all the keypads are fully seated into the front housing, and that all the flexes (LCD Display module, volume and mode) will not be covered by the PCB. Ensure that the GCAI seal is properly placed on the GCAI connector. 2.

  • Page 101: Figure 8-7. Front Panel Disassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 3. Remove the TUC seal from the connector on the front side of the board and discard. Figure 8-7. Front Panel Disassembly 6871769L01-A October 30, 2006...

  • Page 102: Figure 8-8. Tuc Seal Placement

    Disassembly/Reassembly Procedures: Replacement Procedures 8.2.6.3 Mid Power Model Reassembly 1. Install the TUC seal ensuring it is seated properly to the TUC connector then install the remote interconnect board onto the front panel, and replace the screws. Torque the screws to 6-8 in.-lbs.

  • Page 103: Figure 8-9. Front Panel Reassembly

    Disassembly/Reassembly Procedures: Replacement Procedures 4. To reattach the front panel to the front of the radio, follow the reassembly procedure outlined section 8.2.8.2: High Power Models, page 8-39, steps 9-13. Figure 8-9. Front Panel Reassembly 8.2.7 Radio Disassembly 8.2.7.1 Mid Power Models Use the following procedure to disassemble your radio: 1.

  • Page 104: Figure 8-10. Removing The Control Head Screws

    8-10 Disassembly/Reassembly Procedures: Replacement Procedures 2. Remove the two front control head screws using a T-10. Save them for later use. Screws Figure 8-10. Removing the Control Head Screws 3. Firmly grasp the front panel of the control head or the Transceiver Interface Board (TIB) for remote mount, and carefully remove the control head assembly from the headbridge.

  • Page 105: Figure 8-12. Removing The Flex (Control Head Connector)

    Disassembly/Reassembly Procedures: Replacement Procedures 8-11 5. Carefully disconnect the control head flex from the control head or TIB and set the control head or TIB aside. Figure 8-12. Removing the Flex (Control Head Connector) 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.

  • Page 106: Figure 8-14. Removing The Flex (Main-Board Connector)

    8-12 Disassembly/Reassembly Procedures: Replacement Procedures 7. Carefully remove the control head flex from the transceiver by grasping the provided handle and separating it from the connector. Control Head Flex Figure 8-14. Removing the Flex (Main-Board Connector) 8. Remove the headbridge seal from the transceiver. Headbridge Seal MAEPF-27792 -O Figure 8-15.

  • Page 107: Figure 8-16. Removing The Secure Interface Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-13 The following steps MUST be performed for secure-equipped radios, prior to removal of the Main Board from the chassis. Otherwise damage to the transceiver Main Board could occur. C a u t i o n 9.

  • Page 108: Figure 8-17. Removing The Top Cover Screws

    8-14 Disassembly/Reassembly Procedures: Replacement Procedures 10. Remove the 10 top-cover screws using a Torx T20 bit. These screws have sealing washers that should be kept with the screw. MAEPF-27679-O Figure 8-17. 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 109: Figure 8-19. Removing The J2 Rear Accessory Flex From The Main Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-15 12. Disconnect the rear accessory (J2) flex from the main board. MAEPF-27681-O Figure 8-19. Removing the J2 Rear Accessory Flex from the Main Board 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 6871769L01-A October 30, 2006...

  • Page 110: Figure 8-20. Removing The Pa Screws

    8-16 Disassembly/Reassembly Procedures: Replacement Procedures 13. Remove the three PA screws in the order shown using a Torx T10 bit. MAEPF-27682-O Figure 8-20. Removing the PA Screws 14. Remove the RF/DC retention clips by gently prying them out with a flat-blade screwdriver. For leverage, use only the slots provided immediately adjacent to the clips.

  • Page 111: Figure 8-22. 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 pushing up on the 50-pin connector, lifting up the front of the PCB. MAEPF-27683-O Figure 8-22.

  • Page 112: Figure 8-24. Removing The Transceiver Interface Board Screws

    8-18 Disassembly/Reassembly Procedures: Replacement Procedures 8.2.7.2 High Power Models Use the following procedure to disassemble your radio: 1. Ensure all accessory connections, power, antenna, and microphone are unplugged. 2. Remove the two screws that secure the Transceiver Interface Board (TIB) housing using a T10 Torx bit.

  • Page 113: Figure 8-25. Removing The Transceiver Interface Board Assembly

    Disassembly/Reassembly Procedures: Replacement Procedures 8-19 3. Remove the front panel by gently lifting the housing so that it disengages from the hooks underneath and lay it down on a clean, flat surface. It may be necessary to gently pry the housing free of the hooks using a plastic tool.

  • Page 114: Figure 8-27. Removing The Flex (Main-Board Connector)

    8-20 Disassembly/Reassembly Procedures: Replacement Procedures 5. Carefully remove the flex from the transceiver by grasping the provided handle and separating it from the connector. MAEPF-28249-O TIB Flex Figure 8-27. Removing the Flex (Main-Board Connector) 6. Remove the front panel seal from the transceiver. MAEPF-28246-O Front Panel Seal Figure 8-28.

  • Page 115: Figure 8-29. Removing The Secure Interface Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-21 The following steps MUST be performed for secure-equipped radios, prior to removal of the Main Board from the chassis. Otherwise damage to the transceiver Main Board could occur. C a u t i o n 7.

  • Page 116: Figure 8-30. Removing The Top Cover Screws

    8-22 Disassembly/Reassembly Procedures: Replacement Procedures 8. Remove the 12 top-cover screws using a Torx T20 bit. These screws have sealing washers that should be kept with the screw. MAEPF-28223-O Figure 8-30. Removing the Top Cover Screws 9. 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 117: Figure 8-32. Removing The Pa Screws

    Disassembly/Reassembly Procedures: Replacement Procedures 8-23 10. Remove the five PA screws in the order shown using a Torx T10 bit. MAEPF-28225-O Figure 8-32. Removing the PA Screws 11. Remove the RF/DC retention clips by gently prying them out with a flat-blade screwdriver. For leverage, use only the slots provided immediately adjacent to the clips.

  • Page 118: Figure 8-34. Pushing Up The Main Board

    8-24 Disassembly/Reassembly Procedures: Replacement Procedures 12. Remove the main board by sliding a finger into the provided opening at the front of the chassis and gently pressing up on the 60-pin connector, lifting up the front of the PCB. MAEPF-28227-O Figure 8-34.

  • Page 119: Figure 8-35. Inspecting The Chassis Shield Gasketing And Thermal Pads

    Disassembly/Reassembly Procedures: Replacement Procedures 8-25 8.2.8 Radio Reassembly 8.2.8.1 Mid Power Models 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 120: Figure 8-36. Inserting The J2 Rear Accessory Connector

    8-26 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 rear accessory connector by holding onto the flex.

  • Page 121: Figure 8-37. Inserting The Main Board Into The Chassis

    Disassembly/Reassembly Procedures: Replacement Procedures 8-27 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 122: Figure 8-38. Connecting The J2 Rear Accessory Connector Flex To The Main Board

    8-28 Disassembly/Reassembly Procedures: Replacement Procedures 4. Connect the J2 rear accessory connector flex to the main board. MAEPF-27784-O Figure 8-38. Connecting the J2 Rear Accessory Connector Flex to the Main Board October 30, 2006 6871769L01-A...

  • Page 123: Figure 8-39. Inserting The Rf/Dc Retention Clips

    Disassembly/Reassembly Procedures: Replacement Procedures 8-29 5. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to properly locate the main board. MAEPF-27688-O Figure 8-39. Inserting the RF/DC Retention Clips MAEPF-27689-O Figure 8-40. Inserting the RF/DC Retention Clip (DC Side) 6871769L01-A October 30, 2006...

  • Page 124: Figure 8-41. Installing The Pa Screws

    8-30 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. MAEPF-27682-O Figure 8-41. Installing the PA Screws 7. Inspect the reverse polarity thermal pad for the reverse polarity diode located on the top cover, and then inspect and seat the main seal properly on the cover.

  • Page 125: Figure 8-43. Securing The Top Cover To The Chassis

    Disassembly/Reassembly Procedures: Replacement Procedures 8-31 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, seat the seal and make torquing the screws easier. 9. Inspect and reassemble the sealing washers to the ten (10) top cover screws, and then torque down screws in the indicated order.

  • Page 126: Figure 8-44. Installing The Secure Interface Board

    8-32 Disassembly/Reassembly Procedures: Replacement Procedures e. Over-torque of the shield screws will strip out the threads inside chassis. Repair will require re-tapping of the threading. Secure Interface Board Universal Screws Encryption Secure Module Shield MAEPF-27647-A Figure 8-44. Installing the Secure Interface Board 11.

  • Page 127: Figure 8-46. Installing The Control Head Flex In The Transceiver

    Disassembly/Reassembly Procedures: Replacement Procedures 8-33 13. Grasp the handle on the transceiver end of the control head flex, or TIB flex if remote, and plug the flex into the 50-pin connector on the side of the main board. Figure 8-46. Installing the control head Flex in the Transceiver 14.

  • Page 128: Figure 8-48. Installing The Control Head Flex On The Control Head

    8-34 Disassembly/Reassembly Procedures: Replacement Procedures 16. Verify that the headbridge seal and all the seal tabs are properly in place. 17. Reinstall the control head flex onto the control head connector or TIB flex onto the TIB connector. Figure 8-48. Installing the Control Head Flex on the Control Head 18.

  • Page 129: Figure 8-50. Installing The Control Head Screws

    Disassembly/Reassembly Procedures: Replacement Procedures 8-35 19. Secure the control head to the transceiver with the two screws using the T-10. Apply 6-8 in.- lbs. of torque for each screw. Screws Figure 8-50. Installing the Control Head Screws 8.2.8.2 High Power Models Use the procedure that follows to reassemble your radio.

  • Page 130: Figure 8-52. Inserting The Main Board Into The Chassis

    8-36 Disassembly/Reassembly Procedures: Replacement Procedures 2. 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 131: Figure 8-54. Inserting The Rf/Dc Retention Clip (Dc Side)

    Disassembly/Reassembly Procedures: Replacement Procedures 8-37 MAEPF-28231-O Figure 8-54. Inserting the RF/DC Retention Clip (DC Side) 4. Insert and torque the five PA screws to 6-8 in.-lbs. Start all five screws prior to torquing them down. MAEPF-28232-O Figure 8-55. Installing the PA Screws 6871769L01-A October 30, 2006...

  • Page 132: Figure 8-56. Inspecting The Thermal Pad And Installing The Cover Main Seal

    8-38 Disassembly/Reassembly Procedures: Replacement Procedures 5. Inspect the reverse polarity thermal pad for the reverse polarity diode located on the top cover, and then inspect and seat the main seal properly on the cover. Be careful to properly align the tab (see figure below). MAEPF-28233-O Figure 8-56.

  • Page 133: Figure 8-57. Installing The Secure Interface Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-39 e. Over-torque of the shield screws will strip out the threads inside chassis. Repair will require re-tapping of the threading. Secure Interface Board Screws Universal Secure MAEPF-28234-O Encryption Shield Module Figure 8-57. Installing the Secure Interface Board 9.

  • Page 134: Figure 8-59. Installing The Tib Flex In The Transceiver

    8-40 Disassembly/Reassembly Procedures: Replacement Procedures 11. Grasp the handle on the transceiver end of the Transceiver Interface Board (TIB) flex, and plug the flex into the 60-pin connector on the side of the main board. TIB Flex Figure 8-59. Installing the TIB Flex in the Transceiver 12.

  • Page 135: Figure 8-61. Chassis Thermal Pad Locations

    Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure 8-41 Chassis Thermal Pad Replacement Procedure 8.3.1 Mid Power Models Use the following procedures for replacing the chassis thermal pads. MAEPF-27649-O Figure 8-61. Chassis Thermal Pad Locations Table 8-2. Chassis Thermal Pad Parts Item No.
  • Page 136 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 137: Figure 8-62. Chassis Thermal Pad Locations

    Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure 8-43 8.3.2 High Power Models Use the following procedures for replacing the chassis thermal pads. Figure 8-62. Chassis Thermal Pad Locations Table 8-3. Chassis Thermal Pad Parts Item No. Part No. Description 7585366E01 Pad, Thermal, Audio PA 7585477E01 Pad, Thermal, Regulator...

  • Page 138: Table 8-4. Fastener Torque Chart

    8-44 Disassembly/Reassembly Procedures: Fastener Torque Chart Fastener Torque Chart Notes Table 8-4 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 139: Figure 9-1. Gcai Connector

    "Service Aids and Recommended Tools" page 4-2, for the appropriate Motorola service aids and tools parts numbers.) With the exception of some inputs on service monitors, a suitable attenuator rated at 100 W or more should always be used with all test equipment connected to the RF connector.

  • Page 140: Table 9-1. Gcai Connector Signal Descriptions

    Basic Troubleshooting: Accessory Connectors Table 9-1. GCAI Connector Signal Descriptions Signal Name Description Control Head (J1) TIB (J700) Signal used to identify accessory. One-Wire One-Wire Active low Push-to-talk input. Asserting this AUX_PTT input on the TIB results in auxiliary microphone input use (GCAI pin 7).

  • Page 141: Figure 9-2. J2 Rear Accessory Connector

    GROUND Ground Preferred ground for any digital lines on the rear connector. BUS+ SB9600 BUS+ Part of the Motorola SB9600 communications bus to connect external devices. BUS- SB9600 BUS- Part of the Motorola SB9600 communications bus to connect external devices.
  • Page 142 Basic Troubleshooting: Accessory Connectors Table 9-2. J2 Rear Accessory Connector Signal and Voltage Descriptions (Continued) Function Description USB PWR USB Power Used for USB enumeration. Five volts is applied to this pin by the USB Host. CHAN ACT Channel Activity 0-5 volt output used for indicating detection/ unsquelching of a qualified received signal.

  • Page 143: Figure 9-3. J100 Mobile Accessory Port (Map) Connector

    Basic Troubleshooting: Accessory Connectors 9.2.3 J100 CHUC - Mobile Accessory Port Interface for XTL 5000 O5 only J100 is located on the back of the O5 control head assembly in the remote mount configuration. This connector provides pins located identical to connector J2 at the back of a mid power transceiver. Not all the pins are populated at J100 due to identical functionality on connectors J200, J400, J600, and J700.
  • Page 144 Basic Troubleshooting: Accessory Connectors Table 9-3. J100 Remote Mount Control Head Mobile Accessory Port (MAP) (Continued) Function Description VIP OUT 1 Vehicular Interface High voltage open drain output used for enabling Output relays used for accessories such as horn/lights. VIP OUT 2 Vehicular Interface High voltage open drain output used for enabling Output...

  • Page 145: Figure 9-4. J200 Power And Audio Connector

    Basic Troubleshooting: Accessory Connectors 9.2.4 J200 CHUC - Power and Audio Interface J200 is located on the back of the O5 control head assembly in the remote mount configuration. This connector provides the voltage into the transceiver, as well as Ignition sense and speaker lines. An alternate power cable can be used at this connector to provide Earjack audio and TX/RX record out audio.

  • Page 146: Figure 9-5. J300 Controller Area Network (Can) Connector On Chib

    Basic Troubleshooting: Accessory Connectors 9.2.5 J300 CHUC - Controller Area Network (CAN) Interface J300L and J300R are located on the back of the O5 control head assembly in the remote mount configuration. These two connectors are identical, in order to aid in future daisy-chaining of other CAN bus accessories.

  • Page 147: Figure 9-6. J400 Vip And Dek Connector

    Basic Troubleshooting: Accessory Connectors 9.2.6 J400 CHUC - VIP and DEK Interface J400 is located on the back of the O5 control head assembly in the remote mount configuration. This connector provides the ability to utilize up to 3 VIP OUT, 3 VIP IN, the GND and SWB+ pins they require, or DEK signal lines.

  • Page 148: Figure 9-7. J500 Usb Host Connector

    The USB host series "A" Receptacle interface interacts with USB devices through the Host Controller. It is located at the back of the CHIB. This connector supports low and full speed devices that complies with USB 2.0 standard included in the Motorola approved list. Figure 9-7. J500 USB Host Connector Table 9-7.

  • Page 149: Figure 9-8. J600 Connector

    MIC_IN, or VIPOUT_1 (passthrough). MIC_IN routes to the transceiver MIC_HI input. BUS+ SB9600 BUS+ Part of the Motorola SB9600 communications bus to connect external devices. A jumper exists on the TIB to change this pin to DCE_RTS. RX_AUDIO Receive Filtered Audio Out This is a fixed level (independent of volume level) received audio signal, including alert tones.
  • Page 150 J2 connector. BUS- SB9600 BUS- Part of the Motorola SB9600 communications bus to connect external devices. AUX_MIC Auxiliary microphone input HLN1454B has AUX_MIC as the default state of this pin.

  • Page 151: Figure 9-9. J700 Gcai Programming Connector

    Basic Troubleshooting: Accessory Connectors 9-13 9.2.9 J700 TIB - Global Core Accessory Interface (GCAI) Interface J700 is located on the transceiver interface board (TIB) used in the remote mount configuration. This connector is the GCAI connector. Only pins with the purpose of data re-programming or data communications have been placed at this connector.

  • Page 152: Figure 9-11. Rs232 Connector Naming Scheme

    9-14 Basic Troubleshooting: Microphone Bias Table 9-9. J800 Controller Area Network Connector Pin Functions Function Description CAN termination detect pin Pin 4 shorted to GND inside each end of the CAN cable. Only routed on the “03” CAN cable CAN_3_LOW TX- (PWR) Dedicated for System ON/OFF/RESET commands.
  • Page 153 • 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 154: Table 9-10. Power-Up Error Codes

    9-16 Basic Troubleshooting: Power-Up Error Codes Power-Up Error Codes When the radio is turned on (power-up), the radio performs cursory 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.

  • Page 155: Table 9-11. Operational Error Codes

    Basic Troubleshooting: Operational Error Codes 9-17 Table 9-10. Power-Up Error Codes (Continued) Error Code Description Error Type Corrective Action ERROR 09/10 Secure Hardware Error NON-FATAL Ensure secure shield is screwed to chassis and making contact with secure module. Otherwise, replace the secure module and/or secure interconnect board.

  • Page 156: Table 9-12. Transmitter Troubleshooting Chart

    9-18 Basic Troubleshooting: Transmitter Troubleshooting Transmitter Troubleshooting Table 9-12 can help you troubleshoot problems that might occur in the transmitter section of your radio. Table 9-12. Transmitter Troubleshooting Chart Correction or Test (Measurements Taken at Symptom Possible Cause Room Temperature) No RF Power TX Power Level Check TX power level programming (from the...

  • Page 157: Table 9-13. Receiver Troubleshooting Chart

    Basic Troubleshooting: Receiver Troubleshooting 9-19 Receiver Troubleshooting Table 9-13 can help you troubleshoot problems that might occur in the receiver section of your radio. Table 9-13. Receiver Troubleshooting Chart Correction or Test (Measurements Taken at Symptom Possible Cause Room Temperature) Radio does not Blown power fuse Check the fuse in the red cable.
  • Page 158 9-20 Basic Troubleshooting: Receiver Troubleshooting Table 9-13. Receiver Troubleshooting Chart (Continued) Correction or Test (Measurements Taken at Symptom Possible Cause Room Temperature) RF Sensitivity Synthesizer Not On Check the local oscillator frequency. Poor Frequency/Working See “Reference Oscillator Alignment” on page 6-8.

  • Page 159: Figure 10-1. Xtl 5000 Transceiver Functional Block Diagram

    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. XTL 5000 Transceiver Functional Block Diagram 10-3 Figure 10-2.
  • Page 160 10-2 Functional Block Diagrams and Connectors: XTL 5000 Transceiver Functional Block Diagram 10.1 XTL 5000 Transceiver Functional Block Diagram Figure 10-1. XTL 5000 Transceiver Functional Block Diagram October 30, 2006 6871769L01-A...
  • Page 161 Functional Block Diagrams and Connectors: XTL 5000 O3 Dash and Remote Control Head Functional Block Diagram 10-3 10.2 XTL 5000 O3 Dash and Remote Control Head Functional Block Diagram Transceiver Interface Board (TIB) See Figure 10-7 for details Control Head Ca n FPGA OMAP...
  • Page 162 10-4 Functional Block Diagrams and Connectors: XTL 5000 O5 Dash and Remote Control Head Functional Block Diagram 10.3 XTL 5000 O5 Dash and Remote Control Head Functional Block Diagram TO J0401 Control Head Connector Transceiver Interface Board (TIB) See Figure 10-7 for details FPGA Control Head Interface Board (CHIB) See Figure 10-4 for details...

  • Page 163: Figure 10-4. Xtl 5000 O3 Control Head Functional Block Diagram

    Functional Block Diagrams and Connectors: XTL 5000 O3 Control Head Functional Block Diagram 10-5 10.4 XTL 5000 O3 Control Head Functional Block Diagram CAN1 16.8Mhz FPGA 5V REG CAN2 Connector 3.3V REG CAN3 CODEC CAN3 32kHz OSC VCC_1.55 OMAP 12MHz OSC Microprocessor VCC_3.3 Power...

  • Page 164: Figure 10-5. Xtl 5000 O5 Control Head Functional Block Diagram

    10-6 Functional Block Diagrams and Connectors: XTL 5000 O5 Control Head Functional Block Diagram 10.5 XTL 5000 O5 Control Head Functional Block Diagram To Transceiver in Dash. To CHIB in Remote. 80-pin rear connector J11 SW_B+ 3.3V SDRAM ON/OFF 2.8V control and 1.8V 1.5V...

  • Page 165: Figure 10-6. Xtl 5000 O5 Control Head Interface Board (Chib) Functional Block Diagram

    Functional Block Diagrams and Connectors: XTL 5000 O5 Control Head Interface Board (CHIB) Functional Block Diagram 10-7 10.6 XTL 5000 O5 Control Head Interface Board (CHIB) Functional Block Dia- 10.7 XTL 5000 Transceiver Interface Board (TIB) Functional Block Diagram gram To Transceiver Parallel 80-pin rear connector J80...

  • Page 166: Figure 10-8. O3 Dash-Mount Radio Connector Locations (Mid Power Only)

    10-8 Functional Block Diagrams and Connectors: XTL 5000 O3 Radio Connector Locations 10.8 XTL 5000 O3 Radio Connector Locations 10.8.2 High Power Only 10.8.1 Mid Power Only 17’Extension Cable Figure 10-8. O3 Dash-Mount Radio Connector Locations (Mid Power Only) Figure 10-10. O3 Remote-Mount Radio Connector Locations (High Power Only) 17’Extension Cable Figure 10-9.

  • Page 167: Figure 10-11.O5 Dash-Mount Radio Connector Locations (Mid Power Only)

    Functional Block Diagrams and Connectors: XTL 5000 O5 Radio Connector Locations 10-9 10.9 XTL 5000 O5 Radio Connector Locations 10.9.2 High Power Only 10.9.1 Mid Power Only Figure 10-11. O5 Dash-Mount Radio Connector Locations (Mid Power Only) Figure 10-13. O5 Remote-Mount Radio Connector Locations (High Power Only) Figure 10-12.

  • Page 168: Figure 10-14.Main Board Connector Locations - Side 1 (Mid Power Only)

    10-10 Functional Block Diagrams and Connectors: Board Level Connector Locations 10.10 Board Level Connector Locations 10.10.2High Power Only 10.10.1Mid Power Only Front Edge Front Edge of Board of Board Figure 10-16. Main Board Connector Locations - Side 1 (High Power Only) Figure 10-14.

  • Page 169: Figure 10-18.Control Head 50-Pin Connector

    Functional Block Diagrams and Connectors: O5 Control Head Connectors 10-11 10.11 O5 Control Head Connectors 10.11.1For Mid Power Models 10.11.2For High Power Models Figure 10-18 illustrates the pin arrangement and associated signals and voltages for the 50-pin control head Figure 10-19 illustrates the pin arrangement and associated signals and voltages for the 60-pin control head connector.
  • Page 170 10-12 Functional Block Diagrams and Connectors: O5 Control Head Connectors Notes October 30, 2006 6871769L01-A...

  • Page 171: Table 11-1. Table Of Exploded Views

    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 172: Figure 11-1. Xtl 5000 O3 Control Head Exploded View

    Exploded Views and Parts Lists: XTL 5000 O3 Control Head Exploded View 11.1 XTL 5000 O3 Control Head Exploded View Table 11-2. XTL 5000 O3 Control Head Parts List Item No. Quantity Motorola Part No. Description PMHN4082_ Housing, Front, Service Kit PMHN4083_ Housing, Back, Service Kit (includes O-ring [qty.

  • Page 173: Figure 11-2. Xtl 5000 O5 Control Head Exploded View

    Exploded Views and Parts Lists: XTL 5000 O5 Control Head Exploded View 11-3 11.2 XTL 5000 O5 Control Head Exploded View Table 11-3. XTL 5000 O5 Control Head Parts List Item No. Quantity Motorola Part No. Description 3664445H01 KNOB, Mode 3664022H01 KNOB, Volume...

  • Page 174: Figure 11-3. Chib And Chuc Exploded View

    11-4 Exploded Views and Parts Lists: CHIB & CHUC Exploded View 11.3 CHIB & CHUC Exploded View Table 11-4. CHIB and CHUC Parts List Item No. Motorola Part No. Description HLN1467_ Control Head HKN6191_ Flex Assembly 0310944A14 Screw 0764091H01 Retainer Bracket...

  • Page 175: Figure 11-4. Transceiver Interface Board (Tib) Exploded View

    11-4) represents the interface board for all remote mount configurations, for both mid power and high power transceivers (only the flex changes depending on mid power or high power transceiver). Table 11-5. Transceiver Interface Board (TIB) Parts List Item No. Motorola Part No. Description 1564119H01 Housing, Remote Front...

  • Page 176: Figure 11-5. Xtl 5000 O3 Radio Exploded View

    11-6 Exploded Views and Parts Lists: XTL 5000 O3 Radio Exploded View 11.5 XTL 5000 O3 Radio Exploded View Table 11-6. XTL 5000 Dash Mount Radio Parts List Item No. Motorola Part No. Description 0385870E01 SCREW ASSEMBLY, TOP COVER 1585860C02...

  • Page 177: Figure 11-6. Xtl 5000 O5 Dash Mount Radio Exploded View

    Exploded Views and Parts Lists: XTL 5000 O5 Dash Mount Radio Exploded View 11-7 11.6 XTL 5000 O5 Dash Mount Radio Exploded View Table 11-7. XTL 5000 Dash Mount Radio Parts List Item No. Motorola Part No. Description 0385870E01 SCREW ASSEMBLY, TOP COVER 1585860C02...

  • Page 178: Figure 11-7. Xtl 5000 O5 Mid Power Remote Mount Radio Exploded View

    Exploded Views and Parts Lists: XTL 5000 O5 Mid-Power Remote Mount Radio Exploded View 11.7 XTL 5000 O5 Mid-Power Remote Mount Radio Exploded View Table 11-8. XTL 5000 Mid Power Remote Mount Radio Parts List Item No. Motorola Part No. Description 0364332H02 FRONT HOUSING SCREW ASSEMBLY PMUN1036_...

  • Page 179: Figure 11-8. Xtl 5000 100 W Remote Mount Radio Exploded View

    Exploded Views and Parts Lists: XTL 5000 100 W Remote Mount Radio Exploded View 11-9 11.8 XTL 5000 100 W Remote Mount Radio Exploded View Table 11-9. XTL 5000 100 W Remote Mount Radio Parts List Item No. Motorola Part No. Description 0385870E01 SCREW ASSEMBLY, BOTTOM COVER 1564414H02...
  • Page 180 11-10 Exploded Views and Parts Lists: XTL 5000 100 W Remote Mount Radio Exploded View Notes October 30, 2006 6871769L01-A...
  • Page 181 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 182 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 183 The ASTRO Digital XTL 5000 mobile radio control head and transceiver was designed using Design for Environment (DfE) principles. • Motorola has used halogen-reduced printed circuit board material in the production of this product. • Motorola has used No-lead solder in the production of this product.
  • Page 184 Environmental Information: Notes October 30, 2006 6871769L01-A...
  • Page 185 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 186 Glossary-2 Term Definition 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. Controller Area Network protocol. The CAN cable is the remote communications cable which provides audio, data, and power signaling information between the Control head and the Transceiver.
  • Page 187 Glossary-3 Term Definition digital-to-analog Conversion of a digital signal to a voltage that is proportional to the input conversion value. See also A/D. digital-to-analog A device that converts digital data into analog signals. See also ADC. converter Digital Private-Line A type of digital communications that utilizes privacy call, as well as memory channel and busy channel lock out to enhance communication efficiency.
  • Page 188 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 189 SPI data line from a peripheral to the MCU. Master Out Slave In SPI data line from the MCU to a peripheral. See microcontroller unit. Motorola Digital Communications. MCU/DSP Interface internal to the microprocessor IC. See Megahertz. Megahertz One million cycles per second. Used especially as a radio-frequency unit.
  • Page 190 Glossary-6 Term Definition See outbound signaling word. OTAR See over-the-air rekeying. outbound signaling Data transmitted on the control channel from the central controller to the word subscriber unit. over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the radio.
  • Page 191 Glossary-7 Term Definition random access A type of computer memory that can be accessed randomly; that is, any memory byte of memory can be accessed without touching the preceding bytes. 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.
  • Page 192 Glossary-8 Term Definition Signal Qualifier An operating mode in which the radio is muted, but still continues to mode analyze receive data to determine RX signal type. softpot See software potentiometer. software Computer programs, procedures, rules, documentation, and data pertaining to the operation of a system. software A computer-adjustable electronic attenuator.
  • Page 193 Glossary-9 Term Definition UART See Universal Asynchronous Receiver Transmitter. Ultra-High Frequency. Universal A microchip with programming that controls a computer's interface to its Asynchronous attached serial devices. Receiver Transmitter Universal Crypto Module Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps. See Universal Serial Bus.
  • Page 194 Glossary-10 Notes October 30, 2006 6871769L01-A...
  • Page 195 Index Index dash-mount vehicle interface port ......3-16 daughtercard module ..........3-4 descriptions Numerics radio ..............1-1 disassembly/reassembly 700-800 MHz radio specifications ......lxvi introduction ............8-1 radio disassembly ............8-9 reassembly ............8-25 accessory connector, J2 ..........9-3 required tools and supplies ........8-1 advanced secure operation ........7-3 disclaimer information ...........ii alignment procedures...
  • Page 196 Index-ii I/O disclaimer ............9-14 operation advanced secure ........... 7-3 analog mode ............3-23 ASTRO mode ............3-23 control head ............3-9 J2 accessory connector ..........9-3 conventional multikey ..........7-3 multikey ..............7-3 trunked multikey ............ 7-3 operational error codes ........... 9-17 ordering replacement parts ........
  • Page 197 Index-iii front-end ............3-26 ASTRO mode ............3-23 IF circuitry ............3-26 control head mixer ..............3-26 vehicle interface port dash-mount ..........3-16 front-end ............3-25 controller section ........... 3-2 IF circuitry ............3-25 daughtercard module mixer ..............3-25 FLASH IC ............3-4 recycling information, radio ........B-1 microprocessor ..........
  • Page 198 Index-iv Tx power characterization alignment ...... 6-11 types of signaling ............5-4 vehicle interface port dash-mount ............3-16 VHF radio specifications ..........lxiii view, exploded ..........11-6, 11-7 UHF Range 1 radio specifications ......lxiv UHF Range 2 radio specifications ......lxv universal crypto module (UCM) kits ......

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