Motorola ASTRO XTS 5000 Basic Service Manual
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Motorola ASTRO XTS 5000 Basic Service Manual

Digital portable radios
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ASTRO
XTS
VHF
UHF Range 1
UHF Range 2
700 — 800 MHz
Digital Portable Radios
Basic Service Manual
™
5000

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  • Page 1 ® ™ ASTRO 5000 UHF Range 1 UHF Range 2 700 — 800 MHz Digital Portable Radios Basic Service Manual...
  • Page 3 ASTRO XTS™ 5000 ® Title Page VHF/UHF Range 1/UHF Range 2/700–800 MHz Digital Portable Radios Basic Service Manual Motorola, Inc. 8000 West Sunrise Boulevard 6881094C28-D 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

    ASTRO XTS 5000 R (Ruggedized) VHF Model Chart ................xv ASTRO XTS 5000 UHF Range 1 Model Chart..................xvi ASTRO XTS 5000 R (Ruggedized) UHF Range 1 Model Chart ............. xvii ASTRO XTS 5000 UHF Range 2 Model Chart..................xviii ASTRO XTS 5000 R (Ruggedized) UHF Range 2 Model Chart .............. xix ASTRO XTS 5000 700–800 MHz Model Chart ..................xx...
  • Page 6 Table of Contents Chapter 2 Basic Maintenance.............. 2-1 General Maintenance........................2-1 Handling Precautions........................2-1 Chapter 3 Basic Theory of Operation ..........3-1 Major Assemblies........................... 3-1 Analog Mode of Operation ......................3-2 Digital (ASTRO) Mode of Operation ....................3-4 Transceiver Board.......................... 3-4 VOCON Board ..........................
  • Page 7 Surveillance Accessories.......................A-3 Switches ............................A-5 Vehicular Adapters ........................A-5 Appendix B Replacement Parts Ordering..........B-1 Basic Ordering Information ......................B-1 Transceiver Board and VOCON Board Ordering Information............B-1 Motorola Online ..........................B-1 Mail Orders ............................B-1 Telephone Orders..........................B-2 Fax Orders.............................B-2 Parts Identification .........................B-2 Product Customer Service......................B-2 6881094C28-D...
  • Page 8 Table of Contents Glossary ..................Glossary-1 Index ..................... Index-1 July 16, 2004 6881094C28-D...
  • Page 9 List of Tables List of Tables Table 1-1. ASTRO XTS 5000 Basic Features..................1-2 Table 3-1. Local Oscillator and First IF Frequencies ................3-4 Table 4-1. Recommended Test Equipment.................... 4-1 Table 4-2. Service Aids .......................... 4-2 Table 5-1. Initial Equipment Control Settings..................5-2 Table 5-2.
  • Page 10 viii List of Figures List of Figures Figure 3-1. XTS 5000 Overall Block Diagram ..................3-1 Figure 3-2. Receiver Block Diagram......................3-2 Figure 3-3. Transceiver (VHF) Block Diagram (Power and Control Omitted).......... 3-3 Figure 3-4. Transceiver (UHF Range 1, UHF Range 2, and 700–800 MHz) Block Diagram (Power and Control Omitted)3-3 Figure 3-5.

  • Page 11: 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 12: 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 13: 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 14 Commercial Warranty Notes July 16, 2004 6881094C28-D...

  • Page 15: Model Numbering, Charts, And Specifications

    Model Numbering, Charts, and Specifications Portable Radio Model Numbering System Typical Model Number: Position: 12 13 Position 1 - Type of Unit Positions 13 - 16 H = Hand-Held Portable SP Model Suffix Position 12 - Unique Model Variations Positions 2 & 3 - Model Series C = Cenelec 18 = XTS 5000 N = Standard Package...

  • Page 16: Astro Xts 5000 Vhf Model Chart

    Portable Radio Model Numbering System ASTRO XTS 5000 VHF Model Chart MODEL NUMBER DESCRIPTION H18KEC9PW5AN VHF 1-6 Watts ASTRO XTS 5000 Model I H18KEF9PW6AN VHF 1-6 Watts ASTRO XTS 5000 Model II H18KEH9PW7AN VHF 1-6 Watts ASTRO XTS 5000 Model III...

  • Page 17: Astro Xts 5000 R (Ruggedized) Vhf Model Chart

    H18KEH9PW7AN w/Q155FG Opt Ruggedized VHF 1-6 Watts ASTRO XTS 5000 Model III H18KEC9PW5AN w/Q155FS Opt Ruggedized Yellow VHF 1-6 Watts ASTRO XTS 5000 Model I H18KEF9PW6AN w/Q155FT Opt Ruggedized Yellow VHF 1-6 Watts ASTRO XTS 5000 Model II H18KEH9PW7AN w/Q155FU Opt...

  • Page 18: Astro Xts 5000 Uhf Range 1 Model Chart

    UHF Range 1, 1-5 Watts ASTRO XTS 5000 Model III H18QCC9PW5AN UHF Range 1, Low Power, 20 mW - 2 Watts ASTRO XTS 5000 Model I H18QCF9PW6AN UHF Range 1, Low Power, 20 mW - 2 Watts ASTRO XTS 5000 Model II...

  • Page 19: Astro Xts 5000 R (Ruggedized) Uhf Range 1 Model Chart

    Ruggedized Yellow UHF Range 1, 1-5 Watts ASTRO XTS 5000 Model III H18QCC9PW5AN wQ155HW Opt Ruggedized UHF R1, Low Pwr, 20 mW-2 Watts ASTRO XTS 5000 Model I H18QCF9PW6AN wQ155HX Opt Ruggedized UHF R1, Low Pwr, 20 mW-2 Watts ASTRO XTS 5000 Model II...

  • Page 20: Astro Xts 5000 Uhf Range 2 Model Chart

    ASTRO XTS 5000 UHF Range 2 Model Chart MODEL NUMBER DESCRIPTION H18SDC9PW5AN UHF Range 2, 1-5 Watts ASTRO XTS 5000 Model I H18SDF9PW6AN UHF Range 2, 1-5 Watts ASTRO XTS 5000 Model II H18SDH9PW7AN UHF Range 1, 1-5 Watts ASTRO XTS 5000 Model III...

  • Page 21: Astro Xts 5000 R (Ruggedized) Uhf Range 2 Model Chart

    Ruggedized Yellow UHF Range 2, 1-5 Watts ASTRO XTS 5000 Model I H18SDF9PW6AN w/Q155FZ Opt Ruggedized Yellow UHF Range 2, 1-5 Watts ASTRO XTS 5000 Model II H18SDH9PW7AN w/Q155GA Opt Ruggedized Yellow UHF Range 2, 1-5 Watts ASTRO XTS 5000 Model III ITEM NUMBER DESCRIPTION...

  • Page 22: Astro Xts 5000 700-800 Mhz Model Chart

    ASTRO XTS 5000 700–800 MHz Model Chart MODEL NUMBER DESCRIPTION H18UCC9PW5AN 700/800 MHz 1-3 Watts ASTRO XTS 5000 Model I H18UCF9PW6AN 700/800 MHz 1-3 Watts ASTRO XTS 5000 Model II H18UCH9PW7AN 700/800 MHz 1-3 Watts ASTRO XTS 5000 Model III...

  • Page 23: Astro Xts 5000 R (Ruggedized) 700-800 Mhz Model Chart

    Ruggedized Yellow 700/800 MHz 1-3 Watts ASTRO XTS 5000 Model I H18UCF9PW6AN w/Q155GC Opt Ruggedized Yellow 700/800 MHz 1-3 Watts ASTRO XTS 5000 Model II H18UCH9PW7AN w/Q155GD Opt Ruggedized Yellow 700/800 MHz 1-3 Watts ASTRO XTS 5000 Model III ITEM NUMBER DESCRIPTION...

  • Page 24: Specifications For Vhf Radios

    xxii Portable Radio Model Numbering System Specifications for VHF Radios All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted. GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT3804 Frequency Range: 136-174 MHz Frequency Range: 136-174 MHz Temperature Range: Operating: –30°C to +60°C Bandwidth: 38 MHz RF Power:...

  • Page 25: Specifications For Uhf Range 1 Radios

    Portable Radio Model Numbering System xxiii Specifications for UHF Range 1 Radios All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted. GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT4855 Frequency Range: 380-470 MHz Frequency Range: 380-470 MHz Temperature Range: Operating: –30°C to +60°C Bandwidth: 90 MHz...

  • Page 26: Specifications For Uhf Range 2 Radios

    xxiv Portable Radio Model Numbering System Specifications for UHF Range 2 Radios All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted. GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT4864 Frequency Range: 450-520 MHz Frequency Range: 450-520 MHz Temperature Range: Operating: –30°C to +60°C Bandwidth: 70 MHz...

  • Page 27: Specifications For 700-800 Mhz Radios

    Portable Radio Model Numbering System Specifications for 700–800 MHz Radios All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted. GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT5806 Frequency Range: Frequency Range: Temperature Range: 700 MHz: 764 to 767; 773 to 776 MHz 700 MHz: 764 to 767;...
  • Page 28 xxvi Portable Radio Model Numbering System Notes July 16, 2004 6881094C28-D...

  • Page 29: Chapter 1 Introduction

    Chapter 1 Introduction This manual contains information needed for Levels One and Two radio servicing. Level One servicing consists of radio programming, radio alignment, knobs replacement, and installation and removal of the antenna, belt clip, battery, and universal connector cover. Level Two servicing covers disassembly and reassembly of the radio to replace circuit boards.

  • Page 30: Radio Description

    VHF (136–174 MHz), UHF Range 1 (380–470 MHz), UHF Range 2 (450- 520 MHz), and 764-870 MHz frequency bands. The ASTRO XTS 5000 radio provides improved voice quality across more coverage area. The digital process, called embedded signaling, intermixes system signaling information with digital voice, resulting in improved system reliability and the capability of supporting a multitude of advanced features.

  • Page 31: Chapter 2 Basic Maintenance

    In order to avoid operating outside the limits set by the FCC, we recommend that you align the ASTRO XTS 5000 radio’s reference oscillator every time the radio is taken apart, or once per year, whichever comes first. Periodic visual inspection and cleaning is also recommended.
  • Page 32 Basic Maintenance: Handling Precautions • The XTS 5000 radio casting has two vent ports that allow for pressure equalization in the radio. Never poke these vents with any objects, such as needles, tweezers, or screwdrivers. This could create a leak path into the radio and, in the case of XTS 5000 R radios, the radio’s submergibility C a u t i o n will be lost.

  • Page 33: Chapter 3 Basic Theory Of Operation

    VHF (136–174 MHz), UHF Range 1 (380–470 MHz), UHF Range 2 (450-520 MHz), and 764 to 870 MHz frequency bands. All ASTRO XTS 5000 radios are capable of both analog operation (12.5 kHz or 25 kHz bandwidths) and ASTRO mode (digital) operation (12.5 kHz only).

  • Page 34: Analog Mode Of Operation

    Basic Theory of Operation: Analog Mode of Operation Analog Mode of Operation This section provides an overview of the analog mode receive and transmit theory of operation. 3.2.1 Receiving When the radio is receiving (See Figure 3-2), the signal comes from the antenna connector to the Transceiver board, passing through the antenna switch and the receiver front end.

  • Page 35: Figure 3-3. Transceiver (Vhf) Block Diagram (Power And Control Omitted)

    Basic Theory of Operation: Analog Mode of Operation 3.2.2 Transmitting When the radio is transmitting, microphone audio is passed through gain stages to the CODEC, where the signal is digitized. The CODEC passes digital data to the DSP, where pre-emphasis and low-pass (splatter) filtering are done.

  • Page 36: Digital (Astro) Mode Of Operation

    Basic Theory of Operation: Digital (ASTRO) Mode of Operation Transmitted signaling information is applied to the DSP from the microcontrol unit, where it is coded, and passed to the DAC, which handles it the same as a voice signal. The DAC output connects to the synthesizer modulation input.

  • Page 37: Vocon Board

    Basic Theory of Operation: VOCON Board VOCON Board The vocoder and controller (VOCON) board (See Figure 3-5) comprises the dual-core processor (Patriot), which contains the radio’s microcontrol unit (MCU) and digital signal processor (DSP) in a single integrated circuit (IC) package; its memory ICs; an audio and power supply IC (GCAP II); a digital support IC (Flipper);...
  • Page 38 Basic Theory of Operation: VOCON Board The digital support IC also monitors the position of the on/off switch and controls the shutdown of the regulators on the audio and power supply IC. Finally, the digital support IC interfaces to the radio’s universal (accessory) connector.

  • Page 39: Chapter 4 Recommended Test Equipment And Service Aids

    Chapter 4 Recommended Test Equipment and Service Aids This chapter provides lists of recommended test equipment and service aids, as well as information on field programming equipment that can be used in servicing and programming ASTRO XTS 5000 radios. Recommended Test Equipment...

  • Page 40: Service Aids

    “Appendix B Replacement Parts Ordering” on page B-1. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 4-2. Service Aids...

  • Page 41: Field Programming

    Recommended Test Equipment and Service Aids: Field Programming Field Programming This family of radios can be aligned and programmed in the field. This requires specific equipment and special instructions. Refer to the online help in the Customer Programming Software (CPS) for complete field programming information.
  • Page 42 Recommended Test Equipment and Service Aids: Field Programming Notes July 16, 2004 6881094C28-D...

  • Page 43: Chapter 5 Performance Checks

    Chapter 5 Performance Checks This chapter covers performance checks used to ensure that the ASTRO XTS 5000 radio meets published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the test equipment must be maintained in compliance with the manufacturer’s recommended calibration...

  • Page 44: Display Radio Test Mode (Models Ii And Iii)

    Performance Checks: Display Radio Test Mode (Models II and III) Initial equipment control settings should be as indicated in Table 5-1 and should be the same for all performance checks and alignment procedures, except as noted. Table 5-1. Initial Equipment Control Settings System Analyzer Test Set Power Supply...
  • Page 45 5.2.2 RF Test Mode When the ASTRO XTS 5000 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment using a special routine, called RF TEST MODE.

  • Page 46: Table 5-3. Test Frequencies (Mhz)

    Performance Checks: Display Radio Test Mode (Models II and III) While in RF test mode: • Each additional press of Side Button 2 advances to the next test channel. (Refer to Table 5-3.) • Pressing Side Button 1 scrolls through and accesses the test environments shown in Table 5-4.
  • Page 47 Performance Checks: Display Radio Test Mode (Models II and III) 5.2.3 Control Top and Keypad Test Mode This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected. 5.2.3.1 Control Top Checks To perform the control top checks: 1.

  • Page 48: Non-Display Radio Test Mode (Model I)

    5.3.2 RF Test Mode When the ASTRO XTS 5000 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment via a special routine, called RF TEST MODE.

  • Page 49: Receiver Performance Checks

    Performance Checks: Receiver Performance Checks 3. Press the Top Button again; the radio beeps, indicating that the Top Button is in the closed position. 4. Rotate the Two-Position Concentric Switch; the radio beeps in each switch position. 5. Rotate the 16-Position Select Switch; the radio beeps in each switch position. 6.

  • Page 50: Transmitter Performance Checks

    Performance Checks: Transmitter Performance Checks Table 5-6. Receiver Tests for ASTRO Conventional Channels* Test Name System Analyzer Radio Test Set Comments Bit Error rate Mode: Proj 25 Std Radio Tuner PTT to OFF BER < 0.01% (BER) Floor RF Control: Gen Software (Bit Error (center) (Use test setup shown in...

  • Page 51: Table 5-8. Transmitter Tests For Astro Conventional Channels

    Performance Checks: Transmitter Performance Checks Table 5-7. Transmitter Performance Checks (Continued) Test Name System Analyzer Radio Test Set Comments Voice As above. Set fixed 1 kHz As above As above Deviation: (12.5 kHz) ≥ 2.1 kHz, but Modulation audio level to 400 mV. ≤...
  • Page 52 5-10 Performance Checks: Transmitter Performance Checks Table 5-8. Transmitter Tests for ASTRO Conventional Channels* (Continued) Test Name System Analyzer Radio Test Set Comments Frequency As above Radio Tuner PTT to OFF HIGH ≥ 2.543 kHz but Deviation Software (center) ≤ 3.110 kHz (Transmitter Test Pattern screen) is ≥...

  • Page 53: Chapter 6 Radio Alignment Procedures

    Chapter 6 Radio Alignment Procedures This chapter describes both receiver and transmitter radio alignment procedures. Test Setup A personal computer (PC) and tuner software are required to align the radio. Refer to the applicable manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC and to a universal test set.

  • Page 54: Tuner Main Menu

    Radio Alignment Procedures: Tuner Main Menu Tuner Main Menu Select Tuner from the START menu. To read the radio, use the File Read Device menu or click Figure 6-2 illustrates how the alignment screens are organized. To access a screen, double- click on the desired screen name in the Tuner menu.

  • Page 55: Softpot

    Radio Alignment Procedures: Softpot Softpot The alignment screens introduce the concept of the “softpot,” an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls. DO NOT switch radios in the middle of any alignment procedure. Always left-click the Close button on the screen to return to the Main Menu screen before disconnecting the radio.

  • Page 56: Radio Information

    Radio Alignment Procedures: Radio Information Radio Information Figure 6-4 shows a typical Radio Information screen. This screen is informational only and cannot be directly changed. Figure 6-4. Radio Information Screen Reference Oscillator Alignment Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will result not only in poor operation, but also in a misaligned radio that will interfere with other users operating on adjacent channels.

  • Page 57: Table 6-1. Reference Oscillator Alignment

    Radio Alignment Procedures: Reference Oscillator Alignment - Type 7.1 followed by SPCL button to set the 8901B_ modulation analyzer for maximum accuracy. To align the reference oscillator: 1. Select the Reference Oscillator alignment screen. See Figure 6-5. Figure 6-5. Reference Oscillator Alignment Screen 2.

  • Page 58: Transmit Power Alignment

    Radio Alignment Procedures: Transmit Power Alignment Transmit Power Alignment This alignment procedure adjusts the transmit power of the radio and must be performed for three different power levels (Low, Mid, and High), at multiple frequencies for each power level, to allow for proper alignment across the entire RF band.

  • Page 59: Transmit Deviation Balance Alignment

    Radio Alignment Procedures: Transmit Deviation Balance Alignment Figure 6-6. Transmit Power Alignment Screen (Typical) Transmit Deviation Balance Alignment This alignment procedure balances the modulation contributions of the low- and high-frequency portions of a baseband signal. Proper alignment is critical to the operation of signalling schemes that have very low frequency components (for example, DPL) and could result in distorted waveforms if improperly adjusted.

  • Page 60: Figure 6-7. Transmit Deviation Balance Alignment Screen

    Radio Alignment Procedures: Transmit Deviation Balance Alignment - 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 61: Transmit Deviation Limit Alignment

    Radio Alignment Procedures: Transmit Deviation Limit Alignment 7. 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. 8.

  • Page 62: Figure 6-8. Transmit Deviation Limit Alignment Screen

    6-10 Radio Alignment Procedures: Transmit Deviation Limit Alignment Figure 6-8. Transmit Deviation Limit Alignment Screen 4. Left-click the desired frequency field (starting with the highest frequency shown). 5. 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.

  • Page 63: Front End Filter Alignment

    Radio Alignment Procedures: Front End Filter Alignment 6-11 Front End Filter Alignment This procedure should only be attempted by qualified service technicians. C a u t i o n This alignment procedure adjusts the front end receiver bandpass filters for the best receiver sensitivity and selectivity.

  • Page 64: 6.10 Bit Error Rate

    6-12 Radio Alignment Procedures: Bit Error Rate Figure 6-9. Front End Filter Alignment Screen 6.10 Bit Error Rate This section describes the Bit Error Rate (BER) test of the radio’s receiver at a desired frequency (see Figure 6-10 on page 6-13).

  • Page 65: Figure 6-10. Bit Error Rate Screen

    Radio Alignment Procedures: Bit Error Rate 6-13 The bit error rate screen contains the following fields: • Rx Frequency: This field selects the Receive Frequency directly in MHz. • Test Pattern: This field selects the Digital test pattern — TIA. Choices are: Standard Tone Test Pattern (Framed 1011) and Standard Interface Test Pattern (CCITT V.52).

  • Page 66: 6.11 Transmitter Test Pattern

    6-14 Radio Alignment Procedures: Transmitter Test Pattern 6.11 Transmitter Test Pattern The Transmitter Test Pattern test is used to transmit specific test patterns at a desired frequency so that the user can perform tests on the radio’s transmitter (see Figure 6-11).

  • Page 67: Chapter 7 Encryption

    Chapter 7 Encryption This chapter provides procedures for using the encryption capability of your radio. The following procedures are outlined: • Loading an encryption key • Selecting an encryption key • Selecting an Index • Erasing an encryption key Load an Encryption Key To load an encryption key: 1.

  • Page 68: Select An Encryption Index

    Encryption: Select an Encryption Index 4. Press D, E, or F directly below the desired menu. • PSET = selects the preset or default encryption key. • SEL = saves the newly selected key and returns to the home display. 5.

  • Page 69: Erase An Encryption Key

    Encryption: Erase an Encryption Key b. To exit this menu without changing the index selection, press h or the PTT button, or turn the 16-Position Select knob. 7.4.2 Use the Keypad To select an index using the keypad: 1. Press U until the display shows “INDX.” 2.
  • Page 70 Encryption: Erase an Encryption Key 7.5.2 Method 2—All Keys Erased To erase all encryption keys at one time: With the radio on, press and hold the Top Side button and, while holding this button down, press the Top button. NOTE: DO NOT press the Top button before pressing the Top Side button unless you are in an emergency situation.

  • Page 71: Chapter 8 Disassembly/Reassembly Procedures

    Chapter 8 Disassembly/Reassembly Procedures This chapter provides detailed procedures for disassembling/reassembling XTS 5000 radios, and ensuring the submergibility of ruggedized radios. When performing these procedures, refer to “Chapter 10: Exploded Views and Parts Lists” on page 10-1 and the diagrams that accompany the text.

  • Page 72: Figure 8-1. Xts 5000 Partial Exploded View

    Disassembly/Reassembly Procedures: XTS 5000 Exploded View (Partial) Alignment Tabs Alignment Notch MAEPF-27211-A Figure 8-1. XTS 5000 Partial Exploded View July 16, 2004 6881094C28-D...

  • Page 73: Table 8-1. Xts 5000 Partial Exploded View Parts List

    Disassembly/Reassembly Procedures: XTS 5000 Exploded View (Partial) Table 8-1. XTS 5000 Partial Exploded View Parts List Item Motorola Description Number Part Number 3305630Z01 LABEL, Motorola Bottom 3285757D01 MEMBRANE, Microphone Front 3385221D01 LABEL, Motorola, Front 1505579Z01 COVER, Universal Connector 3605371Z01 KNOB, Volume...

  • Page 74: Antenna

    Disassembly/Reassembly Procedures: Antenna Antenna This section explains how to attach and remove the antenna. 8.2.1 Attach the Antenna To attach the antenna: With the radio turned off, turn the antenna clockwise to attach it to the radio. Figure 8-2. Attaching the Antenna 8.2.2 Remove the Antenna To remove the antenna:...

  • Page 75: Battery

    C a u t i o n NOTE: The Motorola-approved battery shipped with the XTS 5000 radio is uncharged. Prior to using a new battery, charge it for a minimum of 16 hours to ensure optimum capacity and performance.

  • Page 76: Figure 8-6. Pressing The Release Button

    Disassembly/Reassembly Procedures: Battery 8.3.2 Remove the Battery To remove the battery: 1. With the radio turned off, press the release button on the bottom of the battery until the bat- tery releases from the radio. Figure 8-6. Pressing the Release Button 2.

  • Page 77: Belt Clip

    Disassembly/Reassembly Procedures: Belt Clip Belt Clip This section explains how to attach and remove the belt clip. NOTE: The battery must be removed from the radio before the belt clip can be installed or removed. 8.4.1 Attach the Belt Clip To attach the belt clip: 1.

  • Page 78: Universal Connector Cover

    Disassembly/Reassembly Procedures: Universal Connector Cover Universal Connector Cover This section explains how to remove and attach the universal connector cover. When the universal connector is not in use, keep it covered with the universal connector cover. C a u t i o n 8.5.1 Remove the Universal Connector Cover To remove the universal connector cover:...

  • Page 79: Figure 8-14. Hooking The End Into The Slot

    Disassembly/Reassembly Procedures: Universal Connector Cover 8.5.2 Attach the Universal Connector Cover To attach the universal connector cover: 1. Insert the hooked end of the cover into the slot above the connector. Press downward on the cover’s top to seat it in the slot. Slot Hooked End Figure 8-14.

  • Page 80: Frequency Knob

    8-10 Disassembly/Reassembly Procedures: Frequency Knob Frequency Knob This section explains how to remove and attach the frequency knob. 8.6.1 Remove the Frequency Knob To remove the frequency knob: 1. Hold the radio in one hand so that the top of the radio faces upward, and the front of the radio faces you.

  • Page 81: Volume Knob

    Disassembly/Reassembly Procedures: Volume Knob 8-11 Volume Knob This section explains how to remove and install the volume knob. NOTES: • Refer to Figure 8-1 on page 8-2, the Partial Exploded View, and Table 8-1 on page 8-3, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 8-1 Table 8-1.

  • Page 82: Radio Disassembly

    8-12 Disassembly/Reassembly Procedures: Radio Disassembly Radio Disassembly This section contains instructions for disassembling the radio. 8.8.1 Separate the Casting and Housing Assemblies To separate the housing assembly from the casting assembly: 1. Turn off the radio by rotating the On/Off/Volume control fully counterclockwise until you hear a click.
  • Page 83 Disassembly/Reassembly Procedures: Radio Disassembly 8-13 NOTE: If the radio is equipped with hardware encryption, the encryption board (45) is attached to the back side of the VOCON board via a 40-pin connector. When the VOCON board is lifted out of the casting, the encryption board is removed with it. 9.

  • Page 84: Radio Reassembly

    8-14 Disassembly/Reassembly Procedures: Radio Reassembly Radio Reassembly This section contains instructions for reassembling the radio. 8.9.1 Reassemble the Housing Assembly To reassemble the housing assembly: 1. Inspect the housing seal surfaces for debris. Remove any debris. 2. Install the controls seal (35). 3.
  • Page 85 Disassembly/Reassembly Procedures: Radio Reassembly 8-15 6. Plug the coaxial cable’s connector (52) into the transceiver board’s (48) surface-mount con- nector, making sure to lead the coax’s connector straight into the surface-mount connector. An angled lead-in can damage the surface-mount connector or the center of the coax. 7.

  • Page 86: 8.10 Ensuring Radio Submergibility

    The pressure pump kit includes a pressure pump with gauge, and a pressure hose; the pressure pump kit is also used on Motorola ASTRO SABER R radio models. As with the vacuum pump kit above, the NTN9279A adapter connects the pressure hose to the radio's casting.
  • Page 87 Other items needed for testing the submersible radio include: • Large water container • Deionized (DI) water • A supply of replacement seals, O-rings, and gaskets (refer to the ASTRO XTS 5000 R exploded view parts list) 8.10.5 Disassembly Disassemble the radio according to Section “8.8.1 Separate the Casting and Housing Assemblies”...
  • Page 88 8-18 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility 8.10.7 Vacuum Test The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly sealed, watertight unit.
  • Page 89 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility 8-19 8.10.8 Pressure Test Pressure testing the radio is necessary only if the radio has failed the vacuum test. Do not perform the pressure test until the vacuum test has been completed. Pressure testing involves creating a positive pressure condition inside the radio, submerging the radio in water, and observing the radio for a stream of bubbles (leak).
  • Page 90 8-20 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility To avoid equipment damage, keep the area around the port seal dry by ensuring that there is no water around the casting’s vacuum port. C a u t i o n 10. Remove the adapter and pressure hose added in steps 1 and 2, above. 11.
  • Page 91 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility 8-21 4. Install new antenna bushing gasket (54). 5. Install a new main seal O-ring (55) around the casting assembly (51). 6. Reassemble the housing assembly (2) to the radio. 7. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal O-ring is not pinched between the housing (2) and the casting (51).
  • Page 92 8-22 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility 8.10.9.4 Frequency Switch, Toggle, and On/Off/Volume Control Switch To replace the frequency switch, toggle, and On/Off volume control switch: 1. Referring to Section “8.8.1 Separate the Casting and Housing Assemblies” on page 8-12, remove the housing assembly (2) from the radio. 2.
  • Page 93 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility 8-23 8.10.9.5 Main Seal To replace the main seal: 1. Referring to Section “8.8.1 Separate the Casting and Housing Assemblies” on page 8-12, remove the housing assembly (2) from the radio. 2. Remove and discard the main seal (55). 3.

  • Page 94: Table 8-2. Submersible Radio Torque Specifications

    8-24 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility 5. Install a new main seal O-ring (55) around the casting assembly (51). 6. Reassemble the housing assembly (2) to the radio. 7. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal O-ring is not pinched between the housing (2) and the casting (51).

  • Page 95: Chapter 9 Basic Troubleshooting

    Level one and two troubleshooting will support only radio alignment, programming, battery replacement, and knob replacement, and circuit board replacement. Component-level service information can be found in the “ASTRO XTS 5000 Portable Radios Detailed Service Manual,” Motorola publication number 68P81094C31.

  • Page 96: Operational Error Codes

    Basic Troubleshooting: Operational Error Codes Table 9-1. Power-Up Error Code Displays (Continued) Error Description Corrective Action Code 09/10 Secure Hardware Error Turn the radio off, then on 09/90 Secure Hardware Fatal Error Turn the radio off, then on Note: If the corrective action does not fix the failure, send the radio to the depot. Operational Error Codes During radio operation, the radio performs dynamic tests to determine if the radio is working properly.

  • Page 97: Transmitter Troubleshooting

    Basic Troubleshooting: Transmitter Troubleshooting Table 9-3. Receiver Troubleshooting Chart (Continued) Correction or Test Symptom Possible Cause (Measurements at Room Temperature) Audio Distorted or Not Loud Synthesizer Not On Check synthesizer frequency by measuring the Enough Frequency transmitter frequency; realign if off by more than ±1000 Hz RF Sensitivity Poor 1.

  • Page 98: Encryption Troubleshooting

    Basic Troubleshooting: Encryption Troubleshooting Encryption Troubleshooting Table 9-5 lists the possible causes of, and corrections for, encryption problems. Table 9-5. Encryption Troubleshooting Chart Symptom Possible Cause Corrective Action KEYLOAD No “ ” on Radio Display When 1. Defective Keyload Cable Send radio to depot Keyloading Cable is Attached to the Radio 2.
  • Page 99 &KDSWHU  ([SORGHG 9LHZV DQG 3DUWV /LVWV 7KLV FKDSWHU FRQWDLQV H[SORGHG YLHZV DQG DVVRFLDWHG SDUWV OLVWV IRU WKH $6752 ;76  GLJLWDO SRUWDEOH UDGLRV 7KH IROORZLQJ WDEOH OLVWV WKH H[SORGHG YLHZV IRU HDFK RI WKH ;76  UDGLR PRGHOV 7DEOH  ;76  ([SORGHG 9LHZV 9LHZ 3DJH 0RGHO , ([SORGHG 9LHZ...
  • Page 100  ([SORGHG 9LHZV DQG 3DUWV /LVWV 0RGHO , ([SORGHG 9LHZ  0RGHO , ([SORGHG 9LHZ MAEPF-27209-O )LJXUH  0RGHO , ([SORGHG 9LHZ $XJXVW   &'...
  • Page 101 ([SORGHG 9LHZV DQG 3DUWV /LVWV 0RGHO , ([SORGHG 9LHZ 3DUWV /LVW   0RGHO , ([SORGHG 9LHZ 3DUWV D‡r€Ã H‚‡‚…‚yhÃQh…‡Ã /LVW 9r†p…vƒ‡v‚ I‚ Iˆ€ir… "% #!'$#9 S@U6DI@SÃTƒrhxr… D‡r€Ã H‚‡‚…‚yhÃQh…‡Ã #!$%" a 8GDQ Ã8‚‡…‚yÃG‚pxvtÃh…‡Ã‚sÃv‡r€Ã#  9r†p…vƒ‡v‚ I‚ Iˆ€ir… #Ã…r„ˆv…rq !%'$$%&9 TCD@G9Ã8‚‡…‚yyr…ÃA…‚‡Ãvpyˆqr†Ãv‡r€†Ã#Ãhqà ""$%"a! G67@GÃH‚‡‚…‚yhÃ7‚‡‡‚€Ã‚v‡…v†vpÃh…‡Ã‚sÃ...
  • Page 102  ([SORGHG 9LHZV DQG 3DUWV /LVWV 0RGHOV ,, DQG ,,, ([SORGHG 9LHZ  0RGHOV ,, DQG ,,, ([SORGHG 9LHZ MAEPF-27210-O )LJXUH  0RGHOV ,, DQG ,,, ([SORGHG 9LHZ $XJXVW   &'...
  • Page 103 ([SORGHG 9LHZV DQG 3DUWV /LVWV 0RGHOV ,, DQG ,,, ([SORGHG 9LHZ 3DUWV /LVW   0RGHOV ,, DQG ,,, ([SORGHG 9LHZ D‡r€ H‚‡‚…‚yh D‡r€ H‚‡‚…‚yh 3DUWV /LVW 9r†p…vƒ‡v‚ 9r†p…vƒ‡v‚ I‚ Qh…‡ÃIˆ€ir… I‚ Qh…‡ÃIˆ€ir… " #'% %#6! 7PPUÃHvp…‚ƒu‚rÃ7‚‚‡Ãƒh…‡Ã‚sÃv‡r€Ã ' "!'$'&&7! T@6GÃQ‚…‡ D‡r€...
  • Page 104  ([SORGHG 9LHZV DQG 3DUWV /LVWV 0RGHOV ,, DQG ,,, ([SORGHG 9LHZ 3DUWV /LVW 1RWHV $XJXVW   &'...

  • Page 105: Appendix A Accessories

    Appendix A Accessories Motorola provides the following approved optional accessories to improve the productivity of the XTS 5000 portable radio. For a complete list of Motorola-approved antennas, batteries, and other accessories, visit the following web site: http://www.motorola.com/cgiss/index.shtml. Antennas NAD6563 136-174 MHz helical NAD6566 136-150.8 MHz helical...

  • Page 106: Carry Accessories

    Accessories: Carry Accessories Carry Accessories A.3.1 Belt Clips NTN8266 Belt clip kit, 2.25", plastic (compatible with clamshell batteries) NTN8460 Public Safety belt clip, 3.0”, metal (VHF use only) NTN9179 Combo, high-activity D clip (NTN9212) and high-activity belt loop (NTN9213) NTN9212 D clip, high-activity, swivel (for use with NTN9213) A.3.2 Belt Loops NTN8039...

  • Page 107: Surveillance Accessories

    Accessories: Surveillance Accessories Surveillance Accessories A.5.1 Earpieces BDN6664 Earpiece with standard earphone, beige BDN6665 Earpiece with extra-loud earphone (exceeds OSHA limits), beige BDN6666 Earpiece with volume control, beige BDN6667 Earpiece, mic and PTT combined, beige BDN6668 Earpiece, mic and PTT separate, beige BDN6669 Earpiece, mic and PTT combined, with extra-loud earphone (exceeds OSHA limits), beige...
  • Page 108 Accessories: Surveillance Accessories A.5.2 Headsets and Headset Accessories BDN6635 Heavy-duty VOX headset with noise-canceling boom mic (requires BDN6673 adapter cable) BDN6636 Heavy-duty VOX headset with throat mic (requires BDN6673 adapter cable) BDN6645 Noise-canceling boom mic headset with PTT on earcup BDN6673 Headset adapter cable (for use with BDN6635, BDN6636, and BDN6645)

  • Page 109: Switches

    Accessories: Switches ® A.5.5 CommPort Integrated Microphone/Receiver NTN1624 CommPort with palm PTT NTN1625 CommPort ear mic with PTT for noise levels up to 100 dB (requires BDN6676 adapter) NTN1663 CommPort ear mic with ring PTT for noise levels up to 100 dB (requires BDN6676 adapter) NTN1736 CommPort ear mic with snap-on side PTT for noise levels up to 100 dB...
  • Page 110 Accessories: Vehicular Adapters Notes July 16, 2004 6881094C28-D...

  • Page 111: Appendix B Replacement Parts Ordering

    Chart in the front of this manual, read the Transceiver Board or VOCON Board note, and include the proper information with your order. 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 112: Telephone Orders

    Replacement Parts Ordering: Telephone Orders Telephone Orders Radio Products Services Division* (United States and Canada) 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday (Chicago, U.S.A.) 1-800-422-4210 (International Orders) 1-847-538-8023 U.S. Federal Government Markets Division (USFGMD) 1-800-826-1913 Federal Government Parts - Credit Cards Only 8:30 AM to 5:00 PM (Eastern Standard Time) Fax Orders Radio Products Services Division*...
  • Page 113 Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products. Term Definition See analog-to-digital conversion. Abacus IC A custom integrated circuit providing a digital receiver intermediate frequency (IF) backend.
  • Page 114 Glossary-2 Term Definition codeplug Firmware that contains the unique personality for a system or device. A codeplug is programmable and allows changes to system and unit parameters. See also firmware. coder/decoder A device that encodes or decodes a signal. See Customer Programming Software. Customer Software with a graphical user interface containing the feature set of an Programming...
  • Page 115 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 116 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 Patriot IC. See Megahertz. Megahertz One million cycles per second. Used especially as a radio-frequency unit.
  • Page 117 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. over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the radio.
  • Page 118 Glossary-6 Term Definition PROM See Programmable Read-Only Memory. See Push-to-Talk. Push-to-Talk The switch or button usually located on the left side of the radio which, when pressed, causes the radio to transmit. When the PTT is released, the unit returns to receive operation. radio frequency The portion of the electromagnetic spectrum between audio sound and infrared light (approximately 10 kHz to 10 GHz).
  • Page 119 Glossary-7 Term Definition See read-only memory. RPCIC Regulator/power control IC. RPT/TA See repeater/talkaround. See Radio Service Software. See real-time clock. Receive. RX DATA Recovered digital data line. See Serial Audio CODEC Port. SCI IN Serial Communications Interface Input line. Serial Audio CODEC SSI to and from the GCAP II IC CODEC used to transfer transmit and Port receive audio data.
  • Page 120 Glossary-8 Term Definition Standby mode An operating mode in which the radio is muted but still continues to monitor data. static RAM A type of memory used for volatile, program/data memory that does not need to be refreshed. Synchronous Serial DSP interface to peripherals that consists of a clock signal line, a frame Interface synchronization signal line, and a data line.
  • Page 121 Glossary-9 Term Definition vocoder An electronic device for synthesizing speech by implementing a compression algorithm particular to voice. See also voice encoder. vocoder/controller A PC board that contains an ASTRO radio’s microcontroller, DSP, memory, audio and power functions, and interface support circuitry. voice encoder The DSP-based system for digitally processing analog signals, and includes the capabilities of performing voice compression algorithms or...
  • Page 122 Glossary-10 Notes July 16, 2004 6881094C28-D...
  • Page 123 Index Index battery attaching 8-5 Numerics removing 8-6 types A-1 belt 700-800 MHz clips A-2 front end filter alignment 6-11 loops A-2 model chart belt clip non-ruggedized 4-xx attaching 8-7 ruggedized 4-xxi removing 8-7 radio specifications 4-xxv bit error rate test 6-12 buffer, VCO 3-4 Abacus III theory of operation 3-4 accessories...
  • Page 124 Index-2 entering test mode 5-2 RF test mode 5-3 test mode key, encryption test environments 5-4 erasing test frequencies 5-4 all keys 7-4 key zeroization 7-3 loading 7-1 selecting with keypad 7-2 selecting with menu 7-1 earpiece accessories A-3 knob encryption frequency index...
  • Page 125 Index-3 analog mode 3-2 ASTRO mode 3-4 reference oscillator alignment 6-4 parts, ordering replacement B-1 reference oscillator theory of operation 3-4 performance checks replacement parts, ordering B-1 receiver 5-7 RF exposure compliance information i-ii test setup 5-1 RF test mode transmitter 5-8 display radio 5-3 power amplifier theory of operation 3-4...
  • Page 126 Index-4 major assemblies 3-1 overview 3-1 receiver backend 3-4 reference oscillator 3-4 model chart synthesizer 3-4 non-ruggedized 4-xvi, 4-xviii transceiver (XCVR) board 3-4 ruggedized 4-xvii, 4-xix transmitter power amplifier 3-4 UHF Range 1 1-1, 1-2, 3-1, 3-3, 3-4, A-4 VCO 3-4 UHF Range 1 &...
  • Page 128 Motorola, Inc. 8000 West Sunrise Boulevard Ft. Lauderdale, FL 33322 MOTOROLA, the Stylized M Logo, ASTRO, FLASHport, and CommPort are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners.

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