Motorola Astro Digital Mobile Radio Xtl5000 Basic 6881096c73 O Manual

							Basic Service Manual
ASTRO®  
XTLTM 
5000
700–800 MHz
Digital Mobile Radio 
						

							Tit le Pag eASTRO® XTL™ 5000
700–800 MHz
Digital Mobile Radio
Basic Service Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322
6881096C73-O 
						

							Foreword
This manual covers all models of the ASTRO® XTL™ 5000 700–800 MHz Digital Mobile Radio (control head models W3, 
W4, W5, W7, and W9), unless otherwise specified. It includes all the information necessary to maintain peak product 
performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to 
the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.
For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A 
list of related publications is provided in the section, “Related Publications,” on page xii.
Product Safety and RF Exposure Compliance
ATTENTION!
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements. 
Before using this product, read the RF energy awareness information and operating instructions in the 
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 
6881095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site 
which lists approved accessories: http://www.motorola.com/cgiss/index.shtml
Manual Revisions
Changes which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs provide 
complete replacement pages for all added, changed, and deleted items. To obtain FMRs, go to
https://businessonline.motorola.com
.
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored in 
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain 
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in 
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the 
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in 
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not 
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or 
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the 
sale of a product.
Document Copyrights
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.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is 
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve 
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product 
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA, the Stylized M logo, ASTRO, and FLASHport are registered in the US Patent & Trademark Office. All other 
product or service names are the property of their respective owners.
© Motorola, Inc. 2003.
Before using this product, read the operating instructions 
for safe usage contained in the Product Safety and RF 
Exposure booklet enclosed with your radio.
!
C a u t i o n 
						

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6881096C73-OJune 11, 2003
Table of Contents
Foreword .........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ ii
Manual Revisions ........................................................................................................................................ ii
Computer Software Copyrights ................................................................................................................... ii
Document Copyrights .................................................................................................................................. ii
Disclaimer .................................................................................................................................................... ii
Trademarks ................................................................................................................................................. ii
Commercial Warranty .................................................................................xiii
Limited Warranty ...................................................................................................................................... xiii
MOTOROLA COMMUNICATION PRODUCTS .............................................................................. xiii
I. What This Warranty Covers And For How Long ................................................................... xiii
II. General Provisions ............................................................................................................... xiii
III. State Law Rights ................................................................................................................. xiv
IV. How To Get Warranty Service ............................................................................................ xiv
V. What This Warranty Does Not Cover................................................................................... xiv
VI. Patent And Software Provisions .......................................................................................... xv
VII. Governing Law .................................................................................................................... xv
Model Numbering, Charts, and Specifications ........................................xvii
Mobile Radio Model Numbering Scheme ................................................................................................ xvii
ASTRO XTL 5000 Motorcycle 3.5–35 Watt Model Chart ....................................................................... xviii
ASTRO XTL 5000 3.5–35 Watt Model Chart............................................................................................ xix
700–800 MHz Radio Specifications.......................................................................................................... xxi
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual ...................................................................................................... 1-1
1.2 Radio Description .......................................................................................................................... 1-1
1.3 FLASHport
®................................................................................................................................... 1-2
1.4 Control Head Descriptions ............................................................................................................. 1-2
1.4.1 W3 Control Head .............................................................................................................. 1-3
1.4.2 W3 Controls ...................................................................................................................... 1-3
1.4.3 W4, W5, W7, and W9 Controls Heads ............................................................................. 1-4
1.4.4 W4, W5, W7, and W9 Controls ......................................................................................... 1-5
Chapter 2 Basic Maintenance .............................................................. 2-1
2.1 Introduction .................................................................................................................................... 2-1
2.2 Preventive Maintenance ................................................................................................................ 2-1
2.2.1 Inspection ......................................................................................................................... 2-1
2.2.2 Cleaning............................................................................................................................ 2-1
2.2.2.1 Cleaning External Plastic Surfaces.......................................................................... 2-1 
						

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2.2.2.2 Cleaning Internal Circuit Boards and Components .................................................. 2-2
2.2.3 General Radio Care and Handling Precautions ................................................................ 2-2
2.2.4 RF Power Amplifier (RF PA) Heatsinking ......................................................................... 2-2
2.3 Handling Precautions ..................................................................................................................... 2-2
Chapter 3 Basic Theory of Operation ................................................. 3-1
3.1 Introduction .................................................................................................................................... 3-1
3.2 General Overview .......................................................................................................................... 3-1
3.3 Controller Section .......................................................................................................................... 3-2
3.3.1 Introduction ....................................................................................................................... 3-2
3.3.2 Location ............................................................................................................................ 3-2
3.4 Daughtercard Module .................................................................................................................... 3-2
3.4.1 Microprocessor ................................................................................................................. 3-3
3.4.2 FLASH IC .......................................................................................................................... 3-3
3.4.3 SRAM IC ........................................................................................................................... 3-3
3.5 Surrounding Controller Region ...................................................................................................... 3-3
3.5.1 Introduction ....................................................................................................................... 3-3
3.5.2 Voltage Regulation............................................................................................................ 3-4
3.5.3 Emergency ........................................................................................................................ 3-4
3.5.4 Front and Rear Connectors .............................................................................................. 3-4
3.5.4.1 Audio ........................................................................................................................ 3-5
3.5.4.2 Program Cable ......................................................................................................... 3-5
3.5.4.3 SB9600 .................................................................................................................... 3-5
3.5.4.4 VIP ........................................................................................................................... 3-5
3.5.4.5 RS232 ...................................................................................................................... 3-5
3.5.4.6 One-Wire.................................................................................................................. 3-5
3.6 Analog Mode of Operation ............................................................................................................. 3-6
3.6.1 Receive Operation ............................................................................................................ 3-6
3.6.2 Transmit Operation ........................................................................................................... 3-6
3.7 ASTRO Mode of Operation ............................................................................................................ 3-6
3.8 Control Head Assembly ................................................................................................................. 3-6
3.8.1 Display (W4, W5, and W7 Control Heads) ........................................................................ 3-6
3.8.2 Display (W9 Control Head) ............................................................................................... 3-7
3.8.3 Vacuum Fluorescent (VF) Display Driver.......................................................................... 3-7
3.8.4 Vacuum Fluorescent (VF) Voltage Source (W9)............................................................... 3-7
3.8.5 Controls and Indicators ..................................................................................................... 3-7
3.8.6 Status LEDs ...................................................................................................................... 3-7
3.8.7 Backlight LEDs.................................................................................................................. 3-7
3.8.8 Vehicle Interface Port (VIP) ..............................................................................................3-8
3.8.8.1 Remote-Mount ......................................................................................................... 3-8
3.8.8.2 Dash-Mount ............................................................................................................. 3-8
3.8.9 Control-Head Power Supplies........................................................................................... 3-8
3.8.9.1 W3 Control Head ..................................................................................................... 3-8
3.8.9.2 W4 Control Head ..................................................................................................... 3-8
3.8.9.3 W5, W7, W9 Control Heads ..................................................................................... 3-8
3.8.10 Ignition Sense Circuits ...................................................................................................... 3-8
3.9 Radio-Frequency Power Amplifier (RF PA) and Output Network (ON) ......................................... 3-9
3.9.1 Gain Stages ...................................................................................................................... 3-9
3.9.2 Power Control ................................................................................................................... 3-9
3.9.3 Circuit Protection............................................................................................................... 3-9
3.9.4 DC Interconnect ................................................................................................................ 3-9
3.10 700–800 Receiver Overview ........................................................................................................ 3-10 
						

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3.10.1 Receiver Front-End......................................................................................................... 3-10
3.10.2 Mixer ............................................................................................................................... 3-10
3.10.3 IF Circuitry ...................................................................................................................... 3-10
3.10.4 Abacus III Back-End .......................................................................................................3-10
3.11 Frequency Generation Unit (FGU)............................................................................................... 3-11
Chapter 4 Test Equipment, Service Aids, and Tools......................... 4-1
4.1 Recommended Test Equipment .................................................................................................... 4-1
4.2 Service Aids and Recommended Tools......................................................................................... 4-2
4.3 Field Programming Equipment ...................................................................................................... 4-3
4.3.1 XTL 5000 Field Programming ........................................................................................... 4-3
4.3.1.1 Dash-Mounted Radios ............................................................................................. 4-3
4.3.1.2 Remote-Mounted Radios ......................................................................................... 4-4
4.3.1.3 Field-Programming Items ........................................................................................ 4-4
4.3.1.4 W3 Control-Head Error Message ............................................................................ 4-4
Chapter 5 Performance Checks .......................................................... 5-1
5.1 Introduction .................................................................................................................................... 5-1
5.2 Test Setup ..................................................................................................................................... 5-1
5.3 Test Mode ...................................................................................................................................... 5-1
5.3.1 Entering Test Mode .......................................................................................................... 5-1
5.3.2 RF Test Mode ................................................................................................................... 5-3
5.3.3 Control Head Test Mode................................................................................................... 5-4
5.4 Receiver Performance Checks ...................................................................................................... 5-5
5.5 Transmitter Performance Checks .................................................................................................. 5-6
Chapter 6 Radio Alignment Procedures ............................................. 6-1
6.1 Introduction .................................................................................................................................... 6-1
6.2 ASTRO XTL 5000 Tuner Software ................................................................................................6-1
6.3 Radio Information .......................................................................................................................... 6-3
6.4 Transmitter Alignments .................................................................................................................. 6-3
6.4.1 PA Bias 1 Alignment ......................................................................................................... 6-3
6.4.2 PA Bias 2 Alignment ......................................................................................................... 6-4
6.4.3 PA Bias 3 Alignment ......................................................................................................... 6-5
6.4.4 Reference Oscillator Alignment ........................................................................................ 6-6
6.4.5 Power Detector Calibration ............................................................................................... 6-8
6.4.6 Tx Power Characterization ............................................................................................... 6-9
6.4.7 Tx Current Limit .............................................................................................................. 6-10
6.4.8 Tx Deviation Balance (Compensation) ........................................................................... 6-12
6.4.9 Tx Deviation Limit ........................................................................................................... 6-14
6.5 Performance Testing ................................................................................................................... 6-16
6.5.1 Bit Error Rate (BER) Test ............................................................................................... 6-16
6.5.2 Transmitter Test Pattern ................................................................................................. 6-17
6.6 Mic Sensitivity Calibration ............................................................................................................ 6-18
Chapter 7 Encryption ........................................................................... 7-1 
						

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7.1 Universal Crypto Module Kits......................................................................................................... 7-1
7.1.1 Secure Interface Boards ...................................................................................................7-1
7.1.2 Secure Dispatch Operation ............................................................................................... 7-1
7.1.3 Secure Emergency Operation........................................................................................... 7-2
7.2 Load an Encryption Key ................................................................................................................. 7-2
7.2.1 W3 Control Head .............................................................................................................. 7-2
7.2.2 W4, W5, W7, and W9 Control Heads ............................................................................... 7-3
7.3 Advanced Secure Operation .......................................................................................................... 7-3
7.3.1 Multikey Operation ............................................................................................................ 7-3
7.4 Erase a Key ................................................................................................................................... 7-3
7.4.1 W3 Control Head .............................................................................................................. 7-4
7.4.2 W4, W5, W7, and W9 Control Heads ............................................................................... 7-5
7.5 Erase a Single Key (W3 Control Head) .........................................................................................7-6
7.6 Erase All Keys................................................................................................................................ 7-6
7.6.1 W3 Control Head .............................................................................................................. 7-6
7.6.2 W4, W5, W7, and W9 Control Heads ............................................................................... 7-7
7.7 Over-the-Air Rekeying ................................................................................................................... 7-7
7.7.1 W3 Control Head .............................................................................................................. 7-8
7.7.2 W4, W5, W7, and W9 Control Heads ............................................................................... 7-9
Chapter 8 Disassembly/Reassembly Procedures ............................. 8-1
8.1 Introduction .................................................................................................................................... 8-1
8.2 Replacement Procedures .............................................................................................................. 8-1
8.2.1 Required Tools and Supplies ............................................................................................ 8-1
8.2.2 Control Head Boards Disassembly/Reassembly .............................................................. 8-2
8.2.2.1 W3 Disassembly ...................................................................................................... 8-2
8.2.2.2 W3 Reassembly ....................................................................................................... 8-3
8.2.2.3 W4, W5, and W7 Disassembly ................................................................................ 8-4
8.2.2.4 W4, W5, and W7 Reassembly ................................................................................. 8-5
8.2.2.5 W9 Disassembly ...................................................................................................... 8-6
8.2.2.6 W9 Reassembly ....................................................................................................... 8-6
8.2.3 Remote Back Housing Interface Board Disassembly/Reassembly .................................. 8-7
8.2.3.1 W4, W5, and W7 Disassembly ................................................................................ 8-7
8.2.3.2 W4, W5, and W7 Reassembly ................................................................................. 8-7
8.2.4 Remote Interconnect Board Assembly/Reassembly......................................................... 8-7
8.2.4.1 Assembly .................................................................................................................8-7
8.2.4.2 Reassembly ............................................................................................................. 8-8
8.2.5 Radio Disassembly ........................................................................................................... 8-8
8.2.6 Radio Reassembly ..........................................................................................................8-19
8.3 Chassis Thermal Pad Replacement Procedure ........................................................................... 8-30
8.4 Fastener Torque Chart................................................................................................................. 8-32
Chapter 9 Basic Troubleshooting ....................................................... 9-1
9.1 Introduction .................................................................................................................................... 9-1
9.1.1 J2 Accessory Connector ................................................................................................... 9-1
9.1.2 I/O Disclaimer ................................................................................................................... 9-3
9.1.3 Microphone Bias ............................................................................................................... 9-4
9.1.4 Audio PA Out Bias ............................................................................................................ 9-5
9.1.5 High Power RF Precaution ............................................................................................... 9-5
9.2 Replacement Board Procedures .................................................................................................... 9-5 
						

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9.3 Power-Up Error Codes .................................................................................................................. 9-5
9.4 Operational Error Codes ................................................................................................................ 9-7
9.5 Transmitter Troubleshooting .......................................................................................................... 9-7
9.6 Receiver Troubleshooting .............................................................................................................. 9-8
Chapter 10 Functional Block Diagrams and Connectors ................. 10-1
10.1 XTL 5000 Functional Block Diagram ...........................................................................................10-2
10.2 Radio Connectors ........................................................................................................................ 10-3
10.3 Radio Connector Locations ......................................................................................................... 10-4
10.4 Radio Connector Locations (cont.) .............................................................................................. 10-4
10.5 Control Head Cabling Diagram .................................................................................................... 10-5
10.6 Control Head Connector .............................................................................................................. 10-6
10.7 Connector Naming Schemes ....................................................................................................... 10-7
Chapter 11 Exploded Views and Parts Lists ...................................... 11-1
11.1 W3 Hand-Held Control Head Exploded View .............................................................................. 11-2
11.2 W4 Rotary Control Head Exploded View ..................................................................................... 11-3
11.3 W5 and W7 Pushbutton Control Head Exploded View ................................................................ 11-4
11.4 W9 Pushbutton Control Head Exploded View ............................................................................. 11-5
11.5 XTL 5000 (3.5-35 W) Radio Exploded View ................................................................................ 11-6
11.6 Motorcycle Interconnect Board and Assembly ............................................................................ 11-7
11.7 Interconnect Board and Assembly ............................................................................................... 11-7
11.8 Motorcycle Radio Remote-Mount Control Head with Speaker and Microphone ......................... 11-8
11.9 Handlebar Installation (Control Head and Speaker Mounted Together ....................................... 11-9
11.10 Handlebar Installation (Control Head and Speaker Mounted Separately) ................................... 11-9
11.11 Fuel-Tank Console Installation (Control Head and Speaker Mounted Together) ...................... 11-10
11.12 Fuel-Tank Console Installation (Control Head and Speaker Mounted Separately) ................... 11-10
11.13 HMN1062_ Motorcycle Microphone .......................................................................................... 11-11
11.14 HSN6003_ Motorcycle Weather-Resistant Speaker.................................................................. 11-11
11.15 Motorcycle Weather-Resistant Radio Enclosure ....................................................................... 11-12
11.16 Motorcycle Universal Mounting Plate ........................................................................................ 11-13
11.17 Small Pushbutton Parts ............................................................................................................. 11-13
11.18 Large Pushbutton Parts ............................................................................................................. 11-13
Appendix A Replacement Parts Ordering.............................................. A-1
A.1 Basic Ordering Information ............................................................................................................ A-1
A.2 Motorola Online ............................................................................................................................. A-1
A.3 Mail Orders .................................................................................................................................... A-1
A.4 Telephone Orders .......................................................................................................................... A-1
A.5 Fax Orders ..................................................................................................................................... A-2
A.6 Parts Identification ......................................................................................................................... A-2
A.7 Product Customer Service ............................................................................................................. A-2
Appendix B Environmental Information ................................................ B-1
Glossary ......................................................................................... Glossary-1 
						

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Index ...................................................................................................... Index-i