Motorola Astro Digital Mobile Radio Xtl5000 Basic 6881096c73 O Manual

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-25
8. Place the cover on the chassis and seat it properly. You can compress the cover and chassis 
together to squeeze the seal into place and make torquing the screws easier.
Figure 8-29.  Preparing to Place the Top Cover on the Chassis
9. Inspect and reassemble the sealing washers to the ten (10) top cover screws, and then 
torque down screws in the indicated order.
All the screws must be torqued to 24-28 in.-lbs, and you should follow the torque sequence 
shown in Figure 8-30 at least twice to ensure that each screw is torqued down all the way.
Figure 8-30.  Securing the Top Cover to the Chassis
7
58
6
12
910
34 
						

							June 11, 20036881096C73-O
8-26Disassembly/Reassembly Procedures: Replacement Procedures
10. For secure option-equipped radios, do the following:
a. Inspect the kapton tape on the back of the secure interface board for damage and replace 
if necessary.
b. Ensure the universal encryption module (UCM) is securely plugged into the secure inter-
face board.
c. Carefully align the secure interface board in its chassis pocket, and plug it into the main 
board. Press down along the edges of the board to fully seat it, and then verify that the 
UCM is still fully plugged in.
d. Position the secure shield over the secure interface board, and secure it with the two 
screws. Torque the screws to 6-8 in.-lbs. using a Torx T10 bit.
Figure 8-31.  Installing the Secure Interface Board
11. Verify that the headbridge seal has no defects; replace the seal if it does.
12. Align the headbridge seal on the transceiver, and insert the seal tabs into their slots along the 
front edge of the transceiver (Figure 8-32 on page 8-27). Ensure that all the seal tabs are in 
place.
Universal
Encryption
Module Secure
Shield Screws
Secure
Interface
Board
MAEPF-27647-A  
						

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-27
Figure 8-32.  Installing the Headbridge Seal
13. Grasp the handle on the transceiver end of the control-head flex (dash or remote), and plug 
the flex into the 50-pin connector on the side of the main board.
Figure 8-33.  Installing the Control-Head Flex in the Transceiver 
						

							June 11, 20036881096C73-O
8-28Disassembly/Reassembly Procedures: Replacement Procedures
14. Hold the headbridge with one hand, and squeeze the center of the long span.
15. Align the headbridge with the transceiver, thread the control-head flex through the 
headbridge, and push the headbridge into place. You might hear a small snap as the 
alignment tabs engage. If the headbridge does not align properly on the first try, do not try to 
slide it back and forth on the transceiver. This will cause the seal to roll out of place. Instead, 
remove the headbridge and try again, taking care to align it properly before fully seating it.
Figure 8-34.  Installing the Headbridge on the Transceiver
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 remote interface plate.
Figure 8-35.  Installing the Control-Head Flex on the Control Head 
						

							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-29
18. Insert the control head to the transceiver.
Figure 8-36.  Inserting the Control Head Into the Transceiver
19. Secure the control head to the transceiver with the two screws using the 2.5 mm hex-key bit. 
Apply 6-8 in.-lbs. of torque for each screw.
Figure 8-37.  Installing the Control-Head Screws 
						

							June 11, 20036881096C73-O
8-30Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure
8.3 Chassis Thermal Pad Replacement Procedure
Use the following procedures for replacing the chassis thermal pads.
Figure 8-38.  Chassis Thermal Pad Locations
To replace the pink thermal pads (Items 1, 2, and 4):
1. Use a plastic flat-edge tool (like a black-stick solder aid) to lift the pad from the chassis 
surface.
2. Discard the old pad. Use a soft cloth to remove any remaining residue. Alcohol can also be 
used, if necessary. Care should be taken to minimize any cleaning-agent contact with the 
surrounding shield gasket.
3. Once the surface is clean and dry, use tweezers to remove a new pad from the shipping liner, 
and place it yellow-side down on the chassis.
4. Apply pressure to the pad to activate the pressure-sensitive adhesive. Remove the blue liner 
with tweezers.Table 8-2.  Chassis Thermal Pad Parts
Item No.Part No.Description
1 7585366E01 Pad, Thermal, Audio PA
2 7585477E01 Pad, Thermal, Regulator
3 7585365E02 Pad, Thermal, Power Amplifier
4 7585476E01 Pad, Thermal, Harmonic Filter
MAEPF-27649-O
3
4 2
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							6881096C73-OJune 11, 2003
Disassembly/Reassembly Procedures: Chassis Thermal Pad Replacement Procedure 8-31
To repair the black thermal pad (Item 3):
1. Use a plastic flat-edge tool (like a black-stick solder aid) to lift the pad from the chassis 
surface. 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).
3. After scraping off as much residue as possible, use a soft cloth with alcohol to remove the 
remaining residue. Care should be taken to minimize any cleaning-agent contact with the 
surrounding shield gasket.
4. Once the surface is clean and dry, use tweezers to remove a new pad from the shipping liner.
5. Position the pad on the chassis using any two screw holes as a visual cue.
6. Carefully place the pad down to avoid wrinkling the pad or trapping air bubbles under the pad. 
7. Apply even pressure to activate the pressure-sensitive adhesive.
To repair the cover pad (7585860F01) shown in the exploded view, Figure 11.5 “XTL 5000 (3.5-
35 W) Radio Exploded View” on page 11-6:
1. Use a plastic flat-edge tool (like a black-stick solder aid) to lift the pad from the top cover 
boss.
2. Discard the old pad, and use a soft cloth to remove any remaining residue. Alcohol can also 
be used, if necessary. Care should be taken to minimize any cleaning-agent contact with the 
surrounding shield gasket.
3. Once the surface is clean and dry, use tweezers to remove the blue liner from the pad.
4. Place the pad pink-side-down on the cover boss.
5. Use your finger to apply pressure to the pad. The yellow side is visible when the pad is 
installed correctly.Use of a metal tool will scratch the heat sink surface and reduce 
the thermal effectiveness.
!
C a u t i o n 
						

							June 11, 20036881096C73-O
8-32Disassembly/Reassembly Procedures: Fastener Torque Chart
8.4 Fastener Torque Chart
Table 8-3 lists the various fasteners by part number and description, followed by the torque values 
and the location where used. Torque all fasteners to the recommended value when assembling the 
radio.
Table 8-3.  Fastener Torque Chart
Part NumberDescription
Repair 
Torque
(in.-lbs.)
Where Used
0310907A20 Screw, Torx M3x10 6-8 Mainboard (3), Secure Shield (2)
0385870E01 Screw, Torx M4x25 24-28 Top Cover (10)
0380077M07 Screw, Hex M3x35 6-8 Control head (2) and remote 
interconnect (2) mounting
0310945A11 Screw, Plastite M3x16 6-8 Control Head and remote dash board 
attachment (varies)
0310945A14 Screw, Plastite M3x8 6-8 Remote control cable cover
0310908A33 Screw, machine 6-8 Back housing W9 control head (3)
0380041S01 Screw, captive 6-8 Control head leaf spring (4)
0380077M04 Screw, hex M3x22 6-8 Remote cable mounting (2)
0384244C06 Wing Screw M5x10 12-16 Radio Mounting (2) 
						

							Chapter 9 Basic Troubleshooting
9.1 Introduction
This section of the manual contains troubleshooting charts, error codes, and flexible circuit 
information. This section can help you isolate a problem to the board level. Board-level 
troubleshooting does not attempt to isolate problems to the component level. Component-level 
service information can be found in the ASTRO XTL 5000 Digital Mobile Radio Detailed Service 
Manual. (Refer to the Related Publications section of this manual on page xii for the specific 
manual number.)
NOTE:To access the various connector pins, use the housing eliminator/test fixture along with the 
diagrams found in this section of the manual. (Refer to the section, Service Aids and 
Recommended Tools on page 4-2, for the appropriate Motorola service aids and tools parts 
numbers.)
9.1.1 J2 Accessory Connector
Figure 9-1 illustrates the J2 accessory connector and its associated signals and voltages while 
Table 9-1 describes the function of each pin.
Figure 9-1.  J2 Accessory Connector Pin-Out Arrangement
Table 9-1.  J2 Accessory Connector Signal and Voltage Descriptions
PinFunctionDescription
1GROUNDGroundUsed as a ground for any reference on rear 
connector.
2BUS+SB9600 BUS+This is part of the Motorola SB9600 
communications bus to connect external 
devices.
3BUS-SB9600 BUS-This is part of the Motorola SB9600 
communications bus to connect external 
devices.
1 2 3 4 11 12 137
6
5 18 19 20
26
25
10 17 24
23
16
9
15 22
21 8
14
USB+
USB-
UARTA_RX
UARTA_TX
BUS-
BUS+
GROUND RX_FILT_AUDIOMONITORMIC HI SW_B+ IGNITIONSPKR-
EMERGENCY
GROUNDPTT ONE WIRE VIP 1 OUT (12 V) VIP 2 OUT (12 V) SPKR+
CHAN_ACT
USB_PWR
Standard
RS-232 levels
SB9600 at
5 V logic level UARTA_RTS
UARTA_CTS
BUSY
RESET
MAEPF-27549-A 
						

							June 11, 20036881096C73-O
9-2Basic Troubleshooting: Introduction
4TXDRS232 Transmit DataThis is part of the 4-wire RS232 interface to 
external data accessories, programming 
cables, etc.
5RXDRS232 Receive DataThis is part of the 4-wire RS232 interface to 
external data accessories, programming 
cables, etc.
6USB-USB - DataThis is part of the 2-wire USB differential data 
bus for future USB accessories.
7USB+USB + DataThis is part of the 2-wire USB differential data 
bus for future USB accessories.
8RESETSB9600 RESETThis is part of the Motorola SB9600 
communications bus to connect external 
devices.
9BUSYSB9600 BUSYThis is part of the Motorola SB9600 
communications bus to connect external 
devices.
10CTSRS232 Clear-To-SendThis is part of the 4-wire RS232 interface to 
external data accessories, programming 
cables, etc.
11RTSRS232 Request-To-
SendThis is part of the 4-wire RS232 interface to 
external data accessories, programming 
cables, etc.
12USB PWRUSB PowerThis is the supply (5V) for the USB data bus, 
supplied by the USB accessory/cable.
13CHAN ACTChannel ActivityThis is an output used for indicating detection/
unsquelching of a qualified received signal.
14GROUNDGroundUsed as a ground for any reference on rear 
connector.
15EMERGENCYEmergencyThis pin must be connected to ground by 
jumper on accessory cable if emergency is 
disabled, even if disabled by CPS. If enabled, 
this line must be grounded via a switch, which 
is normally closed. The emergency debounce 
time is programmable via CPS.
16PTT*P u s h  To  Ta l kPulling this line to ground will activate PTT 
function, activating the AUX_MIC input.
17ONE WIREOne-Wire dataTo be used for identification of future smart 
accessories/cables.
18VIP OUT 1Vehicular Interface 
OutputHigh voltage output used for enabling relays 
used for accessories such as horn/lights.
19VIP OUT 2Vehicular Interface 
OutputHigh voltage output used for enabling relays 
used for accessories such as horn/lights.
20SPKR+Speaker +Used along with SPKR- to connect an external 
speaker. The audio PA is a bridge amplifier 
with a 3.2-ohm minimum impedance.
Table 9-1.  J2 Accessory Connector Signal and Voltage Descriptions (Continued)
PinFunctionDescription