XTS Series/XTS5000 Basic Service Manual 6881094C28 O XTS5000

User Manual: -XTS Series/XTS5000 Basic service manual 6881094C28-O

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ASTRO XTS 5000 Digital Portable Radios Basic Service Manual

ASTRO

XTS 5000

™

Digital Portable Radios

Basic Service Manual

Model I

Model II

Model III

Foreword This manual covers all models of the ASTRO® Digital XTS 5000™

Portable Radio, 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.

Included in this manual are: radio specifications for the 700/800 MHz

frequency band; a general description of ASTRO Digital XTS 5000

models; recommended test equipment, service aids, and tools; radio

alignment procedures; disassembly/reassembly procedures; exploded

views and parts lists, and general maintenance recommendations.

For details on the operation of the radio, or component-level

troubleshooting, refer to the applicable manuals, available separately.

To help you with your selection, a list is provided under “Related

Publications” at the front of this manual.

Safety Before operating an ASTRO XTS 5000 Radio, please read the “User

Safety, Training, and General Information” section in the front of this

manual.

Manual Revisions Changes which occur after this manual is printed are described in

“FMRs.” These FMRs provide complete information on changes,

including pertinent parts list data.

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.

Table of Contents ➠

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside front cover

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover

Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover

Computer Software Copyrights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

Commercial Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Motorola Communication Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Portable Radio Model Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

ASTRO Digital XTS 5000 Model Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

ASTRO Digital XTS 5000 R (Ruggedized) Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Specifications for 700/800 MHz Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

User Safety, Training, and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

Compliance with RF Energy Exposure Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Operational Instructions and Training Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Electromagnetic Interference/Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Medical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Driver Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Operational Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Operational Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Intrinsically Safe Radio Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xix

FMRC Approved Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xix

Repair of FMRC Approved Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notations Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Radio Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FLASHport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

, Motorola, ASTRO, and Private-Line are registered trademarks of Motorola, Inc.

XTS 5000, FLASHport, and Digital Private-Line are trademarks of Motorola, Inc.

All other product or service names are the property of their respective owners.

8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322

Printed in U.S.A. 11/01

Basic Service Manual

68P81094C28-O

Commercial, Government and Industrial Solutions Sector

Table of Contents

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

XTS 5000 R Radios Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 - Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Analog Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transmitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ASTRO Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Transceiver (XCVR) Board Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VOCON Board Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 - Recommended Test Equipment and Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Field Programming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 - Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Display Radio Test Mode (Models II/III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Entering Display Radio Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

RF Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Control Top and Keypad Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Non-Display Radio Test Mode (Model I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Entering Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

RF Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Top and Keypad Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6 - Radio Alignment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Softpot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Radio Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transmit Power Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Transmit Deviation Balance Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Transmit Deviation Limit Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Front End Filter Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure for 700 MHz Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure for 800 MHz Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure for UHF/VHF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Bit Error Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Bit Error Rate Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Transmitter Test Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Transmitter Test Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7 - Encryption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Loading an Encryption Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Multikey Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Selecting a Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of Contents

iii

Using the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Using the Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Selecting an Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Using the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Using the Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Erasing a Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Method 1 — Key Zeroization (Multikey Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Method 2 — All Keys Erased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8 - Disassembly/Reassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Attach the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Remove the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Attach the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Attach the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Remove the Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remove the Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Attach the Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Remove the Frequency Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install the Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remove the Volume Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Install the Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Radio Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Ensuring Radio Submergibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Specialized Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Troubleshooting Leak Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

9 - Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Power-Up Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Operational Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10 - Exploded Views and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

11 - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Audio Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Carry Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Belt Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Belt Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Carry Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Table of Contents

Enhanced and Multi-Unit Line Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Commport Integrated Microphone/Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Headset / Surveillance Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Earpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Headset Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Ear Microphones (Require Radio Interface Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Radio Interface Modules for Ear Microphones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Remote Speaker and Public Safety Microphones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Vehicular Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Allied Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

12 - Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

List of Figures

Figure 1. XTS 5000 Overall Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2. Receiver Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 3. Transceiver Block Diagram (Power and Control Omitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 4. Radio Alignment Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 5. Tuner Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 6. Typical Softpot Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 7. Radio Information Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 8. Reference Oscillator Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 9. Transmit Power Alignment Screen (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 10. Transmit Deviation Balance Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Figure 11. Transmit Deviation Limit Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 12. Front End Filter Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 13. Bit Error Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 14. Transmitter Test Pattern Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 15. Attach the antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 16. Remove the antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 17. Insert the top edge of the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 18. Press the battery into place. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 19. Press the release button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 20. Remove the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 21. Align the belt clip with the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 22. Press the belt clip into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 23. Press the belt clip tab away from the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 24. Remove the belt clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 25. Insert a screwdriver below the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 26. Remove the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Figure 27. Hook the end into the slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 28. Press the cover into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 29. Partial Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

List of Tables

Table 1. ASTRO XTS 5000 Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table 2. Local Oscillator and First IF Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 3. Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table 4. Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Table 5. Initial Equipment Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 6. Front-Panel Access Test-Mode Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 7. Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 8. Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 9. Receiver Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 10. Receiver Tests for ASTRO Conventional Channels*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table 11. Transmitter Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 12. Transmitter Tests for ASTRO Conventional Channels* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 13. Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 14. Transmit Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 15. Partial Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Table 16. Submersible Radio Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Table 17. Power-Up Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Table 18. Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Table 19. Receiver Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Table 20. Transmitter Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Table 21. Encryption Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

vii

Commercial Warranty ➠

Limited Warranty

Motorola Communication Products

I.What This

Warranty Covers

And For How Long

MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured

Communication Products listed below (“Product”) against defects in material

and workmanship under normal use and service for a period of time from the

date of purchase as scheduled below:

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. All replaced parts of Product shall become the property of

MOTOROLA.

This express limited warranty is extended by MOTOROLA to the original end

user purchaser only and is not assignable or transferable to any other party.

This is the complete warranty for the Product manufactured by MOTOROLA.

MOTOROLA assumes no obligations or liability for additions or modifications

to this warranty unless made in writing and signed by an officer of

MOTOROLA. Unless made in a separate agreement between MOTOROLA and

the original end user purchaser, MOTOROLA does not warrant the

installation, maintenance or service of the Product.

MOTOROLA cannot be responsible in any way for any ancillary equipment

not furnished by MOTOROLA which is attached to or used in connection with

the Product, or for operation of the Product with any ancillary equipment, and

all such equipment is expressly excluded from this warranty. Because each

system which may use the Product is unique, MOTOROLA disclaims liability

for range, coverage, or operation of the system as a whole under this warranty.

II.General

Provisions

This warranty sets forth the full extent of MOTOROLA'S responsibilities

regarding the Product. Repair, replacement or refund of the purchase price, at

MOTOROLA’s option, is the exclusive remedy. THIS WARRANTY IS GIVEN IN

LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES,

INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE

LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. IN NO EVENT

SHALL MOTOROLA BE LIABLE FOR DAMAGES IN EXCESS OF THE

ASTRO XTS 5000 Portable Units One (1) Year

Product Accessories One (1) Year

Commercial Warranty

viii

PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME,

INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR

OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING

OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL

EXTENT SUCH MAY BE DISCLAIMED BY LAW.

III.State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW

LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR

EXCLUSIONS MAY NOT APPLY.

This warranty gives specific legal rights, and there may be other rights which

may vary from state to state.

IV.How To Get

Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product

item serial number) in order to receive warranty service and, also, deliver or

send the Product item, transportation and insurance prepaid, to an authorized

warranty service location. 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.

V.What This

Warranty Does Not

Cover

A) Defects or damage resulting from use of the Product in other than its

normal and customary manner.

B) Defects or damage from misuse, accident, water, or neglect.

C) Defects or damage from improper testing, operation, maintenance,

installation, alteration, modification, or adjustment.

D) Breakage or damage to antennas unless caused directly by defects in

material workmanship.

E) A Product subjected to unauthorized Product modifications, disassemblies

or repairs (including, without limitation, the addition to the Product of

non-Motorola supplied equipment) which adversely affect performance of

the Product or interfere with Motorola’s normal warranty inspection and

testing of the Product to verify any warranty claim.

F) Product which has had the serial number removed or made illegible.

G) Rechargeable batteries if:

•any of the seals on the battery enclosure of cells are broken or show

evidence of tampering.

•the damage or defect is caused by charging or using the battery in

equipment or service other than the Product for which it is specified.

H) Freight costs to the repair depot.

I) A Product which, due to illegal or unauthorized alteration of the software/

firmware in the Product, does not function in accordance with

MOTOROLA’s published specifications or the FCC type acceptance

labeling in effect for the Product at the time the Product was initially

distributed from MOTOROLA.

Commercial Warranty

J) Scratches or other cosmetic damage to Product surfaces that does not

affect the operation of the Product.

K) Normal and customary wear and tear.

VI.Patent And

Software

Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end

user purchaser to the extent that it is based on a claim that the Product or parts

infringe a United States patent, and MOTOROLA will pay those costs and

damages finally awarded against the end user purchaser in any such suit which

are attributable to any such claim, but such defense and payments are

conditioned on the following:

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) should the Product or parts become, or in MOTOROLA’s opinion be likely

to become, the subject of a claim of infringement of a United States patent,

that such purchaser will permit MOTOROLA, at its option and expense,

either to procure for such purchaser the right to continue using the

Product or parts or to replace or modify the same so that it becomes non-

infringing or to grant such purchaser a credit for the Product or parts as

depreciated and accept its return. The depreciation will be an equal

amount per year over the lifetime of the Product or parts as established by

MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent

infringement which is based upon the combination of the Product or parts

furnished hereunder with software, apparatus or devices not furnished by

MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary

equipment or software not furnished by MOTOROLA which is attached to or

used in connection with the Product. The foregoing states the entire liability

of MOTOROLA with respect to infringement of patents by the Product or any

parts thereof.

Laws in the United States and other countries preserve for MOTOROLA certain

exclusive rights for copyrighted MOTOROLA software such as the exclusive

rights to reproduce in copies and distribute copies of such Motorola software.

MOTOROLA software may be used in only the Product in which the software

was originally embodied and such software in such Product may not be

replaced, copied, distributed, modified in any way, or used to produce any

derivative thereof. No other use including, without limitation, alteration,

modification, reproduction, distribution, or reverse engineering of such

MOTOROLA software or exercise of rights in such MOTOROLA software is

permitted. No license is granted by implication, estoppel or otherwise under

MOTOROLA patent rights or copyrights.

VII.Governing Law This Warranty is governed by the laws of the State of Illinois, USA.

Portable Radio Model Numbering System

Position 1 - Type of Unit

D = Dash-Mounted Mobile Radio

M = Motorcycle Mobile Radio

T =Trunk-Mounted Mobile Radio

Positions 2 & 3 - Model Series

Position 4 - Frequency Band

Less than 29.7MHz

29.7 to 35.99MHz

36 to 41.99MHz

42 to 50MHz

66 to 80MHz

74 to 90MHz

Product Specific

136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

336 to 410MHz

403 to 437MHz

438 to 482MHz

470 to 520MHz

Product Specific

806 to 870MHz

825 to 870MHz

896 to 941MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

Values given represent range only; they are

not absolute.

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Position 7 - Channel Spacing

1 = 5kHz

2 = 6.25kHz

3 = 10kHz

4 = 12.5kHz

5 = 15kHz

6 = 20/25kHz

7 = 30kHz

9 = Variable/Programmable

Typical Model Number:

Position:

Position 8 - Primary Operation

Conventinal/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Programmable

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

Position 9 - Primary System Type

Conventional

Privacy Plus¤

Clear SMARTNET“

Advanced Conventional Stat-Alert“

Enhanced Privacy Plus¤

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS“

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet¤

Programmable

Secure Conventional

Secure SMARTNET“

* MPT = Ministry of Posts and Telecommunications

Position 10 - Feature Level

1 = Basic

2 = Limited Package

3 = Limited Plus

4 = Intermediate

5 = Standard Package

6 = Standard Plus

7 = Expanded Package

8 = Expanded Plus

9 = Full Feature/

Programmable

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 12 -

Unique Model Variations

C = Cenelec

N = Standard Package

Positions 13 - 16

SP Model Suffix

1 23 4 5 6 7 8 9 10 11 1213141516

T04 S LF 9 P W 7 A N S P 0 1

04 = ASTRO

10.1 to 15 Watts

16 to 25 Watts

26 to 35 Watts

36 to 60 Watts

= 61 to 110 Watts

H = Hand-Held Portable

H18 U C F 9 P W 7 A N S P 0 1

18 = XTS 5000

U = 764 to 870 MHz

Phonenet

ASTRO Digital XTS 5000 Model Chart

Notes:

X=Item Included

*= The radio’s model number, FLASHcode, Host code, and DSP code are required when placing an order for the VOCON Board.

•The model number and (sometimes) the FLASHcode, can be found on the FCC label on the back of the radio.

•The model number, Host code, DSP code, and (sometimes) the FLASHcode, can be found by putting a Model II or III

radio into the Test Mode.

•The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (RKN4105_ or

RKN4106_) and the CPS to read a Model I, II, or III radio.

MODEL NUMBER DESCRIPTION

H18UCC9PW5AN 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model I

H18UCF9PW6AN 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model II

H18UCH9PW7AN 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model III

ITEM NUMBER DESCRIPTION

XXX NUF3577_ Board, Transceiver (700/800MHz)

XXX NTN9564_ Board, VOCON *

XXX NTN8266_ Belt Clip Kit

XXX HNN9031_ Battery, Nickel-Cadmium, Ultra-High Capacity

XNTN9682_ Kit, Front Cover, Model I

XNTN9681_ Kit, Front Cover, Model II

XNTN9680_ Kit, Front Cover, Model III

XXX NAF5080_ Antenna, 700/800 MHz

XXX 0985973B01 Assembly, B+ Connector

XXX 1505579Z01 Cover, Accessory Connector

X2685567D01 Assembly, VOCON Shield, Model I

X2685567D02 Assembly, VOCON Shield-Keypad, Model II

X2685567D03 Assembly, VOCON Shield-Keypad, Model III

XXX 2685220D02 Shield, RF Board

XXX 2785219D01 Assembly, Casting

XXX 2885866A01 Connector, Compression, 26-Pin

XXX 3205082E96 Gasket, Antenna O-Ring

XXX 3205349Z03 Seal, Main

XXX 3205351Z02 Seal, B+

XXX 3285877B02 Seal, Port

XXX 3385873B01 Label, Port

X X 7285726C01 Module, LCD Display

X X 7585189D01 Pad, Display Locator

X7585104D02 Keypad, Model II

X7585104D01 Keypad, Model III

xii

ASTRO Digital XTS 5000 R (Ruggedized) Model Chart

Notes:

X=Item Included

*= The radio’s model number, FLASHcode, Host code, and DSP code are required when placing an order for the VOCON Board.

•The model number and (sometimes) the FLASHcode, can be found on the FCC label on the back of the radio.

•The model number, Host code, DSP code, and (sometimes) the FLASHcode, can be found by putting a Model II or III

radio into the Test Mode.

•The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (RKN4105_ or

RKN4106_) and the CPS to read a Model I, II, or III radio.

MODEL NUMBER DESCRIPTION

H18UCC9PW5AN w/Q155FP Opt Ruggedized 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model I

H18UCF9PW6AN w/Q155FQ Opt Ruggedized 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model II

H18UCH9PW7AN w/Q155FR Opt Ruggedized 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model III

H18UCC9PW5AN w/Q155GB Opt Ruggedized Yellow 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model I

H18UCF9PW6AN w/Q155GC Opt Ruggedized Yellow 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model II

H18UCH9PW7AN w/Q155GD Opt Ruggedized Yellow 700/800MHz 1-3 Watts ASTRO Digital XTS 5000 Model III

ITEM NUMBER DESCRIPTION

X X X X X X NUF3577_ Board, Transceiver (700/800 MHz)

X X X X X X NTN9564_ Board, VOCON *

X X X X X X NTN8266_ Belt Clip Kit

X X X X X X NTN8297_ Battery, Nickel-Cadmium (1525mAh)

XNNTN4059_ Kit, Front Cover, Model I, Ruggedized

XNNTN4060_ Kit, Front Cover, Model II, Ruggedized

XNNTN4061_ Kit, Front Cover, Model III, Ruggedized

XNTN9685_ Kit, Yellow Front Cover, Model I, Ruggedized

XNTN9684_ Kit, Yellow Front Cover, Model II, Ruggedized

XNTN9683_ Kit, Yellow Front Cover, Model III, Ruggedized

X X X X X X NAF5080_ Antenna, 700/800 MHz

X X X X X X 0985973B02 Assembly, B+ Connector

X X X X X X 1505579Z01 Cover, Accessory Connector

X X 2685567D01 Assembly, VoCon Shield, Model I

X X 2685567D02 Assembly, VoCon Shield-Keypad, Model II

X X 2685567D03 Assembly, VoCon Shield-Keypad, Model III

X X X X X X 2685220D02 Shield, RF Board

X X X X X X 2785219D04 Assembly, Ruggedized Casting

X X X X X X 2885866A01 Connector, Compression, 26-Pin

X X X X X X 3205082E96 Gasket, Antenna O-Ring

X X X X X X 3205349Z03 Seal, Main

X X X X X X 3205351Z02 Seal, B+ Ruggedized

X X X X X X 3285877B02 Seal, Port

X X X X X X 3385873B01 Label, Port

X X X X 7285726C01 Module, LCD Display

X X X X 7585189D01 Pad, Display Locator

X X 7585104D02 Keypad, Model II

X X 7585104D01 Keypad, Model III

xiii

SPECIFICATIONS FOR 700/800 MHZ RADIOS

All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted

GENERAL RECEIVER TRANSMITTER

FCC Designation: AZ489FT5806

Temperature Range:

Operating: –30°C to +60°C

Storage: –40°C to +85°C

Power Supply: Nickel-Cadmium Battery (NiCd)

or Nickel-Metal-Hydride Battery (NiMH)

or Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal: 7.5 Vdc

Range: 6 to 9 Vdc

Transmit Current Drain (Typical): 1400mA

Receive Current Drain (Rated Audio): 240mA

Standby Current Drain: 80mA

Recommended Battery:

Ultra-HIgh-Capacity Smart NiCd: HNN9031_

or Ultra-HIgh-Capacity NiCd: NTN8294_

or Extended-Capacity NiMH: NTN8293_

or Li-Ion: NTN8610_

or Ultra–High-Capacity NiCd FM: NTN8295_*

or Ultra–High-Capacity NiMH FM: NTN8299_*

Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1,

Groups C, D,E, F, and G. FM Non-incendive:

Class 1, Division 2, Groups A, B, C, and D.

Dimensions (H x W x D)

Note: 2.44" = width at PTT; 2.34" = width at

bottom; 1.83" = depth at speaker; 0.97" = depth

at keypad

Without Battery (Radio Only):

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"

(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm)

With Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 1.65"

(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

Weight: (w/ Antenna)

Less Battery: 14.10oz. (383gm)

With Ultra-High Cap. NiCd: 25.19oz. (693gm)

With Li-Ion: 20.41oz. (583gm)

With Ultra-High Cap. NiMH:23.45oz. (644gm)

With Extended- Cap. NiMH: 24.04oz. (682gm)

Frequency Range: 764-870MHz

Bandwidth: 106MHz

Usable Sensitivity (typical)

(12dB SINAD): 0.20µV

Intermodulation (typical): –75dB

Selectivity (typical)

(25/30kHz Channel): –72dB

(12.5kHz Channel): –63dB

Spurious Rejection (typical): –75dB

Frequency Stability

(–30+60°C; 25°C reference): ±.00015%

Rated Audio: 500mW

FM Hum and Noise (typical):

25kHz –48dB

12.5kHz –40dB

Distortion (typical): 1.5%

Channel Spacing: 12.5/25 kHz

Frequency Range: 764-870MHz

RF Power:

764-806MHz: 2.5 Watts

806-870MHz: 3 Watts

Frequency Stability (typical)

(–30 to +60°C; 25°C ref.): ±.00015%

Emission (typical conducted): –75dBc

FM Hum and Noise (typical)

(Companion Receiver): 25kHz –45dB

12.5kHz –40dB

Distortion (typical): 1.5% (typical)

Modulation Limiting: 25kHz chnls ±5.0kHz

12.5kHz chnls ±2.5kHz

Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E,

8K10F1D, and 8K10F1E

Specifications subject to change without notice

xiv

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User Safety, Training,

and General Information ➠

READ THIS IMPORTANT INFORMATION ON SAFE AND EFFICIENT

OPERATION BEFORE USING YOUR MOTOROLA HANDHELD PORTABLE

TWO-WAY RADIO

The information provided in this document supersedes the general safety

information contained in user guides published prior to June 2001. For

information regarding radio use in a hazardous atmosphere please refer to the

Factory Mutual (FM) Approval Manual Supplement or Instruction Card, which

is included with radio models that offer this capability.

Compliance

with RF Energy

Exposure

Standards

Your Motorola two-way radio is designed and tested to comply with a number

of national and international standards and guidelines (listed below)

regarding human exposure to radio frequency electromagnetic energy. This

radio complies with the IEEE (FCC) and ICNIRP exposure limits for

occupational/controlled RF exposure environment at duty cycles of up to 50%

talk-50% listen and should be used for occupational use only. In terms of

measuring RF energy for compliance with the FCC exposure guidelines, your

radio radiates measurable RF energy only while it is transmitting (during

talking), not when it is receiving (listening) or in standby mode. Note that the

approved, supplied batteries for this radio are rated for a 5-5-90 duty cycle (5%

talk-5% listen - 90% standby), even though this radio complies with the FCC

occupational exposure limits at duty cycles of up to 50% talk.

Your Motorola two-way radio complies with the following RF energy

exposure standards and guidelines:

•United States Federal Communications Commission, Code of Federal

Regulations; 47CFR part 2 sub-part J

•American National Standards Institute (ANSI) / Institute of Electrical

and Electronic Engineers (IEEE) C95. 1-1992

•Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999

Edition

•International Commission on Non-Ionizing Radiation Protection

(ICNIRP) 1998

•Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure

to Radiofrequency Electromagnetic Fields in the Frequency Range from

3 kHz to 300 GHz, 1999

•Australian Communications Authority Radiocommunications

(Electromagnetic Radiation - Human Exposure) Standard 1999

(applicable to wireless phones only)

User Safety, Training, and General Information

xvi

•ANATEL, Brasil Regulatory Authority, Resolution 256 (April 11, 2001)

"additional requirements for SMR, cellular and PCS product

certification."

Operational

Instructions and

Training

Guidelines

To ensure optimal performance and compliance with the

occupational/controlled environment RF energy exposure

limits in the above standards and guidelines, users should

transmit no more than 50% of the time and always adhere to

the following procedures:

Transmit and

Receive

•To transmit (talk), push the Push-To-Talk (PTT) button; to receive,

release the PTT button.

Hand-held radio

operation

•Hold the radio in a vertical position with the microphone one to

two inches (2.5 to 5 cm) away from the lips.

Body-worn

operation

•Always place the radio in a Motorola approved clip, holder, holster,

case, or body harness for this product. Use of non-Motorola-approved

accessories may exceed FCC RF exposure guidelines.

•If you do not use a Motorola approved body-worn accessory and are not

using the radio in the intended use position in front of the face, then

ensure the antenna and the radio are kept 2.5 cm (one inch) from the

body when transmitting.

Antennas &

Batteries

•Use only Motorola approved supplied antenna or Motorola

approved replacement antenna. Unauthorized antennas,

modifications, or attachments could damage the radio and may violate

FCC regulations.

•Use only Motorola approved, supplied batteries or Motorola

approved replacement batteries. Use of non-Motorola-approved

antennas or batteries may exceed FCC RF exposure guidelines.

Approved

Accessories

•For a list of Motorola approved accessories see the appendix of this user

manual or visit the following website which lists approved accessories:

http://www.motorola.com/cgiss/portables/xts5000.shtml

Electromagnetic

Interference/

Compatibility

NOTE: Nearly every electronic device is susceptible to

electromagnetic interference (EMI) if inadequately shielded,

designed, or otherwise configured for electromagnetic

compatibility.

Facilities To avoid electromagnetic interference and/or compatibility conflicts, turn off

your radio in any facility where posted notices instruct you to do so. Hospitals

or health care facilities may be using equipment that is sensitive to external RF

energy.

Aircraft When instructed to do so, turn off your radio when on board an aircraft. Any

use of a radio must be in accordance with applicable regulations per airline

crew instructions.

User Safety, Training, and General Information

xvii

Medical Devices

Pacemakers The Advanced Medical Technology Association (AdvaMed) recommends that

a minimum separation of 6 inches (15 centimeters) be maintained between a

handheld wireless radio and a pacemaker. These recommendations are

consistent with those of the U.S. Food and Drug Administration.

Persons with pacemakers should:

•ALWAYS keep the radio more than 6 inches (15 centimeters) from their

pacemaker when the radio is turned ON.

•not carry the radio in the breast pocket.

•use the ear opposite the pacemaker to minimize the potential for

interference.

•turn the radio OFF immediately if you have any reason to suspect that

interference is taking place.

Hearing Aids Some digital wireless radios may interfere with some hearing aids. In the event

of such interference, you may want to consult your hearing aid manufacturer

to discuss alternatives.

Other Medical

Devices

If you use any other personal medical device, consult the manufacturer of your

device to determine if it is adequately shielded from RF energy. Your physician

may be able to assist you in obtaining this information.

Driver Safety Check the laws and regulations on the use of radios in the area where you

drive. Always obey them.

When using your radio while driving, please:

•Give full attention to driving and to the road.

•Use hands-free operation, if available.

•Pull off the road and park before making or answering a call if driving

conditions so require.

User Safety, Training, and General Information

xviii

Operational

Warnings

Operational

Cautions

For Vehicles With an Air Bag

Do not place a portable radio in the area over an air bag or in the air bag deployment

area. Air bags inflate with great force. If a portable radio is placed in the air bag

deployment area and the air bag inflates, the radio may be propelled with great force

and cause serious injury to occupants of the vehicle.

Potentially Explosive Atmospheres

Turn off your radio prior to entering any area with a potentially explosive

atmosphere, unless it is a radio type especially qualified for use in such areas as

“Intrinsically Safe” (for example, Factory Mutual, CSA, UL, or CENELEC). Do not

remove, install, or charge batteries in such areas. Sparks in a potentially explosive

atmosphere can cause an explosion or fire resulting in bodily injury or even death.

NOTE: The areas with potentially explosive atmospheres referred to above

include fueling areas such as below decks on boats, fuel or chemical

transfer or storage facilities, areas where the air contains chemicals or

particles, such as grain, dust or metal powders, and any other area where

you would normally be advised to turn off your vehicle engine. Areas

with potentially explosive atmospheres are often but not always posted.

Blasting Caps and Blasting Areas

To avoid possible interference with blasting operations, turn off your radio when you

are near electrical blasting caps, in a blasting area, or in areas posted: “Turn off two-

way radio.” Obey all signs and instructions.

W A R N I N G

Antennas

Do not use any portable radio that has a damaged antenna. If a damaged antenna comes

into contact with your skin, a minor burn can result.

Batteries

All batteries can cause property damage and/or bodily injury such as burns if a conductive

material such as jewelry, keys, or beaded chains touches exposed terminals. The

conductive material may complete an electrical circuit (short circuit) and become quite

hot. Exercise care in handling any charged battery, particularly when placing it inside a

pocket, purse, or other container with metal objects.

C a u t i o n

User Safety, Training, and General Information

xix

Intrinsically

Safe Radio

Information

FMRC Approved

Equipment

Anyone intending to use a radio in a location where hazardous concentrations

of flammable materials exist (hazardous atmosphere) is advised to become

familiar with the subject of intrinsic safety and with the National Electric Code

NFPA 70 (National Fire Protection Association) Article 500 (hazardous

[classified] locations).

An Approval Guide, issued by Factory Mutual Research Corporation (FMRC),

lists manufacturers and the products approved by FMRC for use in such

locations. FMRC has also issued a voluntary approval standard for repair

service (“Class Number 3605”).

FMRC Approval labels are attached to the radio to identify the unit as being

FM Approved for specified hazardous atmospheres. This label specifies the

hazardous Class/Division/Group along with the part number of the battery

that must be used. Depending on the design of the portable unit, this FM label

can be found on the back or the bottom of the radio housing. The FM

Approval mark is shown below:

Radios must ship from the Motorola manufacturing facility with the

hazardous atmosphere capability and FM Approval labeling. Radios will not be

“upgraded” to this capability and labeled in the field.

APPROVED

•Do not operate radio communications equipment in a hazardous atmosphere

unless it is a type especially qualified (for example, FMRC Approved) for such

use. An explosion or fire may result.

•Do not operate an FMRC Approved Product in a hazardous atmosphere if it has

been physically damaged (for example, cracked housing). An explosion or fire

may result.

•Do not replace or charge batteries in a hazardous atmosphere. Contact sparking

may occur while installing or removing batteries and cause an explosion or fire.

•Do not replace or change accessories in a hazardous atmosphere. Contact

sparking may occur while installing or removing accessories and cause an

explosion or fire.

•Do not operate an FMRC Approved Product unit in a hazardous location with the

accessory contacts exposed. Keep the connector cover in place when accessories

are not used.

•Turn a radio off before removing or installing a battery or accessory.

•Do not disassemble an FMRC Approved Product unit in any way that exposes the

internal electrical circuits of the unit.

W A R N I N G

User Safety, Training, and General Information

A modification changes the unit’s hardware from its original design

configuration. Modifications can only be made by the original product

manufacturer at one of its FMRC-audited manufacturing facilities.

Repair of FMRC

Approved

Products

REPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL ARE THE

RESPONSIBILITY OF THE USER.

You should not repair or relabel any Motorola-manufactured communication

equipment bearing the FMRC Approval label (“FMRC Approved Product”)

unless you are familiar with the current FMRC Approval standard for repairs

and service (“Class Number 3605”).

You may want to consider using a repair facility that operates under 3605

repair service approval.

FMRC’s Approval Standard Class Number 3605 is subject to change at any time

without notice to you, so you may want to obtain a current copy of 3605 from

FMRC. Per the December 1994 publication of 3605, some key definitions and

service requirements are as follows:

Repair A repair constitutes something done internally to the unit that would bring it

back to its original condition—Approved by FMRC. A repair should be done in

an FMRC Approved facility.

Items not considered as repairs are those in which an action is performed on

a unit which does not require the outer casing of the unit to be opened in a

manner which exposes the internal electrical circuits of the unit. You do not

have to be an FMRC Approved Repair Facility to perform these actions.

Relabeling The repair facility shall have a method by which the replacement of FMRC

Approval labels are controlled to ensure that any relabeling is limited to units

that were originally shipped from the Manufacturer with an FM Approval label

in place. FMRC Approval labels shall not be stocked by the repair facility. An

FMRC Approval label shall be ordered from the original manufacturer, as

needed, to repair a specific unit. Replacement labels may be obtained and

applied by the repair facility, provided there is satisfactory evidence that the

unit being relabeled was originally an FMRC Approved unit. Verification may

include, but is not limited to: a unit with a damaged Approval label, a unit

with a defective housing displaying an Approval label, or a customer invoice

indicating the serial number of the unit and purchase of an FMRC Approved

model.

•Failure to use an FMRC Approved Product unit with an FMRC Approved battery or

FMRC Approved accessories specifically approved for that product may result in

the dangerously unsafe condition of an unapproved radio combination being

used in a hazardous location.

•Unauthorized or incorrect modification of an FMRC Approved Product unit will

negate the Approval rating of the product.

W A R N I N G

•Incorrect repair or relabeling of any FMRC Approved Product unit could

adversely affect the Approval rating of the unit.

•Use of a radio that is not intrinsically safe in a hazardous atmosphere could result

in serious injury or death.

W A R N I N G

User Safety, Training, and General Information

xxi

Do Not Substitute

Options or

Accessories

The Motorola communications equipment certified by Factory Mutual is

tested as a system and consists of the FM Approved portable, FM Approved

battery, and FM Approved accessories or options, or both. This FM Approved

portable and battery combination must be strictly observed. There must be no

substitution of items, even if the substitute has been previously Approved with

a different Motorola communications equipment unit. Approved

configurations are listed in the FM Approval Guide published by FMRC, or in

the product FM Supplement. This FM Supplement is shipped from the

manufacturer with the FM Approved radio and battery combination. The

Approval Guide, or the Approval Standard Class Number 3605 document for

repairs and service, can be ordered directly from Factory Mutual Research

Corporation located in Norwood, Massachusetts.

User Safety, Training, and General Information

xxii

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Introduction 1

General This manual covers information needed for levels one and two

troubleshooting. Level one troubleshooting consists of radio

programming, radio alignment, knobs replacement, and installation

and removal of antenna, belt clip, battery, and universal connector

cover. Level two troubleshooting covers disassembly and reassembly of

the radio to replace circuit boards.

Included in this manual are radio specifications for the 764-870 MHz

frequency band, a general description of XTS 5000 models,

recommended test equipment, service aids, radio alignment

procedures, general maintenance recommendations, procedures for

assembly and disassembly, and exploded views and parts lists.

Notations Used in

This Manual

Throughout the text in this publication, you will notice the use of

warnings, cautions, and notes. These notations are used to emphasize

that safety hazards exist, and care must be taken and observed.

NOTE: An operational procedure, practice, or condition,

etc., which is essential to emphasize.

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in equipment damage.

C a u t i o n

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or injury.

W A R N I N G

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death

or injury.

D A N G E R

Introduction

Radio Description The ASTRO Digital XTS 5000 radios are among the most sophisticated

two-way radios available. The radios are available in the 764-870 MHz

band.

The ASTRO Digital 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.

ASTRO Digital XTS 5000 radios are available in three basic models.

Table 1 describes their basic features.

FLASHport The ASTRO Digital XTS 5000 radio utilizes Motorola’s FLASHport

technology. FLASHport makes it possible to add software that drives

the radio’s capabilities both at the time of purchase and later on.

Previously, changing a radio’s features and capabilities meant

significant modifications, or buying a new radio. But now, similar to

how a computer can be loaded with different software, the radio’s

features and capabilities can be upgraded with FLASHport software.

Table 1. ASTRO XTS 5000 Basic Features

Feature Model I Model II Model III

Display None LCD

Fully bit-mapped.

•Normal operation = 4 lines/12 characters per line

•WAP (Wireless Application Protocol) mode =

6 lines/16 characters per line

Keypad None 3 x 2 Menu Buttons

(with 4-way Navigation

button)

3 x 2 Menu Buttons

(with 4-way

Navigation button),

and

3 x 4

Alphanumeric Keypad

Channel Capability 48 512 512

Dialing from Prestored List No Yes Yes

Programmable Softkeys No Yes Yes

Basic Maintenance 2

Introduction This section of the manual describes preventive maintenance and handling

precautions. Each of these topics provides information vital to the successful

operation and maintenance of your radio.

General

Maintenance

In order to avoid operating outside the limits set by the FCC, it is

recommended that the ASTRO Digital XTS 5000 radio’s reference oscillator be

aligned every time the radio is taken apart, or once per year, whichever comes

first. Periodic visual inspection and cleaning is also recommended.

For XTS 5000R Radios - It is recommended that radio submergibility be

checked annually by qualified service personnel.

Inspection Check that the external surfaces of the radio are clean, and that all external

controls and switches are functional. A detailed inspection of the interior

electronic circuitry is not needed.

Cleaning The following procedures describe the recommended cleaning agents and the

methods to be used when cleaning the external surfaces of the radio. External

surfaces include the housing assembly and battery case. These surfaces should

be cleaned whenever a periodic visual inspection reveals the presence of

smudges, grease, and/or grime.

The only recommended agent for cleaning the external radio surfaces is a 0.5%

solution of a mild dishwashing detergent in water.

Cleaning External

Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff, non-

metallic, short-bristled brush to work all loose dirt away from the radio. A soft,

absorbent, lintless cloth or tissue should be used to remove the solution and

dry the radio. Make sure that no water remains entrapped near the connectors,

cracks, or crevices.

The effects of certain chemicals and their vapors can have

harmful results on certain plastics. Aerosol sprays, tuner

cleaners, and other chemicals should be avoided.

C a u t i o n

Basic Maintenance

Handling

Precautions

Complementary metal-oxide semiconductor (CMOS) devices, and

other high-technology devices, are used in this family of radios. While

the attributes of these devices are many, their characteristics make

them susceptible to damage by electrostatic discharge (ESD) or high-

voltage charges. Damage can be latent, resulting in failures occurring

weeks or months later. Therefore, special precautions must be taken to

prevent device damage during disassembly, troubleshooting, and

repair. Handling precautions are mandatory for this radio, and are

especially important in low-humidity conditions.

• 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 will be lost.

• The pressure equalization vent is located on the chassis,

just below the battery contact. Never obstruct or cover the

two slots with any object, including a label. Ensure that no

oily substances come in contact with this vent.

•(XTS 5000 R Radios Only) The XTS 5000 R radio is

designed to be submerged to a maximum depth of 6 feet,

with a maximum submersion time of 4 hours. Exceeding

either maximum limit may result in damage to the radio.

XTS 5000 R Radios Only 1. If the radio battery contact area has been submerged in water, dry

and clean the radio battery contacts before attaching a battery to

the radio. Otherwise, the water could short-circuit the radio.

2. If the radio has been submerged in water, shake the radio well so

that any water that may be trapped inside the speaker grille and

microphone port can be removed. Otherwise, the water will

decrease the audio quality of the radio.

C a u t i o n

Basic Theory of

Operation 3

General

Overview

The ASTRO Digital XTS 5000 radio is a wideband, synthesized radio available

in the 764 to 870 MHz band. All ASTRO Digital 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).

The ASTRO Digital XTS 5000 radio includes the following major assemblies

(see Figure 1.):

•VOCON Board — contains a dual-core processor which includes both the

microcontroller unit (MCU) and a digital signal processor (DSP) core, the

processor’s memory devices, an audio and power supply support

integrated circuit (IC), a digital support IC, and the audio power amplifier.

•Transceiver (XCVR) Board — contains all transmit, receive, and frequency

generation circuitry, including the digital receiver back-end IC and the

reference oscillator.

•Controls/Universal Flex — contains volume/on/off switch, frequency

selector switch, push-to-talk (PTT) switch, monitor button, several

function-selectable switches, universal connector, speaker, and

microphone.

•Display (Models II and III Only) — 96 pixels x 64 pixels bit-mapped,

liquid-crystal display (LCD).

•Keypad (Models II and III Only) — Model II - a 3 x 2 Menu keypad with 4-

way navigation button; Model III - a 3 x 2 Menu keypad with 4-way

navigation button, and a 3 x 4 alphanumeric keypad.

Basic Theory of Operation

Figure 1. XTS 5000 Overall Block Diagram

Analog Mode of

Operation

Receiving When the radio is receiving (see Figure 2.), the signal comes from the

antenna connector to the Transceiver board, passing through the

antenna switch and the receiver front end. The signal is then filtered,

amplified, and mixed with the first local-oscillator signal, generated by

the voltage-controlled oscillator (VCO).

Figure 2. Receiver Block Diagram

Universal

Flex

External

Accessory

Connector

(Side Connector,

Controls, LEDs,

Speaker,

Microphone)

Note:

indicates 26

wires

VOCON

Board

Transceiver

Board

Encryption

Module

(Optional)

7.5V

Battery

Keypad

Antenna

Display

J301

J107

J701

J101

J1 P101

P201 J2

RF Input

RX Front End

Harmonic

Filter

ADC

LO CKO

RX_SSI_ DATA

to VOCON Board

XTAL

Filter

ABACUS III - RX Back End

Antenna

Switch Tuneable

Preslector RF

Amp

Tuneable

Preselector

Filter 1st

Mixer

1st LO

LNA

Basic Theory of Operation

The resulting intermediate frequency (IF) signal is fed to the IF

circuitry, where it is again filtered and passed to the Abacus III digital

back-end IC. In the digital back-end IC, the IF signal is mixed with the

second local oscillator to create the second IF at 2.25 MHz. In the back-

end IC, a bandpass, sigma-delta, analog-to-digital converter then

decodes the second IF signal, and outputs, on the radio’s serial

synchronous interface (SSI) bus, digital audio to the VOCON board.

On the VOCON board, the dual-core processor’s digital-signal

processor (DSP) digitally filters the PCM audio. The DSP decodes the

information in the signal and identifies the appropriate destination

for it.

•For a voice signal, the DSP will route the digital voice data to the

CODEC inside the audio and power supply support IC, for

conversion to an analog signal. The CODEC will then present the

signal to the receive audio pre-amplifier, then to the audio power

amplifier, which drives the speaker.

•For signaling information, the DSP will decode the message and

pass it internally to the microcontrol unit of the dual-core

processor.

Transmitting When the radio is transmitting (see Figure 3.), 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. The DSP passes this

signal to a digital/analog converter (DAC), where it is reconverted into

an analog signal and scaled for application to the voltage-controlled

oscillator as a modulation signal.

Figure 3. Transceiver Block Diagram (Power and Control Omitted)

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. A modulated carrier is provided to the

Reference

Oscillator

FracN

U203

MOD

Loop

Filter

LPF

FL200

EPIC

Y200

DAC

U203

VCO

VCOBIC

U202

VCO

Crystal

Filter

FL403

Mixer

U401

2ND

Sample

Clk

RX_SSI to

VOCON Board

TX_SSI from

VOCON Board

Preselector

Filter

FL401

PCIC

U104

Power

Module

Buffer

Q304

TX Driver

Amplifier

U102

RF Power

Detector

D103

Directional

Coupler

U101

Antenna

Switch

Preselector

Filter

FL402

RX LNA

Q401

Antenna

Harmonic

Filter

Serial EE

PROM

ABACUS III U500

VCO

Basic Theory of Operation

transmitter power amplifier, which transmits the signal under

dynamic power control.

ASTRO Mode of

Operation

In the ASTRO (digital) mode of operation, the transmitted or received

signal is limited to a discrete set of frequency deviation levels. The

receiver handles an ASTRO-mode signal identically to an analog-mode

signal, up to the point where the DSP decodes the received data. In the

ASTRO receive mode, the DSP uses a different algorithm to recover

data.

In the ASTRO transmit mode, microphone audio is processed

identically to an analog mode, with the exception of the algorithm the

DSP uses to encode the information. Using this algorithm, transmitter

FM deviation is limited to discrete levels.

Transceiver (XCVR)

Board Basic Theory

of Operation

The receiver front end consists of a preselector filter, low-noise

amplifier, a second preselector, and a mixer. Both preselectors are

varactor-tuned band pass filters, controlled by the microcontroller. See

Table 2 for local oscillator (LO) and first IF information.

The frequency generation function is performed by three ICs, three

VCOs, and associated circuitry. The reference oscillator IC provides a

frequency standard to the synthesizer. The fractional-N synthesizer

turns on one of three external VCOs, and tunes it to the RX LO or TX

carrier frequency. The VCO buffer and a transistor amplify the signal

to the required power level. The synthesizer is controlled by the

microcontrol unit through a serial peripheral interface (SPI) bus. Most

of the synthesizer circuitry is enclosed in rigid metal cans on the XCVR

board to reduce interference and microphonic effects.

The receiver back end consists of a bandpass crystal filter, input and

output impedance matching networks, and the digital back-end IC.

Final filtering is done digitally in the DSP.

The Abacus III digital back-end IC contains a low-noise amplifier, a

mixer, a variable gain amplifier with integral anti-alias filter, a

bandpass, sigma delta, analog-to-digital converter, and a decimation

filter with a programmable decimation factor. The Abacus III also

contains an automatic gain control (AGC) circuit to provide 25 dB of

continuous gain adjustments. For the second LO, the Abacus III has an

internal, integer-N frequency synthesizer, and an external, discrete

loop filter and voltage-controlled oscillator (VCO). The output of the

Abacus III is digital data on the RX_SSI bus.

The transmitter power amplifier (PA) consists of a driver amplifier IC

and a discrete final-stage. Transmit power is controlled by a power

control IC (PCIC) that monitors the output of a directional coupler

Table 2. Local Oscillator and First IF Frequencies

700/800 MHz

LO Frequency Range 741.35-885.65 MHz

First IF Frequency 109.65 MHz

Basic Theory of Operation

and adjusts PA control voltages. The transmitter RF signal then passes

through a PIN diode antenna switch and a low-pass harmonic filter,

which connects to the antenna connector.

VOCON Board Basic

Theory of

Operation

The vocoder and controller (VOCON) board comprises the dual-core

processor, which contains the radio’s microcontrol unit and digital

signal processor (DSP) in a single integrated circuit (IC) package, its

memory ICs, an audio and power supply IC, a digital support IC, and

the audio power amplifier. Connected to the VOCON board are the

liquid-crystal display (LCD) board, XCVR board, keypad flex, controls/

universal flex, and (optional) encryption module.

The microcontrol unit portion of the dual-core processor controls

receive/transmit frequencies, power levels, display, and other radio

functions, using either direct logic control or serial communications

paths to the devices. The microcontrol unit executes a stored program

located in the FLASH memory device. Data is transferred to and from

memory by the microcontrol unit data bus. The memory location

from which data is read, or to which data is written, is selected by the

address lines. The microcontrol unit of the dual-core processor

requires a 16.8MHz clock on its CKIH pin and a 32kHz clock on its

CKIL pin.

The DSP portion of the dual-core processor performs signaling and

voice encoding and decoding, as well as audio filtering and volume

control. The DSP performs Private-Line®/Digital Private Line™ (PL/

DPL) encode and alert-tone generation. The DSP transmits pre-

emphasis on analog signals, and applies a low-pass (splatter) filter to

all transmitted signals. The DSP controls squelch, deviation, and

executes receiver and transmitter filtering. The DSP executes a stored

program located in the FLASH memory device.

The DSP of the dual-core processor requires a 16.8MHz clock on the

CKIH pin. Additionally, it requires the 520kHz clock and 8kHz

interrupt signal from the digital support IC, as well as clocks from the

Abacus III digital back-end IC on the XCVR board.

The digital support IC is supplied with a 16.8MHz clock from the

XCVR board. Using this clock, the digital support IC generates a

13MHz clock for the analog and power supply IC, and a 520kHz clock

and an 8kHz interrupt signal for both the DSP and the analog and

power supply IC. Additionally, the digital support IC uses a crystal to

generate the 32kHz clock used by the dual-core processor and audio

and power supply IC. It 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 13-pin

universal (accessory) connector. This IC is programmed by the dual-

core processor.

The analog and power supply IC has many functions. This IC supplies

most of the voltages used on the VOCON board, while an external

linear regulator supplies 5 volts. It also has microphone audio

amplifiers, switching between internal and accessory microphones,

and the audio CODEC. The audio CODEC performs analog-to-digital

and digital-to-analog conversions on audio signals. It also has an

Basic Theory of Operation

analog/digital converter (ADC), which is used to monitor volume

setting and battery voltage. This IC is programmed by the dual-core

processor.

The audio power amplifier (PA) drives the speakers with the received

audio from the analog output of the CODEC from the audio and

power supply IC. The audio PA is sourced from the battery (nominal

value of 7.5 volts). It is programmed by the dual-core processor.

Recommended Test

Equipment and Service Aids 4

Recommended

Test

Equipment

The list of equipment contained in Table 3 includes all of the standard test

equipment required for servicing two-way portable radios, as well as several

unique items designed specifically for servicing this family of radios. The

“Characteristics” column is included so that equivalent equipment may 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.

Service Aids Refer to Table 4, “Service Aids,” for a listing and description of the service aids

designed specifically for servicing this family of radios. These kits and/or parts

are available from the Accessories and Aftermarkets Division offices listed in

the “Replacement Parts Ordering” section located on the inside back cover of

this manual. While all of these items are available from Motorola, most are

Table 3. Recommended Test Equipment

Motorola

Model Number Description Characteristics Application

R2600 Series with

applicable options

Communications

System Analyzer

This monitor will substitute for

items with an asterisk (*).

Frequency/deviation meter and

signal generator for wide-range

troubleshooting and alignment.

Agilent 8901B Modulation Analyzer Transmitter parameter testing.

Deviation balance and limit for <2%

accuracy.

Fluke 8012 Digital Multimeter Recommended for ac/dc voltage

and current measurements

R1150_* Code Synthesizer Injection of audio and digital

signaling codes

R1377_* AC Voltmeter 1mV to 300V, 10-Megohm

input impedance

Audio voltage measurements

R1094_ Dual-Trace

Oscilloscope

20MHz bandwidth 5mV to

5V/division

Waveform measurements

R1443_* Wattmeter Fixed-Element, Broadband Transmitter power output

measurements

S1339_ RF Millivolt Meter 100µV to 3V RF RF-level measurements

R1013_* SINAD Meter Receiver sensitivity measurements

S1348_

(programmable)

DC Power Supply 0-20Vdc, 0-5 Amps

current limited

Bench supply for 7.5Vdc

Recommended Test Equipment and Service Aids

standard shop equipment items, and any equivalent item capable of

the same performance may be substituted for the item listed.

Field Programming

Equipment

This family of radios can be aligned and programmed in the field. This

requires specific equipment and special instructions. Refer to the on-

line help in the Customer Programming Software (CPS) for complete

field programming information.

Table 4. Service Aids

Motorola Part

Number Description Application

81-80384M64 Housing Eliminator Fixture Special fixture that allows radio’s internal board to be

mounted externally. Provides easy access to electronic

circuits, required for board-level troubleshooting.

58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test

equipment.

66-85833D01 Housing/Casting Separation

Tool

Special tool used to separate housing and casting near

battery latch area for access to inside of radio.

NLN9839_ Vacuum Pump Kit Submersible radios only. Vacuum pump with gauge and

vacuum hose. Requires NTN9279_ Adapter Kit.

NTN4265_ Pressure Pump Kit Submersible radios only. Pressure pump with gauge and

pressure hose. Requires NTN9279_ Adapter Kit.

NTN9279_ Vacuum Adapter with Gasket

Kit

Submersible radios only. Connects the vacuum/pressure

hose to the radio’s casting.

REX4424_ Battery Eliminator Used in place of battery to connect radio to external power

supply.

RKN4105_ USB Cable Kit Connects radio to RLN-4460_ Portable Test Set for radio

performance checks, and to Universal Serial Bus (USB) port

on personal computer for CPS programming and tuner

alignments.

RKN4106_ RS232 Cable Kit Connects radio to RLN-4460_ Portable Test Set for radio

performance checks, and to serial port on personal

computer for CPS programming and tuner alignments.

RLN4460_ Portable Test Set Used for radio performance checks. Connects to radio’s

universal connector and allows remote switching and signal

injection/outputs for test equipment measurements.

RVN4181_ Customer Programming

Software (CPS) and Tuner

Software

CPS allows customer-specific programming of modes and

features. Tuner software required to perform alignment of

radio parameters. Can be used for both XTS 5000 and XTS

2500 products.

Performance Checks 5

Introduction This section covers performance checks used to ensure that the 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 schedule.

Checks should be performed if radio performance degradation is suspected.

Setup Supply voltage can be connected from the battery eliminator. The equipment

required for alignment procedures is connected as shown in Figure 4.

Figure 4. Radio Alignment Test Setup

Initial equipment control settings should be as indicated in Table 5 on

page 14, and should hold for all alignment procedures, except as noted.

BNC

COMPUTER

AUDIO GENERATOR

SINAD METER

AC VOLTMETER

30 dB PAD

RF GENERATOR

SYSTEM ANALYZER

OR COUNTER

WATTMETER

BATTERY

ELIMINATOR

REX-4424

TRANSMIT

RECEIVE

RADIO

PROGRAM/TEST CABLE

RKN4105_ OR RKN4106_

AUDIO IN

SET TO APPROX. 450mV FOR Tx

MEASURE 80mV FOR Tx

SMA-BNC

58-80348B33

TEST SET

RLN-4460_

RKN4105_ OR RKN4106_

Performance Checks

Display Radio Test

Mode (Models II/III)

Entering Display Radio

Test Mode

1. Turn the radio on.

2. Within 10 seconds after “SELF TEST” is complete, press Side

Button 2 five times in succession.

3. The radio will show a series of displays that give information

regarding various version numbers and subscriber specific

information. The displays are described in Table 6.

Table 5. Initial Equipment Control Settings

System Analyzer Test Set Power Supply

Monitor Mode: Standard* Spkr/Load: Speaker Voltage: 7.5Vdc

Receiver Checks

RF Control: GEN

Output Level: -47 dBm

Modulation: 1kHz tone

@3kHz deviation

Frequency: Set to selected

radio RX frequency

Meter: AC Volts

Transmitter Checks

RF Control: MONITOR

Frequency: Set to selected

radio TX frequency

Meter: RF Display

Modulation Type: FM

Attenuation: 20 dB

PTT: OFF (center) DC On/Standby: Standby

Meter Out: RX Volt Range: 10Vdc

Opt Sel: ON Current: 2.5 Amps

* Use “PROJ 25 STD” if testing ASTRO Conventional channels.

Table 6. Front-Panel Access Test-Mode Displays

Name of Display Description Appears

“SERVICE”The literal string indicates the radio has entered test

mode.

Always

Host Software Version The version of host firmware is displayed. Always

DSP Software Version The version of DSP firmware is displayed. Always

EMC Secure Version Version of the encryption hardware When the radio is secure equipped

Encryption Type 1 Type of encryption being used When the radio is secure equipped

Encryption Type 2 Type of encryption being used When the radio is secure equipped

Model Number The radio’s model number, as programmed in the

codeplug

Always

Performance Checks

NOTE: All displays are temporary and will expire without any

user intervention. If information is longer than the

physical length of the radio’s display, the information

will wrap around to the next display. After the last

display, “RF TEST” is displayed.

4a. Press the Top Side Button to stop the displays and put the radio

into the Control Top and Keypad test mode. The test mode menu

“CH TEST” will be displayed. Go to “Control Top and Keypad Test

Mode” on page 16.

NOTE: Each press of the Top Side Button will toggle

between “CH TEST” and “RF TEST.”

4b. Press the Top Button (Orange button) to stop the displays and

put the radio into the RF test mode. The test mode menu, “1

CSQ”, will be displayed, indicating test frequency 1, Carrier

SQuelch mode. Go to “RF Test Mode”, below.

RF Test Mode When the ASTRO Digital 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 TEST MODE or “air

test.”

1. Each additional press of Side Button 2 will advance to the next

test channel. (Refer to Table 7.)

2. Pressing Side Button 1 will scroll through and access test

environments as shown in Table 8.

NOTE: Transmit into a load when keying a radio under test.

Serial Number The radio’s serial number, as programmed in the

codeplug

Always

ROM Size The memory capacity of the host FLASH part Always

FLASHcode The FLASH codes as programmed in the codeplug Always

Table 6. Front-Panel Access Test-Mode Displays (Continued)

Name of Display Description Appears

Table 7. Test Frequencies

Test

Channel

700/800 MHz RX

(MHz)

700/800 MHz TX

(MHz)

F1 764.0625 764.0125

F2 769.0625 769.0125

F3 775.9375 775.9875

F4 851.0625 794.0125

F5 860.0625 809.0125

Performance Checks

** All deviation values are based on deviation tuning of this mode

*** On radios equipped with secure option

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.

1. Press and hold the Top Button (Orange button); all segments on

the display will light, and the LED lights red.

2. Release the Top Button; “3/0” appears, which indicates that the

Top Button is in the open condition.

3. Press the Top Button again; “3/1” appears, which indicates that

the Top Button is in the closed condition.

4. Rotate the 16-Position Select Switch; “4/0” through “4/15”

appears, which indicates that the selector switch is in mode/zone

position 1 through 16.

5. Rotate the Two-Position Concentric Switch; “65/0” and “65/1”

appear.

6. Cycle through the Three-Position A/B/C Switch; “67/0,”

“67/1,” and “67/2” appear.

7. Rotate the Volume Control; “2/0” through “2/255” appear.

8. Press the Top Side Button; “96/1” appears; release, “96/0”

appears.

9. Press Side Button 1; “97/1”appears; release, “97/0” appears.

10. Press Side Button 2; “98/1”appears; release, “98/0” appears.

F6 869.9375 823.9875

F7 851.0625 851.0125

F8 860.0625 860.0125

F9 869.9375 869.8875

Table 7. Test Frequencies (Continued)

Test

Channel

700/800 MHz RX

(MHz)

700/800 MHz TX

(MHz)

Table 8. Test Environments

No. of

Tones Display Description Function

1CSQ Carrier Squelch RX: unsquelch if carrier detected

TX: mic audio

3TPL Tone

Private-Line

RX: unsquelch if carrier and tone (192.8 Hz)

detected

TX: mic audio + tone (192.8 Hz)

9SEC Secure*** RX: auto-coded clear

TX: with key present—encrypted audio

with key absent—constant unsquelch

11 AST ASTRO RX: none

TX: 1200Hz tone **

12 USQ Carrier

Unsquelch

RX: unsquelch always

TX: mic audio

Performance Checks

11. Press the PTT Button; “1/1” appears; release, “1/0” appears.

12. Keypad Checks:

Model III Only—

-Press 0, “48/1” appears; release, “48/0” appears.

-Press 1, “49/1” appears; release, “49/0” appears.

-Press 2, “50/1” appears; release, “50/0” appears.

-Press 3, “51/1” appears; release, “51/0” appears.

-Press 4, “52/1” appears; release, “52/0” appears.

-Press 5, “53/1” appears; release, “53/0” appears.

-Press 6, “54/1” appears; release, “54/0” appears.

-Press 7, “55/1” appears; release, “55/0” appears.

-Press 8, “56/1” appears; release, “56/0” appears.

-Press 9, “57/1” appears; release, “57/0” appears.

-Press *, “58/1” appears; release, “58/0” appears.

-Press #, “59/1” appears; release, “59/0” appears.

Models II and III—

-Press V, “128/1” appears; release, “128/0” appears.

-Press h, “129/1” appears; release, “129/0” appears.

-Press U, “130/1” appears; release, “130/0” appears.

-Press D, “131/1” appears; release, “131/0” appears.

-Press E, “132/1” appears; release, “132/0” appears.

-Press F, “133/1” appears; release, “133/0” appears.

-Press @, “134/1” appears; release, “134/0” appears.

-Press X, “135/1” appears; release, “135/0” appears.

-Press Y, “136/1” appears; release, “136/0” appears.

Non-Display

Radio Test

Mode

(Model I)

Entering Non-

Display Radio Test

Mode

1. Turn the radio on.

2. Within 10 seconds after the top green LED turns off, press Side button 2

five times in succession.

3a. Press the Top Side Button to put the radio into the Control Top and

Keypad test mode. Go to “Control Top and Keypad Test Mode” on

page 18.

NOTE: Each press of the Top Side Button will toggle between

Control Top and Keypad test mode (non-display radio) and

RF test mode (non-display radio).

Performance Checks

3b. Press the Top Button (Orange button) to stop the displays and

put the radio into the RF test mode. Go to “RF Test Mode”, below.

RF Test Mode When the ASTRO Digital 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 TEST MODE or “air

test.”

1. Each additional press of Side Button 2 will advance to the next

test channel. (Refer to Table 7 on page 15) The channel number is

represented by the number of tones emitted by the radio after the

button press (for example, five tones indicates channel 5).

2. Pressing Side Button 1 will scroll through and access test

environments as shown in Table 8 on page 16. The test

environment is represented by the number of tones emitted by

the radio after the button press (for example, 11 tones indicate

AST).

NOTE: Transmit into a load when keying a radio under test.

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.

1. Press and hold the Top Button (Orange button); the LED lights

red, and the radio beeps.

2. Release the Top Button; the radio beeps again.

3. Press the Top Button again; the radio beeps, indicating that the

Top Button is in the closed condition.

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. Cycle through the Three-Position A/B/C Switch; the radio beeps

in each switch position.

7. Rotate the Volume Control; the radio beeps at each new volume

setting.

8. Press the Top Side Button; the radio beeps.

9. Press Side Button 1; the radio beeps.

10. Press Side Button 2; the radio beeps.

Performance Checks

Table 9. Receiver Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference

Frequency

RF Control: Monitor

Meter: RF Display

Display: Bar Graphs

Freq: Selected radio TX freq.

TEST MODE

CSQ channel*

programmed

conventional

channel

PTT to continuous

(during the

performance check)

Frequency error to

be ≤ ±1.2kHz

Rated Audio RF Control: Gen

Output Level: -47 dBm

Freq: Selected radio RX freq.

Mod: 1kHz tone @ 3kHz dev.

Meter: AC Volts

As above PTT to OFF (center) Set volume

control to

3.74Vrms

Distortion As above, except

Meter: Ext Dist.

As above As above Distortion < 3.0%

Sensitivity

(SINAD)

As above, except

Meter: SINAD

As above As above RF input to be <

0.35µV

Noise Squelch

Threshold (only

radios with

conventional

system need to

be tested)

Set as for rated audio check Out of TEST

MODE; select a

conventional

system

As above Set volume

control to

3.74Vrms.

Set RF level to -

130 dBm and raise

until radio

unsquelches.

Unsquelch to

occur at < 0.25µV.

Preferred SINAD =

6-8dB

* See Table 8 on page 16.

Performance Checks

Table 10. Receiver Tests for ASTRO Conventional Channels*

Test Name System Analyzer Radio/Tuner

Software Test Set Comments

Bit Error rate

(BER) Floor

Mode: Proj 25 Std

RF Control: Gen

Output Level: -47 dBm

Proj 25 Dev: 2.83 kHz

Code: 1011 Hz PAT

Radio Tuner

Software is

required; Bit

Error Rate

Screen

PTT to OFF (center) BER <0.01%

Reference

Sensitivity

As above; lower the output

level until 5% BER is obtained

As above As above Output level

<0.35 µV

(-116 dBm)

Audio Output

Distortion

Mode: Proj 25 Std

RF Control: Gen

Output Level: -47 dBm

Proj 25 Dev: 2.83 kHz

Code: 1011 Hz PAT

Meter: Ext. Distortion

Radio Tuner

Software not

used;

Radio: Out of

TEST MODE;

Select a

conventional

ASTRO channel

PTT to OFF (center)

Meter selector to

Audio PA

Spkr/Load to

Speaker

Distortion < 3.0%

Residual Audio

Noise Ratio

Mode: Proj 25 Std

RF Control: Gen

Output Level: -47 dBm

Proj 25 Dev: 2.83 kHz

Code:

A) 1011 Hz PAT

B) Silence PAT

Meter: AC Volts

As above As above Residual Audio

Noise Ratio >45dB

* These tests require a communications system analyzer with the ASTRO 25 test options.

Some tests require the use of the Radio Tuner Software.

Performance Checks

Table 11. Transmitter Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference

Frequency

RF Control: Monitor

Meter: RF Display

Display: Bar Graphs

Freq: Selected radio TX

freq.

TEST MODE

CSQ channel*

programmed

conventional

channel

PTT to continuous

(during the

performance check).

Frequency error to be ≥

±1.2kHz.

Power RF As above As above As above Refer to Maintenance

Specifications page in front

of manual.

Voice

Modulation

(External)

As above. Set fixed 1kHz

audio level to 400 mV.

As above As above Deviation:

(12.5kHz) ≥ 2.1kHz but ≤

2.5kHz

(25kHz) ≥ 4.1kHz but ≤

5.0kHz

Voice

Modulation

(internal)

RF Control: Monitor

Meter: RF Display

Display: Bar Graphs

Freq: Selected radio TX

freq.

As above Remove modulation

input. PTT to OFF

(center)

Press PTT button on radio.

Say “four” loudly into the

radio mic. Measure

deviation:

(12.5kHz) ≥ 2.1kHz but ≤

2.5kHz

(25kHz) ≥ 4.1kHz but ≤

5.0kHz

PL Modu-

lation (radios

with conven-

tional, clear

mode, coded

squelch oper-

ation only)

As above Conventional

coded squelch

personality

(clear mode

operation) or

TPL channel

(test mode*)

PTT to continuous

(during the

performance check)

Deviation:

(12.5kHz) ≥ 375Hz but ≤

500Hz

(25kHz) ≥ 500Hz but ≤

1000Hz

Secure

Modulation

(radios with

conventional,

secure mode,

talkaround

operation

only)

As above Programmed

conventional

channel

(secure mode

operation)

Load key into

radio.

As above Deviation:

≥ 3.7kHz but ≤ 4.3kHz

* See Table 8 on page 16

Performance Checks

Table 12. Transmitter Tests for ASTRO Conventional Channels*

Test Name System Analyzer Radio Test Set Comments

RF Output

Power

Mode: Proj 25 Std

RF Control: Monitor

Meter: RF Display

Radio Tuner

Software not

used.

Radio: Out of

TEST MODE;

Select a

conventional

ASTRO

channel

PTT to continuous

(during

measurement).

Refer to Maintenance

Specifications page in front

of manual.

Frequency

Error

As above As above As above Error ≤ ±1.0 kHz

Frequency

Deviation

As above Radio Tuner

Software is

required;

Transmitter Bit

Patterns

screen.

High use:

Symbol Rate

PAT

Low use: Low

Symbol Rate P

PTT to OFF (center) DHIGH

≥ 2.543 kHz

but ≤ 3.110 kHz

DLOW

≥ 0.841 kHz

but ≤ 1.037 kHz

* These tests require a communications system analyzer with the ASTRO 25 test options.

Some tests require the use of the Radio Tuner Software.

Radio Alignment

Procedures 6

Introduction This section describes both receiver and transmitter radio alignment

procedures.

General 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 as shown in Table 4 on page 13.

Select Tuner from the START menu. To read the radio, use the File ➝ Read

Device menu or click on . Figure 5 illustrates how the alignment screens

are organized. To access a screen, double-click on the desired screen name in

the Tuner menu.

Figure 5. Tuner Menu Layout

These procedures should only be attempted by qualified service

personnel. Failure to perform alignment procedures properly may

result in seriously degraded radio or system performance.

C a u t i o n

123ABC1234

Radio Information (page 25)

Transmitter Alignments

Reference Oscillator (page 25)

Tx Power High (page 27)

Tx Power Mid (page 27)

Tx Power Low (page 27)

Tx Deviation Balance (page 28)

Tx Deviation Limit (page 29)

Receiver Alignments

Front End Filter (page 31)

Performance Testing

Bit Error Rate (page 32)

Transmitter Test Pattern (page 33)

Radio Alignment Procedures

Softpot The alignment screens introduce the concept of 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 a slider or the screen’s UP/DOWN arrow keys (▲

▼), or by entering the new value from the keyboard. A graphical scale

on the display indicates the minimum, maximum, and proposed value

of the softpot; see Figure 6.

Figure 6. Typical Softpot Screen

Adjusting the softpot value sends information to the radio to increase

(or decrease) the voltage in the corresponding circuit. For example,

left-clicking the UP arrow ▲ on the Reference Oscillator screen

instructs the radio’s microcomputer to increase the voltage across a

varactor in the reference oscillator, which increases the frequency.

In ALL cases, the softpot value is just a relative number corresponding

to a digital-to-analog (D/A) generated voltage in the radio.

Perform the following procedures in the sequence indicated.

NOTE: Some of the following screens may vary depending

upon the radio under test and the version of tuner

software you are using. Refer to the software’s on-line

help.

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. Improper exits from the Alignment screens may leave

the radio in an improperly configured state and result in

seriously degraded radio or system performance.

C a u t i o n

Radio Alignment Procedures

Radio Information Figure 7 shows a typical Radio Information screen.

Figure 7. 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. For this reason, the reference

oscillator should be checked every time the radio is serviced, or once a

year, whichever comes first. The frequency counter used for this

procedure must have a stability of 0.1 ppm (or better).

NOTE: Reference oscillator alignment is required after

replacing (or servicing) the transceiver board.

1. Select the Reference Oscillator alignment screen. See Figure 8.

Figure 8. Reference Oscillator Alignment Screen

Radio Alignment Procedures

2. Left-click the PTT Toggle button on the screen to make the radio

transmit. The screen indicates whether the radio is transmitting.

3. Measure the transmit RF frequency with your service monitor.

4. Adjust the reference oscillator’s softpot value until the measured

value is as close as possible to the frequency shown on the screen.

See Table 13.

5. Left-click the Program All button on the screen to dekey the

radio and save the tuned values.

6. Left-click the Close button on the screen to return to the

Transmitter Alignments menu.

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. The RF band is divided into

frequency zones with a calibration point (value) in each zone.

NOTES:

•The same softpot attenuation value will result in DIFFERENT

radio output power levels at different frequencies.

•All power measurements are to be made at the antenna port.

•Transmit Power alignment is required after replacing (or

servicing) the transceiver board.

1. Select the TX Power alignment screen. The screen will indicate the

transmit frequencies to be used. See Figure 9.

2. Left-click the desired frequency field (starting with the highest

frequency shown).

3. Left-click the PTT Toggle button on the screen to make the radio

transmit. The screen indicates whether the radio is transmitting.

4. Measure the transmit power of the radio with a service monitor.

5. Adjust the softpot value until the required power, as shown in

Table 14, is indicated on the service monitor.

6. Repeat the above process for all frequencies and all power levels.

Table 13. Reference Oscillator Alignment

Band Target

700/800 MHz ±100 Hz

Table 14. Transmit Power Settings

Power Level Test Frequencies

700/800 MHz

Low (1 Watt) 1.2W - 1.4W

Mid (2 Watts) 2.5W - 2.7W

High (3 Watts) 3.2W - 3.4W

Radio Alignment Procedures

7. Left-click the Program All button on the screen to dekey the

radio and save the tuned values.

8. Left-click the Close button on the screen to return to the

Transmitter Alignments menu.

Figure 9. 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.

This procedure needs to be performed at multiple frequencies to allow

for proper alignment across the entire RF band. The RF band is divided

into frequency zones with a calibration point (value) in each zone.

NOTE: This alignment is required after replacing (or servicing)

the VOCON board or the transceiver board.

1. Select the TX Deviation Balance alignment screen. The screen

will indicate the transmit frequencies to be used. See Figure 10.

2. Left-click the desired frequency field (starting with the highest

frequency shown).

Radio Alignment Procedures

3. Left-click the PTT Toggle button on the screen to make the radio

transmit. The screen indicates whether the radio is transmitting.

Figure 10. Transmit Deviation Balance Alignment Screen

4. Left-click the PTT Tone: Low button.

5. Measure the transmitted signal deviation of the radio with a

service monitor.

6. Left-click the PTT Tone: High button.

7. Adjust the softpot value until the measured deviation, when using

the high tone, is a close as possible to that observed when using

the low tone.

8. Repeat the above process for all frequencies.

9. Left-click the Program All button on the screen to dekey the

radio and save the tuned values.

10. Left-click the Close button on the screen to return to the

Transmitter Alignments menu.

Transmit Deviation

Limit Alignment

This alignment procedure limits the modulation of a baseband signal.

It is used for primary modulation limiting.

This procedure needs to be performed at multiple frequencies to allow

for proper alignment across the entire RF band. The RF band is divided

into frequency zones with a calibration point (value) in each zone.

Radio Alignment Procedures

NOTE: This alignment is required after replacing (or servicing)

the VOCON board or the transceiver board.

1. Select the TX Deviation Limit alignment screen. The screen will

indicate the transmit frequencies to be used. See Figure 11.

Figure 11. Transmit Deviation Limit Alignment Screen

2. Left-click the desired frequency field (starting with the highest

frequency shown).

3. Left-click the PTT Toggle button on the screen to make the radio

transmit. The screen indicates whether the radio is transmitting.

4. Measure the transmitted signal deviation of the radio with a

service monitor.

5. Adjust softpot value until the measured deviation is as close as

possible to 2.83 kHz.

6. Repeat the above process for all frequencies.

7. Left-click the Program All button on the screen to dekey the

radio and save the tuned values.

8. Left-click the Close button on the screen to return to the

Transmitter Alignments menu.

Radio Alignment Procedures

Front End Filter

Alignment

Definition This alignment procedure adjusts the front end receiver bandpass filters for

best receiver sensitivity and selectivity. It should be performed for all test

frequencies to allow for proper software interpolation for frequencies in

between the test frequencies in the band (see Figure 12).

NOTE: Rx Front End Filter Alignment is required after

replacing (or servicing) the transceiver board.

Procedure for 700 MHz

Frequencies

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current

operating frequency.

3. Start with a softpot value (approximately 10 or 20), increase

softpot in ascending order, and note the RSSI values. The RSSI will

reach a peak value and remain stable and then decrease. Allow the

limits of the peak range to be defined as RSSI PEAK - 3. Choose

the middle of the peak range and program the corresponding

softpot value as the tuned softpot value.

4. Repeat the above process for all 700MHz frequencies.

5. Click on the “Program All” button to save the tuned values in the

radio.

Procedure for 800 MHz

Frequencies

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current

operating frequency.

3. Start with a softpot value of 50, increase softpot in ascending

order, and note the RSSI values. The RSSI will reach a peak value

and remain stable and then decrease. Allow the limits of the peak

range to be defined as RSSI PEAK - 3. Note the upper end of the

peak range and program the corresponding softpot value as the

tuned softpot value.

4. Repeat the above process for all 800MHz frequencies.

5. Click on the “Program All” button to save the tuned values in the

radio.

Procedure for UHF/VHF 1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current

operating frequency.

3. Adjust the softpot value until the maximum RSSI value is found.

4. Repeat the above process for all frequencies.

5. Click on the “Program All” button to save the tuned values in the

radio.

This procedure should only be attempted by qualified service

personnel.

C a u t i o n

Radio Alignment Procedures

Figure 12. Front End Filter Alignment Screen

Bit Error Rate

Definition This screen is used to test the Bit Error Rate (BER) of the radio’s receiver at a

desired frequency (see Figure 13).

Bit Error Rate

Fields

This 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).

Modulation Type:

This field represents the digital modulation type of the incoming signal on

which BER is to be calculated.

Radio Alignment Procedures

Continuous Operation:

This field allows the user the option to repeat the BER test indefinitely.

A selection of Yes will cause the radio to calculate BER on a continuous

basis and update the results on this screen after each integration time.

A selection of No will cause the BER test to execute for only one sample

of the integration time and then update the display.

Audio:

This field allows the user to select the audio output during a test.

Selecting Internal will cause the radio’s built-in speaker to unmute to

any signals at the desired frequency which are present during the test.

Selecting External will route the same signal to the radio’s accessory

connector audio output. Selecting Mute will disable the audio output.

Integration Time:

This field represents the amount of time over which the Bit Error Rate

is to be calculated. The range is from 0.360 to 91.8 seconds in

increments of 0.360 seconds.

NOTE: When Continuous Operation = Yes, all

fields will be grayed out while test is in

progress. They will be enabled when the

STOP button is pressed.

When Continuous Operation = No, a

wait cursor will be displayed while the

test is in progress and return to normal

when the test is done.

Figure 13. Bit Error Rate Screen

Radio Alignment Procedures

Transmitter

Test Pattern

Definition This screen 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 14).

Transmitter Test

Fields

This screen contains the following fields:

Tx Frequency:

This field selects the Transmit Frequency directly in MHz.

Channel Spacing:

This field allows the user to select the desired transmit deviation.

Test Pattern Type:

This field represents the type of test pattern which will be transmitted by the

radio when “PTT TOGGLE” button is pressed.

NOTE: Channel Spacing and Test Pattern Type fields will

be grayed out while radio is transmitting.

Figure 14. Transmitter Test Pattern Screen

Radio Alignment Procedures

Notes

Encryption 7

Loading an

Encryption Key

1. Refer to the key-variable loader (KVL) manual for equipment connections

and setup.

2. Attach the KVL to the radio. The display shows “KEYLOADING.” All other

radio functions, except for power down, backlight, and volume, are

locked out.

3. Refer to the KVL manual for how to load the encryption keys into the

radio.

4. When the key is loaded successfully, you will hear:

-On single-key radios — a short tone.

-On multikey radios — an alternating tone.

Multikey

Feature

This feature allows the radio to be equipped with multiple encryption keys. It

can support up to two different encryption algorithms simultaneously (e.g.,

DVP-XL and DES-XL).

•Conventional Multikey — The encryption keys can be tied (strapped), on

a one-per-channel basis. In addition, the radio can have operator-

selectable keys, operator-selectable indices, and operator-selectable key

erasure. If talkgroups are enabled in conventional, then the encryption

keys are strapped to the talkgroups.

•Trunked Multikey — If the radio is used for both conventional and

trunked applications, strap the encryption keys for trunking on a per-

talkgroup or announcement group basis. In addition, a different key can

be strapped to other features; for example, dynamic regrouping, failsoft, or

emergency talkgroup. The radio can have operator-selectable key erasure.

Selecting a Key

Using the Menu 1. Press U until the display shows “KEY.”

2. Press D, E, or F directly below “KEY.” The display shows the last

user selected and stored encryption key, and the available menu

selections.

3. Press V or U to scroll through the list of encryption keys.

NOTE: If you select an erased key, the display shows the key and

“ERASED KEY.”

4. Press D, E, or F directly below the desired menu.

-PSET = selects the preset or default encryption key.

Encryption

-SEL = saves the newly selected key and returns to the home

display.

5. Press h, the PTT button, or D, E, or F directly below the

ABRT menu, or turn the 16-Position Select knob to exit this

menu.

-If the selected key is erased, the display shows “KEY FAIL” and

the radio sounds a momentary keyfail tone.

-If the selected key is not allowed, the display shows “ILLEGAL

KEY” and the radio sounds a momentary illegal key tone.

Using the Keypad 1. Press U until the display shows “KEY.”

2. Press D, E, or F directly below “KEY.” The display shows

the last user selected and stored encryption key, and the available

menu selections.

3. Enter the number of the desired key, using the keypad.

NOTE: If you select an erased key, the display shows the key

and “ERASED KEY.”

4. Press V or U to select from the menu.

-PSET = selects the preset or default encryption key.

-SEL = saves the newly selected key and returns to the home

display.

5. Press h, the PTT button, or D, E, or F directly below the

ABRT menu, or turn the 16-Position Select knob to exit this

menu.

-If the selected key is erased, the display shows “KEY FAIL” and

the radio sounds a momentary keyfail tone.

-If the selected key is not allowed, the display shows “ILLEGAL

KEY” and the radio sounds a momentary illegal key tone.

Selecting an Index This feature lets the user select one or more groups of several

encryption keys from among the available keys stored in the radio. For

example, the radio could have a group of three keys structured to one

index, and another group of three different keys structured to another

index. Changing indices makes the radio automatically switch from

one set of keys to the other. Every channel to which one of the original

keys was tied to will now have the equivalent new key instead.

Using the Menu 1. Press U until the display shows “INDX.”

2. Press D, E, or F directly below “INDX.” The display shows

the last user selected and stored index, and the available index

menu selections.

3. Press D, E, or F directly below the desired index. The

display shows the last user selected and stored index, and the

available index menu selections.

Encryption

4. To save the index, press D, E, or F directly below “SEL.”

To exit this menu without changing the index selection, press h

or the PTT button, or turn the 16-Position Select knob.

Using the Keypad 1. Press U until the display shows “INDX.”

2. Press D, E, or F directly below “INDX.” The display shows

the last user selected and stored index, and the available index

menu selections.

3. Enter the number of the desired index, using the keypad.

4. To save the index, press D, E, or F directly below “SEL.”

To exit this menu without changing the index selection, press h

or the PTT button, or turn the 16-Position Select knob.

Erasing a Key

Method 1 — Key

Zeroization (Multikey

Only)

1. Press U until the display shows “ERAS.”

2. Press D, E, or F directly below “ERAS.” The display shows

the last user selected and stored encryption key, and the available

menu selections:

-ALL = erases all the encryption keys in the radio. The display

shows “ERS ALL KEYS” and “YES” and “NO.”

-SNGL = selects the displayed encryption key to be erased.The

display shows “ERS SNGL KEY” and “YES” and “NO.”

-ABRT = exits this menu and returns to the home display.

NOTE: To exit this menu at any time without changing the

index selection, press h or the PTT button, or turn the

16-Position Select knob.

3. Press D, E, or F directly below the desired menu.

Press V or U to find the desired encryption key. The display

shows the selected key, and the available menu selections shown

in step 2. Press D, E, or F directly below the desired menu.

Enter the location number of the desired key, using the keypad.

The display shows the selected key, and the available menu

selections shown in step 2. Press D, E, or F directly below

the desired menu.

4. Press h, the PTT button, or turn the 16-Position Select knob to

exit this menu.

Encryption

Method 2 — All Keys

Erased

NOTE: This is the method used for erasing the key in radios

with the “single key” option.

1. With the radio on, press and hold the Top Side button; 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;

this would send an emergency alarm.

Before the keys are erased, the display shows “PLEASE WAIT.”

When all the encryption keys have been erased, the display

shows “ERASED.”

Disassembly/Reassembly

Procedures 8

Introduction This section gives detailed procedures for disassembling/reassembling

XTS 5000 radios, and ensuring the submergibility of ruggedized radios. When

performing these procedures, refer to “Exploded Views and Parts Lists” on

page 67 and the diagrams that accompany the text. Items in parentheses ( )

refer to item numbers in the exploded view diagrams.

This section also has procedures for removing and installing the XTS 5000

radio’s standard accessories and changing the Volume and Frequency Knobs.

Antenna

Attach the

Antenna

With the radio turned off, turn the antenna clockwise to attach it to the radio.

Figure 15. Attach the antenna

Remove the

Antenna

With the radio turned off, turn the antenna counter-clockwise to remove it

from the radio.

Figure 16. Remove the antenna

Disassembly/Reassembly Procedures

Battery

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.

Attach the Battery 1. With the radio turned off, insert the top edge of the battery into

the radio’s frame as shown.

Figure 17. Insert the top edge of the battery

2. Rotate the battery toward the radio and press down until the

battery clicks into place.

Figure 18. Press the battery into place

Remove the Battery 1. With the radio turned off, press the release button on the bottom

of the battery until the battery releases from the radio.

Figure 19. Press the release button

To avoid a possible explosion:

• DO NOT replace the battery in an area labeled

“hazardous atmosphere.”

• DO NOT discard batteries in a fire.

W A R N I N G

If the radio is programmed with volatile-key

retention, encryption keys will be retained for

approximately 30 seconds after battery removal.

C a u t i o n

Disassembly/Reassembly Procedures

2. Remove the battery from the radio.

Figure 20. Remove the battery

Belt Clip NOTE: The battery must be removed from the radio before

the belt clip can be installed or removed.

Attach the Belt Clip 1. Align the grooves of the belt clip with those of the battery.

Figure 21. Align the belt clip with the battery

2. Press the belt clip downward until you clear a click.

Figure 22. Press the belt clip into place

Remove the Belt Clip 1. Use a flat-bladed object to press the belt clip tab away from the

battery.

Figure 23. Press the belt clip tab away from the battery

Slots

Battery

Grooves

Slots

Battery

Metal

Tab

Disassembly/Reassembly Procedures

2. Slide the belt clip upward to remove it.

Figure 24. Remove the belt clip

Universal Connector

Cover

Remove the Universal

Connector Cover

1. Insert a flat-blade screwdriver into the area between the bottom of

the cover and the slot below the connector.

Figure 25. Insert a screwdriver below the cover

2. Hold the top of the cover with your thumb while you pry the

bottom of the cover away from the radio with the screwdriver.

Figure 26. Remove the cover

Metal

Tab

When the universal connector is not in use, keep it covered

with the universal connector cover.

C a u t i o n

Disassembly/Reassembly Procedures

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.

Figure 27. Hook the end into the slot

2. Press the cover’s lower tab into the slot below the connector until

it snaps in place.

Figure 28. Press the cover into place

Top

Slot

Top

Hooked End

Bottom

Slot

Bottom

Hooked End

Tab

Disassembly/Reassembly Procedures

Frequency Knob NOTES:

•Refer to Figure 29, the Partial Exploded View, and Table 15, the

Partial Exploded View Parts List. Numbers in parentheses ( )

refer to item numbers in Figure 29 and Table 15.

•The battery (56) should be removed from the radio before

installing or removing the frequency knob (13).

•In cases where the frequency knob retainer insert (11) and

frequency dial escutcheon (12) must be removed, a new insert

and new escutcheon must be used for reassembly.

Figure 29. Partial Exploded View

Alignment Tabs

Alignment Notch

Disassembly/Reassembly Procedures

Table 15. Partial Exploded View Parts List

ITEM

NO.

MOTOROLA

PART NO. DESCRIPTION

13305630Z01 LABEL, Motorola Bottom

33285757D01 MEMBRANE, Microphone Front

43385221D01 LABEL, Motorola, Front

51505579Z01 COVER, Universal Connector

63605371Z01 KNOB, Volume

74305372Z01 INSERT, Volume Knob Retainer

83205379W01 O-RING, Volume Torque

96105376Z01 LIGHTPIPE, Indicator

10 4505375Z01 LEVER, Secure

11 4305373Z02 INSERT, Frequency Knob Retainer

12 1305374Z03 ESCUTCHEON, Frequency Dial

13 3605370Z01 KNOB, Frequency

14 NAF5037_

or NAF5042_

or NAF5080_

ANTENNA, Whip, Halfwave (806-870 MHz)

ANTENNA, Stubby, 1/4 Wave (806-870 MHz)

ANTENNA, Whip (764-870 MHz)

17 3305574Z01 LABEL, Motorola Back

56 NTN8294_ BATTERY, NiCd

57 NTN8266_ CLIP, Belt

65 3585741D01 MESH, Microphone

66 3385658D01 ESCUTCHEON, Concentric Switch

67 3385657D01 ESCUTCHEON, Toggle

68 - - - - - - - - - - LABEL, Flashport

69 - - - - - - - - - - LABEL, Radio Serial Number

70 - - - - - - - - - - LABEL, Approval Agency

Disassembly/Reassembly Procedures

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.

2. With the other hand, grasp the frequency knob (13) and pull it

upward, while rocking the knob back and forth, until it is free

from the frequency knob retainer insert (11), or the insert is free

from the shaft.

3. If necessary, while pressing the insert’s (11) two snap tabs away

from the frequency control shaft so that the insert disengages

from the shaft, use needle-nosed pliers to lift the insert up and off

of the frequency control shaft. Discard the removed insert.

4. Remove the secure lever (10) and the indicator lightpipe (9).

Install the Frequency

Knob

1. Hold the radio so that the top of the radio faces upward, and the

front of the radio faces you.

2. Align the lightpipe indicator (9) so that its straight tab is over the

slot for the illuminated pointer. Push the tab down into the slot

so that it is securely seated.

3. Place the secure lever (10) on the frequency control shaft,

aligning it so that its pointer is at the front of the radio and its

two inner slots line up with the two keys on the shaft. Slide the

secure lever down to the bottom of the shaft.

4. If you are replacing the frequency dial escutcheon (12):

a. Remove the backing paper from the escutcheon.

b. Align the number “1” on the escutcheon with the alignment

notch on the frequency knob retainer insert (11).

c. Slide the escutcheon down over the insert, ensuring that the

alignment tab on the escutcheon fits inside the tab recess on

the insert.

d. Press the escutcheon firmly onto the insert to ensure proper

adhesion.

5. Place a new frequency knob retainer insert (11) and new

frequency dial escutcheon (12) on the frequency control shaft,

aligning the insert’s D-shaped hole with the D-shaped shaft. Press

downward firmly on the insert until it snaps in place on the shaft.

6. Place the frequency knob (13) on the insert (11), aligning it’s

pointer with the number “1” on the escutcheon (12). Press firmly

downward on the knob until it seats securely in place.

Disassembly/Reassembly Procedures

Volume Knob NOTES:

•Refer to Figure 29. on page 44, the Partial Exploded View,

and Table 15 on page 45, the Partial Exploded View Parts

List. Numbers in parentheses ( ) refer to item numbers in

Figure 29 and Table 15.

•The battery (56) should be removed from the radio before

installing or removing the volume knob (6).

•In cases where the volume insert (7) must be removed, a

new volume insert must be used for reassembly.

Remove the Volume

Knob

1. Turn the volume knob (6) to the off position.

2. Hold the radio in one hand so that the top of the radio faces

upward, and the front of the radio faces you.

3. With the other hand, grasp the volume knob (6) and pull it

upward, while pushing it toward the back of the radio, until it is

free from the volume knob retainer insert (7).

4. Bend the volume knob retainer insert’s (7) two snap tabs away

from the volume control shaft so that the insert disengages from

the shaft, then use needle-nosed pliers to pull the insert up and

off of the volume control shaft. Discard the removed volume

insert.

5. Using needle-nosed pliers or some other pointed instrument,

remove the volume torque o-ring (8).

Install the Volume Knob 1. Place the volume torque o-ring (8) inside a new volume knob

retainer insert (7), and press it downward until it seats securely at

the bottom of the insert.

2. Hold the radio so that the top of the radio faces upward, and the

front of the radio faces you.

3. Place a new volume knob retainer insert (7) on the volume

control shaft, aligning the insert’s D-shaped hole with the D-

shaped shaft. Press downward firmly on the insert until it snaps

in place on the shaft.

4. Place the volume knob (6) on the volume knob retainer insert (7),

aligning the two lugs on the inside of the knob with the insert’s

two snap tabs. Press firmly downward on the knob until it seats

securely in place.

Disassembly/Reassembly Procedures

Radio Disassembly

and Reassembly

Disassembly 1. Turn off the radio by rotating the On/Off/Volume control fully

counterclockwise until you hear a click.

2. Remove the antenna, the battery, and the universal connector

cover or any accessory connected to the radio.

NOTE: It is not necessary to remove the volume knob (6)

and insert (7) or frequency knob (13) and insert (11)

to service the casting assembly. However, if any top

control is suspected, then the knobs and inserts

should be removed prior to removing the casting

assembly (51) from the housing assembly (2). Refer to

“Frequency Knob” on page 44 and “Volume Knob”

on page 47.

3. With the back of the radio facing

upward, insert the 6685833D01

special tool at the bottom of the

radio between the housing

assembly (2) and the two housing

tabs on the casting assembly (51)

until the special tool’s latch

engages the two battery tabs on

the casting assembly. With the

latch engaged, gently pull the

casting away to remove it from the

housing (do not use a prying motion). Making sure that the

antenna bushing has cleared the hole in the control top, carefully

lift the casting assembly clear of the housing assembly.

4. While holding the casting assembly (51) in one hand and the

housing assembly (2) in the other, unplug the 40-pin connector,

on the controls flex assembly (18), from the VOCON board (44).

NOTE: This can easily be done using the thumb of the

hand holding the housing assembly.

Put the housing assembly aside.

5. Remove the main seal (55) from around the casting assembly

(51).

6. If you are disassembling a model I radio, skip to step 9; if you are

disassembling a model II or III radio, continue this procedure.

With the front of the radio facing upward, unplug the 22-pin

connector for the LCD module (38) (located to the right and

above the LCD module). Lift the LCD module (38), with display

locator pad (39), up and off of the two locator posts on the

casting (51).

7. Remove the LCD module (38) and put it aside.

8. Unplug the 22-pin connector for the keypad flex (37) (located to

the left and above the LCD module area).

9. Pry upward on all four control locking clips (40) for the VOCON

6685833D01 Tool

Battery Tabs

Disassembly/Reassembly Procedures

board shield assembly (41), alternating diagonally across the

shield. Remove the VOCON board shield assembly, with keypad

flex assembly (37) (models II and III only) and clips still attached,

from the casting.

10. Lift the VOCON board (44) up and away from the casting.

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.

11. Lift out the 26-pin compression connector (46).

12. Using needle-nosed pliers, carefully unplug the coaxial cable’s

connector (52) from the transceiver board’s (48) surface-mount

connector.

13. With the front of the radio facing upward, disengage the clip (63)

that secures the upper left portion of the RF shield (47) by

inserting a thin, flat-bladed screwdriver between the clip and the

casting assembly (51) and prying the clip free. Then, release the

snap on the bottom left side and the two snaps on the right side

of the RF shield. Lift the shield out, with the clip still attached,

rotating it around its top edge.

14. Remove the rubber pad (71).

15. Lift the transceiver board (48) out of the casting assembly. Inspect

the casting to make sure that the thermal pad (58) is attached to

the casting. If the pad is attached to the transceiver board, remove

it from the board and discard it. Attach a new thermal pad to the

casting as shown in the exploded view.

16. Lift the B+ assembly (49) and B+ seal (50) out of the casting

assembly.

Housing Assembly 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. To begin housing disassembly, remove the speaker retainer screw

(23).

3. Remove the speaker retainer (36).

4. Install the universal connector cover (5) (see page 43). This will

hold the universal connector in place when the controls flex is

removed.

Removing the controls flex without installing the universal

connector cover may compromise the universal connector.

5. Disconnect the controls flex (18) from the universal connector by

disengaging the spring tab on the backer from the catch features

on the housing.

6. Disconnect the controls flex’s (18) 22-pin connector from PTT

area of the housing assembly (2).

7. Referring to “Frequency Knob” on page 44 and “Volume Knob”

C a u t i o n

Disassembly/Reassembly Procedures

on page 47, remove the frequency knob, frequency insert, secure

lever, lightpipe, volume knob, volume insert, and o-ring.

8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the

controls bracket assembly (34) first, then unsnap the right snap.

9. Remove the controls bracket assembly (34).

10. Remove the controls seal (35).

Battery Contact and

Battery Contact Seal

1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Completely disassemble the casting assembly (51).

3. Remove the battery contact (49) and battery contact seal (50).

Reassembly 1. Reinstall the B+ assembly (49) and B+ seal (50), making sure that

the seal seats properly in the casting assembly (51). Inspect the B+

assembly from the back of the casting to ensure that the seal

shows evenly around the B+ assembly.

2. Make sure that a thermal pad (58) is attached to the casting. If it is

not, attach a new thermal pad to the casting as indicated in the

exploded view.

3. With the front of the radio facing upward, place the transceiver

board (48) in position, tucking the right side of the board in first

— in the casting slot.

4. Put the rubber pad (71) in place on top of the transceiver board

(48).

5. Reinstall the RF shield (47). Insert the shield’s top edge in first,

aligning the two tabs on the shield’s top edge with the two slots

in the casting, then pivot the shield down into position. Engage

the two snaps on the right side and the snap on the bottom left

side first, then snap down the single left side clip (63).

6. Plug the coaxial cable’s connector (52) into the transceiver board’s

(48) surface-mount connector, 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. Reinstall the 26-pin compression connector (46). It can only be

inserted in one way—with the two-peg edge pointing downward

on the left side.

8. If the radio is equipped with an encryption board (45), connect it

to the back of the VOCON board (44) through the 40-pin

connector. Ensure that these connectors are properly engaged.

9. Reinstall the VOCON board (44). Tuck the tab at the top of the

VOCON board into the retention slot on the casting, rotate the

board into position, and engage the 26-pin connector.

10. Reinstall the VOCON board shield assembly (41), with keypad

(models II and III only) and four clips (40) attached, onto the

casting. Snap the shield’s clips down, alternating diagonally

across the shield.

11. If you are reassembling a model I radio, skip to step 14; if you are

reassembling a model II or III radio, complete the remainder of

Disassembly/Reassembly Procedures

step 10. Plug the 22-pin connector at the end of the keypad flex’s

(43) tail into the connector on the VOCON board (44).

12. Reinstall the LCD module (38) and display locator pad (39).

Position the LCD module, with the display locator pad facing

upward, so that the connector on the flex points toward the

bottom of the radio. Press the display locator pad (39) down over

the two locator posts on the casting, making sure that the locator

pad’s loops are fully captured by the casting posts.

13. Plug the 22-pin connector at the end of the display module (38)

flex into the mating connector on the VOCON board (44).

14. Reinstall the main seal (55) around the casting assembly (51).

Start at the top of the casting and work the seal around the

perimeter of the casting until it is completely in place.

15. While holding the casting assembly (51) in one hand and the

housing assembly (2) in the other, plug the 40-pin connector on

the controls flex assembly (18) into the connector on the VOCON

board (44).

NOTE: This can easily be done using the thumb of the

hand holding the casting.

16. With the fronts of both the casting assembly (51) and housing

assembly (2) facing downward, carefully insert the top of the

casting into the top of the housing assembly. Making sure that

the antenna bushing is inside the antenna hole in the control

top, pivot the bottom of the casting downward toward the

bottom of the housing until they meet. Snap the housing

assembly and casting assembly together.

The main seal o-ring should not be visible when looking

at the back side of the radio. If the seal is visible, it is

improperly installed.

17. Referring to the appropriate section in this manual, reinstall: the

universal connector cover or any accessory connected to the

radio, the antenna, and the battery.

NOTE: If the volume knob (6) or frequency knob (13) were

removed prior to servicing the main casting,

reinstall them.

Housing Assembly 1. Inspect the housing seal surfaces for debris. Remove any debris.

2. Install the controls seal (35).

3. Reassemble the controls bracket assembly (34) into the housing

(2) by snapping in the right side of the bracket first, then

snapping in the left side.

4. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, install the frequency knob, new frequency

escutcheon, new frequency insert, secure lever, lightpipe, volume

knob, new volume insert, and o-ring.

5. Reconnect the controls flex (18) to the universal connector and

the PTT area of the housing assembly (2). Make sure the spring

tabs on the backer fully engage the catch features on the housing.

C a u t i o n

Disassembly/Reassembly Procedures

6. Install the main seal o-ring (55) around the casting assembly (51).

7. Reassemble the housing assembly (2) to the radio.

8. 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).

Battery Contact and

Battery Contact Seal

1. Inspect the casting seal surface for debris or damage. Remove any

debris and replace casting if damaged.

2. Install the battery contact (49) and battery contact seal (50).

When installing the battery contact

seal, make sure that the ledge around

the outside of the seal completely

protrudes through the opening in the

casting and sits flush with the outside

surface of the casting. Also, make sure

that the seal’s shape is not distorted.

3. Reassemble the casting assembly (51).

4. Install the main seal o-ring (55) around the casting assembly (51).

5. Reassemble the housing assembly (2) to the radio.

6. 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).

C a u t i o n

Seal Ledge

Casting

Disassembly/Reassembly Procedures

Ensuring Radio

Submergibility

Introduction ASTRO XTS 5000 R radio models meet the stringent requirements of

U. S. MIL-STD-810C, Method 512.1, Procedure I; MIL-STD-810D,

Method 512.2, Procedure I; MIL-STD-810E, Method 512.3, Procedure

I; and MIL-STD-810F, Method 512.4, Procedure I, which require the

radio to maintain watertight integrity when immersed in three feet of

water for two hours. XTS 5000R radios shipped from the Motorola

factory have passed vacuum testing and should not be disassembled.

If disassembly is necessary, refer to qualified service personnel and

service shops capable of restoring the watertight integrity of the radio.

It is strongly recommended that maintenance of the radio

be deferred to qualified service personnel and service

shops. This is of paramount importance as irreparable

damage to the radio can result from service by

unauthorized persons. If disassembly is necessary,

unauthorized attempts to repair the radio may void any

existing warranties or extended performance agreements

with Motorola. It is also recommended that

submergibility be checked annually by qualified service

personnel.

If the radio is accidentally dropped in water, shake the radio to remove

the excess water from the speaker grille and microphone port area

before operating; otherwise, the sound may be distorted until the

water has evaporated, or is dislodged from these areas.

General Information To ensure that the radio is truly a watertight unit, special testing, test

procedures, and specialized test equipment are required. The special

testing involves a vacuum check of the radio and pressure testing

(troubleshooting) for water leaks if the vacuum check fails. The

specialized test equipment is needed to perform the vacuum check and

pressure testing, if required.

Specialized Test

Equipment

Vacuum Pump Kit

NLN9839

The vacuum pump kit includes a vacuum pump with gauge, and a

vacuum hose. An adapter with gasket (NTN9279A), which must be

ordered separately, connects the vacuum hose to the radio’s casting.

The vacuum pump kit is also used on Motorola ASTRO SABER R radios.

The adapter with gasket is the same as that for the ASTRO XTS 3000R

and XTS 3500 R.

Pressure Pump Kit

NTN4265

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 radios. As with the vacuum pump kit above, the NTN9279A

adapter connects the pressure hose to the radio’s casting.

C a u t i o n

Disassembly/Reassembly Procedures

Miscellaneous

Hardware

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).

Disassembly and

Reassembly

If disassembly and reassembly of the radio is required, refer to“Radio

Disassembly and Reassembly” on page 48.

Disassembly Disassemble the radio according to “Disassembly” on page 48.

Reassembly Reassemble the radio according to “Reassembly” on page 50. Tighten

all hardware that was loosened or removed.

Do not reassemble the radio without first performing the

following preliminary inspection procedure.

1. Remove the main seal o-ring from the casting.

2. Inspect the seal area around the casting for foreign material that

might prevent the main seal o-ring from sealing properly.

3. Install a new main seal o-ring; discard the old o-ring.

4. Reassemble the housing.

The main seal o-ring should not be visible when looking at

the back side of the radio. If the seal is visible, it is

improperly installed.

Vacuum Test Refer to the exploded view diagrams and parts lists in this manual.

General 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. Before starting the vacuum test:

•Remove the battery.

•Remove the universal connector cover to expose the universal

connector.

Conducting the Test 1. Attach the vacuum hose to the vacuum pump. Check the pump

and hose for leaks by blocking off the open end of the hose and

operating the pump a few times. The actual reading of the gauge

at this point is not important; it is important that the gauge

pointer remains steady, indicating no vacuum leaks in the pump.

2. Remove the vacuum test port using a pair of needle-nosed pliers

and pulling upward.

3. Ensure that a rubber gasket is attached to the hose-to-casting

adapter. Screw the adapter into the tapped hole in the casting.

C a u t i o n

Disassembly/Reassembly Procedures

4. Attach the open end of the hose to the adapter.

5. Place the radio on a flat surface with the casting facing upward.

Place two or three drops of water on each slot of the label (62)

that protects the vent port seal (61) on the casting. This will

ensure that no air goes through the seal.

6. Operate the pump a few times until the gauge indicates 5 in. Hg;

do not pull more than 7 in. Hg of vacuum on the radio.

Operate the pump again until the gauge indicates 6 in. Hg.

7. Observe the gauge for approximately 1 minute.

•If the needle falls 1 in. Hg or less (for example, from 6 in. Hg

to 5 in. Hg), then the radio has passed the vacuum test and is

approved for submergibility. No additional testing will be

required.

•If the needle falls more than 1 in. Hg (for example, from 6 in.

Hg to less than 5 in. Hg), then the radio has failed the vacuum

test and the radio might leak if submerged. Additional

troubleshooting of the radio will be required; complete this

procedure, then go to the “Pressure Test” section of this

manual.

8. Dry the water from the slots on the label (62) that protects the

vent port seal to allow the radio to equalize. The pressure should

drop slowly to “0.”

9. Remove the vacuum hose and adapter from the radio.

10. Install the vacuum test port plug by pressing it in, ensuring that

the plug sits flat all around the edges and it is flush with the

casting.

Pressure Test Refer to the exploded view diagrams and parts lists in this manual.

General 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). Since all areas

of the radio are being checked, observe the entire unit carefully for the

possibility of multiple leaks before completing this test.

Conducting the Test 1. Remove the vacuum test port using a pair of needle-nosed pliers

and pulling upward.

2. Screw the adapter (with gasket) into the tapped hole in the

casting.

3. Attach one end of the pressure hose to the adapter and the other

end to the pressure pump.

4. Cover the vent port seal (61) and label (62) on the back of the

casting with your thumb. This will prevent air from going

through the seal. Keep the vent port covered with your thumb

until the test is complete (through step 8).

5. Operate the pump until the gauge reads approximately 1 psig.

Disassembly/Reassembly Procedures

Pressure any greater than 1 psig may push air around the

main seal.

6. Maintain the pressure at 1 psig and submerge the radio into a

water-filled container. Keep the vent port covered with your

thumb while the radio is submerged.

7. Watch for any continuous series of bubbles. A stream of bubbles

indicates a sign of leakage.

NOTE: Some air entrapment may cause the accumulation

of bubbles, especially in the grille area, but the

bubbles should not be continuous.

8. Note all of the seal areas that show signs of leakage. Pinpoint the

problem(s) to one (or more) of the following areas:

•Housing

•Antenna bushing seal

•Controls seal

•Frequency switch, toggle, and on/off/volume control switch

•Main seal

•Battery contact and battery contact seal

•Keypad

9. Remove the radio from the water container, remove your thumb

from the vent port seal, and dry the radio thoroughly. Be

especially careful to dry the area around the main seal to prevent

contamination of the internal electronics while the unit is open.

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.

10. Remove the adapter and pressure hose added in steps 1 and 2,

above.

11. Install the vacuum test port plug by pressing it in, ensuring that

the plug sits flat all around the edges and it is flush with the

casting.

12. Inspect the vent port seal (61) to ensure that the seal behind the

label’s (62) two slots has not been punctured. If it has been

punctured, the seal and the label must be replaced.

Troubleshooting

Leak Areas

Before repairing any leak, read all applicable area repair paragraphs.

This will help to eliminate unnecessary disassembly and reassembly of

a radio with multiple leaks. Troubleshoot only the faulty seal areas

listed in “Pressure Test” on page 55, and, when multiple leaks exist, in

the order listed.

NOTE: Before reassembling the radio, always install a new

main seal o-ring, and new seals in the defective area.

C a u t i o n

Disassembly/Reassembly Procedures

Housing 1. If a leak occurs at the lens, universal connector, casting/housing

interface, or PTT/Ratt button area of the housing, replace the

housing. Referring to “Disassembly” on page 48:

a. Remove the housing assembly (2) from the radio.

b. Discard the housing assembly (2) and main seal o-ring (55).

c. Install a new main seal o-ring (55) around the casting

assembly (51).

d. Install a new housing assembly (2) to the radio.

e. Inspect the main seal (55) for proper seating.

f. Observe carefully to ensure that the main seal o-ring (55) is

not pinched between the housing (2) and the casting (51).

2. If the leak occurs at the control top area, remove the knobs, knob

inserts and antenna in order to determine the leak location:

a. Conduct the Pressure Test.

b. Identify the leak location.

Antenna Bushing Seal 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove and discard the antenna bushing gasket (54).

3. Inspect the housing seal surface for debris or damage. Remove

any debris and replace housing if damaged.

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).

Controls Seal 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove the speaker retainer screw (23).

3. Remove the speaker retainer (36).

4. Install the universal connector cover (5) (see page 43). This will

hold the universal connector in place when the controls flex is

removed.

Removing the controls flex without installing the universal

connector cover may compromise the universal connector.

5. Disconnect the controls flex (18) from the universal connector by

disengaging the spring tab on the backer from the catch features

on the housing.

6. Disconnect the controls flex’s (18) 22-pin connector from PTT

area of the housing assembly (2).

C a u t i o n

Disassembly/Reassembly Procedures

7. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, remove the frequency knob, frequency insert, secure

lever, lightpipe, volume knob, volume insert, and o-ring.

8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the

controls bracket assembly (34) first, then unsnap the right snap.

9. Remove the controls bracket assembly (34).

10. Remove and discard the controls seal (35).

11. Inspect the housing seal surfaces for debris. Remove any debris.

12. Install a new controls seal (35).

13. Reassemble the controls bracket assembly (34) into the housing

(2) by snapping in the right side of the bracket first, then

snapping in the left side.

14. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, install the frequency knob, new frequency

escutcheon, new frequency insert, secure lever, lightpipe, volume

knob, new volume insert, and o-ring.

15. Reconnect the controls flex (18) to the universal connector and

the PTT area of the housing assembly (2). Make sure the spring

tabs on the backer fully engage the catch features on the housing.

16. Install a new main seal o-ring (55) around the casting assembly

(51).

17. Reassemble the housing assembly (2) to the radio.

18. 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).

Frequency Switch,

Toggle, and On/Off/

Volume Control Switch

1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove the speaker retainer screw (23).

3. Remove the speaker retainer (36).

4. Install the universal connector cover (5) (see page 43). This will

hold the universal connector in place when the controls flex is

removed.

Removing the controls flex without installing the universal

connector cover may compromise the universal connector.

5. Disconnect the controls flex (18) from the universal connector by

disengaging the spring tab on the backer from the catch features

on the housing.

6. Disconnect the controls flex (18) 22-pin connector from PTT area

of the housing assembly (2).

7. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, remove the frequency knob, frequency insert, secure

lever, lightpipe, volume knob, volume insert, and o-ring.

8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the

C a u t i o n

Disassembly/Reassembly Procedures

controls bracket assembly (34) first, then unsnap the right snap.

9. Remove the controls bracket assembly (34).

10. Remove the controls seal (35).

11. Disassemble the controls bracket assembly (34) by disengaging

the snaps to remove the bottom bracket (33)

12. Replace the switch that leaks by following the unsoldering and

replacement instructions contained in the new switch’s

instruction sheet.

13. Reassemble the controls bracket assembly (34) by snapping the

two brackets together.

14. Install the controls seal (35).

15. Reassemble the controls bracket assembly (34) into the housing

(2) by snapping in the right side of the bracket first, then

snapping in the left side.

16. Referring to “Frequency Knob” on page 44 and “Volume Knob”

on page 47, install the frequency knob, new frequency

escutcheon, new frequency insert, secure lever, lightpipe, volume

knob, new volume insert, and o-ring.

17. Reconnect the controls flex (18) to the universal connector and

the PTT area of the housing assembly (2). Make sure the spring

tabs on the backer fully engage the catch features on the housing.

18. Install a new main seal o-ring (55) around the casting assembly

(51).

19. Reassemble the housing assembly (2) to the radio.

20. 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).

Main Seal 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove and discard the main seal (55).

3. Inspect the housing and casting seal surfaces for debris or

damage. Remove any debris and replace the housing (2) or casting

(51) if damaged.

4. Install a new main seal o-ring (55) around the casting assembly

(51).

5. Reassemble the housing assembly (2) to the radio.

6. 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).

Battery Contact and

Battery Contact Seal

1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Completely disassemble the casting assembly (51).

3. Remove and discard the leaking component.

4. Inspect the casting seal surface for debris or damage. Remove any

debris and replace casting if damaged.

Disassembly/Reassembly Procedures

5. Install a new battery contact (49) and a new battery contact seal

(50), if necessary.

When installing the battery contact

seal, make sure that the ledge around

the outside of the seal completely

protrudes through the opening in the

casting and sits flush with the outside

surface of the casting. Also, make sure

that the seal’s shape is not distorted.

6. Reassemble the casting assembly (51).

7. Install a new main seal o-ring (55) around the casting assembly

(51).

8. Reassemble the housing assembly (2) to the radio.

9. 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).

Keypad 1. Referring to “Radio Disassembly and Reassembly” on page 48,

remove the housing assembly (2) from the radio.

2. Remove and discard the keypad (15).

3. Inspect the housing seal surface for debris or damage. Remove

any debris and replace housing if damaged.

4. Install new keypad (15).

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).

Vacuum Port Seal 1. Remove the vacuum port plug (59), using a pair of needle-nosed

pliers and pulling upward.

2. Inspect the casting seal surface for debris or damage. Remove any

debris and replace the casting if damaged.

3. Install a new vacuum port plug (59) by pressing it in, ensuring

that the plug sits flat all around the edges and it is flush with the

casting.

Vent Port Seal 1. Remove the seal label (62) that covers the vent port seal (61).

2. Remove the vent port seal (61).

3. Ensure that the casting’s surfaces are clean and free from any

adhesive or other foreign materials.

C a u t i o n

Seal Ledge

Casting

Table 16. Submersible Radio Torque Specifications

Application Torque

(in.-lbs)

Torque

(N•m)

Torque Bit Part

No.

Speaker Bracket Screw 20.23 66-80321B79

Disassembly/Reassembly Procedures

4. Install a new vent port seal (61), covering the two vent port holes,

in the small recessed area in the casting. Ensure that no oily

substances come in contact with the seal.

5. Install a new seal label (62) over the vent port seal (61) in the

larger recessed area in the casting. Press down evenly over the

label’s surface to ensure good adhesion.

Disassembly/Reassembly Procedures

Notes

Basic Troubleshooting 9

Introduction

to This Section

This section of the manual contains troubleshooting charts and error codes

that will help you to isolate a problem. 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 Digital

XTS 5000 Portable Radios Detailed Service Manual,” Motorola publication

number 68P81094C31.

Power-Up

Error Codes

When the radio is turned on (power-up), the radio performs self-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.

For non-display radios, the problem will be presented at power-up by a single,

low-frequency tone. The radio should be sent to the depot if cycling power

and reprogramming the code plug do not solve the problem. The presence of

an error should prompt the user that a problem exists and that a service

technician should be contacted.

Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit

user operation; non-fatal errors will not. Use Table 17 on page 64 to aid in

understanding particular power-up error code displays.

Basic Troubleshooting

Operational Error

Codes

During radio operation, the radio performs dynamic tests to determine

if the radio is working properly. Problems detected during these tests

are presented as error codes on the radio’s display. The presence of an

error code should prompt a user that a problem exists and that a

service technician should be contacted. Use Table 18 to aid in

understanding particular operational error codes.

Table 17. Power-Up Error Code Displays

Error

Code Description Corrective Action

01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug

01/12 Security Partition Checksum Non-Fatal Error Send radio to depot

01/20 ABACUS Tune Failure Non-Fatal Error Turn the radio off, then on

01/22 Tuning Codeplug Checksum Non-Fatal Error Send radio to depot

01/81 Host ROM Checksum Fatal Error Send radio to depot

01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug

01/88 External RAM Fatal Error — Note: not a checksum failure Send radio to depot

01/90 General Hardware Failure Fatal Error Turn the radio off, then on

01/92 Security Partition Checksum Fatal Error Send radio to depot

01/93 FLASHport Authentication Code Failure Send radio to depot

01/98 Internal RAM Fail Fatal Error Send radio to depot

01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot

02/81 DSP ROM Checksum Fatal Error Send radio to depot

02/88 DSP RAM Fatal Error — Note: not a checksum failure Turn the radio off, then on

02/90 General DSP Hardware Failure (DSP startup message not

received correctly)

Turn the radio off, then on

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.

Table 18. Operational Error Code Displays

Error Code Description Corrective Action

FAIL 001 Synthesizer Out-of-Lock a. Reprogram external codeplug

b. Send radio to depot

FAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram external codeplug

Basic Troubleshooting

Table 19. Receiver Troubleshooting Chart

Symptom Possible Cause Correction or Test (Measurements

Taken at Room Temperature)

Radio Dead; Display Does Not

Turn On

1. Dead Battery Replace with charged battery.

2. Blown Fuse Send radio to depot.

3. On/Off Switch

4. Regulators

Radio Dead; Display

Turns Off

1. VOCON Board Send radio to depot.

2. RF Board

No Receive Audio or Receiver

Does Not Unmute

Programming a. Does the transmitted signal match the receiver

configuration (PL, DPL, etc.)?

b. With the monitor function enabled, can the radio

be unmuted?

Audio Distorted or Not Loud

Enough

Synthesizer Not On

Frequency

Check synthesizer frequency by measuring the transmitter

frequency; if off by more than ±1000Hz, realign.

RF Sensitivity Poor 1. Synthesizer Not

On Frequency

Check synthesizer frequency by measuring the transmitter

frequency; if off by more than ≤ ±1000Hz, realign.

2. Antenna Switch/

Connector

Send radio to depot.

3. Receiver Front-

End Tuning

Check RF front-end tuning for optimum sensitivity using the

tuner.

Radio Will Not Turn Off VOCON Board Send radio to depot.

Table 20. Transmitter Troubleshooting Chart

Symptom Possible Cause Correction or Test (Measurements

Taken at Room Temperature)

No RF Power Out 1. TX Power Level or Frequency Check TX power level and frequency

programming (from tuner).

2. No Injection To Power Amplifier Send radio to depot.

3. Antenna Switch/Connector

No Modulation;

Distorted Modulation

1. Programming Check deviation and compensation

settings using the tuner.

2. VOCON Board Send radio to depot.

Bad Microphone Sensitivity 1. Check Deviation and Compensation Realign if necessary.

2. Microphone Send radio to depot.

No/Low signaling

(PL, DPL, MDC)

1. Programming Check programming

2. VOCON Board Send radio to depot.

Cannot Set Deviation

Balance

RF Board Send radio to depot.

Basic Troubleshooting

Table 21. Encryption Troubleshooting Chart

Symptom Possible Cause Corrective Action

No “KEYLOAD” on Radio Display When Keyloading

Cable is Attached to the Radio Side Connector

1. Defective Keyload Cable Send radio to depot.

2. Defective Radio

Keyloader Displays “FAIL.” 1. Wrong Keyloader Type Use correct keyloader

type. Refer to Keyloader

User Guide for more

information.

2. Bad Keyloader Try another keyloader

3. Defective Radio Send radio to depot.

Model I Exploded View Parts List

Model I

Exploded View Parts List

ITEM

NO. MOTOROLA

PART NUMBER DESCRIPTION

1 3305630Z02

3305630Z04 LABEL, Motorola Bottom (non-intrinsic) (part of item 2)

LABEL, Motorola Bottom (intrinsic) (part of item 2)

2 1585468D07

or 1585468D10

or 1585468D13

ASSEMBLY, Model I Housing (Standard Models) (includes

items 1, 3, 4, 5, 16, 17, and 65 thru 67)

ASSEMBLY, Model I Housing (R Models) (includes items 1,

3, 4, 5, 16, 17, and 65 thru 67)

ASSEMBLY, Model I Housing (Yellow R Model) (includes

items 1, 3, 4, 5, 16, 17, and 65 thru 67)

3 3285757D01 MEMBRANE, Microphone (part of item 2)

4 3385221D01

or 3385221D02

or 3385221D03

LABEL, Motorola Front (part of item 2)

LABEL, Motorola Front (R Model) (part of item 2)

LABEL, Motorola Front (Yellow R Model) (part of item 2)

5 1505579Z01 COVER, Universal Connector (part of item 2)

6 3605371Z01 KNOB, Volume

7 4305372Z01 INSERT, Volume Knob Retainer

8 3205379W01 O-RING, Volume Torque

9 6105376Z01 LIGHTPIPE, Indicator

10 4505375Z01 LEVER, Secure

11 4305373Z02 INSERT, Frequency Knob Retainer

12 1305374Z03 ESCUTCHEON, Frequency Dial

13 3605370Z01 KNOB, Frequency

14 NAF5037_ ANTENNA, 800MHz Whip (806-870MHz)

or NAF5042_ ANTENNA, 800MHz Stubby1/4 Wave (806-870MHz)

or NAF5080_ ANTENNA, 700/800MHz Whip (764-870MHz)

16 3585340D01 MESH, Speaker (part of item 2)

17 3305574Z01

or 3305574Z02 LABEL, Motorola Back (part of item 2)

LABEL, Motorola Back (Yellow R Model) (part of item 2)

18 0105956T85 ASSEMBLY, Controls Universal Flex (includes items 19, 21,

22, 24 thru 28, and 30 thru 34)

19 5085272D01 SPEAKER (part of item 18)

21 - - - - - - - - - - MICROPHONE, Electret (part of item 18)

(Not Field Replaceable)

22 - - - - - - - - - - CAPACITOR, 56pF (part of item 18)

(Not Field Replaceable)

23 0300140332 SCREW, Tapping - 28 x 3/16

24 0660076A93 RESISTOR, 68kΩ (part of item 18)

25 0660076A96 RESISTOR, 91kΩ (part of item 18)

26 0660076B05 RESISTOR, 150kΩ (part of item 18)

27 4805729G99 LED, Green/Red (5 req’d) (part of item 18)

28 1805629V04 POTENTIOMETER, Volume (part of item 18)

30 1486164A02 BOOT, Microphone Boot (part of item 18)

31 4005572W04 SWITCH, Toggle, 3 Pos. A/B/C (part of item 18)

32 4002622J04 SWITCH, Frequency (part of item 18)

33 0705357Z01 BRACKET, Controls Bottom (part of item 18)

34 0705352Z01 BRACKET, Controls (part of item 18)

35 3205354Z02 SEAL, Controls

36 4285400D01 RETAINER, Speaker

40 4205631Z01 CLIP, Control Locking (Part of item 41) (4 req’d)

41 2685567D01 SHIELD, Controller Front (Includes items 40 and 42)

42 4285288D01 RETAINER (Part of item 41)

44 NTN9564_ KIT, VOCON Board

45 NTN9837A

NTN9838A

NTN9839A

NNTN4006A

DES, DES-XL, DES-OFB with DVP-XL Encryption Kit - UCM

DVI-XL Encryption Kit - UCM

DVP-XL Encryption Kit - UCM

DES, DES-XL, DES-OFB Encryption Kit - UCM

46 2885866A01 CONNECTOR, Compression, 26-Pin

47 2685220D02 SHIELD, RF with Insulator and Clip (Includes item 63)

48 NUF3577_ KIT, Transceiver Board, 700/800MHz

49 0985973B01 ASSEMBLY, B+

or 0985973B02 ASSEMBLY, B+ (R Models)

50 3205351Z02 SEAL, B+

51 2785219D01 ASSEMBLY, Casting

or 2785219D04 ASSEMBLY, Casting (R Models)

52 3005664Z01 ASSEMBLY, Coaxial Cable

53 7505487Z01 PAD, Coaxial

54 3205082E96 GASKET, O-Ring Bushing

55 3205349Z03 SEAL, Main

56 HNN9031_ BATTERY, NiCd, Ultra-High Capacity

57 NTN8266_ KIT, Belt Clip

58 3262737D01 PAD, Thermal

59 3285688D01 PLUG, Vacuum Test Port

61 3285877B02 SEAL, Port

62 3385873B01 LABEL, Seal

63 4285704D01 CLIP, RF Locking (Part of item 47)

65 3585741D01 MESH, Microphone (part of item 2)

66 3385658D01 ESCUTCHEON, Concentric Switch (part of item 2)

67 3385657D01 ESCUTCHEON, Toggle (part of item 2)

71 7585936D01 PAD

ITEM

NO. MOTOROLA

PART NUMBER DESCRIPTION Exploded Views

and Parts Lists 10

Exploded Views and Parts Lists

23 22

966

MAEPF-27209-O

56 55 54

Model I Exploded View

Exploded Views and Parts Lists

Models II and III Exploded View Parts List

Models II and III

Exploded View Parts List

ITEM

NO. MOTOROLA

PART NUMBER DESCRIPTION

1 3305630Z02

3305630Z04 LABEL, Motorola Bottom (non-intrinsic) (part of item 2)

LABEL, Motorola Bottom (intrinsic) (part of item 2)

2 1585468D08

or 1585468D11

or 1585468D14

ASSEMBLY, Model II Housing (Standard Models) (includes items

1, 3, 4, 5, 16, 17, and 64 thru 67)

ASSEMBLY, Model II Housing (R Models) (includes items 1, 3, 4,

5, 16, 17, and 64 thru 67)

ASSEMBLY, Model II Housing (Yellow R Model) (includes items

1, 3, 4, 5, 16, 17, and 64 thru 67)

1585468D09

or 1585468D12

or 1585468D15

ASSEMBLY, Model III Housing (Standard Models) (includes

items 1, 3, 4, 16, 17, and 64 thru 67)

ASSEMBLY, Model III Housing (R Models) (includes items 1, 3,

4, 16, 17, and 64 thru 67)

ASSEMBLY, Model III Housing (Yellow R Model) (includes items

1, 3, 4, 5, 16, 17, and 64 thru 67)

3 3285757D01 MEMBRANE, Microphone (part of item 2)

4 3385221D01

or 3385221D02

or 3385221D03

LABEL, Motorola Front (part of item 2)

LABEL, Motorola Front (R Models) (part of item 2)

LABEL, Motorola Front (Yellow R Models) (part of item 2)

5 1505579Z01 COVER, Universal Connector (part of item 2)

6 3605371Z01 KNOB, Volume

7 4305372Z01 INSERT, Volume Knob Retainer

8 3205379W01 O-RING, Volume Torque

9 6105376Z01 LIGHTPIPE, Indicator

10 4505375Z01 LEVER, Secure

11 4305373Z02 INSERT, Frequency Knob Retainer

12 1305374Z03 ESCUTCHEON, Frequency Dial

13 3605370Z01 KNOB, Frequency

14 NAF5037_ ANTENNA, 800MHz Whip (806-870MHz)

or NAF5039_ ANTENNA, 800MHz Dipole (806-870MHz)

or NAF5042_ ANTENNA, 800MHz Stubby1/4 Wave (806-870MHz)

or NAF5080_ ANTENNA, 700/800MHz Whip (764-870MHz)

15 7585104D01 KEYPAD, Model III

or 7585104D02 KEYPAD, Model II

16 3585340D01 MESH, Speaker (part of item 2)

17 3305574Z01 LABEL, Motorola Back (part of item 2)

or 3305574Z02 LABEL, Motorola Back (Yellow R Models) (part of item 2)

18 0105956T85 ASSEMBLY, Controls Universal Flex (includes items 19, 21, 22,

24 thru 28, and 30 thru 34)

19 5085272D01 SPEAKER (part of item 18)

21 - - - - - - - - - - MICROPHONE, Electret (part of item 18)

(Not Field Replaceable)

22 - - - - - - - - - - CAPACITOR, 56pF (part of item 18)

(Not Field Replaceable)

23 0300140332 SCREW, Tapping - 28 x 3/16

24 0660076A93 RESISTOR, 68kΩ (part of item 18)

25 0660076A96 RESISTOR, 91kΩ (part of item 18)

26 0660076B05 RESISTOR, 150kΩ (part of item 18)

27 4805729G99 LED, Green/Red (5 req’d) (part of item 18)

28 1805629V04 POTENTIOMETER, Volume (part of item 18)

30 1486164A02 BOOT, Microphone Boot (part of item 18)

31 4005572W04 SWITCH, Toggle, 3 Pos. A/B/C (part of item 18)

32 4002622J04 SWITCH, Frequency (part of item 18)

33 0705357Z01 BRACKET, Controls Bottom (part of item 18)

34 0705352Z01 BRACKET, Controls (part of item 18)

35 3205354Z02 SEAL, Controls

36 4285400D01 RETAINER, Speaker

37 2685567D03 ASSEMBLY, Keypad Flex, Model III (Includes items 41 and 43)

or 2685567D02 ASSEMBLY, Keypad Flex, Model II (Includes item 41 and 43)

38 7285726C01 MODULE, LCD

39 7585189D01 PAD, Display Locator

40 4205631Z01 CLIP, Control Locking (part of item 41) (4 req’d)

41 2685567D01 SHIELD, Controller Front (Includes items 40 and 42)

42 - - - - - - - - - - RETAINER (Part of item 41)

43 8485188D01 FLEX, Keypad, Model III (part of item 37)

or 8485187D01 FLEX, Keypad, Model III (part of item 37)

44 NTN9564_ KIT, VOCON Board

45 NTN9837A

NTN9838A

NTN9839A

NNTN4006A

DES, DES-XL, DES-OFB with DVP-XL Encryption Kit - UCM

DVI-XL Encryption Kit - UCM

DVP-XL Encryption Kit - UCM

DES, DES-XL, DES-OFB Encryption Kit - UCM

46 2885866A01 CONNECTOR, Compression, 26-Pin

47 2685220D02 SHIELD, RF with Insulator and Clip (Includes item 63)

48 NUF3577_ KIT, Transceiver Board, 700/800MHz

49 0985973B01 ASSEMBLY, B+

or 0985973B02 ASSEMBLY, B+ (R Models)

50 3205351Z02 SEAL, B+

51 2785219D01 ASSEMBLY, Casting

or 2785219D04 ASSEMBLY, Casting (R Models)

52 3005664Z01 ASSEMBLY, Coaxial Cable

53 7505487Z01 PAD, Coax

54 3205082E96 GASKET, O-Ring Bushing

55 3205349Z03 SEAL, Main

56 HNN9031_ BATTERY, NiCd, Ultra-High Capacity

57 NTN8266_ KIT, Belt Clip

58 3262737D01 PAD, Thermal

59 3285688D01 PLUG, Vacuum Test Port

61 3285877B02 SEAL, Port

62 3385873B01 LABEL, Seal

63 4285704D01 CLIP, RF Locking (Part of item 47)

64 3385419C01

3385419C07 BEZEL, Display - Titanium Silver (part of item 2)

BEZEL, Display - Black (part of item 2)

or NNTN4071_ Bezel Display Kit

65 3585741D01 MESH, Microphone (part of item 2)

66 3385658D01 ESCUTCHEON, Concentric Switch (part of item 2)

67 3385657D01 ESCUTCHEON, Toggle (part of item 2)

71 7585936D01 PAD

ITEM

NO. MOTOROLA

PART NUMBER DESCRIPTION

Exploded Views and Parts Lists

MAEPF-27210-O

56 55 54

23 22

966

Models II and III Exploded View

ASTRO® XTS 5000™ Digital Portable Radios Accessory Section Changes

This FMR applies to the accessory section of the following publications and CDs:

• 68P81094C25-O ASTRO XTS 5000 Digital Portable Radio Model I User Guide

• 68P81094C26-O ASTRO XTS 5000 Digital Portable Radio Model II User Guide

• 68P81094C27-O ASTRO XTS 5000 Digital Portable Radio Model III User Guide

• 68P81094C28-O ASTRO XTS 5000 Digital Portable Radio Basic Service Manual

• 9985901D01 ASTRO XTS 5000 Digital Portable Radio Models I, II, and III User Guides CD

• 9985902D01 ASTRO XTS 5000 Digital Portable Radio Basic Service Manual CD

The accessories listed below are not compatible with the XTS 5000 at this time. Please refer to the

following web site for a complete list of approved accessories:

http://www.motorola.com/cgiss/portables/xts5000.shtml

Motorola Kit Numbers

BDN6664 BDN6669 BDN6728 BDN6780 NMN6246

BDN6665 BDN6670 BDN6729 BDN6781 NTN1624

BDN6666 BDN6676 BDN6730 BDN6782 NTN1625

BDN6667 BDN6726 BDN6731 NMN1020 NTN1663

BDN6668 BDN6727 BDN6732 NMN6245 NTN1736

A, Motorola, ASTRO, and XTS 5000 are trademarks of Motorola, Inc.

Printed in U.S.A. 12/01.

FMR-2014-1

ASTRO® XTS 5000™ Digital Portable Radios Accessory Section Changes

This FMR applies to the accessory section of the following user’s guides and CDs: