Motorola Astro Digital Mobile Radio Xtl5000 Detailled 6881096c74 B Manual

							
Deta ile d S erv ic e  M anual
A STR O® 
VH F
UHF R an ge  1  a n d 2
7 00– 800  M Hz
M obile  R adio 
						

							
Title PageASTRO® Digital XTL™5000
VHF/UHF Range 1/UHF Range 2/700
–800 MHz
Mobile Radio
Detailed Service Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322
6881096C74-B 
						

							
Foreword
The information contained in this manual relates to all ASTRO® Digital XTL™ 5000 VHF/UHF Range 1/UHF Range 2/700–
800 MHz mobile radios equipped with W3, W4, W5, W7, or W9  control heads, unless otherwise specified. This manual 
provides sufficient information to enable qualified service  technicians to troubleshoot and repair XTL 5000 radios to the 
component level.
For details on radio operation or basic troubleshooting, refer  to the applicable manuals available separately. A list of relate d 
publications is provided in the section,  “Related Publications,” on page xxii.
Product Safety and RF Exposure Compliance
ATTENTION!
This radio is restricted to occupational use only  to satisfy FCC RF energy exposure requirements. 
Before using this product, read the RF energy awareness information and operating instructions in the 
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 
6881095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries,  and other accessories, visit the following web site 
which lists approved accessories: http ://www.motorola.com/cgiss/index.shtml
.
Manual Revisions
Changes which occur after this manual is printed are described  in FMRs (Florida Manual Revisions). These FMRs provide 
complete replacement pages for all added, changed, and deleted  items, including pertinent parts list data, schematics, and 
component layout diagrams. To obtain FMRs, contact th e Radio Products and Services Division (refer to “Appendix B 
Replacement Parts Ordering ).
Computer Software Copyrights
The Motorola products described in this manual may incl ude 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, bu t not limited to, the exclusive right to copy or reproduce in 
any form the copyrighted computer progra m. 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-excl usive license to use that arises by operation of law in the 
sale of a product.
Document Copyrights
No duplication or distribution of this document or any porti on thereof shall take place without the express written permission 
of Motorola. No part of this manual may be reproduced, distribu ted, or transmitted in any form or by any means, electronic 
or mechanical, for any purp ose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is  believed to be entirely reliable. However, no responsibility is 
assumed for inaccuracies. Furthe rmore, Motorola reserves the right to make changes to any products herein to improve 
readability, function, or design. Motorola does not assume any  liability arising out of the applications or use of any product 
or circuit described herein; nor does it cover any li cense under its patent rights nor the rights of others.
Trademarks
MOTOROLA, the Stylized M logo, and ASTRO are registered in  the US Patent & Trademark Office. All other product or 
service names are the property of their respective owners.
© Motorola, Inc. 2005.
Before using this product, read the operating instructions 
for safe usage contained in the Product Safety and RF 
Exposure booklet enclosed with your radio.
!
C a u t i o n 
						

							iii
Document History
The following major changes have been implemented in this manual since the previous edition:
EditionDescriptionDate
6881096C74-BAdded VHF High Power and UHF R1 High Power 
models.May, 2005 
						

							iv
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							Table of Contentsv
6881096C74-BMay 25, 2005
Table of Contents
Foreword......................................................................................................... ii
Document History ......................................................................................... iii
List of Figures .............................................................................................. xv
List of Tables ............................................................................................... xxi
Related Publications.................................................................................. xxii
Commercial Warranty............................................................................... xxiii
Limited Warranty ..................................................................................................................................... xxiii
MOTOROLA COMMUNICATION PRODUCTS ............................................................................ xxiii
I. What This Warranty Covers And For How Long .................................................................. xxiii
II. General Provisions.............................................................................................................. xxiii
III. State Law Rights ................................................................................................................xxiv
IV. How To Get Warranty Service ...........................................................................................xxiv
V. What This Warranty Does Not Cover .................................................................................xxiv
VI. Patent And Software Provisions ........................................................................................ xxv
VII. Governing Law ................................................................................................................. xxv
Model Numbering, Charts, and Specifications ..................................... xxvii
Mobile Radio Model Numbering Scheme............................................................................................... xxvii
ASTRO XTL 5000 Motorcycle VHF 10-50 Watt Model Chart ............................................................... xxviii
ASTRO XTL 5000 VHF 10-50 Watt Model Chart ....................................................................................xxix
ASTRO XTL 5000 VHF 10-50 Watt Model Chart (cont.)......................................................................... xxx
ASTRO XTL 5000 VHF 25-110 Watt Model Chart ..................................................................................xxxi
ASTRO XTL 5000 VHF 25-110 Watt Model Chart (cont.)...................................................................... xxxii
ASTRO XTL 5000 Motorcycle UHF Range 1 4-15 Watt Model Chart................................................... xxxiii
ASTRO XTL 5000 UHF Range 1 4-40 Watt Model Chart ..................................................................... xxxiv
ASTRO XTL 5000 UHF Range 1 4-40 Watt Model Chart (cont.) ...........................................................xxxv
ASTRO XTL 5000 UHF Range 1 25-110 Watt Model Chart ................................................................. xxxvi
ASTRO XTL 5000 UHF Range 1 25-110 Watt Model Chart (cont.) ..................................................... xxxvii
ASTRO XTL 5000 Motorcycle UHF Range 2 4-15 Watt Model Chart................................................. xxxviii
ASTRO XTL 5000 UHF Range 2 4-45 Watt Model Chart ..................................................................... xxxix
ASTRO XTL 5000 UHF Range 2 4-45 Watt Model Chart (cont.) ............................................................... xl
ASTRO XTL 5000 Motorcycle 700-800 MHz 3.5-15 Watt Model Chart .................................................... xli
ASTRO XTL 5000 700-800 MHz 3.5-35 Watt Model Chart ......................................................................xlii
ASTRO XTL 5000 700-800 MHz 3.5-35 Watt Model Chart (cont.) .......................................................... xliii
VHF Radio Specifications ........................................................................................................................xliv
UHF Range 1 Radio Specifications.......................................................................................................... xlv
UHF Range 2 Radio Specifications..........................................................................................................xlvi
700–800 MHz Radio Specifications (Mid Power Models Only) ............................................................... xlvii 
						

							
viTable of Contents
May 25, 2005 6881096C74-B
Chapter 1 Introduction .......................................................................... 1-1
1.1 Notations Used in This Manual .................. ....................................................................................1-1
1.2 General..................................................................................................................... ......................1-1
Chapter 2 Product Overview................................................................ 2-1
2.1 Introduction................................................................................................................ .....................2-1
2.2 Functional Blocks ........................................................................................................... ................2-1
2.3 Control-Head Assembly ....................................................................................................... ..........2-2
2.3.1 Display, Vacuum Fluorescent Display Dr iver, Vacuum Fluorescent Voltage Source, 
Controls and Indicators, Status LEDs and Backlight LEDs ...............................................2-2
2.3.2 Vehicle Interface Ports ................................................................................................... ...2-2
2.3.2.1 Dash-Mount Control-Head  Configuration (Mid Power Only) ....................................2-2
2.3.2.5 VIP Output Connections: ..........................................................................................2-6
2.3.2.6 VIP Input Connections:.............................................................................................2-6
2.3.2.7 DEK Interface With Radi o: Remote-Mount (W4, W5, W7, W9)................................2-7
2.3.3 Power Supplies ............................................................................................................ .....2-7
2.3.4 Ignition Sense Circuits................................................................................................... ....2-7
2.4 Receiver Section ............................................................................................................ ................2-8
2.4.1 VHF Band Radios........................................................................................................... ...2-8
2.4.1.1 Front-End Section ....................................................................................................2-8
2.4.1.2 Back-End Section .....................................................................................................2-8
2.4.2 UHF Range 1/UHF Range 2 Band Radios ........ ................................................................2-8
2.4.2.1 Front-End Section ....................................................................................................2-8
2.4.2.2 Intermediate Frequency and Back-End .... ................................................................2-8
2.4.3 700–800 MHz Band Radios ..............................................................................................2-9 2.4.3.1 Front-End Section ....................................................................................................2-9
2.4.3.2 Back-End Section .....................................................................................................2-9
2.5 Transmitter Section ......................................................................................................... ...............2-9
2.5.1 VHF Radios ................................................................................................................ .......2-9
2.5.2 UHF Range 1/UHF Range 2 Radios ................. ................................................................2-9
2.5.3 700–800 MHz Radios ......................................................................................................2-1 0
2.5.3.1 RFPA .................................................................................................................... ..2-10
2.5.3.2 Output Network ......................................................................................................2-10
2.5.3.3 Power Control.........................................................................................................2- 10
2.5.3.4 Circuit Protection ....................................................................................................2- 10
2.6 Frequency Generation Unit ................................................................................................... .......2-10
2.6.1 VHF MHz Radios............................................................................................................. 2-10
2.6.2 UHF Range 1/UHF Range 2 Radios ................. ..............................................................2-11
2.6.3 700–800 MHz Radios ......................................................................................................2-1 1
2.7 Controller Section .......................................................................................................... ...............2-12
2.7.1 Analog Mode of Operation ......................... .....................................................................2-12
2.7.2 Digital (ASTRO) Mode of  Operation ................................................................................2-13
2.7.3 Controller Section Circuitry.............................................................................................. 2-13
Chapter 3 Theory of Operation ............................................................ 3-1
3.1 Main Board .................................................................................................................. ...................3-1
3.2 Main Board Major Sections ................................................................................................... .........3-1
3.2.1 VHF (136–174 MHz) Band ................................................................................................3-1
3.2.2 UHF Range 1 (380-470 MHz) and UHF Rang e 2 (450-520 MHz) Band...........................3-6 
						

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6881096C74-BMay 25, 2005
3.2.3 700–800 MHz Band.........................................................................................................3-10
3.3 Radio Power Distribution ..............................................................................................................3-12
3.4 Receiver Front-End ......................................................................................................................3-13
3.4.1 VHF (136–174 MHz) Band ..............................................................................................3-13
3.4.1.1 15 dB Step Attenuator (U3250) ..............................................................................3-14
3.4.1.2 PIN Diode Switches................................................................................................3-14
3.4.1.3 Preselector Filters ..................................................................................................3-14
3.4.1.4 Low-Noise Amplifiers (Q3255, Q3252)...................................................................3-14
3.4.1.5 Mixer (D3258).........................................................................................................3-15
3.4.2 UHF Range 1 (380–470 MHz) Band ...............................................................................3-15
3.4.2.1 Highpass Filter and First Low-Noise Amplifier .......................................................3-16
3.4.2.2 Preselector Filter ....................................................................................................3-16
3.4.2.3 Switchable 15 dB Attenuator ..................................................................................3-16
3.4.2.4 Low-Noise Amplifier (LNA, U5302) ........................................................................3-16
3.4.2.5 Image Filter ............................................................................................................3-16
3.4.2.6 Mixer.......................................................................................................................3-16
3.4.3 UHF Range 2 (450–520 MHz) Band ...............................................................................3-17
3.4.3.1 Highpass Filter and First Low-Noise Amplifier .......................................................3-17
3.4.3.2 Preselector Filter ....................................................................................................3-18
3.4.3.3 Switchable 15 dB Attenuator ..................................................................................3-18
3.4.3.4 Low-Noise Amplifier (LNA, U5302) ........................................................................3-18
3.4.3.5 Image Filter ............................................................................................................3-18
3.4.3.6 Mixer.......................................................................................................................3-18
3.4.4 700–800 MHz Band.........................................................................................................3-19
3.4.4.1 Preselector Filters ..................................................................................................3-19
3.4.4.2 Low-Noise Amplifier (LNA, U6250) ........................................................................3-19
3.4.4.3 Mixer (U6251).........................................................................................................3-20
3.5 Receiver Back-End.......................................................................................................................3-20
3.5.1 VHF (136-174 MHz) Band ...............................................................................................3-20
3.5.1.1 Intermediate Frequency (IF) Section ......................................................................3-20
3.5.1.2 ABACUS III IC ........................................................................................................3-20
3.5.2 UHF Range 1 (380-470 MHz) Band ................................................................................3-21
3.5.2.1 Intermediate Frequency (IF) Filter ..........................................................................3-22
3.5.2.2 ABACUS III IC (U5002) ..........................................................................................3-22
3.5.3 UHF Range 2 (450-520 MHz) Band ................................................................................3-23
3.5.3.1 Intermediate Frequency (IF) Filter ..........................................................................3-23
3.5.3.2 ABACUS III IC (U5002) ..........................................................................................3-23
3.5.4 700–800 MHz Band.........................................................................................................3-24
3.5.4.1 Intermediate Frequency (IF) Filter ..........................................................................3-25
3.5.4.2 ABACUS III IC (U6000) ..........................................................................................3-25
3.6 Transmitter ...................................................................................................................................3-26
3.6.1 VHF (136-174 MHz) Band ...............................................................................................3-26
3.6.1.1 50-Watt Transmitter................................................................................................3-26
3.6.1.2 100-Watt Transmitter..............................................................................................3-28
3.6.1.3 Output Network (ON) - (for 50W and 100W Transmitter) .......................................3-29
3.6.1.4 Power Control (for 50W and 100W Transmitter) ....................................................3-30
3.6.2 UHF Range 1 (380-470 MHz) Band ................................................................................3-31
3.6.2.1 40-Watt Transmitter................................................................................................3-31
3.6.2.2 100-Watt Transmitter..............................................................................................3-33
3.6.2.3 Output Network (ON) - (for 40W and 100W Transmitter) .......................................3-34
3.6.2.4 Power Control (for 40W and 100W Transmitter) ....................................................3-35
3.6.3 UHF Range 2 (450-520 MHz) Band ................................................................................3-37
3.6.3.1 45-Watt Transmitter................................................................................................3-37
3.6.4 700–800 MHz Band.........................................................................................................3-41 
						

							viiiTable of Contents
May 25, 20056881096C74-B
3.6.4.1 35-Watt Transmitter................................................................................................3-41
3.7 Frequency Generation Unit (FGU) ...............................................................................................3-45
3.7.1 VHF (136-174 MHz) Band ...............................................................................................3-45
3.7.1.1 Reference Oscillator ...............................................................................................3-46
3.7.1.2 LV Frac-N Synthesizer IC.......................................................................................3-46
3.7.1.3 Voltage Multiplier ....................................................................................................3-47
3.7.1.4 Superfilter ...............................................................................................................3-47
3.7.1.5 Modulation ..............................................................................................................3-47
3.7.1.6 Charge Pump Bias .................................................................................................3-48
3.7.1.7 Loop Filter ..............................................................................................................3-48
3.7.1.8 Lock Detect ............................................................................................................3-48
3.7.1.9 Transmitter Injection ...............................................................................................3-48
3.7.1.10 Receiver Injection ...................................................................................................3-49
3.7.1.11 Transmitter VCOs...................................................................................................3-49
3.7.1.12 Receiver VCOs.......................................................................................................3-49
3.7.1.13 Prescaler Feedback ...............................................................................................3-49
3.7.2 UHF Range 1 (380–470 MHz) Band ...............................................................................3-49
3.7.2.1 Reference Oscillator ...............................................................................................3-50
3.7.2.2 LV Frac-N Synthesizer IC.......................................................................................3-50
3.7.2.3 Voltage Multiplier ....................................................................................................3-51
3.7.2.4 Superfilter ...............................................................................................................3-51
3.7.2.5 Modulation ..............................................................................................................3-51
3.7.2.6 Charge Pump Bias .................................................................................................3-52
3.7.2.7 Loop Filter ..............................................................................................................3-52
3.7.2.8 Lock Detect ............................................................................................................3-52
3.7.2.9 Transmitter Injection ...............................................................................................3-52
3.7.2.10 Receiver Injection ...................................................................................................3-52
3.7.2.11 Transmitter VCOs...................................................................................................3-53
3.7.2.12 Receiver VCOs.......................................................................................................3-53
3.7.2.13 Prescaler Feedback ...............................................................................................3-53
3.7.3 UHF Range 2 (450–520 MHz) Band ...............................................................................3-54
3.7.3.1 Reference Oscillator ...............................................................................................3-55
3.7.3.2 LV Frac-N Synthesizer IC.......................................................................................3-55
3.7.3.3 Voltage Multiplier ....................................................................................................3-55
3.7.3.4 Superfilter ...............................................................................................................3-56
3.7.3.5 Modulation ..............................................................................................................3-56
3.7.3.6 Charge Pump Bias .................................................................................................3-56
3.7.3.7 Loop Filter ..............................................................................................................3-56
3.7.3.8 Lock Detect ............................................................................................................3-56
3.7.3.9 Transmitter Injection ...............................................................................................3-57
3.7.3.10 Receiver Injection ...................................................................................................3-57
3.7.3.11 Transmitter VCOs...................................................................................................3-57
3.7.3.12 Receiver VCOs.......................................................................................................3-57
3.7.3.13 Prescaler Feedback ...............................................................................................3-58
3.7.4 700–800 MHz Band.........................................................................................................3-58
3.7.4.1 Reference Oscillator ...............................................................................................3-59
3.7.4.2 LV Frac-N Synthesizer IC.......................................................................................3-59
3.7.4.3 Voltage Multiplier ....................................................................................................3-59
3.7.4.4 Superfilter ...............................................................................................................3-60
3.7.4.5 Modulation ..............................................................................................................3-60
3.7.4.6 Charge Pump Bias .................................................................................................3-60
3.7.4.7 Loop Filter ..............................................................................................................3-60
3.7.4.8 Lock Detect ............................................................................................................3-60
3.7.4.9 Transmitter Injection ...............................................................................................3-61