Motorola Astro Digital Spectra Digital Spectra Plus Basic 6881076c20 E Manual

							ASTRO
®
 Digital Spectra®
 
and Digital Spectra Plus
     UHF
     VHF
     800 MHz
Mobile Radios
Basic Service Manual 
						

							i
Tit le Pag e® Digital Spectra®
and Digital Spectra Plus
VHF/UHF/800 MHz Digital Mobile Radios
Basic Service Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322
6881076C20-E 
						

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

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6881076C20-EFebruary 3, 2003
Table of Contents
Foreword .........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ ii
Manual Revisions ........................................................................................................................................ ii
Computer Software Copyrights ................................................................................................................... ii
Document Copyrights .................................................................................................................................. ii
Disclaimer .................................................................................................................................................... ii
Trademarks ................................................................................................................................................. ii
Commercial Warranty ..................................................................................xii
Limited Warranty ....................................................................................................................................... xii
MOTOROLA COMMUNICATION PRODUCTS ............................................................................ 1-xii
I. What This Warranty Covers And For How Long .................................................................... xii
II. General Provisions ................................................................................................................ xii
III. State Law Rights ................................................................................................................. xiii
IV. How To Get Warranty Service ............................................................................................ xiii
V. What This Warranty Does Not Cover................................................................................... xiii
VI. Patent And Software Provisions ......................................................................................... xiv
VII. Governing Law ................................................................................................................... xiv
Model Numbering, Charts, and Specifications ..........................................xv
Mobile Radio Model Numbering Scheme .................................................................................................. xv
ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 1 and 2) Model Chart............................................ xvi
ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 3 and 3.5) Model Chart........................................ xvii
ASTRO Digital Spectra VHF 10–25 Watt Model Chart........................................................................... xviii
ASTRO Digital Spectra VHF 25–50 and 50–110 Watt Model Chart......................................................... xix
ASTRO Digital Spectra VHF 10–25 and 50–110 Watt Model Chart (cont.) .............................................. xx
ASTRO Digital Spectra UHF 10–25 Watt Model Chart ............................................................................ xxi
ASTRO Digital Spectra UHF 20–40 Watt Model Chart ........................................................................... xxii
ASTRO Digital Spectra UHF 20–40 Watt Model Chart (cont.) ............................................................... xxiii
ASTRO Digital Spectra UHF 50–110 Watt Model Chart ........................................................................ xxiv
ASTRO Digital Spectra UHF 50–110 Watt Model Chart (cont.) .............................................................. xxv
ASTRO Digital Spectra 800 MHz Model Chart .......................................................................................xxvi
ASTRO Digital Spectra Plus VHF 25–50 and 50–110 Watt Model Chart.............................................. xxvii
ASTRO Digital Spectra Plus VHF 25–50 and 50–110 Watt Model Chart (cont.) ..................................xxviii
ASTRO Digital Spectra Plus UHF 20–40 Watt Model Chart .................................................................. xxix
ASTRO Digital Spectra Plus UHF 20–40 Watt Model Chart (cont.) ........................................................ xxx
ASTRO Digital Spectra Plus UHF 50–110 Watt Model Chart ................................................................ xxxi
ASTRO Digital Spectra Plus UHF 50–110 Watt Model Chart (cont.) .................................................... xxxii
ASTRO Digital Spectra Plus 800 MHz Model Chart ..............................................................................xxxiii
ASTRO Digital Spectra Plus 800 MHz Model Chart (cont.).................................................................. xxxiv
VHF Radio Specifications ...................................................................................................................... xxxv
UHF Radio Specifications..................................................................................................................... xxxvi
800 MHz Radio Specifications..............................................................................................................xxxvii 
						

							ivTable of Contents
February 3, 20036881076C20-E
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual ...................................................................................................... 1-1
1.2 Radio Descriptions ......................................................................................................................... 1-1
1.2.1 FLASHport®...................................................................................................................... 1-2
1.3 Control Head Descriptions ............................................................................................................. 1-2
1.3.1 General ............................................................................................................................. 1-2
1.3.1.1 Model W3 Control Head........................................................................................... 1-3
1.3.1.2 Model W3 Controls .................................................................................................. 1-3
1.3.1.3 Models W4, W5, W7, and W9 Controls Head .......................................................... 1-4
1.3.1.4 Models W4, W5, W7, and W9 Controls ................................................................... 1-5
Chapter 2 Basic Maintenance .............................................................. 2-1
2.1 Introduction .................................................................................................................................... 2-1
2.2 Preventive Maintenance ................................................................................................................ 2-1
2.2.1 Reference Oscillator ......................................................................................................... 2-1
2.2.2 Inspection.......................................................................................................................... 2-1
2.2.3 Cleaning ............................................................................................................................ 2-1
2.2.4 Cleaning External Plastic Surfaces ................................................................................... 2-2
2.2.5 Cleaning Internal Circuit Boards and Components ........................................................... 2-2
2.3 Handling Precautions ..................................................................................................................... 2-2
Chapter 3 Basic Theory of Operation ................................................. 3-1
3.1 Introduction .................................................................................................................................... 3-1
3.2 General Overview .......................................................................................................................... 3-1
3.3 Analog Mode of Operation ............................................................................................................. 3-2
3.3.1 Receive Operation ............................................................................................................ 3-2
3.3.2 Transmit Operation ........................................................................................................... 3-2
3.4 ASTRO Mode of Operation ............................................................................................................ 3-2
3.5 Control Head Assembly ................................................................................................................. 3-2
3.5.1 Display (W4, W5, and W7 Models) ................................................................................... 3-2
3.5.2 Display (W9 Model)........................................................................................................... 3-3
3.5.3 Vacuum Fluorescent (VF) Display Driver.......................................................................... 3-3
3.5.4 Vacuum Fluorescent (VF) Voltage Source (W9 Model) .................................................... 3-3
3.5.5 Controls and Indicators ..................................................................................................... 3-3
3.5.6 Status LEDs ...................................................................................................................... 3-3
3.5.7 Backlight LEDs.................................................................................................................. 3-3
3.5.8 Vehicle Interface Port (VIP) ..............................................................................................3-4
3.5.8.1 Remote-Mount ......................................................................................................... 3-4
3.5.8.2 Dash-Mount ............................................................................................................. 3-4
3.5.9 Power Supplies ................................................................................................................. 3-4
3.5.10 Ignition Sense Circuits ...................................................................................................... 3-4
3.6 Power Amplifier .............................................................................................................................. 3-4
3.6.1 Gain Stages ...................................................................................................................... 3-4
3.6.2 Power Control ................................................................................................................... 3-5
3.6.3 Circuit Protection............................................................................................................... 3-5
3.6.4 DC Interconnect ................................................................................................................ 3-5
3.7 Front-End Receiver Assembly ....................................................................................................... 3-5
3.8 Radio Frequency (RF) Board ......................................................................................................... 3-5
3.9 Voltage-Controlled Oscillator (VCO) .............................................................................................. 3-6 
						

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6881076C20-EFebruary 3, 2003
3.9.1 VHF Radios ...................................................................................................................... 3-6
3.9.2 UHF and 800 MHz Radios ................................................................................................ 3-6
3.10 Command Board............................................................................................................................ 3-6
3.11 VOCON (Vocoder/Controller) Board.............................................................................................. 3-7
3.11.1 ASTRO Digital Spectra .....................................................................................................3-7
3.11.2 ASTRO Digital Spectra Plus ............................................................................................. 3-7
Chapter 4 Test Equipment, Service Aids, and Tools......................... 4-1
4.1 Recommended Test Equipment .................................................................................................... 4-1
4.2 Service Aids and Recommended Tools......................................................................................... 4-2
4.3 Field Programming Equipment ...................................................................................................... 4-5
4.3.1 ASTRO Digital Spectra .....................................................................................................4-5
4.3.1.1 ASTRO Digital Spectra W3 Smart RIB Issue .......................................................... 4-6
4.3.1.2 ASTRO Digital Spectra Remote W3 Y Cable .......................................................... 4-6
4.3.2 ASTRO Digital Spectra Plus ............................................................................................. 4-7
4.3.2.1 ASTRO Digital Spectra Plus Model W3 ................................................................... 4-7
Chapter 5 Performance Checks .......................................................... 5-1
5.1 Introduction .................................................................................................................................... 5-1
5.2 Test Setup ..................................................................................................................................... 5-1
5.2.1 ASTRO Digital Spectra .....................................................................................................5-1
5.2.2 ASTRO Digital Spectra Plus ............................................................................................. 5-2
5.3 Test Mode ...................................................................................................................................... 5-2
5.3.1 Entering Test Mode .......................................................................................................... 5-2
5.3.2 RF Test Mode ................................................................................................................... 5-3
5.3.3 Control Head Test Mode................................................................................................... 5-5
5.4 Receiver Performance Checks ...................................................................................................... 5-6
5.5 Transmitter Performance Checks .................................................................................................. 5-7
Chapter 6 Radio Alignment Procedure ............................................... 6-1
6.1 Introduction .................................................................................................................................... 6-1
6.2 RSS ............................................................................................................................................... 6-1
6.2.1 ASTRO Digital Spectra .....................................................................................................6-1
6.2.2 Softpot .............................................................................................................................. 6-2
6.2.3 Reference Oscillator Alignment ........................................................................................ 6-3
6.2.4 Transmit Power Alignment................................................................................................ 6-4
6.2.5 Transmit Current Limit Alignment ..................................................................................... 6-6
6.2.6 Transmit Deviation Balance (Compensation) Alignment .................................................. 6-7
6.2.7 Transmit Deviation Limit Alignment .................................................................................. 6-8
6.2.8 Bit Error Rate (BER) Performance Check ...................................................................... 6-10
6.3 ASTRO Digital Spectra and Digital Spectra Plus Tuner Software ............................................... 6-10
6.3.1 Radio Information ........................................................................................................... 6-14
6.3.2 Reference Oscillator Alignment ...................................................................................... 6-14
6.3.3 Transmit Power Alignment.............................................................................................. 6-16
6.3.4 Transmit Current Limit Alignment ................................................................................... 6-18
6.3.5 Transmit Deviation Balance (Compensation) Alignment ................................................ 6-18
6.3.6 Transmit Deviation Limit Alignment ................................................................................ 6-20
6.3.7 Bit Error Rate (BER) Test ............................................................................................... 6-22 
						

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6.3.8 Transmitter Test Pattern ................................................................................................. 6-23
Chapter 7 Encryption ........................................................................... 7-1
7.1 Universal Crypto Module Kits......................................................................................................... 7-1
7.1.1 ASTRO Digital Spectra .....................................................................................................7-1
7.1.2 ASTRO Digital Spectra Plus ............................................................................................. 7-1
7.1.3 Secure Dispatch Operation ............................................................................................... 7-1
7.1.4 Secure Emergency Operation........................................................................................... 7-2
7.2 Load an Encryption Key ................................................................................................................. 7-2
7.2.1 Model W3 .......................................................................................................................... 7-2
7.2.2 Models W4, W5, W7, and W9 ........................................................................................... 7-3
7.3 Erase a Key ................................................................................................................................... 7-3
7.3.1 Model W3 .......................................................................................................................... 7-3
7.3.2 Models W4, W5, W7, and W9 ........................................................................................... 7-4
7.4 Erase a Single Key (Model W3) ..................................................................................................... 7-5
7.5 Erase All Keys................................................................................................................................ 7-5
7.5.1 Model W3 .......................................................................................................................... 7-5
7.5.2 Models W4, W5, W7, and W9 ........................................................................................... 7-6
7.6 Over-the-Air Rekeying ................................................................................................................... 7-6
7.6.1 ASTRO Digital Spectra Model W3 .................................................................................... 7-7
7.6.2 ASTRO Digital Spectra Models W4, W5, W7, and W9 ..................................................... 7-9
7.7 Advanced Secure Operation ........................................................................................................ 7-10
7.7.1 Multikey Operation .......................................................................................................... 7-10
Chapter 8 Disassembly/Reassembly Procedures ............................. 8-1
8.1 Introduction .................................................................................................................................... 8-1
8.2 Replacement Procedures .............................................................................................................. 8-1
8.2.1 Required Tools and Supplies ............................................................................................ 8-2
8.2.2 Control Head Boards ........................................................................................................8-2
8.2.2.1 Model W3 .................................................................................................................8-2
8.2.2.2 Models W4, W5, and W7 ......................................................................................... 8-3
8.2.2.3 Model W9 .................................................................................................................8-4
8.2.3 Remote Back Housing Interface Board............................................................................. 8-5
8.2.3.1 Models W4, W5, and W7 ......................................................................................... 8-5
8.2.4 Remote Interconnect Board .............................................................................................. 8-6
8.2.4.1 Low-/Mid-Power Radios ........................................................................................... 8-6
8.2.4.2 High-Power Radios .................................................................................................. 8-6
8.2.5 Power Amplifier Board ......................................................................................................8-7
8.2.5.1 Low-/Mid-Power Radios ........................................................................................... 8-7
8.2.5.2 High-Power Radios .................................................................................................. 8-7
8.2.5.3 800 MHz Radios ...................................................................................................... 8-8
8.2.5.3.1 Back-End Removal ........................................................................................... 8-8
8.2.5.3.2 PC Board Removal ........................................................................................... 8-8
8.2.5.3.3 PC Board Installation ........................................................................................ 8-9
8.2.5.3.4 Back-End Installation ...................................................................................... 8-10
8.2.6 VOCON (Vocoder/Controller) Board ............................................................................... 8-11
8.2.7 Command Board .............................................................................................................8-11
8.2.7.1 Low-/Mid-Power Radios ......................................................................................... 8-11
8.2.7.2 High-Power Radios ................................................................................................ 8-12
8.2.8 Receiver Front-End Board .............................................................................................. 8-13 
						

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6881076C20-EFebruary 3, 2003
8.2.8.1 Low-/Mid-Power Radio .......................................................................................... 8-13
8.2.8.2 High-Power Radio.................................................................................................. 8-13
8.2.9 VCO Board ..................................................................................................................... 8-14
8.2.9.1 Low-/Mid-Power Radio .......................................................................................... 8-14
8.2.9.2 High-Power Radio.................................................................................................. 8-15
8.2.10 RF Board ........................................................................................................................ 8-15
8.2.10.1 Low-/Mid-Power Radio .......................................................................................... 8-15
8.2.10.2 High-Power Radio.................................................................................................. 8-16
8.3 Final Reassembly ........................................................................................................................ 8-16
8.3.1 Power Amplifiers ............................................................................................................. 8-16
8.3.2 Command Board.............................................................................................................8-17
8.3.3 Dash Control Head Board............................................................................................... 8-17
8.3.4 Model W3 Hand-Held Control Head ............................................................................... 8-17
8.4 Fastener Torque Chart ................................................................................................................ 8-18
Chapter 9 Basic Troubleshooting ....................................................... 9-1
9.1 Introduction .................................................................................................................................... 9-1
9.2 Replacement Board Procedures.................................................................................................... 9-1
9.3 Power-Up Error Codes .................................................................................................................. 9-1
9.3.1 ASTRO Digital Spectra .....................................................................................................9-2
9.3.2 ASTRO Digital Spectra Plus ............................................................................................. 9-3
9.4 Operational Error Codes ................................................................................................................ 9-4
9.4.1 ASTRO Digital Spectra .....................................................................................................9-4
9.4.2 ASTRO Digital Spectra Plus ............................................................................................. 9-5
9.5 Transmitter Troubleshooting .......................................................................................................... 9-5
9.6 Receiver Troubleshooting .............................................................................................................. 9-9
9.7 Synthesizer Troubleshooting ....................................................................................................... 9-12
Chapter 10 Functional Block Diagrams and Connectors ................. 10-1
10.1 Digital Spectra Functional Block Diagram (Models W3, W4, W5, W7, and W9) ......................... 10-2
10.2 Digital Spectra Plus Functional Block Diagram (Models W3, W4, W5, W7, and W9) ................. 10-3
10.3 Radio Connectors ........................................................................................................................ 10-4
10.4 Radio Connector Locations ......................................................................................................... 10-5
10.5 Radio Connector Locations (cont.) .............................................................................................. 10-5
10.6 Extender Cable (P501) ................................................................................................................ 10-6
10.7 Control Head Cabling Diagram .................................................................................................... 10-6
Chapter 11 Exploded Views and Parts Lists ...................................... 11-1
11.1 Model W3 Hand-Held Control Head Exploded View ................................................................... 11-2
11.2 Model W4 Rotary Control Head Exploded View .......................................................................... 11-3
11.3 Models W5 and W7 Pushbutton Control Head Exploded View ................................................... 11-4
11.4 Model W9 Pushbutton Control Head Exploded View .................................................................. 11-5
11.5 Low-Power (15W) Radio Exploded View ..................................................................................... 11-6
11.6 Mid-Power (20-40/25-50/35W) Radio Exploded View ................................................................. 11-7
11.7 High-Power (50-110W) Radio Exploded View ............................................................................. 11-8
11.8 Motorcycle Interconnect Board and Assembly ............................................................................ 11-9
11.9 Low- and Mid-Power Interconnect Board and Assembly ............................................................. 11-9
11.10 Small Pushbutton Parts ............................................................................................................. 11-10 
						

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11.11 Large Pushbutton Parts ............................................................................................................. 11-10
Appendix A Replacement Parts Ordering.............................................. A-1
A.1 Basic Ordering Information ............................................................................................................A-1
A.2 Transceiver Board and VOCON Board Ordering Information ........................................................A-1
A.3 Motorola Online..............................................................................................................................A-1
A.4 Mail Orders ....................................................................................................................................A-1
A.5 Telephone Orders ..........................................................................................................................A-2
A.6 Fax Orders .....................................................................................................................................A-2
A.7 Parts Identification .........................................................................................................................A-2
A.8 Product Customer Service .............................................................................................................A-2
Glossary ......................................................................................... Glossary-1
Index ...................................................................................................... Index-i