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

							6881076C20-EFebruary 3, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-13
17. Replace the section VOCON board shield and the top cover, and then torque the screws to 6-
8 in.-lbs.
8.2.8 Receiver Front-End Board
8.2.8.1  Low-/Mid-Power Radio
1. Remove the radio top cover.
2. Remove the two mounting screws and unplug the control head.
3. Remove the EMI metallic shielding tape (Motorola Part No.11-85984D01).
Be careful to prevent any tape particles from falling inside the chassis.
4. Disconnect the coaxial cable that passes through the front of the chassis from the RF board.
5. Remove the PA assembly.
6. Disconnect the coaxial cable that passes through the rear of the chassis to the receiver front 
end.
7. Remove the four screws and front-end cover, and carefully lift the receiver front-end board 
from the chassis.
NOTE:Be careful to insert the Rx injection coaxial cable straight into the receptacle on the 
VCO board, and be sure it is fully inserted. Be careful not to bend the tip of the 
coaxial cable, which provides the contact for the connection.
8. Install the new assembly, being careful not to damage the RF connection that passes through 
the chassis to the VCO.
9. Reconnect both coaxial cables.
10. Clean the chassis surface with isopropyl alcohol, and place a new piece of EMI metallic 
shielding tape (Motorola Part No. 11-85984D01) over the coaxial cable passing through the 
front of the chassis.
NOTE:The EMI metallic shielding tape must cover the hole in the receiver front-end board. 
This same piece of tape must also cover at least half of the coaxial cable.
11. Install the front end cover and four mounting screws.
12. Install the PA assembly, control head, and radio cover.
NOTE:No alignment is necessary.
8.2.8.2  High-Power Radio
1. Turn the radio top side down and use a Torx T15 driver to remove the four bottom-cover 
screws.
2. Remove the bottom cover.
3. Remove the power amplifier and RF board shields.
4. Disconnect the RX coaxial cable that comes through the power amplifier board.
5. Disconnect the coaxial cable from the RF board.
6. Feed both cables back to the top side of the radio.
7. Using a Torx T15 driver, remove the two top cover screws, and then remove the radio top 
cover.
8. Using a Torx T15 driver remove the four screws to the receiver front-end shield, and then 
remove the shield. 
						

							February 3, 20036881076C20-E
8-14Disassembly/Reassembly Procedures: Replacement Procedures
9. Carefully remove the front-end receiver board from the radio chassis cavity and disconnect 
the coaxial cable beneath it.
NOTE:Be careful to insert the Rx injection coaxial cable straight into the receptacle on the 
VCO board, and be sure it is fully inserted.
Also, be careful to not bend the tip of the coaxial cable, which provides the contact 
for the connection. Make sure all connections are tight, and that all shields are 
pressed firmly into their proper cavities.
10. Install the new front-end receiver board into the radio chassis cavity.
11. Reconnect the coaxial cable beneath the front-end board.
12. Feed the coaxial cables through the chassis into the opposite side.
13. Using four new screws and a Torx T15 driver, install the receiver front-end shield, and then 
torque the screws to 8-10 in.-lbs. Ensure the screws are aligned with the holes.
14. Replace the radio top cover, and torque the two top-cover screws to 6-8 in.-lbs.
15. Turn the radio topside down and reconnect the coaxial cable into the power amplifier board 
and RF board receptacles.
16. Replace the power amplifier shield, RF board shield, and bottom cover.
17. Torque the four bottom-cover screws to 6-8 in.-lbs.
NOTE:No alignment is necessary.
8.2.9 VCO Board
8.2.9.1  Low-/Mid-Power Radio
1. Remove the radio bottom cover.
2. Remove the PA assembly and disconnect the TX injection coax that passes through the 
chassis to the VCO board.
3. Remove the RF board cover.
4. Remove the six mounting screws and the cover.
5. Carefully lift the board far enough to expose the Rx injection coaxial cable underneath, which 
runs from a receptacle on the VCO through a hole in the chassis to the receiver front end 
assembly.
6. Unplug the coaxial cable from the receptacle on the VCO board, and then lift straight up on 
the VCO board to remove it from the chassis.
7. To install the new board, plug in the Rx injection coaxial cable (from the receiver front end) 
into the receptacle near the outer edge of the board.
8. Align the opposite edge connector with the RF board connector and snap it into place.
NOTE:Be sure the board and gasket are straight and that the board does not bind as the 
screws are tightened, pulling the board down to the cavity ledge. Tighten the screws 
evenly to avoid warping the board. It is very important to use proper screw torque 
to ensure proper operation in vibration environments. Use only new screws.
9. Connect the PA board’s RF cable to the VCO board connector (through the chassis).
10. Using six new mounting screws, install the VCO cover, and then torque the screws to 8-10 
in.-lbs. Ensure the screws are aligned with the holes.
11. Install the PA assembly and the radio cover. 
						

							6881076C20-EFebruary 3, 2003
Disassembly/Reassembly Procedures: Replacement Procedures 8-15
8.2.9.2  High-Power Radio
1. Turn the radio topside down and remove the four bottom-cover screws, and remove the 
bottom cover.
2. Remove the power amplifier and RF board shields.
3. Remove the six VCO board shield screws and remove the VCO board shield.
4. Gently pry up on the VCO board, where it extends over the RF board, until the VCO board is 
disconnected from the RF board.
5. Disconnect the two coaxial cables that plug into the VCO board and remove the board.
6. Remove the metal VCO gasket from around the VCO board.
7. Place the VCO metal gasket around the new VCO board.
NOTE:Be sure the board and gasket are straight and that the board does not bind as the 
screws are tightened, pulling the board down to the cavity ledge. Tighten the screws 
evenly to avoid warping the board. It is very important to use proper screw torque 
to ensure proper operation in vibration environments. Use only new screws.
8. Reconnect both of the coaxial cables to the VCO board.
9. Place the board into the chassis cavity by aligning the pins on the VCO board with the mating 
part on the RF board, and pressing the board firmly into place.
10. Replace the VCO board shield using six new mounting screws, and then torque the screws to 
8-10 in.-lbs.
11. Install the power amplifier and RF board shields.
12. Replace the bottom cover, and torque the four bottom-cover screws to 6-8 in.-lbs.
8.2.10 RF Board
8.2.10.1 Low-/Mid-Power Radio
1. See the previous paragraph and remove the VCO board.
2. Remove the control head.
3. Disconnect the RF cable that passes through the chassis to the RF board.
4. Remove the six mounting screws, and then remove the RF board.
5. Install the new RF board, and connect the RF cable through the front of the chassis to the RF 
board.
6. Install six new mounting screws in the RF board, but wait to tighten them until after you install 
the VCO board. Ensure the screws are aligned with the holes.
NOTE:Make sure the male-to-male command board header is fully seated in the command 
board before installing the RF board.
7. Install the VCO board.
8. Tighten the new RF and VCO board mounting screws (torque to 8-10 in.-lbs.). Ensure the 
screws are aligned with the holes.
NOTE:It is very important to use proper screw torque on both boards to ensure proper 
operation in vibration environments.
9. Install the control head and radio covers. 
						

							February 3, 20036881076C20-E
8-16Disassembly/Reassembly Procedures: Final Reassembly
8.2.10.2 High-Power Radio
1. Turn the radio topside down, remove the four bottom-cover screws, and then remove the 
bottom cover.
2. Remove the six VCO board shield screws.
3. Remove the VCO board and the RF board shields from the radio chassis.
4. Gently pry up on the VCO board, where it extends over the RF board, until the VCO board is 
disconnected from the RF board.
5. Remove the six RF board screws, and then move the VCO board out of the way.
NOTE:The coaxial cables that go to the VCO board do not need to be disconnected in 
order to move the VCO board out of the way. Make sure the male-to-male command 
board header is fully seated in the command board before installing the RF board.
6. Gently pry the RF board up away from the chassis cavity to disconnect the RF board from the 
command board on the other side of the chassis.
7. Plug the 24-pin connector from between the RF board and the command board into the new 
RF board.
8. Carefully place the new RF board into the chassis cavity.
9. Connect the RF board to the command board with the 24-pin connector.
10. Install the VCO board into place, making sure that the VCO board is properly connected to 
the RF board.
11. Install six new mounting screws in the RF board, and then torque them to 8-10 in.-lbs. Ensure 
the screws are aligned with the holes.
12. Replace the VCO board shield.
13. Install six new mounting screws in the VCO board, and then torque them to 8-10 in.-lbs. 
Ensure the screws are aligned with the holes.
14. Replace the bottom cover, and torque the four bottom-cover screws to 6-8 in.-lbs.
8.3 Final Reassembly
8.3.1 Power Amplifiers
1. Apply a thin coat of thermal compound (for example, Motorola Part No. 11-83166A01) to the 
pre-driver, driver and final device heatsink mounting surfaces.
NOTE:Do not use a thick coating of compound as it could degrade the thermal efficiency 
of the heatsink.
2. Tighten mounting screws on the pre-driver, driver, and final device before you attempt to 
transmit. This will insure proper thermal conduction.
3. Tighten the antenna connector nut (refer to 
Table 8-3: “Fastener Torque Chart” on page 8-18 
for torque value) to ensure the connector is well grounded.
Do not bend or twist the PA board. Such stress may crack the surface 
mount components and hybrid circuit.!
C a u t i o n 
						

							6881076C20-EFebruary 3, 2003
Disassembly/Reassembly Procedures: Final Reassembly 8-17
8.3.2 Command Board
NOTE:This assumes the PA is attached, the control head is detached, and the control head 
interconnect board is disconnected.
1. Before reassembly, apply a thin coat of thermal compound (for example, Motorola Part No. 
11-83166A01) to the bottom of the audio PA.
2. Insert the command board into the PA accessory connector (J503) before inserting it into the 
RF board connector (P500). It might be necessary to angle the command board towards the 
PA .
3. Ensure the accurate placement of the insulator between Q500, Q502, and Q521 and the 
chassis wall. Be careful, when placing the command board, not to fold or damage the 
insulator.
4. Start all six of the mounting screws before tightening and then tighten them evenly to ensure 
you do not warp the board.
5. Reconnect the control head interconnect board to command board.
6. Plug and secure the control head with two screws.
7. Reconnect the VOCON board and option board (if any) prior to installing covers.
8.3.3 Dash Control Head Board
When reassembling the control head, make sure the microphone pins are properly inserted through 
the elastomeric keypad. Also make sure the elastomeric keypad inserts are secured to the PC board.
8.3.4 Model W3 Hand-Held Control Head
NOTE:Numbers shown in parentheses in the following procedure refer to item numbers in 
Table 11.1, “Model W3 Hand-Held Control Head Exploded View,” on page 11-2.
1. To reassemble the housing assembly [7]:
A. Insert the transmit indicator [11] into the housing. Ensure that the top surface of the 
lightpipe is below the label recess of the housing.
B. Attach the nameplate label [13] to the front of the housing. Ensure that the label is 
securely attached.
C. Install the PTT actuator [9] into the housing. Ensure that its lip is seated in the grove in the 
housing.
D. Install the PTT lever [10] and the PTT boot [12] into the housing. Ensure that the lever is 
seated in its nest and the boot is located properly in the recesses in the housing.
E. Install the keypad [6] into the housing. Ensure that all of the keys are located in the correct 
openings in the housing.
2. Install the microphone assembly [8] into the keypad. Ensure that the front surface of the 
cartridge is located up against the keypad membrane.
NOTE:The membrane is the rain seal and is very sensitive to puncture by sharp objects.
3. Connect the microphone cable connector to the mating location on the circuit board [5].
4. Install the circuit board [5] into the housing assembly [7] as follows:
A. Hold the housing assembly so that its key openings face downward and its top faces away 
from you. 
						

							February 3, 20036881076C20-E
8-18Disassembly/Reassembly Procedures: Fastener Torque Chart
B. Pivot the circuit board’s display down under the retention features in the housing and 
rotate the board downward, ensuring that the board is positioned between the snap fea-
tures. Ensure that the microphone assembly’s [8] wire passes through the opening in the 
circuit board. 
C. Press downward firmly on the board until the seven snap features lock the board into 
place.
5. Install the two snap retainers [4] between the circuit board and the side wall of the housing 
assembly [7], one on each side.
6. Install the main seal [3] onto the rear cover assembly [2], placing the seal under the retainer 
features around the perimeter of the cover.
7. Install the rear cover assembly [2] onto the housing assembly [7].
Starting at the top of the cover, pivot the cover toward the housing and squeeze the two 
halves together until the snap features at the lower end of the rear cover engage the 
housing’s features and snap closed.
8. Insert the cable assembly’s [15] telco connector into the opening in the bottom of the housing, 
ensuring that it correctly is oriented.
9. Press the telco connector in place until it snaps in (like a phone plug).
10. Place the seal support wedge [14] into the housing’s opening, orientating it so that its long 
portion is under the telco connector lever, and then push until it is properly seated.
11. Push the rubber seal (part of the cable assembly [15]) into the housing’s opening and ensure 
that it is properly seated.
NOTE:This seal must be inserted completely into the housing to ensure the rain seal.
12. Push the strain relief boot (part of the cable assembly [15]) into the housing, and ensure that 
it is properly seated.
13. Insert the kit label [1] into the recess on the rear cover, ensuring that it is securely attached.
8.4 Fastener Torque Chart
Table 8-3 lists the various fasteners by part number and description, followed by the torque values 
and the location where used. Torque all fasteners to the recommended value when assembling the 
radio.
Table 8-3.  Fastener Torque Chart
Part NumberDescription
Repair 
Torque
(in.-lbs.)
Where Used
N/A Hex nut, 7/16 6-8 Mini-UHF antenna 
connector
03-10907A97 Screw, M3.5X30 10-12 Interconnect board (high-
power)
03-10911A11 Screw, machine M3X8 6-8 PA boards device 
attachment
03-10943A10 Screw, machine M3X6 8-10 TO-39 heatsink
(PA, Q3804) (very low-, low-, 
and mid-power) 
						

							6881076C20-EFebruary 3, 2003
Disassembly/Reassembly Procedures: Fastener Torque Chart 8-19
03-10943J15 Screw, tapping M3.5X8 8-10 Controller board attachment 
(except for control head and 
remote dash board)
03-10943R55 Screw, tapping M3X8 6-8 Pivot pin (high-power)
03-10945A11 Screw, plastite M3X16 6-8 Control head and remote 
dash board attachment
03-10945A14 Screw, plastite M3X8 6-8 Remote control cable cover
03-1098A33 Screw, machine 6-8 Back housing W9 control 
head
03-12016A27 Screw, tapping, 
M3.5X228-10 All PC board attachment 
(except for control head, 
controller board, and remote 
dash board)
03-80041S01 Screw, captive 6-8 Control head leaf spring
03-80043L01 Screw, tapping M3X10 6-8 External power connector 
accessory clip
03-80043L01 Screw, M3.0X10 6-8 Lock housing (high-power)
03-80077M01 Screw, hex M3X18 4-6 Control heat mounting 
Remote front housing 
mounting
03-80077M04 Screw, hex M3X22 6-8 Remote cable mounting
03-80077M06 Screw, hex M4X16 10-12 Mid-power heatsink 
mounting
03-80102P01 Screw, tapping 
M3.5X106-8 Mid-power PA cover, top and 
bottom radio covers (high-, 
mid-, and low-power)
03-80114M02 Screw, machine M5X10 10-12 Radio mounting (very
low-, low-, and mid-power)
03-84244C06 Wing screw M5X10 10-12 Radio mounting
Table 8-3.  Fastener Torque Chart (Continued)
Part NumberDescription
Repair 
Torque
(in.-lbs.)
Where Used 
						

							February 3, 20036881076C20-E
Notes
8-20Disassembly/Reassembly Procedures: Fastener Torque Chart 
						

							Chapter 9 Basic Troubleshooting
9.1 Introduction
This section of the manual contains troubleshooting charts, error codes, a functional block diagram, 
interconnect diagrams, and flexible circuit information. This section can help you isolate a problem to 
the board level. Board-level troubleshooting does not attempt to isolate problems to the component 
level. Component-level service information can be found in the ASTRO Digital Spectra and Digital 
Spectra Plus Mobile Radios Detailed Service Manual. (Refer to the “Related Publications” section of 
this manual on page xii for the specific manual number.)
NOTE:To access the various connector pins, use the housing eliminator/test fixture along with the 
diagrams found in this section of the manual. (Refer to the section, “Service Aids and 
Recommended Tools,” on 
page 4-2 for the appropriate Motorola service aids and tools parts 
numbers.)
9.2 Replacement Board Procedures
Once a problem has been isolated to a specific board, use one of the following recommended repair 
procedures:
 Install a good board from your inventory into the radio.
 Order a replacement board from Customer Care and Services Division at 1-800-422-4210.
 Troubleshoot the defective board using the ASTRO Digital Spectra and Digital Spectra Plus 
Mobile Radios Detailed Service Manual. (Refer to the “Related Publications” section of this 
manual on page xii for the specific manual number.)
9.3 Power-Up Error Codes
When the radio is turned on (power-up), the radio performs cursory 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. 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 inhibit user operation; non-fatal 
errors do not. Use the following tables to aid in understanding particular power-up error code 
displays. 
						

							February 3, 20036881076C20-E
9-2Basic Troubleshooting: Power-Up Error Codes
9.3.1 ASTRO Digital Spectra
Table 9-1.  ASTRO Digital Spectra Power-Up Error Codes
Error CodeDescriptionCorrective Action
01/02 External EEPROM checksum 
non-fatal errorReprogram the codeplug.
01/81 ROM checksum failure Reprogram the FLASH memory.
01/82 External EEPROM checksum 
failureReprogram the codeplug.
01/84 EEPROM is blank Program the EEPROM.
01/88 RAM failure - Note: not a 
checksum failureTurn the radio off, then on.
01/90 General hardware failure Turn the radio off, then on.
01/92 Internal EEPROM checksum 
failureReprogram the codeplug.
02/10 DSP support IC checksum non-
fatal errorTurn the radio off, then on.
02/81 DSP ROM checksum failure Reprogram the FLASH memory.
02/82 DSP RAM 1 failure Replace the VOCON board.
02/84 DSP RAM 2 failure Replace the VOCON board.
02/88 DSP RAM failure - Note: not a 
checksum failureTurn the radio off, then on.
02/90 General DSP hardware failure 
(DSP startup message not 
received correctly)Turn the radio off, then on.
02/A0 ADSIC checksum failure Replace the VOCON board.
05/10 Control head not communicating 
with radioTurn the radio off, then on.
05/81 Control head ROM checksum 
failureReplace the control head.
08/10 Siren/PA not communicating with 
radioTurn the radio off, then on.
09/10 Secure option not 
communicating with radioTurn the radio off, then on.