Motorola ASTRO Digital Spectra User manual

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

i
Title Page ®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

Table of Contents iii
6881076C20-E February 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

iv Table of Contents
February 3, 2003 6881076C20-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-E February 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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February 3, 2003 6881076C20-E
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

Table of Contents vii
6881076C20-E February 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

viii Table of Contents
February 3, 2003 6881076C20-E
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

List of Figures ix
6881076C20-E February 3, 2003
List of Figures
Figure 1-1. Typical W3 Hand-Held Control Head....................................................................................1-3
Figure 1-2. Typical W4 Rotary Control Head...........................................................................................1-4
Figure 1-3. Typical W5 Pushbutton Control Head...................................................................................1-4
Figure 1-4. Typical W7 Pushbutton Control Head...................................................................................1-4
Figure 1-5. Typical W9 Pushbutton Control Head...................................................................................1-5
Figure 5-1. ASTRO Digital Spectra Performance Checks Test Setup.....................................................5-1
Figure 5-2. ASTRO Digital Spectra Plus Performance Checks Test Setup.............................................5-2
Figure 5-3. Rotary Control Head Key-Closure Displays (W4).................................................................5-5
Figure 5-4. Pushbutton Control Head Key-Closure Displays (W5 and W7)............................................5-6
Figure 5-5. Pushbutton Control Head Key-Closure Displays (W9) .........................................................5-6
Figure 6-1. ASTRO Digital Spectra Radio Alignment Test Setup............................................................6-1
Figure 6-2. RSS Service Menu Layout....................................................................................................6-2
Figure 6-3. Softpot Concept....................................................................................................................6-2
Figure 6-4. Reference Oscillator Alignment Screen................................................................................6-4
Figure 6-5. Transmit Power Alignment Screen .......................................................................................6-5
Figure 6-6. Transmit Current Limit Alignment Screen.............................................................................6-6
Figure 6-7. Transmit Deviation Balance (Compensation) Alignment Screen..........................................6-8
Figure 6-8. Transmit Deviation Limit Alignment Screen.......................................................................... 6-9
Figure 6-9. ASTRO Digital Spectra Plus Radio Alignment Test Setup.................................................. 6-11
Figure 6-10. Tuner Menu Layout.............................................................................................................6-12
Figure 6-11. Typical Softpot Adjustment Screen.....................................................................................6-13
Figure 6-12. Radio Information Screen...................................................................................................6-14
Figure 6-13. Reference Oscillator Alignment Screen..............................................................................6-15
Figure 6-14. Typical Transmit Power Alignment Screen.........................................................................6-16
Figure 6-15. Transmit Current Limit Alignment Screen...........................................................................6-18
Figure 6-16. Transmit Deviation Balance (Compensation) Alignment Screen........................................ 6-20
Figure 6-17. Transmit Deviation Limit Alignment Screen........................................................................6-21
Figure 6-18. Bit Error Rate Test Screen..................................................................................................6-23
Figure 6-19. Transmitter Test Pattern Screen .........................................................................................6-23
Figure 8-1. Model W4 Rotary Control Head Assembly Screw and Snap Sequence...............................8-3
Figure 8-2. Models W5 and W7 Pushbutton Control Head Assembly Screw Sequence ........................8-3
Figure 8-3. PA Board Screw Fastening Sequence (800 MHz 15-Watt PA).............................................8-9
Figure 8-4. PA Board Screw Fastening Sequence (800 MHz 20- and 35-Watt PA)..............................8-10
Figure 8-5. Installing the Final Device................................................................................................... 8-10
Figure 10-1. Digital Spectra Models W3, W4, W5, W7, and W9 Functional Block Diagram...................10-2
Figure 10-2. Digital Spectra Plus Models W3, W4, W5, W7, and W9 Functional Block Diagram........... 10-3
Figure 10-3. J0103 Remote-Mount Control Head Connector..................................................................10-4
Figure 10-4. J5 Control Cable for Remote-Mount Control Head.............................................................10-4
Figure 10-5. J6 Radio Operations Connector..........................................................................................10-4
Figure 10-6. J2 Rear Accessory Connector............................................................................................10-4
Figure 10-7. P104 Microphone Jack .......................................................................................................10-4
Figure 10-8. Dash-Mount Radio Connector Locations............................................................................10-5
Figure 10-9. Remote-Mount Radio Connector Locations........................................................................ 10-5
Figure 10-10.Command Board Connector Locations.............................................................................. 10-5
Figure 10-11.VOCON Board Connector Locations .................................................................................10-5
Figure 10-12.P501 Extender Cable......................................................................................................... 10-6
Figure 10-13.Control Head Cabling Diagram..........................................................................................10-6
Figure 11-1. Model W3 Hand-Held Control Head Exploded View........................................................... 11-2
Figure 11-2. Model W4 Rotary Control Head Exploded View................................................................. 11-3
Figure 11-3. Models W5 and W7 Pushbutton Control Head Exploded View .......................................... 11-4

xList of Figures
February 3, 2003 6881076C20-E
Figure 11-4. Model W9 Pushbutton Control Head Exploded View..........................................................11-5
Figure 11-5. Low-Power (15W) Radio Exploded View............................................................................11-6
Figure 11-6. Mid-Power (20-40/25-50/35W) Radio Exploded View.........................................................11-7
Figure 11-7. High-Power (50-110W) Radio Exploded View ....................................................................11-8
Figure 11-8. Motorcycle Interconnect Board and Assembly (HLN6365) Exploded View ........................ 11-9
Figure 11-9. Low- and Mid-Power Interconnect Board and Assembly (HLN6344) Exploded View.........11-9

List of Tables xi
6881076C20-E February 3, 2003
List of Tables
Table 1-1. ASTRO Digital Spectra/Spectra Plus Basic Features...........................................................1-2
Table 4-1. Recommended Motorola Test Equipment.............................................................................4-1
Table 4-2. Wattmeter Plug-In Elements.................................................................................................4-2
Table 4-3. Recommended Non-Motorola Test Equipment.....................................................................4-2
Table 4-4. Common Service Aids for Board-Level Troubleshooting......................................................4-3
Table 4-5. Service Aids for ASTRO Digital Spectra Board-Level Troubleshooting................................4-4
Table 4-6. Service Aids for ASTRO Digital Spectra Plus Board-Level Troubleshooting........................4-5
Table 4-7. Recommended Tools for Board-Level Troubleshooting........................................................ 4-5
Table 4-8. ASTRO Digital Spectra Field Programming Items................................................................4-6
Table 4-9. ASTRO Digital Spectra Plus Field Programming Items........................................................4-7
Table 5-1. Test-Mode Displays ..............................................................................................................5-2
Table 5-2. Test Frequencies ..................................................................................................................5-4
Table 5-3. Signaling Types ....................................................................................................................5-5
Table 5-4. Receiver Performance Checks............................................................................................. 5-6
Table 5-5. Transmitter Performance Checks.........................................................................................5-7
Table 6-1. Reference Oscillator Alignment ............................................................................................6-4
Table 6-2. Transmit Power Settings.......................................................................................................6-5
Table 6-3. Reference Oscillator Alignment ..........................................................................................6-16
Table 6-4. Transmit Power Settings.....................................................................................................6-17
Table 7-1. ASTRO Digital Spectra UCM Listing.....................................................................................7-1
Table 7-2. ASTRO Digital Spectra Plus UCM Listing.............................................................................7-1
Table 8-1. Required Alignments After Board Replacement...................................................................8-1
Table 8-2. Required Tools and Supplies................................................................................................8-2
Table 8-3. Fastener Torque Chart........................................................................................................ 8-18
Table 9-1. ASTRO Digital Spectra Power-Up Error Codes....................................................................9-2
Table 9-2. ASTRO Digital Spectra Plus Power-Up Error Codes............................................................9-3
Table 9-3. ASTRO Digital Spectra Operational Error Codes .................................................................9-4
Table 9-4. ASTRO Digital Spectra Plus Operational Error Codes .........................................................9-5
Table 9-5. Transmitter Troubleshooting Chart .......................................................................................9-5
Table 9-6. Receiver Troubleshooting Chart ...........................................................................................9-9
Table 9-7. Synthesizer Troubleshooting Chart.....................................................................................9-12
Table 11-1. Model W3 Hand-Held Control Head Exploded View Parts List........................................... 11-2
Table 11-2. Model W4 Rotary Control Head Parts List.......................................................................... 11-3
Table 11-3. Models W5 and W7 Pushbutton Control Head Parts List................................................... 11-4
Table 11-4. Model W9 Pushbutton Control Head Parts List ................................................................. 11-5
Table 11-5. Low-Power (15W) Radio Parts List.....................................................................................11-6
Table 11-6. Mid-Power (20-40/25-50/35W) Radio Parts List................................................................. 11-7
Table 11-7. High-Power (50-110W) Radio Parts List............................................................................. 11-8
Table 11-8. Motorcycle Interconnect Board and Assembly (HLN6365) Parts List................................. 11-9
Table 11-9. Low- and Mid-Power Interconnect Board and Assembly (HLN6344) Parts List ................. 11-9
Table 11-10. Small Pushbutton Parts List.............................................................................................. 11-10
Table 11-11. Large Pushbutton Parts List.............................................................................................. 11-10

xii Related Publications
February 3, 2003 6881076C20-E
Related Publications
ASTRO Digital Spectra and Digital Spectra Plus Model W3 User’s Guide..................................6881090C61
ASTRO Digital Spectra and Digital Spectra Plus Models W4, W5, W7, and W9 User’s Guide ..6881090C62
ASTRO Digital Spectra Hand-Held Control Head User’s Guide (Model W3)...............................6881073C25
ASTRO Digital Spectra (Model W4, W5, W7, and W9) User’s Guide..........................................6881074C80
ASTRO Digital Spectra and Digital Spectra Plus Mobile Radios Detailed Service Manual .........6881076C25
ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual.........6881091C78
ASTRO Spectra and Digital Spectra FM Two-Way Mobile Radios Installation Manual ...............6881070C85
ASTRO Spectra Motorcycle Radios Supplemental Installation Manual......................................6880103W01
CPS Programming Installation Guide..........................................................................................6881095C44
KVL 3000 User’s Manual.............................................................................................................6881131E16
Spectra VHF VCO Section Detailed Service Manual Supplement...............................................6881074C48
Spectra High-Power Power Amplifier Detailed Service Manual Supplement...............................6881077C25
Spectra Systems 9000 Control Unit Detailed Service Manual Supplement.................................6881077C30
Spectra A5 and A7 Control Head Instruction Manual ..................................................................6881109C33
Spectra A4 Control Head Instruction Manual ..............................................................................6881109C34

6881076C20-E February 3, 2003
Commercial Warranty xiii
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 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.
ASTRO Digital Spectra and DigitalSpectra
Plus Units One (1) Year
Product Accessories One (1) Year

February 3, 2003 6881076C20-E
xiv CommercialWarranty
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 (includ-
ing, 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 tamper-
ing.
- 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 Prod-
uct, 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 distrib-
uted from MOTOROLA.
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.

6881076C20-E February 3, 2003
Commercial Warranty xv
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 con-
tinue using the Product or parts or to replace or modify the same so that it becomes nonin-
fringing 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.

January 29, 2003 6881076C20-E
xvi Model Numbering, Charts, and Specifications
Model Numbering, Charts, and Specifications
Mobile Radio Model Numbering Scheme
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
T
ypical 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
Integrated Voice and Data
* 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
123 4 5 6 7 8 9 1011 1213141516
T04S LF 9 P W7 A N S P 0 1
04 = ASTRO
A
B
C
D
F
G
H
J
K
L
M
=
=
=
=
=
=
=
=
=
=
=
P
Q
R
S
T
U
V
W
Y
Z
=
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
=
=
=
=
=
=
10.1 to 15 Watts
16 to 25 Watts
26 to 35 Watts
36 to 60 Watts
G
H
J
K
L
=
=
=
=
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
G
H
J
K
L
M
P
S
=
=
=
=
=
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
W
X
Y
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
= 61 to 110 Watts
MAEPF-27247-O

6881076C20-E January 29, 2003
Model Numbering, Charts, and Specifications xvii
ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 1 and 2) Model Chart
Model Number Description
M04JGF9PW4AN Model W4 (136-162 MHz), Range 1, 15 Watt, 128 Channels
M04JGF9PW5AN Model W5 (136-162 MHz), Range 1, 15 Watt, 128 Channels
M04JGH9PW7AN Model W7 (136-162 MHz), Range 1, 15 Watt, 128 Channels
M04KGF9PW4AN Model W4 (146-174 MHz), Range 2, 15 Watt, 128 Channels
M04KGF9PW5AN Model W5 (146-174 MHz), Range 2, 15 Watt, 128 Channels
M04KGH9PW7AN Model W7 (146-174 MHz), Range 2, 15 Watt, 128 Channels
M04RGF9PW4AN Model W4 (438-470 MHz), Range 2, 15 Watt, 128 Channels
M04RGF9PW5AN Model W5 (438-470 MHz), Range 2, 15 Watt, 128 Channels
M04RGH9PW7AN Model W7 (438-470 MHz), Range 2, 15 Watt, 128 Channels
M04UGF9PW4AN Model W4 (800 MHz), 15 Watt, 128 Channels
M04UGF9PW5AN Model W5 (800 MHz), 15 Watt, 128 Channels
M04UGH9PW7AN Model W7 (800 MHz), 15 Watt, 128 Channels
Item No. Description
XXXHLD6066_ VHF Power Amplifier Board, 25-Watt
XXXXXXXXXXXX HKN6062_ Cable, Control Head to Radio
XXXHLD4342_ VHF VCO Carrier
XXXHLD4343_ VHF VCO Carrier, CEPT
XXXHLD6032_ VHF Power Amplifier Board, Range 2, 25-Watt
XXXHLD6061_ VHF VCO, Range 1, 136-162 MHz
XXXHLD6062_ VHF VCO Board, Range 2, 146-174 MHz
XXXHLE6046_ UHF VCO Carrier, Range 2
XXXHLE6062_ UHF RF Power Amplifier Board, Range 2, 25-Watt
XXXHLE6102_ UHF VCO Board, Range 2
XXX HLF6078_ 800 MHz RF Power Amplifier Board, 15-Watt
XXX HLF6079_ 800 MHz VCO Board
XXX HLF6080_ 800 MHz VCO Carrier Board
XXXXXXXXXXXX HLN1368_ White Motorcycle Enclosure and Hardware
XXXXXXXXXXXX HLN6127_* Low-Power Dash Hardware
XXXXXXXXXX HLN6193_ MPL Button Kit
XXXXXXXXXXXX HLN6342_* Motorcycle Hardware
XXXXXXXXXXXX HLN6365_ Interface Board Kit
XXXXXXXXXXXX HLN6418_* Transceiver Hardware
XXX X X HLN6444_* W5 Motorcycle Control Head Hardware
XXX HLN6445_* W7 Motorcycle Control Head Hardware
XHLN6454_ Motorcycle Control Head Board Kit
XXXXXXXXXXXX HLN6458_ Vocoder Controller
XXHLN6459_ Interface Board
XXXX HLN6523_* W7 Button Kit
XXXXHLN6548_* W5 Button Kit
X X HLN6549_* W4 Button Kit
XXXXXXXXXXXX HLN6562_ Motorcycle Command Board Kit
XXXXXXXX HLN6563_ Motorcycle Control Head
XXXXHLN6571_ Spare Button Kit
XXXXXXXXXXXX HMN1079_ Weatherproof Microphone
XXXHRD6001_ VHF Receiver Board, Range 1, Standard
XXXHRD6002_ VHF Receiver Board, Range 2, Standard
XXXHRE6002_ UHF Receiver Board, Range 2, Standard
XXX HRF6004_ 800 MHz FX Front-End
XXXHRN4009_ VHF RF Board
XXXHRN4010_ UHF RF Board
XXXHRN6014_ VHF RF Board, ASTRO
XXX HRN6019_ 800 MHz RF Board, ASTRO
XXXXXXXXXXXX HSN6003_ Weatherproof Speaker
XXXXPMLN4019_ W4 Motorcycle Control Head
XRAE4024_ UHF Antenna, Quarterwave
XXX RAF4011_ 800 MHz Antenna, 3 dB Gain
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
* = kit not available. Order piece parts from the Customer Care and Services Division.

January 29, 2003 6881076C20-E
xviii Model Numbering, Charts, and Specifications
ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 3 and 3.5)
Model Chart
Model Number Description
M04RGF9PW4ANSP02 Model W4 (450-482 MHz), Range 3, 15 Watt, 128 Channels
M04RGF9PW5ANSP02 Model W5 (450-482 MHz), Range 3, 15 Watt, 128 Channels
M04RGF9PW4ANSP01 Model W4 (453-488 MHz), Range 3.5, 15 Watt, 128 Channels
M04RGF9PW5ANSP01 Model W5 (453-488 MHz), Range 3.5, 15 Watt, 128 Channels
M04RGH9PW7ANSP01 Model W7 (453-488 MHz), Range 3.5, 15 Watt, 128 Channels
Item No. Description
XXXX X HKN6062_ Cable, Control Head to Radio
XXHLE6000_ UHF VCO Carrier, Range 3
XX X HLE6000_SP01 UHF VCO Carrier, Range 3.5
XXHLE6043_ UHF RF Power Amplifier Board, Range 3, 40-Watt
XX X HLE6043_SP01 UHF RF Power Amplifier Board, Range 3.5, 40-Watt
XXHLE6103_ UHF VCO Hybrid, Range 3
XX X HLE6103_SP01 UHF VCO Hybrid, Range 3.5
XXXX X HLN1368_ White Motorcycle Enclosure and Hardware
XXXX X HLN6127_* Low-Power Dash Hardware
XX X HLN6193_ MPL Button Kit
XXXX X HLN6342_* Motorcycle Hardware
XXXX X HLN6365_ Interface Board Kit
XXXX X HLN6418_* Transceiver Hardware
XX HLN6444_* W5 Motorcycle Control Head Hardware
X HLN6445_* W7 Motorcycle Control Head Hardware
XXXX X HLN6458_ Vocoder Controller
X HLN6523_* W7 Button Kit
XX HLN6548_* W5 Button Kit
XXHLN6549_* W4 Button Kit
XXXX X HLN6562_ Motorcycle Command Board Kit
XX X HLN6563_ Motorcycle Control Head
XXXX X HLN6571_ Spare Button Kit
XXXX X HMN1079_ Weatherproof Microphone
XXHRE6003_ UHF Receiver Board, Range 3, Standard
XX X HRE6003_SP01 UHF Receiver Board, Range 3.5, Standard
XXXX X HRN6020_ UHF RF Board, ASTRO
XXXX X HSN6003_ Weatherproof Speaker
XXPMLN4019_ W4 Motorcycle Control Head
XXXX X RAE4024_ UHF Antenna, Quarterwave
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
* = kit not available. Order piece parts from the Customer Care and Services Division.