Motorola Astro XTL 5000 User manual

Title Page1301 ASTRO® Digital XTL™ 5000
VHF/UHF Range 1/UHF Range 2/
700–800 MHz
Mobile Radio
Basic Service Manual
Motorola, Inc.
1301 E. Algonquin Rd,
Schaumburg, IL 60196-1078 USA 6871769L01-A

Foreword
This manual covers all models of the ASTRO®Digital XTL™ 5000 VHF/UHF Range 1/UHF Range 2/700–800 MHz Mobile
Radio, unless otherwise specified. It includes all the information necessary to maintain peak product performance and
maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board
replacement level and is typical of some local service centers, self-maintained customers, and distributors.
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 xvi.
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/governmentandenterprise.
Manual Revisions
Changes which occur after this manual is printed are described in PMRs (Publication Manual Revisions). These PMRs
provide complete replacement pages for all added, changed, and deleted items. To obtain PMRs, go to
https://businessonline.motorola.com.
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, ASTRO, and FLASHport are registered in the US Patent & Trademark Office. All other
product or service names are the property of their respective owners.
© 2006 by Motorola, Inc. All rights reserved.
Before using this product, read the operating instructions
for safe usage contained in the Product Safety and RF
Exposure booklet enclosed with your radio.
!
C a u t i o n

iii
6871769L01-A October 30, 2006
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
6871769L01-A Initial Release Oct. 2006

iv
October 30, 2006 6871769L01-A
Notes

Table of Contents v
6871769L01-A October 30, 2006
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
Document History ........................................................................................ iii
Commercial Warranty ................................................................................xvii
Limited Warranty ..................................................................................................................................... xvii
MOTOROLA COMMUNICATION PRODUCTS........................................................................... xvii
I. What This Warranty Covers And For How Long .................................................................. xvii
II. General Provisions .............................................................................................................. xvii
III. State Law Rights ............................................................................................................... xviii
IV. How To Get Warranty Service .......................................................................................... xviii
V. What This Warranty Does Not Cover................................................................................. xviii
VI. Patent And Software Provisions ......................................................................................... xix
VII. Governing Law................................................................................................................... xix
Model Numbering, Charts, and Specifications.........................................xxi
Mobile Radio Model Numbering Scheme................................................................................................. xxi
ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart .............................................................................. xxii
ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart (Cont.) ................................................................. xxiii
ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart (Cont.) ................................................................. xxiv
ASTRO XTL 5000 O3 VHF 100 Watt Model Chart.................................................................................. xxv
ASTRO XTL 5000 O3 VHF 100 Watt Model Chart (Cont.)..................................................................... xxvi
ASTRO XTL 5000 O3 VHF 100 Watt Model Chart (Cont.).................................................................... xxvii
ASTRO XTL 5000 O3 UHF Range 1 10-40 Watt Model Chart..............................................................xxviii
ASTRO XTL 5000 O3 UHF Range 1 10-40 Watt Model Chart (Cont.)................................................... xxix
ASTRO XTL 5000 O3 UHF Range 1 10-40 Watt Model Chart (Cont.).................................................... xxx
ASTRO XTL 5000 O3 UHF Range 1 100 Watt Model Chart.................................................................. xxxi
ASTRO XTL 5000 O3 UHF Range 1 100 Watt Model Chart (Cont.)..................................................... xxxii
ASTRO XTL 5000 O3 UHF Range 1 100 Watt Model Chart (Cont.).....................................................xxxiii
ASTRO XTL 5000 O3 UHF Range 2 10-40 Watt Model Chart............................................................. xxxiv
ASTRO XTL 5000 O3 UHF Range 2 10-40 Watt Model Chart (Cont.).................................................. xxxv
ASTRO XTL 5000 O3 UHF Range 2 10-40 Watt Model Chart (Cont.)................................................. xxxvi
ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart .............................................................xxxvii
ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart (Cont.)................................................xxxviii
ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt Model Chart (Cont.)................................................. xxxix
ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt (Reband) Model Chart ...................................................xl
ASTRO XTL 5000 O3 700-800 MHz 10-35 Watt (Reband) Model Chart (Cont.)...................................... xli
ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart ............................................................................... xlii
ASTRO XTL 5000 O5 VHF 10-50 Watt Model Chart (Cont.) .................................................................. xliii

Table of Contents xi
6871769L01-A October 30, 2006
A.5 Fax Orders...................................................................................................................................A-2
A.6 Parts Identification .......................................................................................................................A-2
A.7 Product Customer Service...........................................................................................................A-2
Appendix B Environmental Information ................................................B-1
Glossary.........................................................................................Glossary-1
Index......................................................................................................Index-i

xii List of Figures
October 30, 2006 6871769L01-A
List of Figures
Figure 1-1. XTL 5000 O3 Control Head.................................................................................................. 1-4
Figure 1-2. XTL 5000 Control Head ....................................................................................................... 1-5
Figure 3-1. Controller Sections (Mid Power) .......................................................................................... 3-3
Figure 3-2. Controller Sections (High Power)......................................................................................... 3-3
Figure 3-3. Audio Receive Path in XTL 5000 Transceiver...................................................................... 3-6
Figure 3-4. Audio Transmit Path in XTL 5000 Transceiver..................................................................... 3-7
Figure 3-5. O3 Dash Mount Configuration............................................................................................3-12
Figure 3-6. O3 Remote Mount Configuration ....................................................................................... 3-13
Figure 3-7. Single O3 Control Head + VIPS ......................................................................................... 3-14
Figure 3-8. Single O5 Control Head + VIPS ......................................................................................... 3-15
Figure 3-9. Multiple O5 Control Heads + VIPS.....................................................................................3-15
Figure 3-10. Single Control Head + VIPS............................................................................................... 3-16
Figure 3-11. Single O3 Control Head + DEK + VIPS ............................................................................. 3-17
Figure 3-12. Single O5 Control Head + DEK + VIPS .............................................................................3-17
Figure 3-13. Multiple Control Heads + DEK +VIPS ................................................................................ 3-18
Figure 3-14. Two node system with CAN terminations enabled............................................................. 3-19
Figure 3-15. CAN Termination Section. ..................................................................................................3-19
Figure 3-16. Control Head Interface Board (CHIB) ................................................................................3-20
Figure 3-17. Control Head Universal Connector (CHUC)....................................................................... 3-21
Figure 3-18. Transceiver Interface Board (TIB) ...................................................................................... 3-22
Figure 3-19. VHF Frequency Generation Unit Diagram .........................................................................3-28
Figure 3-20. UHF Frequency Generation Unit Diagram ......................................................................... 3-29
Figure 3-21. 700–800 MHz Frequency Generation Unit Diagram .......................................................... 3-30
Figure 5-1. Performance Checks Test Setup..........................................................................................5-1
Figure 5-2. XTL 5000 O3 Control Head.................................................................................................. 5-5
Figure 5-3. XTL 5000 Control Head ....................................................................................................... 5-6
Figure 6-1. Radio Alignment Test Setup................................................................................................. 6-1
Figure 6-2. VHF/700-800 MHz Tuner Main Menu .................................................................................. 6-2
Figure 6-3. UHF Tuner Main Menu......................................................................................................... 6-2
Figure 6-4. Radio Information Screen .................................................................................................... 6-3
Figure 6-5. PA Bias 1 Alignment Screen ................................................................................................ 6-4
Figure 6-6. PA Bias 2 Alignment Screen ................................................................................................ 6-6
Figure 6-7. PA Bias 3 Alignment Screen ................................................................................................ 6-7
Figure 6-8. Reference Oscillator Window............................................................................................... 6-9
Figure 6-9. Power Detection Calibration Alignment Screen ................................................................. 6-11
Figure 6-10. Tx Power Characterization Alignment Screen ................................................................... 6-12
Figure 6-11. Tx Current Limit Alignment Screen .................................................................................... 6-14
Figure 6-12. Tx Deviation Balance (Compensation) Alignment Screen ................................................. 6-16
Figure 6-13. Tx Deviation Limit Alignment Screen .................................................................................6-18
Figure 6-14. Rx Front-End Filter Alignment Screen ...............................................................................6-19
Figure 6-15. Bit Error Rate Screen ......................................................................................................... 6-20
Figure 6-16. Transmitter Test Pattern Screen......................................................................................... 6-21
Figure 8-1. Cable Lock Detachment....................................................................................................... 8-2
Figure 8-2. Front Housing and Back Housing Detachment .................................................................... 8-3
Figure 8-3. Separate Front Housing and Back Housing......................................................................... 8-3
Figure 8-4. PCB Detachment.................................................................................................................. 8-4
Figure 8-5. Disconnecting the 2-pin Connector ...................................................................................... 8-4
Figure 8-6. Control Head Screw Sequence............................................................................................ 8-5
Figure 8-7. Front Panel Disassembly ..................................................................................................... 8-7
Figure 8-8. TUC Seal Placement............................................................................................................ 8-8

List of Figures xiii
6871769L01-A October 30, 2006
Figure 8-9. Front Panel Reassembly...................................................................................................... 8-9
Figure 8-10. Removing the Control Head Screws.................................................................................. 8-10
Figure 8-11. Removing the Control Head............................................................................................... 8-10
Figure 8-12. Removing the Flex (Control Head Connector)................................................................... 8-11
Figure 8-13. Removing the Headbridge ................................................................................................. 8-11
Figure 8-14. Removing the Flex (Main-Board Connector)...................................................................... 8-12
Figure 8-15. Removing the Headbridge Seal ......................................................................................... 8-12
Figure 8-16. Removing the Secure Interface Board............................................................................... 8-13
Figure 8-17. Removing the Top Cover Screws.......................................................................................8-14
Figure 8-18. Lifting the Top Cover .......................................................................................................... 8-14
Figure 8-19. Removing the J2 Rear Accessory Flex from the Main Board ............................................ 8-15
Figure 8-20. Removing the PA Screws................................................................................................... 8-16
Figure 8-21. Removing the RF/DC Retention Clips................................................................................ 8-16
Figure 8-22. Pushing Up the Main Board ............................................................................................... 8-17
Figure 8-23. Removing the J2 Rear Accessory Connector .................................................................... 8-17
Figure 8-24. Removing the Transceiver Interface Board Screws........................................................... 8-18
Figure 8-25. Removing the Transceiver Interface Board Assembly ....................................................... 8-19
Figure 8-26. Removing the Flex (Transceiver Interface Board Connector)............................................ 8-19
Figure 8-27. Removing the Flex (Main-Board Connector)...................................................................... 8-20
Figure 8-28. Removing the Front Panel Seal ......................................................................................... 8-20
Figure 8-29. Removing the Secure Interface Board............................................................................... 8-21
Figure 8-30. Removing the Top Cover Screws.......................................................................................8-22
Figure 8-31. Lifting the Top Cover .......................................................................................................... 8-22
Figure 8-32. Removing the PA Screws................................................................................................... 8-23
Figure 8-33. Removing the RF/DC Retention Clips................................................................................ 8-23
Figure 8-34. Pushing Up the Main Board ............................................................................................... 8-24
Figure 8-35. Inspecting the Chassis Shield Gasketing and Thermal Pads ............................................ 8-25
Figure 8-36. Inserting the J2 Rear Accessory Connector....................................................................... 8-26
Figure 8-37. Inserting the Main Board into the Chassis ......................................................................... 8-27
Figure 8-38. Connecting the J2 Rear Accessory Connector Flex to the Main Board............................. 8-28
Figure 8-39. Inserting the RF/DC Retention Clips.................................................................................. 8-29
Figure 8-40. Inserting the RF/DC Retention Clip (DC Side)................................................................... 8-29
Figure 8-41. Installing the PA Screws..................................................................................................... 8-30
Figure 8-42. Inspecting the Thermal Pad and Installing the Cover Main Seal ....................................... 8-30
Figure 8-43. Securing the Top Cover to the Chassis.............................................................................. 8-31
Figure 8-44. Installing the Secure Interface Board................................................................................. 8-32
Figure 8-45. Installing the Headbridge Seal ........................................................................................... 8-32
Figure 8-46. Installing the control head Flex in the Transceiver............................................................. 8-33
Figure 8-47. Installing the Headbridge on the Transceiver..................................................................... 8-33
Figure 8-48. Installing the Control Head Flex on the Control Head........................................................ 8-34
Figure 8-49. Inserting the Control Head Into the Transceiver ................................................................ 8-34
Figure 8-50. Installing the Control Head Screws.................................................................................... 8-35
Figure 8-51. Inspecting the Chassis Shield Gasketing and Thermal Pads ............................................ 8-35
Figure 8-52. Inserting the Main Board into the Chassis ......................................................................... 8-36
Figure 8-53. Inserting the RF/DC Retention Clips.................................................................................. 8-36
Figure 8-54. Inserting the RF/DC Retention Clip (DC Side)................................................................... 8-37
Figure 8-55. Installing the PA Screws..................................................................................................... 8-37
Figure 8-56. Inspecting the Thermal Pad and Installing the Cover Main Seal ....................................... 8-38
Figure 8-57. Installing the Secure Interface Board................................................................................. 8-39
Figure 8-58. Installing the Front Panel Seal ........................................................................................... 8-39
Figure 8-59. Installing the TIB Flex in the Transceiver ........................................................................... 8-40
Figure 8-60. Installing the Transceiver Interface Board Assembly Screws ............................................ 8-40
Figure 8-61. Chassis Thermal Pad Locations ........................................................................................ 8-41
Figure 8-62. Chassis Thermal Pad Locations ........................................................................................ 8-43

xiv List of Figures
October 30, 2006 6871769L01-A
Figure 9-1. GCAI Connector................................................................................................................... 9-1
Figure 9-2. J2 Rear Accessory Connector ............................................................................................. 9-3
Figure 9-3. J100 Mobile Accessory Port (MAP) Connector.................................................................... 9-5
Figure 9-4. J200 Power and Audio Connector .......................................................................................9-7
Figure 9-5. J300 Controller Area Network (CAN) Connector on CHIB................................................... 9-8
Figure 9-6. J400 VIP and DEK Connector.............................................................................................. 9-9
Figure 9-7. J500 USB Host Connector ................................................................................................. 9-10
Figure 9-8. J600 Connector.................................................................................................................. 9-11
Figure 9-9. J700 GCAI Programming Connector .................................................................................9-13
Figure 9-10. J800 Controller Area Network (CAN) Connector on TIB.................................................... 9-13
Figure 9-11. RS232 Connector Naming Scheme ................................................................................... 9-14
Figure 10-1. XTL 5000 Transceiver Functional Block Diagram .............................................................. 10-2
Figure 10-2. XTL 5000 O3 Dash and Remote Control Head Functional Block Diagram........................ 10-3
Figure 10-3. XTL 5000 O5 Dash and Remote Control Head Functional Block Diagram........................ 10-4
Figure 10-4. XTL 5000 O3 Control Head Functional Block Diagram...................................................... 10-5
Figure 10-5. XTL 5000 O5 Control Head Functional Block Diagram...................................................... 10-6
Figure 10-6. XTL 5000 O5 Control Head Interface Board (CHIB) Functional Block Diagram ................ 10-7
Figure 10-7. XTL 5000 Transceiver Interface Board (TIB) Functional Block Diagram ........................... 10-7
Figure 10-8. O3 Dash-Mount Radio Connector Locations (Mid Power Only)......................................... 10-8
Figure 10-9. O3 Remote-Mount Radio Connector Locations ................................................................. 10-8
Figure 10-10.O3 Remote-Mount Radio Connector Locations (High Power Only)................................... 10-8
Figure 10-11.O5 Dash-Mount Radio Connector Locations (Mid Power Only)......................................... 10-9
Figure 10-12.O5 Remote-Mount Radio Connector Locations (Mid Power Only) ....................................10-9
Figure 10-13.O5 Remote-Mount Radio Connector Locations (High Power Only)................................... 10-9
Figure 10-14.Main Board Connector Locations - Side 1 (Mid Power Only)........................................... 10-10
Figure 10-15.Main Board Connector Locations - Side 2 (Mid Power Only)........................................... 10-10
Figure 10-16.Main Board Connector Locations - Side 1 (High Power Only) .........................................10-10
Figure 10-17.Main Board Connector Locations - Side 2 (High Power Only) .........................................10-10
Figure 10-18.Control Head 50-pin Connector ....................................................................................... 10-11
Figure 10-19.Control Head 60-pin Connector ....................................................................................... 10-11
Figure 11-1. XTL 5000 O3 Control Head Exploded View....................................................................... 11-2
Figure 11-2. XTL 5000 O5 Control Head Exploded View....................................................................... 11-3
Figure 11-3. CHIB and CHUC Exploded View........................................................................................ 11-4
Figure 11-4. Transceiver Interface Board (TIB) Exploded View ............................................................. 11-5
Figure 11-5. XTL 5000 O3 Radio Exploded View................................................................................... 11-6
Figure 11-6. XTL 5000 O5 Dash Mount Radio Exploded View .............................................................. 11-7
Figure 11-7. XTL 5000 O5 Mid Power Remote Mount Radio Exploded View ........................................ 11-8
Figure 11-8. XTL 5000 100 W Remote Mount Radio Exploded View..................................................... 11-9

List of Tables xv
6871769L01-A October 30, 2006
List of Tables
Table 1-1. XTL 5000 Radio Frequency Ranges and Power Levels ...................................................... 1-1
Table 1-2. O3 Control Head Basic Features ......................................................................................... 1-2
Table 1-3. O5 Control Head Basic Features ......................................................................................... 1-2
Table 4-1. Recommended Motorola Test Equipment............................................................................ 4-1
Table 4-2. Wattmeter Plug-In Elements ................................................................................................ 4-1
Table 4-3. Recommended Non-Motorola Test Equipment .................................................................... 4-2
Table 4-4. Service Aids for XTL 5000 Board-Level Troubleshooting .................................................... 4-3
Table 4-5. Recommended Motorola Tools for Board-Level Troubleshooting ........................................ 4-3
Table 4-6. Recommended Non-Motorola Tools for Board-Level Troubleshooting ................................ 4-4
Table 4-7. XTL 5000 Radio Field-Programming Items.......................................................................... 4-4
Table 5-1. Test-Mode Displays ............................................................................................................. 5-2
Table 5-2. Test Frequencies.................................................................................................................. 5-3
Table 5-3. Signaling Types.................................................................................................................... 5-4
Table 5-4. Receiver Performance Checks ............................................................................................ 5-6
Table 5-5. Transmitter Performance Checks ........................................................................................5-7
Table 6-1. PA Bias 1 Alignment RF Power Amplifier Devices............................................................... 6-3
Table 6-2. Power Supply Voltage Settings............................................................................................ 6-4
Table 6-3. PA Bias 1 Alignment Device Bias Current............................................................................ 6-4
Table 6-4. PA Bias 2 Alignment Amplifier Devices................................................................................ 6-5
Table 6-5. Power Supply Voltage Settings............................................................................................ 6-5
Table 6-6. PA Bias 2 Alignment Device Bias Current............................................................................ 6-6
Table 6-7. PA Bias 3 Alignment Amplifier Devices................................................................................ 6-7
Table 6-8. Power Supply Voltage Settings............................................................................................ 6-7
Table 6-9. PA Bias 3 Alignment Device Bias Current............................................................................ 6-8
Table 6-10. Reference Oscillator Alignment............................................................................................ 6-9
Table 6-11. Power Supply Voltage Settings.......................................................................................... 6-10
Table 6-12. Power Supply Voltage Settings.......................................................................................... 6-11
Table 6-13. Power Supply Voltage Settings.......................................................................................... 6-13
Table 6-14. Transmit Current Limit Offset ............................................................................................. 6-15
Table 6-15. Transmit Current Limit Devices.......................................................................................... 6-15
Table 6-16. Bit Error Rate Test Fields ................................................................................................... 6-20
Table 6-17. Transmitter Test Pattern Fields .......................................................................................... 6-21
Table 7-1. UCM Kit Listing .................................................................................................................... 7-1
Table 7-2. Secure Interface Board Kits ................................................................................................. 7-2
Table 8-1. Required Tools and Supplies ............................................................................................... 8-1
Table 8-2. Chassis Thermal Pad Parts ............................................................................................... 8-41
Table 8-3. Chassis Thermal Pad Parts ............................................................................................... 8-43
Table 8-4. Fastener Torque Chart ....................................................................................................... 8-44
Table 9-1. GCAI Connector Signal Descriptions................................................................................... 9-2
Table 9-2. J2 Rear Accessory Connector Signal and Voltage Descriptions.......................................... 9-3
Table 9-3. J100 Remote Mount Control Head Mobile Accessory Port (MAP)....................................... 9-5
Table 9-4. J200 Power and Audio Connector Pin Functions................................................................. 9-7
Table 9-5. J300 Controller Area Network Connector Pin Functions...................................................... 9-8
Table 9-6. J400 VIP and DEK Connector Functionality ........................................................................ 9-9
Table 9-7. J500 USB Host Connector................................................................................................. 9-10
Table 9-8. J600 Remote Mount Accessory Connector........................................................................ 9-11
Table 9-9. J800 Controller Area Network Connector Pin Functions.................................................... 9-13
Table 9-10. Power-Up Error Codes....................................................................................................... 9-16
Table 9-11. Operational Error Codes .................................................................................................... 9-17
Table 9-12. Transmitter Troubleshooting Chart..................................................................................... 9-18
Table 9-13. Receiver Troubleshooting Chart ........................................................................................ 9-19
Table 10-1. Table of Functional Block Diagrams and Connectors......................................................... 10-1
Table 11-1. Table of Exploded Views .................................................................................................... 11-1
Table 11-2. XTL 5000 O3 Control Head Parts List................................................................................ 11-2
Table 11-3. XTL 5000 O5 Control Head Parts List................................................................................ 11-3
Table 11-4. CHIB and CHUC Parts List ................................................................................................ 11-4

xvi Related Publications
October 30, 2006 6871769L01-A
Table 11-5. Transceiver Interface Board (TIB) Parts List ...................................................................... 11-5
Table 11-6. XTL 5000 Dash Mount Radio Parts List............................................................................. 11-6
Table 11-7. XTL 5000 Dash Mount Radio Parts List............................................................................. 11-7
Table 11-8. XTL 5000 Mid Power Remote Mount Radio Parts List....................................................... 11-8
Table 11-9. XTL 5000 100 W Remote Mount Radio Parts List ............................................................. 11-9
Related Publications
ASTRO Digital XTL 5000 Mobile Radio User’s Guide .................................................................... HLN6951_
ASTRO Digital XTL 5000 Mobile Radio Installation Manual ........................................................... HLN6947_
ASTRO Digital XTL 5000 VHF/UHF Range 1/700-800 MHz Mobile Radio
Detailed Service Manual........................................................................................................... 6871770L01
CPS Programming Installation Guide ..........................................................................................6881095C44
KVL 3000 User’s Manual ............................................................................................................. 6881131E16

6871769L01-A October 30, 2006
Commercial Warranty xvii
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 XTL 5000 One (1) Year
Product Accessories One (1) Year

October 30, 2006 6871769L01-A
xviii Commercial Warranty
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.

6871769L01-A October 30, 2006
Commercial Warranty xix
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.

October 30, 2006 6871769L01-A
Notes
xx Commercial Warranty

6871769L01-A October 30, 2006
Model Numbering, Charts, and Specifications xxi
Model Numbering, Charts, and Specifications
Mobile Radio Model Numbering Scheme
Position 1 - Type of Unit
M = Mobile
L = Table Top Station
Positions 2 & 3 - Model Series
Position 4 - Frequency Band
Less than 29.7MHz
29.7 to 35.99MHz
36 to 41MHz
42 to 50MHz
300 to 345MHz
66 to 80MHz
74 to 90MHz
Product Specific
VHF Range
136 to 162MHz
146 to 178MHz
174 to 210MHz
190 to 235MHz
330 to 370MHz
366 to 410MHz
403 to 437MHz
438 to 482MHz
470 to 620MHz
Product Specific
UHF Range
806 to 870MHz*
825 to 870MHz
896 to 941MHz
403-470MHz
1.0 to 1.6GHz
1.5 to 2.0GHz
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
10.1 to 15 Watts
16 to 25 Watts
26 to 35 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
Tranceiver with Selectable Control Head
VDV Control Head
Control Head #2
Position 7 - Channel Spacing
0 =
1 = 5KHz
2 = 6.25KHz
3 = 10KHz
4 = 12.5KHz
5 = 15KHz
6 = 20/25KHz
7 = 30KHz
8 = 12.5/25KHz
9 = Variable/Programmable
Typical Model Number:
Position:
Position 8 - Primary Operation
Conventional/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)
Digital Dispatch
Programmable
Digital Interconnect
Digital Multi-Service
9600 Capable
TDMA
* FDMA = Frequency Division Multiple Access
** TDMA = Time Division Multiple Access
Position 9 - Primary SystemType
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
IDEN Basic
IDEN Advanced Feature
JSMR Digital
LTR Protocol
Single Sideband
Programmable
Secure Conventional
Secure SMARTNET
TETRA
SmartZone
* MPT = Ministry of Posts and Telecommunications
Position 10 - Feature Level
1 = Basic
2 = Limited Package
3 = Limited Plus
4 = Intermediate
5 = Standard Package
6 = Standard Plus
7 = Expanded Package
8 = Expanded Plus
9 = Full Feature/
Programmable
Position 11 - Version
Version Letter (Alpha) - Major Change
Position 12 -
Unique Model Variations
C = Cenelec
N = Standard Package
Positions 13 - 16
SP Model Suffix
1 23 4 5 6 7 8 9 10 11 1213141516
M20 U R S 9 P W 1 A N S P 0 1
20 = XTL 5000
A
B
C
D
E
F
G
H
J
K
L
M
=
=
=
=
=
=
=
=
=
=
=
=
N
P
Q
R
S
T
U
V
W
X
Y
Z
=
=
=
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
G
H
J
=
=
=
=
=
=
=
=
=
36 to 60 Watts
61 to 110 Watts
Up to 125 Watts
1 to 25 Watts
25 to 40 Watts
25 to 45 Watts
10 to 35 Watts
10 to 50 Watts
25 to 110 Watts
K
L
M
N
P
Q
R
S
T
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U
V
W
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z
2
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
MAEPF-27634-B
* For XTL 5000 "K" in Position 4 represents
136-174MHz.
* For XTL 5000 "Q" in Position 4 represents
380-470MHz.
* For XTL 5000 "S" in Position 4 represents
470-520MHz.
* For XTL 5000 "U" in Position 4 represents
762-870MHz.
Note: Values represented are not absolute,
and are given to indicate range only.
Note: Values represented are not absolute,
and are given to indicate range only.

October 30, 2006 6871769L01-A
xxii Model Numbering, Charts, and Specifications
ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart
(Chart Continued on the next page)
M20KSS9PW1AN
Option Description
G66AH ADD: Dash Mount Mid Power O3
G67AZ ADD: Remote Mount Mid Power O3
G67AY ADD: Remote Mount High Power O3
G655AH ADD: Quick Release Remote Mount O3 High Power
G72AC ADD: XTL5000 O3 Control Head
G159AH ADD: XTL Encryption UCM HW 30 Sec Key
G159AJ ADD: XTL Encryption UCM HW 3 Day Sec Key Ret
Item No. Description
XXXX0364332H02 M3 x 5 screw
X0364583H01 Screw, M6 x 1, Hex Socket
X X 3064658H04 High Power TIB Flex Kit
XXXX3285471E01 Seal Headbridge
X5564610H02 Handle Assembly
X5564957H01 Key Lock
XXXX5684275A05 Bag Air Plastic 10” x 10”
XXHKN4192B Mobile Power CBL High Power 20'
X X HKN6110_ Cable, Power, 100W
XXHKN6190B Mid Power TIB Flex Kit
XXHLN6861A Hardware XTL 5000 Standard Install
XXXXHLN6863A Accessory Connection XTL 5000
XHLN6909_ Quick Release HiPower Trunnion
XHLN6910_ Screw, HiPower Trunnion
XXXXHLN6954_ Cover, Dust, Kit
XXXPMLN4958A O3 CAN 17' Extension Cable
XXXPMLN4959A O3 Accessory Cable
XPMUN1034A O3 Handheld Control Head
XXXXPMUN1036A Remote Assy, Radio End with QuickDisconnect
X HLN6919_ Secure Interface Board 30 Sec Key Retention
X HLN6918_ Secure Interface Board 3 Day Key Retention
X X NNTN5032_ UCM II Mode
XHUD1793_ Tanapa VHF 50W
X X 0310907A20 Screw M3 x 0.5 x 10
X X 2685498E02 Shield
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

6871769L01-A October 30, 2006
Model Numbering, Charts, and Specifications xxiii
ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart (Cont.)
(Chart Continued on the next page)
M20KSS9PW1AN
Option Description
G927AA INT: Connector Remote Mount
W874AA ADD: Handset/Hangup Armored Cable (GCAI)
G874AA ADD: Handset/Hangup (GCAI)
G876AA ADD: Hangup/Cradle w/Coiled CBL, GCAI
W872AA ADD: Visor Mic Standard
W22AW ADD: STD Palm Mic GCAI
G233AC ADD: Gooseneck PTT Millennium
W20BX ALT: Keypad Microphone
W382AH ALT: Control Station Palm Microphone
W665BE ADD: Control Station Base Mount
G91AB ADD: Control Station Power Supply
W688AP ADD: External Emergency Pushbutton
W81AL ADD: Key Lock Mount
W116AN ADD: External Alarm and Relay Cable
Item No. Description
XHLN6961_ Accessory Connector Remote Mount
XHKN1018_ Handset/Hangup Normal Armored Cable
XHLN1457_ Handset/Hangup (Hangup Cup)
XHKN1017_ Handset/Hangup Coiled Cable
XHMN4089_ Visor Mic Remote Mount
XHMN1090_ Std Palm Mic GCAI
XHMN1087_ Gooseneck PTT
XHMN4079_ Keypad Microphone
XHMN1088_ Control Station Desk Microphone
XHLN6042_ Control Station Mount
XHPN4007_ Power Supply
XHLN6188_ Emergency Pushbutton
X HLN6372_ Keylock Mount
X TLN4533_ Relays
X HKN4258_ Cable Relay
XHLN5131_ Emergency Button
XHLN6047_ Hardware Installation Base Tray
X6880101W87 Spectra Controller Station Instructor Manual
X6880102W93 Spectra Maxtrac Controller Base Manual
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

October 30, 2006 6871769L01-A
xxiv Model Numbering, Charts, and Specifications
ASTRO XTL 5000 O3 VHF 10-50 Watt Model Chart (Cont.)
M20KSS9PW1AN
Option Description
W591AP ADD: Auxiliary Switch Panel
B18CL ADD: Auxiliary Spkr Spectra 5 Watt
W432AE ADD: External 13 Watt Speaker
G296AA ADD: Antenna 1/4 Wave Whip Roof Top 136-144 MHz
G297AA ADD: Antenna 1/4 Wave Roof Top VHF 144-150.8 MHz
G299AA ADD: Antenna 1/4 Wave Roof Top VHF 150.8-162 MHz
G300AA ADD: Antenna 1/4 Wave Roof Top VHF 162-174 MHz
G301AA ADD: Antenna 3 dB Roof Top VHF 136-174 MHz
W652AE ADD: 1/4 Wave Broadband Antenna 136-162 MHz
G629AA ADD: 1/4 Wave Broadband Antenna 146-174 MHz
G792AA ADD: Wideband Antenna 136-174 MHz
Item No. Description
XHLN1196_ Auxiliary Switch Panel
XHSN4031_ External 7.5 Watt Speaker
XHSN4032_ External 13 Watt Speaker
XHAD4006_ 1/4 Wave Whip Antenna Roof Top
XHAD4007_ 1/4 Wave, Roof Top VHF
XHAD4008_ 1/4 Wave Roof Top
XHAD4009_ 1/4 Wave Roof Top
XHAD4016_ 1/4 Wave Broadband Antenna 136-162 MHz
X HAD4017_ 1/4 Wave Broadband Antenna 146-174 MHz
X HAD4021_ Wideband Antenna 136-174 MHz
XRAD4010ARB 3 dB Antenna 136-174 MHz
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.