W3 / W4 / W5 / W7/ W9 Control Head Models Service …® Digital Spectra® and Digital Spectra Plus...

ASTRO® Digital Spectra

®

and Digital Spectra Plus

Mobile Radios

W3 / W4 / W5 / W7/ W9

Control Head Models

Service Manual

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Title Page ASTRO® Digital Specand Digital Spectra P

Mobile Ra

W3/W4/W5/W7/Control Head Mod

Service Man

Motorola, Inc.8000 West Sunrise BoulevardFort Lauderdale, Florida 33322 6881096C

i

ForewordThis manual covers the ASTRO® Digital Spectra® and Digital Spectra Plus control heads (Models W3, W4, W5, W7, and W9), unless otherwise specified. This manual provides sufficient information to enable qualified service shop technicians to troubleshoot and repair ASTRO® Digital Spectra® and Digital Spectra Plus control heads to the component level.

For details on radio operation, refer to the applicable manuals available separately. A list of related publications is provided in the section, “Related Publications,” on page ix.

Product Safety and RF Exposure Compliance

ATTENTION!

The radio that comes with this control head 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 68P81095C99) 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 Radio Parts 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, ASTRO, and Spectra are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners.

© Motorola, Inc. 2003.

CAUTION: Before using this product, read the operating instruc-tions for safe usage contained in the Product Safety and RF Expo-sure booklet enclosed with your radio.

!C a u t i o n

ii

http://www.motorola.com/cgiss/index.shtml

Table of Contents iii

Table of Contents

Foreword.........................................................................................................ii

Product Safety and RF Exposure Compliance ............................................................................................ iiManual Revisions ........................................................................................................................................ iiComputer Software Copyrights ...................................................................................................................iiDocument Copyrights .................................................................................................................................. iiDisclaimer.................................................................................................................................................... iiTrademarks ................................................................................................................................................. ii

Commercial Warranty ...................................................................................xi

Limited Warranty ........................................................................................................................................xiMOTOROLA COMMUNICATION PRODUCTS................................................................................xi

I. What This Warranty Covers And For How Long .....................................................................xiII. General Provisions .................................................................................................................xiIII. State Law Rights .................................................................................................................. xiiIV. How To Get Warranty Service ............................................................................................. xiiV. What This Warranty Does Not Cover.................................................................................... xiiVI. Patent And Software Provisions ......................................................................................... xiiiVII. Governing Law................................................................................................................... xiii

Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual...................................................................................................... 1-11.2 Control Head Features .................................................................................................................. 1-21.3 Control Heads................................................................................................................................ 1-2

1.3.1 W3 Control Head .............................................................................................................. 1-21.3.1.1 W3 Controls ............................................................................................................. 1-3

1.3.2 W4, W5, W7, and W9 Control Heads ............................................................................... 1-41.3.2.1 W4, W5, W7, and W9 Controls................................................................................ 1-6

Chapter 2 Basic Maintenance.............................................................. 2-1

2.1 Inspection ...................................................................................................................................... 2-12.2 Cleaning......................................................................................................................................... 2-1

2.2.1 Cleaning External Plastic Surfaces................................................................................... 2-12.2.2 Cleaning Internal Circuit Boards and Components........................................................... 2-1

2.3 Handling Precautions..................................................................................................................... 2-2

Chapter 3 Theory of Operation............................................................ 3-1

3.1 W3 Control Head ........................................................................................................................... 3-13.1.1 SB9600 Serial Bus Interface............................................................................................. 3-13.1.2 Display Circuit ................................................................................................................... 3-13.1.3 Keypad Side Keys and Top Keys ..................................................................................... 3-23.1.4 Microphone Preamplifier and PTT .................................................................................... 3-2

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iv Table of Contents

3.1.5 On-/Off-Hook Control ........................................................................................................ 3-33.1.6 Backlight Circuit ................................................................................................................ 3-33.1.7 Power Supply.................................................................................................................... 3-33.1.8 Status LEDs ...................................................................................................................... 3-33.1.9 Jumper Selection .............................................................................................................. 3-33.1.10 Power On/Off .................................................................................................................... 3-43.1.11 Miscellaneous Functions................................................................................................... 3-4

3.2 W4, W5, and W7 Control Heads.................................................................................................... 3-43.2.1 Power Switch/Ignition........................................................................................................ 3-43.2.2 Voltage Regulator ............................................................................................................. 3-53.2.3 Microcomputer ..................................................................................................................3-53.2.4 Interface Circuitry.............................................................................................................. 3-53.2.5 Reset................................................................................................................................. 3-63.2.6 Bus Busy........................................................................................................................... 3-63.2.7 Serial Bus Data ................................................................................................................. 3-63.2.8 Push-To-Talk (PTT) .......................................................................................................... 3-73.2.9 Hang-Up Button (HUB) .....................................................................................................3-73.2.10 Ignition Sense Circuitry .....................................................................................................3-73.2.11 Keypad Scan..................................................................................................................... 3-73.2.12 Vacuum Fluorescent (VF) Voltage Converter Circuitry..................................................... 3-73.2.13 Vacuum Fluorescent Display Driver IC ............................................................................. 3-83.2.14 Vacuum Fluorescent Display ............................................................................................ 3-83.2.15 Backlight LEDs..................................................................................................................3-8

3.3 W9 Control Head ........................................................................................................................... 3-83.3.1 Display .............................................................................................................................. 3-83.3.2 W9 Controls and Indicators............................................................................................... 3-93.3.3 Control Board.................................................................................................................... 3-9

3.3.3.1 Microprocessor ........................................................................................................ 3-93.3.3.2 Watchdog Timer....................................................................................................... 3-93.3.3.3 Bus Transceiver ..................................................................................................... 3-103.3.3.4 Vacuum Fluorescent Voltage Converter ................................................................ 3-103.3.3.5 Vehicle Interface Ports........................................................................................... 3-103.3.3.6 Power Supply.........................................................................................................3-103.3.3.7 Ignition Sense Circuits ........................................................................................... 3-103.3.3.8 EEPROM Write-Protect Circuit .............................................................................. 3-11

3.3.4 Display Board.................................................................................................................. 3-113.3.4.1 VF Display..............................................................................................................3-113.3.4.2 VF Display Driver ...................................................................................................3-113.3.4.3 Status LEDs........................................................................................................... 3-113.3.4.4 Backlight LEDs....................................................................................................... 3-11

3.3.5 Default Jumper Settings.................................................................................................. 3-113.4 Vehicle Interface Port (VIP) .........................................................................................................3-12

3.4.1 W4, W5, and W7 Control Heads..................................................................................... 3-123.4.1.1 VIP Output Connections ........................................................................................ 3-12

3.4.1.1.1 Dash-Mount Installations ................................................................................ 3-123.4.1.1.2 Remote-Mount Installations ............................................................................ 3-13

3.4.1.2 VIP Input Connections (Remote-Mount Only)........................................................ 3-133.4.2 W9 Control Heads........................................................................................................... 3-14

3.4.2.1 VIP Output Connections ........................................................................................ 3-143.4.2.2 VIP Input Connections ........................................................................................... 3-14

Chapter 4 Test Equipment and Service Aids ..................................... 4-1

September 26, 2003 6881096C77-O

Table of Contents v

4.1 Recommended Test Equipment and Service Aids ........................................................................ 4-1

Chapter 5 Troubleshooting................................................................. 5-1

5.1 Required Tools and Supplies......................................................................................................... 5-15.2 Troubleshooting Waveforms.......................................................................................................... 5-2

5.2.1 ASTRO Digital Spectra Waveforms.................................................................................. 5-25.3 Replacing the Vacuum Fluorescent Display (W4, W5, and W7 Control Heads) ........................... 5-5

5.3.1 Removing the Display....................................................................................................... 5-55.3.2 Installing the Display ......................................................................................................... 5-5

5.4 Replacing the Remote Back-Housing Interface Board .................................................................. 5-55.4.1 W4, W5, and W7 Control Heads....................................................................................... 5-5

5.5 Replacing the Remote Interconnect Board.................................................................................... 5-65.5.1 Low-/Mid-Power Radios.................................................................................................... 5-65.5.2 High-Power Radios........................................................................................................... 5-6

5.6 Replacing the Control-Head Board................................................................................................ 5-75.6.1 W3 Control Heads ............................................................................................................ 5-75.6.2 W4, W5, and W7 Control Heads....................................................................................... 5-85.6.3 W9 Control Heads .......................................................................................................... 5-10

5.7 Final Reassembly–W3 Control Head........................................................................................... 5-115.8 Troubleshooting Charts ............................................................................................................... 5-12

Chapter 6 Radio Connectors ............................................................... 6-1

6.1 Radio Connectors .......................................................................................................................... 6-26.2 Radio Connector Locations ........................................................................................................... 6-36.3 Extender Cable (P501) .................................................................................................................. 6-46.4 Control-Head Cabling Diagram...................................................................................................... 6-4

Chapter 7 Exploded Views and Parts Lists ........................................ 7-1

7.1 Model W3 Hand-Held Control Head Exploded View ..................................................................... 7-27.2 W4 Rotary Control Head Exploded View...................................................................................... 7-37.3 W5 and W7 Pushbutton Control Head Exploded View................................................................. 7-47.4 W9 Pushbutton Control Head Exploded View .............................................................................. 7-57.5 HMN1080A, HMN1061A, HMN1079A Microphone Exploded View .............................................. 7-67.6 Small Pushbutton Parts ................................................................................................................. 7-77.7 Large Pushbutton Parts ................................................................................................................. 7-7

Chapter 8 Schematics, Overlays, and Parts Lists ............................. 8-1

8.1 List of Schematics, Component Location Diagrams, and Parts Lists ............................................ 8-1

Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information ............................................................................................................A-1A.2 Motorola Online .............................................................................................................................A-1A.3 Mail Orders ....................................................................................................................................A-1A.4 Telephone Orders..........................................................................................................................A-2

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vi Table of Contents

A.5 Fax Orders .....................................................................................................................................A-2A.6 Parts Identification .........................................................................................................................A-2A.7 Product Customer Service .............................................................................................................A-2

Index..................................................................................................... Index-1

September 26, 2003 6881096C77-O

List of Figures vii

6881096C77-O September 26, 2003

List of Figures

Figure 1-1. Typical W3 Hand-Held Control Head.................................................................................... 1-3Figure 1-2. Typical W4 Rotary Control Head........................................................................................... 1-4Figure 1-3. Typical W5 Pushbutton Control Head................................................................................... 1-4Figure 1-4. Typical W7 Pushbutton Control Head................................................................................... 1-5Figure 1-5. Typical W9 Pushbutton Control Head................................................................................... 1-5Figure 3-1. Astro Spectra Control Head Block Diagram.......................................................................... 3-4Figure 3-2. Cabling Interconnect Diagram for Dash Mount................................................................... 3-13Figure 3-3. Cabling Interconnect Diagram for Remote Mount............................................................... 3-13Figure 5-1. Replacing the Vacuum Fluorescent Display ......................................................................... 5-5Figure 5-2. Model W4 Rotary Control Head Assembly Screw and Snap Sequence............................... 5-8Figure 5-3. Models W5 and W7 Pushbutton Control Head Assembly Screw Sequence ........................ 5-8Figure 5-4. W9 Control Head Control Board and Display Board........................................................... 5-10Figure 6-1. J0103 Remote-Mount Control Head Connector.................................................................... 6-2Figure 6-2. J5 Control Cable for Remote-Mount Control Head............................................................... 6-2Figure 6-3. J6 Radio Operations Connector............................................................................................ 6-2Figure 6-4. J2 Rear Accessory Connector .............................................................................................. 6-2Figure 6-5. P104 Microphone Jack ......................................................................................................... 6-2Figure 6-6. Dash-Mount Radio Connector Locations.............................................................................. 6-3Figure 6-7. Remote-Mount Radio Connector Locations.......................................................................... 6-3Figure 6-8. Command Board Connector Locations................................................................................. 6-3Figure 6-9. VOCON Board Connector Locations .................................................................................... 6-3Figure 6-10. P501 Extender Cable............................................................................................................ 6-4Figure 6-11. Control-Head Cabling Diagram............................................................................................. 6-4Figure 7-1. W3 Hand-Held Control Head Exploded View ....................................................................... 7-2Figure 7-2. W4 Rotary Control Head Exploded View .............................................................................. 7-3Figure 7-3. W5 and W7 Pushbutton Control Head Exploded View ......................................................... 7-4Figure 7-4. W9 Pushbutton Control Head Exploded View ...................................................................... 7-5Figure 7-5. HMN1080A, HMN1061A, HMN1079A Microphone Exploded View...................................... 7-6

viii Related Publications

List of Tables

Table 1-1. ASTRO Digital Spectra/Spectra Plus Basic Features ........................................................... 1-2Table 1-2. 12-Button Keypad (W7 and W9) ........................................................................................... 1-7Table 3-1. W3 Jumper Selection............................................................................................................ 3-3Table 3-2. Types of Operations.............................................................................................................. 3-4Table 3-3. Serial Data Bus Logic............................................................................................................ 3-6Table 3-4. PTT Logic States................................................................................................................... 3-7Table 3-5. HUB Logic States ..................................................................................................................3-7Table 3-6. Standard Jumper Configurations......................................................................................... 3-11Table 3-7. VIP Output Connections ..................................................................................................... 3-14Table 3-8. VIP Input Connections ........................................................................................................ 3-14Table 4-1. Recommended Motorola Test Equipment and Service Aids .................................................4-1Table 5-1. Required Tools and Supplies ................................................................................................ 5-1Table 7-1. Exploded Views..................................................................................................................... 7-1Table 7-2. W3 Hand-Held Control Head Exploded View Parts List........................................................ 7-2Table 7-3. Model W4 Rotary Control Head Parts List ............................................................................ 7-3Table 7-4. W5 and W7 Pushbutton Control Head Parts List .................................................................. 7-4Table 7-5. W9 Pushbutton Control Head Parts List .............................................................................. 7-5Table 7-6. HMN1080A, HMN1061A, HMN1079A Microphone Parts List............................................... 7-6Table 7-7. Small Pushbutton Parts List .................................................................................................. 7-7Table 7-8. Large Pushbutton Parts List.................................................................................................. 7-7

September 26, 2003 6881096C77-O

List of Tables ix

Related PublicationsASTRO Digital Spectra and Digital Spectra Plus Model W3 User’s Guide ..................................6881090C61ASTRO Digital Spectra and Digital Spectra Plus Models W4, W5, W7, and W9 User’s Guide ..6881090C62ASTRO Digital Spectra Hand-Held Control Head User’s Guide (Model W3) ..............................6881073C25ASTRO Digital Spectra (Model W4, W5, W7, and W9) User’s Guide..........................................6881074C80ASTRO Digital Spectra and Digital Spectra Plus Mobile Radios Detailed Service Manual .........6881076C25ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual.........6881091C78ASTRO Spectra and Digital Spectra FM Two-Way Mobile Radios Installation Manual ...............6881070C85ASTRO Spectra Motorcycle Radios Supplemental Installation Manual...................................... 6880103W01CPS Programming Installation Guide ..........................................................................................6881095C44KVL 3000 User’s Manual ............................................................................................................. 6881131E16

6881096C77-O September 26, 2003

x List of Tables

Notes

September 26, 2003 6881096C77-O

Commercial Warranty xi

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 Digital Spectra Plus Units

One (1) Year

Product Accessories One (1) Year

6881096C77-O September 26, 2003

xii 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.

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Commercial Warranty xiii

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.

6881096C77-O September 26, 2003

xiv Commercial Warranty

Notes

September 26, 2003 6881096C77-O

Chapter 1 Introduction

ASTRO Digital Spectra and Digital Spectra Plus control heads are available in five radio models: W3, W4, W5, W7, and W9. This chapter describes the control heads used with these radios.

1.1 Notations Used in This ManualThroughout the text in this publication, you will notice the use of note, caution, warning, and danger notations. These notations are used to emphasize that safety hazards exist, and care must be taken and observed.

NOTE: An operational procedure, practice, or condition that is essential to emphasize.

CAUTION indicates a potentially hazardous situation which, if not avoided, might result in equipment damage.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury.

!C a u t i o n

!W A R N I N G

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D A N G E R

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1-2 Introduction: Control Head Features

1.2 Control Head FeaturesThe table below outlines the basic features of the five control heads covered in this manual.

1.3 Control Heads The control heads used with ASTRO Digital Spectra and Digital Spectra Plus radios have microprocessor circuitry that operates the standard and optional features built into the system. The control-head design allows for installation in even the smallest of vehicles. The control head may be field-programmed to add options or alter the information stored in certain areas of its electronic memory.

The following sections describe the control head used by each of the five models.

1.3.1 W3 Control Head

The W3 Hand-Held Control Head (HHCH) is shown below. THe HHCH has been designed as an alternative to the standard radio control-head approach. It can emulate most radio control-head functions, including LCD display, volume control, power On/Off, and mode. The HHCH can either replace the radio control head or be used in dual-control applications, either in conjunction with a radio control head or another HHCH.

Table 1-1. ASTRO Digital Spectra/Spectra Plus Basic Features

Feature W3 W4 W5 W7 W9

Display 2 line/14 characters Liquid-Crystal Display (LCD) with 8 Status Annunciators

1 line/8 charactersVacuum Fluorescent Display




Mode & Volume Controls

Rocker Switches Rotary Mode & Volume Controls

Rocker Switch Mode & Volume Controls



Numeric Keypad

Yes No No Yes Yes

Channel Capability (Digital Spectra)

255 128 128 255 255

Channel Capability (Digital Spectra Plus)

512 128 128 512 512

Remote Mount Available Available Available Available Available

Dash Mount Available Available Available Available Not Available

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Introduction: Control Heads 1-3

Figure 1-1. Typical W3 Hand-Held Control Head

1.3.1.1 W3 Controls

On/Off Button (T1): Turns the radio on and off. Can be used as an additional programmable button if the on/off function is not used.

Orange Programmable Button (T2): Programmed at the factory for emergency use. Field programmable by a qualified radio technician.

Programmable Button (T3): Field programmable by a qualified radio technician.

LED Indicator: Green/red light-emitting diode. Indicates operating status.

Display: 2-line by 14-character display. Provides visual information about many radio features.

Keypad. Provides control of, and data interface with, many features.

Programmable Side Button 1 (S1): Field programmable by a qualified radio technician.



Mode Control: Used for selecting modes and programming menus.

Volume Control: Used for selecting volume level, editing names, and making certain radio adjustments.

Push-To-Talk (PTT) Button: Engages the transmitter.

MODE

HOME

2ABC1 Q Z 3DEF

4GHI 5JKL 6MNO

7PRS 8TUV 9WXY

0

VOL

Side Button 1 (S1)

Side Button 2 (S2)

Side Button 3 (S3)

On/OffButton(T1)

Push-To-Talk(PTT) Switch

LEDIndicator

AlphanumericKeypad

VolumeControl Mode Control

Orange ProgrammableButton(T2)

ProgrammableButton(T3)

Display

Button

6881096C77-O September 26, 2003

1-4 Introduction: Control Heads

1.3.2 W4, W5, W7, and W9 Control Heads

Figure 1-2. Typical W4 Rotary Control Head

Figure 1-3. Typical W5 Pushbutton Control Head

PHONE

PAGEor

SECUREor

EMERGENCY

Page

Emer

CALL DIRECT

XMIT

BUSY

Mode Volume

Pwr

Phon Call SelScan

Mic

Home

Dim

H/L

Dir Mon

SCAN SELECT MONITOR

MODEKNOB

POWER ON/OFF/VOLUME KNOB

HOMEHORN/

LIGHTS

PRIORITY/NON-PRIORITYINDICATORS

DIRECTINDICATOR

Mode

Vol

Mic

Phon Call Sel

H/L Mon Dir

PWR

Scan

XMIT

BUSYDIM

HOME

MODEPOWERON/OFF

PAGEor

SECUREor

EMERGENCY

Page

Emer

PHONE

SCAN

CALL

SELECT

VOLUME PRIORITY/NON-PRIORITYINDICATORS

DIRECTINDICATOR

HORN/LIGHTS

MONITOR

DIRECTHOME

September 26, 2003 6881096C77-O




POWERON/OFF

2

2Pgeor

SITE

LOCK

MESSAGEREPROGRAM

DIRECTO #Del Rcl

Mode

Vol

Mic

Phon Call SelPWR

Scan

XMIT

BUSYDIM

HOME

1Ste 2 3Lck

4Sts 5Rpg 6Msg

7H/L 8Mon 9Dir

MODE

EMERGENCYor

SECURE

Emer

PHONE

SCAN

CALL

SELECT

PAGE

VOLUME

DIRECTINDICATOR

DELETERECALL

MONITOR

STATUS

HORN/LIGHTS

HOME

PRIORITY/NON-PRIORITYINDICATORS

XMIT BUSY

CallScanEmer

DIM

PriNon

Pri

1 2 3

4 5 6

7 8 9

Mode Vol Sel Home

Phon H/L

Rcl Sql Del

Dir

Sts Msg

VOLUMEROCKER

MODEROCKER

SELECT HOME

KEYPAD

RECALLDELETE

DIMMERCONTROL

PRIORITYINDICATOR

FUNCTIONBUTTON

NON-PRIORITYINDICATOR

FUNCTIONON/OFF

INDICATORS

* Optional buttons (included but not installed or programmed)

MESSAGE*

POWERSWITCH

STATUS*

0

6881096C77-O September 26, 2003


1.3.2.1 W4, W5, W7, and W9 Controls

Power Switch (PWR): Turns the radio and its accessories on or off. The Power switch is part of the rotary volume knob on the W4 model, a push-type switch on the W5 and W7 models, and a slide switch on the right-hand bottom surface of the W9 model.

Mode Switch: Used for selecting modes and programming menus. The Mode switch is a rotary switch on the W4 model and a rocker switch on the W5, W7, and W9 models. Press the right side of the rocker switch to increase the mode number and the left side to decrease the mode number. Press and hold the switch to scroll the mode number up or down. The mode names appear in the display window.

Volume Switch: Used for selecting the volume level, editing names, and making certain radio adjustments. The Volume switch is a rotary switch on the W4 model and a rocker switch on the W5, W7, and W9 models. On the pushbutton models, pressing and releasing the Volume switch checks the volume setting. Your display will show “VOLUME_ _” and a number value (0-15). Pressing and holding the left side decreases the volume. The number value scrolls up or down to your desired level. The Volume rocker switch also controls the volume level of the public address (PA) and external radio speaker (Ex Rd) options when they are enabled. The display window shows “PA VOL _ _” when public address is on and the Volume rocker switch is pressed.

Dim Button: Used to control the brightness of the display and button backlighting. When you turn on the system, the display comes on at the brightness level it was on before the system was last turned off. Press the DIM button once to reduce the brightness of the display to medium level and twice for low brightness level. Press the DIM button a third time to turn the display and button backlighting off. This is called the “surveillance” mode.

Home Button: Used for restoring preprogrammed mode, establishing programmed mode, selecting programming entries, etc. Press the Home button to go to the radio’s preprogrammed “home” mode. On the W7 models, you can use the Home button instead of the Mode switch to change modes. Hold the Home button until a beep sounds to enter the configuration state. The display shows an entry prompt. Use the keypad to enter your new mode choice and press the Home button again. Your mode is now changed without scrolling.

Select Button: Used to configure radio options.

Option Buttons: Used for turning options on and off, such as Phone, Scan, Emergency Call, and Secure.

Display: The vacuum fluorescent (VF) display’s primary function is to display mode numbers, mode names, volume level, and the status of options. It also functions as an on-off indicator for the entire system and plays an integral role in the operator’s reconfiguration of options. The display is 8 characters on W4, W5, and W7 models and 11 characters on the W9 model.

XMIT and BUSY Indicators: The XMIT indicator lights when the radio is transmitting. The BUSY indicator lights when the selected channel is busy.

Scan Indicators: When scan operation detects activity on a non-priority (NON-PRI) channel, the NON-PRI indicator light comes on. Activity on a second priority channel causes the priority (PRI) indicator to light. First priority channel activity causes PRI to flash.

12-Button Keypad (W7 and W9): Used to change the status of options and for entering numbers. Several keys serve multiple functions. The following buttons can be programmed to W7 and W9 control heads. The table below describes the buttons preinstalled on the W7 model. (See the ASTRO Digital Spectra or Digital Spectra Plus User’s Guide for a complete description of keypad operation.)

September 26, 2003 6881096C77-O


Table 1-2. 12-Button Keypad (W7 and W9)

Key Description

#1 keySite (STE)

Forces the radio to scan for a new site when the automatic multiple-site select (AMSS) feature for wide-area coverage is in use.

#2 KeyPage (2 or 2Pge)

Initiates a Call Alert page or enters Call ID list programming.

#3 keyLock (Lck)

Locks the radio onto the current site when the AMSS feature is in use.

#4 keyStatus (Sts)

Used alone or in conjunction with other keypad buttons and the Sel button to send a status transmission, indicating a predetermined condition change.

#5 keyRegroup (Rpg)

Requests a change in the radio’s talkgroup assignment when the dynamic regrouping feature is used.

#6 keyMessage (Msg)

Used alone or in conjunction with other keypad buttons and the Sel button to transmit a message, indicating a response or temporary condition.

#7 keyHorn/Lights (H/L)

Selects/enables radio external alarms.

#8 keyMonitor (Mon)

Monitors the radio for channel traffic.

#9 keyDirect/Simplex (Dir)

Used for talkaround (mobile-to-mobile) conversations.

* keyRecall (Rcl)

Reviews modes in scan and phone lists.

# keyDelete (Del)

Used when editing stored lists.

6881096C77-O September 26, 2003


Notes

September 26, 2003 6881096C77-O

Chapter 2 Basic Maintenance

This chapter describes inspection, cleaning, and handling precautions for the control heads. Each of these topics provides information vital to the successful operation and maintenance of your radio.

2.1 InspectionCheck that the external surfaces of the control head are clean, and that all external controls and switches are functional. A detailed inspection of the interior electronic circuitry is not needed.

2.2 CleaningThe following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the control head. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime. Internal surfaces should be cleaned only when the control head is disassembled for servicing or repair.

The only recommended agent for cleaning the external control head surfaces is a 0.5% solution of a mild dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (70% by volume).

2.2.1 Cleaning External Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the control head. A soft, absorbent, lint-free cloth or tissue should be used to remove the solution and dry the control head. Make sure that no water remains entrapped near the connectors, cracks, or crevices.

2.2.2 Cleaning Internal Circuit Boards and Components

Isopropyl alcohol may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded or caked materials located in hard-to-reach areas.

Alcohol is a high-wetting liquid and can carry contamination into unwanted places if an excessive quantity is used. Make sure that controls or tunable components are not soaked with the liquid. Do not use high-pressure air to hasten the drying process, since this could cause the liquid to puddle and collect in unwanted places.

Upon completion of the cleaning process, use a soft, absorbent, lint-free cloth to dry the area.

NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).

The effects of certain chemicals and their vapors can have harmful results on certain plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided.

!C a u t i o n

2-2 Basic Maintenance: Handling Precautions

2.3 Handling Precautions

Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices, are used in this family of radios. While the attributes of these devices are many, their characteristics make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair. Handling precautions are mandatory for this radio, and are especially important in low-humidity conditions. DO NOT attempt to disassemble the radio without observing the following handling precautions:

• Eliminate static generators (plastics, Styrofoam, etc.) in the work area.

• Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back loose-hanging neckties.

• Store and transport all static-sensitive devices in ESD-protective containers.

• Disconnect all power from the unit before ESD-sensitive components are removed or inserted unless otherwise noted.

• Use a static-safeguarded workstation through the use of an anti-static kit (Motorola part number 01-80386A82). This kit includes a wrist strap, two ground cords, a static-control table mat and a static-control floor mat.

NOTE:Be sure that the table and floor mats are properly grounded.

When these items are not readily available, observing the following techniques will minimize the chance of damage:

- If a static-sensitive device is to be temporarily set down, use a conductive surface for place-ment of the device.

- Make skin contact with a conductive work surface first and maintain this contact when the device is set down or picked up.

- Always wear a conductive wrist strap when servicing this equipment. The Motorola part number for a replacement wrist strap that connects to the table mat is 42-80385A59

Components used in this equipment can be damaged by accumulated static charge. Avoid unnecessary handling. When handling devices, use a group strap, conductive benches, and floor mats to ensure that a static charge does not develop on component terminals. Always pick up components by the body when possible, avoiding the electrical terminals. Exposed connections should be shorted together via conductive foam when not in use.

Use grounded equipment when performing tests. DO NOT connect components to or disconnect components from test equipment while power is applied.

!C a u t i o n

September 26, 2003 6881096C77-O

Chapter 3 Theory of Operation

This chapter describes the operational theory of the control heads for the W3, W4, W5, W7, and W9 radio models. It includes vehicular interface port (VIP) information.

3.1 W3 Control HeadThe W3 Hand-Held Control Head (HHCH) contains the U3 microcomputer, which runs on a 4 MHz clock and performs the following basic functions:

• SB9600 data encode and decode for communication to host radio.

• Liquid-crystal display (LCD) drive comprising two rows of 14 dot-matrix characters plus 10 annunciators.

• Scans a 22-key keypad.

• Scans three side keys and three top keys.

• Determines what type of radio is connected from the bus data and selects either portable or mobile/vehicle adaptor (VA) modes.

• Scans the PTT switch.

• Provides display drive and programmable adjustment for display contrast.

• Provides display and keypad backlight control.

• Activates the red PTT LED and yellow status LED as required.

• Provides remote keying of the microphone via the SB9600 serial bus as required.

• Detects off-hook/on-hook conditions in mobile/VA mode.

• Provides SPI serial communications to U8 for serial-to-parallel output expansion, U12 for parallel-to-serial input compression, U14 for analog-to-serial input compression, and option connector J2.

3.1.1 SB9600 Serial Bus Interface

The serial interface circuit, comprising transistors Q1, Q2, and Q8, and comparator U2, provides an interface between the microphone/message and a host radio for two-way SB9600 serial bus communications. This is necessary to control the radio from the HHCH and have radio status messages displayed on the HHCH. The interface circuit performs the following functions:

• Buffering of the input and output data by Q1 and U2 to improve isolation and drive capability.

• Conversion of balanced to unbalanced SB9600 data input to SB96 bus interface by Q1, U2.

• Bidirectional busy control through U3-20, -21, and -41 to J 1-3. U320 and -21 are paralleled to provide increased drive capability.

3.1.2 Display Circuit

The display is a liquid-crystal display (LCD) and comprises two rows of 14 dot-matrix characters and 10 annunciators. The display circuit consists of sections involving character generation, backplane drive, negative voltage generation, temperature compensation, and contrast control. A 200 kHz clock is derived from U4-25, which also supplies U14.

3-2 Theory of Operation: W3 Control Head

Operation of the circuit is complex; a brief description is detailed below:

• Display data exits U3-5/12 as eight bits of parallel data. This data addresses a character look-up table in LCD driver/controller U4. This provides the relevant segment output data from U4, as well as LCD drivers U5, U6, and U7, to activate the relevant display dots that form the characters as defined in the look-up table.

• The LCD is multiplexed with eight backplanes that are driven separately by U4-47 to -54. Each backplane is driven sequentially, one after the other, by a stepped a.c. voltage of between approximately -2 volts and +5 volts. LCD dots are displayed when a maximum or minimum of one of the backplane drives coincides with a minimum or maximum, respectively, of the relevant segment drive voltage.

• Negative voltage generation necessary for correct operation of the display is derived from a timed clock output from U3-38. This is fed to a voltage doubler comprising C21, C22, and D30. The d.c. output of the doubler is fed to voltage divider R16 to R20. This divider provides evenly spaced voltage increments from approximately -2 volts to +5 volts, which are then fed to U4, U5, U6, and U7 to form the stepped backplane and segment drive voltages.

• Temperature compensation is provided by U3 and U14 in conjunction with D32. This diode provides a temperature-dependent voltage to analog input pin 1 of A/D converter U14. This is sent as serial data input to U3-34, where it is compared to a reference in U3. The amount of deviation from this reference determines the duty cycle of the output drive voltage from U3-38. This results in a change to the drive voltage across C22, which is fed to analog input pin 6 of U14 via voltage divider R26 and R2, which is then fed to U3 as serial data. U3 checks this voltage for accuracy, using the temperature-dependent voltage at U14-1 as a reference, and corrects the drive duty cycle accordingly.

• Contrast control is achieved by adjusting the display drive duty cycle U3-38 by either keypad control or radio programming via the SB9600 bus. U3 contains a reference that presets the drive duty cycle to an average value when first connected to a new radio. Adjustment of the contrast setting will set up a new reference, which will be retained by the radio in EEPROM for future use so that the new setting will be retained if the microphone is turned off.

3.1.3 Keypad Side Keys and Top Keys

The HHCH keypad is configured as a matrix of five columns by six rows. The keyboard is scanned by taking each column output low in turn (each one 1 ms) and reading the corresponding row inputs through the data input latch, U10. After all five columns have been scanned, the row data is then decoded to see which keys, if any, are pressed. The HHCH then waits for debounce until the keypad is scanned again. The keypad is scanned every 25 ms. If the same key is still pressed, the key register value is determined from a key table. If the SB9600 serial bus is not busy, a serial-bus "BUTCTL" message transmission is initiated. The same process also applies when a key is released.

3.1.4 Microphone Preamplifier and PTT

PTT is achieved by activating switch S1. This places a ground on the microphone pre-amplifier circuit, comprising Q6 and associated components, and effectively turns it on. Activation of S7 also places a low on U10-6 input, which is passed on to U3 and transmitted as an SB9600 message back to the radio. When this message is received by the radio, (if required) an SB9600 message is sent back to the microphone and detected by U3, and the PTT LED is activated through U8. However, illumination of the PTT LED is under radio control and is therefore dependent upon radio programming. Q7 is also connected across the PTT line. Its purpose is to remotely enable the microphone pre-amplifier through a received SB9600 serial-bus message, as required.

September 26, 2003 6881096C77-O

Theory of Operation: W3 Control Head 3-3

Microphone cartridge M1 contains a capacitive transducer coupled to a FET amplifier. Microphone audio is obtained from the output of MI and fed to Q6-b via C28, which provides either 0dB of gain in portable mode or 20dB in mobile mode, during transmit. This gain change is achieved by the action of Q5, which is turned on in mobile mode only, and bypasses R71. (Note that this gain is with respect to a radio input impedance of 2k.Ω for portables and 600Ω for mobiles.)

3.1.5 On-/Off-Hook Control

The on-/off-hook control circuit comprises U8 and Hall switch U9. This circuit is only active in mobile mode, during which the output at U8-6 and -7 is driven high by U3. This provides supply volts for U9, the output of which still remains in its normally high state, provided that the microphone is off-hook. During the on-hook condition, when the microphone is retained in its hang-up bracket, a magnet in the hang-up bracket activates the Hall switch, which in turn pulls U9-3 low. This is detected by U3, which then sends an appropriate SB9600 message back to the radio. When the microphone is removed from the hang-up bracket, U9-3 returns high, causing U3 to send another SB9600 message back to the radio.

3.1.6 Backlight Circuit

The backlight circuit comprises U3, U15, Q3, Q4, and LEDs D3 to D17. U3 enables the backlights, as required, by placing a low at U3-16. This, in turn, turns on Q3 and Q4, causing the LEDs to turn on. The action of D35 and R34 provides a constant current source for the LEDs over a supply voltage range of 5.5 to 17 volts. U15 provides current balance between the individual pairs of LEDs, and R34 controls the total current to about 60 mA.

3.1.7 Power Supply

The power supply consists of a 5-volt linear regulator, U1, which provides the necessary 5-volt supply for all of the digital circuits. It has a low drop-out voltage to enable operation from an input voltage of about 5 volts up to 17 volts. This regulator also contains internal current-Iimiting protection, which will normally protect against damage from short-circuit faults. In addition, current is supplied directly from the unregulated input to the backlight LEDs for power dissipation reasons.

3.1.8 Status LEDs

D22 is provided as a status LED for programmable radio functions. It is activated by an SB9600 message from the radio which is detected by U3, resulting in a high at U8-2 and -3. In addition, the PTT LED, D21, can provide flashing radio status messages and can also be activated at the same time as D22.

3.1.9 Jumper Selection

The only jumpers that may normally be installed are JU10, JU11, and JU12. When these jumpers are installed, the ground provided is passed on to U3. These jumpers indicate whether a speaker is installed in the unit, the SB9600 serial-bus device address, and single- or dual-control head control, as defined in the table below.

Table 3-1. W3 Jumper Selection

Jumper IN OUT

JU10 Internal Speaker No internal speaker

JU11 SB9600 address = 6 BS9600 address = 5

JU12 Dual control Single control

6881096C77-O September 26, 2003

3-4 Theory of Operation: W4, W5, and W7 Control Heads

3.1.10 Power On/Off

The HHCH has the ability to turn a host radio on or off by activating S6, which then places a momentary logic low on the Mic Hi line. This is detected by appropriate circuitry in the host radio, which then reverses the power on/off state of the radio. Since the microphone power is supplied by a switched Opt B+ line from the radio, the microphone power on/off state follows that of the radio.

3.1.11 Miscellaneous Functions

If TP1 contacts are momentarily shorted or certain key combinations are pressed simultaneously, the HHCH is placed in its test mode to carry out various diagnostic checks.

Transient protection diodes D24, D25, D37, D38, and D39 provide electrostatic transient protection for sensitive components within the HHCH by preventing voltages from going outside the specified ranges for these components.

3.2 W4, W5, and W7 Control HeadsThe following pages describe the operational theory of the components of the W4, W5, and W7 control heads. Refer to Figure 3-1 for the control-head components.

Figure 3-1. Astro Spectra Control Head Block Diagram

3.2.1 Power Switch/Ignition

For dash-mounted radios, a pushbutton On/Off switch (S1) (or rotary knob on the W4 control head) on the front panel controls power to the radio and accessories. In addition to this switch, you can wire the vehicle’s ignition and add or remove control-head jumpers to further control radio operation.

Table 3-2. Types of Operations

Type How it OperatesControl Head

Jumper/StatusIgnition Wiring

1 RECEIVE and TRANSMIT enabled via control head ON/OFF switch (ignition has no effect).

JU1OUT; JU2/IN Connect ignition cable to “Battery Hot” at fuse block.

2 RECEIVE and TRANSMIT enabled only when ignition switch is ON.

JU1/OUT; JU2/IN Connect ignition cable to “Ignition” at fuse block.

VOLTAGECONVERTERCIRCUITRY

5 VOLTREGULATOR

U45

(U3, Q50, T60)

A+/IGN

13.8V 37 VDC

+5 VDC

JU1

JU2

1 2

1 2

A+

IGNITION

U101

VF DRIVERIC

VACUUMFLUORESCENT

DISPLAY

U102

34 VDC

2.5 VAC

VIP OUTPUTS

U1

U4

MICRO-COMPUTER

INTERFACEAND

WATCHDOGTIMER IC

SERIAL DATA BUS

VIP INPUTS

IGNITION SENSE

PTT SENSEHUB SENSE

BACKLIGHTLEDS

1

2

4.0 MHzY1

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Theory of Operation: W4, W5, and W7 Control Heads 3-5

The ignition cable is the fused wire attached to the accessory connector. The control head is shipped with jumper JU1 OUT and jumper JU2 IN. The three options are:

1. Connect the ignition cable to “Battery Hot” on the fuse block to TRANSMIT and RECEIVE via the front panel pushbutton On/Off switch, regardless of the ignition setting.

OR

2. Connect the ignition cable to “Ignition” at the fuse block to disable TRANSMIT and RECEIVE except when the ignition is on. This method is more convenient because you need only to switch off your ignition; the radio will not drain your car’s battery when you leave the radio switch on.

3. To allow receive via front panel On/Offf, but inhibit transit when the ignition is off, control head jumpers and radio software settings must be changed. Follow the disassembly procedures in Chapter 5 to remove the control head PC board from its housing, and then locate JU1 and JU2 using the board overlays in Chapter 8. Carefully unsolder JU2 from the board and solder it in a JU1. Change the “ignition switch” field in CPS (Radio Wide/Advanced) or RSS (F4/F3/F3/F3) to “TX inhibit.”

For remote mounted radios, the same options of operation are available to the customer. The fused GREEN wire coming from the control-head end of the interconnect cable is connected to “Battery Hot.” The ignition cable is the fused ORANGE wire also coming from the interconnect cable. The control head is shipped with jumper JU1 OUT and JU2 IN. Configured this way, connections to the ignition cable are made following options (1) or (2) above.

3.2.2 Voltage Regulator

Switch B+ is applied to U45, a 5-volt regulator. C45 and C58 filter SWB+ and the 5-volt line to ensure U45 operated properly. CR90 protects against accidental reverse-polarity connections during installation. The 5-volt supply operates the microcomputer circuitry, interface circuitry, vacuum fluorescent (VF) driver U101, and comparator U3.

3.2.3 Microcomputer

The microcomputer, U1, operates on the 5-volt supply and is filtered by L1. A resonator, Y1, oscillates at 4 MHz to provide a stable clock for microcomputer timing. U1 handles all communication with the radio command board over the serial bus, scans the keyboard for button presses, and generates the display information needed by the VF driver (U101) to drive the VF display (U102).

3.2.4 Interface Circuitry

The bulk of the interface circuitry is contained in bipolar, custom IC, U4. This IC includes watchdog timer circuits, serial-bus communication drive circuits, and input buffer circuits to protect microprocessor U1.

3 RECEIVE enabled by control head ON/OFF switch; TRANSIT enabled only when ignition switch is ON.

JU1 IN; JU2 OUT Connect ignition cable to “ignition” at fuse block. Enable “TX inhibit” ignition switch setting in RSS or CPS.

Table 3-2. Types of Operations (Continued)

Type How it OperatesControl Head

Jumper/StatusIgnition Wiring

6881096C77-O September 26, 2003

3-6 Theory of Operation: W4, W5, and W7 Control Heads

3.2.5 Reset

On initial power-up, the RESET line to U1-1 is held low by U4 for approximately 120 milliseconds before going high. This resets U1 and starts it operating properly. Then, a pulse train generated at U1-38 sends tickle pulses to the watchdog timer circuitry in U4 and sends a STROBE signal to the VF display driver, U101. Capacitor C6 charges to about 3.3 volts and triggers a reset as described above. Any time a reset occurs, U4-9 goes high, causing radio circuitry in the command board to also reset. Should radio circuitry initiate the reset, pin 23 of the control unit PC board connector is forced high, triggering the same events described above. The control head can reset the radio command board, and vice-versa, via the reset line. See Table 3-3.

3.2.6 Bus Busy

The control head prepares to send data on the serial bus when U-15 (BUSY OUT) goes low, causing U4-10 to go high. This signals the radio command board that the control head has data to send. U4-11 (BUSY IN) goes low whenever U4-10 goes high. This informs the control-head microcomputer that the serial bus is in use. See Table 3-3.

3.2.7 Serial Bus Data

See Table 3-3 for Serial Data Bus Logic. Two lines, BUS+ and BUS-, send data between the control head and the radio command board. Under the normal condition of inactivity, BUS+ is high and BUS- is low. This is the “inactive state” on the serial bus. When the two lines invert (BUS+ goes low, BUS- goes high), the serial bus is in the “active state.”

The control head uses the TX DATA line (U1-33) to send data over the serial bus. When TX DATA goes low, the bus is placed in the active state by U4; when TX DATA goes high, the bus returns to the inactive state.

Data is sent to the microcomputer on the RX DATA line (U1-32). Whenever the serial bus is in the active state, RX DATA is low. An inactive state on the bus causes RX DATA to go high.

Table 3-3. Serial Data Bus Logic

Data LineNo Bus Activity

(NormalReceiving Data)

Bus Activity(Sending or

Receiving Data)In Reset*

Busy Low High Low

BUSY IN High Low High

BUSY OUT High Low* High

BUS+ High Low and High High

BUS- Low High and Low Low

TX DATA High Low and High** High

RX DATA High Low and High High

RESET Low Low High

RESET High High Low

* Bus activity will occur immediately after a reset.** Sending only.

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Theory of Operation: W4, W5, and W7 Control Heads 3-7

3.2.8 Push-To-Talk (PTT)

The PTT line from the microphone keys the transmitter. This line (U4-37) is normally biased at 5 volts, but goes to DIG GND when the microphone PTT button is pressed. This causes the PTT line (U1-21) to go high. The transmit command is then sent over the serial bus to the radio command board. Releasing the PTT reverses this process. There is no PTT hardware connection from the control head to the radio command board. See Table 3-4.

3.2.9 Hang-Up Button (HUB)

The control head senses when the microphone is off-hook by monitoring the HUB line from the microphone. When the microphone is on-hook, the HUB line (U4-31) is connected to ground, placing a high on the inverted HUB line (U1-20) and sending the on-hook command over the serial bus. When the microphone is off-hook, U4-31 biases to 5 volts, reversing the process and sending the off-hook command over the serial bus. See Table 3-5.

3.2.10 Ignition Sense Circuitry

Ignition sense voltage is sensed by U4-28. When this voltage is high, U4-29 goes low, resulting in U1-39 going low, and sending the “ignition-on” command over the serial bus. When the ignition voltage drops off, the process is reversed.

3.2.11 Keypad Scan

U1 scans the keypad switches for a button press by sending out periodic low-going pulses in sequence on pins 8 through 12. Keypad sense lines connect back to U1 on pins 13 through 17. Resistors R120 through R124 ensure that the sense lines are high until a key is pressed. When a button is pressed, keypad contacts close, allowing the low-going pulse to return to the microcomputer on the appropriate sense line. This informs U1 that a particular button was pressed.

3.2.12 Vacuum Fluorescent (VF) Voltage Converter Circuitry

Voltage for the VF display is generated by a fixed-frequency, variable duty-cycle controlled, flyback voltage converter. The switching frequency is about 210 kHz. One half of U3, pins 5-7, forms a 210 kHz sawtooth oscillator. The sawtooth waveform is produced at U3-6 and is applied to pin 3 of the other half of U3. This portion of U3 is a duty-cycle controlled comparator.

Table 3-4. PTT Logic States

Microphone Push-to-Talk PTT PTT

PRESSED Low High

RELEASED High Low

Table 3-5. HUB Logic States

Microphone Hang-Up Button

HUB LineInverted

HUB

ON-HOOK Low High

OFF-HOOK High Low

6881096C77-O September 26, 2003


U1-6 controls the entire voltage converter. During startup, U1-6 pulls to ground, biasing U3-2 to about 1.85 volts via R51 and R52. U3-1 and R61 then begin to switch Q50 on and off at a 210 kHz rate. This allows current to flow through T60, building a magnetic field, then collapsing it. When the field collapses, the back EMF (flyback) forward biases CR51 and charges C52 (after a few cycles) to about 37 volts, causing zener diode VR50 to conduct. The high voltage is regulated by the effect that VR50 has on the bias voltage at U3-2. If the high-voltage supply increases, VR50 pulls U3-2 higher in voltage resulting in a decreased duty-cycle for Q50 (the switching frequency remains constant; only the duty-cycle of on-time versus off-time decreases). Less power is up-converted to C52 when the duty cycle decreases; hence, regulation is maintained.

The voltage converter also produces an a.c. filament voltage for the VF display across T60 pins 4 and 6. R101 drops this voltage to approximately 2.4 Vrms. This a.c. voltage rides on a positive d.c. offset due to R50, depending on brightness. The positive offset allows a VF display grid to be reverse-biased with respect to the filament when that particular grid is supposed to be shut off. This prevents “character ghosting.” Display dimming is exclusively controlled by multiplexing information sent from U1 to the VF driver IC, U101. Display dimming has no effect on the voltage converter circuitry except in the OFF mode. In this mode, U1-6 goes high, resulting in U3-2 going to +5 volts. This keeps U3-1 low and Q50 turned off. The high-voltage supply drops to about 12 volts and the a.c. filament voltage drops to zero, shutting off the display.

3.2.13 Vacuum Fluorescent Display Driver IC

The VF driver IC, U101, receives data directly from the microcomputer for multiplexing the VF display. All of the grid and anode driver lines from U101 are either at, or about, 34 volts (ON) or ground (OFF).

3.2.14 Vacuum Fluorescent Display

The VF display is an 8-character, 14-segment device. Anodes are the actual phosphorescent segments, and grids are the wire-mesh structures located over each character. Multiplexing allows character generation with a minimum of interconnecting lines between display and driver. Anodes and grids operate at, or about, 34 volts when ON and are at zero when OFF. The filament operates on ac at about 2.4 Vrms, with current flow at 100 mA through the filament. The d.c. current flowing from anodes and grids to the filament and through R50 to ground increases filament voltage by up to 5 Vdc.

3.2.15 Backlight LEDs

Most buttons on the control head are backlit by ten LEDs for easy night-time viewing. In medium and low brightness level settings, U1-19 goes high, turning on Q131 and causing a fixed current to flow through the LEDs.

In the OFF mode and the maximum brightness mode, U1-19 goes low, turning off Q131 and the LEDs. Microprocessor U1 does not duty-cycle change the brightness level of the backlighting LEDs.

3.3 W9 Control HeadThe W9 control head has solid-state microprocessor circuitry that operates the standard and optional features built into the system. The control-head design allows installation in even the smallest of down-sized vehicles.

3.3.1 Display

The control head has an 11-character alphanumeric VF display for indicating the following:

• Zone/Mode names

• Squelch level

September 26, 2003 6881096C77-O


• Volume level

• Status codes

• Message codes

• Telephone numbers

• Identification numbers

• Alarm displays

• Option status

3.3.2 W9 Controls and Indicators

The W9 control head 12-button keypad contains traditional alphanumeric keys. These keys double as function keys for options. Six ON/OFF option buttons and indicator lights above the display window tell whether these options are on or off. All buttons are backlit to allow operation in low-light conditions.

Other indicators include BUSY, XMIT, Pri, and Non-Pri. The BUSY indicator lights when activity is detected on the channel. The XMIT (transmit) indicator lights when you are transmitting. The Non-Pri (non-priority) or Pri (priority) indicators light when activity occurs during scanning. If the detected activity is in the non-priority mode, the Non-Pri indicator lights. If the activity is in the priority mode, the Pri indicator lights (steady on for second priority mode, and flashing for first priority mode).

3.3.3 Control Board

NOTE: Refer to the W9 control head foldout block diagram and schematic diagram for the following discussion.

The control board's microprocessor unit (MPU) communicates on the serial bus, receives and interprets keypad data, and controls the volume. The MPU (U2) sends data to a driver to control the display and sends data to turn the LEDs on or off. The control board has a watchdog timer that senses the need for a system reset. The vehicle interface ports are also controlled on this board.

3.3.3.1 Microprocessor

The MPU operates in expanded bus mode with internal Read-Only Memory (ROM) active. The clock frequency is 7.9488 MHz, which results in an internal operating frequency of 1987 kHz. The limited number of I/O ports is augmented by using a serial-to-parallel shift register (U6) to scan the keypad and to switch the VIP drivers Q71, Q72, and Q73.

3.3.3.2 Watchdog Timer

The watchdog timer is on the serial input/output integrated circuit (SIOIC) U4. On system power-up, capacitor C6 pulls U4, pin 43, high while the RESET output at pin 4 goes low, and the microprocessor resets.

As C6 charges, the voltage on U4, pin 43, drops, causing the output to go high and the microprocessor to start operating. At this point, the bias on U4, pin 43, shifts toward positive, causing the voltage to begin to rise, eventually causing another reset cycle. A high on U4, pin 9, (RESET input) also initiates a reset.

When the microprocessor operates correctly, the microprocessor sends "tickle" pulses to U4-2. These pulses tickle the watchdog timer and keep the voltage on U4, pin 43, low enough to prevent reset. If the tickle pulses stop for more than 250 ms, the reset cycle repeats.

The watchdog timer can be disabled by shorting U4, pin 43, to ground.

6881096C77-O September 26, 2003


3.3.3.3 Bus Transceiver

The serial bus transceiver is on SIOIC U4. The timer on SIOIC U4, pins 10, 16, and 17, connects to the external bus. Pins 11, 13, 19, and 20 connect to MPO 2. These pins act as a serial-communication buffer.

3.3.3.4 Vacuum Fluorescent Voltage Converter

Voltage for the vacuum fluorescent (VF) display filaments is generated by a fixed-frequency, variable-duty-cycle-driven, flyback voltage converter. Dual Comparator U3B, with resistors R56 through R60, form a triangle-wave generator that has an output swing between 1.5 and 3.2 volts at a frequency of 160 kHz. The output of this triangle goes to U3A-3, where it is compared to a feedback signal on U3A-2. The d.c. feedback signal comes from the voltage converter output through diode CR51 and is regulated by VR50 to 43 volts. The U3A output voltage increases or decreases as its input voltage rises or falls. Consequently, the duty cycle seen at the gate of MOSFET transistor Q50 varies inversely with the triangle output voltage. The output of Q50, varying at 160 kHz, is applied to the primary of transformer T60, pins 1 and 3. The secondary of T60, pins 4 and 6, supplies 3.5 Vac for the VF display (U102) filaments.

3.3.3.5 Vehicle Interface Ports

The control-head connector, P103, provides connections for three vehicle interface port (VIP) inputs and three VIP outputs.

The three VIP inputs enter the control head at P103, pins 4, 3, and 37. Zener diodes YR10, YR9, and YR8 limit the input voltages to 15 volts. VIP input 2 can be strapped through jumper JU11 to provide various control functions connected to P103, pins 41, 43, and 44. The three inputs are connected to SIOIC U4 at pins 25, 22, and 35. The input signals are buffered in U4 and are output on pins 24, 21, and 36. From U4, the signals are fed through 10K resistors R44, R14, and R15 to the MPU, U2. The MPU directs the signals as required by programming.

Programmable switches on the control head are connected through J101, pins 11, 10, 9, 8, and 7 (KRl through KRS, respectively) to CPU U2, pins 49, 44, 46, 48, and 50. The other contacts of the switches are connected through J101, pins 14, 15, 16, 17, and 19 (KSl through KSS), to CMOS shift register U6, pins 4, 5, 6, 7, and 14.

Shift register U6 outputs, pins 13, 12, and 11, go to Darlington transistors Q71, Q72, and Q73. These three transistors drive the VIP outputs (up to 300 mA each) through control-head connector PI03, pins 2, 1, and 34. Primarily, these transistors control external relays. VIP outputs 1 and 2 are connected to jumpers JU12 and JU13 to provide control functions connected to P103, pins 28 and 29. VIP output 1 can also be connected through JU22 to MIC-PTT, pin 24.

3.3.3.6 Power Supply

The +5-volt power supply U46 is a three-terminal regulator IC that regulates the 12-volt SWB+ down to +5 volts for the digital logic circuits. The regulated +5 volts enters the control-head PC board through connector J101, pin 4.

3.3.3.7 Ignition Sense Circuits

SIOIC U4 senses the vehicle ignition’s state through its pin 28, disabling transmit when the ignition is off. For negative-ground systems, the orange lead is typically connected to +l2 volts. For more information, see the cable kit section in the Detailed Service Manual 68P80102W61.

NOTE: Q40 supplies an inverting path for positive-ground ignition service.

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3.3.3.8 EEPROM Write-Protect Circuit

Transistors Q161, Q162, and associated circuitry guard against inadvertently writing into the EEPROM U5 by inhibiting the Write Enable input. The circuitry guarantees the EEPROM is protected during reset and when shift register U6 is not in the proper programming state.

3.3.4 Display Board

The display board contains the main operator interface points of the system, including the vacuum fluorescent display, the status indicator LEDs, and the user keypad.

NOTE: Refer to the foldout schematic diagram of the display board for this discussion.

3.3.4.1 VF Display

The (VF) display is an 11-digit, 14-segment display that needs two separate voltages to operate, The anode and grids use +43 volts to accelerate electrons from the cathode, and the filament uses 3.5 vac at 80 mA. These voltages are obtained from the VF voltage converter on the controller board.

3.3.4.2 VF Display Driver

VF display driver U101 receives 14-segment display data, digit enable data, and indicator state data from the microprocessor on the controller circuit board. This data is clocked using CLOCK (pin 23) and DATA-IN (pin 43) lines, then framed using LATCH-ENABLE (pin 24) and STROBE (pin 21) to control brightness. The 32-bit data frame is updated every millisecond so that a coherent display is maintained and totally updated every 11 ms.

3.3.4.3 Status LEDs

Status LEDs CR111 through CR120 are driven by the display driver as though they were decimal points on the VF display. Level-shifting transistors are required for this since the display driver uses 43 volts for control signals.

3.3.4.4 Backlight LEDs

The same signal (VF-CONTROL) that turns the VF voltage converter on and off also operates the backlight LEDs. Transistor Q134 supplies base current to the individual driver transistors. The driver transistors act as current sources to the LEDs. Backlight LEDs CR131 through CR134 are connected to thermistor RT133 via Q132. This circuit allows more current to flow through these LEDs at room temperature and reduces current as the temperature rises.

3.3.5 Default Jumper Settings

The factory installs jumpers in each control head according to customer-ordered options. See Table 3-6 for the standard jumper configurations. See the diagrams on the foldout pages for other configurations.

Table 3-6. Standard Jumper Configurations

Jumper Number Normally

JU1 IN

JU2 OUT

JU3 IN

JU4 OUT

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3-12 Theory of Operation: Vehicle Interface Port (VIP)

3.4 Vehicle Interface Port (VIP)The vehicle interface port (VIP) allows the control head to control outside circuits in the vehicle and to receive inputs from outside the control head. This results in greater flexibility and ease of installation when interfacing to other systems in the vehicle. There are up to three VIP outputs that can be used for relay control. There are also up to three VIP inputs that can accept input from switches, etc.

3.4.1 W4, W5, and W7 Control Heads

The VIP outputs are controlled by microcomputer U1 pins 26, 27, and 28. A high level causes the associated transistors Q71-73 to conduct up to 300 mA of current to ground. Primarily, these transistors control external relays. The relay coil is connected between the VIP output pin and SWB+. See the installation manual for connection details.

The VIP input lines connect to U4, pins 22, 25, and 35. U4 acts as an inverting stage, passing the VIP input signals to U1, pins 29-31, to be read by the microcomputer. VIP inputs normally connect to ground via a normally open or normally closed switch.

3.4.1.1 VIP Output Connections

3.4.1.1.1 Dash-Mount Installations

Two VIP outputs are available in dash-mount installations. VIP OUT 1 is on pin 12 of the rear accessory connector; VIP OUT 2 is on pin 3. These connections are used to control relays. Connect one terminal of the relay coil to SWB+ (Rear Accessory Connector pin 4). Connect the other relay coil terminal to one of the VIP outputs. See the installation manual for the horn and lights connection.

JU5 IN

JU7 IN

JU8 OUT

JU9 OUT

JU10 OUT

JU11 OUT

JU12 OUT

JU13 OUT

JU16 OUT

JU17 OUT

JU18 IN

JU19 IN

JU20 IN

JU21 OUT

JU22 OUT

Table 3-6. Standard Jumper Configurations (Continued)

Jumper Number Normally

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Theory of Operation: Vehicle Interface Port (VIP) 3-13

Figure 3-2. Cabling Interconnect Diagram for Dash Mount

3.4.1.1.2 Remote-Mount Installations

VIP outputs function exactly the same in remote-mount installations as the dash mount. However, three VIP outputs are available at the remote-mount accessory cable connector. VIP OUT 1 is on pin 12, VIP OUT 2 is on pin 3, and VIP OUT 3 is on pin 15.

Figure 3-3. Cabling Interconnect Diagram for Remote Mount

3.4.1.2 VIP Input Connections (Remote-Mount Only)

Three VIP input lines are also available in remote-mount installations. VIP IN 1 is on pin 14, VIP IN 2 is on pin 10, and VIP 3 is on pin 9. These connections are used to accept input from switches or other circuits in the vehicle. The VIPs are biased at about 5 volts, and to be activated the inputs are switched to ground. Normally, a switch is connected from a VIP input line to ground. The switch can be normally open or normally closed, depending on VIP programming and the particular function being performed.

RADIO COMPARTMENT = OPERATOR COMPARTMENT VEHICLE BATTERYCOMPARTMENT

A good chassis connection via the black primary power cable is essential for radio operation and to prevent damage to the radio and cable kit. Connection to the vehicle frame is desirable.

VEHICLE BATTERY

15A OR 20AFUSE

PART OFVEHICLEWIRING

VEHICLEIGNITION SWITCH

ON/ACC

GROMMET

RADIO POWER CABLE(RED/BATTERY HOT)

RADIO IGNITIONCABLE (thin RED)

SPEAKER

3A OR 4A FUSE

MICROPHONE

RADIO POWER CABLE (BLK/GROUND)

RADIO

(-)(+)

CAUTION

MAEPF-27646-O

Rear connector

CH SEE NOTE

NOTE:Caution: if you choose to connect the radio’s IGNITION line directly to the car’s battery, excess use of the radio when the car’s ignition is not running (i.e. alternator running) could result in a slow discharge of the car’s battery. This configuration allows the radio to operate with the car’s ignition switch ON or OFF.

If the radio’s IGNITION line is wired to the car’s ignition switch, the radio will only function when the car’s ignition switch is turned ON.

RADIO COMPARTMENT OPERATOR COMPARTMENT VEHICLE BATTERYCOMPARTMENT

A good chassis connection viathe black primary power cableis essential for radio operationand to prevent damage to theradio and cable kit. Connectionto the vehicle frame is desirable.

VEHICLE BATTERY

15A OR 20AFUSE

PART OFVEHICLEWIRING

VEHICLEIGNITION SWITCH

ON/ACC

GROMMET

GROMMETSEE NOTE

RADIO POWER CABLE(RED/BATTERY HOT)

RECEIVERCONTROL

CABLE (GRN)

RADIO CONTROLCABLE (BLK/MULTI-

CONDUCTOR)

SPEAKER

TRANSMITTERCONTROL

CABLE (ORG)

4.0A FUSE

MICROPHONE

VIP

MIC

RADIO (ORG)

(GRN)

RADIOPOWER CABLE(BLK/GROUND)

RADIO (-)(+)

CAUTION

NOTE:The orange and green power cables connect to either the vehicle battery or the ignition switch. Connect the green cable directly to the battery. The receiver operates when the control head is on. Connect the orange cable to the ignition switch. The transmitter operates only when the ignition switch is on. Alternate connections:Connecting both green and orange cables to the battery allows the control head to turn the receiver and transmitter on or off. Connecting both green and orange cables to the ignition switch allows the ignition switch to turn the receiver and transmitter on or off. (Alternator whine and other noise problems may occur. Isolate the green cable with a Motorola relay, part #59-00813674.)

MAEPF-27616-O

6881096C77-O September 26, 2003

3-14 Theory of Operation: Vehicle Interface Port (VIP)

3.4.2 W9 Control Heads

The VIPs allow the W9 control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs that are used for relay control. There are also three VIP inputs that accept inputs from switches. See the cable kit section for typical connections of VIP input switches and VIP output relays.

3.4.2.1 VIP Output Connections

The VIP output pins are located on the back of the control head below the area labeled VIP. These connections are used to control relays. One end of the relay should be connected to switched B+, while the other side is connected to a software-controlled on/off switch inside the control head. The relay can be normally On or normally Off depending on how the VIP outputs are configured. The control-head connector P103 pins that are connected to the external relays are listed in Table 3-7.

The function of the VIP outputs can be defined by field programming of the control head. Typical applications for VIP outputs are external horn/lights alarm and horn-ring transfer relay control.

3.4.2.2 VIP Input Connections

The VIP input pins are located on the back of the control head below the area labeled VIP. These connections accept inputs from switches. One side of the switch is connected to ground while the other side is connected to a buffered input to the control head. The switch can be normally closed or normally open, depending on how the VIP inputs are configured. The control head provides three VIP input connections. The control-head connector P103 pins that are connected to the external switches are listed in Table 3-8.

The function of the VIP inputs is defined by field programming of the control head. Typical applications for the VIP inputs are for a foot switch or a horn ring switch.

Table 3-7. VIP Output Connections

VIP Output No.

Switched B+ Pin No.

VIP Output Pin No.

Default Function Is Changed with Field Programmer

1 18 2 Horn Relay (Alarm)

2 19 1 Light Relay (Alarm)

3 35 34 Siren-Horn Transfer

Table 3-8. VIP Input Connections

VIP Input No.

Switched B+ Pin No.

VIP Output Pin No.

Default Function Is Changed with Field Programmer

1 20 4 Siren; Horn Ring

2 21 3 Emergency (if option is present)

3 36 37 None

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Chapter 4 Test Equipment and Service Aids

4.1 Recommended Test Equipment and Service AidsThe list of equipment contained in Table 4-1includes most of the standard test equipment required for servicing Motorola control heads. The Characteristics column is included so that equivalent equipment can be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended.

Table 4-1. Recommended Motorola Test Equipment and Service Aids

MotorolaModel Number

Description Characteristics Application

6032A* DC power supply (Agilent)

0-20 Vdc, 0-50 A current-limited Bench supply for 13.8 Vdc

FLUKE 87* Digital Multimeter True RMS metering, 200 kHz frequency counter, 32-segment bar graph with backlit display

Recommended for AC/DC voltage and current measurements

54622A* Oscilloscope (Agilent) Two-channel, 100 MHz bandwidth, 200 MSa/s sample rate, 2 MB memory/channel

Waveform Measurements

3080369B99 (dash mount)3080369B97 (remote mount)

Extender Cable—Allows operation of control head while extended from radio

Control head troubleshooting

* or equivalent

4-2 Test Equipment and Service Aids: Recommended Test Equipment and Service Aids

Notes

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Chapter 5 Troubleshooting

This chapter, along with the theory of operation in Chapter 3 and the schematics, overlays, and parts lists in Chapter 8, will aid you in troubleshooting a malfunctioning ASTRO Digital Spectra or Digital Spectra Plus control head. If the board is severely damaged or otherwise non-repairable, refer to the board replacement instructions in the section, “Replacing the Control Head Board” on page 5-7.

NOTE: To access W9 control-head boards for troubleshooting, remove them from the plastic housing using the procedure on page 5-10. To access W4, W5, and W7 control-head boards, use a control-head extender cable and the procedure on page 5-8. (Refer to the chapter, “Recommended Test Equipment and Service Aids” on page 4-1 for the appropriate Motorola test equipment and service aids part numbers.)

5.1 Required Tools and SuppliesTable 5-1lists the tools and supplies needed for basic troubleshooting.

Table 5-1. Required Tools and Supplies

Tools and Supplies

Small, flat-blade screwdriver

2.5 mm hex-key driver

Torx® T8, T10, and T15 drivers

3.0 mm Allen wrench

5-2 Troubleshooting: Troubleshooting Waveforms

5.2 Troubleshooting WaveformsThis section contains images of waveforms that might be useful in verifying operation of certain parts of the circuitry. These waveforms are for reference only; the actual data depicted will vary depending upon the operating conditions.

5.2.1 ASTRO Digital Spectra Waveforms

Waveform W1: Oscillator Out, U4 Pin 42

Waveform W2: Sawtooth Oscillator: U3 Pin 3

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Troubleshooting: Troubleshooting Waveforms 5-3

Waveform W3: U3 Output: U3 pin 1 (output to Q50)

Waveform W4: Q50 Drain

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5-4 Troubleshooting: Troubleshooting Waveforms

Waveform W5: Transmit / Receive Data: U4 pins 19 and 20

Waveform W6: Serial Bus lines: U1 pins 17, 16, 10

NOTE: Serial bus data can be seen during power up and button presses.

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Troubleshooting: Replacing the Vacuum Fluorescent Display (W4, W5, and W7 Control Heads) 5-5

5.3 Replacing the Vacuum Fluorescent Display (W4, W5, and W7 Control Heads)

5.3.1 Removing the Display

1. Figure 5-1 below, Detail A, shows the removal procedure. Cut through the shock pad located opposite the side of the display with the soldered leads.

Figure 5-1. Replacing the Vacuum Fluorescent Display

2. Wear finger protection to prevent cutting your fingers on the sharp edges of the glass. Pull up on the edge of the display (see Figure 5-1 above, Detail B), bending the solder leads. Then cut through the remaining shock pad.

3. Unsolder the leads from the PC board to remove the display. Use organic solvent to remove the remaining shock pad and adhesive residue from the board.

5.3.2 Installing the Display

1. Apply the adhesive-backed shock pads to the new display. Carefully align the solder leads and insert the display into the PC board.

2. Solder the leads of the new display to the PC board. Do not reuse the old display.

5.4 Replacing the Remote Back-Housing Interface Board


1. Unplug the microphone.

2. Disconnect the control cable from the control head on remote models.

3. Remove the two front-panel screws using a 2.5 mm hex-key driver.

4. Grasp the front panel firmly, and carefully unplug the control-head assembly from the radio or remote control-head back housing.

5. Remove the two remote back-housing interface attachment screws.

6. Remove the remote control-head interface board from the remote control-head back housing.

PRI

PRIN

DIR

PRI

PRI

N

DIR

DETAIL A

DETAIL B

KNIFE

SHOCKPAD

DISPLAY

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5-6 Troubleshooting: Replacing the Remote Interconnect Board

7. Before installing a new Interface PC board (P/N 0105950T92), check to ensure that all gaskets are in place. Gasket (P/N 3205197X01) fits the perimeter of the plastic housing on the bottom surface, and is placed against the sealing rim in back housing. Gasket (P/N 3205198X01) fits inside the pin-out area on bottom of plastic housing. Gasket (P/N 3205082E90) O-rings (2) fit into recessed areas around the bottom of the screw clearance holes.

8. Attach the new interface PC board to the back housing with the two screws: torqued to 6-8 in.-lbs.

9. Reassemble the back housing to the front housing with the two screws: torqued to 4-6 in.-lbs.

5.5 Replacing the Remote Interconnect Board

5.5.1 Low-/Mid-Power Radios

1. Remove the two front panel screws using a 2.5 mm hex-key driver.

2. Grasp the front panel firmly, and carefully unplug it from the radio.

3. Remove the three screws that hold the remote interconnect board to the front panel using a Torx T10 driver.

4. Install the new remote interconnect board onto the front panel, and replace the screws. Torque the screws to 6-8 in.-lbs.

5. Reassemble the front panel into the radio and replace the screws.

6. Torque the screws to 4-6 in.-lbs.

5.5.2 High-Power Radios

1. Use a Torx T15 driver to remove the two screws in the radio top cover and then remove the radio top cover.

2. Remove the ribbon cable (38-conductor) from between the command board and the interconnect board by first disconnecting the cable at the command board side and then at the interconnect board.

3. Disengage the retaining wire on the back of the interconnect board at the chassis side.

4. Use the radio key to unlatch the radio handle, and use a Torx T15 driver to remove the two interconnect board screws that are inside the handle.

5. Turn the radio upside down and use a Torx T15 driver to remove the four bottom-cover screws. Remove the bottom cover.

6. Remove the RF-board shield and unplug the coaxial cable that comes up from the other side of the radio. Move the end of the coaxial cable out from behind the interconnect board.

Take care to avoid misalignment of connector pins.

Take care to avoid misalignment of connector pins. Remove the radio top cover to allow visual inspection during connector alignment.

!C a u t i o n

!C a u t i o n

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Troubleshooting: Replacing the Control-Head Board 5-7

7. Pull the retaining wire up into position so that the interconnect board can be slid back away from the front of the radio, and then up and out from the radio chassis.

8. Remove the rubber gasket from the front of the interconnect board by pulling it up and over the D-connectors.

9. Gently pry each of the arms on the interconnect board spacer so that the snap feature on the arms can be slid past the interconnect board.

10. Place the interconnect board spacer onto the new interconnect board, making sure that each arm is aligned in the proper slot and snaps securely into place.

11. Replace the rubber gasket, retaining wire, coaxial cable, bottom cover (torque four screws to 6-8 in.-lbs), and interconnect board screws (torque two screws to 10-12 in.-lbs).

12. Turn the radio top side up and re-insert the ribbon cable (38-conductor) by first connecting the command board side and then the interconnect board side. This cable is connected to two 38-pin connectors. The cable is keyed so that the cable fits only in the correct position.

13. Fold the ribbon cable down flat. Replace the top cover and torque the two screws to 6-8 in.-lbs. These screws are self-tapping and caution should be used so that the screws properly enter the previously cut threads.

5.6 Replacing the Control-Head Board


NOTE: Numbers shown in brackets in the following procedure refer to item numbers in Figure 7-1, “W3 Hand-Held Control Head Exploded View,” on page 7-2, and in Table 7-2, “W3 Hand-Held Control Head Exploded View Parts List,” on page 7-2.

1. Remove the strain-relief boot (part of cable assembly [15]) from the housing assembly [7] by applying downward pressure on the boot and pulling it away from the control head until they are completely separated.

2. Carefully remove the rubber seal (part of cable assembly [15]) from the housing assembly [7] opening.

NOTE:Take care to avoid damaging this seal.

3. Using a small screwdriver, remove the seal support wedge [14] from the control head.

4. Using a small screwdriver to depress the telco lever, remove the telco connector (part of cable assembly [15]) from the control head, and pull the cable assembly away from the housing (like a telephone jack).

5. Remove the rear-cover assembly [2] from the control head.

6. Locate the recesses in the lower portion of the housing on both sides of the rear-cover’s snap features and, prying the snaps until the two parts separate, remove the rear cover from the unit.

7. Remove the two snap retainers [4] from between the circuit board [5] and the housing assembly [7].

8. Disconnect the microphone assembly [8] connector from the circuit board [5].

9. Carefully remove the microphone cable assembly from the keypad [6].

10. Carefully pry the housing’s snap features from the circuit board [5].

NOTE:Be careful to avoid damaging circuit-board components.

There are seven snaps locking the circuit board to the housing. As the snap features are deflected, push the circuit board upward, using the keypad, to release the circuit board from the snap features.

6881096C77-O September 26, 2003

5-8 Troubleshooting: Replacing the Control-Head Board

11. Remove the circuit-board assembly from the housing.

12. Remove the keypad [6] from the housing assembly [7].


NOTE: For the following procedure, refer to Chapter 7: Exploded Views and Parts Lists, beginning on page 7-1, for the exploded view and associated parts list applicable to the model being disassembled.

1. Unplug the microphone.

2. Remove the two front-panel screws using a 2.5 mm hex-key driver.

3. Disconnect the control cable on remote models.

4. Grasp the front panel firmly, and carefully unplug the control-head assembly from the radio or remote control-head back housing.

5. Lay the control head face down on a clean, flat surface, being careful not to scratch or mar the display.

6. Using a Torx T10 driver, remove the control-head screws:

- W4 Control Head: four screws [callouts 5-8], as shown in Figure 5-2.

The W4 control head has, in addition to the screws, four snap features [callouts 1-4], which are shown in Figure 5-2.

- W5 and W7 Control Heads: seven screws, as shown in Figure 5-3.

Figure 5-2. Model W4 Rotary Control Head Assembly Screw and Snap Sequence

Figure 5-3. Models W5 and W7 Pushbutton Control Head Assembly Screw Sequence

7 158

34 2 6

416

253

7

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Troubleshooting: Replacing the Control-Head Board 5-9

7. Carefully separate the PC board, internal spacer, and elastomer keypad assembly from the front panel.

- On rotary control-head models, care must be taken not to damage the flex circuit when separating the printed circuit board from the front housing. Do not disturb the buttons in the front panel.

- On rotary control-head models, the flex circuit must also be unplugged.

8. On rotary control-head models, desolder the XMIT and BUSY LED before removing the elastomer keypad.

9. Remove the elastomer keypad from the PC board.

NOTE:Before you unsnap the PC board, note that the board slips under a hook on the right and snaps on the left. This will facilitate the assembly.

10. Remove the PC board from the internal spacer. The PC board snaps into and out of the spacer.

11. To reassemble, snap the PC board into the internal spacer. Before you press the elastomer keypad into the board, make sure that the conductive pads in the board and the elastomer keypad are clean and free of any foreign material.

12. On rotary control head models, solder the XMIT and Busy LEDs onto the PC board.

NOTE:On rotary control head models, the flex circuit must be connected to the PC board prior to attaching the PC board to the spacer.

13. Install the PC board internal spacer and elastomer keypad assembly into the front panel. Replace the screws and torque them to 6-8 in.-lbs.

14. Do one of the following:

- For dash-mounted radios, plug the interconnect board into the radio, and then plug in the control-head assembly and fasten it with the two front-panel screws (torqued to 4-6 in.-lbs).

- For remote-mount control heads, replace the front panel into the remote control-head back housing, make sure the gasket is in place, and then torque the screws to 4-6 in.-lbs. Replace any plugs and cables on the rear of the control head.

Take care to avoid misalignment of connector pins. On dash mount radios, remove the radio top cover to allow visual inspection during connector alignment.

!C a u t i o n

6881096C77-O September 26, 2003

5-10 Troubleshooting: Replacing the Control-Head Board


NOTE: Before disassembling the W9 control head, note the location of the labeled buttons.

NOTE: Refer to Figure 7-4, “W9 Pushbutton Control Head Exploded View,” on page 7-5 and Table 7-5, “W9 Pushbutton Control Head Parts List,” on page 7-5 for the callout numbers in this section.

Figure 5-4. W9 Control Head Control Board and Display Board

1. Using a Torx T15 driver, remove the two 30 mm machine screws [29] from the back housing [31] of the control head.

2. Fold the front housing [41] over so that the front housing is face down and the back housing is on your working surface with the flex cable [18] attached.

3. Using a Torx T10 driver, remove the five 8 mm self-tapping screws [17] from the Display Board Kit [37], the two 10 mm captive screws [12] with the leaf assembly spring [11], and the two 16 mm tapping screws [38] from the control PC board.

4. Remove the Command Board Kit [36] from the back housing and the Display Board Kit [37] from the front housing.

5. Remove the elastomer keypad [7], ON/OFF switch gasket [34], the “D” Connector Gasket [33], the solder-side shield [16], and the component-side shield [19] from the PC boards.

Control Board

Display Board

16 mnm self-tapping screws(2)

8 mnm self-tapping screws(5)

September 26, 2003 6881096C77-O

Troubleshooting: Final Reassembly–W3 Control Head 5-11

6. Install the new PC board with the elastomer keypad, the ON/OFF switch gasket, the “D” Connector Gasket, the “D” Connector O-ring, the solder-side shield, and the component-side shield in the appropriate locations.

7. Reassemble the Command Board Kit [36] into the back housing [31], making sure that the power switch is in the proper location and then replace the two tapping screws [38], torquing them to 6-8 in.-lbs.

8. Reassemble the Display Board Kit [37] into the front housing [41], making sure that the elastomer keypad [7] is in the proper location.

9. Replace the captive screws [12] and the leaf assembly spring [11] in the front housing, and then torque them to 6-8 in.-lbs.

NOTE:Before assembling the leaf assembly spring, ensure that the insulator [10] on the board is present. Also ensure that the leaf assembly spring and captive screws are aligned properly to prevent stripping the front housing screw bosses.

10. Close the assembly by replacing the front housing [41] and the two screws in the back housing [31]. Torque the screws to 6-8 in.-lbs.

5.7 Final Reassembly–W3 Control HeadWhen reassembling the control head, make sure the microphone pins are properly inserted through the elastomeric keypad. Also make sure the elastomeric keypad inserts are secured to the PC board.

NOTE: Numbers shown in parentheses in the following procedure refer to item numbers in Table 7-2, “W3 Hand-Held Control Head Exploded View Parts List,” on page 7-2.

1. To reassemble the housing assembly [7]:

A. Insert the transmit indicator [11] into the housing. Ensure that the top surface of the lightpipe is below the label recess of the housing.

B. Attach the nameplate label [13] to the front of the housing. Ensure that the label is securely attached.

C. Install the PTT actuator [9] into the housing. Ensure that its lip is seated in the grove in the housing.

D. Install the PTT lever [10] and the PTT boot [12] into the housing. Ensure that the lever is seated in its nest and the boot is located properly in the recesses in the housing.

E. Install the keypad [6] into the housing. Ensure that all of the keys are located in the correct openings in the housing.

2. Install the microphone assembly [8] into the keypad. Ensure that the front surface of the cartridge is located up against the keypad membrane.

NOTE:The membrane is the rain seal and is very sensitive to puncture by sharp objects.

3. Connect the microphone cable connector to the mating location on the circuit board [5].

Be careful to not bend the tabs on the shields when removing them and align them carefully when replacing the shields. When working with chips and SOT (small-outline transistor) parts, use extreme caution when heating. Never reuse a chip or SOT part; always replace with the correct Motorola part.

!C a u t i o n

6881096C77-O September 26, 2003

5-12 Troubleshooting: Troubleshooting Charts

4. Install the circuit board [5] into the housing assembly [7] as follows:

A. Hold the housing assembly so that its key openings face downward and its top faces away from you.

B. Pivot the circuit board’s display down under the retention features in the housing and rotate the board downward, ensuring that the board is positioned between the snap features. Ensure that the microphone assembly’s [8] wire passes through the opening in the circuit board.

C. Press downward firmly on the board until the seven snap features lock the board into place.

5. Install the two snap retainers [4] between the circuit board and the side wall of the housing assembly [7], one on each side.

6. Install the main seal [3] onto the rear cover assembly [2], placing the seal under the retainer features around the perimeter of the cover.

7. Install the rear cover assembly [2] onto the housing assembly [7].

Starting at the top of the cover, pivot the cover toward the housing and squeeze the two halves together until the snap features at the lower end of the rear cover engage the housing’s features and snap closed.

8. Insert the cable assembly’s [15] telco connector into the opening in the bottom of the housing, and ensure that it is correctly oriented.

9. Press the telco connector in place until it snaps in (like a phone plug).

10. Place the seal-support wedge [14] into the housing’s opening, orienting it so that its long portion is under the telco connector lever, and then push until it is properly seated.

11. Push the rubber seal (part of the cable assembly [15]) into the housing’s opening and ensure that it is properly seated.

NOTE:This seal must be inserted completely into the housing to ensure the rain seal.

12. Push the strain-relief boot (part of the cable assembly [15]) into the housing and ensure that it is properly seated.

13. Insert the kit label [1] into the recess on the rear cover, and ensure that it is securely attached.

5.8 Troubleshooting ChartsThis section contains detailed troubleshooting flowcharts. These charts should be used as a guide in determining the problem areas. They are not a substitute for knowledge of circuit operation and astute troubleshooting techniques. It is advisable to refer to the related detailed circuit descriptions in the theory section prior to troubleshooting a radio.

September 26, 2003 6881096C77-O

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NN

AP

WR

CO

MM

AN

D B

OA

RD

(VIE

WE

D F

RO

M S

IDE

1)

P5

03

F5

00

U4

50

15

24

19

16

J50

0

25

0 49

12

53

0 P5

01

P5

02

138

29 10

20

19

13 12

14

13

12

11

10

98

3

65

4 217

121

4 13

25

26

VO

CO

N B

OA

RD

(VIE

WE

D F

RO

M S

IDE

2)

49 50

J50

1

25

24

J80

12 1

1 2

6-4

Rad

io C

on

nec

tors

: E

xten

der

Cab

le (

P50

1)

Sep

tem

ber

26, 2

003

6881

096C

77-O

6.3

Ext

end

er C

able

(P

501)

Fig

ure

6-10

. P

501

Ext

ende

r C

able

6.4

Co

ntr

ol-

Hea

d C

ablin

g D

iag

ram

Fig

ure

6-11

. C

ontr

ol-H

ead

Cab

ling

Dia

gram

1517

1913

119

75

31

2123

2527

2931

3335

3739

4143

4547

49

1618

2014

1210

86

42

2224

2628

3032

3436

3840

4244

4648

50

P50

1E

XT

EN

DE

RC

AB

LE(3

0803

70E

06)

(FA

CIN

G T

OW

AR

DC

ON

TR

OL

HE

AD

)

J501

CO

MM

AN

D B

OA

RD

P10

01

SP

AR

E 2

EM

ER

GE

NC

Y

SP

AR

E 1

DIG

GN

D

SW

B+

BU

S +

BU

S -

BU

SY

BU

S S

HIE

LD

RE

SE

T

DE

T A

UD

IO

AN

A G

ND

PT

T

MIC

HI

MIC

LO

SP

KR

HI

SP

KR

LO

A+

RS

SI

RX

AU

DIO

RE

D

VIO

BR

N

BLU

YE

L

WH

T

BLK

BLK

/RE

D

BA

RE

BLK

/OR

G

BLK

/BR

N

SH

IELD

BLK

/GR

N

SH

IELD

BLK

/YE

L

SH

IELD

OR

G

GR

N

CO

NT

RO

L H

EA

D

OR

G

GR

N

NC

NC

MIC

LO

MIC

HI

SW

B+

HU

B

PT

T

PT

T/H

UB

RE

F

SW

B+

SW

B+

SW

B+

DIG

GN

D

DIG

GN

D

DIG

GN

D

(DA

TA

IN)

(ST

RO

BE

)

(CLO

CK

)

(DA

TA

OU

T)

BU

S +

BU

S -

BU

SY

RE

SE

T

DE

T A

UD

IO

AN

A G

ND

PT

T

IGN

+

IGN

-

BA

TT

+

BA

TT

+

BA

TT

-

SP

AR

E 2

BA

TT

-

EM

ER

GE

NC

Y

SP

AR

E 1

BLK

/GR

N

BLK

/OR

G

DIG

GR

D

SW

B+

P5

RA

DIO

15 32 47 30 31 29 14 27 28 49 48 17 50 33 26 45 16 46 12 13 44 11 10 43 7 8 41 40 24 23 18 19 3 20 21 36 4 3 37 2 1 34 38 5

SP

EA

KE

R

17 13 16 18 22 5 14 23 21 19 9 0 1 12 11 25 24 20 15 71 2 3 1 2 3

VIP

IN

VIP

OU

T

Ch

apte

r 7

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts

Thi

s ch

apte

r co

ntai

ns th

e ex

plod

ed v

iew

s an

d as

soci

ated

par

ts li

sts

for

each

of t

he A

ST

RO

Dig

ital S

pect

ra a

nd D

igita

l Spe

ctra

Plu

s co

ntro

l hea

ds. T

able

s co

ntai

ning

pus

hbut

ton

part

s lis

ts a

re a

lso

incl

uded

.

Tabl

e 7-

1. E

xplo

ded

Vie

ws

Fig

#D

escr

ipti

on

Pag

e #

Fig

ure

7-1

W3

Han

d-H

eld

Con

trol

Hea

d E

xplo

ded

Vie

w7-

2

Fig

ure

7-2

W4

Rot

ary

Con

trol

Hea

d E

xplo

ded

Vie

w7-

3

Fig

ure

7-3

W5

and

W7

Pus

hbut

ton

Con

trol

Hea

d E

xplo

ded

Vie

w7-

4

Fig

ure

7-4

W9

Pus

hbut

ton

Con

trol

Hea

d E

xplo

ded

Vie

w7-

5

Fig

ure

7-5

HM

N10

80A

, HM

N10

61A

, HM

N10

79A

Mic

roph

one

Exp

lode

d V

iew

7-6

Sep

tem

ber

26, 2

003

6881

096C

77-O

7-2

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

Mod

el W

3 H

and-

Hel

d C

ontr

ol H

ead

Exp

lode

d V

iew

7.1

Mo

del

W3

Han

d-H

eld

Co

ntr

ol H

ead

Exp

lod

ed V

iew

Fig

ure

7-1.

W3

Han

d-H

eld

Con

trol

Hea

d E

xplo

ded

Vie

w

2

1

3

4

5

6

7

8

4 15

14

10

9

1211

13

Tabl

e 7-

2. W

3 H

and-

Hel

d C

ontr

ol H

ead

Exp

lode

d V

iew

Par

ts L

ist

Item

No

.M

oto

rola

Par

t N

o.

Des

crip

tio

n

1N

ot a

vaila

ble

LAB

EL

201

0595

5T26

AS

SE

MB

LY, R

ear

Cov

er

332

0508

2E93

SE

AL,

Mai

n

442

0534

3Y01

RE

TAIN

ER

, Sna

p (Q

ty 2

)

501

0270

7D81

BO

AR

D, S

B96

00 C

ircui

t

675

0583

2X01

KE

YP

AD

(P

art o

f Ite

m 7

)

701

0270

7D86

AS

SE

MB

LY, H

ousi

ng (

Incl

udes

Item

s 6

and

9 th

ru 1

3)

801

0270

8D08

AS

SE

MB

LY, M

icro

phon

e

975

0561

8V02

AC

TU

AT

OR

, PT

T (

Par

t of I

tem

7)

1045

0585

0X01

LEV

ER

, PT

T (

Par

t of I

tem

7)

1132

0583

9X01

IND

ICA

TO

R, T

rans

mit

(Par

t of I

tem

7)

1238

0583

5X01

BO

OT,

PT

T (

Par

t of I

tem

7)

1333

0540

9X17

LAB

EL

(Par

t of I

tem

7)

1432

0527

4V01

WE

DG

E, S

eal S

uppo

rt

15H

KN

6095

_A

SS

EM

BLY

, Cab

le

No

te:

_ =

The

late

st v

ersi

on k

it. W

hen

orde

ring,

ref

er to

you

r sp

ecifi

c ki

t for

th

is s

uffix

lette

r.

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

W4

Rot

ary

Con

trol

Hea

d E

xplo

ded

Vie

w7-

3

6881

096C

77-O

Sep

tem

ber

26, 2

003

7.2

W4

Ro

tary

Co

ntr

ol H

ead

Exp

lod

ed V

iew

Fig

ure

7-2.

W4

Rot

ary

Con

trol

Hea

d E

xplo

ded

Vie

w

Tabl

e 7-

3. M

odel

W4

Rot

ary

Con

trol

Hea

d P

arts

Lis

t

Item

No

.M

oto

rola

Par

t N

o.

Des

crip

tio

n

103

8007

7M01

SC

RE

W, C

ontr

ol H

ead

Mou

ntin

g (Q

ty 2

)

236

0211

3Z05

KN

OB

, Vol

ume

Con

trol

332

0580

5V01

GA

SK

ET,

W4

Sha

ft (Q

ty 2

)

402

8421

8M01

NU

T, V

olum

e S

witc

h

504

8421

9M01

LOC

KW

AS

HE

R, V

olum

e S

witc

h

615

0211

7Z07

or

1502

117Z

08H

OU

SIN

G, F

ront

Cov

er (

Mob

ile)

HO

US

ING

, Fro

nt C

over

(M

otor

cycl

e)

701

0270

9J83

AS

SE

MB

LY, V

olum

e an

d R

otar

y S

witc

h

836

0211

3Z03

KN

OB

, Mod

e C

ontr

ol

932

0580

5V01

GA

SK

ET,

W4

Sha

ft (Q

ty 2

)

1002

8421

8M02

NU

T, M

ode

Sw

itch

1104

8421

9M02

LOC

KW

AS

HE

R, M

ode

Sw

itch

1261

0512

9X01

LIG

HT

PIP

E

1375

0512

8X01

KE

YP

AD

14A

AH

N40

45_

orP

MLN

4019

_A

SS

EM

BLY

, Circ

uit B

oard

(M

obile

)A

SS

EM

BLY

, Circ

uit B

oard

(M

otor

cycl

e)

1543

0211

2Z02

SP

AC

ER

, Int

erna

l

1603

1094

5A14

SC

RE

W, M

achi

ne (

Qty

4)

1732

8028

9L02

GA

SK

ET,

Hou

sing

18H

LN64

01_

AS

SE

MB

LY, C

ircui

t Boa

rd In

terc

onne

ct

No

tes:

_ =

The

late

st v

ersi

on k

it. W

hen

orde

ring,

ref

er to

you

r sp

ecifi

c ki

t fo

r th

is s

uffix

lette

r.T

he H

KN

4356

_ R

adio

Cab

le is

use

d to

rem

ote

mou

nt th

e W

4 C

ontr

ol H

ead.

Sep

tem

ber

26, 2

003

6881

096C

77-O

7-4

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

W5

and

W7

Pus

hbut

ton

Con

trol

Hea

d E

xplo

ded

Vie

w

7.3

W5

and

W7

Pu

shb

utt

on

Co

ntr

ol H

ead

Exp

lod

ed V

iew

Fig

ure

7-3.

W5

and

W7

Pus

hbut

ton

Con

trol

Hea

d E

xplo

ded

Vie

w

Tabl

e 7-

4. W

5 an

d W

7 P

ushb

utto

n C

ontr

ol H

ead

Par

ts L

ist

Item

No

.M

oto

rola

Par

t N

o.

Des

crip

tio

n

138

8022

7M04

SW

ITC

H, O

n/O

ff C

ap

238

8000

9P01

SW

ITC

H, M

ode

Roc

ker

338

8000

9P02

SW

ITC

H, V

olum

e R

ocke

r

415

8002

0S17

or

1580

020S

19H

OU

SIN

G, W

5 F

ront

Cov

er (

Mob

ile)

HO

US

ING

, W5

Fro

nt C

over

(M

otor

cycl

e)

538

8009

2J05

PU

SH

BU

TT

ON

, HO

ME

638

8009

2J05

PU

SH

BU

TT

ON

, DIM

703

8007

7M01

SC

RE

W, (

Qty

2)

815

8002

0S16

or

1580

020S

18H

OU

SIN

G, W

7 F

ront

Cov

er (

Mob

ile)

HO

US

ING

, W7

Fro

nt C

over

(M

otor

cycl

e)

961

8001

7S01

LIG

HT

PIP

E

1075

8001

2S03

KE

YP

AD

1143

8001

9S02

SP

AC

ER

, Int

erna

l Fra

me

1203

1094

5A14

SC

RE

W, T

appi

ng (

Qty

7)

1332

8028

9L02

GA

SK

ET,

Hou

sing

14H

LN64

01_

BO

AR

D, I

nter

conn

ect

15H

LN63

96_

orH

LN65

63_

BO

AR

D, C

ontr

ol H

ead

(Mob

ile)

BO

AR

D, C

ontr

ol H

ead

(Mot

orcy

cle)

1601

8004

9S09

or

0180

049S

11 o

r01

8004

9S08

or

0180

049S

10

AS

SE

MB

LY, W

5 F

ront

Cov

er (

Mob

ile)

AS

SE

MB

LY, W

5 F

ront

Cov

er (

Mot

orcy

cle)

AS

SE

MB

LY, W

7 F

ront

Cov

er (

Mob

ile)

AS

SE

MB

LY, W

7 F

ront

Cov

er (

Mot

orcy

cle)

Item

16

incl

udes

item

s 1,

2, 3

, 4 o

r 8,

5, 6

, 9, a

nd 1

0

No

tes:

_ =

The

late

st v

ersi

on k

it. W

hen

orde

ring,

ref

er to

you

r sp

ecifi

c ki

t fo

r th

is s

uffix

lette

r.T

he H

KN

4356

_ R

adio

Cab

le is

use

d to

rem

ote

mou

nt th

e W

5 an

d W

7 C

ontr

ol H

ead.

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

W9

Pus

hbut

ton

Con

trol

Hea

d E

xplo

ded

Vie

w7-

5

6881

096C

77-O

Sep

tem

ber

26, 2

003

7.4

W9

Pu

shb

utt

on

Co

ntr

ol H

ead

Exp

lod

ed V

iew

Fig

ure

7-4.

W9

Pus

hbut

ton

Con

trol

Hea

d E

xplo

ded

Vie

w

Tabl

e 7-

5. W

9 P

ushb

utto

n C

ontr

ol H

ead

Par

ts L

ist

Item

No

.M

oto

rola

Par

t N

o.

Des

crip

tio

n

113

8008

7J01

ES

CU

TC

HE

ON

2H

LN50

83_

HLN

5091

_H

LN50

66_

HLN

5256

_H

LN50

74_

HLN

5268

_H

LN52

59_

HLN

5258

_H

LN50

90_

HLN

5072

_H

LN52

57_

HLN

5076

_H

LN50

85_

HLN

5078

_H

LN50

87_

HLN

5079

_H

LN50

95_

BU

TT

ON

, Em

erge

ncy

BU

TT

ON

, Dir

BU

TT

ON

, Sca

nB

UT

TO

N, S

rch

BU

TT

ON

, Cal

lB

UT

TO

N, P

age

BU

TT

ON

, RP

GM

BU

TT

ON

, Site

BU

TT

ON

, PH

ON

BU

TT

ON

, H/L

BU

TT

ON

, Loc

kB

UT

TO

N, R

CL

BU

TT

ON

, SQ

LB

UT

TO

N, D

elB

UT

TO

N, H

ome

BU

TT

ON

, Sel

BU

TT

ON

, Bla

nk

338

8025

3K01

PLU

G

438

8019

5P03

SW

ITC

H, M

ode

Roc

ker

532

0514

5X01

GA

SK

ET,

Inte

rnal

Fra

me

661

0512

6X01

LIG

HT

PIP

E, K

eypa

d

775

0512

7X01

KE

YP

AD

872

8024

2J01

DIS

PLA

Y, V

F

975

8009

4M05

PA

D, S

hock

(Q

ty 3

)

1014

0541

0X01

INS

ULA

TO

R

1141

8004

2S01

SP

RIN

G, L

eaf A

ssy

1203

8004

1S01

SC

RE

W, C

aptiv

e (Q

ty 4

)

1361

8002

6R02

SP

AC

ER

, LE

D (

8-P

ositi

on)

1461

8002

7R02

SP

AC

ER

, LE

D (

2-P

ositi

on)

1626

8019

0P02

SH

IELD

, Sol

der

Sid

e (I

nclu

des

two

1480

269K

01 in

sula

tors

)

1703

1094

5A11

SC

RE

W, T

appi

ng (

Qty

5)

1830

8003

4K01

CA

BLE

, Fle

x

1926

8019

0P02

SH

IELD

, Com

pone

nt S

ide

2032

0508

2E90

O-R

ING

"D

" C

onne

ctor

(Q

ty 2

)

2133

8017

8M01

NA

ME

PLA

TE

2207

8432

3C01

BR

AC

KE

T, S

trai

n R

elie

f

2303

1090

8A18

SC

RE

W, M

achi

ne

24H

KN

4356

_C

AB

LE, R

adio

25H

MN

1050

_ or

HM

N10

80_

orH

MN

1061

_

KIT

, Mic

roph

one

2615

8022

1J01

HO

US

ING

, VIP

Con

nect

or (

Opt

iona

l)

2775

0211

8Z01

CO

VE

R, R

ubbe

r D

ust (

MIC

)

2875

0211

8Z02

CO

VE

R, R

ubbe

r D

ust (

VIP

)

2903

1090

8A33

SC

RE

W, M

achi

ne (

Qty

2)

3032

0519

8X01

GA

SK

ET,

Fac

e

3115

0519

9X01

HO

US

ING

, Bac

k

3228

0577

8W01

CO

NN

EC

TO

R, M

ini "

D"

50 C

onta

ct

3332

0514

3X01

GA

SK

ET,

"D

" C

onne

ctor

3432

0514

3X01

GA

SK

ET,

On/

Off

Sw

itch

3538

8012

8J01

KE

Y, O

n/O

ff

36H

CN

4046

_B

OA

RD

KIT

, Com

man

d (in

clud

es D

ispl

ay B

oard

)

37H

CN

4046

_B

OA

RD

KIT

, Dis

play

(in

clud

es C

omm

and

Boa

rd)

3803

1094

5A14

SC

RE

W, T

appi

ng (

Qty

2)

3938

8009

2J05

KE

Y, B

lank

4038

8019

5P02

SW

ITC

H, V

olum

e R

ocke

r

4115

0512

5X09

HO

US

ING

, Fro

nt

4232

0514

4X01

GA

SK

ET,

Len

s

4361

0514

6X01

LEN

S, V

F D

ispl

ay

No

te:

_ =

The

late

st v

ersi

on k

it. W

hen

orde

ring,

ref

er to

you

r sp

ecifi

c ki

t for

this

suf

fix

lette

r.

Tabl

e 7-

5. W

9 P

ushb

utto

n C

ontr

ol H

ead

Par

ts L

ist (

Con

tinue

d)

Item

No

.M

oto

rola

Par

t N

o.

Des

crip

tio

n

7-6

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

HM

N10

80A

, HM

N10

61A

, HM

N10

79A

Mic

roph

one

Exp

lode

d V

iew

Sep

tem

ber

26, 2

003

6881

096C

77-O

7.5

HM

N10

80A

, HM

N10

61A

, HM

N10

79A

Mic

rop

ho

ne

Exp

lod

ed V

iew

Fig

ure

7-5.

HM

N10

80A

, HM

N10

61A

, HM

N10

79A

Mic

roph

one

Exp

lode

d V

iew

4

2

1

158

9

3

1013

14

1211

7

MIC

RO

PHO

NE

BOAR

D

MAE

PF-2

7700

-O

56

Tabl

e 7-

6. H

MN

1080

A, H

MN

1061

A, H

MN

1079

A M

icro

phon

e P

arts

Lis

t

Item

No

.M

oto

rola

Par

t N

o.

Des

crip

tio

n

115

8012

7D05

Mic

roph

one

Fro

nt H

ousi

ng

238

8014

4D05

Mic

roph

one

PT

T B

utto

n

330

8022

3J05

or

3080

210P

01 o

r30

8022

3J01

HM

N10

80A

Coi

led

6 C

ond

HM

N10

79A

Coi

led

6 C

ond

HM

N10

61A

Coi

led

6 C

ond

405

8022

1K01

PT

T S

witc

h G

rom

met

503

1094

3M09

Tapp

ing

Scr

ew (

3 x

0.5

x 6)

630

8020

6L01

PC

B to

Mic

Wei

ght W

ire

732

8005

8H03

Hou

sing

Gas

ket

801

8075

0T91

Mic

roph

one

Rea

r H

ousi

ng

903

8007

6E04

Hi-l

o M

etric

Scr

ew

1003

1200

2C01

Scr

ew, S

elf-

drill

ing,

6-2

0 x

1/2”

1135

8008

9D01

Mic

roph

one

Fel

t Baf

fle

1205

8014

8D01

Mic

roph

one

Gro

mm

et

1301

8074

3T91

Han

gup

Clip

1401

8075

0T52

Gro

und

Wire

1503

0013

8015

Scr

ew, S

elf-

drill

ing,

8-1

8 x

1/2”

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

Sm

all P

ushb

utto

n P

arts

7-7

6881

096C

77-O

Sep

tem

ber

26, 2

003

7.6

Sm

all P

ush

bu

tto

n P

arts

7.7

Lar

ge

Pu

shb

utt

on

Par

ts

Tabl

e 7-

7. S

mal

l Pus

hbut

ton

Par

ts L

ist

Par

t N

um

ber

Gra

ph

ic

Leg

end

Par

t N

um

ber

Gra

ph

ic

Leg

end

3805

671X

021

3805

671X

219w

xy

3805

671X

032

3805

671X

22*

Rcl

3805

671X

043

3805

671X

23#D

el

3805

671X

054

3805

671X

241S

te

3805

671X

065

3805

671X

252P

ge

3805

671X

076

3805

671X

263L

ck

3805

671X

087

3805

671X

274S

ts

3805

671X

098

3805

671X

285R

pg

3805

671X

109

3805

671X

296M

sg

3805

671X

110

3805

671X

307H

/L

3805

671X

12*

3805

671X

318M

on

3805

671X

13#

3805

671X

329D

ir

3805

671X

142a

bc38

0567

1X33

Mon

3805

671X

153d

ef38

0567

1X34

H/L

3805

671X

164g

hi38

0567

1X35

DIR

3805

671X

175j

kl38

0567

1X36

Urg

3805

671X

186m

no38

0567

1X37

RT

T

3805

671X

197p

rs38

0567

1X38

Hom

e

3805

671X

208t

uv38

0567

1X39

Dim

Tabl

e 7-

8. L

arge

Pus

hbut

ton

Par

ts L

ist

Par

t N

um

ber

Gra

ph

ic

Leg

end

Par

t N

um

ber

Gra

ph

ic

Leg

end

3805

672X

01-

-38

0567

2X10

H/L

3805

672X

02M

PL

3805

672X

11S

ts

3805

672X

03S

can

3805

672X

12C

all

3805

672X

04D

VP

3805

672X

13M

sg

3805

672X

05P

A38

0567

2X14

Rcl

3805

672X

06S

irn38

0567

2X15

Mod

e

3805

672X

07W

ail

3805

672X

16E

xRd

3805

672X

08H

i/Lo

3805

672X

17D

el

3805

672X

09M

an38

0567

2X18

Sel

3805

672X

19M

on38

0567

2X52

Em

er

3805

672X

20D

TM

F38

0567

2X53

Std

y

3805

672X

21Ye

lp38

0567

2X54

EC

C

3805

672X

22M

VS

3805

672X

55R

ptr

3805

672X

23P

lay

3805

672X

56S

tate

3805

672X

24R

ply

3805

672X

57R

eg

3805

672X

25R

crd

3805

672X

58A

irHn

3805

672X

26E

mer

3805

672X

59T

B S

cn

3805

672X

27E

xt38

0567

2X60

SC

C

3805

672X

28F

/R38

0567

2X61

Src

h

3805

672X

29A

lt38

0567

2X62

Lock

3805

672X

30Te

l38

0567

2X63

Pag

e

3805

672X

31S

ql38

0567

2X64

Rea

r

3805

672X

32D

ES

3805

672X

65X

fer

3805

672X

33T

xt38

0567

2X66

ST

3805

672X

34In

dv38

0567

2X67

VH

F

3805

672X

35P

vt38

0567

2X68

UH

F

3805

672X

36S

ite38

0567

2X69

Aux

3805

672X

37A

A38

0567

2X70

QC

II

3805

672X

38S

ub38

0567

2X71

Mut

e

3805

672X

39H

ome

3805

672X

72P

ri

3805

672X

40M

enu

3805

672X

73B

lu

3805

672X

41R

pgm

3805

672X

74D

iv

3805

672X

42S

tep

3805

672X

75R

TT

3805

672X

4338

0567

2X76

Sen

d

3805

672X

44P

hon

3805

672X

77F

ront

3805

672X

45D

ir38

0567

2X78

Bid

3805

672X

46Te

xt38

0567

2X79

ZO

NE

3805

672X

47R

vw38

0567

2X80

TR

BL

3805

672X

48S

ec38

0567

2X81

OV

HD

3805

672X

49Ø

3805

672X

82U

NG

D

3805

672X

50L/

S38

0567

2X83

RS

SI

3805

672X

51S

/S38

0567

2X84

VR

S

3805

672X

85A

/B38

0566

9X12

ETr

p

3805

672X

86C

han

3805

669X

13Lv

Te

3805

672X

87P

RT

T38

0566

9X14

ArT

e

3805

672X

88R

tRn

3805

669X

15Lv

Gg

3805

672X

89E

mp#

3805

669X

16A

rGg

3805

672X

90P

ass

3805

669X

17P

/in

3805

672X

91C

ir38

0566

9X18

P/o

ut

3805

672X

92U

RG

3805

669X

19S

erv

3805

672X

93A

3805

669X

200/

S

3805

672X

94B

3805

669X

21R

ev

3805

672X

95C

3805

669X

22S

tby

3805

672X

96D

3805

669X

23S

ts 1

3805

672X

97E

3805

669X

24S

ts 2

3805

672X

98F

3805

669X

25S

ts 3

3805

672X

99G

3805

669X

26S

ts 4

3805

669X

01K

3805

669X

27S

ts 5

3805

669X

02L

3805

669X

28S

ts 6

3805

669X

03T

/Z38

0566

9X29

Sts

7

3805

669X

0430

3805

669X

30S

ts 8

Tabl

e 7-

8. L

arge

Pus

hbut

ton

Par

ts L

ist (

Con

tinue

d)

Par

t N

um

ber

Gra

ph

ic

Leg

end

Par

t N

um

ber

Gra

ph

ic

Leg

end

3805

669X

05E

ntr

3805

669X

31D

rvr

3805

669X

06M

/WT

3805

669X

32B

dg#

3805

669X

07M

Ack

3805

669X

33Ln

BI

3805

669X

08Ti

me

3805

669X

34R

tBl

3805

669X

09S

Run

3805

669X

35Ln

Rn

3805

669X

10E

Run

3805

669X

36s

3805

669X

11S

Trp

3805

669X

37t

3800

028M

01“E

mer

Hou

sing

”38

0002

9M01

“Em

er P

lung

er”

Tabl

e 7-

8. L

arge

Pus

hbut

ton

Par

ts L

ist (

Con

tinue

d)

Par

t N

um

ber

Gra

ph

ic

Leg

end

Par

t N

um

ber

Gra

ph

ic

Leg

end

7-8

Exp

lod

ed V

iew

s an

d P

arts

Lis

ts:

Larg

e P

ushb

utto

n P

arts

Sep

tem

ber

26, 2

003

6881

096C

77-O

No

tes

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts8-

1

6881

096C

77-O

Sep

tem

ber

26, 2

003

Ch

apte

r 8

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

8.1

Lis

t o

f S

chem

atic

s, C

om

po

nen

t L

oca

tio

n D

iag

ram

s, a

nd

Par

ts

Lis

tsT

he fo

llow

ing

tabl

e lis

ts th

e sc

hem

atic

s,

com

pone

nt lo

catio

n di

agra

ms,

and

par

ts li

sts

cont

aine

d in

this

cha

pter

.

Tabl

e 8-

1. L

ist o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts

Fig

ure

Tit

leP

age

HM

N40

44E

W3

Con

trol

Hea

d S

chem

atic

8-2

HM

N40

44E

W3

Con

trol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am8-

3

HM

N40

44E

W3

Con

trol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am8-

4

HM

N40

44E

Par

ts L

ist

8-5

HK

N60

96B

Rem

ote

“Y”

Cab

le W

iring

Dia

gram

8-6

AA

HN

4045

F/G

(S

tand

ard)

, HLN

4071

A/B

(R

ear)

, P

MLN

4019

C/D

(M

otor

cycl

e) W

4 C

ontr

ol H

ead

Sch

emat

ic (

She

et 1

of 2

)

8-7

AA

HN

4045

F/G

(S

tand

ard)

, HLN

4071

A/B

(R

ear)

, P

MLN

4019

C/D

(M

otor

cycl

e) W

4 C

ontr

ol H

ead

Sch

emat

ic (

She

et 2

of 2

)

8-8

AA

HN

4045

(Sta

ndar

d), H

LN40

71 (R

ear)

, PM

LN40

19

(Mot

orcy

cle)

W4

Con

trol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am

8-9

AA

HN

4045

G S

tand

ard

Par

ts L

ist

8-10

HC

N40

71B

Rea

r P

arts

Lis

t8-

12

PM

LN40

19D

Mot

orcy

cle

Par

ts L

ist

8-14

HLN

6396

F/G

/H (

Sta

ndar

d), H

LN68

14A

/B/C

(R

ear)

, H

LN65

63B

/C/D

(M

otor

cycl

e) W

5/W

7 C

ontr

ol H

ead

Sch

emat

ic (

She

et 1

of 2

)

8-16

HLN

6396

F/G

/H (

Sta

ndar

d),H

LN68

14A

/B/C

(R

ear)

, H

LN65

63B

/C/D

(M

otor

cycl

e) W

5/W

7 C

ontr

ol H

ead

Sch

emat

ic (

She

et 2

of 2

)

8-17

HLN

6396

F/G

(S

tand

ard)

, HLN

6814

A/B

(R

ear)

, H

LN65

63B

/C (

Mot

orcy

cle)

W5/

W7

Con

trol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am (

Vie

wed

from

Sid

e 1)

8-18

HLN

6396

F/G

(S

tand

ard)

, HLN

6814

A/B

(R

ear)

, H

LN65

63B

/C (

Mot

orcy

cle)

W5/

W7

Con

trol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am (

Vie

wed

from

Sid

e 2)

8-18

HLN

6396

H_H

LN68

14C

_HLN

6563

C W

5/W

7 C

ontr

ol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am (

Vie

wed

from

S

ide

1)

8-19

HLN

6396

H_H

LN68

14C

_HLN

6563

C W

5/W

7 C

ontr

ol

Hea

d C

ompo

nent

Loc

atio

n D

iagr

am (

Vie

wed

from

S

ide

2)

8-19

HLN

6396

H S

tand

ard

Par

ts L

ist

8-20

HLN

6814

C R

ear

Par

ts L

ist

8-22

HLN

6563

D M

otor

cycl

e P

arts

Lis

t8-

24

HC

N10

78J

(Sta

ndar

d), H

CN

1121

D (

Rea

r) W

9 C

ontr

ol H

ead

Sch

emat

ic (

Sid

e 1

of 2

)8-

26

HC

N10

78J

(Sta

ndar

d), H

CN

1121

D (

Rea

r) W

9 C

ontr

ol H

ead

Sch

emat

ic (

Sid

e 2

of 2

)8-

27

HC

N10

78J

(Sta

ndar

d), H

CN

1121

D (

Rea

r) W

9 C

ontr

ol H

ead

Com

pone

nt L

ocat

ion

Dia

gram

(Vie

wed

fr

om S

ide

1)

8-28

HC

N10

78J

(Sta

ndar

d), H

CN

1121

D (

Rea

r) W

9 C

ontr

ol H

ead

Com

pone

nt L

ocat

ion

Dia

gram

(Vie

wed

fr

om S

ide

2)

8-29

HC

N10

78J

(Sta

ndar

d), H

CN

1121

D (

Rea

r) P

arts

Lis

t8-

30

W4,

W5,

and

W7

Con

trol

Hea

d Lo

w-/

Mid

-Pow

er

Inte

rcon

nect

ion

Dia

gram

8-33

W4,

W5,

and

W7

Hig

h P

ower

Inte

rcon

nect

ion

Dia

gram

8-34

W5

and

W7

Con

trol

Hea

d In

terf

ace

Boa

rd S

chem

atic

8-35

HLN

6432

D W

5/W

7 C

ontr

ol H

ead

Inte

rfac

e B

oard

C

ompo

nent

Loc

atio

n D

iagr

am8-

36

HLN

6401

A C

ontr

ol H

ead

Inte

rcon

nect

Boa

rd, (

Das

h-M

ount

)8-

37

HLN

6486

D/E

Hig

h P

ower

Sta

ndar

d In

terc

onne

ct

Boa

rd8-

38

HLN

6486

D/E

Hig

h-P

ower

Inte

rcon

nect

Boa

rd

(Vie

wed

from

Sid

e 1)

8-39

HLN

6486

D/E

Hig

h-P

ower

Inte

rcon

nect

Boa

rd

(Vie

wed

from

Sid

e 2)

8-39

HLN

6486

E S

tand

ard

Inte

rcon

nect

Par

ts L

ist

8-40

HLN

6574

E W

3 C

ontr

ol H

ead

Hig

h-P

ower

In

terc

onne

ct B

oard

Sch

emat

ic D

esig

n8-

41

Tabl

e 8-

1. L

ist o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts (

Con

tinue

d)

Fig

ure

Tit

leP

age

HLN

6574

E W

3 H

igh

Pow

er In

terc

onne

ct B

oard

C

ompo

nent

Loc

atio

n D

iagr

ams

8-42

HLN

6574

E W

3 H

igh-

Pow

er In

terc

onne

ct P

arts

Lis

t8-

43

HLN

6459

D, H

LN63

44E

, and

HLN

6365

E L

ow-P

ower

In

terc

onne

ct B

oard

Sch

emat

ic8-

45

HLN

6459

D, H

LN63

44E

, and

HLN

6365

Low

-Pow

er

Inte

rcon

nect

Com

pone

nt L

ocat

ion

Dia

gram

8-46

HLN

6459

D W

3 Lo

w-P

ower

Inte

rcon

nect

Par

ts L

ist

8-47

HLN

6365

E M

otor

cycl

e In

terc

onne

ct P

arts

Lis

t8-

49

HLN

6344

E S

tand

ard

Inte

rcon

nect

Par

ts L

ist

8-50

HM

N10

80A

, HM

N10

61A

, HM

N10

79A

Mic

roph

one

Boa

rd O

verla

y8-

51

HM

N10

80A

, HM

N10

61A

, HM

N10

79A

Mic

roph

one

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ts L

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Tabl

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1. L

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f Sch

emat

ics,

Com

pone

nt L

ocat

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Dia

gram

s, a

nd P

arts

Lis

ts (

Con

tinue

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Fig

ure

Tit

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age

8-2

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

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: Li

st o

f Sch

emat

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pone

nt L

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Dia

gram

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arts

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ts

Sep

tem

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26, 2

003

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77-O

Fig

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Con

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ref

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ce o

nly

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ot fi

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pone

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3

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RA

MIC

4.0

0 M

HZ

ITE

MM

OT

OR

OL

A

PA

RT

N

UM

BE

RD

ES

CR

IPT

ION

8-16

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts

Sep

tem

ber

26, 2

003

6881

096C

77-O

Fig

ure

8-8.

HLN

6396

F/G

/H (

Sta

ndar

d), H

LN68

14A

/B/C

(R

ear)

, HLN

6563

B/C

/D (

Mot

orcy

cle)

W5/

W7

Con

trol

Hea

d S

chem

atic

(S

heet

1 o

f 2)

VIP

IN 1

KE

Y S

LOT

2. P

AR

T U

SA

GE

MAY

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RY

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PP

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RE

FE

R T

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AR

TS

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T F

OR

US

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E IN

FO

RM

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TE

S:

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RE

SE

T

VIP

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MIC

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HU

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SP

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VIP

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ST

RO

BE

EX

T_O

SC

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VIP

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SE

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VIP

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VIP

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emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts8-

17

6881

096C

77-O

Sep

tem

ber

26, 2

003

Fig

ure

8-9.

HLN

6396

F/G

/H (

Sta

ndar

d),H

LN68

14A

/B/C

(R

ear)

, HLN

6563

B/C

/D (

Mot

orcy

cle)

W5/

W7

Con

trol

Hea

d S

chem

atic

(S

heet

2 o

f 2)

G

S

WAR

NIN

G!

(RED

)(Y

ELLO

W)

VF D

ISPL

AY

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AGE

TO T

HE

CIR

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IT

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GN

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IC T

EST

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PIN

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MAY

OC

CU

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WIT

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ER A

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ED.

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. FO

R

SHO

RT

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HT

NO

TES:

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TAN

CE

IS IN

OH

MS.

ALL

CAP

ACIT

ANC

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OTE

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PAR

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TO

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FOR

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9

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2

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444

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IGN

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OU

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28

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DAT

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TX_D

ATA

33

DAT

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15

PB3

16

PB4

17 19BK

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V_H

UB

20

PTT

21

VIP_

IN_3

31

VIP_

IN_2

30

VIP_

IN_1

29

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9

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8 7LT

CH

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13

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PB2

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FIL

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IGN

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143

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242

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12

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11

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10

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MC

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2IR

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3

470p

FC

54

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F

470p

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FC

34

4 26

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30

100K

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CR

134

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30

26

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12

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2

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1

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124

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NC

13 2911

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1014

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F

22K

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72

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2

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6

470p

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37

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31

8 4

3231

15 16

C10

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2

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22

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272

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1

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122

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12

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470p

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14

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1000

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0

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241

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10

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28

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3

24

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8

100K

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1

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12

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15

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1

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23

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0

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342

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VDISP 1

CR

137

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31Q

323

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538

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736

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9

1312Q

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279

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8Q

297

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40

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17Q

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17 41Q

2

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2115

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23

29

42Q

1

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16

STR

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LK

DAT

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43

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6N

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NC

218

NC

328

NC

4

12

2729

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1

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OPT

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22

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3

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13

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33K

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CR

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S7

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12

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CH

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CH

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2

SWIT

CH

S5

1 2

SWIT

CH

12

SWIT

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S2

1

SWIT

CH

STAR

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PND

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SWIT

CH

OPT

1

1 2

SWIT

CH

1 2

SWIT

CH

VD

1

SWIT

CH

S0

1 2

S9

G5

G4

G3

G2

G1 R Y

PBPF PA PK PG PN PJ PO

DAT

A_INCLK

STR

OBE

VIP_

IN_1

*

VIP_

IN_2

*

VIP_

OU

T_3

SP-1

_VF-

SEN

SE-1

EXT_

OSC

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HU

B_IN

VPT

T

STR

OBE

CLO

CK

RX_

DAT

ATX

_DAT

A

VIP_

IN_3

*

SP-2

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SEN

SE-2

G8

P0VDIS

P

LTC

H_E

NBL

PD PE PM PH PC PLG8

G7

G6

PI

BUS3(32:1)

VDIS

P

IGN

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RES

ET*

DAT

A_IN

BUSY

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*

LTC

H_E

NBL

VIP_

OU

T_1

VIP_

OU

T_2

BKLT

STR

OBE

BUSY

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G7

G6

G5

G4

G3

G2

G1

G8

F2F1YR

PBP0F2 PI PL PH PM PC PE PD PJ PN PG PK PA PF F1

8-18

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts

Sep

tem

ber

26, 2

003

6881

096C

77-O

Fig

ure

8-10

. HLN

6396

F/G

(S

tand

ard)

, HLN

6814

A/B

(R

ear)

, HLN

6563

B/C

(M

otor

cycl

e) W

5/W

7 C

ontr

ol H

ead

Com

pone

nt L

ocat

ion

Dia

gram

(V

iew

ed fr

om S

ide

1)

Fig

ure

8-11

. HLN

6396

F/G

(S

tand

ard)

, HLN

6814

A/B

(R

ear)

, HLN

6563

B/C

(M

otor

cycl

e) W

5/W

7 C

ontr

ol H

ead

Com

pone

nt L

ocat

ion

Dia

gram

(V

iew

ed fr

om S

ide

2)

JU10

0R

29 C39

C9

C41

C40

C38

C20

C19

C15

C44C14 C11 C10

Q74

C24

C21

R123

C23R30

C18Y1

R122

R124

R121

R120

C35

C34

C33

C32

C31

C30

C29

C28

C27

C26

C22

C2

C16

C42

R28

C37

C17

7

7

6

6

1

1

17

17

U1

40

40

39

39

29

29

28

28

18

18

12

34

56

78

910

1112

1314

12

34

56

78

910

1112

1314

2827

2625

25

24

24

23

23

22

22

21

21

20

20

19

19

18

18

17

17

16

16

15

15

T60

U4

U10

1

Q51

U45

C45

C52

C50

JU17

R131

C39RR25

R87

JU6

R174

R1

JU12

JU13

C17

5

C17

4

CR90

JU7

JU1

R31

R4

R3

C5

C4

C8

CR52

CR54

R34

C58

VR11

C57

CR55C46

C6

R200

R182R99

R8JU15

CR71

Q71

CR72

R72

Q73

R73

VR4

VR3

C3

CR

53

JU2

R17

7R

2

C53

R9

VR6

C47

JU18R

7C

176

R81

C1

VR10

VR1

VR2 VR

7

C7

VR21

C48

R55

JU8

L50

VR8

VR9

VR5

C43

C56

Q52Q72

R75

R77

CR

73

Q75

R17

5

JU16

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1

R50

R98

C25

C36L1R

178

JU19

R71

R76R74C12

R17

6

R18

0

R18

1

C10

1

7

61

17

40

3929

28 18

1236 5 4

R113

R111

R115

R116Q50

R59

R60

R58

JU4

R101

JU3

R56

R61

R51

C51

VR50

R6

*#

VR22

VR20

C55

CR

76

JU14

JU5

R5

PWR

MD

MU VU

VD

DIM

HO

ME

OPT

1O

PT2

OPT

3O

PT4

SEL

C54

R57

P104

U3

JU9

C13

R52

R11

4

R11

2 Q11

2

CR

51

Q11

1

CR

111

CR

112

12

34

56

78

910

1112

1314

2827

2625

2423

2221

2019

1817

1615

1

1

22

3

3

44

5

5

66

7

7

88

9

9

1010

1112

1314

2524

2322

2120

1918

1716

15

CR138

CR139 CR140

CR137

CR136

CR135

CR134

CR133

CR131

CR132

12

3

45

6

78

9

0

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts8-

19

6881

096C

77-O

Sep

tem

ber

26, 2

003

Fig

ure

8-12

. HLN

6396

H_H

LN68

14C

_HLN

6563

C W

5/W

7 C

ontr

ol H

ead

Com

pone

nt L

ocat

ion

Dia

gram

(V

iew

ed fr

om S

ide

1)

Fig

ure

8-13

. HLN

6396

H_H

LN68

14C

_HLN

6563

C W

5/W

7 C

ontr

ol H

ead

Com

pone

nt L

ocat

ion

Dia

gram

(V

iew

ed fr

om S

ide

2)

C1

C2

C3

C4

C5

C6

C7

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MM

AND

BO

ARD

CO

NN

ECTO

R (P

502)

24 25 13

DIG

ITAL

GR

OU

ND

BUS

-

BUS

+

BUS

SHIE

LD

SPEA

KER

LO

SPEA

KER

HI

17SP

ARE

1

34

17 22 18 24 25

CO

NTR

OL

HEA

D S

IDEM

ICR

OPO

HO

NE

HI (

BLK/

YEL)

12M

IC H

I

DET

ECTE

D A

UD

IO

ANAL

OG

GR

OU

ND

PTT

12

MIC

RO

POH

ON

E LO

(SH

IELD

)

DET

ECTE

D A

UD

IO (B

LK/B

RN

)

DET

ECTE

D A

UD

IO (S

HIE

LD/A

NAL

OG

GR

OU

ND

)

SP 1

(BLK

/GR

N)

SP 1

(SH

IELD

)

BUSY

(BLK

/RED

)

REM

OTE

RAD

IO IN

TER

CO

NN

ECT

BOAR

D (H

IGH

PO

WER

)

REM

OTE

CO

NTR

OL

HEA

D C

ABLE

12 13 45

27 3 28

RES

ET

SPAR

E 1

BUSY

SWB+

18

28 29 48 49 11

CO

NTR

OL

HEA

D S

IDE

17

10 22

2623

RES

ET28 29

SPAR

E 1

SPAR

E 2

8 7

48

47 15

11 9 10 1 23

NC

24

21

9 22

IGN

ITIO

N

16 49

REM

OTE

CO

NTR

OL

HEA

D IN

TER

CO

NN

CEC

T BO

ARD

W4/

W5/

W7

20 36

SNET

-KEY

SNET

-KID

SNET

-WE

9 20 2112

SWB+

MIC

-HI

MIC

-LO

PTT

EMER

G/H

UB

BUS

- (BL

ACK)

BUS

+ (W

HIT

E)

BUS

SHIE

LD (B

ARE)

RES

ET (B

LK/O

RG

)

SPAR

E 1

(BR

OW

N)

13 45 16

3325

50

MIC

HI

MIC

LO

VIP SECTION MIC SECTIONRADIO SECTION

RAD

IO S

IDE

CAB

LE S

IDE

VF S

ENSE

2VF

SEN

SE 2

2

NC

VIP-

OU

T-1

VIP-

OU

T-2

VIP-

OU

T-3/

DEK

-STR

OBE

VIP-

IN-1

VIP-

IN-2

VIP-

IN-3

/DEK

-DAT

A-IN

DEK

-DAT

A-O

UT

DEK

-CLO

CK

SWB+

SWB+

4

11 44 43 1027

MIC

LO

15

14 5

5

19 16

15

DIG

-GN

D

DIG

-GN

D

DIG

-GN

D

214624

PTT

BUSY

BUS

-

BUS

+

SPAR

E 1

SPAR

E 2

RES

ET

SW B

+

SHIE

LD G

ND

EMER

30 14

PTT/

HU

B-R

EF

841 7 4024 23

26

46 33

GN

D

17 26

22

SPEA

KER

LO

1

3

3 374 3852 1918

A+ VF S

ENSE

11

VF S

ENSE

1

IGN

ITIO

N

B+/A

+

2

SWB+

35

VIP-

OU

T-1/

DEK

-CLO

CK

18 19VI

P-O

UT-

2/D

EK-D

ATA-

OU

T

VIP-

OU

T-3/

DEK

-STR

OBE

1411

47

KEY

SLO

T

SW B

+

B+/A

+

A+30

20A+

RES

ET

BUSY

BUS

-

BUS

+

10 28

ANA-

GN

D

DIG

-GN

D

19.

6V

PTT

MIC

HI

MIC

LO

TO W

4/W

5/W

7 C

ON

TRO

L H

EAD

BUSY

31 32 1 34

NC

NC

NC

NC

6 13G

ND

JU64

3

JU63

6

JU60

1

JU60

9

JU64

2

JU10

04

JU64

4

JU64

1

JU10

01

JU60

8

JU60

7

JU66

2

JU60

6

JU66

3

JU65

9

JU61

6

JU10

03

JU10

07

JU64

0

JU65

3

JU63

2

JU65

7JU

633

JU61

4JU

645

JU63

9

JU65

5

JU10

02

JU61

5

JU65

0JU

646

JU10

06

JU10

08

JU60

4

JU10

05

JU63

8

JU63

7

JU63

0

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts8-

35

6881

096C

77-O

Sep

tem

ber

26, 2

003

Fig

ure

8-20

. W5

and

W7

Con

trol

Hea

d In

terf

ace

Boa

rd S

chem

atic

33 B

USY

46 P

TT

12 M

IC-H

I13

MIC

-L0

45 H

UB

9000

CAB

LEIN

TER

FAC

E C

ON

N.

P010

0

HLN

6432

D W

5/W

7 C

ON

TRO

L H

EAD

INTE

RFA

CE

BO

AR

D

MAE

PF-2

3570

-A

CO

NTR

OL

HEA

DC

ON

NEC

TOR

J010

3M

IC-H

I 27

MIC

-LO

3H

UB

28

JU10

05*

PTT

2

4

JU10

06*

BUSY

25

17 B

US+

BUS+

22

50 B

US

BUS

10

26 R

ESET

RES

ET 2

3

28 S

PAR

E

1SP

ARE

1

8

29 S

PAR

E

2SP

ARE

2

7

47 A

+A+

5

15 IG

NIG

N 1

1

48 S

WB+

SWB+

4 12

11 S

PKR

LO

44 S

PKR

H

I43

SPK

R

HI

10 S

PKR

LO

27 E

MER

GEN

CY

VR10

03**

VR10

01

VR10

0215

V

15V

VF S

ENSE

1

1VF

SEN

SE 2

2

JU10

01*

16 S

HIE

LD G

ND

14 V

F SE

NSE

1JU

1008

49 D

IGIT

AL G

ND

30 A

+31

VF

SEN

SE 2

32

JU10

07

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Y SL

OT

6 13G

ND

GN

D

2 VI

P-O

UT-

1VI

P-O

UT-

1/D

EK-C

LOC

K 18

1 VI

P-O

UT-

2VI

P-O

UT-

2/D

EK-D

ATA-

OU

T 19

34 V

IP-O

UT-

3/D

EK-S

TRO

BEVI

P-O

UT-

3/D

EK-S

TRO

BE 1

44

VIP-

IN-1

VIP-

IN-1

17

3 VI

P-IN

-2VI

P-IN

-2 1

637

VIP

-IN-3

/DEK

-DAT

A-IN

VIP-

IN-3

/DEK

-DAT

A-IN

15

5 D

EK-D

ATA-

OU

T38

DEK

-CLO

CK

18 S

WB+

19 S

WB+

35 S

WB+

20 D

IG-G

ND

21 D

IG-G

ND

36 D

IG-G

ND

9SN

ET-K

EY

20SN

ET-K

ID

21SN

ET-W

E

* = P

ARTS

NO

T PL

ACED

** =

010

5950

T92

ON

LY41

SW

B+8

MIC

-HI

7 M

IC-L

O

24 P

TT

40 E

MER

G/H

UB

23 P

TT/H

UB-

REF

JU10

02*

JU10

03*

JU10

04*

MIC SECTIONVIP SECTIONRADIO SECTION

8-36

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts

Sep

tem

ber

26, 2

003

6881

096C

77-O

Fig

ure

8-21

. HLN

6432

D W

5/W

7 C

ontr

ol H

ead

Inte

rfac

e B

oard

Com

pone

nt L

ocat

ion

Dia

gram

JU1002

JU1003

JU1006

VR10

03

JU1004JU1005

VR10

01VR

1002

JU1007

JU1008

JU1001

HL

N64

32D

W5/

W7

Par

ts L

ist

Item

Mo

toro

laP

art

Nu

mb

erD

escr

ipti

on

JU10

01N

OT

PLA

CE

D64

AM

DU

MM

Y P

AR

T N

UM

BE

R

JU10

02N

OT

PLA

CE

D64

AM

DU

MM

Y P

AR

T N

UM

BE

R

JU10

03N

OT

PLA

CE

D64

AM

DU

MM

Y P

AR

T N

UM

BE

R

JU10

04N

OT

PLA

CE

D64

AM

DU

MM

Y P

AR

T N

UM

BE

R

JU10

05N

OT

PLA

CE

D64

AM

DU

MM

Y P

AR

T N

UM

BE

R

JU10

06N

OT

PLA

CE

D64

AM

DU

MM

Y P

AR

T N

UM

BE

R

JU10

0706

1107

7A01

RE

S C

HIP

JU

MP

ER

JU10

0806

1107

7A01

RE

S C

HIP

JU

MP

ER

VR

1001

4813

830A

28D

IOD

E 1

5V 5

% 2

25M

W

MM

BZ

5245

B_

VR

1002

4813

830A

28D

IOD

E 1

5V 5

% 2

25M

W

MM

BZ

5245

B_

VR

1003

NO

TP

LAC

ED

64A

M D

UM

MY

PA

RT

NU

MB

ER

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts8-

37

6881

096C

77-O

Sep

tem

ber

26, 2

003

Fig

ure

8-22

. HLN

6401

A C

ontr

ol H

ead

Inte

rcon

nect

Boa

rd, (

Das

h-M

ount

)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

NC

NC

MIC

-LO

WN

C

NC

J103

P

502

HL

N64

01A

CO

NT

RO

L H

EA

D IN

TE

RC

ON

NE

CT

BO

AR

D(D

ash

Mo

un

t)

MA

EP

F-2

3575

-O

1 3 7 31 30 28 27 14 23 22 21 4 5 8 10 12 13 18 17 16 15 25 11 2 9 32 6 29 19 20 24 26 33 34 35 36 37 38

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

NC

KE

YE

D-S

LOT

KE

YE

D-S

LOT

NC

NC

NC

NC

NC

NC

NO

TE

CR

10

JU11

NO

TE

JU

10N

OT

E

SW

B+

A+

DIG

-GN

D

SP

AR

E-2

SP

AR

E-1

SE

RIA

L B

US

RE

SE

TB

US

-IG

N

VIP

-OU

T-1

VIP

-OU

T-2

S.N

ET

_KID

/PR

OG

-VP

P

S.N

ET

_WE

/PR

OG

-RX

DB

US

+S

.NE

T_K

EY

/PR

OG

-TX

D

MIC

PT

T/P

RO

G-R

ES

ET

BU

SY

MIC

-HI/P

RO

G-M

OD

-CO

NT

RO

LH

UB

/PR

OG

BU

SY

NO

TE

: NO

T C

OM

PA

TIB

LE W

ITH

S

PE

CT

RA

E J

U10

, JU

11, C

R10

INS

TA

LLE

D

FO

R A

VL

OP

TIO

N.

TR

AC

E C

UT

ON

LY W

HE

N

CR

10 IN

ST

ALL

ED

.

8-38

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts

Sep

tem

ber

26, 2

003

6881

096C

77-O

Fig

ure

8-23

. HLN

6486

D/E

Hig

h P

ower

Sta

ndar

d In

terc

onne

ct B

oard

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts8-

39

6881

096C

77-O

Sep

tem

ber

26, 2

003

Fig

ure

8-24

. HLN

6486

D/E

Hig

h-P

ower

Inte

rcon

nect

Boa

rd (

Vie

wed

from

Sid

e 1)

Fig

ure

8-25

. HLN

6486

D/E

Hig

h-P

ower

Inte

rcon

nect

Boa

rd (

Vie

wed

from

Sid

e 2)

13

24

5 67 8

9 10

8-40

Sch

emat

ics,

Ove

rlay

s, a

nd

Par

ts L

ists

: Li

st o

f Sch

emat

ics,

Com

pone

nt L

ocat

ion

Dia

gram

s, a

nd P

arts

Lis

ts

Sep

tem

ber

26, 2

003

6881

096C

77-O

HL

N64

86E

Sta

nd

ard

Inte

rco

nn

ect

Par

ts L

ist

ITE

MM

OT

OR

OL

A

PA

RT

N

UM

BE

RD

ES

CR

IPT

ION

C75

021

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C75

121

1374

1N69

CA

P C

HIP

CL2

X7R

10%

10

0000

C75

221

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C75

421

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C75

521

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C75

621

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C75

721

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C76

321

1374

1N45

CA

P C

HIP

CL2

X7R

10%

100

00

C76

421

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C76

521

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C76

821

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C77

021

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C77

121

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

30 1

00

C77

221

1374

0B49

CA

P C

HIP

RE

EL

CL1

+/-

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00

C77

321

1374

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CA

P C

HIP

RE

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CL1

+/-

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00

C77

421

1374

0B65

CA

P C

HIP

RE

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CL1

+/-

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70

C77

521

1374

0B65

CA

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HIP

RE

EL

CL1

+/-

30 4

70

C77

621

1374

0B65

CA

P C

HIP

RE

EL

CL1

+/-

30 4

70

C77

721

1374

0B65

CA

P C

HIP

RE

EL

CL1

+/-

30 4

70

H00

0103

0013

9581

SC

R M

CH

4-4

0X5/

16 P

HLP

AN

S

TL

H00

0203

0013

9581

SC

R M

CH

4-4

0X5/

16 P

HLP

AN

S

TL

H00

0303

0013

9581

SC

R M

CH

4-4

0X5/

16 P

HLP

AN

S

TL

H00

0403

0013

9581

SC

R M

CH

4-4

0X5/

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HLP

AN

S

TL

J000

509

8015

9P02

CO

NN

EC

TO

R 2

5-P

IN

J000

609

8015

9P02

CO

NN

EC

TO

R 2

5-P

IN

JU60

106

1107

7A01

RE

S C

HIP

JU

MP

ER

JU60

406

1107

7A01

RE

S C

HIP

JU

MP

ER

JU60

606

1107

7A01

RE

S C

HIP

JU

MP

ER

JU60

706

1107

7A01

RE

S C

HIP

JU

MP

ER

JU60

806

1107

7A01

RE

S C

HIP

JU

MP

ER

JU60

906

1107

7A01

RE

S C

HIP

JU

MP

ER

JU61

306

1107

7A01

RE

S C

HIP

JU

MP

ER

JU61

806

1107

7A01

RE

S C

HIP

JU

MP

ER

JU61

906

1107

7A01

RE

S C

HIP

JU

MP

ER

JU62

006

1107

7A01

RE

S C

HIP

JU

MP

ER

JU62

106

1107

7A01

RE

S C

HIP

JU

MP

ER

JU62

206

1107

7A01

RE

S C

HIP

JU

MP

ER

JU62

306

1107

7A01

RE

S C

HIP

JU

MP

ER

JU62

606

1107

7A01

RE

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HIP

JU

MP

ER

JU62

906

1107

7A01

RE

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HIP

JU

MP

ER

JU63

006

1107

7A01

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HIP

JU

MP

ER

JU63

206

1107

7A01

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HIP

JU

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ER

JU63

606

1107

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JU

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ER

JU63

706

1107

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JU

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JU63

806

1107

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JU63

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1107

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MP

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JU64

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1107

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JU64

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1107

7A01

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JU

MP

ER

JU64

506

1107

7A01

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JU

MP

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JU64

606

1107

7A01

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JU

MP

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JU65

206

1107

7A01

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JU

MP

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JU65

306

1107

7A01

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JU65

506

1107

7A01

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JU

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ER

JU65

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1107

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JU65

806

1107

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JU

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ER

JU66

206

1107

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JU

MP

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JU66

406

1107

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JU66

506

1107

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ER

JU66

606

1107

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Appendix A Replacement Parts Ordering

A.1 Basic Ordering InformationWhen ordering replacement parts or equipment information, the complete identification number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufficient description of the desired component to identify it.

Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model number in which the part is used.

The ASTRO Digital Spectra/Digital Spectra Plus Mobile Radios Control Head Manual (Motorola publication part number 6881096C77) includes complete parts lists and parts numbers.

A.2 Motorola OnlineMotorola Online users can access our online catalog at

https://www.motorola.com/businessonline

To register for online access:

• Domestic customers: please call 800-814-0601 (U.S. and Canada).

• International customers: please go to https://www.motorola.com/businessonline and click on “Sign Up Now.”

A.3 Mail OrdersSend written orders to the following addresses:

*The Radio Products Services Division (RPSD) was formerly known as the Customer Care and Services Division (CCSD) and/or the Accessories and Aftermarket Division (AAD).

Replacement Parts/Test Equipment/Manuals/Crystal Service Items:

Motorola Inc.Radio Products Services Division*Attention: Order Processing2200 Galvin DriveElgin, IL 60123U.S.A.

Federal Government Orders:

Motorola Inc.U.S. Federal Government Markets DivisionAttention: Order Processing7230 Parkway DriveLandover, MD 21076U.S.A.

International Orders:

Motorola Inc.Radio Products Services Division*Attention: Order Processing2200 Galvin DriveElgin, IL 60123U.S.A.

https://www.motorola.com/businessonline

A-2 Replacement Parts Ordering: Telephone Orders

A.4 Telephone OrdersRadio Products Services Division*(United States and Canada)7:00 AM to 7:00 PM (Central Standard Time)Monday through Friday (Chicago, U.S.A.)1-800-422-42101-847-538-8023 (International Orders)

U.S. Federal Government Markets Division (USFGMD)1-800-826-1913 Federal Government Parts - Credit Cards Only8:30 AM to 5:00 PM (Eastern Standard Time)

A.5 Fax OrdersRadio Products Services Division*(United States and Canada)1-800-622-62101-847-576-3023 (International)

USFGMD(Federal Government Orders)1-800-526-8641 (For Parts and Equipment Purchase Orders)

A.6 Parts IdentificationRadio Products Services Division*(United States and Canada)1-800-422-4210, menu 3

A.7 Product Customer ServiceCustomer Response Center(Non-technical Issues)1-800-247-2346FAX:1-800-247-2347

*The Radio Products Services Division (RPSD) was formerly known as the Customer Care and Services Division (CCSD) and/or the Accessories and Aftermarket Division (AAD).

September 26, 2003 6881096C77-O

Index-1

Index Index

C

cable, P501 extender 6-4cautions 1-1charts, troubleshooting 5-12cleaning

circuit boards 2-1components 2-1external surfaces 2-1

component location diagrams 8-1control heads

cabling 6-4Model W3 1-2Models W4, W5, W7, W9 1-4overview 1-2replacing 5-7

Model W3 5-7Model W4, W5, W7 5-8Model W9 5-10

vehicle interface port (VIP) 3-12controls

Model W3 1-3Model W4, W5, W7, W9 1-6

copyrightscomputer software iidocument ii

E

extender cable, P501 6-4

H

handling precautions 2-2

J

jumper configurations 3-11

M

maintenancecleaning 2-1inspection 2-1

manualnotations 1-1revisions ii

Microphoneexploded view 7-6parts list 7-6

Model W3backlight circuit 3-3display circuit 3-1exploded view 7-2final reassembly 5-11jumper selection 3-3keypad side keys and top keys 3-2microphone preamplifier and PTT 3-2

On/0ff hook control 3-3operation 3-1parts list 7-2power On/Off 3-4power supply 3-3replacing the control head 5-7SB9600 Serial Bus Interface 3-1status LEDs 3-3

Model W9control board 3-9

bus transceiver 3-10EEPROM write-protect circuit 3-11ignition sense circuits 3-10microprocessor 3-9power supply 3-10vacuum fluorescent voltage converter 3-10vehicle interface ports 3-10watchdog timer 3-9

controls and indicators 3-9default jumper settings 3-11display 3-8display board 3-11

backlight LEDs 3-11status LEDs 3-11vacuum fluorescent display 3-11vacuum fluorescent display driver 3-11

exploded view 7-5operation 3-8parts list 7-5replacing the control head 5-10vehicle interface port (VIP) 3-14

Models W4, W5, W7backlight LEDs 3-8bus busy 3-6hang-up button (HUB) 3-7ignition sense circuitry 3-7interface circuitry 3-5keypad scan 3-7microcomputer 3-5Model W4 exploded view 7-3Model W4 parts list 7-3Models W5, W7 exploded view 7-4Models W5, W7 parts list 7-4operation 3-4power switch/ignition 3-4push-to-talk (PTT) 3-7replacing the control head 5-8replacing the remote back housing

interface board 5-5replacing the vacuum fluorescent display 5-5reset 3-6serial bus data 3-6vacuum fluorescent display 3-8vacuum fluorescent display driver IC 3-8vacuum fluorescent voltage converter circuitry 3-7vehicle interface port 3-12voltage regulator 3-5

N

notations 1-1

6881096C77-O September 26, 2003

Index-2

P

parts list 8-1large pushbutton parts 7-7Microphone 7-6Model W3 7-2Model W4 7-3Model W5 7-4Model W7 7-4Model W9 7-5small pushbutton parts 7-7

parts, ordering replacement A-1product safety information iiPTT (push-to-talk) 3-7

R

reassembly, final 5-11Model W3 5-11

remote back housing interface board, replacing 5-5remote interconnect board, replacing 5-6replacement parts, ordering A-1replacing

control head 5-7remote back housing interface board 5-5remote interconnect board 5-6vacuum fluorescent display 5-5

RF exposure compliance information ii

S

schematics 8-1Serial Bus Data 3-6

T

test equipment and service aids 4-1trademark information iitroubleshooting 5-1

charts 5-12final reassembly 5-11replacing the control head 5-7replacing the remote back housing

interface board 5-5replacing the remote interconnect board 5-6replacing the vacuum fluorescent display 5-5tools and supplies 5-1waveforms 5-2

V

vacuum fluorescent display, replacing 5-5vehicle interface port (VIP) 3-12

Model W4, W5, W7 3-12VIP input connections 3-13VIP output connections 3-12

Model W9 3-14VIP input connections 3-14VIP output connections 3-14

VIP output connectionsdash-mount installations 3-12remote-mount installations 3-13

W

warranty xiwaveforms

troubleshooting 5-2

September 26, 2003 6881096C77-O

6881096C77-O

*6881096C77*

MOTOROLA, the Stylized M Logo, ASTRO, and Spectra are

registered in the U.S. Patent and Trademark Office. All other

product or service names are the property of their respective owners.

© Motorola, Inc. 2003

All rights reserved. Printed in U.S.A.

Motorola, Inc.

8000 West Sunrise Boulevard

Ft. Lauderdale, FL 33322

W3 / W4 / W5 / W7/ W9 Control Head Models Service …® Digital Spectra® and Digital Spectra Plus...

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Transcript of W3 / W4 / W5 / W7/ W9 Control Head Models Service …® Digital Spectra® and Digital Spectra Plus...