Communications - VHF - Motorola Control Head Service Manual

®
ASTRO Digital Spectra

®
and Digital Spectra Plus
Mobile Radios
W3 / W4 / W5 / W7/ W9
Control Head Models
Service Manual
Title Page
ASTRO® Digital Spectra®
and Digital Spectra Plus
Mobile Radios
W3/W4/W5/W7/W9
Control Head Models
Service Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322 6881096C77-O
i
Foreword
This 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

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.
Caution
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.
ii
Table of Contents iii
Table of Contents
Foreword .........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ii
Manual Revisions ........................................................................................................................................ii
Computer Software Copyrights ...................................................................................................................ii
Document Copyrights ..................................................................................................................................ii
Disclaimer....................................................................................................................................................ii
Trademarks .................................................................................................................................................ii
Commercial Warranty ...................................................................................xi

Limited Warranty ........................................................................................................................................xi
MOTOROLA COMMUNICATION PRODUCTS ................................................................................xi
I. What This Warranty Covers And For How Long .....................................................................xi
II. General Provisions .................................................................................................................xi
III. State Law Rights .................................................................................................................. xii
IV. How To Get Warranty Service ............................................................................................. xii
V. What This Warranty Does Not Cover.................................................................................... xii
VI. Patent And Software Provisions ......................................................................................... xiii
VII. Governing Law................................................................................................................... xiii
Chapter 1 Introduction ......................................................................... 1-1

1.1 Notations Used in This Manual...................................................................................................... 1-1
1.2 Control Head Features .................................................................................................................. 1-2
1.3 Control Heads................................................................................................................................ 1-2
1.3.1 W3 Control Head .............................................................................................................. 1-2
1.3.1.1 W3 Controls ............................................................................................................. 1-3
1.3.2 W4, W5, W7, and W9 Control Heads ............................................................................... 1-4
1.3.2.1 W4, W5, W7, and W9 Controls................................................................................ 1-6
Chapter 2 Basic Maintenance.............................................................. 2-1

2.1 Inspection ...................................................................................................................................... 2-1
2.2 Cleaning......................................................................................................................................... 2-1
2.2.1 Cleaning External Plastic Surfaces................................................................................... 2-1
2.2.2 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 ........................................................................................................................... 3-1
3.1.1 SB9600 Serial Bus Interface............................................................................................. 3-1
3.1.2 Display Circuit ................................................................................................................... 3-1
3.1.3 Keypad Side Keys and Top Keys ..................................................................................... 3-2
3.1.4 Microphone Preamplifier and PTT .................................................................................... 3-2
6881096C77-O September 26, 2003

iv Table of Contents
3.1.5 On-/Off-Hook Control ........................................................................................................ 3-3

3.1.6 Backlight Circuit ................................................................................................................ 3-3
3.1.7 Power Supply.................................................................................................................... 3-3
3.1.8 Status LEDs ...................................................................................................................... 3-3
3.1.9 Jumper Selection .............................................................................................................. 3-3
3.1.10 Power On/Off .................................................................................................................... 3-4
3.1.11 Miscellaneous Functions................................................................................................... 3-4
3.2 W4, W5, and W7 Control Heads.................................................................................................... 3-4
3.2.1 Power Switch/Ignition........................................................................................................ 3-4
3.2.2 Voltage Regulator ............................................................................................................. 3-5
3.2.3 Microcomputer .................................................................................................................. 3-5
3.2.4 Interface Circuitry.............................................................................................................. 3-5
3.2.5 Reset................................................................................................................................. 3-6
3.2.6 Bus Busy........................................................................................................................... 3-6
3.2.7 Serial Bus Data ................................................................................................................. 3-6
3.2.8 Push-To-Talk (PTT) .......................................................................................................... 3-7
3.2.9 Hang-Up Button (HUB) ..................................................................................................... 3-7
3.2.10 Ignition Sense Circuitry ..................................................................................................... 3-7
3.2.11 Keypad Scan..................................................................................................................... 3-7
3.2.12 Vacuum Fluorescent (VF) Voltage Converter Circuitry..................................................... 3-7
3.2.13 Vacuum Fluorescent Display Driver IC ............................................................................. 3-8
3.2.14 Vacuum Fluorescent Display ............................................................................................ 3-8
3.2.15 Backlight LEDs.................................................................................................................. 3-8
3.3 W9 Control Head ........................................................................................................................... 3-8
3.3.1 Display .............................................................................................................................. 3-8
3.3.2 W9 Controls and Indicators............................................................................................... 3-9
3.3.3 Control Board.................................................................................................................... 3-9
3.3.3.1 Microprocessor ........................................................................................................ 3-9
3.3.3.2 Watchdog Timer....................................................................................................... 3-9
3.3.3.3 Bus Transceiver ..................................................................................................... 3-10
3.3.3.4 Vacuum Fluorescent Voltage Converter ................................................................ 3-10
3.3.3.5 Vehicle Interface Ports........................................................................................... 3-10
3.3.3.6 Power Supply......................................................................................................... 3-10
3.3.3.7 Ignition Sense Circuits ........................................................................................... 3-10
3.3.3.8 EEPROM Write-Protect Circuit .............................................................................. 3-11
3.3.4 Display Board.................................................................................................................. 3-11
3.3.4.1 VF Display.............................................................................................................. 3-11
3.3.4.2 VF Display Driver ................................................................................................... 3-11
3.3.4.3 Status LEDs ........................................................................................................... 3-11
3.3.4.4 Backlight LEDs....................................................................................................... 3-11
3.3.5 Default Jumper Settings.................................................................................................. 3-11
3.4 Vehicle Interface Port (VIP) ......................................................................................................... 3-12
3.4.1 W4, W5, and W7 Control Heads..................................................................................... 3-12
3.4.1.1 VIP Output Connections ........................................................................................ 3-12
3.4.1.1.1 Dash-Mount Installations ................................................................................ 3-12
3.4.1.1.2 Remote-Mount Installations ............................................................................ 3-13
3.4.1.2 VIP Input Connections (Remote-Mount Only)........................................................ 3-13
3.4.2 W9 Control Heads........................................................................................................... 3-14
3.4.2.1 VIP Output Connections ........................................................................................ 3-14
3.4.2.2 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......................................................................................................... 5-1
5.2 Troubleshooting Waveforms.......................................................................................................... 5-2
5.2.1 ASTRO Digital Spectra Waveforms .................................................................................. 5-2
5.3 Replacing the Vacuum Fluorescent Display (W4, W5, and W7 Control Heads) ........................... 5-5
5.3.1 Removing the Display ....................................................................................................... 5-5
5.3.2 Installing the Display ......................................................................................................... 5-5
5.4 Replacing the Remote Back-Housing Interface Board .................................................................. 5-5
5.4.1 W4, W5, and W7 Control Heads....................................................................................... 5-5
5.5 Replacing the Remote Interconnect Board.................................................................................... 5-6
5.5.1 Low-/Mid-Power Radios.................................................................................................... 5-6
5.5.2 High-Power Radios ........................................................................................................... 5-6
5.6 Replacing the Control-Head Board................................................................................................ 5-7
5.6.1 W3 Control Heads ............................................................................................................ 5-7
5.6.2 W4, W5, and W7 Control Heads....................................................................................... 5-8
5.6.3 W9 Control Heads .......................................................................................................... 5-10
5.7 Final Reassembly–W3 Control Head........................................................................................... 5-11
5.8 Troubleshooting Charts ............................................................................................................... 5-12
Chapter 6 Radio Connectors ............................................................... 6-1

6.1 Radio Connectors .......................................................................................................................... 6-2
6.2 Radio Connector Locations ........................................................................................................... 6-3
6.3 Extender Cable (P501) .................................................................................................................. 6-4
6.4 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 ..................................................................... 7-2
7.2 W4 Rotary Control Head Exploded View...................................................................................... 7-3
7.3 W5 and W7 Pushbutton Control Head Exploded View................................................................. 7-4
7.4 W9 Pushbutton Control Head Exploded View .............................................................................. 7-5
7.5 HMN1080A, HMN1061A, HMN1079A Microphone Exploded View .............................................. 7-6
7.6 Small Pushbutton Parts ................................................................................................................. 7-7
7.7 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-1
A.2 Motorola Online .............................................................................................................................A-1
A.3 Mail Orders ....................................................................................................................................A-1
A.4 Telephone Orders..........................................................................................................................A-2
6881096C77-O September 26, 2003

vi Table of Contents
A.5 Fax Orders .....................................................................................................................................A-2

A.6 Parts Identification .........................................................................................................................A-2
A.7 Product Customer Service .............................................................................................................A-2
Index..................................................................................................... Index-1
September 26, 2003 6881096C77-O

List of Figures vii
List of Figures
Figure 1-1. Typical W3 Hand-Held Control Head .................................................................................... 1-3

Figure 1-2. Typical W4 Rotary Control Head........................................................................................... 1-4
Figure 1-3. Typical W5 Pushbutton Control Head ................................................................................... 1-4
Figure 3-1. Astro Spectra Control Head Block Diagram.......................................................................... 3-4
Figure 3-2. Cabling Interconnect Diagram for Dash Mount................................................................... 3-13
Figure 3-3. Cabling Interconnect Diagram for Remote Mount............................................................... 3-13
Figure 5-1. Replacing the Vacuum Fluorescent Display ......................................................................... 5-5
Figure 5-2. Model W4 Rotary Control Head Assembly Screw and Snap Sequence............................... 5-8
Figure 5-3. Models W5 and W7 Pushbutton Control Head Assembly Screw Sequence ........................ 5-8
Figure 5-4. W9 Control Head Control Board and Display Board........................................................... 5-10
Figure 6-1. J0103 Remote-Mount Control Head Connector.................................................................... 6-2
Figure 6-2. J5 Control Cable for Remote-Mount Control Head ............................................................... 6-2
Figure 6-3. J6 Radio Operations Connector............................................................................................ 6-2
Figure 6-4. J2 Rear Accessory Connector .............................................................................................. 6-2
Figure 6-5. P104 Microphone Jack ......................................................................................................... 6-2
Figure 6-6. Dash-Mount Radio Connector Locations .............................................................................. 6-3
Figure 6-7. Remote-Mount Radio Connector Locations.......................................................................... 6-3
Figure 6-8. Command Board Connector Locations................................................................................. 6-3
Figure 6-9. VOCON Board Connector Locations .................................................................................... 6-3
Figure 6-10. P501 Extender Cable............................................................................................................ 6-4
Figure 6-11. Control-Head Cabling Diagram............................................................................................. 6-4
Figure 7-1. W3 Hand-Held Control Head Exploded View ....................................................................... 7-2
Figure 7-2. W4 Rotary Control Head Exploded View .............................................................................. 7-3
Figure 7-3. W5 and W7 Pushbutton Control Head Exploded View ......................................................... 7-4
Figure 7-4. W9 Pushbutton Control Head Exploded View ...................................................................... 7-5
Figure 7-5. HMN1080A, HMN1061A, HMN1079A Microphone Exploded View...................................... 7-6
6881096C77-O September 26, 2003

viii Related Publications
List of Tables
Table 1-1. ASTRO Digital Spectra/Spectra Plus Basic Features ........................................................... 1-2
Table 1-2. 12-Button Keypad (W7 and W9) ........................................................................................... 1-7
Table 3-1. W3 Jumper Selection ............................................................................................................ 3-3
Table 3-2. Types of Operations .............................................................................................................. 3-4
Table 3-3. Serial Data Bus Logic............................................................................................................ 3-6
Table 3-4. PTT Logic States................................................................................................................... 3-7
Table 3-5. HUB Logic States .................................................................................................................. 3-7
Table 3-6. Standard Jumper Configurations......................................................................................... 3-11
Table 3-7. VIP Output Connections ..................................................................................................... 3-14
Table 3-8. VIP Input Connections ........................................................................................................ 3-14
Table 4-1. Recommended Motorola Test Equipment and Service Aids ................................................. 4-1
Table 5-1. Required Tools and Supplies ................................................................................................ 5-1
Table 7-1. Exploded Views..................................................................................................................... 7-1
Table 7-2. W3 Hand-Held Control Head Exploded View Parts List........................................................ 7-2
Table 7-3. Model W4 Rotary Control Head Parts List ............................................................................ 7-3
Table 7-4. W5 and W7 Pushbutton Control Head Parts List .................................................................. 7-4
Table 7-5. W9 Pushbutton Control Head Parts List .............................................................................. 7-5
Table 7-6. HMN1080A, HMN1061A, HMN1079A Microphone Parts List............................................... 7-6
Table 7-7. Small Pushbutton Parts List .................................................................................................. 7-7
Table 7-8. Large Pushbutton Parts List.................................................................................................. 7-7
September 26, 2003 6881096C77-O

List of Tables ix
Related Publications
ASTRO Digital Spectra and Digital Spectra Plus Model W3 User’s Guide ..................................6881090C61
ASTRO Digital Spectra and Digital Spectra Plus Models W4, W5, W7, and W9 User’s Guide ..6881090C62
ASTRO Digital Spectra Hand-Held Control Head User’s Guide (Model W3) ..............................6881073C25
ASTRO Digital Spectra (Model W4, W5, W7, and W9) User’s Guide..........................................6881074C80
ASTRO Digital Spectra and Digital Spectra Plus Mobile Radios Detailed Service Manual .........6881076C25
ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual.........6881091C78
ASTRO Spectra and Digital Spectra FM Two-Way Mobile Radios Installation Manual ...............6881070C85
ASTRO Spectra Motorcycle Radios Supplemental Installation Manual...................................... 6880103W01
CPS Programming Installation Guide ..........................................................................................6881095C44
KVL 3000 User’s Manual ............................................................................................................. 6881131E16
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:
ASTRO Digital Spectra and Digital Spectra One (1) Year

Plus Units
Product Accessories One (1) Year
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.
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.
September 26, 2003 6881096C77-O

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 Manual

Throughout 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.
Caution
! WARNING indicates a potentially hazardous situation

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

! situation which, if not avoided, will result in death or
injury.
DANGER
1-2 Introduction: Control Head Features
1.2 Control Head Features

The table below outlines the basic features of the five control heads covered in this manual.
Table 1-1. ASTRO Digital Spectra/Spectra Plus Basic Features
Feature W3 W4 W5 W7 W9
Display 2 line/ 1 line/ 1 line/ 1 line/ 1 line/

14 characters 8 characters 8 characters 8 characters 11 characters
Liquid-Crystal Vacuum Vacuum Vacuum Vacuum
Display (LCD) Fluorescent Fluorescent Fluorescent Fluorescent
with 8 Status Display Display Display Display
Annunciators
Mode & Rocker Switches Rotary Mode & Rocker Switch Rocker Switch Rocker Switch
Volume Volume Controls Mode & Volume Mode & Volume Mode & Volume
Controls Controls Controls Controls
Numeric Yes No No Yes Yes

Keypad
Channel 255 128 128 255 255

Capability
(Digital
Spectra)
Channel 512 128 128 512 512

Capability
(Digital
Spectra Plus)
Remote Mount Available Available Available Available Available
Dash Mount Available Available Available Available Not Available
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.
September 26, 2003 6881096C77-O

Introduction: Control Heads 1-3
On/Off Orange Programmable Programmable

Button Button Button
(T1) (T2) (T3)
LED
Indicator
Display
Push-To-Talk
(PTT) Button
Switch
Side Button 1 (S1)
HOME
Side Button 2 (S2)
Side Button 3 (S3)

Volume VOL MODE
Control Mode Control
1Q Z 2 ABC 3 DEF
4 GHI 5 JKL 6 MNO Alphanumeric

Keypad
7 PRS 8 TUV 9 WXY
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.
6881096C77-O September 26, 2003

1-4 Introduction: Control Heads
1.3.2 W4, W5, W7, and W9 Control Heads
PAGE Page
or
SECURE
or Emer
EMERGENCY
SCAN SELECT MONITOR
PHONE CALL DIRECT
HOME Home Phon Scan Call Sel Dir Mon
HORN/ H/L
Mode Volume
LIGHTS
XMIT
Dim
BUSY
Mic Pwr
PRIORITY/ MODE POWER ON/OFF/

NON-PRIORITY DIRECT KNOB VOLUME KNOB
INDICATORS INDICATOR
Figure 1-2. Typical W4 Rotary Control Head
PAGE Page
or
SECURE
or
EMERGENCY Emer
POWER SCAN SELECT

ON/OFF MODE PHONE CALL
PWR
Mode Phon Scan Call Sel
Vol
XMIT
DIM BUSY H/L Mon Dir
HOME
Mic
DIRECT HORN/ DIRECT

HOME
INDICATOR LIGHTS
VOLUME
PRIORITY/ MONITOR
NON-PRIORITY
INDICATORS
Figure 1-3. Typical W5 Pushbutton Control Head
September 26, 2003 6881096C77-O

EMERGENCY Emer
or 2
SECURE or
2Pge
POWER
PHONE CALL SITE PAGE
ON/OFF
MODE SCAN SELECT LOCK
PWR
Mode Phon Scan Call Sel 1Ste 2 3Lck
REPROGRAM
4Sts 5Rpg 6Msg MESSAGE
Vol
XMIT
HORN/LIGHTS
DIM BUSY 7H/L 8Mon 9Dir
DIRECT
HOME
Mic Rcl O #Del
HOME DIRECT RECALL DELETE

VOLUME INDICATOR
PRIORITY/ MONITOR
NON-PRIORITY STATUS
INDICATORS
FUNCTION PRIORITY DIMMER

BUTTON INDICATOR STATUS* CONTROL
XMIT BUSY
DIM
1 2 3
Emer Dir Scan Call
FUNCTION
ON/OFF 4 5 6
INDICATORS Pri Phon H/L
Non
Pri 7 8 9 KEYPAD
Sts Msg MESSAGE*
0 RECALL
Mode Vol Sel Home Rcl Sql Del DELETE
MODE VOLUME SELECT HOME

ROCKER ROCKER POWER
NON-PRIORITY SWITCH
INDICATOR
* Optional buttons (included but not installed or programmed)
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 key Forces the radio to scan for a new site when the automatic multiple-site select
Site (STE) (AMSS) feature for wide-area coverage is in use.
#2 Key Initiates a Call Alert page or enters Call ID list programming.

Page (2 or 2Pge)
#3 key Locks the radio onto the current site when the AMSS feature is in use.
Lock (Lck)
#4 key Used alone or in conjunction with other keypad buttons and the Sel button to
Status (Sts) send a status transmission, indicating a predetermined condition change.
#5 key Requests a change in the radio’s talkgroup assignment when the dynamic
Regroup (Rpg) regrouping feature is used.
#6 key Used alone or in conjunction with other keypad buttons and the Sel button to
Message (Msg) transmit a message, indicating a response or temporary condition.
#7 key Selects/enables radio external alarms.

Horn/Lights (H/L)
#8 key Monitors the radio for channel traffic.

Monitor (Mon)
#9 key Used for talkaround (mobile-to-mobile) conversations.

Direct/Simplex (Dir)
* key Reviews modes in scan and phone lists.

Recall (Rcl)
# key Used when editing stored lists.

Delete (Del)
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 Inspection
Check 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 Cleaning
The 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).
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.
Caution
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).
2-2 Basic Maintenance: Handling Precautions
2.3 Handling Precautions
Components used in this equipment can be damaged by
! accumulated static charge. Avoid unnecessary handling.

When handling devices, use a group strap, conductive
Caution 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.
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
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 Head

The 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 Heads

The 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.
A+/IGN
(U3, Q50, T60) U101 U102

1 JU1 2 13.8V 37 VDC 34 VDC
A+ VOLTAGE VF DRIVER VACUUM BACKLIGHT
CONVERTER IC FLUORESCENT LEDS
CIRCUITRY DISPLAY
+5 VDC 2.5 VAC

U45 U1
1 JU2 2
IGNITION 5 VOLT 1
MICRO- Y1
REGULATOR VIP OUTPUTS 4.0 MHz
COMPUTER
2
U4
SERIAL DATA BUS INTERFACE

AND
VIP INPUTS WATCHDOG
IGNITION SENSE TIMER IC
PTT SENSE
HUB SENSE
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
Control Head
Type How it Operates Ignition Wiring
Jumper/Status
1 RECEIVE and TRANSMIT enabled JU1OUT; JU2/IN Connect ignition cable to

via control head ON/OFF switch “Battery Hot” at fuse block.
(ignition has no effect).
2 RECEIVE and TRANSMIT enabled JU1/OUT; JU2/IN Connect ignition cable to

only when ignition switch is ON. “Ignition” at fuse block.
September 26, 2003 6881096C77-O

Theory of Operation: W4, W5, and W7 Control Heads 3-5
Table 3-2. Types of Operations (Continued)
Control Head
Type How it Operates Ignition Wiring
Jumper/Status
3 RECEIVE enabled by control head JU1 IN; JU2 OUT Connect ignition cable to
ON/OFF switch; TRANSIT enabled “ignition” at fuse block.
only when ignition switch is ON. Enable “TX inhibit” ignition
switch setting in RSS or
CPS.
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.
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.
Table 3-3. Serial Data Bus Logic
No Bus Activity Bus Activity

Data Line (Normal (Sending or In Reset*
Receiving Data) Receiving Data)
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.
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.
September 26, 2003 6881096C77-O

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.
Table 3-4. PTT Logic States
Microphone Push-to-Talk PTT PTT
PRESSED Low High
RELEASED High Low
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.
Table 3-5. HUB Logic States
Microphone
Inverted
Hang-Up HUB Line
HUB
Button
ON-HOOK Low High
OFF-HOOK High Low
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.
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 Head

The 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.
September 26, 2003 6881096C77-O

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
6881096C77-O September 26, 2003

3-12 Theory of Operation: Vehicle Interface Port (VIP)
Table 3-6. Standard Jumper Configurations (Continued)
Jumper Number Normally
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
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.
September 26, 2003 6881096C77-O

Theory of Operation: Vehicle Interface Port (VIP) 3-13
RADIO COMPARTMENT = OPERATOR COMPARTMENT VEHICLE BATTERY

CAUTION COMPARTMENT
A good chassis connection via the black primary
power cable is essential for radio operation and VEHICLE
IGNITION SWITCH
to prevent damage to the radio and cable kit.
Connection to the vehicle frame is desirable. ON/ACC PART OF
RADIO POWER CABLE (BLK/GROUND) RADIO IGNITION
VEHICLE
CABLE (thin RED) GROMMET
3A OR 4A FUSE WIRING
RADIO CH MICROPHONE SEE NOTE
(+) (-)
Rear connector SPEAKER
RADIO POWER CABLE 15A OR 20A
(RED/BATTERY HOT) FUSE
VEHICLE
BATTERY
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.
MAEPF-27646-O
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.
RADIO COMPARTMENT OPERATOR COMPARTMENT VEHICLE BATTERY

CAUTION
COMPARTMENT
MICROPHONE
A good chassis connection via
VEHICLE
the black primary power cable IGNITION SWITCH
is essential for radio operation
TRANSMITTER
and to prevent damage to the VIP RADIO (ORG) CONTROL ON/ACC PART OF
radio and cable kit. Connection (GRN) CABLE (ORG) VEHICLE
MIC GROMMET
to the vehicle frame is desirable. WIRING
4.0A FUSE
GROMMET
SPEAKER SEE NOTE
RADIO (+) (-)
RADIO RADIO CONTROL RECEIVER RADIO POWER CABLE 15A OR 20A

POWER CABLE CABLE (BLK/MULTI- CONTROL (RED/BATTERY HOT) FUSE
VEHICLE
(BLK/GROUND) CONDUCTOR) CABLE (GRN) BATTERY
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
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.
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.
Table 3-7. VIP Output Connections
VIP Output Switched VIP Output Default Function Is Changed

No. B+ Pin No. Pin No. with Field Programmer
1 18 2 Horn Relay (Alarm)
2 19 1 Light Relay (Alarm)
3 35 34 Siren-Horn Transfer
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.
Table 3-8. VIP Input Connections
VIP Input Switched VIP Output Default Function Is Changed

No. B+ Pin No. Pin No. with Field Programmer
1 20 4 Siren; Horn Ring
2 21 3 Emergency (if option is present)
3 36 37 None
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.
September 26, 2003 6881096C77-O

Chapter 4 Test Equipment and Service Aids
4.1 Recommended Test Equipment and Service Aids

The 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
Motorola
Description Characteristics Application
Model Number
6032A* DC power supply 0-20 Vdc, 0-50 A current-limited Bench supply for 13.8 Vdc
(Agilent)
FLUKE 87* Digital Multimeter True RMS metering, 200 kHz Recommended for AC/DC
frequency counter, 32-segment voltage and current
bar graph with backlit display measurements
54622A* Oscilloscope (Agilent) Two-channel, 100 MHz Waveform Measurements

bandwidth, 200 MSa/s sample
rate, 2 MB memory/channel
3080369B99 Extender Cable— Control head troubleshooting

(dash mount) Allows operation of
3080369B97 control head while
(remote mount) extended from radio
* or equivalent
4-2 Test Equipment and Service Aids: Recommended Test Equipment and Service Aids
Notes
September 26, 2003 6881096C77-O

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 Supplies

Table 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 Waveforms

This 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
September 26, 2003 6881096C77-O

Troubleshooting: Troubleshooting Waveforms 5-3
Waveform W3: U3 Output: U3 pin 1 (output to Q50)
Waveform W4: Q50 Drain
6881096C77-O September 26, 2003

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.
September 26, 2003 6881096C77-O

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.
DISPLAY
DIR
KNIFE I
PR
N
I
PR
DETAIL A
SHOCK
PAD
DIR
I
PR
N
I
PR
DETAIL B
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.
6881096C77-O September 26, 2003

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.
! Take care to avoid misalignment of connector pins.

Caution
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.
! Take care to avoid misalignment of connector pins. Remove the

radio top cover to allow visual inspection during connector alignment.
Caution
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.
September 26, 2003 6881096C77-O

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.
8 5 7 1
4 3 2 6
Figure 5-2. Model W4 Rotary Control Head Assembly Screw and Snap Sequence
6 1 4 7
3 5 2
Figure 5-3. Models W5 and W7 Pushbutton Control Head Assembly Screw Sequence
September 26, 2003 6881096C77-O

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.
Take care to avoid misalignment of connector pins. On dash mount

! radios, remove the radio top cover to allow visual inspection during
connector alignment.
Caution
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.
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.
16 mnm self-tapping screws

(2)
Control Board
8 mnm self-tapping screws

(5)
Display Board
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.
September 26, 2003 6881096C77-O

Troubleshooting: Final Reassembly–W3 Control Head 5-11
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)
Caution parts, use extreme caution when heating. Never reuse a chip
or SOT part; always replace with the correct Motorola part.
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 Head

When reassembling the control head, make sure the microphone pins are properly inserted through
the elastomeric keypad. Also make sure the elastomeric keypad inserts are secured to the PC board.
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].
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 Charts

This 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

Troubleshooting 5-13
CONTROL UNIT POWERS UP

PROPERLY BUT BUTTON PRESSES
DO NOT WORK.
START
Check U45
(+5V Reg.)
Is NO
+5V OK Repair
?
YES
With no buttons pressed, check U1

pins 8-11 for activity.
Activity Press buttons and

on all pins YES check return lines NO
Repair
? (U1 pins 13-17).
(8-11) Check R120-R124
NO
Activity Check that pin for a shorted button

on one pin YES closure somewhere on the line.
only Check return lines (U1 pins 13-15).
? Check R120-R122.
NO
Check U1 for
No activity proper operation
at all and repair
MAEPF-22619-A
Figure 5-5. W4 Control Head (Sheet 1 of 2)
6881096C77-O September 26, 2003

5-14 Troubleshooting
NO DISPLAY OR VERY BRIGHT DISPLAY

VERY DIM DISPLAY VARIES WITH SUPPLY VOLTAGE
START
START
Turn Power on
with Control Head CR50 is
connected to radio Probably Open
Is
display at proper YES Check
No Problem
brightness END U101-1
level Voltage
?
NO
Check for SWB+ Is Check VF Display Is Check R50 Is Q50 may have been
Voltage YES NO NO Repair and waveform NO Check U3, C54, overstressed Return
voltage on Control Filament Voltage with an Voltage and T60 OK To
33 to 39V Return to correct R56-R60 during failure.
Head PC Board AC voltmeter between pins Correct pins 4, 5, 6 ? Start
? Start ? and Repair Replace Q50
1 and 25 of VF Display. The ? for continuity
voltage should be 2 to 3 Vrms
NO
YES YES YES
Is Check U101
Check SW1, J102, NO Is CR50 is and U1 for Check DC voltage
P102 and Repair: SWB+ On Voltage YES probably open Check R51, R52, Return Check VF Display
proper on U3-2. It should
Return to Start ? over 40V Remove VF C51, C52 To Filament
operation be 1.5 to 2.0 VDC
? Display and repair Start For Open
YES NO
Is CR51 is probably Is Remove VF Repair and Is

Check U45 YES Check T60 YES Check CR51, YES voltage NO Check R52,
Voltage open Filament Display and Return to
(+5V REG) pins 1, 2, 3 OK Q50 and correct R51, C51
below 10V Remove VF Open Replace Start
continuity ? Repair ? and Repair
? Display ?
NO NO NO YES
Is NO Is Q50 may have Check U3-1

+5V OK Repair and Voltage YES Is NO Repair and Check R101, T60 Return Waveform W3
Check been overstressed
? Return to 20 to 25V C52 OK Return to and To in section 5.8
C52 during failure
Start ? ? Start Repair Start
Replace Q50
YES NO
YES
Is Is
Check L50, YES Possible sawtooth NO
Voltage Return Return waveform Check U3, Q50 may have been Return
R55 oscillator problem
11 to 14V To To present R61, Q50, overstressed during To
Continuity Remove VF Start
? Start Start ? and Repair failure. Replace Q50
Display
NO
YES
Choose the
closest voltage Check Q50 drain.
NO Repair and range and Is
OK Observe waveform Compare to waveform NO Check R61, Return
Return to proceed To
? Start at U3-3. Compare Waveform W5 in present Replace Q50
with section 5.8 ? Start
Waveform W2
A in section 5.8
YES
YES
Check Q50 may have been

U1-6 Check T60 Return
and Repair overstressed during To
Is failure. Replace Q50 Start
NO Check U4 and
Reset Line
cabling for source
OK
of problem
?
Is Check Reset YES MAEPF-22618-O

NO line to see if it is
Voltage
Low being held high Check U1: U4: Y1 for proper Repair and
? by radio operation. U1-1 must go Return to
malfunction low momentarily after Start
power up, then stay high
YES to properly initialize U1
A
Repair and
Return to
Start
Figure 5-6. W4 Control Head (Sheet 2 of 2)
September 26, 2003 6881096C77-O

Chapter 6 Radio Connectors
This chapter contains the ASTRO Digital Spectra and Digital Spectra Plus connector locations.
6-2 Radio Connectors: Radio Connectors
6.1 Radio Connectors MIC ANA TX FLT FIL AUD

BATT -
HI GND AUD AUD NC SHLD
VIP 1 DATA MIC BATT + VF ANALOG
MIC DET RX PTT/
DIG
OUT GND OUT PTT EMGCY HI (A+) SENSE GND EMER LO AUD AUD BUS + IGN VIP IN 1
2
VIP 2 DIG MIC SPKR SPARE MIC
SWB + IN GND LO LO -1 LO BATT - IGN - BUS +
VF
VIP 2 VIP 1 PTT/HUB MIC SPKR SPARE SENSE
OUT SWB + IN REF HI RESET LO -2 1 IGN + BUSY
13 12 11 10 9 8 7 6 5 4 3 2 1
25 24 23 22 21 20 19 18 17 16 15 14
1 2 3 4 5 7 8 10 11 12 13 14 15 16 17
34 18 35 19 36 20 37 21 38 23 40 24 41 26 43 27 44 28 45 29 46 30 47 31 48 32 49 33 50
SPKR BUSY BUS RESET SPARE RSSI/

HI SHIELD 2 VIP IN 2
SPKR SWB + A+ DIG SPARE BUS -
VIP 3 DIG CLOCK HUB SPKR NC BATT + DIG LO GND 1
OUT GND HI GND MAEPF-21669-A
SWB + VIP 3 SWB + SPKR NC NC BUS
IN HI
Figure 6-3. J6 Radio Operations Connector
VIP MIC RADIO
MAEPF-21670-A
VIP OUT 2
NOTE 1
SPKR NOTE 1 VRS TX/
Figure 6-1. J0103 Remote-Mount Control Head Connector LO IGNITION CTS-RS232
DIG SPKR
GND HI SWB+ EMER
MIC ANA TX FLT RESET (FILT-AUD
HI GND AUD AUDIO B+ SHLD)
MIC DET RX
EMER LO AUD AUDIO BUS + IGN (PTT *)
8 7 6 5 4 3 2 1 DIG
HUB/ GND MIC
15 14 13 12 11 10 9 * GND BUSY LO * Vpp
13 12 11 10 9 8 7 6 5 4 3 2 1
5
25 24 23 22 21 20 19 18 17 16 15 14 1 3 7 9
6
BUS+ VIP OUT 1 BUS- 2 4 8 10
NOTE1
MIC HI/RESET/ BUSY
SPKR BUSY BUS RESET SPARE-2 RSSI RTS-RS232
PTT/ DISC. AUD/ * KEYFAIL/
HI SHLD * PROG SWB+
PTT/
TX-RS232 RX-RS232 RX PROG
SPKR SWB + A+ DIG SPARE-1 BUS - DATA PROGRAM TX DATA
LO GND NOTES: RESET
MIC HI/
1. FUNCTIONAL ONLY IN DASH-MOUNT PROG
MAEPF-23798-O RX/TX ENABLE
CONFIGURATION. N.C. IN REMOTE-MOUNT
Figure 6-2. J5 Control Cable for Remote-Mount Control Head CONFIGURATION.
* PINS 1, 2, 9, AND 10 ARE NO CONNECTIONS (NC)
MAEPF-23799-O ON P104 OF A REMOTE-MOUNT CONTROL HEAD.
DETAIL SHOWN FROM
CONTROL HEAP FRONT VIEW
Figure 6-4. J2 Rear Accessory Connector (MALE PIN VIEW)
MAEPF-23800-A
Figure 6-5. P104 Microphone Jack
September 26, 2003 6881096C77-O

Radio Connectors: Radio Connector Locations 6-3
6.2 Radio Connector Locations

COMMAND BOARD
(VIEWED FROM SIDE 1)
DASH-MOUNT RADIO
P503
2 14 26
J2 ANTENNA PWR
1 13 25
F500
P502
15
14
13
12
11
10
PWR 9
U450 8 24 19 13
Mod 7
e
0
6
Vol Phon 5
Scan 4 J500
DIM Call 3
Sel
HOME 1 2
2 1
3 1 6 12
XMIT 4 Sts
5
BUSY 6 Msg
7H/L 50 30 2
8 Mon
9 Dir
Rcl 49 25 1
0
Del
P104 P501
MAEPF-24496-O
Figure 6-6. Dash-Mount Radio Connector Locations

38 29 20
P502
J2 ANTENNA PWR 1 10 19
Figure 6-8. Command Board Connector Locations

REMOTE-MOUNT VOCON BOARD
RADIO (VIEWED FROM SIDE 2)
P506
49 1
J5 J501
50 2
J0103
PWR
Mod
e
J6
0
Vol Phon
Scan
DIM Call
Sel 2 24
HOME 1
P104 2 J801
XMIT
3
4 Sts
5 REMOTE-MOUNT 1 25
BUSY 6 Msg
7H/L
8 Mon
9 Dir CONTROL HEAD
Rcl
0
Del
MAEPF-24497-A
Figure 6-9. VOCON Board Connector Locations
Figure 6-7. Remote-Mount Radio Connector Locations
6881096C77-O September 26, 2003

6-4 Radio Connectors: Extender Cable (P501)
6.3 Extender Cable (P501) 6.4 Control-Head Cabling Diagram

CONTROL HEAD RADIO
P1001 P5
15
ORG
IGN+
IGN- 32 NC
P501
BATT+ GRN
EXTENDER 47
BATT+
CABLE 30 NC
(3080370E06) BATT-
31
(FACING TOWARD RED
SPARE 2
SPARE 2 29 17
CONTROL HEAD) BATT-
14
VIO
EMERGENCY 27 13 EMERGENCY
BRN
SPARE 1 28 16 SPARE 1
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11 9 7 5 3 1 DIG GRD BLU

49 18 DIG GND
SWB+ YEL
50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 48 22 SWB+
BUS + WHT
17 5 BUS +
BUS - BLK
50 14 BUS -
BUSY BLK/RED
33 23 BUSY
BARE
21 BUS SHIELD
BLK/ORG
RESET 26 19 RESET
BLK/BRN
DET AUDIO 45 9 DET AUDIO
SHIELD
ANA GND 16 0 ANA GND
BLK/GRN
PTT 46 1 PTT
SHIELD
BLK/YEL
12 12 MIC HI
SHIELD
13 11 MIC LO
ORG
44 25 SPKR HI
GRN
11 24 SPKR LO
BLK/GRN
10
J501 BLK/ORG
43
7 MIC LO
COMMAND BOARD
8 MIC HI 20 A+
Figure 6-10. P501 Extender Cable 41 SWB+
40 HUB SPEAKER
24 PTT
23 PTT/HUB REF
18 SWB+
19 SWB+
3 SWB+
20 DIG GND 15 RSSI
21 DIG GND
36 DIG GND
4 7 RX AUDIO
1
VIP IN 2 3
3
37 (DATA IN)
2
1
VIP OUT 2 1
3
34 (STROBE)
38 (CLOCK)
5 (DATA OUT)
Figure 6-11. Control-Head Cabling Diagram
September 26, 2003 6881096C77-O

Chapter 7 Exploded Views and Parts Lists
This chapter contains the exploded views and associated parts lists for each of the ASTRO Digital Spectra and Digital Spectra Plus control heads. Tables containing pushbutton parts lists are also included.
Table 7-1. Exploded Views
Fig # Description Page #
Figure 7-1 W3 Hand-Held Control Head Exploded View 7-2

Figure 7-2 W4 Rotary Control Head Exploded View 7-3
Figure 7-3 W5 and W7 Pushbutton Control Head Exploded View 7-4
Figure 7-4 W9 Pushbutton Control Head Exploded View 7-5
Figure 7-5 HMN1080A, HMN1061A, HMN1079A Microphone Exploded View 7-6
7-2 Exploded Views and Parts Lists: Model W3 Hand-Held Control Head Exploded View
7.1 Model W3 Hand-Held Control Head Exploded View

Table 7-2. W3 Hand-Held Control Head Exploded View Parts List
Item No. Motorola Part No. Description

1
1 Not available LABEL
2 0105955T26 ASSEMBLY, Rear Cover

2 3 3205082E93 SEAL, Main
4 4205343Y01 RETAINER, Snap (Qty 2)

3 5 0102707D81 BOARD, SB9600 Circuit
6 7505832X01 KEYPAD (Part of Item 7)

4
4 7 0102707D86 ASSEMBLY, Housing (Includes Items 6 and 9 thru 13)
8
8 0102708D08 ASSEMBLY, Microphone
5 9 9 7505618V02 ACTUATOR, PTT (Part of Item 7)
10 10 4505850X01 LEVER, PTT (Part of Item 7)
6 11 3205839X01 INDICATOR, Transmit (Part of Item 7)
12 3805835X01 BOOT, PTT (Part of Item 7)

11 12 13 3305409X17 LABEL (Part of Item 7)
7
14 3205274V01 WEDGE, Seal Support
13 15 HKN6095_ ASSEMBLY, Cable
Note: _ = The latest version kit. When ordering, refer to your specific kit for
this suffix letter.
14
15
Figure 7-1. W3 Hand-Held Control Head Exploded View
September 26, 2003 6881096C77-O

Exploded Views and Parts Lists: W4 Rotary Control Head Exploded View 7-3
7.2 W4 Rotary Control Head Exploded View

Table 7-3. Model W4 Rotary Control Head Parts List
1 0380077M01 SCREW, Control Head Mounting (Qty 2)
2 3602113Z05 KNOB, Volume Control
3 3205805V01 GASKET, W4 Shaft (Qty 2)
4 0284218M01 NUT, Volume Switch
5 0484219M01 LOCKWASHER, Volume Switch
6 1502117Z07 or HOUSING, Front Cover (Mobile)

1502117Z08 HOUSING, Front Cover (Motorcycle)
7 0102709J83 ASSEMBLY, Volume and Rotary Switch
8 3602113Z03 KNOB, Mode Control
9 3205805V01 GASKET, W4 Shaft (Qty 2)
10 0284218M02 NUT, Mode Switch
11 0484219M02 LOCKWASHER, Mode Switch
12 6105129X01 LIGHTPIPE
13 7505128X01 KEYPAD
14 AAHN4045_ or ASSEMBLY, Circuit Board (Mobile)

PMLN4019_ ASSEMBLY, Circuit Board (Motorcycle)
15 4302112Z02 SPACER, Internal
16 0310945A14 SCREW, Machine (Qty 4)
17 3280289L02 GASKET, Housing
18 HLN6401_ ASSEMBLY, Circuit Board Interconnect
Notes: _ = The latest version kit. When ordering, refer to your specific kit
Figure 7-2. W4 Rotary Control Head Exploded View for this suffix letter.
The HKN4356_ Radio Cable is used to remote mount the W4
Control Head.
6881096C77-O September 26, 2003

7-4 Exploded Views and Parts Lists: W5 and W7 Pushbutton Control Head Exploded View
7.3 W5 and W7 Pushbutton Control Head Exploded View

Table 7-4. W5 and W7 Pushbutton Control Head Parts List
1 3880227M04 SWITCH, On/Off Cap
2 3880009P01 SWITCH, Mode Rocker
3 3880009P02 SWITCH, Volume Rocker
4 1580020S17 or HOUSING, W5 Front Cover (Mobile)

1580020S19 HOUSING, W5 Front Cover (Motorcycle)
5 3880092J05 PUSHBUTTON, HOME
6 3880092J05 PUSHBUTTON, DIM
7 0380077M01 SCREW, (Qty 2)
8 1580020S16 or HOUSING, W7 Front Cover (Mobile)

1580020S18 HOUSING, W7 Front Cover (Motorcycle)
9 6180017S01 LIGHTPIPE
10 7580012S03 KEYPAD
11 4380019S02 SPACER, Internal Frame
12 0310945A14 SCREW, Tapping (Qty 7)
13 3280289L02 GASKET, Housing
14 HLN6401_ BOARD, Interconnect
15 HLN6396_ or BOARD, Control Head (Mobile)

HLN6563_ BOARD, Control Head (Motorcycle)
Figure 7-3. W5 and W7 Pushbutton Control Head Exploded View 16 0180049S09 or ASSEMBLY, W5 Front Cover (Mobile)
0180049S11 or ASSEMBLY, W5 Front Cover (Motorcycle)
0180049S08 or ASSEMBLY, W7 Front Cover (Mobile)
0180049S10 ASSEMBLY, W7 Front Cover (Motorcycle)
Item 16 includes items 1, 2, 3, 4 or 8, 5, 6, 9, and 10
Notes: _ = The latest version kit. When ordering, refer to your specific kit
for this suffix letter.
The HKN4356_ Radio Cable is used to remote mount the W5 and
W7 Control Head.
September 26, 2003 6881096C77-O

Exploded Views and Parts Lists: W9 Pushbutton Control Head Exploded View 7-5
7.4 W9 Pushbutton Control Head Exploded View Table 7-5. W9 Pushbutton Control Head Parts List (Continued)
5 3205145X01 GASKET, Internal Frame
6 6105126X01 LIGHTPIPE, Keypad
7 7505127X01 KEYPAD
8 7280242J01 DISPLAY, VF
9 7580094M05 PAD, Shock (Qty 3)
10 1405410X01 INSULATOR
11 4180042S01 SPRING, Leaf Assy
12 0380041S01 SCREW, Captive (Qty 4)
13 6180026R02 SPACER, LED (8-Position)
14 6180027R02 SPACER, LED (2-Position)
16 2680190P02 SHIELD, Solder Side (Includes two 1480269K01 insulators)
17 0310945A11 SCREW, Tapping (Qty 5)
18 3080034K01 CABLE, Flex
19 2680190P02 SHIELD, Component Side
20 3205082E90 O-RING "D" Connector (Qty 2)
21 3380178M01 NAMEPLATE
22 0784323C01 BRACKET, Strain Relief
23 0310908A18 SCREW, Machine
24 HKN4356_ CABLE, Radio
25 HMN1050_ or KIT, Microphone
HMN1080_ or
HMN1061_
26 1580221J01 HOUSING, VIP Connector (Optional)
Figure 7-4. W9 Pushbutton Control Head Exploded View 27 7502118Z01 COVER, Rubber Dust (MIC)
28 7502118Z02 COVER, Rubber Dust (VIP)
Table 7-5. W9 Pushbutton Control Head Parts List
29 0310908A33 SCREW, Machine (Qty 2)
30 3205198X01 GASKET, Face
1 1380087J01 ESCUTCHEON
31 1505199X01 HOUSING, Back
2 HLN5083_ BUTTON, Emergency
32 2805778W01 CONNECTOR, Mini "D" 50 Contact
HLN5091_ BUTTON, Dir
HLN5066_ BUTTON, Scan 33 3205143X01 GASKET, "D" Connector
HLN5256_ BUTTON, Srch 34 3205143X01 GASKET, On/Off Switch
HLN5074_ BUTTON, Call
HLN5268_ BUTTON, Page 35 3880128J01 KEY, On/Off
HLN5259_ BUTTON, RPGM 36 HCN4046_ BOARD KIT, Command (includes Display Board)
HLN5258_ BUTTON, Site 37 HCN4046_ BOARD KIT, Display (includes Command Board)
HLN5090_ BUTTON, PHON
HLN5072_ BUTTON, H/L 38 0310945A14 SCREW, Tapping (Qty 2)
HLN5257_ BUTTON, Lock 39 3880092J05 KEY, Blank
HLN5076_ BUTTON, RCL
40 3880195P02 SWITCH, Volume Rocker
HLN5085_ BUTTON, SQL
HLN5078_ BUTTON, Del 41 1505125X09 HOUSING, Front
HLN5087_ BUTTON, Home 42 3205144X01 GASKET, Lens
HLN5079_ BUTTON, Sel
HLN5095_ BUTTON, Blank 43 6105146X01 LENS, VF Display
3 3880253K01 PLUG Note: _ = The latest version kit. When ordering, refer to your specific kit for this suffix
letter.
4 3880195P03 SWITCH, Mode Rocker
6881096C77-O September 26, 2003

7-6 Exploded Views and Parts Lists: HMN1080A, HMN1061A, HMN1079A Microphone Exploded View
7.5 HMN1080A, HMN1061A, HMN1079A Microphone Exploded View

Table 7-6. HMN1080A, HMN1061A, HMN1079A Microphone Parts List
2
4 Item No. Motorola Part No. Description
1 1580127D05 Microphone Front Housing

1
2 3880144D05 Microphone PTT Button
7
8 3 3080223J05 or HMN1080A Coiled 6 Cond
3080210P01 or HMN1079A Coiled 6 Cond
3080223J01 HMN1061A Coiled 6 Cond
9 4 0580221K01 PTT Switch Grommet
10 5 0310943M09 Tapping Screw (3 x 0.5 x 6)

13 6 3080206L01 PCB to Mic Weight Wire
7 3280058H03 Housing Gasket

MICROPHONE
12 BOARD 8 0180750T91 Microphone Rear Housing
5
11 6 9 0380076E04 Hi-lo Metric Screw
14
10 0312002C01 Screw, Self-drilling, 6-20 x 1/2”
15 11 3580089D01 Microphone Felt Baffle

3
12 0580148D01 Microphone Grommet
13 0180743T91 Hangup Clip
14 0180750T52 Ground Wire
15 0300138015 Screw, Self-drilling, 8-18 x 1/2”
MAEPF-27700-O
Figure 7-5. HMN1080A, HMN1061A, HMN1079A Microphone Exploded View
September 26, 2003 6881096C77-O

Exploded Views and Parts Lists: Small Pushbutton Parts 7-7
7.6 Small Pushbutton Parts 7.7 Large Pushbutton Parts Table 7-8. Large Pushbutton Parts List (Continued) Table 7-8. Large Pushbutton Parts List (Continued)
Table 7-7. Small Pushbutton Parts List Table 7-8. Large Pushbutton Parts List Graphic Graphic Graphic Graphic
Part Number Part Number Part Number Part Number
Legend Legend Legend Legend
Graphic Graphic Graphic Graphic
Part Number Part Number Part Number Part Number 3805672X40 Menu 3805672X73 Blu 3805669X05 Entr 3805669X31 Drvr
Legend Legend Legend Legend
3805672X41 Rpgm 3805672X74 Div 3805669X06 M/WT 3805669X32 Bdg#
3805671X02 1 3805671X21 9wxy 3805672X01 -- 3805672X10 H/L
3805671X03 2 3805671X22 * Rcl 3805672X42 Step 3805672X75 RTT 3805669X07 MAck 3805669X33 LnBI
3805672X02 MPL 3805672X11 Sts
3805671X04 3 3805671X23 #Del 3805672X43 3805672X76 Send 3805669X08 Time 3805669X34 RtBl
3805672X03 Scan 3805672X12 Call
3805671X05 4 3805671X24 1Ste 3805672X44 Phon 3805672X77 Front 3805669X09 SRun 3805669X35 LnRn
3805672X04 DVP 3805672X13 Msg
3805671X06 5 3805671X25 2Pge 3805672X45 Dir 3805672X78 Bid 3805669X10 ERun 3805669X36 s
3805672X05 PA 3805672X14 Rcl
3805671X07 6 3805671X26 3Lck
3805672X46 Text 3805672X79 ZONE 3805669X11 STrp 3805669X37 t
3805671X08 7 3805671X27 4Sts 3805672X06 Sirn 3805672X15 Mode
3805672X47 Rvw 3805672X80 TRBL 3800028M01 3800029M01
3805671X09 8 3805671X28 5Rpg 3805672X07 Wail 3805672X16 ExRd “Emer Housing” “Emer Plunger”
3805672X48 Sec 3805672X81 OVHD
3805671X10 9 3805671X29 6Msg 3805672X08 Hi/Lo 3805672X17 Del
3805672X49 Ø 3805672X82 UNGD
3805671X11 0 3805671X30 7H/L 3805672X09 Man 3805672X18 Sel
3805671X12 * 3805671X31 8Mon 3805672X50 L/S 3805672X83 RSSI
3805672X19 Mon 3805672X52 Emer
3805671X13 # 3805671X32 9Dir 3805672X51 S/S 3805672X84 VRS
3805672X20 DTMF 3805672X53 Stdy
3805671X14 2abc 3805671X33 Mon 3805672X85 A/B 3805669X12 ETrp
3805672X21 Yelp 3805672X54 ECC
3805671X15 3def 3805671X34 H/L 3805672X86 Chan 3805669X13 LvTe
3805672X22 MVS 3805672X55 Rptr
3805671X16 4ghi 3805671X35 DIR 3805672X87 PRTT 3805669X14 ArTe
3805671X17 5jkl 3805671X36 Urg 3805672X23 Play 3805672X56 State
3805672X88 RtRn 3805669X15 LvGg
3805671X18 6mno 3805671X37 RTT 3805672X24 Rply 3805672X57 Reg
3805672X89 Emp# 3805669X16 ArGg
3805671X19 7prs 3805671X38 Home 3805672X25 Rcrd 3805672X58 AirHn
3805672X90 Pass 3805669X17 P/in
3805671X20 8tuv 3805671X39 Dim 3805672X26 Emer 3805672X59 TB Scn
3805672X91 Cir 3805669X18 P/out
3805672X27 Ext 3805672X60 SCC
3805672X92 URG 3805669X19 Serv
3805672X28 F/R 3805672X61 Srch
3805672X93 A 3805669X20 0/S
3805672X29 Alt 3805672X62 Lock
3805672X94 B 3805669X21 Rev
3805672X30 Tel 3805672X63 Page
3805672X95 C 3805669X22 Stby
3805672X31 Sql 3805672X64 Rear
3805672X96 D 3805669X23 Sts 1
3805672X32 DES 3805672X65 Xfer
3805672X97 E 3805669X24 Sts 2
3805672X33 Txt 3805672X66 ST
3805672X98 F 3805669X25 Sts 3
3805672X34 Indv 3805672X67 VHF
3805672X99 G 3805669X26 Sts 4
3805672X35 Pvt 3805672X68 UHF
3805669X01 K 3805669X27 Sts 5
3805672X36 Site 3805672X69 Aux
3805669X02 L 3805669X28 Sts 6
3805672X37 AA 3805672X70 QC II
3805669X03 T/Z 3805669X29 Sts 7
3805672X38 Sub 3805672X71 Mute
3805669X04 30 3805669X30 Sts 8
3805672X39 Home 3805672X72 Pri
6881096C77-O September 26, 2003

7-8 Exploded Views and Parts Lists: Large Pushbutton Parts
Notes
September 26, 2003 6881096C77-O

Schematics, Overlays, and Parts Lists: List of Schematics, Component Location Diagrams, and Parts Lists 8-1
Chapter 8 Schematics, Overlays, and Parts Lists
8.1 List of Schematics, Component Table 8-1. List of Schematics, Component Location Table 8-1. List of Schematics, Component Location
Diagrams, and Parts Lists (Continued) Diagrams, and Parts Lists (Continued)
Location Diagrams, and Parts
Lists Figure Title Page Figure Title Page
The following table lists the schematics, HLN6396H_HLN6814C_HLN6563C W5/W7 Control 8-19 HLN6574E W3 High Power Interconnect Board 8-42
component location diagrams, and parts lists Head Component Location Diagram (Viewed from Component Location Diagrams
contained in this chapter. Side 1)
HLN6574E W3 High-Power Interconnect Parts List 8-43
HLN6396H_HLN6814C_HLN6563C W5/W7 Control 8-19
HLN6459D, HLN6344E, and HLN6365E Low-Power 8-45
Head Component Location Diagram (Viewed from
Interconnect Board Schematic
Table 8-1. List of Schematics, Component Location Side 2)
Diagrams, and Parts Lists HLN6459D, HLN6344E, and HLN6365 Low-Power 8-46
HLN6396H Standard Parts List 8-20
Interconnect Component Location Diagram
Figure Title Page HLN6814C Rear Parts List 8-22
HLN6459D W3 Low-Power Interconnect Parts List 8-47
HLN6563D Motorcycle Parts List 8-24
HMN4044E W3 Control Head Schematic 8-2 HLN6365E Motorcycle Interconnect Parts List 8-49
HCN1078J (Standard), HCN1121D (Rear) W9 8-26
HMN4044E W3 Control Head Component Location 8-3 HLN6344E Standard Interconnect Parts List 8-50
Control Head Schematic (Side 1 of 2)
Diagram HMN1080A, HMN1061A, HMN1079A Microphone 8-51
HMN4044E W3 Control Head Component Location 8-4 Board Overlay
Control Head Schematic (Side 2 of 2)
Diagram HMN1080A, HMN1061A, HMN1079A Microphone 8-51
HMN4044E Parts List 8-5 Schematic
Control Head Component Location Diagram (Viewed
HKN6096B Remote “Y” Cable Wiring Diagram 8-6 from Side 1) HMN1080A, HMN1061A, HMN1079A Microphone 8-51
Parts List
AAHN4045F/G (Standard), HLN4071A/B (Rear), 8-7 HCN1078J (Standard), HCN1121D (Rear) W9 8-29
PMLN4019C/D (Motorcycle) W4 Control Head Control Head Component Location Diagram (Viewed
Schematic (Sheet 1 of 2) from Side 2)
AAHN4045F/G (Standard), HLN4071A/B (Rear), 8-8 HCN1078J (Standard), HCN1121D (Rear) Parts List 8-30
PMLN4019C/D (Motorcycle) W4 Control Head W4, W5, and W7 Control Head Low-/Mid-Power 8-33
Schematic (Sheet 2 of 2) Interconnection Diagram
AAHN4045 (Standard), HLN4071 (Rear), PMLN4019 8-9 W4, W5, and W7 High Power Interconnection 8-34
(Motorcycle) W4 Control Head Component Location Diagram
Diagram
W5 and W7 Control Head Interface Board Schematic 8-35
AAHN4045G Standard Parts List 8-10
HLN6432D W5/W7 Control Head Interface Board 8-36
HCN4071B Rear Parts List 8-12 Component Location Diagram
PMLN4019D Motorcycle Parts List 8-14 HLN6401A Control Head Interconnect Board, (Dash- 8-37
HLN6396F/G/H (Standard), HLN6814A/B/C (Rear), 8-16 Mount)
HLN6563B/C/D (Motorcycle) W5/W7 Control Head HLN6486D/E High Power Standard Interconnect 8-38
Schematic (Sheet 1 of 2) Board
HLN6396F/G/H (Standard),HLN6814A/B/C (Rear), 8-17 HLN6486D/E High-Power Interconnect Board 8-39
HLN6563B/C/D (Motorcycle) W5/W7 Control Head (Viewed from Side 1)
Schematic (Sheet 2 of 2)
HLN6486D/E High-Power Interconnect Board 8-39
HLN6396F/G (Standard), HLN6814A/B (Rear), 8-18 (Viewed from Side 2)
HLN6563B/C (Motorcycle) W5/W7 Control Head
Component Location Diagram (Viewed from Side 1) HLN6486E Standard Interconnect Parts List 8-40
HLN6396F/G (Standard), HLN6814A/B (Rear), 8-18 HLN6574E W3 Control Head High-Power 8-41
HLN6563B/C (Motorcycle) W5/W7 Control Head Interconnect Board Schematic Design
Component Location Diagram (Viewed from Side 2)
6881096C77-O September 26, 2003

8-2 Schematics, Overlays, and Parts Lists: List of Schematics, Component Location Diagrams, and Parts Lists
63B81084C78-O
Figure 8-1. HMN4044E W3 Control Head Schematic

(For reference only - board is not field-repairable)
September 26, 2003 6881096C77-O

MAEPF-25560-O
(Viewed from Side 1)

Figure 8-2. HMN4044E W3 Control Head Component Location Diagram
6881096C77-O September 26, 2003

MAEPF-25561-O
(Viewed from Side 2)

Figure 8-3. HMN4044E W3 Control Head Component Location Diagram
September 26, 2003 6881096C77-O

HMN4044E Parts List

MOTOROLA MOTOROLA MOTOROLA
(For reference only - board is not field-repairable) ITEM PART DESCRIPTION ITEM PART DESCRIPTION ITEM PART DESCRIPTION
NUMBER NUMBER NUMBER
MOTOROLA
ITEM PART DESCRIPTION D21 4805729G83 LED Green R16-R20 0662057A81 22k R108 0662057A33 220
NUMBER
D22 4805729G81 LED Red R22 0662057A97 100k R109 0662057A69 6.8k
C1 2380090M24 10µF ± 20%; 50V
D24 4880140L25 20V R26-R27 0662057B22 1M S1-S7 4005840X01
C2 2113743A19 0.1µF
D25-D27 4813833C05 Dual; 70V R28-R29 0662057A97 100k U1 5105469E65 Voltage Regulator
C3 2113740F51 100pF
D28-D29 4805729G85 LED Green R30 0662057A81 22k U2 5105663U34 IC Comparator
C4 2113743A19 0.1µF
D30 4813833C05 Dual; 70V R31 0662057A97 100k U3 5113802A07 IC Comparator µP
C5 2311049A07 1µF ± 1%; 16V
D32 4813833C05 Dual; 70V R32 0662057A81 22k U4 5102074D01 LDC
C6 2113743A19 0.1µF
D35 4813833C05 Dual; 70V R33 0662057A53 1.5k U5-U7 5102074D01 Driver
C8-C10 2113743A19 0.1µF
D37-D39 4813833C05 Dual; 70V R34 0662057A01 10 U8 5113805A75 8-Bit Shift Register
C11 2113740F51 100pF
D80-D81 4813833C05 Dual; 70V R36 0662057A97 100k U9 5105625U63 IC Voltage Detector
C12 2113741F25 1000pF
J1 0984875T03 Jack R41 0662057A97 100k U10 5113805A74 Shift Register
C13 2113740F51 100pF
L1 2480140E01 1.2µH R42-R43 0662057A33 220 U13 0604267J01 In-line Resistor Package
C15 2113743A19 0.1µF
P1 2809926G01 Header R44 0662057A65 4.7k U14 5102073D01 Analog/Digital Converter
C17-C18 2113740F37 27pF
Q1 4805128M12 SOT R46 0662057B22 1M Y1 4880065M01 Resonator; 4.0 MHz
C21 2311049A07 1µF ± 1%; 16V
Q2 4880214G02 MMBT 3904 R50 0662057B10 330k
C22 2311049A57 10µF ±1%;
Q3 4805128M12 SOT R51 0662057A65 4.7k
C23 2113743A19 0.1µF
Q4 4805780V01 R52 0662057A57 2.2k
C24 2113743A19 0.1µF
Q5-Q8 4880214G02 MMBT 3904 R54 0662057B02 150k
C27 2113741A61 .047µF
Q9 4805128M12 SOT R55 0662057A75 12k
C28-C29 2113741F25 1000pF
Q10 4880214G02 MMBT 3904 R56 0662057A97 100k
C30 2113741A61 .047µF
R1 0662057A33 220 R63 0662057A01 10
C32 2113741F25 1000pF
R2 0662057A18 51 R64 0662057B47 0
C34-C35 2113741F49 .010µF
R3 0662057A53 1.5k R65 0662057A61 3.3k
C36 2113741F25 1000pF
R4 0662057A65 4.7k R68 0662057B02 150k
C37 2311049A57 10µF ±1%; 16V
R5 0662057A61 3.3k R70 0662057A15 39
C38 2113741F25 1000pF
R7 0662057A65 4.7k R71 0662057A57 2.2k
C39 2113743A19 0.1µF
R8 0662057A75 12k R73-R74 0662057A81 22k
C40 2113741F25 1000pF
R9 0662057A18 51 R75 0662057A53 1.5k
C41 2113740F59 220pF
R10 0662057A65 4.7k R80-R81 0662057A97 100k
C80 2113741F25 1000pF
R11-R12 0662057A97 100k R82 0662057A81 22k
D1 4813830A15 Zener; 5.6V
R13 0662057A18 51 R83 0662057A97 100k
D3-D16 4805729G75 LED Green
R14 0662057A97 100k R100-R105 0662057A33 220
D17-D18 4805729G85 LED Green
R15 0662057A65 4.7k R106-R107 0662057A15 39
D19 4805729G82 LED Yellow
6881096C77-O September 26, 2003

PIN 14
PIN 1
P1 J1 PIN 1 PIN 14
WHT/BLUE WHT/BLUE
5 5
YELLOW/BLK YELLOW/BLK
14 14
YELLOW/RED YELLOW/RED
23 23 PIN 9
DRAIN DRAIN PIN 13 PIN 1
18 18
WHT/BLK PIN 25
17
NC NC
15 PIN 13 19
NC NC
19 1
NC PIN 25 NC
20 6 PIN 15
GRAY NC PIN 8
4 10
ORANGE GRAY J2
3 4
YELLOW/GRN NC ORANGE
12 2 5
NC ORANGE/BLUE YELLOW/GRN BLACK
10 12 4
DRAIN ORANGE/BLUE NC YELLOW
11 21 12
BLACK DRAIN GREEN
22 11 2
NC BLACK BROWN
21 22 6
GREEN RED
13 7
BROWN RED NC
25 24 14
RED NC
24 11
NC BROWN GRAY
6 25 8
NC NC
9 10
NC YELLOW NC
1 9
NC NC
2 1
NC ORANGE WHT/BLK
7 3
NC
8
YELLOW GREEN
8
WHT/BLK SOLDER WIRE

SECURELY CONNECTOR
IN POSITION METAL SHROUD
MAEPF-25562-O
Figure 8-4. HKN6096B Remote “Y” Cable Wiring Diagram
September 26, 2003 6881096C77-O

SWB+ NOTES:
P103
R71
SWB+ +5V 1. ALL RESISTANCE IS IN OHMS. ALL CAPACITANCE IN PICO-FARADS UNLESS NOTED OTHERWISE.
470
2. PART USAGE MAY VARY WITH APPLICATION. REFER TO PARTS LIST FOR USAGE INFORMATION.
CR71
C174 VIP_OUT_1
470pF R1* Q74
10K SWB+
VIPOUT1 R76 R79
18 470 470
JU12* Q71 SWB+

R74 CR72 VIP_OUT_2
Q75
SP1 100K
8 C175
470pF
VIPOUT2
19 JU4*
SWB+
KEY SLOT +5V SWB+ C82 R77
26 NC 0.1uF 470
CR73
JU13* JU9* Q72
SP2 R175
7 4.7K C176
470pF R80
100K
VIPOUT 3
14 R73
33K
Q73 VIP_OUT_3
A+
JU6*
+5V
R81 R99 +5V
10K 10K CR55
VIP IN 1
17
R84
VIP IN 2 10K
16 R98*
R87 100K
10K C48
6
3
39
VIP IN 3 0.1uF VIP_IN_1*
15
VIP_IN_2*
+5V
R174 VIP_IN_3*
A+/IGN
4.7K
+5V_REG
VR8 VR9 VR10
15V 15V 15V 43 2
JU18* WDT_T_CAP WDT_TICKLE
25 42
VIP_IN_1
+5V 22 41
VIP_IN_2
35 24
RESET VIP_IN_3 VIP_IN_1*
9 11
23 RESET BUSY_IN*
10 4
BUSY RESET*
16 29
R9* VR6 BUS_NEG IGN*
10K 15V 17 21
BUS_POS VIP_IN_2*
7 36
RESET_FILTR VIP_IN_3*
44 30
WDT_IN_T_CAP HUB_INV
BUSY 28 38 PTT
25 VR7 VR1 VR2 IGN PTT
J1 15V 15V 15V 32 20
HUB_POL RX_DATA
BUS- 14 13
10 5 C7 BUSY_OUT*
.01uF +5V 8 19
SW1 TX_DATA
BUS+ R7 40 37
22 JU20 PTT*
(NOTE 2) ROTARY +5V 27 U4 31
C6 SC74487F RES_HUB
SWB+ 26 12
4 1uF SERIAL I/O
J2 U45 33 18
R31
MC78M05 C1 15 23
SWB+ 47K
12 .01uF
GND
GND1
GND2
SWB+ 1 3 HUB_INV
4 IN OUT
1
5
34
C58 JU8* C41
GND
C45 VR3 470pF
C57 10uF .01uF
IGN 2 JU15* 15V
JU2* 470pF R34 RESET*
11 47K
A+ R25 SWB+
47K R10
1MEG
A+ BUSY_IN*
JU1*
+5V +5V
5
SWB+ RX_DATA
P104
VR5 R176 R177
GND 15V 4.7K 4.7K
VR4 TX_DATA
6 4
GND 15V
CR76 PTT
13 6
JU14* IGN*
HUB
3
MIC HI
8
MIC LO
7
BUSY_OUT*
MIC HI S.NET-WE
27 2
MIC LO VR20 S.NET-KEY

3 10
15V S.NET-KID
9
S.NET-WE VR21
21
15V VR22 5
S.NET-KEY 15V
9
1
S.NET-KID
20
STROBE
JU5
PTT
24
JU3
HUB
28
SP-1/VF-SENSE-1 SP-1_VF-SENSE-1
1
SP-2/VF-SENSE-2 SP-2_VF-SENSE-2
2
Figure 8-5. AAHN4045F/G (Standard), HLN4071A/B (Rear), PMLN4019C/D (Motorcycle) W4 Control Head Schematic (Sheet 1 of 2)
6881096C77-O September 26, 2003

1 P001 VR30
J10 10V
2 P001 VR27
J8 10V
SW2
ROTARY
P001 VR28
3 J7 10V
P001 VR29
5 J6 10V
P001
+5V +5V_FIL J9
SWB+ SWB+
L1 R90
9.107uH 10K
C46 C21 C2 R93 R91 NOTES: CR112 CR111

1uF 470pF R92 470pF
R28 10K 10K 10K BUSY XMIT
10K VR25 1. ALL RESISTANCE IS IN OHMS. ALL CAPACITANCE IN PICO-FARADS UNLESS NOTED OTHERWISE. R112 R111
(YELLOW) (RED)
22
10V 2. PART USAGE MAY VARY WITH APPLICATION. REFER TO PARTS LIST FOR USAGE INFORMATION. 100K 100K 31
3. U1 PINS 3,18,23,40 ARE NOT CONNECTED WITHMC68HC05C8AMICROPROCESSOR Q112 Q111 R
GND
C92 C93 C91 C90 2
470pF JU19 470pF 470pF 470pF
3 G8 1
C42 Q32
29 4 G7 2
.01uF NC4 Q31
28 5 G6 3
R116 R114 R115 R113 NC3 Q30
1K 33K 1K 33K 18 7 G5 4
NC2 Q29
+5V +5V 6 8 G4 5
NC1 Q28
9 G3 6
32 Q27
Y 10 G2 7
26 Q26
VDISP 11 G1 8
C51 R51 Q25
VIP_OUT_1 22K C52 CR51 12
VR50 Q24
10uF R200 13
36V Q23
VIP_OUT_2 +5V 22K 14
R52 Q22
VIP_OUT_3 15 R 31
10K Q21
16 Y 32
Q20
VIP_IN_1* +5V 17
C37 Q50 D T60 R101 Q19
VIP_IN_2* SWB+ 77J03 19
470pF 12 25 Q18
VIP_IN_3* R61 1 4 F1 20
Q17
U101
2 8 1K R50 25
L50 NC 560 Q16
UCQ5818EPF
U3A 1 2 5 26 PF 24
LM2903 9.107uH Q15
3 G 27 PA 23
4 9 Q14
PTT +5V 3 6 F2 30 PK 22
S Q13
HUB_INV VR26 31 PG 21
C15* C14* C44* C12* C11* C10* R55 Q12
10V 32 PN 20
C25* 12 C50 Q11
U1 +5V 33 PJ 19
R56 10uF CR140 Q10
VR24 MC68HC705C8A 33K R58 34 18
33K Q9 PD
10V 17
44
4
35 PE
Q8
WARNING! +5V 36 PM 15
Q7
VDD
RESET* 1 DO NOT PROBE U3 PIN 5 6 8 R59 43 37 14
RESET* 10K CR139 DATA_IN Q6 PH
2 PB0 13 WITH POWER APPLIED. U3B 7 38 PC 16
C16* IRQ* Q5
43 PB1 14 DAMAGE TO THE CIRCUIT 5 LM2903 24 39 13
OSC1 LTCH_ENBL Q4 PL
42 PB2 15 MAY OCCUR. 4 +5V 21 40 12
OSC2 STROBE Q3 PI
BUSY_IN* 41 PB3 16 +5V 23 41 PB 11
BUSY_IN CR138 CLK Q2
PB4 17 42 PO 10
R57 Q1
VCC1
VDISP
RX_DATA 32 BKLT 19 47K C54 R123

RX_DATA
1
R60
TX_DATA 33 20 470pF 10K 8
44
HUB
TX_DATA 1.5K 26
C19* 34 PTT 21 CR137 VDISP
C20 DATA_IN C24* 27
VCC
+5V_FIL 35 7 CLK
DATA_IN CLK 28
R29 36 VIP_IN_3 31 U2 STROBE
470pF 100K CLOCK 63A81 29
37 VIP_IN_2 30 3 1 6 LTCH_ENBL
WDT_TKL CS* DOUT 30
IGN* 39 VIP_IN_1 29 1 CR136 DATA_IN
IGN* Q76
VIP_OUT_3 28 5 +5V
C22 VREF
30pF VIP_OUT_2 27 2 C101*
C81 W+
12 VIP_OUT_1 26 3
C9* PA0 0.1uF
11 BUSY_IN 25 CR135
PA1 2
GND
C23 Y1 R30 10 24 +5V_FIL 9 G8 1

PA2 G8
4
30pF FREQ=4MHz 1MEG 9 10 2

PA3 G7 G7
8 STROBE 38 C30 11 G6 3
PA4 470pF C29 G6
7 +5V_FIL 3 CR134 12 G5 4
LTCH_ENBL 470pF R140 C141 G5
6 18 C35 R120 R121 R122 470pF 14 G4 5
HV_CNTRL 10K G4
BUSY_OUT* 5 23 470pF 100K 100K 100K 15 G3 6
BUSY_OUT G3
+5V_FIL 40 +5V 16 G2 7
G2
CR133 17 G1 8
C17 G1
470pF C18* U102
ROTARY R6 VF DISPLAY
C140
VSS
C34 ZU ZD MON 100 C43 32M01
470pF SWITCH 470pF
SWITCH SWITCH SWITCH J5 0.1uF 25 F2 9
22
CR132 F2
VR31 24 P0 10
PO
BUS3(32:1)
R7 J4 VOLUME 10V 23 PB 11
SW1 PB
C40 22 PI 12
470pF PI
C33 CALL DVP/EMER SEL J3 CR131 21 PL 13
470pF PL
SWITCH SWITCH SWITCH 20 PH 14
PH
R8 19 PM 15
VR32 100 PM
VR33 18 PC 16
10V 10V PC
C32 Q131 13 PE 17
470pF PE
SCAN DIR DIM 8 PD 18
PD
SWITCH SWITCH SWITCH 7 PJ 19
PJ
C38 6 PN 20
470pF PN
R131 5 PG 21
PG
C30 560 4 PK 22
470pF PK
C39 PHON H/L HOME 3 PA 23
470pF C28 PA
SWITCH SWITCH SWITCH 2 PF 24
470pF PF
1 F1 25
F1
+5V
JU17*
BKLT JU16
C36
470pF
SWB+ SWB+
DATA_IN 30
C55 C53
1000uF 1000uF
LTCH_ENBL 29
STROBE STROBE 28
CLOCK 27
R2
SP-1_VF-SENSE-1 4.7K G8 1
R5
SP-2_VF-SENSE-2 4.7K P0 10
Figure 8-6. AAHN4045F/G (Standard), HLN4071A/B (Rear), PMLN4019C/D (Motorcycle) W4 Control Head Schematic (Sheet 2 of 2)
September 26, 2003 6881096C77-O

SIDE 1
A A A A
R9
E E VR2 VR1 VR7 VR6 5 4
C18
C12
R200
CR73
E B
C9
C K C1
R98
C K
Q73
U3
C41
C40
C38
C20
C15
R58
Q71
K K
R57
R29
C19
R56
R60
C54
A 17 7
R51
K R73 B Q74 C52
C22
B 8 1
39 29 C83
VR32
R79
C C14
R71 B 18 6 39 29
C K R74 R76 R101 C16
Q75
R59
CR71
40 28 E A R84
R61
R5
R114
Q50
R116
R30
R52
R112
R77 A 40 28
C11
C10
Y1
R80 4
JU8 K A
VR9
R113
R115
E C B A C51
1 U4 Q112 A G D S
C23 R93 R121 E B 1 K K
VR50
C7
CR51
U1
R99
C101
VR26
1
C44
R92 Q72 2 T60 5 Q111 R122
C2 K U101
R176
C34 1
C43
R10 A
C CR90 A JU14
R34
C24 R28 A C176
C17 JU1 K
VR10
A C6 CR76
JU15
CR72 28 40 K
R2
K C37 C25 3 6 C53
6 18 L1 K R50 C48 R140 C45
R81
R25 29 39 K
JU18
JU3
R177
C42 6 18
CR55
C30
C39
A JU5 A
JU20
K 7 17 C46 R31 C55
C140 L50 A
A
JU16
C141
VR31 VR33
C92 C21 K 7
VR5
13
R55
1 17 A
C29
A A
VR30
VR8 14 13 12 11 10 9 8 7 6 5 4 3 2 1
R8 E P103 1 1 1 VR22 VR3 VR4
C35
K
C R131 A A R87 U45
K 15 16 17 18 19 20 21 22 23 24 25 27 28 U2 K
Q131
C28 C36 B 4 K K
P1 R6 K VR24
JU2
C90
K C80 JU4
VR25
JU17
R111
C50 VR29 C 7 8
JU9 C82 A 3
C32 C93 VR28 A K JU12 K Q76
JU6
C91 R91 R90 C57 A
JU13
R176
VR23
R174
R123
A K R1 C58 A
C33 JU19 C174 B E C57 VR20
R120 C175 VR21
VR27
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 K
K
A
SIDE 2
H/L OPT1 OPT2 OPT3 OPT4 SEL ZD ZU DIR MON
CR138
CR137
CR133
CR131
CR136
CR134
CR132
CR135
CR139
DIM
CR111
CR140
CR112
HOME U102
P104
5
1 3 7 9
6
2 4 8 1
Figure 8-7. AAHN4045 (Standard), HLN4071 (Rear), PMLN4019 (Motorcycle) W4 Control Head Component Location Diagram
6881096C77-O September 26, 2003

AAHN4045G Standard Parts List

ITEM PART DESCRIPTION ITEM PART DESCRIPTION ITEM PART DESCRIPTION
MOTOROLA NUMBER NUMBER NUMBER
ITEM PART DESCRIPTION
NUMBER C38 2113741M13 CAP CHIP CL2 X7R 10% 470 CR112 4880026P02 DIODE LED YELLOW JU6 NOTPLACED 64AM DUMMY PART NUMBER
C1 2113741N45 CAP CHIP CL2 X7R 10% 10000 C39 2113741M13 CAP CHIP CL2 X7R 10% 470 CR131 4880052R03 DIODE LIGHT EMITTING GRN JU8 NOTPLACED 64AM DUMMY PART NUMBER
C10 2113741M13 CAP CHIP CL2 X7R 10% 470 C40 2113741M13 CAP CHIP CL2 X7R 10% 470 CR132 4880052R03 DIODE LIGHT EMITTING GRN JU9 NOTPLACED 64AM DUMMY PART NUMBER
C101 2113740B65 CAP CHIP REEL CL1 +/-30 470 C41 2113741M13 CAP CHIP CL2 X7R 10% 470 CR133 4880052R03 DIODE LIGHT EMITTING GRN L1 2480140E16 INDUCTOR CHIP 10UH
C11 2113741M13 CAP CHIP CL2 X7R 10% 470 C42 2113741N45 CAP CHIP CL2 X7R 10% 10000 CR134 4880052R03 DIODE LIGHT EMITTING GRN L50 2480140E16 INDUCTOR CHIP 10UH
C12 2113741M13 CAP CHIP CL2 X7R 10% 470 C43 2113741N69 CAP CHIP CL2 X7R 10% CR135 4880052R03 DIODE LIGHT EMITTING GRN P001 0905573P02 SKT 13 POSTN
100000
C14 2113741M13 CAP CHIP CL2 X7R 10% 470 CR136 4880052R03 DIODE LIGHT EMITTING GRN P103 2880102M07 PLUG VERTICAL 28 POSITION
C44 2113741M13 CAP CHIP CL2 X7R 10% 470
C140 2113741M13 CAP CHIP CL2 X7R 10% 470 CR137 4880052R03 DIODE LIGHT EMITTING GRN P104 2880068M01 HEADER MIC
C45 2380090M24 CAP ALU 10 20 50V SURF MT
C141 2113741M13 CAP CHIP CL2 X7R 10% 470 CR138 4880052R03 DIODE LIGHT EMITTING GRN Q111 4813824A10 TSTR NPN 40V .2A GEN PURP
C46 2311049A37 CAP TANT CHIP 1 20 20
C48 2113741N69 CAP CHIP CL2 X7R 10%
C16 2113741M13 CAP CHIP CL2 X7R 10% 470 100000 CR140 4880052R03 DIODE LIGHT EMITTING GRN Q131 4813824A10 TSTR NPN 40V .2A GEN PURP
C17 2113741M13 CAP CHIP CL2 X7R 10% 470 C50 2311049A95 CAP TANT CHIP 10 UF 25V CR51 4813833C09 DIODE GEN PURP .1A 100V Q50 4880053M03 TSTR N/CH SOT 89 200V B ST
10% ‘DX’ 84
C174 2113741M13 CAP CHIP CL2 X7R 10% 470
C51 2113741N21 CAP CHIP CL2 X7R 10% 1000 CR55 4813833C09 DIODE GEN PURP .1A 100V Q71 4880053M02 TSTR NPN MXT2222A
C175 2113741M13 CAP CHIP CL2 X7R 10% 470 ‘DX’
C52 2380090M24 CAP ALU 10 20 50V SURF MT Q72 4880053M02 TSTR NPN MXT2222A
C176 2113741M13 CAP CHIP CL2 X7R 10% 470 CR71 4813833C09 DIODE GEN PURP .1A 100V
C53 2113741N21 CAP CHIP CL2 X7R 10% 1000 ‘DX’ Q73 4880053M02 TSTR NPN MXT2222A
C18 2113741M13 CAP CHIP CL2 X7R 10% 470
C54 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR72 4813833C09 DIODE GEN PURP .1A 100V Q74 4813824A10 TSTR NPN 40V .2A GEN PURP
C19 2113741M13 CAP CHIP CL2 X7R 10% 470
‘DX’
C55 2113741N21 CAP CHIP CL2 X7R 10% 1000 Q75 4813824A10 TSTR NPN 40V .2A GEN PURP
C2 2113741M13 CAP CHIP CL2 X7R 10% 470
CR73 4813833C09 DIODE GEN PURP .1A 100V
C57 2113741M13 CAP CHIP CL2 X7R 10% 470 Q76 4880048M01 TSTR NPN DIG 47K/47K
C58 2113741N45 CAP CHIP CL2 X7R 10% 10000 R1 NOTPLACED 64AM DUMMY PART NUMBER
C21 2113741M13 CAP CHIP CL2 X7R 10% 470 CR90 4882960R02 DIODE RECT 48R82960R01 A/P
C6 2311049A37 CAP TANT CHIP 1 20 20 R10 0611077B47 RES CHIP 1 MEG 5 1/8W
C22 2113740B36 CAP CHIP REEL CL1 +/-30 30 JU1 NOTPLACED 64AM DUMMY PART NUMBER
C7 2113741N45 CAP CHIP CL2 X7R 10% 10000 R101 0611077A28 RES CHIP 12 5 1/8W
C80 NOTPLACED 64AM DUMMY PART NUMBER R111 0611077B23 RES CHIP 100K 5 1/8W
C24 2113741M13 CAP CHIP CL2 X7R 10% 470 JU13 NOTPLACED 64AM DUMMY PART NUMBER
C81 2113743A19 CAP CHIP .100 UF 10% X7R R112 0611077B23 RES CHIP 100K 5 1/8W
C29 2113741M13 CAP CHIP CL2 X7R 10% 470 JU16 0611077A01 RES CHIP JUMPER
C9 2113741M13 CAP CHIP CL2 X7R 10% 470 R115 0611077A74 RES CHIP 1000 5 1/8
C91 2113741M13 CAP CHIP CL2 X7R 10% 470 R120 0611077B23 RES CHIP 100K 5 1/8W
CR0076 4813833C09 DIODE GEN PURP .1A 100V R123 0611077A98 RES CHIP 10K 5 1/8W
‘DX’
R131 0611077A68 RES CHIP 560 5 1/8W
CR111 4880026P01 DIODE LED RED
R140 0611077A98 RES CHIP 10K 5 1/8W
JU5 0611077A01 RES CHIP JUMPER
September 26, 2003 6881096C77-O


R174 0611077A90 RES CHIP 4700 5 1/8 R84 0611077A98 RES CHIP 10K 5 1/8W VR27 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
R175 0611077A90 RES CHIP 4700 5 1/8 R87 0611077A98 RES CHIP 10K 5 1/8W
VR28 4813830A23 DIODE 10V 5% 225MW
R176 0611077A90 RES CHIP 4700 5 1/8 R9 NOTPLACED 64AM DUMMY PART NUMBER MMBZ5240B_
MMBZ5240B_
VR3 4813830A28 DIODE 15V 5% 225MW
R200 0611077B07 RES CHIP 22K 5 1/8W R92 0611077A98 RES CHIP 10K 5 1/8W
MMBZ5245B_
VR30 4813830A23 DIODE 10V 5% 225MW
R28 0611077A98 RES CHIP 10K 5 1/8W R98 NOTPLACED 64AM DUMMY PART NUMBER MMBZ5240B_
R29 0611077B23 RES CHIP 100K 5 1/8W R99 0611077A98 RES CHIP 10K 5 1/8W VR31 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
R30 0611077B47 RES CHIP 1 MEG 5 1/8W T60 2580277J03 XFMR VLTG CONVERSION
VR32 4813830A23 DIODE 10V 5% 225MW
R31 0611077B15 RES CHIP 47K 5 1/8W U1 0104002J91 PRGMD MICROP ASSEM MMBZ5240B_
R34 0611077B15 RES CHIP 47K 5 1/8W U101 5180236C05 IC VF DRVR SN75518FN VR33 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
R5 0611077A90 RES CHIP 4700 5 1/8 U102 7280032M01 DSPLY VF 14 SEG 8 CHAR
BLUGRN VR4 4813830A28 DIODE 15V 5% 225MW
R50 0611077A68 RES CHIP 560 5 1/8W MMBZ5245B_
U2 5185963A81 MODE 8-BIT SER I/O
R51 0611077B07 RES CHIP 22K 5 1/8W TLCO831DR VR5 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R52 0611077A98 RES CHIP 10K 5 1/8W U3 5113820A02 IC DUAL SING SPLY LO PWR
2903 VR50 4813830C41 DIODE 36V ‘M3’ MMSZ5258BT1
R55 0611077A28 RES CHIP 12 5 1/8W
U4 5180057S04 “IC CUST SER I/O 13”” REEL” VR6 4813830A28 DIODE 15V 5% 225MW
R56 0611077B11 RES CHIP 33K 5 1/8W MMBZ5245B_
U45 5113816G04 IC +5V REG 78M05
R57 0611077B15 RES CHIP 47K 5 1/8W VR7 4813830A28 DIODE 15V 5% 225MW
VR1 4813830A28 DIODE 15V 5% 225MW MMBZ5245B_
R58 0611077B11 RES CHIP 33K 5 1/8W
MMBZ5245B_
VR8 4813830A28 DIODE 15V 5% 225MW
R59 0611077A98 RES CHIP 10K 5 1/8W
VR9 4813830A28 DIODE 15V 5% 225MW
R60 0611077A78 RES CHIP 1500 5 1/8 VR2 4813830A28 DIODE 15V 5% 225MW MMBZ5245B_
MMBZ5245B_
R61 0611077A74 RES CHIP 1000 5 1/8 Y1 4880065M01 RESONTR CERAMIC 4.00 MHZ
VR20 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R74 0611077B23 RES CHIP 100K 5 1/8W
VR22 4813830A28 DIODE 15V 5% 225MW
R77 0611077A66 RES CHIP 470 5 1/8W VR23 NOTPLACED 64AM DUMMY PART NUMBER
R79 0611077A66 RES CHIP 470 5 1/8W VR24 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
R8 0611077A50 RES CHIP 100 5 1/8W
VR25 4813830A23 DIODE 10V 5% 225MW
R81 0611077A98 RES CHIP 10K 5 1/8W VR26 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
6881096C77-O September 26, 2003

HCN4071B Rear Parts List

NUMBER C38 2113741M13 CAP CHIP CL2 X7R 10% 470 CR112 4880026P02 DIODE LED YELLOW JU6 NOTPLACED 64AM DUMMY PART NUMBER
100000
C44 2113741M13 CAP CHIP CL2 X7R 10% 470
C46 2311049A37 CAP TANT CHIP 1 20 20
C48 2113741N69 CAP CHIP CL2 X7R 10%
10% ‘DX’ 84
C174 2113741M13 CAP CHIP CL2 X7R 10% 470
C52 2380090M24 CAP ALU 10 20 50V SURF MT Q72 4880053M02 TSTR NPN MXT2222A
C18 2113741M13 CAP CHIP CL2 X7R 10% 470
C54 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR72 4813833C09 DIODE GEN PURP .1A 100V Q74 4813824A10 TSTR NPN 40V .2A GEN PURP
C19 2113741M13 CAP CHIP CL2 X7R 10% 470
‘DX’
C55 2113741N21 CAP CHIP CL2 X7R 10% 1000 Q75 4813824A10 TSTR NPN 40V .2A GEN PURP
C2 2113741M13 CAP CHIP CL2 X7R 10% 470
CR73 4813833C09 DIODE GEN PURP .1A 100V
C21 2113741M13 CAP CHIP CL2 X7R 10% 470 CR90 4882960R02 DIODE RECT 48R82960R01 A/P
C22 2113740B36 CAP CHIP REEL CL1 +/-30 30 JU1 0611077A01 RES CHIP JUMPER
CR0076 4813833C09 DIODE GEN PURP .1A 100V R123 0611077A98 RES CHIP 10K 5 1/8W
‘DX’
R131 0611077A68 RES CHIP 560 5 1/8W
R140 0611077A98 RES CHIP 10K 5 1/8W
September 26, 2003 6881096C77-O


MMBZ5240B_
VR28 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
VR3 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR30 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
VR32 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
MMBZ5245B_
R55 0611077A28 RES CHIP 12 5 1/8W
U45 5113816G04 IC +5V REG 78M05
R58 0611077B11 RES CHIP 33K 5 1/8W
MMBZ5245B_
VR8 4813830A28 DIODE 15V 5% 225MW
R59 0611077A98 RES CHIP 10K 5 1/8W
VR9 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR20 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R74 0611077B23 RES CHIP 100K 5 1/8W
VR22 4813830A28 DIODE 15V 5% 225MW
MMBZ5240B_
R8 0611077A50 RES CHIP 100 5 1/8W
VR25 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
6881096C77-O September 26, 2003

PMLN4019D Motorcycle Parts List

NUMBER C38 2113741M13 CAP CHIP CL2 X7R 10% 470 CR112 4880026P02 DIODE LED YELLOW JU6 0611077A01 RES CHIP JUMPER
100000
C44 2113741M13 CAP CHIP CL2 X7R 10% 470
C46 2311049A37 CAP TANT CHIP 1 20 20
C48 2113741N69 CAP CHIP CL2 X7R 10%
10% ‘DX’ 84
C174 2113741M13 CAP CHIP CL2 X7R 10% 470
C52 2380090M24 CAP ALU 10 20 50V SURF MT Q72 NOTPLACED 64AM DUMMY PART NUMBER
C18 2113741M13 CAP CHIP CL2 X7R 10% 470
C54 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR72 NOTPLACED 64AM DUMMY PART NUMBER Q74 4813824A10 TSTR NPN 40V .2A GEN PURP
C19 2113741M13 CAP CHIP CL2 X7R 10% 470
C55 2113741N21 CAP CHIP CL2 X7R 10% 1000 CR73 4813833C09 DIODE GEN PURP .1A 100V Q75 4813824A10 TSTR NPN 40V .2A GEN PURP
C2 2113741M13 CAP CHIP CL2 X7R 10% 470
‘DX’
C20 2113741M13 CAP CHIP CL2 X7R 10% 470
CR90 4882960R02 DIODE RECT 48R82960R01 A/P
C21 2113741M13 CAP CHIP CL2 X7R 10% 470
C22 2113740B36 CAP CHIP REEL CL1 +/-30 30
JU12 NOTPLACED 64AM DUMMY PART NUMBER
C24 2113741M13 CAP CHIP CL2 X7R 10% 470
C25 2113741M13 CAP CHIP CL2 X7R 10% 470
C82 2113741N69 CAP CHIP CL2 X7R 10% R113 0611077B11 RES CHIP 33K 5 1/8W
C28 2113741M13 CAP CHIP CL2 X7R 10% 470
100000 JU16 NOTPLACED 64AM DUMMY PART NUMBER
R114 0611077B11 RES CHIP 33K 5 1/8W
C29 2113741M13 CAP CHIP CL2 X7R 10% 470
C83 2113743A19 CAP CHIP .100 UF 10% X7R JU17 0611077A01 RES CHIP JUMPER
R115 0611077A74 RES CHIP 1000 5 1/8
C30 2113741M13 CAP CHIP CL2 X7R 10% 470
R116 0611077A74 RES CHIP 1000 5 1/8
C32 2113741M13 CAP CHIP CL2 X7R 10% 470
R120 0611077B23 RES CHIP 100K 5 1/8W
C33 2113741M13 CAP CHIP CL2 X7R 10% 470
R121 0611077B23 RES CHIP 100K 5 1/8W
C34 2113741M13 CAP CHIP CL2 X7R 10% 470
R122 0611077B23 RES CHIP 100K 5 1/8W
C35 2113741M13 CAP CHIP CL2 X7R 10% 470
R123 0611077A98 RES CHIP 10K 5 1/8W
C36 2113741M13 CAP CHIP CL2 X7R 10% 470
CR0076 4813833C09 DIODE GEN PURP .1A 100V JU4 NOTPLACED 64AM DUMMY PART NUMBER
R131 0611077A68 RES CHIP 560 5 1/8W
R140 0611077A98 RES CHIP 10K 5 1/8W
September 26, 2003 6881096C77-O


MMBZ5240B_
VR28 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
VR3 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR30 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
VR32 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
MMBZ5245B_
R55 0611077A28 RES CHIP 12 5 1/8W
U45 5113816G04 IC +5V REG 78M05
R58 0611077B11 RES CHIP 33K 5 1/8W
MMBZ5245B_
VR8 4813830A28 DIODE 15V 5% 225MW
R59 0611077A98 RES CHIP 10K 5 1/8W
VR9 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR20 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R74 0611077B23 RES CHIP 100K 5 1/8W
VR22 4813830A28 DIODE 15V 5% 225MW
MMBZ5240B_
R8 0611077A50 RES CHIP 100 5 1/8W
VR25 4813830A23 DIODE 10V 5% 225MW
R81 NOTPLACED 64AM DUMMY PART NUMBER VR26 4813830A23 DIODE 10V 5% 225MW
MMBZ5240B_
6881096C77-O September 26, 2003

SWB+ NOTES:
P103 R71
SWB+ +5V 1. ALL RESISTANCE IS IN OHMS. ALL CAPACITANCE IN PICO-FARADS UNLESS NOTED OTHERWISE.
470
2. PART USAGE MAY VARY WITH APPLICATION. REFER TO PARTS LIST FOR USAGE INFORMATION.
CR71
C174 VIP_OUT_1
470pF R1* Q74
10K SWB+
VIPOUT1 R76 R72
18 470 470
JU12* Q71 SWB+

R74 CR72 VIP_OUT_2
Q75
33K
8 C8
C175 A+_IGN .01uF A+
470pF VR11
R3 R4 36V
VIPOUT2
19 JU4* 22K 1MEG D
SWB+
KEY SLOT SWB+ R77
26 NC 470 C5
CR73 CR52 CR53 CR54 SWB+ A+_IGN
JU13* JU9* Q72 0.1uF Q51
C3 C4 G
7 C176 .01uF .01uF
470pF R75 JU7*
33K S
VIPOUT 3
14 R73
33K
Q73 VIP_OUT_3
JU6*
+5V
R81 R99 +5V
10K 10K
VIP IN 1
17
R84
VIP IN 2 10K +5V +5V
16 R98*
R87 100K
10K
6
3
39
VIP IN 3 VIP_IN_1*
15
R174 VIP_IN_2*
+5V
R175 4.7K VIP_IN_3*
A+/IGN
4.7K
+5V_REG
VR8 VR9 VR10
15V 15V 15V 43 2
JU18* WDT_T_CAP WDT_TICKLE
25 42
VIP_IN_1 OSC_OUT
22 41 EXT_OSC_IN
VIP_IN_2 EXT_OSC_IN
35 24
RESET VIP_IN_3 VIP_IN_1*
9 11
23 RESET BUSY_IN*
10 4
BUSY RESET*
16 29
R9 VR6 BUS_NEG IGN*
10K 15V 17 21
BUS_POS VIP_IN_2*
7 36
R25 RESET_FILTR VIP_IN_3*
44 30
47K WDT_IN_T_CAP HUB_INV
BUSY 28 38 PTT
25 IGN PTT
32 20
HUB_POL RX_DATA
BUS- 14 13
10 C7 BUSY_OUT*
.01uF +5V 8 19
TX_DATA
BUS+ 40 37
22 VR7 VR1 VR2 PTT*
+5V 15V 15V 15V 27 U4 31
VR5 RES_HUB
SWB+ 15V C6 26 SC74487F 12
1.5uF SERIAL I/O
U45 33 18
R31
MC78M05 C1 15 23
SWB+ A+ 47K
12 .01uF
GND
GND1
GND2
SWB+ 1 3 HUB_INV
4 IN OUT
1
5
34
A+_IGN C58 JU8* C41
GND
C45 CR55 VR3 470pF
C57 10uF .01uF
IGN 2 JU15* 15V
JU2 470pF R34 RESET*
11 C48 47K
R6 0.1uF
PWR 10K C56
SWITCH 470pF
A+ SWB+
R200*
R7 1MEG
A+ 10K
BUSY_IN*
JU1*
Q52 +5V +5V
5
CR90 C47 SWB+ RX_DATA

P104
0.1uF C43
0.1uF R8 R176 R177
GND 1K 4.7K 4.7K
VR4 TX_DATA
6 4
GND 15V
CR76 PTT
13 6
JU14* IGN*
HUB
3
MIC HI
8
MIC LO
7
BUSY_OUT*
MIC HI S.NET-WE
27 2
MIC LO VR20 S.NET-KEY

3 10
15V S.NET-KID
9
S.NET-WE VR21
21
15V VR22 5
S.NET-KEY 15V
9
1
S.NET-KID
20
STROBE
JU5
PTT
24
JU3
HUB
28
SP-1_VF-SENSE-1 SP-1_VF-SENSE-1
1
SP-2_VF-SENSE-2 SP-2_VF-SENSE-2
2
Figure 8-8. HLN6396F/G/H (Standard), HLN6814A/B/C (Rear), HLN6563B/C/D (Motorcycle) W5/W7 Control Head Schematic (Sheet 1 of 2)
September 26, 2003 6881096C77-O

+5V_FIL SWB+ SWB+

+5V
L1
9.107uH CR112 CR111
BUSY R112 XMIT
C46 C21 C2 (YELLOW) (RED) R111
22
100K 100K
1uF 470pF 470pF 31
R28 NOTES: Q112 Q111 R
GND
1K 2
1. ALL RESISTANCE IS IN OHMS. ALL CAPACITANCE IN PICO-FARADS UNLESS NOTED OTHERWISE. UCQ5818EPF 3 1
G8
2. PART USAGE MAY VARY WITH APPLICATION. REFER TO PARTS LIST FOR USAGE INFORMATION. Q32
29 4 G7 2
3.U1 PINS 3,18,23,40 ARE NOT CONNECTED WITH MC68HC05C8A MICROPROCESSOR. NC4 Q31
R178 R116 R114 R115 R113 28 5 G6 3
NC3 Q30
C42* 10K 1K 33K 1K 33K 18 7 G5 4
SHORT TO GND. FOR NC2 Q29
+5V +5V 6 8 G4 5
DIAGNOSTIC TEST JU19 NC1 Q28
9 G3 6
32 Q27
VR50 Y 10 G2 7
26 Q26
C51 R51 VDISP 11 G1 8
Q25
VIP_OUT_1 .01uF 22K C52 CR51 12
36V R180 Q24
10uF R181 13
12 Q23
VIP_OUT_2 +5V 22K U101 14
R52 Q22
VIP_OUT_3 15 R 31
10K Q21
16 Y 32
VIP_IN_1* Q20
+5V 17
Q50 D T60 R101 Q19
VIP_IN_2* C37 SWB+ 77J03 19
12 25 Q18
470pF R61 1 4 F1 20
Q17
VIP_IN_3* 2 8 6.8K R50 25
C13 Q16
U3-1 1 L50 NC 2 5 560 26 PF 24
0.1uF
LM2903 9.107uH Q15
EXT_OSC_IN 3 G 27 PA 23
4 9 Q14
PTT +5V 3 6 F2 30 PK 22
S Q13
HUB_INV 31 PG 21
C15* C14* C44* C12* C11* C10* R55 Q12
32 PN 20
12 Q11
U1 +5V 33 PJ 19
VR24 C25* C24* R56 R182 CR140 Q10
MC68HC705C8A 33K R58 12 34 PD 18
10V 33K Q9
44
4
35 PE 17
Q8
WARNING! +5V 36 PM 15
R59 Q7
VDD
RESET* 1 DO NOT PROBE U3 PIN 5 6 8 CR139 43 37 PH 14
RESET* 10K DATA_IN Q6
C16* 2 13 WITH POWER APPLIED. U3-2 7 38 PC 16
IRQ* PB0 C50 Q5
43 14 DAMAGE TO THE CIRCUIT 5 LM2903 24 39 PL 13
OSC1 PB1 4 10uF LTCH_ENBL Q4
42 15 MAY OCCUR. 21 40 PI 12
OSC2 PB2 STROBE Q3
BUSY_IN* 41 BUSY_IN* 16 CR138 23 41 PB 11
PB3 CLK Q2
17 R57 42 PO 10
PB4 Q1
VCC1
VDISP
RX_DATA 32 19 47K C54

RX_DATA BKLT
1
TX_DATA 470pF R60

44
33 20
TX_DATA INV_HUB 1.5K
C19* C20 34 21 CR137 VDISP 26
DATA_IN PTT
+5V_FIL 35 +5V CLK 27
DATA_IN
R29 36 31 STROBE28
100K CLOCK VIP_IN_3
470pF 37 30 LTCH_ENBL 29
WDT_TKL VIP_IN_2
IGN* 39 29 CR136 DATA_IN 30
IGN* VIP_IN_1 C35
28 470pF R120 R121 R122 R123 R124 +5V
C22 VIP_OUT_3
30pF 27 100K 100K 100K 100K 100K C101*
VIP_OUT_2
12 26 SHORT TO DISABLE
C9* PA0 VIP_OUT_1
11 25 KEYPAD BACKLIGHT
PA1 BUSY_IN CR135
1
1
1
1
1
C23 R30 10 24 +5V_FIL 9 G8 1
Y1 PA2 C34 S1 S2 S3 S4 S5 G8
30pF 1MEG 9 470pF 10 G7 2
PA3 SWITCH SWITCH SWITCH SWITCH SWITCH G7
FREQ=4MHz 8 38 C30 11 G6 3
PA4 STROBE G6
2
2
2
2
2
7 3 470pF CR134 12 G5 4
LTCH_ENBL +5V_FIL G5
6 18 14 G4 5
HV_CNTRL G4
1
1
2
2
1
BUSY_OUT* 5 23 15 G3 6
BUSY_OUT* C33 G3
40 470pF SWITCH SWITCH SEL S7 16 G2 7
IGN* OPT4 MU SWITCH SWITCH G2
SWITCH S6 CR133 17 G1 8
G1
2
2
1
1
2
C29 JU100*
C18*
C17 470pF VF DISPLAY
VSS
2
2
2
1
1
470pF C40 C32 U102
470pF S8 S9 32M01 25 F2
22
470pF OPT3 MD DIM CR132 9
SWITCH SWITCH F2
SWITCH SWITCH SWITCH 24 P0 10
C38 PO
BUS3(32:1)
1
1
1
2
2
23 PB 11
PB
22 PI 12
470pF PI
2
1
2
1
CR131 21 PL 13
C31 PL
470pF OPT2 SWITCH HOME S0 20 PH 14
VU SWITCH PH
SWITCH SWITCH 19 PM 15
PM
1
2
1
2
18 PC 16
PC
Q131 13 PE 17
PE
1
1
1
2
+5V 8 PD 18
PND PD
7 PJ 19
SWITCH SWITCH SWITCH SWITCH PJ
C28 OPT1 VD STAR 6 PN 20
C27 PN
2
2
2
1
470pF JU17* R131 5 PG 21

470pF PG
C26 560 4 PK 22
C39 BKLT JU16 PK
470pF 3 PA 23
PA
2 PF 24
470pF PF
C36 1 F1 25
F1
SWB+ SWB+ 470pF
C55 DATA_IN 30
C53
1000uF LTCH_ENBL 29
1000uF
STROBE STROBE 28
CLOCK 27
R2
SP-1_VF-SENSE-1 4.7K G8 1
R5
SP-2_VF-SENSE-2 4.7K
P0 10
Figure 8-9. HLN6396F/G/H (Standard),HLN6814A/B/C (Rear), HLN6563B/C/D (Motorcycle) W5/W7 Control Head Schematic (Sheet 2 of 2)
6881096C77-O September 26, 2003

R77
JU100 R29 CR73 17 7 VR10 VR1 39 29
R75 VR2
R99
CR53
R73
C1
C8
Q73
Q75
40
CR52
18 6 28
C9
C41
C40
C38
C20
C19
C15
C44
C3
R72
R81 C101
Q72
R30
C50
Y1
C5
R3
CR72
39 29
C14
C12 VR7 C4
CR54
C52
Q71
U4 1 R181 1 U101
C23
CR71
40 28 R74 C176
C7
C11
JU15
R7 R180
C18
R182
Q74
C10
C22 6 3 JU18
Q52
C6
R200
28 40 6 18
C46
1 R76
C2 U1 R178 C47
C56
R71 29 39 C45 7 17
C16 C42 5 T60 2 C43 VR6
L1 JU8
CR55
JU19 C48 VR21
1
R8
R28 6 18 R55
R98
R4
C24
C58
VR5
R25
4 14 13 12 11 10 9 8 7 6 5 4 3 2 1
7 17 R50 VR4
C57
VR11
R34
C36 C25
C21
VR9 15 16 17 18 19 20 21 22 23 24 25 26 27 28
C37 L50
R175
C175 Q51
U45
R122
R124
R121
R120
R9 C53
C39
C35
C34
C33
C32
C31
C30
C29
C28
C27
C26
C17 R176
R1
R87
Q131
JU6
JU12
VR8
R174
JU13
C174
JU17
R131
JU16
C39R
R2 R177 VR3
CR90
JU7
JU1
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
R31
R123
JU2
Figure 8-10. HLN6396F/G (Standard), HLN6814A/B (Rear), HLN6563B/C (Motorcycle) W5/W7 Control Head Component Location Diagram (Viewed from Side 1)
MD MU OPT1 OPT2 OPT3 OPT4 SEL
CR138
1 2 3
CR135
CR137
CR136
CR139
PWR
CR133
CR134
CR111
4 5 6
VD VU R57 C13 R112
CR140
R58
C54 R115
R111
R113
U3 R114
Q112
R51
CR112
R59
R61
R60
C51
Q111
R116
R56
JU4
JU9 R52
R6
7 8 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14
DIM
Q50
P104 28 27 26 25 24 23 22 21 20 19 18 17 16 15 CR51
VR50
CR132
CR131
5
CR76
1 3 7 9 JU5
VR20 VR22
JU3
C55
R101
JU14 R5
0 #
6 HOME
2 4 8 10 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
*
Figure 8-11. HLN6396F/G (Standard), HLN6814A/B (Rear), HLN6563B/C (Motorcycle) W5/W7 Control Head Component Location Diagram (Viewed from Side 2)
September 26, 2003 6881096C77-O

8480251R07
VR10 CR53
CR52
CR73 R77 C1
C8
Q73 17 7 39 29
Q75
18 6 40 28
C9*
C41
C40
C20
C38
C19*
C15*
C14*
C44*
R29
R73 R99 R81 JU18* R177 C3
R30
R72 Q72
R75
Y1 C12* R74
R3
C5
C4
CR71 CR72 C46 C101*

Q71 C50
R31
39 29 C11*
U4 1 C7 R181 1 U101 CR54
C23
40 28
C18*
R76
C10* Q74
C52
JU15*
C6 R180
C22
JU19
R182
6 3 R7
R200*
Q52
R71
28 40 6 18
R178
C16*
1 U1 L1
29 39 7 17
C42* C56 C45
C24* T60 C176 R2
5 2
C58
R176
R28 C48
JU13*
VR24
C43 VR1
R98*
C25* JU8* C53
VR8
VR11
1
C2 6 18 CR55
7 17 JU16
R50 R34
R4
C17 4 14
R8
VR5
Q131
VR3 VR4
C57
P103
R87
C36
C37 R25 15 28 3 Q51 VR22
1
JU100*
JU17*
C174 U45
R131
L50
R84
R121
VR9 VR2 VR6
R120
R122
R124
R175
C39
C21
C35
C34
C33
C32
C31
C30
C29
C28
C27
C26
CR90
VR20
R9
R1*
JU6*
VR21
R174
JU12*
R55 C175 2
R123
JU2
C47
JU7*
JU1*
Figure 8-12. HLN6396H_HLN6814C_HLN6563C W5/W7 Control Head Component Location Diagram (Viewed from Side 1)
MD MU OPT1 OPT2 OPT3 OPT4 SEL S1 S2 S3
CR139 CR138 CR137 CR136 CR135

PWR
CR134 CR133
S4 S5 S6
VD VU CR111
R58 R112
R57 5 4
C13
R115
R111
CR140
R113
U3 R114
R61
C51
R51
Q112
8 1
R5
R56
C54
R60
R59
R116
C55 R6 Q111 CR112
R52 VR50 S7 S8 S9
U102
DIM CR51
Q50
JU3
CR131 CR132
5 JU14* JU9*
JU5 JU4*
3 P104 7 9 CR76 VR7
6 R101 STAR S0 PND
HOME
2 4 8 10
25
Figure 8-13. HLN6396H_HLN6814C_HLN6563C W5/W7 Control Head Component Location Diagram (Viewed from Side 2)
6881096C77-O September 26, 2003

HLN6396H Standard Parts List

NUMBER C33 2113741M13 CAP CHIP CL2 X7R 10% 470 CR131 4880052R03 DIODE LIGHT EMITTING GRN JU4 NOTPLACED 64AM DUMMY PART NUMBER
C10 NOTPLACED 64AM DUMMY PART NUMBER C37 2113741M13 CAP CHIP CL2 X7R 10% 470 CR135 4880052R03 DIODE LIGHT EMITTING GRN JU9 NOTPLACED 64AM DUMMY PART NUMBER
C101 NOTPLACED 64AM DUMMY PART NUMBER C38 2113741M13 CAP CHIP CL2 X7R 10% 470 CR136 4880052R03 DIODE LIGHT EMITTING GRN L1 2480140E16 INDUCTOR CHIP 10UH
C12 NOTPLACED 64AM DUMMY PART NUMBER C4 2113741N45 CAP CHIP CL2 X7R 10% 10000 CR138 4880052R03 DIODE LIGHT EMITTING GRN MP0103 4380290L01 SPACER LED
C13 2113741N69 CAP CHIP CL2 X7R 10% C40 2113741M13 CAP CHIP CL2 X7R 10% 470 CR139 4880052R03 DIODE LIGHT EMITTING GRN MP0106 5480004N01 LABEL BARCODE
100000
C14 NOTPLACED 64AM DUMMY PART NUMBER
C42 NOTPLACED 64AM DUMMY PART NUMBER CR51 4811058B11 DIODE 48S11058A11 A/P P0104 2880068M01 HEADER MIC
C43 2113741N69 CAP CHIP CL2 X7R 10% CR52 4811058B11 DIODE 48S11058A11 A/P Q111 4880141L02 TSTR NPN SOT23 LO PROFILE
C16 NOTPLACED 64AM DUMMY PART NUMBER 100000 TAPE
CR53 4811058B11 DIODE 48S11058A11 A/P
C17 2113741M13 CAP CHIP CL2 X7R 10% 470 C44 NOTPLACED 64AM DUMMY PART NUMBER Q112 4880141L02 TSTR NPN SOT23 LO PROFILE
CR54 4811058B11 DIODE 48S11058A11 A/P TAPE
C174 2113741M13 CAP CHIP CL2 X7R 10% 470 C45 2380090M24 CAP ALU 10 20 50V SURF MT
CR55 4811058B11 DIODE 48S11058A11 A/P Q131 4880141L02 TSTR NPN SOT23 LO PROFILE
C175 2113741M13 CAP CHIP CL2 X7R 10% 470 C46 2311049A37 CAP TANT CHIP 1 20 20 TAPE
CR71 4811058B11 DIODE 48S11058A11 A/P
C176 2113741M13 CAP CHIP CL2 X7R 10% 470 C47 2113741N69 CAP CHIP CL2 X7R 10% Q50 4880053M03 TSTR N/CH SOT 89 200V B ST
100000 CR72 4811058B11 DIODE 48S11058A11 A/P
84
C48 2113741N69 CAP CHIP CL2 X7R 10% CR73 4811058B11 DIODE 48S11058A11 A/P
Q51 4813821A30 MOSFET N-CH 60V 15A
C19 NOTPLACED 64AM DUMMY PART NUMBER 100000
CR76 4811058B11 DIODE 48S11058A11 A/P
Q52 4880141L01 TSTR PNP SOT23 LO PROFILE
C2 2113741M13 CAP CHIP CL2 X7R 10% 470 C5 2113741N69 CAP CHIP CL2 X7R 10%
CR90 4882960R02 DIODE RECT 48R82960R01 A/P TAPE
100000
C20 2113741M13 CAP CHIP CL2 X7R 10% 470
JU0003 0611077A01 RES CHIP JUMPER Q71 4880053M02 TSTR NPN MXT2222A
C50 2311049A95 CAP TANT CHIP 10 UF 25V
C21 2113741M13 CAP CHIP CL2 X7R 10% 470
10% JU0005 0611077A01 RES CHIP JUMPER Q72 4880053M02 TSTR NPN MXT2222A
C51 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU0016 0611077A01 RES CHIP JUMPER Q73 4880053M02 TSTR NPN MXT2222A
C52 2380090M24 CAP ALU 10 20 50V SURF MT JU0017 NOTPLACED 64AM DUMMY PART NUMBER Q74 4880141L02 TSTR NPN SOT23 LO PROFILE
C24 NOTPLACED 64AM DUMMY PART NUMBER TAPE
C25 NOTPLACED 64AM DUMMY PART NUMBER Q75 4880141L02 TSTR NPN SOT23 LO PROFILE
C56 2113741M13 CAP CHIP CL2 X7R 10% 470 JU100 NOTPLACED 64AM DUMMY PART NUMBER TAPE
C26 2113741M13 CAP CHIP CL2 X7R 10% 470
C57 2113741M13 CAP CHIP CL2 X7R 10% 470 JU12 NOTPLACED 64AM DUMMY PART NUMBER R0002 0611077A90 RES CHIP 4700 5 1/8
C27 2113741M13 CAP CHIP CL2 X7R 10% 470
C58 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU13 NOTPLACED 64AM DUMMY PART NUMBER R0005 0611077A90 RES CHIP 4700 5 1/8
C28 2113741M13 CAP CHIP CL2 X7R 10% 470
C6 2311049A38 CAP TANT CHIP 1.5 10 16 JU14 NOTPLACED 64AM DUMMY PART NUMBER R1 NOTPLACED 64AM DUMMY PART NUMBER
C29 2113741M13 CAP CHIP CL2 X7R 10% 470
C7 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU15 NOTPLACED 64AM DUMMY PART NUMBER R101 0611077A28 RES CHIP 12 5 1/8W
C3 2113741N45 CAP CHIP CL2 X7R 10% 10000
C8 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU18 NOTPLACED 64AM DUMMY PART NUMBER R111 0611077B23 RES CHIP 100K 5 1/8W
C30 2113741M13 CAP CHIP CL2 X7R 10% 470
C9 NOTPLACED 64AM DUMMY PART NUMBER JU19 NOTPLACED 64AM DUMMY PART NUMBER R112 0611077B23 RES CHIP 100K 5 1/8W
C31 2113741M13 CAP CHIP CL2 X7R 10% 470
CR111 4880026P01 DIODE LED RED JU2 0611077A01 RES CHIP JUMPER R113 0611077B11 RES CHIP 33K 5 1/8W
C32 2113741M13 CAP CHIP CL2 X7R 10% 470
CR112 4880026P02 DIODE LED YELLOW
September 26, 2003 6881096C77-O


MMBZ5245B_
VR20 4813830A28 DIODE 15V 5% 225MW
R116 0611077A74 RES CHIP 1000 5 1/8 R60 0611077A78 RES CHIP 1500 5 1/8 MMBZ5245B_
R120 0611077B23 RES CHIP 100K 5 1/8W R61 0611077A94 RES CHIP 6.8K 5 1/8 VR21 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR22 4813830A28 DIODE 15V 5% 225MW
R122 0611077B23 RES CHIP 100K 5 1/8W R71 0611077A66 RES CHIP 470 5 1/8W
MMBZ5245B_
VR3 4813830A28 DIODE 15V 5% 225MW
R124 0611077B23 RES CHIP 100K 5 1/8W R73 0611077B11 RES CHIP 33K 5 1/8W MMBZ5245B_
R131 0611077A68 RES CHIP 560 5 1/8W R74 0611077B11 RES CHIP 33K 5 1/8W VR4 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R174 0611077A90 RES CHIP 4700 5 1/8 R75 0611077B11 RES CHIP 33K 5 1/8W
VR5 4813830A28 DIODE 15V 5% 225MW
R175 0611077A90 RES CHIP 4700 5 1/8 R76 0611077A66 RES CHIP 470 5 1/8W MMBZ5245B_
R176 0611077A90 RES CHIP 4700 5 1/8 R77 0611077A66 RES CHIP 470 5 1/8W VR50 4813830C41 DIODE 36V ‘M3’ MMSZ5258BT1
R177 0611077A90 RES CHIP 4700 5 1/8 R8 0611077A74 RES CHIP 1000 5 1/8 VR6 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R178 0611077A98 RES CHIP 10K 5 1/8W R81 0611077A98 RES CHIP 10K 5 1/8W
VR7 4813830A28 DIODE 15V 5% 225MW
R180 0611077A28 RES CHIP 12 5 1/8W R87 0611077A98 RES CHIP 10K 5 1/8W MMBZ5245B_
R181 0611077B07 RES CHIP 22K 5 1/8W R9 0611077A98 RES CHIP 10K 5 1/8W Y1 4880065M01 RESONTR CERAMIC 4.00 MHZ
R182 0611077A28 RES CHIP 12 5 1/8W R98 NOTPLACED 64AM DUMMY PART NUMBER
R200 0611077B47 RES CHIP 1 MEG 5 1/8W R99 0611077A98 RES CHIP 10K 5 1/8W
R25 0611077B15 RES CHIP 47K 5 1/8W U0102 7280032M01 DSPLY VF 14 SEG 8 CHAR
BLUGRN
R28 0611077A74 RES CHIP 1000 5 1/8
U1 0104002J91 PRGMD MICROP ASSEM
R29 0611077B23 RES CHIP 100K 5 1/8W
U101 5180236C05 IC VF DRVR SN75518FN
R3 0611077B07 RES CHIP 22K 5 1/8W
U3 5113820A02 IC DUAL SING SPLY LO PWR
R30 0611077B47 RES CHIP 1 MEG 5 1/8W 2903
R31 0611077B15 RES CHIP 47K 5 1/8W U4 5180057S04 “IC CUST SER I/O 13”” REEL”
R34 0611077B15 RES CHIP 47K 5 1/8W U45 5113816G04 IC +5V REG 78M05
R4 0611077B47 RES CHIP 1 MEG 5 1/8W VR0011 4813830C41 DIODE 36V ‘M3’ MMSZ5258BT1
MMBZ5245B_
R51 0611077B07 RES CHIP 22K 5 1/8W
VR09 4813830A28 DIODE 15V 5% 225MW
R52 0611077A98 RES CHIP 10K 5 1/8W
MMBZ5245B_
R55 0611077A28 RES CHIP 12 5 1/8W
VR1 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R58 0611077B11 RES CHIP 33K 5 1/8W
6881096C77-O September 26, 2003

HLN6814C Rear Parts List

C0053 2113741N21 CAP CHIP CL2 X7R 10% 1000 C34 2113741M13 CAP CHIP CL2 X7R 10% 470 CR133 4880052R03 DIODE LIGHT EMITTING GRN JU7 0611077A01 RES CHIP JUMPER
C11 NOTPLACED 64AM DUMMY PART NUMBER C39 2113741M13 CAP CHIP CL2 X7R 10% 470 CR138 4880052R03 DIODE LIGHT EMITTING GRN MP0101 7580094M05 “SHOCK PAD, VF”
C12 NOTPLACED 64AM DUMMY PART NUMBER C4 NOTPLACED 64AM DUMMY PART NUMBER CR139 4880052R03 DIODE LIGHT EMITTING GRN MP0102 7580094M05 “SHOCK PAD, VF”
C13 NOTPLACED 64AM DUMMY PART NUMBER C40 2113741M13 CAP CHIP CL2 X7R 10% 470 CR140 4880052R03 DIODE LIGHT EMITTING GRN MP0103 7580094M05 “SHOCK PAD, VF”
C14 NOTPLACED 64AM DUMMY PART NUMBER C41 2113741M13 CAP CHIP CL2 X7R 10% 470 CR51 4811058B11 DIODE 48S11058A11 A/P MP0106 5480004N01 LABEL BARCODE
C15 NOTPLACED 64AM DUMMY PART NUMBER C42 NOTPLACED 64AM DUMMY PART NUMBER CR52 NOTPLACED 64AM DUMMY PART NUMBER P0103 2880102M07 PLUG VERTICAL 28 POSITION
C16 NOTPLACED 64AM DUMMY PART NUMBER C43 NOTPLACED 64AM DUMMY PART NUMBER CR53 NOTPLACED 64AM DUMMY PART NUMBER P0104 2880068M01 HEADER MIC
C17 2113741M13 CAP CHIP CL2 X7R 10% 470 C44 NOTPLACED 64AM DUMMY PART NUMBER CR54 NOTPLACED 64AM DUMMY PART NUMBER Q111 4880141L02 TSTR NPN SOT23 LO PRO-
FILE TAPE
C174 2113741M13 CAP CHIP CL2 X7R 10% 470 C45 2380090M24 CAP ALU 10 20 50V SURF MT CR55 4811058B11 DIODE 48S11058A11 A/P
Q112 4880141L02 TSTR NPN SOT23 LO PRO-
C175 2113741M13 CAP CHIP CL2 X7R 10% 470 C46 2311049A37 CAP TANT CHIP 1 20 20 CR71 4811058B11 DIODE 48S11058A11 A/P FILE TAPE
C176 2113741M13 CAP CHIP CL2 X7R 10% 470 C47 2113741N69 CAP CHIP CL2 X7R 10% CR72 4811058B11 DIODE 48S11058A11 A/P Q131 4880141L02 TSTR NPN SOT23 LO PRO-
100000 FILE TAPE
C18 NOTPLACED 64AM DUMMY PART NUMBER CR73 4811058B11 DIODE 48S11058A11 A/P
C48 NOTPLACED 64AM DUMMY PART NUMBER Q50 4880053M03 TSTR N/CH SOT 89 200V B ST
C19 NOTPLACED 64AM DUMMY PART NUMBER CR76 4811058B11 DIODE 48S11058A11 A/P
84
C2 2113741M13 CAP CHIP CL2 X7R 10% 470 CR90 NOTPLACED 64AM DUMMY PART NUMBER
Q51 NOTPLACED 64AM DUMMY PART NUMBER
C50 2311049A95 CAP TANT CHIP 10 UF 25V
C20 2113741M13 CAP CHIP CL2 X7R 10% 470 10% JU0003 0611077A01 RES CHIP JUMPER
Q52 NOTPLACED 64AM DUMMY PART NUMBER
C21 2113741M13 CAP CHIP CL2 X7R 10% 470 C51 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU0005 0611077A01 RES CHIP JUMPER
Q71 4880053M02 TSTR NPN MXT2222A
C22 2113740B36 CAP CHIP REEL CL1 +/-30 30 C52 2380090M24 CAP ALU 10 20 50V SURF MT JU0016 0611077A01 RES CHIP JUMPER
C23 2113740B36 CAP CHIP REEL CL1 +/-30 30 C54 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU0017 NOTPLACED 64AM DUMMY PART NUMBER
C24 NOTPLACED 64AM DUMMY PART NUMBER C56 NOTPLACED 64AM DUMMY PART NUMBER JU1 0611077A01 RES CHIP JUMPER
Q74 4880141L02 TSTR NPN SOT23 LO PRO-
C25 NOTPLACED 64AM DUMMY PART NUMBER JU100 NOTPLACED 64AM DUMMY PART NUMBER FILE TAPE
C57 2113741M13 CAP CHIP CL2 X7R 10% 470
C26 2113741M13 CAP CHIP CL2 X7R 10% 470 JU12 NOTPLACED 64AM DUMMY PART NUMBER Q75 4880141L02 TSTR NPN SOT23 LO PRO-
C58 2113741N45 CAP CHIP CL2 X7R 10% 10000
FILE TAPE
C27 2113741M13 CAP CHIP CL2 X7R 10% 470 C6 2311049A38 CAP TANT CHIP 1.5 10 16 JU13 NOTPLACED 64AM DUMMY PART NUMBER
R0002 0611077A90 RES CHIP 4700 5 1/8
C28 2113741M13 CAP CHIP CL2 X7R 10% 470 C7 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU14 NOTPLACED 64AM DUMMY PART NUMBER
R0005 0611077A90 RES CHIP 4700 5 1/8
C29 2113741M13 CAP CHIP CL2 X7R 10% 470 C8 NOTPLACED 64AM DUMMY PART NUMBER JU15 NOTPLACED 64AM DUMMY PART NUMBER
R1 NOTPLACED 64AM DUMMY PART NUMBER
C3 NOTPLACED 64AM DUMMY PART NUMBER C9 NOTPLACED 64AM DUMMY PART NUMBER JU18 NOTPLACED 64AM DUMMY PART NUMBER
R101 0611077A28 RES CHIP 12 5 1/8W
C30 2113741M13 CAP CHIP CL2 X7R 10% 470 CR111 4880026P01 DIODE LED RED JU19 0611077A01 RES CHIP JUMPER
R111 0611077B23 RES CHIP 100K 5 1/8W
C31 2113741M13 CAP CHIP CL2 X7R 10% 470 CR112 4880026P02 DIODE LED YELLOW JU2 NOTPLACED 64AM DUMMY PART NUMBER
R112 0611077B23 RES CHIP 100K 5 1/8W
C32 2113741M13 CAP CHIP CL2 X7R 10% 470 CR131 4880052R03 DIODE LIGHT EMITTING GRN JU4 NOTPLACED 64AM DUMMY PART NUMBER
R113 0611077B11 RES CHIP 33K 5 1/8W
September 26, 2003 6881096C77-O


MMBZ5245B_
R115 0611077A74 RES CHIP 1000 5 1/8 R6 NOTPLACED 64AM DUMMY PART NUMBER
VR21 4813830A28 DIODE 15V 5% 225MW
R116 0611077A74 RES CHIP 1000 5 1/8 R60 0611077A78 RES CHIP 1500 5 1/8 MMBZ5245B_
R120 0611077B23 RES CHIP 100K 5 1/8W R61 0611077A94 RES CHIP 6.8K 5 1/8 VR22 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R121 0611077B23 RES CHIP 100K 5 1/8W R7 NOTPLACED 64AM DUMMY PART NUMBER
VR3 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR4 4813830A28 DIODE 15V 5% 225MW
R131 0611077A68 RES CHIP 560 5 1/8W R74 0611077B11 RES CHIP 33K 5 1/8W VR5 NOTPLACED 64AM DUMMY PART NUMBER
R174 0611077A90 RES CHIP 4700 5 1/8 R75 0611077B11 RES CHIP 33K 5 1/8W VR50 4813830C41 DIODE 36V ‘M3’
MMSZ5258BT1
R175 0611077A90 RES CHIP 4700 5 1/8 R76 0611077A66 RES CHIP 470 5 1/8W
VR6 4813830A28 DIODE 15V 5% 225MW
R177 0611077A90 RES CHIP 4700 5 1/8 R8 NOTPLACED 64AM DUMMY PART NUMBER VR7 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR8 4813830A28 DIODE 15V 5% 225MW
R180 0611077A28 RES CHIP 12 5 1/8W R84 NOTPLACED 64AM DUMMY PART NUMBER MMBZ5245B_
MMBZ5245B_
R182 0611077A28 RES CHIP 12 5 1/8W R9 0611077A98 RES CHIP 10K 5 1/8W
Y1 4880065M01 RESONTR CERAMIC 4.00 MHZ
R200 0611077B47 RES CHIP 1 MEG 5 1/8W R98 NOTPLACED 64AM DUMMY PART NUMBER
R25 NOTPLACED 64AM DUMMY PART NUMBER R99 0611077A98 RES CHIP 10K 5 1/8W
R28 0611077A74 RES CHIP 1000 5 1/8 T60 2580277J03 XFMR VLTG CONVERSION
R29 0611077B23 RES CHIP 100K 5 1/8W U0102 7280032M01 DSPLY VF 14 SEG 8 CHAR
BLUGRN
R30 0611077B47 RES CHIP 1 MEG 5 1/8W
U101 5180236C05 IC VF DRVR SN75518FN
R31 0611077B15 RES CHIP 47K 5 1/8W
R34 0611077B15 RES CHIP 47K 5 1/8W 2903
R4 NOTPLACED 64AM DUMMY PART NUMBER U4 5180057S04 “IC CUST SER I/O 13”” REEL”
R50 0611077A68 RES CHIP 560 5 1/8W U45 5113816G04 IC +5V REG 78M05
R51 0611077B07 RES CHIP 22K 5 1/8W VR0011 NOTPLACED 64AM DUMMY PART NUMBER
MMBZ5245B_
R55 0611077A28 RES CHIP 12 5 1/8W
VR10 4813830A28 DIODE 15V 5% 225MW
R56 0611077B11 RES CHIP 33K 5 1/8W
MMBZ5245B_
R57 0611077B15 RES CHIP 47K 5 1/8W
VR2 4813830A28 DIODE 15V 5% 225MW
6881096C77-O September 26, 2003

HLN6563D Motorcycle Parts List

C0055 2113741N21 CAP CHIP CL2 X7R 10% 1000 C35 2113741M13 CAP CHIP CL2 X7R 10% 470 CR133 4880052R03 DIODE LIGHT EMITTING GRN JU6 0611077A01 RES CHIP JUMPER
C12 NOTPLACED 64AM DUMMY PART NUMBER C4 2113741N45 CAP CHIP CL2 X7R 10% 10000 CR138 4880052R03 DIODE LIGHT EMITTING GRN L50 2480140E16 INDUCTOR CHIP 10UH
C13 2113741N69 CAP CHIP CL2 X7R 10% C40 2113741M13 CAP CHIP CL2 X7R 10% 470 CR139 4880052R03 DIODE LIGHT EMITTING GRN MP0101 7580094M05 “SHOCK PAD, VF”
100000
C41 2113741M13 CAP CHIP CL2 X7R 10% 470 CR140 4880052R03 DIODE LIGHT EMITTING GRN MP0102 7580094M05 “SHOCK PAD, VF”
C42 NOTPLACED 64AM DUMMY PART NUMBER CR51 4811058B11 DIODE 48S11058A11 A/P MP0103 7580094M05 “SHOCK PAD, VF”
C43 2113741N69 CAP CHIP CL2 X7R 10% CR52 4811058B11 DIODE 48S11058A11 A/P MP0106 5480004N01 LABEL BARCODE
C16 NOTPLACED 64AM DUMMY PART NUMBER 100000
CR53 4811058B11 DIODE 48S11058A11 A/P P0103 2880102M07 PLUG VERTICAL 28 POSITION
C17 2113741M13 CAP CHIP CL2 X7R 10% 470 C44 NOTPLACED 64AM DUMMY PART NUMBER
CR54 4811058B11 DIODE 48S11058A11 A/P P0104 2880068M01 HEADER MIC
C174 2113741M13 CAP CHIP CL2 X7R 10% 470 C45 2380090M24 CAP ALU 10 20 50V SURF MT
CR55 4811058B11 DIODE 48S11058A11 A/P Q111 4880141L02 TSTR NPN SOT23 LO PROFILE
C175 2113741M13 CAP CHIP CL2 X7R 10% 470 C46 2311049A37 CAP TANT CHIP 1 20 20 TAPE
CR71 4811058B11 DIODE 48S11058A11 A/P
C176 2113741M13 CAP CHIP CL2 X7R 10% 470 C47 2113741N69 CAP CHIP CL2 X7R 10% Q112 4880141L02 TSTR NPN SOT23 LO PROFILE
100000 CR72 NOTPLACED 64AM DUMMY PART NUMBER TAPE
C48 2113741N69 CAP CHIP CL2 X7R 10% CR73 4811058B11 DIODE 48S11058A11 A/P Q131 4880141L02 TSTR NPN SOT23 LO PROFILE
C19 NOTPLACED 64AM DUMMY PART NUMBER 100000 TAPE
CR76 4811058B11 DIODE 48S11058A11 A/P
C2 2113741M13 CAP CHIP CL2 X7R 10% 470 C5 2113741N69 CAP CHIP CL2 X7R 10% Q50 4880053M03 TSTR N/CH SOT 89 200V B ST
CR90 4882960R02 DIODE RECT 48R82960R01 A/P
100000 84
C20 2113741M13 CAP CHIP CL2 X7R 10% 470
E0001 8480251R06 BD CKT CTRL HD
C50 2311049A95 CAP TANT CHIP 10 UF 25V Q51 4813821A30 MOSFET N-CH 60V 15A
C21 2113741M13 CAP CHIP CL2 X7R 10% 470
10% JU0003 NOTPLACED 64AM DUMMY PART NUMBER
Q52 4880141L01 TSTR PNP SOT23 LO PROFILE
C51 NOTPLACED 64AM DUMMY PART NUMBER JU0005 NOTPLACED 64AM DUMMY PART NUMBER TAPE
C52 2380090M24 CAP ALU 10 20 50V SURF MT JU0016 NOTPLACED 64AM DUMMY PART NUMBER Q71 4880053M02 TSTR NPN MXT2222A
C54 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU0017 0611077A01 RES CHIP JUMPER Q72 NOTPLACED 64AM DUMMY PART NUMBER
C56 2113741M13 CAP CHIP CL2 X7R 10% 470 JU1 0611077A01 RES CHIP JUMPER Q73 4880053M02 TSTR NPN MXT2222A
C26 2113741M13 CAP CHIP CL2 X7R 10% 470
C57 2113741M13 CAP CHIP CL2 X7R 10% 470 JU100 NOTPLACED 64AM DUMMY PART NUMBER Q74 4880141L02 TSTR NPN SOT23 LO PROFILE
C27 2113741M13 CAP CHIP CL2 X7R 10% 470 TAPE
C58 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU12 NOTPLACED 64AM DUMMY PART NUMBER
C28 2113741M13 CAP CHIP CL2 X7R 10% 470 Q75 4880141L02 TSTR NPN SOT23 LO PROFILE
C6 2311049A38 CAP TANT CHIP 1.5 10 16 JU13 NOTPLACED 64AM DUMMY PART NUMBER TAPE
C29 2113741M13 CAP CHIP CL2 X7R 10% 470
C7 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU14 0611077A01 RES CHIP JUMPER R0002 0611077A90 RES CHIP 4700 5 1/8
C3 2113741N45 CAP CHIP CL2 X7R 10% 10000
C8 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU15 NOTPLACED 64AM DUMMY PART NUMBER R0005 0611077A90 RES CHIP 4700 5 1/8
C30 2113741M13 CAP CHIP CL2 X7R 10% 470
C9 NOTPLACED 64AM DUMMY PART NUMBER JU18 0611077A01 RES CHIP JUMPER R1 NOTPLACED 64AM DUMMY PART NUMBER
C31 2113741M13 CAP CHIP CL2 X7R 10% 470
CR111 4880026P01 DIODE LED RED JU19 NOTPLACED 64AM DUMMY PART NUMBER R101 0611077A28 RES CHIP 12 5 1/8W
C32 2113741M13 CAP CHIP CL2 X7R 10% 470
CR112 4880026P02 DIODE LED YELLOW
September 26, 2003 6881096C77-O


R111 0611077B23 RES CHIP 100K 5 1/8W R56 0611077B11 RES CHIP 33K 5 1/8W VR2 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R112 0611077B23 RES CHIP 100K 5 1/8W R57 0611077B15 RES CHIP 47K 5 1/8W
VR20 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR22 4813830A28 DIODE 15V 5% 225MW
R116 0611077A74 RES CHIP 1000 5 1/8 R60 0611077A78 RES CHIP 1500 5 1/8
MMBZ5245B_
R120 0611077B23 RES CHIP 100K 5 1/8W R61 0611077A94 RES CHIP 6.8K 5 1/8
VR3 4813830A28 DIODE 15V 5% 225MW
R121 0611077B23 RES CHIP 100K 5 1/8W R7 0611077A98 RES CHIP 10K 5 1/8W MMBZ5245B_
R122 0611077B23 RES CHIP 100K 5 1/8W R71 0611077A66 RES CHIP 470 5 1/8W VR4 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR5 4813830A28 DIODE 15V 5% 225MW
R131 0611077A68 RES CHIP 560 5 1/8W R74 0611077B11 RES CHIP 33K 5 1/8W VR50 4813830C41 DIODE 36V ‘M3’ MMSZ5258BT1
R174 0611077A90 RES CHIP 4700 5 1/8 R75 0611077B11 RES CHIP 33K 5 1/8W VR6 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R175 0611077A90 RES CHIP 4700 5 1/8 R76 0611077A66 RES CHIP 470 5 1/8W
VR7 4813830A28 DIODE 15V 5% 225MW
R177 0611077A90 RES CHIP 4700 5 1/8 R8 0611077A74 RES CHIP 1000 5 1/8 VR8 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R178 0611077A98 RES CHIP 10K 5 1/8W R81 NOTPLACED 64AM DUMMY PART NUMBER
VR9 4813830A28 DIODE 15V 5% 225MW
R180 0611077A28 RES CHIP 12 5 1/8W R84 NOTPLACED 64AM DUMMY PART NUMBER MMBZ5245B_
R181 0611077B07 RES CHIP 22K 5 1/8W R87 0611077A98 RES CHIP 10K 5 1/8W Y1 4880065M01 RESONTR CERAMIC 4.00 MHZ
R182 0611077A28 RES CHIP 12 5 1/8W R9 0611077A98 RES CHIP 10K 5 1/8W
R200 0611077B47 RES CHIP 1 MEG 5 1/8W R98 NOTPLACED 64AM DUMMY PART NUMBER
BLUGRN
R29 0611077B23 RES CHIP 100K 5 1/8W
R3 0611077B07 RES CHIP 22K 5 1/8W
U101 5180236C05 IC VF DRVR SN75518FN
R30 0611077B47 RES CHIP 1 MEG 5 1/8W
R31 0611077B15 RES CHIP 47K 5 1/8W 2903
R34 0611077B15 RES CHIP 47K 5 1/8W U4 5180057S04 “IC CUST SER I/O 13”” REEL”
R4 0611077B47 RES CHIP 1 MEG 5 1/8W U45 5113816G04 IC +5V REG 78M05
MMBZ5245B_
R51 0611077B07 RES CHIP 22K 5 1/8W
VR10 4813830A28 DIODE 15V 5% 225MW
R52 0611077A98 RES CHIP 10K 5 1/8W
MMBZ5245B_
R55 0611077A28 RES CHIP 12 5 1/8W
VR11 4813830C41 DIODE 36V ‘M3’ MMSZ5258BT1
6881096C77-O September 26, 2003

+5V_FIL +5V +5V_FIL

5 3 2 1 18 13 12 21 4 6 20 14 15 16 17 19 22 11 10 9 8 7 L1
J101
+5V SWB+ FLEX CABLE 9.107uH 14
KS1
KS2
KS3
KS4
KS5
KR1
KR2
KR3
KR4
KR5
R172
+43V
VCC
DATA
C66
FIL_1
FIL_2
+5V +5V R37 C21 +5V
LATCH
U8
CLOCK
Q171 0.1uF
STROBE
1K 470pF
SPARE-2
PWR_GND
GROUND
R171 Q170 2.2K L2
+5V GND
R166
VF-CONTROL
R170 +5V 7
47K R56 C246 VR50 9.107uH
C170 33K
C171 100K R0058 R23 2.2K
0.1uF C53 C37
470pF R51 43V C52 +5V 470pF
R173 33K CR51 10K
SWB+ 470pF WARNING! 4.7K 22K +5V C38 C41 ADDRESS(7:0)
DO NOT PROBE U3 PIN C51 10uF T60 R53 R38
SWB+ +5V SWB+ +5V 1 4 .01uF 1K 2
5 WITH POWER APPLIED 470pF 470pF
Q23 L23
OR DAMAGE TO THE C22 C23 Y1 R21
CIRCUITRY MAY OCCUR. .01uF 5.1 16 22uH
CR71 6 8 +5V SWB+ 2 5 C64 15pF 1 4.7pF 7160 1MEG C63
R59 NC 3 0.1uF
U3B 7 R61 0.1uF VDD 9 2 1 32
C175 C174 LM2903 R52 R55 R54 DATA
SWB+ SWB+ 5 2 8 1K Q50 D(1) L50 3 6 3 10 CR161 VCC
10K CLK QS*
470pF R1 470pF 4 U3A 1 15 1 DIGITAL GROUND 7.9488MHz C24 23
10K C57 9.107uH 5.1 77J03 5.1 EN_OE EN_CE
CONTROL 10K 3 LM2903 4 3 25
R57 G(2) U6 Q1 R41 12pF EN_OE
HEAD 4 C50 C56 2 31
33K C54 470pF R50 MC1409B Q2 5 EN_WE
CONNECTOR C176 R60 SWB+ 470 1
CR72 10uF .01uF LATCH Q3 6 10K
P103 C71 S(3) 7 0 11 13 0
Q71 470pF 6.8K Q4 A0 D0
2 470pF 1 1 10 14 1
46 NC 470pF SHIFT Q5 14 A1 D1
REGISTERQ6 13 U8D 3 2 9 A2 U5 2
D2 15
1 R71 2 12 2 MC74HC00 3 3
45 NC SER_DAT_IN Q7 8 A3 AT28HC64 D3 18
11 CR162 4 7 19 4
JU12* 33K Q8 A4 D4
VIP-OUT-1 GND 1 5 6 A5 EEPROM 5
2 D5 20
3 C271 8 3 5 6 6
0 Q72 5 A6 D6 21
SPARE-1 470pF C72 2 2 U8B 6 7 4 22 7
28 R75 A7 D7
470pF 4 MC74HC00 8 29 A8
EMERGENCY JU23* 1 R72 CR75 10K VIP-OUT-1 9 28 A9
27 RDY_BUSY* 2
0 SWB+ VIP-OUT-2 10 24 1 5
C272 33K A10 NC
CR74 VIP-OUT-3 11 27 17
A11 NC1
VIP-OUT-2 3 470pF 12 3 A12
1 R40 NC2 26
JU24* CR73 Q75 30
NC3
JU13* 1K R39 12
R73 NC4
SPARE-2 0 0 33K C279 R30 VSS
29 1K
DEK-CLOCK C75 470pF R29 16
38 10K
DEK-DATA-OUT Q74 C40 C39 R28
5 10K
VIP-OUT-3 R27
34 Q73 470pF 470pF 10K
SPEAKER-HI 2 A+_IGN +5V 470pF C278 10K R26 DATA(7:0)
44 C73
SWB+ SWB+ 470pF C74 10K
PTH-2 470pF +5V 1 CR55 ADDRESS (8:12)
JU18 JU19 12
0 0 +5V +5V 470pF
PTH-3
JU16* JU3 C202 3 C30 C29 C28 C27 C26 +5V_FIL
43
C273 17
0 0 470pF 470pF 470pF 470pF 470pF 470pF 1 NC NC
MIC-SWB+ C206 C6 470pF 6 3 39 +5V_FIL 2 18 3
41 R8 R7 470pF 1.5uF +5V_FIL D3
SWB+ 4.7K 4.7K R99 C76 +5V 3 19 4
18 R200 SHORT TO GROUND TO R35 R33 R32 A12 D4
47K R74 1K 1K 47K 7 20 5
APOS
19 DISABLE WATCH-DOG TIMER 470pF 4 A7 D5
POS5V
JU11*
8
7
4
52
51
32
29
6 5 21 6
35 1MEG 10K A6 U7 D6
POS5_REG
0 43 2 R98 5 6 22 7
48 WDT_T_CAP WDT_TICKLE A5 D7
PTT 34
VRL
R81
VDD 26
VRH
10K
XTAL
VIP-IN-1 42 5 4 23
EXTAL
25 VIP_IN_1 OSC_OUT CLK_E 7 A4 SOCKET CE*
LATCH
4
VIP-IN-2 10K 22 41 43 3 8 24 10
STROBE 30
R84
VIP_IN_3 33
STRA_AS
BUSY_IN*
3 VIP_IN_2 EXT_OSC_IN R44 PE0_AN0 A3 PROM A10

VIP-IN-3 R87 10K 35 24 19 45 2 9 25
BUSY_OUT* 28
DEK_CLOCK 31
37 VIP_IN_3 VIP_IN_1* IRQ VIP_IN_1 A2 OE*

RESET 10K R18 1
DATA(7:0)
11 10K 26
DEK_DATA-OUT 27
9 RESET BUSY_IN* 18 XIRQ VIP_IN_2 47 10 A1 GND

26 U4
BUSY 4 10K R16 0 11 A0 27 11
33 10 BUSY RESET* 17 RESET* KR1 49 A11
BUS- 16 SC74487F 29 10K 6 44 12 28 9
50 BUS- IGN* R14 R12 STRB_R_W* U2 KR2 GND A9
BUS+ 21 0 13 D0 29 8
17 17 BUS+ VIP_IN_2* 3 MODA_LIR* KR3 46 A8
36 10K R15 1K 1 30 +5V_FIL
7 RESET_FILTR VIP_IN_3* 2 MODB_VSTBY MC68HC11A1 KR4 48 14 D1 A13
44 30 50 2 15 31
16 WDT_IN_T_CAP HUB_INV 10K KR5 D2 +5V_FIL
BATT- VR11 VR10 VR9 VR8 VR6 VR7 VR1 VR2 38 R13 0 MICROPROCESSOR 32
14 C173 C1 28 IGN PTT 9 PC0_A0_D0 16 GND +5V_FIL
15V 15V 15V 15V 15V 15V 15V 15V 470pF .01uF R19
C7 +5V 32 HUB_POL 20 10K 1
31 .01uF RX_DATA 10 PC1_A1_D1 PD5_SS* 25
14 13 10K R17 2 11 24
NC BUSY_OUT* PC2_A2_D2 PD4_SCK
IGN+ (ORANGE) 8 19 10K R20 3 12 23 C65
15 NC1 TX_DATA PC3_A3_D3 PD3_MOSI
IGN- 40 NC2 37 10K 4 0.1uF
32 VR514 SERIAL I/0 PTT* 13 PC4_A4_D4
C207 27 31 5
R25 15V NC3 RES_HUB
26 12 C18 C16 C14 C15 C13 C19 C17 C20 C44 C12 6
47 A+ (GREEN) 470pF NC4 NC7
A+_IGN 33 NC5 18 470pF 470pF 470pF 470pF 470pF 470pF 470pF 470pF 470pF 470pF 7
30 47K NC8
PC6_A6_D6
PC7_A7_D7
PB1_A9
PB2_A10
PB5_A13
RX_DATA
SWB+ 15 23
ADDRESS(8:12)
JU4* NC6 NC9

1 VSS
GND
14 PC5_A5_D5
15
16
42 PB0_A8
41
40
39 PB3_A11
38 PB4_A12
37
36 PB6_A14
35 PB7_A15
20
21 TX_DATA
22 PD2_MISO
20
1 GND
5
34 GND
JU22* 0 4 OFF DATA(7:0)
36 G1
49 0 JU2* R182 R183
GROUND 2 VR4 +5V_FIL
21 SWITCH R24 15V
IN +5V 10K
0 S1 R181 47K
MIC-LO 5 C61 ADDRESS (7:0)
13 G2 33K 0.1uF
ON VR5 +5V +5V
7 15V Q40 22K C47
3 R5
8
MIC-HI SWB+ 100K 470pF 20 C62
12 JU1 JU10* C277 0.1uF
8
9
R6 VCC
10
11
12
MIC-HUB R43 22K ADDRESS (8:12)

0 470pF 11
40 0 EN_LE
VR12 R34 SWB+ +5V +5V DATA(7:0)
JU5 JU9* 47K 1 EN_OE
U10
15V 47K
U46
R164 MC74HC373
0 0 R22 NOTE: Q40 USED FOR POSITIVE GROUND R31 MC78M05 0 18 19 0
33K IGNITION SERVICE 47K 5 VOLT
D0 A0
PTT/HUB-REF NOTES: C45 R161 R163 3 9 1 17 D1 16 1
23 CR90 REGULATOR 10K A1
10uF 1 3 10K 10K U8A 8 2 15 2
1.) ALL RESISTANCE IS IN OHMS. ALL CAPACITANCE IN PICO-FARADS UNLESS NOTED OTHERWISE. IN OUT R0165
14 D2
A2
C67 2.) PART USAGE MAY VARY WITH APPLICATION. REFER TO PARTS LIST FOR USAGE INFORMATION. CR76 JU21* JU20 CR164 10 MC74HC00 3 13 D3 12 3
0 C276 C275 GND C46 C274 Q162 A3
0.1uF 3.) ASTERISK (*) INDICATES PARTS NOT NORMALLY PLACED IN STANDARD CONFIGURATION 0 VR3 4 8 D4 LATCH 9 4
10K A4
MIC-PTT 15V 470pF 470pF 2 470pF Q161 3 2 1 5 6 5
24 1uF 7 D5
A5
C165 13 6 4 5 6
D6 A6
PTH-1 R10 U8C 11 7 3 D7 2 7
CR163 1uF A7
220 12 MC74HC00 GND
SPEAKER-LO 2 1 10
10 JU17* DATA(7:0)
11
0
Figure 8-14. HCN1078J (Standard), HCN1121D (Rear) W9 Control Head Schematic (Side 1 of 2)
September 26, 2003 6881096C77-O

P101
SPARE_2
5
FILAMENT 2 SWB+ SWB+

1
FILAMENT 1
2
CR112 CR111
+43V
3 BUSY XMIT
(YEL) (RED)
CLOCK
13
STROBE
18 R112 R111
Q112 Q111
LATCH
12 100K 100K
DATA_IN
20
VF_CONTROL
21 R116 R114 R115 R113
1K 33K 1K 33K
+5V
+5V JU8
+5V 0
4
SWB+ C55
+5V 0.1uF
SWB+ 44 1
6
42
+5V
Q1
+43V
23 41 ANODE 4
FILAMENT 1
1
CLK Q2 B
GND 21 40 ANODE 26 28 SWB+
22 STROBE Q3 I FILAMENT 2
C135 24 39 ANODE 25
LATCH Q4 L
R122 38 ANODE 20
R120 R121 R123 R124 Q5 C
100K 100K 100K 100K 100K 43 37 ANODE 21
470pF DATA_IN Q6 H
36 ANODE 18 JU7
Q7 M
KS5 +5V 35 ANODE 8 SWB+ SWB+ SWB+ SWB+ SWB+ SWB+ 0 SWB+
19 C139 Q8 E
2
2
2
2
2
C141 34 ANODE 16
470pF Q9 D
KS4 S101 S102 S103 S104 S105 470pF 33 ANODE
17 C134 11
Q10 J
1 2 3 4 5 32 ANODE 9
Q11 N
1
1
1
1
1
KS3 31 ANODE 5
16 R129 Q12 G CR113 CR114 CR115 CR116 CR117 CR118 CR119 CR120
470pF ANODE
30 3 R140 R141 R142 R143 R144 R145 R146 R147
Q134 Q13 K
KS2 ANODE 10K 10K 10K 10K 10K 10K 10K 10K
10K 27 2
15 Q14 A
26 ANODE 24
Q15 F
2
2
2
2
2
KS1 25
14 R139 Q16 U102
C133 S124 S132 S135 S106 S107 U101 20
Q17 PR-483-05
KR1 OPT4 MU SEL 6 7 UCQ5818EPF 19
11 2.2K Q18 Q113 Q114 Q115 Q116 Q117 Q118 Q119 Q120
1
1
1
1
1
VF DRIVER
VF DISPLAY
17
470pF Q19
KR2 SWB+ SWB+ SWB+ 16
10 R130 Q20
4.7K +5V 15 R150 R151 R152 R153 R154 R155 R156 R157
Q21
KR3 14 GRID 23 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K
9 Q22 G1
2
2
2
2
2
13 GRID 22
CR137 CR140 CR134 Q23 G2
KR4 S123 S131 S127 S108 S109 12 GRID 19
8 C132 Q24 G3
1
1
OPT3 MD DIM 8 9 R132 11 GRID 17
Q25 G4
1
1
1
KR5 10K 10 GRID 15
7 470pF Q26 G5
9 GRID 14
Q27 G6
6 8 GRID 13
Q132 CR136 Q133 CR133 NC1 Q28 G7
18 7 GRID 12
NC2 Q29 G8
2
2
2
2
2
FLEX CABLE 28 5 GRID 10
NC3 Q30 G9
S122 S134 S136 S100 S125 29 GRID 7 27
C131 R135 4
NC4 Q31 G11 NC
6
1
1
OPT2 VU HOME 0 OPT5 RT133 6.8K 3 GRID
Q32 G10
1
1
1
100K 2
470pF CR135 CR138 CR132 SERIAL_OUT
GND NOTES:
R149
22 Q110 1.) ALL RESISTANCE IS IN OHMS. CAPACITANCE
R136
2
2
2
2
2
R134 33K IS IN PICOFARADS UNLESS NOTED OTHERWISE.
S121 S133 S110 S111 S126 1.5K 2.) ASTERISK (*) DENOTES UN-USED PART PER THIS
2.2K CR131 APPLICATION.
OPT1 VD STAR PND OPT6 Q130 Q131
1
1
1
1
1
R148* R158 R159
0 220 220
R138 R131
220 220
Q133
R137
27
Figure 8-15. HCN1078J (Standard), HCN1121D (Rear) W9 Control Head Schematic (Side 2 of 2)
6881096C77-O September 26, 2003

C277
2
C276
39 29
C14
U46
C44 40 28
46 34 VR51
29 21 C13
11 10 47 33 1 3
C6
30 20
R200
C206
C207
1 U4
C15 K
C275
1 C18
C274
U5 U10 C45
C46
1 U2 S1
CR90
4 6 18
C17 Q73
A Q72
14
R72
5 13 20 1 B C E
7 17 C278
B C E
C74 1 2 3
7 21
2
8 20 C47
Y1 C20
R20 P103
1
29 21 R37 R19 C19
30 20 R16 C16
50 49 48 47 46 45 44 43 41 40 38 37 36 35 34
8 7 C12
R12
1 U7 L1
33 32 31 30 29 28 27 26 24 23 21 20 19 18
U8 L23 17 16 15 14 13 12 11 10 8 7 5 4 3 2 1
C21
4 L2
14 14 1
5 13
C41
C40
C39
C30
C29
C28
C27
C26
C75
C165
16 9
K
3 2 1 C50
A C C170 L50 K
R38
R71
VR50
U6 8 5
CR162 Q170 R163 C64 CR51
E A A
K B T60 A Q71
A 1 8
CR163 S D G
C38
C52 U3
C271
CR161 R172
B C E
R173
K C56 R54 6 5 4
K
Q50 1 4
39 29
40 28
C55
1 U101
CR111 CR112
S127
RT133
6 18
7 17
CR137 CR136 CR135
S121 S122 S123 S124 S125 S126

S101 S102 S103
CR131 CR134
CR113 CR115 CR117 CR119 CR118 CR120
CR114
S104 S105 S106
U102
CR116
S107 S108 S109
1 14 15 28 CR132 CR133
CR140 CR139 CR138
S131 S132 S133 S134 S135 S136

S110 S100 S111
Figure 8-16. HCN1078J (Standard), HCN1121D (Rear) W9 Control Head Component Location Diagram (Viewed from Side 1)
September 26, 2003 6881096C77-O

C76
R8
R7
R98
R5
R6
R44
R14
R13
C7
C62
C61
R33
R35
K K
VR4
R99
K
R34
VR5
R18
A A C
C63
A C272 C273 JU10 K K

A A A A
VR8
R74
CR74 Q74
R17
R15
CR73 VR9 C
R81
CR72 A A VR10
JU9 K K B E
K K A A
R23
K K A A Q23
K C
R32
B E
C1
R31 VR6
C176 Q40
R24
A A
R84 B E
R182
R181
R183
R87 JU11 K
JU6
R25
R22
JU5
R43
VR1
JU1
C73
JU23
JU18
JU19
C174 JU3
C72
R73
A A
C202
C24
C23
R21
C22
C37
34 35 36 37 38 40 41 43 44 45 46 47 48 49 50
C66
18 19 20 21 23 24 26 27 28 29 30 31 32 33 C A
R164
1 2 3 4 5 7 8 10 11 12 13 14 15 16 17 Q162 CR164
C279
B E K K
JU2
K
K
R75
R26
R27
R28
R29
R30
R39
R40
R41
K
C65
JU4
R10
VR12 VR7
VR3 A C
C67
JU21
JU20
R165
JU13
JU12
JU22
R166
A A A A
A A K C173 CR75 Q75
A K
VR11 K K B E
C175 VR2
CR76
A A
JU17
K K A A
A
C
R60
CR71 C246
C
C57
Q171
R55
K K R59
R171
Q161
R161
B E
C171
B E
R170
R1
R51
C51
R52
R61
C71
R56
R57
C54
R58
R53
R50
C53
C C C
Q132 Q133 Q134
R132
R129
B E B E B E
C141
R134
R137
R130
R136
R139
R135
C C
Q112 Q111
R115
R113
R111
R112
R114
R116
B E B E
R120
R124
R123
R122
R121
Q130
R138
B E
C133
C135 C
C C C C C C C
C
JU7
JU8
Q116 Q120 Q119 Q115 Q113 Q110

R143
R140
Q118 Q117
R153
R155
R146
R156
R152
R142
R150
R148
R158
R159
R145
R149
R144
R154
R151
R141
R157
Q114
R147
B E B E B E B E B E B E B E B E
B E
C139
C131 C134
C132 C
Q131
B E
R131
Figure 8-17. HCN1078J (Standard), HCN1121D (Rear) W9 Control Head Component Location Diagram (Viewed from Side 2)
6881096C77-O September 26, 2003

HCN1078J (Standard), HCN1121D (Rear) Parts List

NUMBER C26 2113741M13 CAP CHIP CL2 X7R 10% 470 C61 2113741N69 CAP CHIP CL2 X7R 10% CR136 4880052R03 DIODE LIGHT EMITTING GRN
100000
C1 2113741N45 CAP CHIP CL2 X7R 10% 10000 C27 2113741M13 CAP CHIP CL2 X7R 10% 470 CR137 4880052R03 DIODE LIGHT EMITTING GRN
C62 2113741N69 CAP CHIP CL2 X7R 10%
C12 2113741M13 CAP CHIP CL2 X7R 10% 470 C271 2113741M13 CAP CHIP CL2 X7R 10% 470 100000 CR138 4880052R03 DIODE LIGHT EMITTING GRN
C13 2113741M13 CAP CHIP CL2 X7R 10% 470 C272 2113740B65 CAP CHIP REEL CL1 +/-30 470 C63 2113741N69 CAP CHIP CL2 X7R 10% CR139 4880052R03 DIODE LIGHT EMITTING GRN
100000
C131 2113740B65 CAP CHIP REEL CL1 +/-30 470 C273 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR140 4880052R03 DIODE LIGHT EMITTING GRN
C64 2113741N69 CAP CHIP CL2 X7R 10%
C132 2113740B65 CAP CHIP REEL CL1 +/-30 470 C274 2113741M13 CAP CHIP CL2 X7R 10% 470 CR161 4880236E08 DIODE DUAL SOT 23
100000
C133 2113740B65 CAP CHIP REEL CL1 +/-30 470 C275 2113741M13 CAP CHIP CL2 X7R 10% 470 CR162 4880236E08 DIODE DUAL SOT 23
C65 2113741N69 CAP CHIP CL2 X7R 10%
C134 2113740B65 CAP CHIP REEL CL1 +/-30 470 C277 2113741M13 CAP CHIP CL2 X7R 10% 470 100000 CR163 4880236E08 DIODE DUAL SOT 23
C135 2113740B65 CAP CHIP REEL CL1 +/-30 470 C278 2113740B65 CAP CHIP REEL CL1 +/-30 470 C66 2113741N69 CAP CHIP CL2 X7R 10% CR164 4880236E08 DIODE DUAL SOT 23
100000
C139 2113740B65 CAP CHIP REEL CL1 +/-30 470 C279 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR51 4813833C09 DIODE GEN PURP .1A 100V
C67 2113741N69 CAP CHIP CL2 X7R 10% ‘DX’
C14 2113741M13 CAP CHIP CL2 X7R 10% 470 C28 2113741M13 CAP CHIP CL2 X7R 10% 470 100000
CR71 4880236E08 DIODE DUAL SOT 23
C141 2113740B65 CAP CHIP REEL CL1 +/-30 470 C29 2113741M13 CAP CHIP CL2 X7R 10% 470 C7 2113741N45 CAP CHIP CL2 X7R 10% 10000
C15 2113741M13 CAP CHIP CL2 X7R 10% 470 C30 2113741M13 CAP CHIP CL2 X7R 10% 470 C71 2113740B65 CAP CHIP REEL CL1 +/-30 470
C16 2113741M13 CAP CHIP CL2 X7R 10% 470 C300 2113741M13 CAP CHIP CL2 X7R 10% 470 C72 2113740B65 CAP CHIP REEL CL1 +/-30 470
C165 2311049A37 CAP TANT CHIP 1 20 20 C301 2113741M13 CAP CHIP CL2 X7R 10% 470 C73 2113740B65 CAP CHIP REEL CL1 +/-30 470
C17 2113741M13 CAP CHIP CL2 X7R 10% 470 C37 2113740B65 CAP CHIP REEL CL1 +/-30 470 C74 2113741M13 CAP CHIP CL2 X7R 10% 470
C170 2113741N69 CAP CHIP CL2 X7R 10% C38 2113741M13 CAP CHIP CL2 X7R 10% 470 C75 2113741M13 CAP CHIP CL2 X7R 10% 470
100000 CR90 4882960R02 DIODE RECT 48R82960R01 A/P
C39 2113741M13 CAP CHIP CL2 X7R 10% 470 C76 2113740B65 CAP CHIP REEL CL1 +/-30 470
C40 2113741M13 CAP CHIP CL2 X7R 10% 470 CR111 4880052R01 DIODE LIGHT EMITTING RED
C41 2113741M13 CAP CHIP CL2 X7R 10% 470 CR112 4880052R02 DIODE LIGHT EMITTING YEL
C44 2113741M13 CAP CHIP CL2 X7R 10% 470 CR113 4880052R01 DIODE LIGHT EMITTING RED
C45 2380090M24 CAP ALU 10 20 50V SURF MT CR114 4880052R01 DIODE LIGHT EMITTING RED
C46 2311049A37 CAP TANT CHIP 1 20 20 CR115 4880052R01 DIODE LIGHT EMITTING RED
C47 2113741M13 CAP CHIP CL2 X7R 10% 470 CR116 4880052R02 DIODE LIGHT EMITTING YEL
C50 2311049J27 CAP TANT CHIP 10 10 25 CR117 4880052R01 DIODE LIGHT EMITTING RED
C51 2113741N45 CAP CHIP CL2 X7R 10% 10000 CR118 4880052R01 DIODE LIGHT EMITTING RED
C202 2113740B65 CAP CHIP REEL CL1 +/-30 470 L1 2480140E16 INDUCTOR CHIP 10UH
C52 2380090M24 CAP ALU 10 20 50V SURF MT CR119 4880052R01 DIODE LIGHT EMITTING RED
C206 2113741M13 CAP CHIP CL2 X7R 10% 470 L2 2480140E16 INDUCTOR CHIP 10UH
C53 2113741N45 CAP CHIP CL2 X7R 10% 10000 CR120 4880052R01 DIODE LIGHT EMITTING RED
C207 2113741M13 CAP CHIP CL2 X7R 10% 470 L23 2480289M16 COIL IF 22UH 1611 CS 223
C54 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR131 4880052R03 DIODE LIGHT EMITTING GRN
C21 2113741M13 CAP CHIP CL2 X7R 10% 470 L50 2480140E16 INDUCTOR CHIP 10UH
C55 2113741N69 CAP CHIP CL2 X7R 10% CR132 4880052R03 DIODE LIGHT EMITTING GRN
C22 2113740B29 CAP CHIP REEL CL1 +/-30 15 100000 P7 0980049R01 SOCKET PLCC 32 PIN
CR133 4880052R03 DIODE LIGHT EMITTING GRN
C23 2113740B17 CAP CHIP REEL CL1 +/-30 4.7 C56 2113741N45 CAP CHIP CL2 X7R 10% 10000 Q110 4880141L02 TSTR NPN SOT23 LO PROFILE
TAPE
C24 2113740B27 CAP CHIP REEL CL1 +/-30 12 C57 2113740B65 CAP CHIP REEL CL1 +/-30 470
Q110 4880141L04 TSTR NPN SOT23 LO PROFILE
C246 2113740B65 CAP CHIP REEL CL1 +/-30 470 C6 2311049A38 CAP TANT CHIP 1.5 10 16 TAPE
September 26, 2003 6881096C77-O

MOTOROLA MOTOROLA MOTOROLA MOTOROLA

ITEM PART DESCRIPTION ITEM PART DESCRIPTION ITEM PART DESCRIPTION ITEM PART DESCRIPTION
NUMBER NUMBER NUMBER NUMBER
Q111 4880141L02 TSTR NPN SOT23 LO PROFILE Q50 4880053M03 TSTR N/CH SOT 89 200V B ST R140 0611077A98 RES CHIP 10K 5 1/8W R182 0611077B15 RES CHIP 47K 5 1/8W
TAPE 84
Q112 4880141L02 TSTR NPN SOT23 LO PROFILE Q71 4880052M01 TSTR NPN DRLNGTN MXTA27
TAPE R142 0611077A98 RES CHIP 10K 5 1/8W R19 0611077A98 RES CHIP 10K 5 1/8W
Q72 4880052M01 TSTR NPN DRLNGTN MXTA27
Q113 4880141L02 TSTR NPN SOT23 LO PROFILE R143 0611077A98 RES CHIP 10K 5 1/8W R20 0611077A98 RES CHIP 10K 5 1/8W
TAPE Q73 4880052M01 TSTR NPN DRLNGTN MXTA27
R144 0611077A98 RES CHIP 10K 5 1/8W R200 0611077B47 RES CHIP 1 MEG 5 1/8W
Q114 4880141L02 TSTR NPN SOT23 LO PROFILE Q74 4880141L04 TSTR NPN SOT23 LO PROFILE
TAPE R145 0611077A98 RES CHIP 10K 5 1/8W R21 0611077B47 RES CHIP 1 MEG 5 1/8W
TAPE
Q75 4880141L04 TSTR NPN SOT23 LO PROFILE R146 0611077A98 RES CHIP 10K 5 1/8W R22 0611077B11 RES CHIP 33K 5 1/8W
TAPE TAPE
Q116 4880141L02 TSTR NPN SOT23 LO PROFILE R1 0611077A98 RES CHIP 10K 5 1/8W
R149 0611077B11 RES CHIP 33K 5 1/8W R24 0611077B11 RES CHIP 33K 5 1/8W
TAPE
R10 0611077A58 RES CHIP 220 5 1/8W
R15 0611077A98 RES CHIP 10K 5 1/8W R25 0611077B15 RES CHIP 47K 5 1/8W
R111 0611077B23 RES CHIP 100K 5 1/8W
TAPE R150 0611077A78 RES CHIP 1500 5 1/8 R26 0611077A98 RES CHIP 10K 5 1/8W
R112 0611077B23 RES CHIP 100K 5 1/8W
Q118 4880141L02 TSTR NPN SOT23 LO PROFILE R151 0611077A78 RES CHIP 1500 5 1/8 R27 0611077A98 RES CHIP 10K 5 1/8W
TAPE R113 0611077B11 RES CHIP 33K 5 1/8W
Q119 4880141L02 TSTR NPN SOT23 LO PROFILE R114 0611077B11 RES CHIP 33K 5 1/8W
R115 0611077A74 RES CHIP 1000 5 1/8
Q120 4880141L02 TSTR NPN SOT23 LO PROFILE R154 0611077A78 RES CHIP 1500 5 1/8 R30 0611077A98 RES CHIP 10K 5 1/8W
TAPE R116 0611077A74 RES CHIP 1000 5 1/8
Q130 4880141L02 TSTR NPN SOT23 LO PROFILE R12 0611077A74 RES CHIP 1000 5 1/8
TAPE R156 0611077A78 RES CHIP 1500 5 1/8 R32 0611077B15 RES CHIP 47K 5 1/8W
R120 0611077B23 RES CHIP 100K 5 1/8W
Q131 4880141L02 TSTR NPN SOT23 LO PROFILE R157 0611077A78 RES CHIP 1500 5 1/8 R33 0611077A74 RES CHIP 1000 5 1/8
R158 0611077A58 RES CHIP 220 5 1/8W R34 0611077B15 RES CHIP 47K 5 1/8W
Q132 4880141L02 TSTR NPN SOT23 LO PROFILE R122 0611077B23 RES CHIP 100K 5 1/8W
R159 0611077A58 RES CHIP 220 5 1/8W R35 0611077A74 RES CHIP 1000 5 1/8
TAPE
R123 0611077B23 RES CHIP 100K 5 1/8W
R16 0611077A98 RES CHIP 10K 5 1/8W R37 0611077A74 RES CHIP 1000 5 1/8
Q134 4880141L01 TSTR PNP SOT23 LO PROFILE R129 0611077A98 RES CHIP 10K 5 1/8W
TAPE
R13 0611077A98 RES CHIP 10K 5 1/8W
R130 0611077A90 RES CHIP 4700 5 1/8
TAPE R165 0611077A98 RES CHIP 10K 5 1/8W R41 0611077A98 RES CHIP 10K 5 1/8W
R131 0611077A58 RES CHIP 220 5 1/8W
Q162 4880141L02 TSTR NPN SOT23 LO PROFILE R166 0611077A82 RES CHIP 2200 5 1/8 R43 0611077B15 RES CHIP 47K 5 1/8W
TAPE R132 0611077A98 RES CHIP 10K 5 1/8W
Q170 4880141L01 TSTR PNP SOT23 LO PROFILE R134 0611077A78 RES CHIP 1500 5 1/8
TAPE R170 0611077B23 RES CHIP 100K 5 1/8W R5 0611077B23 RES CHIP 100K 5 1/8W
R135 0611077A94 RES CHIP 6800 5 1/8
Q171 4880141L02 TSTR NPN SOT23 LO PROFILE R171 0611077B15 RES CHIP 47K 5 1/8W R50 0611077A66 RES CHIP 470 5 1/8W
TAPE R136 0611077A82 RES CHIP 2200 5 1/8
Q23 4880141L02 TSTR NPN SOT23 LO PROFILE R137 0611077A36 RES CHIP 27 5 1/8W
R138 0611077A58 RES CHIP 220 5 1/8W
Q40 4880141L01 TSTR PNP SOT23 LO PROFILE R18 0611077A98 RES CHIP 10K 5 1/8W R53 0611077A19 RES CHIP 5.1 5 1/8W
TAPE R139 0611077A82 RES CHIP 2200 5 1/8
R181 0611077B07 RES CHIP 22K 5 1/8W R54 0611077A19 RES CHIP 5.1 5 1/8W
R14 0611077A98 RES CHIP 10K 5 1/8W
6881096C77-O September 26, 2003

MOTOROLA MOTOROLA
ITEM PART DESCRIPTION ITEM PART DESCRIPTION
NUMBER NUMBER
R55 0611077A28 RES CHIP 12 5 1/8W U8 5180177M03 QUAD NAND GATE
MMBZ5245B_
R57 0611077B11 RES CHIP 33K 5 1/8W
VR10 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R6 0611077B07 RES CHIP 22K 5 1/8W
VR12 4813832C28 ZENER BPLR 15V FOR ESD
R60 0611077A94 RES CHIP 6800 5 1/8
SOT23
R61 0611077A74 RES CHIP 1000 5 1/8
VR2 4813830A28 DIODE 15V 5% 225MW
R7 0611077A90 RES CHIP 4700 5 1/8 MMBZ5245B_
MMBZ5245B_
R72 0611077B11 RES CHIP 33K 5 1/8W
R73 0611077B11 RES CHIP 33K 5 1/8W SOT23
MMBZ5245B_
R75 0611077A98 RES CHIP 10K 5 1/8W
VR50 4813830C43 DIODE 43V ‘M5’ MMSZ5260BT1
R8 0611077A90 RES CHIP 4700 5 1/8
VR514 4813830A28 DIODE 15V 5% 225MW
R81 0611077A98 RES CHIP 10K 5 1/8W MMBZ5245B_
MMBZ5245B_
R87 0611077A98 RES CHIP 10K 5 1/8W
VR7 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
RT133 0680149M02 THERMISTOR CHIP 100K OHM
VR9 4813830A28 DIODE 15V 5% 225MW
U10 5180177M02 WIDE BODY SOLC OCTAL
MMBZ5245B_
LATCH
U101 5180236C05 IC VF DRVR SN75518FN
U102 7280242J01 DISPLAY VF
U2 5113802A01 IC 68HC11 W/SCI SPI A/D 512

(HCN1078
only)

2903
U4 5180057S04 “IC CUST SER I/O 13”” REEL”
U46 5113816G04 IC +5V REG 78M05
U5 5197014A10 IC SPECTRA MEMORY BD
U6 5184704M54 IC CMOS REGISTER
U7 Not Available IC PROM
September 26, 2003 6881096C77-O

REMOTE CONTROL HEAD INTERCONNCECT BOARD REMOTE CONTROL HEAD CABLE 25 PIN REMOTE COMMAND BOARD
W4/W5/W7 CONNECTOR (P2) CONNECTOR (P502)
CONTROL HEAD SIDE CABLE SIDE P1 P2
27 12 12 12 12 JU631 JU632 6
MIC HI MIC HI MICROPOHONE HI (BLK/YEL) MIC HI
3 13 13 11 11 7
MIC LO MIC LO MICROPOHONE LO (SHIELD) MIC LO
28 45 45 9 9 JU609 13
HUB HUB DETECTED AUDIO (BLK/BRN) DETECTED AUDIO
JU1005 16 16 10 10 NC
SHIELD GND DETECTED AUDIO (SHIELD/ANALOG GROUND) ANALOG GROUND
24 46 46 1 1 JU650 24
PTT PTT SP 1 (BLK/GRN) PTT/VIP IN 1
JU1006 NC NC
SP 1 (SHIELD)
25 33 33 23 23 9
BUSY BUSY BUSY (BLK/RED) BUSY
TO COMMAND BOARD
10 50 50 14 14 22
BUS - BUS - BUS - (BLACK) BUS -
22 17 17 5 5 25
BUS + BUS + BUS + (WHITE) BUS +
21 21 NC
BUS SHIELD (BARE) BUS SHIELD
23 26 26 19 19 JU601 11
RESET RESET RESET (BLK/ORG) RESET
8 28 28 16 16 JU615 14
SPARE 1 SPARE 1 SPARE 1 (BROWN) SPARE 1 SPARE 1
7 29 29 17 17 JU512 18
SPARE 2 SPARE 2 SPARE 2 (RED) SPARE 2 VIP OUT 1
4 48 48 22 22 JU614 27
SW B+ SW B+ SW B+ (YELLOW) SWB+ SPARE 2
TO W4 / W5/ W 7 CONTROL HEAD 12 49 49 18 18 17
DIGITAL GROUND (BLUE) DIGITAL GROUND JU513 VIP OUT 2
RADIO SECTION
11 11 24 24 JU12 31
SPEAKER LO (GREEN) SPEAKER LO SWB+
26
KEY SLOT NC
JU1008 44 44 25 25
SPEAKER HI (ORANGE) SPEAKER HI
6 34
GND SPEAKER LO
27 27 13 13
EMER EMERGENCY (VIOLET) EMERGENCY
13 35
GND SPEAKER HI
JU1001 43 2 FIL AUD SHLD
CONTROL HEAD SIDE R608 3
EMERGENCY
10 JU604
P9
JU1007
5 B+/A+ 47 1
B+/A+
11 15 2
IGNITION IGNITION
REMOTE RADIO INTERCONNECT BOARD (LOW/MID POWER)
30
A+
1 14 43 E1
VF SENSE 1 VF SENSE 1 SPEAKER HI (BLK/ORG)
2 31 10 E2
VF SENSE 2 VF SENSE 2 SPEAKER LO (BLK/GRN)
32
NC
RADIO SIDE
18 2
VIP-OUT-1/DEK-CLOCK VIP-OUT-1
19 1 47
VIP-OUT-2/DEK-DATA-OUT VIP-OUT-2 B+ (GREEN)
14 34 15
VIP-OUT-3/DEK-STROBE VIP-OUT-3/DEK-STROBE IGNITION (ORANGE)
17 VIP-IN-1 VIP-IN-1 4
15 VIP-IN-3/DEK-DATA-IN VIP-IN-3/DEK-DATA-IN 37
9 SNET-KEY NC DEK-DATA-OUT 5
20 SNET-KID NC DEK-CLOCK 38
VIP SECTION
21 SNET-WE NC SWB+ 18
SWB+ 19
SWB+ 35
DIG-GND 20
DIG-GND 21
DIG-GND 36
41
SWB+
8
MIC-HI
7
MIC-LO
JU1002 24
PTT
JU1003 40
EMERG/HUB
MIC SECTION
JU1004 23
PTT/HUB-REF
Figure 8-18. W4, W5, and W7 Control Head Low-/Mid-Power Interconnection Diagram
6881096C77-O September 26, 2003

REMOTE CONTROL HEAD INTERCONNCECT BOARD REMOTE CONTROL HEAD CABLE

25 PIN REMOTE COMMAND BOARD
W4/W5/W7 CONNECTOR (P2) CONNECTOR (P502)
CONTROL HEAD SIDE CABLE SIDE
27 MIC HI MIC HI 12 12 MICROPOHONE HI (BLK/YEL) 12 12 MIC HI JU632 MIC HI 6
3 MIC LO MIC LO 13 13 MICROPOHONE LO (SHIELD) 11 11 MIC LO MIC LO 7
28 HUB HUB 45 45 DETECTED AUDIO (BLK/BRN) 9 9 DETECTED AUDIO JU641 JU609 13
JU1005 16 16 DETECTED AUDIO (SHIELD/ANALOG GROUND) 10 10 ANALOG GROUND NC
SHIELD GND
24 PTT PTT 46 46 SP 1 (BLK/GRN) 1 1 PTT JU650 JU646 PTT 24
JU1006 NC SP 1 (SHIELD) NC
25 BUSY 33 33 BUSY (BLK/RED) 23 23 BUSY JU638 BUSY 9

BUSY
10 BUS - 50 50 BUS - (BLACK) 14 14 BUS - JU639 BUS - 22
BUS -
22 BUS + 17 17 BUS + (WHITE) 5 5 BUS + JU640 BUS + 25
BUS +
BUS SHIELD (BARE) 21 21 BUS SHIELD JU643 NC

23 RESET RESET 26 26 RESET (BLK/ORG) 19 19 RESET JU601 JU637 RESET 11
8 SPARE 1 28 28 SPARE 1 (BROWN) 16 16 SPARE 1 JU644 JU615 SPARE 1 14
SPARE 1
7 SPARE 2 29 29 SPARE 2 (RED) 17 17 SPARE 2 JU645 JU614 SPARE 2 27
SPARE 2
4 SW B+ 48 48 SW B+ (YELLOW) 22 22 SWB+
SW B+
TO W4 / W 5 / W 7 CONTROL HEAD
RADIO SECTION
12 49 49 DIGITAL GROUND (BLUE) 18 18 DIGITAL GROUND
11 11 24 24 SPEAKER LO JU636 SWB+ 31
26 SPEAKER LO (GREEN)
KEY SLOT NC JU1008 44 44 SPEAKER HI (ORANGE) 25 25 SPEAKER HI JU633 JU657
6 GND SPEAKER LO 34
27 27 EMERGENCY (VIOLET) 13 13 EMERGENCY
EMER
13 JU655 SPEAKER HI 35
GND
JU1001 43 1
JU630 EMERGENCY 3
10 CONTROL HEAD SIDE 2 2
FIL AUD SHLD
JU1007 JU642
5 B+/A+ 47 E1 JU604
B+/A+
11 15 E2 20 A+ JU653 A+ 30
IGNITION IGNITION
30
A+
RADIO SIDE
1 14 43 SPEAKER HI (BLK/ORG) 3 IGN JU616 IGN 21
VF SENSE 1 VF SENSE 1
2 31 10 SPEAKER LO (BLK/GRN)
VF SENSE 2 VF SENSE 2 15 RSSI/VOL (A2) JU659 RSSI/VOL 2
32
NC
8 TX-AUDIO JU606 TX-AUDIO 12
47 B+ (GREEN)
18 2 7 RX-AUDIO JU663 JU607 RX-AUDIO 8
VIP-OUT-1/DEK-CLOCK VIP-OUT-1 15 IGNITION (ORANGE)
19 1 6 FLT_AUDIO JU662 JU608 FLT-AUDIO 5
VIP-OUT-2/DEK-DATA-OUT VIP-OUT-2
14 VIP-OUT-3/DEK-STROBE VIP-OUT-3/DEK-STROBE 34
ANA-GND 10
DIG-GND 28
9 SNET-KEY NC DEK-DATA-OUT 5
20 SNET-KID NC DEK-CLOCK 38
21 SNET-WE NC SWB+ 18 REMOTE RADIO INTERCONNECT BOARD (HIGH POWER) 9.6V 1
VIP SECTION
SWB+ 19
SWB+ 35
DIG-GND 20
DIG-GND 21
DIG-GND 36
41
SWB+
8
MIC-HI
7
MIC-LO
JU1002 24
PTT
JU1003 40
EMERG/HUB
MIC SECTION
JU1004 23
PTT/HUB-REF
Figure 8-19. W4, W5, and W7 High Power Interconnection Diagram
September 26, 2003 6881096C77-O

HLN6432D W5/W7
CONTROL HEAD INTERFACE BOARD
9000 CABLE
INTERFACE CONN. CONTROL HEAD
P0100 CONNECTOR
J0103
12 MIC-HI MIC-HI 27
13 MIC-L0 MIC-LO 3
45 HUB HUB 28
46 PTT JU1005* PTT 24
33 BUSY JU1006* BUSY 25
17 BUS+ BUS+ 22
50 BUS BUS 10
26 RESET RESET 23
28 SPARE 1 SPARE 1 8
29 SPARE 2 SPARE 2 7
47 A+ A+ 5
15 IGN IGN 11
48 SWB+ SWB+ 4
11 SPKR LO VR1001 VR1003** 12
RADIO SECTION
44 SPKR HI 15V VF SENSE 1 1
VF SENSE 2 2
43 SPKR HI VR1002
10 SPKR LO 15V
27 EMERGENCY KEY SLOT 26
16 SHIELD GND JU1001*
14 VF SENSE 1 JU1008
GND 6
49 DIGITAL GND
GND 13
30 A+ JU1007
31 VF SENSE 2
32
2 VIP-OUT-1 VIP-OUT-1/DEK-CLOCK 18
1 VIP-OUT-2 VIP-OUT-2/DEK-DATA-OUT 19
34 VIP-OUT-3/DEK-STROBE VIP-OUT-3/DEK-STROBE 14
5 DEK-DATA-OUT
38 DEK-CLOCK
SNET-KEY 9
18 SWB+
VIP SECTION
19 SWB+ SNET-KID 20
35 SWB+ SNET-WE 21
20 DIG-GND
21 DIG-GND
36 DIG-GND
* = PARTS NOT PLACED
** = 0105950T92 ONLY
41 SWB+
8 MIC-HI
7 MIC-LO
JU1002*
24 PTT
JU1003*
MIC SECTION
40 EMERG/HUB
23 PTT/HUB-REF JU1004*
MAEPF-23570-A
Figure 8-20. W5 and W7 Control Head Interface Board Schematic
6881096C77-O September 26, 2003

HLN6432D W5/W7 Parts List
JU1001
JU1005
VR1001 VR1002
Motorola
JU1008
JU1007
VR1003 Item Part Description
JU1004
Number

JU1006
JU1003
JU1002
VR1001 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR1002 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR1003 NOTPLACED 64AM DUMMY PART NUMBER
Figure 8-21. HLN6432D W5/W7 Control Head Interface Board Component Location Diagram
September 26, 2003 6881096C77-O

HLN6401A
CONTROL HEAD INTERCONNECT BOARD
J103 (Dash Mount)
P502
1 NC NC
CR10 1
2 NC NC 3
3 MIC-LOW NOTE
7
4 SWB+ 31
5 A+ 30
6 DIG-GND 28
7 SPARE-2 27
8 SPARE-1 14
9 SERIAL BUS RESET 23
10 BUS- 22
11 IGN 21
12 NC NC
4
13 NC NC 5
14 NC NC
8
JU10 JU11
15 NC NOTE NOTE
NC
10
16 NC NC 12
17 NC NC 13
18 VIP-OUT-1 18
19 VIP-OUT-2
17
20 S.NET_KID/PROG-VPP 16
21 S.NET_WE/PROG-RXD 15
22 BUS+ 25
23 S.NET_KEY/PROG-TXD 11
24 MIC PTT/PROG-RESET 2
25 BUSY 9
26 KEYED-SLOT KEYED-SLOT
32
27 MIC-HI/PROG-MOD-CONTROL
6
28 HUB/PROG BUSY
29
NC 19
NC 20
NC 24
NOTE: NOT COMPATIBLE WITH NC 26
SPECTRA E JU10, JU11, CR10 INSTALLED NC
FOR AVL OPTION. 33
NC 34
TRACE CUT ONLY WHEN NC 35
CR10 INSTALLED.
NC 36
NC 37
NC 38
MAEPF-23575-O
Figure 8-22. HLN6401A Control Head Interconnect Board, (Dash-Mount)
6881096C77-O September 26, 2003

Figure 8-23. HLN6486D/E High Power Standard Interconnect Board
September 26, 2003 6881096C77-O

Figure 8-24. HLN6486D/E High-Power Interconnect Board (Viewed from Side 1)
5
1 3 7 9
6
2 4 8 10
Figure 8-25. HLN6486D/E High-Power Interconnect Board (Viewed from Side 2)
6881096C77-O September 26, 2003

HLN6486E Standard Interconnect Parts List

NUMBER JU609 0611077A01 RES CHIP JUMPER P0502 2880267M04 PLUG RIGHT ANGLE HDR 38 VR625 4813832C28 ZENER BPLR 15V FOR ESD
POS SOT23
P0506 2880068M01 HEADER MIC VR626 4813832C28 ZENER BPLR 15V FOR ESD
C751 2113741N69 CAP CHIP CL2 X7R 10% JU618 0611077A01 RES CHIP JUMPER SOT23
100000 R601 0611077A01 RES CHIP JUMPER
JU619 0611077A01 RES CHIP JUMPER VR627 4813832C28 ZENER BPLR 15V FOR ESD
C752 2113740B49 CAP CHIP REEL CL1 +/-30 100 R602 0611077A01 RES CHIP JUMPER SOT23
C754 2113740B49 CAP CHIP REEL CL1 +/-30 100 R603 0611077A01 RES CHIP JUMPER VR628 4813832C28 ZENER BPLR 15V FOR ESD
SOT23
C755 2113740B49 CAP CHIP REEL CL1 +/-30 100 R614 0611077A98 RES CHIP 10K 5 1/8W
C756 2113740B49 CAP CHIP REEL CL1 +/-30 100 VR600 4813830A28 DIODE 15V 5% 225MW
JU623 0611077A01 RES CHIP JUMPER MMBZ5245B_
JU626 0611077A01 RES CHIP JUMPER VR601 4813830A28 DIODE 15V 5% 225MW
C763 2113741N45 CAP CHIP CL2 X7R 10% 10000 MMBZ5245B_
MMBZ5245B_
VR603 4813830A28 DIODE 15V 5% 225MW
C771 2113740B49 CAP CHIP REEL CL1 +/-30 100 MMBZ5245B_
H0001 0300139581 SCR MCH 4-40X5/16 PHLPAN VR612 4813830A28 DIODE 15V 5% 225MW
STL JU653 0611077A01 RES CHIP JUMPER MMBZ5245B_
H0002 0300139581 SCR MCH 4-40X5/16 PHLPAN JU655 0611077A01 RES CHIP JUMPER VR613 4813830A28 DIODE 15V 5% 225MW
STL MMBZ5245B_
STL MMBZ5245B_
STL JU664 0611077A01 RES CHIP JUMPER MMBZ5245B_
J0005 0980159P02 CONNECTOR 25-PIN JU665 0611077A01 RES CHIP JUMPER VR617 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
J0006 0980159P02 CONNECTOR 25-PIN JU666 0611077A01 RES CHIP JUMPER
VR618 4813830A28 DIODE 15V 5% 225MW
JU601 0611077A01 RES CHIP JUMPER JU671 0611077A01 RES CHIP JUMPER MMBZ5245B_
JU604 0611077A01 RES CHIP JUMPER JU672 0611077A01 RES CHIP JUMPER VR623 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
JU606 0611077A01 RES CHIP JUMPER JU673 0611077A01 RES CHIP JUMPER
VR624 4813830A28 DIODE 15V 5% 225MW
JU607 0611077A01 RES CHIP JUMPER JU674 0611077A01 RES CHIP JUMPER MMBZ5245B_
September 26, 2003 6881096C77-O

Figure 8-26. HLN6574E W3 Control Head High-Power Interconnect Board Schematic Design
6881096C77-O September 26, 2003

MAEPF-25697-O
MAEPF-25698-O
Figure 8-27. HLN6574E W3 High Power Interconnect Board Component Location Diagrams
September 26, 2003 6881096C77-O

HLN6574E W3 High-Power Interconnect Parts List

NUMBER C4 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU15 NOTPLACED 64AM DUMMY PART NUMBER JU46 0611077A01 RES CHIP JUMPER
C1 2113740B65 CAP CHIP REEL CL1 +/-30 470 C5 2113740B49 CAP CHIP REEL CL1 +/-30 100 JU16 0611077A01 RES CHIP JUMPER JU47 0611077A01 RES CHIP JUMPER
C12 2113740B65 CAP CHIP REEL CL1 +/-30 470 C8 2113740B49 CAP CHIP REEL CL1 +/-30 100 JU19 0611077A01 RES CHIP JUMPER JU5 0611077A74 RES CHIP 1000 5 1/8
C14 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR1 4813833C10 DIODE GEN PUR 70V JU20 0611077A01 RES CHIP JUMPER JU51 0611077A01 RES CHIP JUMPER
MMBD6050
C15 2113740B49 CAP CHIP REEL CL1 +/-30 100 JU21 0611077A01 RES CHIP JUMPER JU52 NOTPLACED 64AM DUMMY PART NUMBER
CR2 4813833C10 DIODE GEN PUR 70V
C16 2113740B49 CAP CHIP REEL CL1 +/-30 100 MMBD6050 JU22 0611077A01 RES CHIP JUMPER JU53 0611077A01 RES CHIP JUMPER
MMBD6050
C18 2113740B49 CAP CHIP REEL CL1 +/-30 100 JU24 NOTPLACED 64AM DUMMY PART NUMBER JU55 NOTPLACED 64AM DUMMY PART NUMBER
C19 2113740B49 CAP CHIP REEL CL1 +/-30 100 JU25 0611077A01 RES CHIP JUMPER JU56 0611077A01 RES CHIP JUMPER
MMBD6050
C20 2113740B49 CAP CHIP REEL CL1 +/-30 100 MMBD6050 JU27 0611077A01 RES CHIP JUMPER JU58 NOTPLACED 64AM DUMMY PART NUMBER
MMBD6050
C23 2113740B49 CAP CHIP REEL CL1 +/-30 100 MMBD6050 JU30 0611077A01 RES CHIP JUMPER JU60 NOTPLACED 64AM DUMMY PART NUMBER
C24 2113740B49 CAP CHIP REEL CL1 +/-30 100 CR8 NOTPLACED 64AM DUMMY PART NUMBER JU31 0611077A01 RES CHIP JUMPER JU61 NOTPLACED 64AM DUMMY PART NUMBER
C25 2113740B49 CAP CHIP REEL CL1 +/-30 100 H0001 0300139581 SCR MCH 4-40X5/16 PHLPAN JU32 0611077A01 RES CHIP JUMPER JU62 0611077A01 RES CHIP JUMPER
STL
H0002 0300139581 SCR MCH 4-40X5/16 PHLPAN
C27 2113740B65 CAP CHIP REEL CL1 +/-30 470 STL JU34 0611077A01 RES CHIP JUMPER JU8 NOTPLACED 64AM DUMMY PART NUMBER
C28 2113740B65 CAP CHIP REEL CL1 +/-30 470 H0003 0300139581 SCR MCH 4-40X5/16 PHLPAN JU35 0611077A01 RES CHIP JUMPER JU9 NOTPLACED 64AM DUMMY PART NUMBER
STL
C29 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU36 0611077A01 RES CHIP JUMPER P502 2880267M04 PLUG RIGHT ANGLE HDR 38
H0004 0300139581 SCR MCH 4-40X5/16 PHLPAN POS
C3 2113740B65 CAP CHIP REEL CL1 +/-30 470 STL JU37 0611077A01 RES CHIP JUMPER
P506 2880068M01 HEADER MIC
C30 2113740B65 CAP CHIP REEL CL1 +/-30 470 HU3 NOTPLACED 64AM DUMMY PART NUMBER JU38 0611077A01 RES CHIP JUMPER
Q2 4880048M01 TSTR NPN DIG 47K/47K
C31 2113741N45 CAP CHIP CL2 X7R 10% 10000 J5 0980159P02 CONNECTOR 25-PIN JU39 0611077A01 RES CHIP JUMPER
Q3 4880052M01 TSTR NPN DRLNGTN MXTA27
C32 2113741N45 CAP CHIP CL2 X7R 10% 10000 J6 0980159P02 CONNECTOR 25-PIN JU4 2113741N69 CAP CHIP CL2 X7R 10%
100000 Q4 4813821A32 TSTR P-CH PWR FET 60V 5A
C33 2113741N69 CAP CHIP CL2 X7R 10% JU1 0611077A01 RES CHIP JUMPER
100000 JU40 0611077A01 RES CHIP JUMPER Q5 4880052M01 TSTR NPN DRLNGTN MXTA27
C34 2113741N69 CAP CHIP CL2 X7R 10% JU41 NOTPLACED 64AM DUMMY PART NUMBER R1 NOTPLACED 64AM DUMMY PART NUMBER
100000 JU11 0611077A01 RES CHIP JUMPER
JU42 0611077A01 RES CHIP JUMPER R10 0611077B15 RES CHIP 47K 5 1/8W
C35 2311049J26 CAP TANT CHIP 10 20 16 JU12 0611077A01 RES CHIP JUMPER
C37 2311049J26 CAP TANT CHIP 10 20 16 JU13 0611077A01 RES CHIP JUMPER
C38 2311049A37 CAP TANT CHIP 1 20 20 JU14 0611077A01 RES CHIP JUMPER
JU45 0611077A01 RES CHIP JUMPER R13 0611077A54 RES CHIP 150 5 1/8W
6881096C77-O September 26, 2003

MOTOROLA MOTOROLA
NUMBER NUMBER
R14 0611077A74 RES CHIP 1000 5 1/8 VR21 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R15 0611077A74 RES CHIP 1000 5 1/8
VR22 4813830A28 DIODE 15V 5% 225MW
R2 NOTPLACED 64AM DUMMY PART NUMBER MMBZ5245B_
MMBZ5245B_
R4 0611077A98 RES CHIP 10K 5 1/8W
VR24 4813830A28 DIODE 15V 5% 225MW
R5 0611077A98 RES CHIP 10K 5 1/8W
MMBZ5245B_
R6 0611077A98 RES CHIP 10K 5 1/8W
VR25 4813830A28 DIODE 15V 5% 225MW
R9 0611077B15 RES CHIP 47K 5 1/8W VR26 4880140L23 DIODE SOT ZENER 18V
TAPE&REEL
U1 5113806A05 IC FLIP-FLOP,DUAL D
VR27 4813830A28 DIODE 15V 5% 225MW
U2 5113806A37 IC SCHMITT TRIGGER,HEX MMBZ5245B_
U3 5113816A19 IC ADJ LO DROPOUT POS VR3 4813832C28 ZENER BPLR 15V FOR ESD
REG .8A SOT23
VR1 4813830A28 DIODE 15V 5% 225MW VR4 4813832C28 ZENER BPLR 15V FOR ESD
MMBZ5245B_ SOT23
VR10 4813830A28 DIODE 15V 5% 225MW VR5 4813832C28 ZENER BPLR 15V FOR ESD
MMBZ5245B_ SOT23
VR11 4813830A28 DIODE 15V 5% 225MW VR6 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_ MMBZ5245B_
VR15 4813830A28 DIODE 15V 5% 225MW

MMBZ5245B_
VR16 4813830A28 DIODE 15V 5% 225MW

MMBZ5245B_
VR17 4813830A28 DIODE 15V 5% 225MW

MMBZ5245B_
VR18 4813830A28 DIODE 15V 5% 225MW

MMBZ5245B_
VR19 4813830A28 DIODE 15V 5% 225MW

MMBZ5245B_

SOT23
VR20 4813830A28 DIODE 15V 5% 225MW

MMBZ5245B_
September 26, 2003 6881096C77-O

- NOT PLACED
MAEPF-27094-O
Figure 8-28. HLN6459D, HLN6344E, and HLN6365E Low-Power Interconnect Board Schematic
6881096C77-O September 26, 2003

MAEPF-27093-O
JU658 Q60I
3 3 1
I E
2 3 B
2 U 3 I 3 Q602 2
I 2
I 2 2
I 3 3
3 I 2 I
JU657
VR625
C792
MAEPF-27703-O
Figure 8-29. HLN6459D, HLN6344E, and HLN6365 Low-Power Interconnect Component Location Diagram
September 26, 2003 6881096C77-O

HLN6459D W3 Low-Power Interconnect Parts List

NUMBER C783 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU513 NOTPLACED 64AM DUMMY PART NUMBER JU632 0611077A01 RES CHIP JUMPER
C732 2113740B65 CAP CHIP REEL CL1 +/-30 470 C784 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU600 0611077A01 RES CHIP JUMPER JU633 NOTPLACED 64AM DUMMY PART NUMBER
C750 2113740B65 CAP CHIP REEL CL1 +/-30 470 C785 2113741N69 CAP CHIP CL2 X7R 10% JU601 NOTPLACED 64AM DUMMY PART NUMBER JU634 NOTPLACED 64AM DUMMY PART NUMBER
100000
C786 2113741N69 CAP CHIP CL2 X7R 10%
C752 2113740B65 CAP CHIP REEL CL1 +/-30 470 100000 JU603 NOTPLACED 64AM DUMMY PART NUMBER JU636 NOTPLACED 64AM DUMMY PART NUMBER
C753 2113740B65 CAP CHIP REEL CL1 +/-30 470 C787 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU604 0611077A01 RES CHIP JUMPER JU637 0611077A01 RES CHIP JUMPER
C754 2113740B65 CAP CHIP REEL CL1 +/-30 470 C788 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU605 NOTPLACED 64AM DUMMY PART NUMBER JU638 0611077A01 RES CHIP JUMPER
C755 2113740B65 CAP CHIP REEL CL1 +/-30 470 C789 2311049J26 CAP TANT CHIP 10 20 16 JU606 0611077A01 RES CHIP JUMPER JU640 0611077A01 RES CHIP JUMPER
C757 2113740B65 CAP CHIP REEL CL1 +/-30 470 C791 2311049J26 CAP TANT CHIP 10 20 16 JU608 0611077A01 RES CHIP JUMPER JU642 0611077A01 RES CHIP JUMPER
C758 2113740B65 CAP CHIP REEL CL1 +/-30 470 C792 2311049A37 CAP TANT CHIP 1 20 20 JU609 0611077A01 RES CHIP JUMPER JU643 NOTPLACED 64AM DUMMY PART NUMBER
C759 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR600 4813833C10 DIODE GEN PUR 70V JU610 NOTPLACED 64AM DUMMY PART NUMBER JU644 NOTPLACED 64AM DUMMY PART NUMBER
MMBD6050
MMBD6050
C763 2113740B65 CAP CHIP REEL CL1 +/-30 470 MMBD6050 JU614 0611077A01 RES CHIP JUMPER JU652 0611077A01 RES CHIP JUMPER
C764 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR603 4813833C10 DIODE GEN PUR 70V JU615 0611077A01 RES CHIP JUMPER JU653 NOTPLACED 64AM DUMMY PART NUMBER
MMBD6050
C766 2113740B65 CAP CHIP REEL CL1 +/-30 470 MMBD6050 JU617 NOTPLACED 64AM DUMMY PART NUMBER JU655 2113741N69 CAP CHIP CL2 X7R 10%
100000
C767 2113740B65 CAP CHIP REEL CL1 +/-30 470 CR605 4813833C10 DIODE GEN PUR 70V JU618 0611077A01 RES CHIP JUMPER
MMBD6050 JU656 0611077A01 RES CHIP JUMPER
F600 NOTPLACED 64AM DUMMY PART NUMBER JU657 NOTPLACED 64AM DUMMY PART NUMBER
HD001 0300139581 SCR MCH 4-40X5/16 PHLPAN JU658 NOTPLACED 64AM DUMMY PART NUMBER
C770 2113740B65 CAP CHIP REEL CL1 +/-30 470 STL JU621 0611077A01 RES CHIP JUMPER
C771 2113740B65 CAP CHIP REEL CL1 +/-30 470 HD002 0300139581 SCR MCH 4-40X5/16 PHLPAN JU622 0611077A01 RES CHIP JUMPER
STL P502 2880102M09 PLUG VERTICAL 38 POSITION
HD003 0300139581 SCR MCH 4-40X5/16 PHLPAN P506 2880068M01 HEADER MIC
C773 2113740B65 CAP CHIP REEL CL1 +/-30 470 STL JU624 NOTPLACED 64AM DUMMY PART NUMBER
Q601 4880048M01 TSTR NPN DIG 47K/47K
C774 2113740B65 CAP CHIP REEL CL1 +/-30 470 HD004 0300139581 SCR MCH 4-40X5/16 PHLPAN JU625 NOTPLACED 64AM DUMMY PART NUMBER
STL Q602 4813821A32 TSTR P-CH PWR FET 60V 5A
C776 NOTPLACED 64AM DUMMY PART NUMBER JU626 0611077A01 RES CHIP JUMPER
J5 0980159P02 CONNECTOR 25-PIN Q603 4880052M01 TSTR NPN DRLNGTN MXTA27
C777 NOTPLACED 64AM DUMMY PART NUMBER JU627 0611077A01 RES CHIP JUMPER
J6 0980159P02 CONNECTOR 25-PIN Q604 4880052M01 TSTR NPN DRLNGTN MXTA27
C778 NOTPLACED 64AM DUMMY PART NUMBER JU628 NOTPLACED 64AM DUMMY PART NUMBER
JU10 NOTPLACED 64AM DUMMY PART NUMBER R600 NOTPLACED 64AM DUMMY PART NUMBER
6881096C77-O September 26, 2003

MOTOROLA MOTOROLA
NUMBER NUMBER
MMBZ5245B_
VR607 4813830A28 DIODE 15V 5% 225MW
R606 NOTPLACED 64AM DUMMY PART NUMBER MMBZ5245B_
MMBZ5245B_
R608 0611077A01 RES CHIP JUMPER
VR609 4813830A28 DIODE 15V 5% 225MW
R609 0611077B15 RES CHIP 47K 5 1/8W
MMBZ5245B_
R610 0611077B15 RES CHIP 47K 5 1/8W
VR610 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R614 0611077A98 RES CHIP 10K 5 1/8W
VR612 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
R617 0611077A98 RES CHIP 10K 5 1/8W
R618 0611077A96 RES CHIP 8200 5 1/8 SOT23
R619 0611077B15 RES CHIP 47K 5 1/8W VR615 4813832C28 ZENER BPLR 15V FOR ESD
SOT23
R620 0611077A54 RES CHIP 150 5 1/8W
R621 0611077A74 RES CHIP 1000 5 1/8 SOT23
R622 0611077A74 RES CHIP 1000 5 1/8 VR617 4813832C28 ZENER BPLR 15V FOR ESD
SOT23
R623 0611077A74 RES CHIP 1000 5 1/8
VR618 4813830A28 DIODE 15V 5% 225MW
U600 NOTPLACED 64AM DUMMY PART NUMBER
MMBZ5245B_
U601 5113806A05 IC FLIP-FLOP,DUAL D
VR619 4813830A28 DIODE 15V 5% 225MW
U602 5113806A37 IC SCHMITT TRIGGER,HEX MMBZ5245B_
U603 5113816A19 IC ADJ LO DROPOUT POS VR620 4813830A28 DIODE 15V 5% 225MW
REG .8A MMBZ5245B_
MMBZ5245B_
MMBZ5245B_
VR622 4813830A28 DIODE 15V 5% 225MW
VR601 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
MMBZ5245B_
VR625 4880140L23 DIODE SOT ZENER 18V
VR604 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_ TAPE&REEL
VR627 NOTPLACED 64AM DUMMY PART NUMBER
September 26, 2003 6881096C77-O

HLN6365E Motorcycle Interconnect Parts List

MOTOROLA MOTOROLA
MOTOROLA NUMBER NUMBER
NUMBER JU651 0611077A01 RES CHIP JUMPER VR619 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR620 4813830A28 DIODE 15V 5% 225MW
C755 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU656 0611077A01 RES CHIP JUMPER MMBZ5245B_
C772 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU657 0611077A01 RES CHIP JUMPER VR621 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
C773 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU659 0611077A01 RES CHIP JUMPER
VR622 4813830A28 DIODE 15V 5% 225MW
GS1 4205747Z01 CLIP GRND P502 2880102M09 PLUG VERTICAL 38 POSITION
MMBZ5245B_
GS2 4205747Z01 CLIP GRND P506 2880068M01 HEADER MIC
J5 0980159P02 CONNECTOR 25-PIN R608 0611077A74 RES CHIP 1000 5 1/8
JU12 0611077A01 RES CHIP JUMPER R618 0611077A96 RES CHIP 8200 5 1/8
MMBZ5245B_
VR601 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR603 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR604 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR606 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR608 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR610 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR612 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR613 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
6881096C77-O September 26, 2003

HLN6344E Standard Interconnect Parts List

MOTOROLA MOTOROLA
MOTOROLA NUMBER NUMBER
NUMBER JU642 0611077A01 RES CHIP JUMPER VR619 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR620 4813830A28 DIODE 15V 5% 225MW
C755 2113740B65 CAP CHIP REEL CL1 +/-30 470 JU654 0611077A01 RES CHIP JUMPER MMBZ5245B_
C772 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU656 0611077A01 RES CHIP JUMPER VR621 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
C773 2113741N45 CAP CHIP CL2 X7R 10% 10000 JU657 0611077A01 RES CHIP JUMPER
VR622 4813830A28 DIODE 15V 5% 225MW
J5 0980159P02 CONNECTOR 25-PIN JU659 0611077A01 RES CHIP JUMPER
MMBZ5245B_
J6 0980159P02 CONNECTOR 25-PIN P502 2880102M09 PLUG VERTICAL 38 POSITION
JU12 0611077A01 RES CHIP JUMPER P506 2880068M01 HEADER MIC
JU512 0611077A01 RES CHIP JUMPER R608 0611077A01 RES CHIP JUMPER
JU513 0611077A01 RES CHIP JUMPER R618 0611077A96 RES CHIP 8200 5 1/8
MMBZ5245B_
VR601 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR603 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR604 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR606 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR608 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR610 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR612 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
VR613 4813830A28 DIODE 15V 5% 225MW
MMBZ5245B_
September 26, 2003 6881096C77-O

CR1301
MK1301 HMN1080A, HMN1061A, HMN1079A Microphone Parts List
C1304
+ + MOTOROLA
C1301
C1302
R1302 NUMBER
C1309 C1301 2111038H35 CAP 27pF 50V

C1302, 2111039B13 CAP 1000 50V
Q1302 C1307
C1308 C1304 2311048C10 CAP 10 50V
R1303
R1305
C1305 0811051A15 CAP .22 63V (HMN1080A & HMN1079A only)
C1307
C1305
C1306
R1306 0811051A11 CAP .047 63V (HMN1061A only)
S1301
C1306 2182133G39 CAP 36 500V (HMN1080A & HMN1079A only)
2111038P50 CAP 220 50V (HMN1061A only)
C1308 2382397D25 CAP .27pF 20V (HMN1080A & HMN1079A only)
0811051A14 CAP .15 63V (HMN1061A only)
GRN BLK BLU WHT RED C1309 2111014H44 CAP 62pF 100V
CR1301 4811034A36 12V Zener
MAEPF-27698-O MK1301 5080258E06 ELECTRET MIC CTRG
Q1302 4811043C05 NPN
Figure 8-30. HMN1080A, HMN1061A, HMN1079A Microphone Board Overlay R1302 0611009C57 RES 2200 1/4
R1303 0611009C49 RES 1000 1/4
R1305 0611009C97 RES 100K 1/4
R1306 0611009C19 RES 56 5 1/4
MK1301 R1302 R1303
2.2K 1K
S1301 4080065E02 SW MOMENTARY
MIC HI (RED)
C1301 C1302
+ C1304
R1305 C1307 C1308 VR1301
S1301
27pF 0.001 10 100K 0.001 0.27 12V
PUSH TO TALK
Q1302
N.C.
M8208
PTT (GRN)
C1309
C1305 62pF
DIG GND (WHT)
0.22
MIC LO (BLK)
C1306 MICROPHONE
36pF CONNECTOR J104
H.U.B. (BLU) (DETAIL SHOWN
R1306 (VEHICLE FROM CONNECTOR
56 CHASSIS FRONT VIEW)
GROUND) MIC MIC
HANG-UP HANG-UP
CLIP STUD
MAEPF-27699-O
Figure 8-31. HMN1080A, HMN1061A, HMN1079A Microphone Schematic

ic
6881096C77-O September 26, 2003

Notes
September 26, 2003 6881096C77-O

Appendix A Replacement Parts Ordering
A.1 Basic Ordering Information

When 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 Online

Motorola 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 Orders

Send written orders to the following addresses:
Replacement Parts/ Federal Government Orders: International Orders:

Test Equipment/Manuals/
Crystal Service Items:
Motorola Inc. Motorola Inc. Motorola Inc.

Radio Products Services Division* U.S. Federal Government Radio Products Services Division*
Attention: Order Processing Markets Division Attention: Order Processing
2200 Galvin Drive Attention: Order Processing 2200 Galvin Drive
Elgin, IL 60123 7230 Parkway Drive Elgin, IL 60123
U.S.A. Landover, MD 21076 U.S.A.
U.S.A.
*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).
A-2 Replacement Parts Ordering: Telephone Orders
A.4 Telephone Orders

Radio Products Services Division*
(United States and Canada)
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
1-847-538-8023 (International Orders)
U.S. Federal Government Markets Division (USFGMD)
1-800-826-1913 Federal Government Parts - Credit Cards Only
8:30 AM to 5:00 PM (Eastern Standard Time)
A.5 Fax Orders

1-800-622-6210
1-847-576-3023 (International)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchase Orders)
A.6 Parts Identification

1-800-422-4210, menu 3
A.7 Product Customer Service

Customer Response Center
(Non-technical Issues)
1-800-247-2346
FAX: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 On/0ff hook control 3-3

operation 3-1
parts list 7-2
power On/Off 3-4
C power supply 3-3
replacing the control head 5-7
cable, P501 extender 6-4 SB9600 Serial Bus Interface 3-1
cautions 1-1 status LEDs 3-3
charts, troubleshooting 5-12 Model W9
cleaning control board 3-9
circuit boards 2-1 bus transceiver 3-10
components 2-1 EEPROM write-protect circuit 3-11
external surfaces 2-1 ignition sense circuits 3-10
component location diagrams 8-1 microprocessor 3-9
control heads power supply 3-10
cabling 6-4 vacuum fluorescent voltage converter 3-10
Model W3 1-2 vehicle interface ports 3-10
Models W4, W5, W7, W9 1-4 watchdog timer 3-9
overview 1-2 controls and indicators 3-9
replacing 5-7 default jumper settings 3-11
Model W3 5-7 display 3-8
Model W4, W5, W7 5-8 display board 3-11
Model W9 5-10 backlight LEDs 3-11
vehicle interface port (VIP) 3-12 status LEDs 3-11
controls vacuum fluorescent display 3-11
Model W3 1-3 vacuum fluorescent display driver 3-11
Model W4, W5, W7, W9 1-6 exploded view 7-5
copyrights operation 3-8
computer software ii parts list 7-5
document ii replacing the control head 5-10
vehicle interface port (VIP) 3-14
Models W4, W5, W7
E backlight LEDs 3-8
bus busy 3-6
extender cable, P501 6-4 hang-up button (HUB) 3-7
ignition sense circuitry 3-7
interface circuitry 3-5
H keypad scan 3-7
microcomputer 3-5
handling precautions 2-2 Model W4 exploded view 7-3
Model W4 parts list 7-3
J Models W5, W7 exploded view 7-4
Models W5, W7 parts list 7-4
jumper configurations 3-11 operation 3-4
power switch/ignition 3-4
push-to-talk (PTT) 3-7
M replacing the control head 5-8
replacing the remote back housing
maintenance interface board 5-5
cleaning 2-1 replacing the vacuum fluorescent display 5-5
inspection 2-1 reset 3-6
manual serial bus data 3-6
notations 1-1 vacuum fluorescent display 3-8
revisions ii vacuum fluorescent display driver IC 3-8
Microphone vacuum fluorescent voltage converter circuitry 3-7
exploded view 7-6 vehicle interface port 3-12
parts list 7-6 voltage regulator 3-5
Model W3
backlight circuit 3-3
display circuit 3-1 N
exploded view 7-2
final reassembly 5-11 notations 1-1
jumper selection 3-3
keypad side keys and top keys 3-2
microphone preamplifier and PTT 3-2
6881096C77-O September 26, 2003

Index-2
P T
parts list 8-1 test equipment and service aids 4-1
large pushbutton parts 7-7 trademark information ii
Microphone 7-6 troubleshooting 5-1
Model W3 7-2 charts 5-12
Model W4 7-3 final reassembly 5-11
Model W5 7-4 replacing the control head 5-7
Model W7 7-4 replacing the remote back housing
Model W9 7-5 interface board 5-5
small pushbutton parts 7-7 replacing the remote interconnect board 5-6
parts, ordering replacement A-1 replacing the vacuum fluorescent display 5-5
product safety information ii tools and supplies 5-1
PTT (push-to-talk) 3-7 waveforms 5-2
R V
reassembly, final 5-11 vacuum fluorescent display, replacing 5-5
Model W3 5-11 vehicle interface port (VIP) 3-12
remote back housing interface board, replacing 5-5 Model W4, W5, W7 3-12
remote interconnect board, replacing 5-6 VIP input connections 3-13
replacement parts, ordering A-1 VIP output connections 3-12
replacing Model W9 3-14
control head 5-7 VIP input connections 3-14
remote back housing interface board 5-5 VIP output connections 3-14
remote interconnect board 5-6 VIP output connections
vacuum fluorescent display 5-5 dash-mount installations 3-12
RF exposure compliance information ii remote-mount installations 3-13
S W
schematics 8-1 warranty xi
Serial Bus Data 3-6 waveforms
troubleshooting 5-2
September 26, 2003 6881096C77-O

Motorola, Inc.
8000 West Sunrise Boulevard
Ft. Lauderdale, FL 33322
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.
*6881096C77*
6881096C77-O

Communications - VHF - Motorola Control Head Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Communications - VHF - Motorola Control Head Service Manual

Uploaded by

Copyright:

Available Formats

®

ASTRO Digital Spectra

and Digital Spectra Plus

Product Safety and RF Exposure Compliance

Computer Software Copyrights

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

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

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

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

6881096C77-O September 26, 2003

3.1.5 On-/Off-Hook Control ........................................................................................................ 3-3

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

September 26, 2003 6881096C77-O

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

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

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

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

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

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

6881096C77-O September 26, 2003

A.5 Fax Orders .....................................................................................................................................A-2

September 26, 2003 6881096C77-O

Figure 1-1. Typical W3 Hand-Held Control Head .................................................................................... 1-3

6881096C77-O September 26, 2003

September 26, 2003 6881096C77-O

6881096C77-O September 26, 2003

September 26, 2003 6881096C77-O

I. What This Warranty Covers And For How Long

ASTRO Digital Spectra and Digital Spectra One (1) Year

Product Accessories One (1) Year

II. General Provisions

6881096C77-O September 26, 2003

III. State Law Rights

IV. How To Get Warranty Service

V. What This Warranty Does Not Cover

September 26, 2003 6881096C77-O

VI. Patent And Software Provisions

VII. Governing Law

6881096C77-O September 26, 2003

September 26, 2003 6881096C77-O

1.1 Notations Used in This Manual

! CAUTION indicates a potentially hazardous situation which, if

! WARNING indicates a potentially hazardous situation

DANGER indicates an imminently hazardous

1.2 Control Head Features

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

Display 2 line/ 1 line/ 1 line/ 1 line/ 1 line/

Numeric Yes No No Yes Yes

Channel 255 128 128 255 255

Channel 512 128 128 512 512

Remote Mount Available Available Available Available Available

Dash Mount Available Available Available Available Not Available

1.3 Control Heads

1.3.1 W3 Control Head

September 26, 2003 6881096C77-O

On/Off Orange Programmable Programmable

Side Button 1 (S1)

Side Button 3 (S3)

Control Mode Control

4 GHI 5 JKL 6 MNO Alphanumeric

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

6881096C77-O September 26, 2003

1.3.2 W4, W5, W7, and W9 Control Heads

HOME Home Phon Scan Call Sel Dir Mon