Motorola XTS4000 basic service manual

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ASTRO

XTS Portable Radio Basic Service Manual

4000

Title Page

ASTRO® XTS™ 4000

Digital Portable Radios

Basic Service Manual

Motorola, Inc. 1301 E. Algonquin Rd. Schaumburg, IL 60196-1078 U.S.A.

6871619L01-C

Foreword

This manual covers all models of the ASTRO® XTS™ 4000 digital portable radio, unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.

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

Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio.

ATTENTION!

This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements. Before using this product, read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 6881095C98) to ensure compliance with RF energy exposure limits.

For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which lists approved accessories: http://www.motorola.com/governmentandenterprise

Manual Revisions

Changes which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs provide complete replacement pages for all added, changed, and deleted items, including pertinent parts list data, schematics, and component layout diagrams. To obtain FMRs, contact the nearest Radio Products and Solutions Organization (refer to

“Appendix B 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, FLASHport, and CommPort are registered in the US Patent & Trademark Office. All other products or service names are the property of their respective owners. © 2007–2008 by Motorola, Inc.

Document History iii

Document History

The following major changes have been implemented in this manual since the previous edition:

Edition Description Date

6871619L01-A Initial edition Mar. 2007

6871619L01-B Added UHF band Jan. 2008

6871619L01-C Added PMNN4083 1260 mAh Li-Ion Battery.

Modified Specifications and Accessories info.

Sep. 2008

6871619L01-C September 10, 2008

iv Document History

Notes

September 10, 2008 6871619L01-C

Table of Contents v

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

Product Safety and RF Exposure Compliance ............................................................................................ii

Manual Revisions ........................................................................................................................................ii

Computer Software Copyrights ................................................................................................................... ii

Document Copyrights .................................................................................................................................. ii

Disclaimer....................................................................................................................................................ii

Trademarks .................................................................................................................................................ii

Document History .........................................................................................iii

Table of Contents...........................................................................................v

List of Tables .................................................................................................ix

Commercial Warranty ..................................................................................xii

Limited Warranty ....................................................................................................................................... xii

MOTOROLA COMMUNICATION PRODUCTS ...............................................................................xii

I. What This Warranty Covers And For How Long .................................................................... xii

II. General Provisions ................................................................................................................ xii

III. State Law Rights ................................................................................................................. xiii

IV. How To Get Warranty Service ............................................................................................ xiii

V. What This Warranty Does Not Cover................................................................................... xiii

VI. Patent And Software Provisions ......................................................................................... xiv

VII. Governing Law................................................................................................................... xiv

Model Numbering, Charts, and Specifications..........................................xv

Portable Radio Model Numbering System ................................................................................................ xv

ASTRO XTS 4000 VHF Model Chart ....................................................................................................... xvi

ASTRO XTS 4000 UHF Model Chart ...................................................................................................... xvii

Specifications for VHF Radios................................................................................................................ xviii

Specifications for UHF Range 1 Radios ................................................................................................... xix

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

1.1 Manual Contents............................................................................................................................ 1-1

1.2 Notations Used in This Manual...................................................................................................... 1-1

1.3 Radio Description .......................................................................................................................... 1-2

1.4 FLASHport

................................................................................................................................... 1-2

6871619L01-C September 10, 2008

vi Table of Contents

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

2.1 General Maintenance..................................................................................................................... 2-1

2.2 Handling Precautions..................................................................................................................... 2-1

2.3 General Repair Procedures and Techniques.................................................................................2-2

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

3.1 Major Assemblies........................................................................................................................... 3-1

3.2 Digital Mode of Operation .............................................................................................................. 3-2

3.3 Main Board.....................................................................................................................................3-3

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

4.1 Recommended Test Equipment .................................................................................................... 4-1

4.2 Service Aids ................................................................................................................................... 4-2

4.3 Field Programming......................................................................................................................... 4-2

Chapter 5 Performance Checks .......................................................... 5-1

5.1 Test Equipment Setup ................................................................................................................... 5-1

5.2 Display Radio Test Mode............................................................................................................... 5-2

5.3 Receiver Performance Checks ...................................................................................................... 5-7

5.4 Transmitter Performance Checks ..................................................................................................5-8

Chapter 6 Radio Alignment Procedures............................................. 6-1

6.1 Test Setup......................................................................................................................................6-1

6.2 Tuner Main Menu........................................................................................................................... 6-2

6.3 Softpot............................................................................................................................................ 6-3

6.4 Radio Information........................................................................................................................... 6-4

6.5 Reference Oscillator Alignment .....................................................................................................6-4

6.6 Transmit Power Alignment............................................................................................................. 6-7

6.7 Transmit Deviation Balance Alignment .......................................................................................... 6-9

6.8 Transmit Deviation Limit Alignment ............................................................................................. 6-11

6.9 Front End Filter Alignment ........................................................................................................... 6-13

6.10 Bit Error Rate ............................................................................................................................... 6-15

6.11 Transmitter Test Pattern ..............................................................................................................6-16

Chapter 7 Encryption ........................................................................... 7-1

7.1 Load an Encryption Key................................................................................................................. 7-1

7.2 Multikey Feature ............................................................................................................................ 7-1

7.3 Select an Encryption Key...............................................................................................................7-1

7.4 Select an Encryption Index ............................................................................................................ 7-2

7.5 Erase an Encryption Key ............................................................................................................... 7-3

September 10, 2008 6871619L01-C

Table of Contents vii

Chapter 8 Disassembly/Reassembly Procedures ............................. 8-1

8.1 XTS 4000 Exploded View (Partial) ................................................................................................ 8-1

8.2 Required Tools and Supplies......................................................................................................... 8-3

8.3 Fastener Torque Chart .................................................................................................................. 8-3

8.4 Antenna ......................................................................................................................................... 8-4

8.5 Battery ........................................................................................................................................... 8-5

8.6 Radio Disassembly ........................................................................................................................ 8-6

8.7 Radio Reassembly....................................................................................................................... 8-17

8.8 Servicing CID Bezel Only ............................................................................................................ 8-30

Chapter 9 Basic Troubleshooting ....................................................... 9-1

9.1 Power-Up Error Codes .................................................................................................................. 9-1

9.2 Operational Error Codes................................................................................................................ 9-2

9.3 Receiver Troubleshooting.............................................................................................................. 9-2

9.4 Transmitter Troubleshooting.......................................................................................................... 9-3

9.5 Encryption Troubleshooting ........................................................................................................... 9-4

Chapter 10 Exploded Views and Parts Lists ...................................... 10-1

10.1 Exploded View and Parts List – Main Assemblies ....................................................................... 10-2

10.2 Exploded View and Parts List – Flip-Front Housing Assemblies ................................................. 10-3

10.3 Exploded View and Parts List – Chassis Assembly..................................................................... 10-4

10.4 Parts List – Service Kit................................................................................................................. 10-5

Appendix A Accessories .........................................................................A-1

A.1 Antennas........................................................................................................................................ A-1

A.2 Batteries and Battery Accessories................................................................................................. A-1

A.3 Carry Accessories..........................................................................................................................A-1

A.4 Chargers........................................................................................................................................ A-1

A.5 Surveillance Accessories...............................................................................................................A-2

Appendix B Replacement Parts Ordering..............................................B-1

B.1 Basic Ordering Information ............................................................................................................B-1

B.2 Motorola Online .............................................................................................................................B-1

B.3 Mail Orders ....................................................................................................................................B-1

B.4 Telephone Orders..........................................................................................................................B-1

B.5 Fax Orders.....................................................................................................................................B-2

B.6 Parts Identification .........................................................................................................................B-2

B.7 Product Customer Service.............................................................................................................B-2

6871619L01-C September 10, 2008

viii Table of Contents

Appendix C Motorola Service Centers...................................................C-1

C.1 Servicing Information .................................................................................................................... C-1

C.2 Motorola Service Center ............................................................................................................... C-1

C.3 Motorola Federal Technical Center............................................................................................... C-1

C.4 Motorola Canadian Technical Logistics Center ............................................................................ C-1

Glossary......................................................................................... Glossary-1

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

September 10, 2008 6871619L01-C

List of Tables ix

List of Tables

Table 1-1. ASTRO XTS 4000 Basic Features........................................................................................ 1-2

Table 2-1. Lead Free Solder Wire Part Number List.............................................................................. 2-2

Table 2-2. Lead Free Solder Paste Part Number List ............................................................................ 2-2

Table 3-1. Local Oscillator and First IF Frequencies .............................................................................3-3

Table 4-1. Recommended Test Equipment............................................................................................4-1

Table 4-2. Service Aids .......................................................................................................................... 4-2

Table 5-1. Initial Equipment Control Settings......................................................................................... 5-2

Table 5-2. Test-Mode Displays............................................................................................................... 5-3

Table 5-3. Test Frequencies (MHz)........................................................................................................ 5-4

Table 5-4. Test Environments ................................................................................................................ 5-5

Table 5-5. Receiver Tests for ASTRO Conventional Channels* ............................................................ 5-7

Table 5-6. Transmitter Tests for ASTRO Conventional Channels* ........................................................ 5-8

Table 6-1. Reference Oscillator Alignment ............................................................................................ 6-6

Table 6-2. Transmit Power Settings ....................................................................................................... 6-8

Table 7-1. Encryption Key Zeroization Options...................................................................................... 7-4

Table 8-1. Corresponding XTS 4000 Exploded View and Parts List...................................................... 8-2

Table 8-2. Required Tools and Supplies ................................................................................................ 8-3

Table 8-3. Fastener Torque Chart.......................................................................................................... 8-3

Table 9-1. Power-Up Error Code Displays............................................................................................. 9-1

Table 9-2. Operational Error Code Displays .......................................................................................... 9-2

Table 9-3. Receiver Troubleshooting Chart ........................................................................................... 9-2

Table 9-4. Transmitter Troubleshooting Chart ....................................................................................... 9-3

Table 9-5. Encryption Troubleshooting Chart ........................................................................................ 9-4

Table 10-1. XTS 4000 Exploded Views and Parts Lists......................................................................... 10-1

Table 10-2. Parts List – Main Assemblies.............................................................................................. 10-2

Table 10-3. Parts List – Flip-Front Housing Assemblies........................................................................ 10-3

Table 10-4. Parts List – Chassis Assembly............................................................................................ 10-4

Table 10-5. Service Kit Table ................................................................................................................. 10-5

Related Publications

XTS 4000 Digital Portable Radio User Guide ............................................................................ 6871618L01

XTS 4000 Digital Portable Radios Detailed Service Manual...................................................... 6871620L01

XTS 4000 Digital Portable Radio User Guide (CD).................................................................... PMLN5057_

Chassis Eliminator Leaflet......................................................................................................... 6871568M01

6871619L01-C September 10, 2008

x List of Figures

List of Figures

Figure 3-1. XTS 4000 Overall Block Diagram ......................................................................................... 3-1

Figure 3-2. Receiver Block Diagram........................................................................................................ 3-2

Figure 3-3. Transceiver (VHF) Block Diagram (Power and Control Omitted).......................................... 3-3

Figure 5-1. Performance Checks Test Setup........................................................................................... 5-1

Figure 6-1. Radio Alignment Test Setup.................................................................................................. 6-1

Figure 6-2. Tuner Software Main Menu................................................................................................... 6-2

Figure 6-3. Typical Softpot Screen – VHF............................................................................................... 6-3

Figure 6-4. Typical Softpot Screen – UHF...............................................................................................6-3

Figure 6-5. Radio Information Screen ..................................................................................................... 6-4

Figure 6-6. Reference Oscillator Alignment Screen – VHF..................................................................... 6-5

Figure 6-7. Reference Oscillator Alignment Screen – UHF..................................................................... 6-6

Figure 6-8. Battery Eliminator with RF Connector and SMA ................................................................... 6-7

Figure 6-9. Transmit Power Alignment Screen (Typical) – VHF .............................................................. 6-8

Figure 6-10. Transmit Power Alignment Screen (Typical) – UHF.............................................................. 6-8

Figure 6-11. Transmit Deviation Balance Alignment Screen – VHF........................................................ 6-10

Figure 6-12. Transmit Deviation Balance Alignment Screen – UHF ....................................................... 6-10

Figure 6-13. Transmit Deviation Limit Alignment Screen – VHF ............................................................. 6-12

Figure 6-14. Transmit Deviation Limit Alignment Screen – UHF............................................................. 6-12

Figure 6-15. Battery Eliminator with RF Connector and SMA ................................................................. 6-13

Figure 6-16. Front End Filter Alignment Screen – VHF........................................................................... 6-14

Figure 6-17. Front End Filter Alignment Screen – UHF........................................................................... 6-14

Figure 6-18. Bit Error Rate Screen .......................................................................................................... 6-16

Figure 6-19. Transmitter Test Pattern Screen – VHF .............................................................................. 6-17

Figure 6-20. Transmitter Test Pattern Screen – UHF ..............................................................................6-17

Figure 8-1. XTS 4000 Partial Exploded View .......................................................................................... 8-2

Figure 8-2. Attaching the Antenna........................................................................................................... 8-4

Figure 8-3. Removing the Antenna .........................................................................................................8-4

Figure 8-4. Attaching the Battery............................................................................................................. 8-5

Figure 8-5. Removing the Battery ...........................................................................................................8-6

Figure 8-6. Separating Flip-Front Housing Assembly From Chassis Assembly......................................8-7

Figure 8-7. Unplugging Flexes ................................................................................................................ 8-8

Figure 8-8. Disconnecting CE-UCM Connector Flex and Lifting Main Board.......................................... 8-8

Figure 8-9. Rotating Main Board 90° and Unplugging Top Control Inner Jumper Flex ...........................8-9

Figure 8-10. Removing Control Band ...................................................................................................... 8-10

Figure 8-11. Removing Audio Jack Dust Cover ......................................................................................8-10

Figure 8-12. Removing CE Dust Cover ................................................................................................... 8-11

Figure 8-13. Removing Audio Jack ......................................................................................................... 8-11

Figure 8-14. Removing CE Retainer and Spacer ....................................................................................8-12

Figure 8-15. Removing CE Board ........................................................................................................... 8-12

Figure 8-16. Disassemble Speaker Compartment Seal, Main Keyboard and UCM Board ..................... 8-13

Figure 8-17. Separating Keypad Backer Inner Jumper Flex ................................................................... 8-14

Figure 8-18. Removing Secure Pad ........................................................................................................8-14

Figure 8-19. Removing Front Housing from Flip Assembly..................................................................... 8-15

Figure 8-20. Removing Tabs from Flip Stopper Pad ............................................................................... 8-15

Figure 8-21. Removing Microphone Boot and Microphone from Front Housing ..................................... 8-16

Figure 8-22. Separating Hinge from Flip Inner Housing ..........................................................................8-16

Figure 8-23. Removing CID Bezel........................................................................................................... 8-17

Figure 8-24. Flip Flex .............................................................................................................................. 8-18

Figure 8-25. Inserting Flip Flex................................................................................................................ 8-19

Figure 8-26. Tongue in CID Bezel into Flip Sub-Assembly...................................................................... 8-19

September 10, 2008 6871619L01-C

List of Figures xi

Figure 8-27. Adhere Flip Flex into Front Housing ................................................................................... 8-20

Figure 8-28. Reassemble UCM Board .................................................................................................... 8-21

Figure 8-29. Attach Secure Pad to Keypad Backer Sub-Assembly ........................................................ 8-21

Figure 8-30. Reassemble Flip Flex ......................................................................................................... 8-22

Figure 8-31. Assemble T6 screws to Front Housing ............................................................................... 8-22

Figure 8-32. Assemble T6 screws to Front Housing ............................................................................... 8-23

Figure 8-33. Inserting Spacer to CE Retainer ......................................................................................... 8-23

Figure 8-34. Reassemble CE Retainer and Spacer ................................................................................ 8-24

Figure 8-35. Reassemble Flip Flex ......................................................................................................... 8-24

Figure 8-36. Slide Audio Jack Insulator into Chassis .............................................................................. 8-25

Figure 8-37. Reassemble CE Connector Dust Cover ............................................................................. 8-25

Figure 8-38. Assemble Audio Jack Dust Cover....................................................................................... 8-26

Figure 8-39. Adhere Assembly Aid.......................................................................................................... 8-26

Figure 8-40. Reassemble Control Band.................................................................................................. 8-27

Figure 8-41. Assemble B Plus Seal to B Plus Connector........................................................................ 8-28

Figure 8-42. Assemble B Plus Seal to B Plus Connector........................................................................ 8-28

Figure 8-43. Holding CE-UCM Flex......................................................................................................... 8-29

Figure 8-44. Reassemble Flexes ............................................................................................................ 8-29

Figure 8-45. Screws Reassemble Sequence ..........................................................................................8-30

Figure 10-1. Exploded View – Main Assemblies .....................................................................................10-2

Figure 10-2. Exploded View – Flip - Front Housing Assemblies ............................................................. 10-3

Figure 10-3. Exploded View – Chassis Assembly................................................................................... 10-4

6871619L01-C September 10, 2008

xii Commercial Warranty

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 XTS 4000 Digital Portable Units One (1) Year

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.

September 10, 2008 6871619L01-C

Commercial Warranty xiii

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

(including, 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:

H. any of the seals on the battery enclosure of cells are broken or show evidence of tampering.

I. 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.

J. Freight costs to the repair depot.

K. A Product which, due to illegal or unauthorized alteration of the software/firmware in the

Product, 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 distributed from MOTOROLA.

L. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of

the Product.

M. Normal and customary wear and tear.

6871619L01-C September 10, 2008

xiv Commercial Warranty

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 continue using the Product or parts or to replace or modify the same so that it becomes noninfringing 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.

September 10, 2008 6871619L01-C

Model Numbering, Charts, and Specifications: Portable Radio Model Numbering System xv

Model Numbering, Charts, and Specifications

Portable Radio Model Numbering System

Typical Model Number:

Position:

Position 1 - Type of Unit

H = Hand-Held Portable

Positions 2 & 3 - Model Series

18 = XTS 4000

Position 4 - Frequency Band

Less than 29.7MHz

29.7 to 35.99MHz

36 to 41.99MHz

42 to 50MHz

66 to 80MHz

74 to 90MHz

Product Specific

136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

Values given represent range only; they are

not absolute.

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Position 7 - Channel Spacing 1 = 5kHz 2 = 6.25kHz 3 = 10kHz 4 = 12.5kHz

H18 K CN 9 P W 9 A N

1234 5 6 7 8 9101112

336 to 410MHz

380 to 470MHz

438 to 482MHz

470 to 520MHz

Product Specific

764 to 870MHz

825 to 870MHz

896 to 941MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

5 = 15kHz 6 = 20/25kHz 7 = 30kHz 9 = Variable/Programmable

Position 12 -

Unique Model Variations

C = Cenelec N = Standard Package

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 10 - Feature Level

1 = Basic 2 = Limited Package 3 = Limited Plus 4 = Intermediate 5 = Standard Package

Position 9 - Primary System Type

Conventional

Privacy Plus

Clear SMARTNET

Advanced Conventional Stat-Alert

Enhanced Privacy Plus

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet

Programmable

Secure Conventional

Secure SMARTNET

6 = Standard Plus 7 = Expanded Package 8 = Expanded Plus 9 = Full Feature/ Programmable

* MPT = Ministry of Posts and Telecommunications

Position 8 - Primary Operation

Conventional/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Programmable

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

6871619L01-C September 10, 2008

xvi Model Numbering, Charts, and Specifications: ASTRO XTS 4000 VHF Model Chart

ASTRO XTS 4000 VHF Model Chart

MODEL NUMBER DESCRIPTION

H18KCN9PW9AN XTS4000 PORTABLE ASTRO DIGITAL 136–174MHZ 1–2W

ITEM NUMBER DESCRIPTION

X NUD2897_ XTS 4000 VHF Tanapa X NUD7115_ XTS 4000 VHF Main X NNTN7097_ XTS 4000 UCM Board X NNTN7098_ Hardware, Tanapa XTS4000 X NNTN7101_ Assembly, Chassis XTS4000 X NNTN7100_ Assembly, Keypad Backer, XTS4000 X NNTN7099_ Assembly, Flip Front Housing, XTS4000 X PMLN5057_ XTS4000 CD UG & Safety X 6871618L01 XTS4000 User Guide

Notes: X = Item Included *•The model number and (sometimes) the FLASHcode can be found on the FCC label on the back of the radio.

• The model number, Host code, DSP code, and (sometimes) the FLASHcode can be found by putting the radio into the Test

Mode.

• The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (NKN1027_ or NKN1029_) and the CPS to read the radio.

September 10, 2008 6871619L01-C

Model Numbering, Charts, and Specifications: ASTRO XTS 4000 UHF Model Chart xvii

ASTRO XTS 4000 UHF Model Chart

MODEL NUMBER DESCRIPTION

H18QCN9PW9AN XTS4000 PORTABLE ASTRO DIGITAL 380–470MHZ 0.25–2W

ITEM NUMBER DESCRIPTION

X NUE3623_ XTS 4000 UHF Tanapa X NUE7350_ XTS 4000 UHF Main X NNTN7097_ XTS 4000 UCM Board X NNTN7098_ Hardware, Tanapa XTS4000 X NNTN7101_ Assembly, Chassis XTS4000 X NNTN7100_ Assembly, Keypad Backer, XTS4000 X NNTN7099_ Assembly, Flip Front Housing, XTS4000 X PMLN5057_ XTS4000 CD UG & Safety X 6871618L01 XTS4000 User Guide

Notes: X = Item Included *•The model number and (sometimes) the FLASHcode can be found on the FCC label on the back of the radio.

• The model number, Host code, DSP code, and (sometimes) the FLASHcode can be found by putting the radio into the Test

Mode.

• The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (NKN1027_ or NKN1029_) and the CPS to read the radio.

6871619L01-C September 10, 2008

xviii Model Numbering, Charts, and Specifications: Specifications for VHF Radios

Specifications for VHF Radios

All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted.

GENERAL

FCC Designation: AZ489FT3814

Frequency Ranges: 136–151 MHz,

(Subject to Antenna operating 145–166 MHz, band - See Appendix A: Antennas

Temperature Range:

Operating: -30°C to +60°C Storage: -40°C to +85°C

Power Supply: Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal: 7.5 Vdc Range: 6 to 9 Vdc

Transmit Current Drain (Typical): 950 mA Receive Current Drain (Rated Audio): 210 mA Standby Current Drain: 89 mA

Recommended Battery:

630 mAh Li-Ion: NNTN6944_

or 1260 mAh Li-Ion: PMNN4083_

Dimensions (H x W x D):

Radio Only (w/o battery, w/o antenna):

(103.2 mm x 55.3 mm x 29.6 mm)

Radio With 630 mAh Li-Ion (NNTN6944_) Only (w/o antenna):

(103.2 mm x 55.3 mm x 34.6 mm)

Radio With 1260 mAh Li-Ion (PMNN4083_) Only (w/o antenna):

(103.2 mm x 55.3 mm x 40.2 mm)

Weight: (w/ Antenna):

Less Battery: 5.6 oz (160 g) With 630 mAh Li-Ion (NNTN6944_):

With 1260 mAh Li-Ion (PMNN4083_):

)162–174 MHz

4.06" x 2.18" x 1.17"

4.06" x 2.18" x 1.36"

4.06" x 2.18" x 1.58"

7.8 oz (220 g)

9.9 oz (280 g)

RECEIVER

(TYPICAL PERFORMANCE)

Bandwidth: 38 MHz

Frequency Stability

(-30 to +60°C; 25°C ref.): ±0.0002%

Rated Audio: 500 mW

Analog Sensitivity*

12 dB SINAD: 0.22 µV

Selectivity*

12.5 kHz Channel: -67 dB 25 kHz Channel: -78 dB

Intermodulation*: -75 dB

Spurious Rejection*: -75 dB

FM Hum and Noise*:

12.5 kHz Channel: -45 dB 25 kHz Channel: -50 dB

Distortion*: 1.50%

Digital Sensitivity**

1% BER: 0.25 µV 5% BER: 0.22 µV

Selectivity**: -63 dB

Intermodulation**: -73 dB

Spurious Rejection**: -75 dB

Residual Audio Noise Ratio (silence)**: -65 dB Residual Audio Noise Power (mute)**:

-65 dBm

Distortion**: 1.00%

TRANSMITTER

(TYPICAL PERFORMANCE)

RF Power:

136–174 MHz: 1–2 Watts

Frequency Stability (typical)

(-30 to +60°C; 25°C ref.): ±0.0002%

Emission (typical conducted): -75 dBc

FM Hum and Noise*

12.5 kHz Channel: -43 dB 25 kHz Channel: -48 dB

Distortion*: 1.0%

Modulation Limiting*

12.5 kHz Channel: ±2.5 kHz 25 kHz Channel: ±5.0 kHz

Adjacent Channel Power Ratio*

12.5 kHz Channel: -67 dB 25 kHz Channel: -78 dB

Modulation Fidelity**

Deviation: 1750 Hz Carrier Frequency Offset: ±0.0002% Error Vector Magnitude: 1.5%

Symbol Rate Accuracy**: 0%

Adjacent Channel Power Ratio**: -69 dB

Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1E

Notes:

Specifications subject to change without notice.

* Measured in ANALOG mode per TIA/EIA 603 under nominal conditions. ** Measured in DIGITAL mode per TIA/EIA IS 102.CAAA under nominal conditions.

September 10, 2008 6871619L01-C

Model Numbering, Charts, and Specifications: Specifications for UHF Range 1 Radios xix

Specifications for UHF Range 1 Radios

All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted.

GENERAL

FCC Designation: AZ489FT4881

Frequency Ranges: 380–470 MHz

(Subject to Antenna operating band - See Appendix A: Antennas

Temperature Range:

Operating: -30°C to +60°C Storage: -40°C to +85°C

Power Supply: Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal: 7.5 Vdc Range: 6 to 9 Vdc

Transmit Current Drain (Typical): 950 mA Receive Current Drain (Rated Audio): 210 mA Standby Current Drain: 89 mA

Recommended Battery:

630 mAh Li-Ion: NNTN6944_

or 1260 mAh Li-Ion: PMNN4083_

Dimensions (H x W x D):

Radio Only (w/o battery, w/o antenna):

(103.2 mm x 55.3 mm x 29.6 mm)

Radio With 630 mAh Li-Ion (NNTN6944_) Only (w/o antenna):

(103.2 mm x 55.3 mm x 34.6 mm)

Radio With 1260 mAh Li-Ion (PMNN4083_) Only (w/o antenna):

(103.2 mm x 55.3 mm x 40.2 mm)

Weight: (w/ Antenna):

Less Battery: 5.6 oz (160 g) With 630 mAh Li-Ion (NNTN6944_):

With 1260 mAh Li-Ion (PMNN4083_):

)

4.06" x 2.18" x 1.17"

4.06" x 2.18" x 1.36"

4.06" x 2.18" x 1.58"

7.8 oz (220 g)

9.9 oz (280 g)

RECEIVER

(TYPICAL PERFORMANCE)

Bandwidth: 90 MHz

Frequency Stability

(-30 to +60°C; 25°C ref.): ±0.0002%

Rated Audio: 500 mW

Analog Sensitivity*

12 dB SINAD: 0.25 µV

Selectivity*

12.5 kHz Channel: -63 dB 25 kHz Channel: -73 dB

Intermodulation*: -70 dB

Spurious Rejection*: -75 dB

FM Hum and Noise*:

12.5 kHz Channel: -40 dB 25 kHz Channel: -45 dB

Distortion*: 2%

Digital Sensitivity**

1% BER: 0.25 µV 5% BER: 0.25 µV

Selectivity**: -63 dB

Intermodulation**: -70 dB

Spurious Rejection**: -75 dB

Residual Audio Noise Ratio (silence)**: -65 dB Residual Audio Noise Power (mute)**:

-53 dBm

Distortion**: 1.00%

TRANSMITTER

(TYPICAL PERFORMANCE)

RF Power:

380–470 MHz: 0.25–2 Watts

Frequency Stability (typical)

(-30 to +60°C; 25°C ref.): ±0.0002%

Emission (typical conducted): -75 dBc

FM Hum and Noise*

12.5 kHz Channel: -40 dB 25 kHz Channel:

Distortion*: 1.2%

Modulation Limiting*

12.5 kHz Channel: ±2.5 kHz 25 kHz Channel: ±5.0 kHz

Adjacent Channel Power Ratio*

12.5 kHz Channel: -67 dB 25 kHz Channel: -75 dB

Modulation Fidelity**

Deviation: 1630 Hz < UHF1 < 1800 Hz Carrier Frequency Offset: ±0.0002% Error Vector Magnitude: < 5%

Symbol Rate Accuracy**: 0%

Adjacent Channel Power Ratio**: -67 dB

Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1E

-43 dB

Notes:

Specifications subject to change without notice.

* Measured in ANALOG mode per TIA/EIA 603 under nominal conditions. ** Measured in DIGITAL mode per TIA/EIA IS 102.CAAA under nominal conditions.

6871619L01-C September 10, 2008

xx Model Numbering, Charts, and Specifications

Notes

September 10, 2008 6871619L01-C

Introduction: Manual Contents 1-1

Chapter 1 Introduction

This manual contains information needed for Levels One and Two radio servicing. Level One servicing consists of radio programming, radio alignment, and installation and removal of the antenna and battery. Level Two servicing covers disassembly and reassembly of the radio to replace circuit boards.

1.1 Manual Contents

Included in this manual are radio specifications for the VHF (136–174 MHz) and UHF (380–470 MHz) frequency bands, a general description of XTS 4000 model, recommended test equipment, service aids, radio alignment procedures, general maintenance recommendations, procedures for assembly and disassembly, and exploded views and parts lists.

1.2 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 due 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

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in equipment damage.

result in death or injury.

DANGER indicates an imminently hazardous situation which, if not avoided, will

result in death or

injury.

6871619L01-C September 10, 2008

1-2 Introduction: Radio Description

1.3 Radio Description

The ASTRO XTS 4000 radios are among the most sophisticated two-way radios available. The radios are available in the VHF (136–174 MHz) and UHF (380–470 MHz) frequency bands.

The ASTRO XTS 4000 radio provides improved voice quality across more coverage area. The digital process, called embedded signaling, intermixes system signaling information with digital voice, resulting in improved system reliability and the capability of supporting a multitude of advanced features.

Table 1-1 describes the basic features of ASTRO XTS 4000 radios.

Table 1-1. ASTRO XTS 4000 Basic Features

Feature XTS4000

Main Display 130 x130 dot matrix, liquid-crystal display (LCD)

CID Display 112 x 32 dot matrix, liquid-crystal display (LCD)

Keypad 3 x 3 Menu Keypad (with 4-way Navigation button)

3 x 4 Alphanumeric Keypad

Channel Capability 850

Dialing from Prestored List Yes

Programmable Softkeys Yes

1.4 FLASHport

The ASTRO XTS 4000 radio utilizes Motorola’s FLASHport technology. FLASHport makes it possible to add software that drives the radio’s capabilities both at the time of purchase and later on. Previously, changing a radio’s features and capabilities meant significant modifications or buying a new radio. But now, similar to how a computer can be loaded with different software, the radio’s features and capabilities can be upgraded with FLASHport software.

September 10, 2008 6871619L01-C

Basic Maintenance: General Maintenance 2-1

Chapter 2 Basic Maintenance

This chapter describes preventive maintenance and handling precautions. Each of these topics provides information vital to the successful operation and maintenance of your radio.

2.1 General Maintenance

In order to avoid operating outside the limits set by the FCC, we recommend that you align the ASTRO XTS 4000 radio’s reference oscillator every time the radio is taken apart, or once per year, whichever comes first. Periodic visual inspection and cleaning is also recommended.

2.1.1 Inspection

Check that the external surfaces of the radio are clean and that all external controls and switches are functional. A detailed inspection of the interior electronic circuitry is not needed.

2.1.2 Cleaning

The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external surfaces of the radio. External surfaces include the housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime.

The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water.

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.

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

2.2 Handling Precautions

Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices, are used in this family of radios. While the attributes of these devices are many, their characteristics make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair. Handling precautions are mandatory for this radio, and are especially important in lowhumidity conditions.

6871619L01-C September 10, 2008

2-2 Basic Maintenance: General Repair Procedures and Techniques

• The XTS 4000 radio casting has a vent port that allow for pressure equalization in the radio. Never poke this vent with any object, such as needles, tweezers, or screwdrivers. This could create a leak path into the radio.

• The pressure equalization vent is located on the chassis, just below the battery contact. Never obstruct or cover the slot with any object, except the designated Audio Jack PC Label (48). Ensure that no oily substances come in contact with this vent.

2.3 General Repair Procedures and Techniques

NOTE

Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit boards — examples shown below) were developed and assembled using environmentally preferred components and solder assembly techniques to comply with the European Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/

95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/ EC. To maintain product compliance and reliability, use only the Motorola specified parts

in this manual.

Any rework or repair on Environmentally Preferred Products must be done using the appropriate lead-free solder wire and lead-free solder paste as stated in the following table:

Table 2-1. Lead Free Solder Wire Part Number List

Motorola

Part Number

1088929Y01 95.5Sn/3.8Ag/0.7Cu RMA Version 2.7-3.2% 217C 52171 0.015” 1lb spool

Alloy Flux Type

Flux Content

by Weight

Melting

Point

Supplier Part

number

Diameter Weight

Table 2-2. Lead Free Solder Paste Part Number List

Motorola Part

Number

1085674C03 NC-SMQ230 900-1000KCPs

Manufacturer Part

Number

Viscosity Type Composition & Percent Metal

Brookfield (5rpm)

Type 3

(-325/+500)

(95.5%Sn-3.8%Ag-0.7%Cu)

89.3%

Liquid

Temperature

217°C

2.3.1 Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement component is not locally available, check the parts list for the proper Motorola part number and order the component from the nearest Motorola Radio Products and Solutions Organization listed in

Appendix B of this manual.

September 10, 2008 6871619L01-C

Basic Maintenance: General Repair Procedures and Techniques 2-3

2.3.2 Rigid Circuit Boards

The family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not accessible, some special considerations are required when soldering and unsoldering components. The through-plated holes may interconnect multiple layers of the printed circuit. Therefore, care should be exercised to avoid pulling the plated circuit out of the hole.

When soldering near the connector pins:

• avoid accidentally getting solder in the connector.

• be careful not to form solder bridges between the connector pins

• closely examine your work for shorts due to solder bridges.

2.3.3 Chip Components

Use the RLN4062 Hot-Air Repair Station for chip component replacement. Adjust the temperature control to 390 °C (735 °F), and adjust the airflow to a minimum setting. Airflow can vary due to component density.

• To remove a chip component:

1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm

(1/8”) above the component to be removed.

2. Begin applying the hot air. Once the solder reflows, remove the component using a pair

of tweezers.

3. Using a solder wick and a soldering iron or a power desoldering station, remove the

excess solder from the pads.

• To replace a chip component using a soldering iron:

1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the

solder pads.

2. Using a pair of tweezers, position the new chip component in place while heating the

fresh solder.

3. Once solder wicks onto the new component, remove the heat from the solder.

4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the

component. If necessary, touch up the first side. All solder joints should be smooth and shiny.

• To replace a chip component using hot air:

1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.

2. Apply a drop of solder paste flux to each pad.

3. Using a pair of tweezers, position the new component in place.

4. Position the hot-air hand piece approximately 0.3 cm (1/8” ) above the component and

begin applying heat.

5. Once the solder wicks to the component, remove the heat and inspect the repair. All

joints should be smooth and shiny.

6871619L01-C September 10, 2008

2-4 Basic Maintenance: General Repair Procedures and Techniques

2.3.4 Shields

Removing and replacing shields is recommended to be done with the Air Blower, BOSCH GHG 603 or equivalent.

• To remove the shield:

1. Place the circuit board in the circuit board holder.

2. Add solder paste flux around the base of the shield.

3. Position the heat-focus head onto the shield.

4. Turn on the heater and wait until the shield lifts off the circuit board.

5. Once the shield is off, turn off the heat, and grab the part with a pair of tweezers.

6. Remove the circuit board from the circuit board holder.

• To replace the shield:

1. Add solder to the shield if necessary, using a micro-tipped soldering iron.

2. Next, rub the soldering iron tip along the edge of the shield to smooth out any excess

solder. Use solder wick and a soldering iron to remove excess solder from the solder pads on the circuit board.

3. Place the circuit board back in the circuit board holder.

4. Place the shield on the circuit board using a pair of tweezers.

5. Position the heat-focus head over the shield.

6. Turn on the heater and wait for the solder to reflow.

7. Once complete, turn off the heat, raise the heat-focus head and wait approximately one

minute for the part to cool.

8. Remove the circuit board and inspect the repair. No cleaning should be necessary.

September 10, 2008 6871619L01-C

Basic Theory of Operation: Major Assemblies 3-1

Chapter 3 Basic Theory of Operation

This chapter discusses the basic operational theory of the ASTRO XTS 4000 radio, which is a wideband, synthesized radio available in the VHF (136–174 MHz) and UHF (380–470 MHz) frequency bands. All ASTRO XTS 4000 radios are capable of ASTRO mode (digital) operation (12.5 kHz).

3.1 Major Assemblies

The ASTRO XTS 4000 radio includes the following major connections to the main board (See Figure 3-1):

• Main Board — contains a dual-core processor which includes both the microcontroller unit

(MCU) and a digital signal processor (DSP) core, the processor’s memory devices, an audio and power supply support integrated circuit (IC), a digital support IC, and the audio power amplifier. It also contains all transmit, receive, and frequency generation circuitry, including the digital receiver back-end IC and the reference oscillator.

• CE-UCM Flex — contains vibrator, speaker, microphone and encryption connector.

• Main Display — 130 x 130 dot matrix, liquid-crystal display (LCD).

• CID Display — 112 x 32 dot matrix, liquid-crystal display (LCD).

• Keypad — a 3 x 3 Menu keypad with 4-way navigation button, and a 3 x 4 alphanumeric keypad.

Display, Keypad and

External Accessory Connector

Vibrator

Speaker and Microphone

Earpiece

Controls

Connector

Main Board

Encryption

Module

Audio jack

Figure 3-1. XTS 4000 Overall Block Diagram

Antenna

7.5V

Battery

6871619L01-C September 10, 2008

3-2 Basic Theory of Operation: Digital Mode of Operation

3.2 Digital Mode of Operation

This section provides an overview of the digital mode receive and transmit theory of operation.

3.2.1 Receiving

When the radio is receiving (See Figure 3-2), the signal comes from the antenna connector to the Main board, passing through the antenna switch and the receiver front end. The signal is then filtered, amplified, and mixed with the first local-oscillator signal, generated by the voltage-controlled oscillator (VCO).

RF Input

Harmonic

XTAL

Filter

Antenna

Switch

Tuneable

Pre-Selector

Filter

ABACUS III - RX Back End

RX Front End

LNA

CKO

Tuneable

Post-Selector

Filter

ADC

1st LO

1st

Mixer

to VOCON Section

MAEPF-27278-A

RX_SSI_ DATA

Figure 3-2. Receiver Block Diagram

The resulting intermediate frequency (IF) signal is fed to the IF circuitry, where it is again filtered and passed to the Abacus III digital back-end IC. In the digital back-end IC, the IF signal is mixed with the second local oscillator to create the second IF at 2.25 MHz. In the back-end IC, a bandpass, sigmadelta, analog-to-digital converter then decodes the second IF signal, and outputs, on the radio’s serial synchronous interface (SSI) bus, digital audio to the digital signal processor (DSP).

The dual-core processor’s digital-signal processor (DSP) digitally filters the PCM audio. The DSP decodes the information in the signal and identifies the appropriate destination for it.

• For a voice signal, the DSP will route the digital voice data to the CODEC inside the audio and power supply support IC, for conversion to an analog signal. The CODEC will then present the signal to the receive audio pre-amplifier, then to the audio power amplifier, which drives the speaker.

• For signaling information, the DSP will decode the message and pass it internally to the microcontrol unit of the dual-core processor.

September 10, 2008 6871619L01-C

Basic Theory of Operation: Main Board 3-3

3.2.2 Transmitting

When the radio is transmitting, microphone audio is passed through gain stages to the CODEC, where the signal is digitized. The CODEC passes digital data to the DSP, where pre-emphasis and low-pass (splatter) filtering are done. The DSP passes this signal to a digital/analog converter (DAC), where it is reconverted into an analog signal and scaled for application to the voltage-controlled oscillator as a modulation signal (See Figure 3-3).

PCIC

Post-Selector

Filter

Power

Module

Current Sensing

RX LNA

Pre-Selector

Filter

MAEPF-27322-O

Antenna Switch

Harmonic

Reference

Oscillator

2ND

Loop Filter

EPIC

FracN

DAC

LPF

Sample

Clk

MOD

ABACUS III

VCO

VCOBIC

Crystal

Filter

Buffer

Mixer

TX Driver

Amplifier

Figure 3-3. Transceiver (VHF) Block Diagram (Power and Control Omitted)

Transmitted signaling information is applied to the DSP from the microcontrol unit, where it is coded, and passed to the DAC, which handles it the same as a voice signal. The DAC output connects to the synthesizer modulation input. A modulated carrier is provided to the transmitter power amplifier, which transmits the signal under dynamic power control.

Filter

Antenna

3.3 Main Board

3.3.1 Transceiver Operation

Refer to Figure 3-3, on page 3-3. The receiver front end consists of a pre-selector filter, low-noise amplifier, a post-selector filter, and a mixer. Both the pre-selector filter and pro-selector filter are varactor-tuned bandpass filters, controlled by the microcontroller. See Table 3-1 for local oscillator (LO) and first IF information.

Table 3-1. Local Oscillator and First IF Frequencies

VHF UHF1

LO Frequency Range 180.85–218.85 MHz 306.65–396.65 MHz

First IF Frequency 44.85 MHz 73.35 MHz

6871619L01-C September 10, 2008

3-4 Basic Theory of Operation: Main Board

The frequency generation function is performed by two ICs - two VCOs, and associated circuitry. The reference oscillator IC provides a frequency standard to the synthesizer. The fractional-N synthesizer turns on the two external VCOs and tunes it to RX LO or TX carrier frequency. The VCO buffer amplifies the signal to the required power level. The synthesizer is controlled by the microcontroller unit through a serial peripheral interface (SPI) bus. Most of the synthesizer circuitry is enclosed in rigid metal cans on the transceiver section to reduce interference and microphonic effects.

The receiver back end consists of a bandpass crystal filter, input and output impedance matching networks, and the digital back-end IC. Final filtering is done digitally in the DSP.

The Abacus III digital back-end IC contains a low-noise amplifier, a mixer, a variable gain amplifier with integral anti-alias filter, a bandpass, sigma delta, analog-to-digital converter, and a decimation filter with a programmable decimation factor. The Abacus III also contains an automatic gain control (AGC) circuit to provide 12 dB of continuous gain adjustments. For the second LO, the Abacus III has an internal, integer-N frequency synthesizer, and an external, discrete loop filter and voltagecontrolled oscillator (VCO). The output of the Abacus III is digital data on the RX_SSI bus.

The transmitter power amplifier (PA) consists of a driver amplifier IC and a discrete final-stage. Transmit power is controlled by a power control IC (PCIC) that monitors the currents and adjusts PA control voltages. The transmitter RF signal then passes through a PIN diode antenna switch and a low-pass harmonic filter, which connects to the antenna connector.

3.3.2 VOCON Operation

The vocoder and controller (VOCON) circuitry contains the radio's microcontroller unit (Patriot) with its memory and support circuits, the DSP, its memory devices, and the DSP-support IC, voltage regulators, audio, and power control circuits. Connected to the VOCON circuitry are the display circuitry, RF circuitry, keypad circuitry, encryption module, microphone, speaker and vibrator.

The microcontrol unit controls receive/transmit frequencies, power levels, display, and other radio functions, using either direct logic control or serial communications paths to the devices.The microcontrol unit executes a stored program located in the FLASH ROM. Data is transferred to and from memory by the microcontrol unit data bus. The memory location from which data is read, or to which data is written, is selected by the address lines.

The DSP-support IC is supplied with a 16.8 MHz clock from the RF circuitry. Both the DSP and the microprocessor have their clocks generated by the DSP-support IC. They can both be adjusted so that the harmonics do not cause interference with the radio’s receive channel.

The regulator and power-control circuits include 3.3-volt analog, 3.3-volt digital, and 5-volt regulators. The audio PA is sourced from 7.5V. The regulator’s power-down mode is controlled by the microcontrol unit, which senses the on/off button.

The DSP performs signalling and voice encoding and decoding, as well as audio filtering and volume control. This IC performs Private-Line

/Digital Private LineTM (PL/DPL) encode and alert-tone generation. The IC transmits pre-emphasis on analog signals and applies a low-pass (splatter) filter to all transmitted signals. It requires a clock on the EXTAL pin. An 8 kHz interrupt signal generated by the DSP-support IC is also required for functionality. It is programmed using parallel programming from the microcontrol unit.

The audio CODEC performs analog-to-digital (A/D), and digital-to-analog conversions on audio signals. The DSP controls squelch, deviation, and executes receiver and transmitter filtering. The DSP-support IC receives a 2.4 MHz clock, and also receives data, which it formats for the DSP.

September 10, 2008 6871619L01-C

Recommended Test Equipment and Service Aids: Recommended Test Equipment 4-1

Chapter 4 Recommended Test Equipment and Service

Aids

This chapter provides lists of recommended test equipment and service aids, as well as information on field programming equipment that can be used in servicing and programming ASTRO XTS 4000 radios.

4.1 Recommended Test Equipment

The list of equipment contained in Table 4-1 includes all of the standard test equipment required for servicing two-way portable radios, as well as several unique items designed specifically for servicing this family of radios. The “Characteristics” column is included so that equivalent equipment may 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 Test Equipment

Motorola

Model Number

Service Monitor

Digital RMS Multimeter *

RF Signal Generator *

Oscilloscope * 2 Channel

Power Meter and Sensor *

Description Characteristics Application

Can be used as a substitute for items marked with an asterisk (*)

100 µV to 300 V 5 Hz to 1 MHz 10 Mega Ohm Impedance

100 MHz to 1 GHz

-130 dBm to +10 dBm FM Modulation 0 kHz to 10 kHz Audio Frequency 100 Hz to 10 kHz

50 MHz Bandwidth 5 mV/div to 20 V/div

5% Accuracy 100 MHz to 500 MHz 50 Watts

Aeroflex 2975

(www.aeroflex.com),

Motorola R2670, or equivalent

Fluke 179 or equivalent

(www.fluke.com)

Agilent N5181A

(www.agilent.com),

Ramsey RSG1000B

(www.ramseyelectronics.com),

or equivalent

Leader LS8050

(www.leaderusa.com),

Tektronix TDS1001b

(www.tektronix.com),

or equivalent

Bird 43 Thruline Watt Meter

(www.bird-electronic.com) or

equivalent

Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment

AC/DC voltage and current measurements. Audio voltage measurements

Receiver measurements

Waveform measurements

Transmitter power output measurements

RF Millivolt Meter 100 mV to 3 V RF

10 kHz to 1 GHz

Power Supply 0 V to 32 V

0 A to 20 A

6871619L01-C September 10, 2008

Boonton 92EA

(www.boonton.com) or

equivalent

B&K Precision 1790

(www.bkprecision.com)

or equivalent

RF level measurements

Voltage supply

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

4.2 Service Aids

Refer to Table 4-2 for a listing and description of the service aids designed specifically for servicing this family of radios. These kits and/or parts are available from the Radio Products Services Division offices listed in “Appendix B Replacement Parts Ordering” on page B-1. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.

Table 4-2. Service Aids

Motorola Part

Number

0182297T15 XTS 4000 Keyload Cable Used to load encryption key into radio. Connects to radio's

NKN1027 RS232 Cable Kit Connects radio to RLN-4460 Portable Test Set for radio

NKN1029 USB Cable Kit Connects radio to RLN-4460 Portable Test Set for radio

NNTN7151 Housing Eliminator Fixture that allows radio’s internal board to be mounted

NNTN7152 Regulated Battery Eliminator,

XTS 4000

NNTN7153 SMA Conversion RF Adapter Adapts radio’s antenna port to RF cabling of test

RLN4460 Portable Test Set Used for radio performance checks. Connects to radio’s CE

Description Application

CE connector and key-variable loader (KVL).

performance checks, and to serial port on personal computer for CPS programming and tuner alignments.

performance checks, and to Universal Serial Bus (USB) port on personal computer for CPS programming and tuner alignments.

externally. Provides easy access to electronic circuits, required for board-level troubleshooting.

Used in place of battery to connect radio to an external power supply.

equipment.

connector and allows remote switching and signal injection/ outputs for test equipment measurements.

RVN4181 Customer Programming

Software (CPS) and Tuner Software

CPS allows customer-specific programming of modes and features. Tuner software required to perform alignment of radio parameters. Can be used for XTS 5000, XTS 4000 and XTS 2500 products.

4.3 Field Programming

This family of radios can be aligned and programmed in the field. This requires specific equipment and special instructions. Refer to the online help in the Customer Programming Software (CPS) for complete field programming information.

September 10, 2008 6871619L01-C

Performance Checks: Test Equipment Setup 5-1

Chapter 5 Performance Checks

This chapter covers performance checks used to ensure that the ASTRO XTS 4000 radio meets published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the test equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule. Checks should be performed if radio performance degradation is suspected.

5.1 Test Equipment Setup

Supply voltage can be connected from the battery eliminator. The equipment required for the performance checks is connected as shown in Figure 5-1.

XTS4000

Radio

COMPUTER

Battery Eliminator with RF connector NNTN7152_

SMA to BNC

RF Adaptor

Figure 5-1. Performance Checks Test Setup

30 dB PAD

TRANSMIT

30 dB PAD

BNC

RECEIVE

TEST SET

RLN-4460

RS232 XTS4000 Program/

Test Cable NKN1027_

USB XTS4000 Program/

Test Cable NKN1029_

RF GENERATOR

Set to approx. 450mV for Tx

AUDIO IN

Measure 80mV for Tx

SYSTEM ANALYZER

OR COUNTER

WATTMETER

AUDIO GENERATOR

SINAD METER

AC VOLTMETER

6871619L01-C September 10, 2008

5-2 Performance Checks: Display Radio Test Mode

Initial equipment control settings should be as indicated in Table 5-1 and should be the same for all performance checks and alignment procedures, except as noted.

Table 5-1. Initial Equipment Control Settings

System Analyzer Test S et Power Supply

Monitor Mode: Standard* Spkr/Load: Speaker Voltage: 7.5 Vdc

Receiver Checks

RF Control: GEN Output Level: -47 dBm Modulation: 1kHz tone

@1.5 kHz deviation Frequency: Set to selected radio RX frequency Meter: AC Volts

Transmitter Checks

RF Control: MONITOR Frequency: Set to selected

radio TX frequency

Meter: RF Display Modulation Type: FM Attenuation: 20 dB

* This Initial Equipment Control Settings is for 12.5 kHz channel

spacing only.

** Use “PROJ 25 STD” if testing ASTRO Conventional channels.

5.2 Display Radio Test Mode

This section provides instructions for performing tests in display radio test mode.

PTT: OFF (center) DC On/Standby: Standby

Meter Out: RX Vo lt R ang e: 10 Vdc

Opt Sel: ON Current: 2.5 Amps

5.2.1 Test Mode Menu

Test Modes available after power up,

• If flip is Opened:

RF test → CH test → RGB test → Vibration test

• If flip is Closed:

RF test → CH test → CID test → Vibration test

5.2.2 Access the Test Mode

To enter the display radio test mode:

1. Turn the radio on.

NOTE: To access the Test Mode from the external display, close the flip once the radio is power up.

September 10, 2008 6871619L01-C

Performance Checks: Display Radio Test Mode 5-3

2. Within 10 seconds after “SELF TEST” is complete, press the Side Button five times in

succession.

The radio shows a series of displays that give information regarding various version numbers and subscriber specific information. The displays are described in Table 5-2.

Table 5-2. Test-Mode Displays

Name of Display Description Appears

“SERVICE” The literal string indicates the radio has

entered test mode.

Host Software Version The version of host firmware is displayed. Always

DSP Software Version The version of DSP firmware is displayed. Always

EMC Secure Version Version of the encryption hardware When the radio is secure

Encryption Type 1 Type of encryption being used When the radio is secure

Encryption Type 2 Type of encryption being used When the radio is secure

Model Number The radio’s model number as

programmed in the codeplug

Serial Number The radio’s serial number, as programmed

in the codeplug

ESN Number The radio’s Electronic Serial Number as

programmed in the codeplug

ROM Size The memory capacity of the host FLASH

part

FLASH Code The FLASH codes as programmed in the

codeplug

Always

equipped

Always

RF Band The radio’s RF band as programmed in

the Tuning codeplug

Tuning Codeplug Version

Processor Version Version of the processor being used Always

Version of the Tuning codeplug being used

Always

NOTE: All displays are temporary and will expire without any user intervention. If

information is longer than the physical length of the radio’s display, the information will wrap around to the next display. After the last display, “RF test” is displayed.

To freeze any of the displays, press the Left Navigation Button. To resume automatic scrolling, press the Right Navigation Button. To rapidly scroll forward through the displays, continue pressing the Right Navigation Button. You cannot scroll backwards.

6871619L01-C September 10, 2008

5-4 Performance Checks: Display Radio Test Mode

3. Do one of the following:

•Press the Secure Button (Programmable, Top Left Button) to stop the displays and toggle

between RF test mode and the Control Top and Keypad test mode. The test mode menu “CH test” is displayed, indicating that you have selected the Control Top and Keypad test mode. Go to Section “5.2.4 CH Test Mode (Control Top and Keypad Test)” on page 5-5.

NOTE: Each press of the Secure Button will toggle between “RF test”, “CH test”,

either “RGB test” or “CID test “ (only if the flip is in close position after powerup) and “Vibration test.”

•Press the Emergency Button (Programmable, Top Right Orange Button) to stop the

displays and put the radio into the RF test mode. The test mode menu, “1 CSQ”, is displayed, indicating test frequency 1

, Carrier SQuelch mode. Go to Section “5.2.3 RF

Test Mode” below.

NOTE: Once your radio is in a particular test mode, you must turn off the radio and turn it

back on again to access the other test mode.

5.2.3 RF Test Mode

When the ASTRO XTS 4000 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment using a special routine, called RF TEST MODE.

While in RF test mode:

• Each additional press of Side Button advances to the next test channel. (Refer to Table 5-3.)

•Pressing Programmable Keypad Bottom scrolls through and accesses the test environments

shown in Table 5-4.

NOTE: Transmit into a load when keying a radio under test.

Table 5-3. Test Frequencies (MHz)

Test

Channel

F1 136.075 136.025 380.075 380.025

F2 142.075 142.125 395.075 395.025

F3 154.275 154.225 409.950 409.9

F4 160.175 160.125 424.9 424.85

F5 168.125 168.075 438.2 438.150

F6 173.925 173.975 444.1 444.05

F7 – – 456.4 456.350

VHF

UHF

F8 – – 463.750 463.7

F9 – – 469.7 469.650

September 10, 2008 6871619L01-C

Performance Checks: Display Radio Test Mode 5-5

Table 5-4. Test Environments

Display Description Function

CSQ

TPL

AST

USQ

* All deviation values are based on deviation tuning of this mode.

Carrier Squelch

Tone Private-Line

ASTRO RX: none

Carrier Unsquelch

RX: unsquelch if carrier detected TX: mic audio

RX: unsquelch if carrier and tone (192.8 Hz) detected TX: mic audio + tone (192.8 Hz)

TX: 1200 Hz tone *

RX: unsquelch always TX: mic audio

5.2.4 CH Test Mode (Control Top and Keypad Test)

This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected.

5.2.4.1 Control Top Checks

To perform the control top checks:

1. Press and hold the Emergency Button (Programmable, Top Right Orange Button); the radio

icons are displayed.

NOTE: Not all radio icons are shown. To check LCD display, perform either RGB or CID

Test Mode. (Refer “5.2.5 RGB Test Mode (Only applicable to Internal Display)” on

page 5-6 / “5.2.6 CID Test Mode (Only applicable to External Display)” on page 5-7.)

2. Release the Emergency Button; “3/0” appears, which indicates that the Emergency Button is in the open position. Your radio is now in the Control Top and Keypad test mode.

3. Press the Emergency Button again; “3/1” appears, which indicates that the Emergency Button is in the closed position.

4. Press the Upper Volume Rocker; “80/1” appears; release “80/0” appears.

5. Press the Lower Volume Rocker; “81/1” appears; release “81/0” appears.

6. Press the Secure Button (Programmable, Top Left Button); “96/1” appears; release, “96/0” appears.

7. Press Programmable Keypad Button; “97/1” appears; release, “97/0” appears.

8. Press Side Button; “98/1” appears; release, “98/0” appears.

9. Press the PTT Button; “1/1” appears; release, “1/0” appears.

6871619L01-C September 10, 2008

5-6 Performance Checks: Display Radio Test Mode

5.2.4.2 Keypad Checks:

To continue to the keypad checks:

-Press 0, “48/1” appears; release, “48/0” appears.

-Press 1, “49/1” appears; release, “49/0” appears.

-Press 2, “50/1” appears; release, “50/0” appears.

-Press 3, “51/1” appears; release, “51/0” appears.

-Press 4, “52/1” appears; release, “52/0” appears.

-Press 5, “53/1” appears; release, “53/0” appears.

-Press 6, “54/1” appears; release, “54/0” appears.

-Press 7, “55/1” appears; release, “55/0” appears.

-Press 8, “56/1” appears; release, “56/0” appears.

-Press 9, “57/1” appears; release, “57/0” appears.

-Press *, “58/1” appears; release, “58/0” appears.

-Press #, “59/1” appears; release, “59/0” appears.

-Press Left Navigation Button, “128/1” appears; release, “128/0” appears.

-Press Right Navigation Button, “130/1” appears; release, “130/0” appears.

-Press Up Navigation Button

-Press Down Navigation Button, “136/1” appears; release, “136/0” appears.

-Press Left Menu Select Button, “131/1” appears; release, “131/0” appears.

-Press Middle Menu Select Button, “132/1” appears; release, “132/0” appears.

-Press Right Menu Select Button “133/1” appears; release, “133/0” appears.

-Press Home Button, “129/1” appears; release, “129/0” appears.

-Press Data Button, “134/1” appears; release, “134/0” appears.

, “135/1” appears; release, “135/0” appears.

5.2.5 RGB Test Mode (Only applicable to Internal Display)

To perform the RGB Color Test:

1. Press and release the Emergency Button (Top Right Orange button); “4 Border test”

appears.

2. Press any key; Crosstalk test patterns appears.

3. Press any key; White color test appears.

4. Press any key; Red color horizontal lines appears.

5. Press any key until all 13 red color horizontal lines appears.

6. Press any key; Green color vertical line appears.

7. Press any key until all 13 green color vertical lines appears.

8. Press any key; Black color test appears.

9. Press any key; Blue color test appears.

10. Press any key; "Test completed" appears.

September 10, 2008 6871619L01-C

Performance Checks: Receiver Performance Checks 5-7

5.2.6 CID Test Mode (Only applicable to External Display)

To perform the CID Test:

1. Press and release the Emergency Button (Top Right Orange button); all pixels are on.

2. Press any key; Checker box 1 test appears.

3. Press any key; Checker box 2 test appears.

4. Press any key; "Test completed" appears.

5.2.7 Vibration Test Mode

To perform the Vibration Test:

1. Press and release the Emergency Button (Top Right Orange button); "Press any key to proceed" appears.

2. Press any key (except the Power Button); the radio produce the vibration.

5.3 Receiver Performance Checks

CAUTION: Remove any accessory connected to the audio jack before making audio

measurement thru the CE port. The audio level is attenuated when both the CE port and audio jack are connected.

The following table outline the performance checks for the receiver.

Table 5-5. Receiver Tests for ASTRO Conventional Channels*

Test Name System Analyzer Radio Test Set Comments

Bit Error rate (BER) Floor

Reference Sensitivity

Mode: Proj 25 Std RF Control: Gen Output Level: -47 dBm Proj 25 Dev: 2.83 kHz Code: 1011 Hz PAT

As above; lower the output level until 5% BER is obtained

Radio Tuner Software (Bit Error Rate screen) is required

As above As above Output level < 0.35 µV

PTT to OFF (center)

BER < 0.01% (Use test setup shown in

Figure 5-1, on page 5-1)

(-116 dBm) (Use test setup shown in

Figure 5-1, on page 5-1)

Audio Output Distortion

Residual Audio Noise Ratio

Mode: Proj 25 Std RF Control: Gen Output Level: -47 dBm Proj 25 Dev: 2.83 kHz Code: 1011 Hz PAT Meter: Ext. Distortion

Mode: Proj 25 Std RF Control: Gen Output Level: -47 dBm Proj 25 Dev: 2.83 kHz Code:

A) 1011 Hz PAT B) Silence PAT Meter: AC Volts

Radio Tuner Software not used; Radio: Out of TEST MODE; Select a conventional ASTRO channel

As above As above Residual Audio Noise Ratio

PTT to OFF (center) Meter selector to

Audio PA

Spkr/Load to

Speaker

Distortion < 3.0%

-45 dB

* These tests require a communications system analyzer with the ASTRO 25 test options.

6871619L01-C September 10, 2008

5-8 Performance Checks: Transmitter Performance Checks

5.4 Transmitter Performance Checks

The following table outline the performance checks for the transmitter.

Table 5-6. Transmitter Tests for ASTRO Conventional Channels*

Test Name System Analyzer Radio Test S et Comments

RF Power Mode: Proj 25 Std

RF Control: Monitor Meter: RF Display

Frequency Error

Frequency Deviation

As above As above As above Error ≤ ±1.0 kHz

As above Radio Tuner

Radio Tuner Software not used. Radio: Out of TEST MODE; Select a conventional ASTRO channel

Software (Transmitter Test Pattern screen) is required) High use: Symbol Ra te PAT Low use: Low Symbol Rate P

PTT to continuous (during measurement).

PTT to OFF (center)

VHF: 1–2 Watts UHF1: 0.25–2 Watts

HIGH

≥ 2.543 kHz but ≤ 3.110 kHz D

LOW

≥ 0.841 kHz but ≤ 1.037 kHz (Use test setup shown in

Figure 5-1, on page 5-1

* These tests require a communications system analyzer with the ASTRO 25 test options.

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Test Setup 6-1

Chapter 6 Radio Alignment Procedures

This chapter describes both receiver and transmitter radio alignment procedures.

6.1 Test Setup

A personal computer (PC) and tuner software are required to align the radio. Refer to the applicable manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC and to a universal test set. The radio alignment test setup is shown in Figure 6-1.

SYSTEM ANALYZER

OR COUNTER

WATTMETER

AUDIO GENERATOR

SINAD METER

AC VOLTMETER

XTS4000

Radio

30 dB PAD

TRANSMIT

30 dB PAD

Battery Eliminator with RF connector NNTN7152_

SMA to BNC

RF Adaptor

BNC

RF GENERATOR

RECEIVE

Set to approx. 450mV for Tx

AUDIO IN

TEST SET

RLN-4460

COMPUTER

RS232 XTS4000 Program/

Test Cable NKN1027_

USB XTS4000 Program/

Test Cable NKN1029_

Measure 80mV for Tx

Figure 6-1. Radio Alignment Test Setup

These radio alignment procedures should only be attempted by qualified service personnel. Failure to perform alignment procedures properly may result in seriously degraded radio or system performance.

6871619L01-C September 10, 2008

6-2 Radio Alignment Procedures: Tuner Main Menu

6.2 Tuner Main Menu

Select Tuner from the START menu. To read the radio, use the File › Read Device menu or click on

. Figure 6-2 illustrates how the alignment screens are organized. To access a screen,

double-click on the desired screen name in the Tuner menu.

Figure 6-2. Tuner Software Main Menu

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Softpot 6-3

6.3 Softpot

The alignment screens introduce the concept of the “softpot,” an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls.

DO NOT switch radios in the middle of any alignment procedure. Always left-click the Close button on the screen to return to the Main Menu screen before disconnecting the radio. Improper exits from the alignment screens might leave the radio in an improperly configured state and result in seriously degraded radio or system performance.

Each alignment screen provides the ability to increase or decrease the softpot value by using a slider or the spin buttons in the New Softpot Value box, or by entering the new value from the keyboard directly into the box. The slider bar indicates the minimum and maximum values of the softpot, while the Radio Softpot Value indicates the recommended value; see Figure 6-3 (VHF)/ Figure 6-4 (UHF).

Figure 6-3. Typical Softpot Screen – VHF

Figure 6-4. Typical Softpot Screen – UHF

6871619L01-C September 10, 2008

6-4 Radio Alignment Procedures: Radio Information

Adjusting the softpot value sends information to the radio to increase (or decrease) the voltage in the corresponding circuit. For example, left-clicking the UP spin button in the New Softpot Value scroll box on the Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage across a varactor in the reference oscillator, which increases the frequency.

In ALL cases, the softpot value is just a relative number corresponding to a digital-to-analog (D/A) generated voltage in the radio.

Perform the following procedures in the sequence indicated.

NOTE: Some of the following screens may vary depending upon the radio under test and the version

of tuner software you are using. Refer to the software’s online help.

When keying the radio during a test, always dummy load.

6.4 Radio Information

Figure 6-5 shows a typical Radio Information screen. This screen is informational only and cannot be

directly changed.

transmit into a

Figure 6-5. Radio Information Screen

6.5 Reference Oscillator Alignment

Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will result not only in poor operation, but also in a misaligned radio that will interfere with other users operating on adjacent channels. For this reason, the reference oscillator should be checked every time the radio is serviced, or once a year, whichever comes first. The frequency counter used for this procedure must have a stability of 0.1 ppm (or better).

NOTE: Reference oscillator alignment is required after replacing (or servicing) the mainboard.

This test can be done with either the R-2670 Communication Analyzer or the 8901_ Modulation Analyzer.

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Reference Oscillator Alignment 6-5

• Initial setup using the R-2670 Communication Analyzer:

– RF Control: MONITOR

– B/W: WB

– Freq: CPS frequency under test

– Attenuation: 20dB

– Mon RF in: RF I/O

– Meter: RF Display

– Mode: STD

– Input Level: uV or W

– Display: Bar Graphs

– Squelch: Mid-range or adjust as necessary

• Initial setup using the 8901_ Series Modulation Analyzer:

– Press the green Automatic Operation button on the analyzer.

– Press the FREQ key.

– Type 7.1 followed by SPCL button to set the 8901B_ modulation analyzer for maximum

accuracy.

To align the reference oscillator:

1. Select the Reference Oscillator alignment screen. See Figure 6-6 (VHF) below/ Figure 6-7 (UHF) on page 6-6.

Figure 6-6. Reference Oscillator Alignment Screen – VHF

6871619L01-C September 10, 2008

6-6 Radio Alignment Procedures: Reference Oscillator Alignment

Figure 6-7. Reference Oscillator Alignment Screen – UHF

2. Click the PTT Toggle button to make the radio transmit. The screen indicates whether the

radio is transmitting.

3. Measure the transmit RF frequency with your service monitor.

4. Adjust the reference oscillator’s softpot value until the measured value is as close as possible to the frequency shown on the screen. See Table 6-1.

Table 6-1. Reference Oscillator Alignment

Band Targ et

VHF ±100 Hz

UHF ±100 Hz

5. Click the Program All button to save the tuned values in the radio.

6. Click the Close button to return to the Transmitter Alignments menu.

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Transmit Power Alignment 6-7

6.6 Transmit Power Alignment

This alignment procedure adjusts the transmit power of the radio and must be performed for three different power levels (Low, Mid, and High), at multiple frequencies for each power level, to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone.

NOTES:

• The same softpot attenuation value will result in different radio output power levels at different

frequencies.

• All power measurements are to be made at the antenna port.

• Transmit Power alignment is required after replacing (or servicing) the mainboard.

RF Connector

Battery Eliminator

To Power Supply

Figure 6-8. Battery Eliminator with RF Connector and SMA

To align transmit power:

1. Select the TX Power (Low, Mid, or High) alignment screen. The screen will indicate the

transmit frequencies to be used. See Figure 6-9 (VHF)/

Figure 6-10 (UHF) on page 6-8.

2. Click the desired frequency field (starting with the highest frequency shown).

3. Click the PTT Toggle button to make the radio transmit. The screen indicates whether the

radio is transmitting.

4. Measure the transmit power of the radio with a service monitor.

5. Adjust the softpot value until the required power, as shown in Table 6-2, is indicated on the service monitor.

6871619L01-C September 10, 2008

6-8 Radio Alignment Procedures: Transmit Power Alignment

Table 6-2. Transmit Power Settings

Power Level

Transmi t

Power

(Watts)

Transmit

Power

(Watts)

VHF UHF

Low 1.2–1.4 0.2–0.3

High 2.2–2.4 2.2–2.4

6. Repeat Steps 2 through 5 for all frequencies and all power levels.

7. Click the Program All button to save the tuned values in the radio.

8. Click the Close button to return to the Transmitter Alignments menu.

Figure 6-9. Transmit Power Alignment Screen (Typical) – VHF

Figure 6-10. Transmit Power Alignment Screen (Typical) – UHF

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Transmit Deviation Balance Alignment 6-9

6.7 Transmit Deviation Balance Alignment

This alignment procedure balances the modulation contributions of the low- and high-frequency portions of a baseband signal. Proper alignment is critical to the operation of signalling schemes that have very low frequency components (for example, DPL) and could result in distorted waveforms if improperly adjusted.

This procedure needs to be performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone.

NOTE: This alignment is required after replacing (or servicing) the main board.

Proper alignment requires a modulation analyzer or meter with a frequency response to less than 10 Hz modulating frequency. The modulation analyzer settings during this test should be set for average deviation, a 15 kHz low-pass filter, no de-emphasis, and no high-pass filter, if these settings are supported.

This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series Modulation Analyzer. The method of choice is the R-2670 analyzer.

1. Initial setup using the R-2670 Communication Analyzer:

– Connect a BNC cable between the “DEMOD OUT” port and the “VERT/SINAD DIST/DMM

COUNTER IN” port on the R-2670.

– Press the SPF key on the R-2670 to display the “SPECIAL FUNCTIONS MENU.” Move the

cursor to “High Pass,” and select 5 Hz on the soft key menu. Select 20 kHz for the “Low Pass” setting.

– In the “RF Control” section of the R-2670, enter the frequency displayed on the RSS screen.

Move the cursor to the “B/W” setting and select “WIDE +/- 100 kHz” on the soft key menu.

– Place the R-2670 cursor in the “Display” zone. Select “AC VOLTS” on the soft key menu.

Move the cursor to the “Range” setting and select “AUTO.”

2. Initial setup using the 8901_ Series Modulation Analyzer:

– Press the FM MEASUREMENT button. (The “Error 03-input level too low” indication is

normal until an input signal is applied.)

– Simultaneously press the Peak – and Peak + buttons. Both LEDs on the buttons should light.

– Press the 15 kHz LP filter key.

3. Select the TX Deviation Balance alignment screen. The screen indicates the transmit frequencies to be used. See Figure 6-11 (VHF)/ Figure 6-12 (UHF) on page 6-10.

4. Click the desired frequency field (starting with the highest frequency shown).

5. Click the PTT Toggle button to make the radio transmit. The screen indicates whether the radio is transmitting.

6871619L01-C September 10, 2008

6-10 Radio Alignment Procedures: Transmit Deviation Balance Alignment

Figure 6-11. Transmit Deviation Balance Alignment Screen – VHF

Figure 6-12. Transmit Deviation Balance Alignment Screen – UHF

6. Click the PTT Tone: Low button.

7. Click the PTT Toggle button on the screen to enable transmission. The screen indicates

whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on R-2670, or the deviation shown on the 8901_ analyzer, stabilizes.

8. Measure and record the ac voltage value from the R-2670 analyzer or the deviation value from the 8901_ series analyzer.

9. Left-click the PTT Tone: High button.

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Transmit Deviation Limit Alignment 6-11

10. Adjust the softpot value until the measured deviation/voltage, when using the high tone, is within +/- 1.5% of the value observed when using the low tone.

11. Repeat the above process for all frequencies.

12. Click the Program All button to save the tuned values in the radio.

13. Click the Close button to return to the Transmitter Alignments menu.

6.8 Transmit Deviation Limit Alignment

This alignment procedure limits the modulation of a baseband signal. It is used for primary modulation limiting.

NOTE: This alignment is required after replacing (or servicing) the main board.

This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series Modulation Analyzer. The method of choice is the R-2670 analyzer.

1. Initial setup using the R-2670 Communication Analyzer:

– Connect a BNC cable between the “DEMOD OUT” port and the “VERT/SINAD DIST/DMM

COUNTER IN” port on the R-2670.

– Press the SPF key on the R-2670 to display the “SPECIAL FUNCTIONS MENU.” Move the

cursor to “High Pass,” and select 5 Hz on the soft key menu. Select 20 kHz for the “Low Pass” setting.

– In the “RF Control” section of the R-2670, enter the frequency displayed on the RSS screen.

Move the cursor to the “B/W” setting and select “WIDE +/- 100 kHz” on the soft key menu.

– Place the R-2670 cursor in the “Display” zone. Select “AC VOLTS” on the soft key menu.

Move the cursor to the “Range” setting and select “AUTO.”

2. Initial setup using the 8901_ Series Modulation Analyzer:

– Press the FM MEASUREMENT button. (The “Error 03-input level too low” indication is

normal until an input signal is applied.)

– Simultaneously press the Peak – and Peak + buttons. Both LEDs on the buttons should light.

– Press the 15 kHz LP filter key.

6871619L01-C September 10, 2008

6-12 Radio Alignment Procedures: Transmit Deviation Limit Alignment

3. Select the TX Deviation Limit alignment screen. The screen will indicate the transmit

frequencies to be used. See Figure 6-13 (VHF)/ Figure 6-14 (UHF) on page 6-12.

Figure 6-13. Transmit Deviation Limit Alignment Screen – VHF

Figure 6-14. Transmit Deviation Limit Alignment Screen – UHF

4. Click the desired frequency field (starting with the highest frequency shown).

5. Click the PTT Toggle button to make the radio transmit. Wait approximately 5 seconds until

the deviation/voltage displayed on the analyzer stabilizes. The screen indicates whether the radio is transmitting.

6. Adjust softpot value until the measured deviation is as close as possible to 2.83 kHz.

7. Repeat the above process for all frequencies.

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Front End Filter Alignment 6-13

8. Click the Program All button to save the tuned values in the radio.

9. Click the Close button to return to the Transmitter Alignments menu.

6.9 Front End Filter Alignment

This procedure should only be attempted by qualified service technicians.

This alignment procedure adjusts the front end receiver bandpass filters for the best receiver sensitivity and selectivity. This procedure should be performed for all test frequencies to allow for proper software interpolation of frequencies between the test frequencies in the band (see Figure 6-16 (VHF) below/ Figure 6-17(UHF) on page 6-14 ).

NOTE: Rx Front End Filter Alignment is required after replacing (or servicing) the mainboard.

RF Connector

Figure 6-15. Battery Eliminator with RF Connector and SMA

6.9.1 Procedure for VHF/ UHF

To align the VHF/ UHF receiver front end:

1. Click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency.

3. Start with a softpot value (approximately 10 or 20), increase softpot in ascending order, and note the RSSI values. The RSSI will reach a peak value and remain stable and then decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3. Choose the middle of the peak range and program the corresponding softpot value as the tuned softpot value.

Battery Eliminator

To Power Supply

6871619L01-C September 10, 2008

6-14 Radio Alignment Procedures: Front End Filter Alignment

4. Repeat the above process for all frequencies.

5. Click the Program All button to save the tuned values in the radio.

Figure 6-16. Front End Filter Alignment Screen – VHF

Figure 6-17. Front End Filter Alignment Screen – UHF

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Bit Error Rate 6-15

6.10 Bit Error Rate

This section describes the Bit Error Rate (BER) test of the radio’s receiver at a desired frequency (see Figure 6-18, on page 6-16).

6.10.1 Bit Error Rate Fields

Set up the R2670 Communication Analyzer as follows:

1. Connect the RF Input port of the radio under test to the RF IN/OUT port of the R2670 Service Monitor.

2. Set up the R2670 Service Monitor:

– In the Display Zone, select PROJ 25 STD mode and set the meter to RF DISPLAY.

– In the RF Zone, configure the analyzer as follows:

RF Control: Generate Preset: B/W: NB Freq: Test frequency (Ex: 136.075 MHz/ 380.075 MHz) Output Level: -50.0 dBm Gen RF Out: RF I/O

– In the Audio Zone, select the 1011 Hz PAT code and set the deviation to “PROJ25Dev:

2.83 kHz ~”.

The bit error rate screen contains the following fields:

• Rx Frequency:

This field selects the Receive Frequency directly in MHz.

• Test Pattern:

This field selects the Digital test pattern — TIA. Choices are: Standard Tone Test Pattern (Framed 1011) and Standard Interface Test Pattern (CCITT V.52).

• Modulation Type:

This field represents the digital modulation type of the incoming signal on which BER is to be calculated.

• Continuous Operation:

This field allows the user the option to repeat the BER test indefinitely. A selection of Yes will cause the radio to calculate BER on a continuous basis and update the results on this screen after each integration time. A selection of No will cause the BER test to execute for only one sample of the integration time and then update the display.

• Audio:

This field allows the user to select the audio output during a test. Selecting Internal will cause the radio's built-in speaker to unmute to any signals at the desired frequency which are present during the test. Selecting External will route the same signal to the radio's accessory connector audio output. Selecting Mute will disable the audio output.

• BER Integration Time:

This field represents the amount of time over which the Bit Error Rate is to be calculated. The range is from 0.360 to 91.8 seconds in increments of 0.360 seconds.

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6-16 Radio Alignment Procedures: Transmitter Test Pattern

NOTE: When Continuous Operation = Yes, all fields will be grayed out while the test is in progress.

They will be enabled when the STOP button is pressed.

When Continuous Operation = No, a wait cursor will be displayed while the test is in progress and return to normal when the test is done.

Figure 6-18. Bit Error Rate Screen

6.11 Transmitter Test Pattern

The Transmitter Test Pattern test is used to transmit specific test patterns at a desired frequency so that the user can perform tests on the radio’s transmitter (see Figure 6-19 below/

Figure 6-20 on page 6-17).

6.11.1 Transmitter Test Fields

This screen contains the following fields:

• Tx Frequency:

This field selects the Transmit Frequency directly in MHz.

• Channel Spacing:

This field allows the user to select the desired transmit deviation in kHz.

• Test Pattern Type: This field represents the type of test pattern which will be transmitted by the radio when PTT

TOGGLE button is pressed.

NOTE: Channel Spacing and Test Pattern Type fields will be grayed out while radio is transmitting.

September 10, 2008 6871619L01-C

Radio Alignment Procedures: Transmitter Test Pattern 6-17

Figure 6-19. Transmitter Test Pattern Screen – VHF

Figure 6-20. Transmitter Test Pattern Screen – UHF

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6-18 Radio Alignment Procedures

Notes

September 10, 2008 6871619L01-C

Encryption: Load an Encryption Key 7-1

Chapter 7 Encryption

This chapter provides procedures for using the encryption capability of your radio. The following procedures are outlined:

• Loading an encryption key

• Selecting an encryption key

• Selecting an Index

• Erasing an encryption key

7.1 Load an Encryption Key

To load an encryption key:

1. Refer to the key-variable loader (KVL) manual for equipment connections and setup.

2. Attach KVL to the bottom connector of the radio using Keyload cable 0182297T15. The display shows “KEYLOADING.” All other radio functions, except for power down, backlight, and volume, are locked out.

3. Refer to the KVL manual for how to load the encryption keys into the radio.

4. When the key is loaded successfully, you will hear:

• On single-key radios—a short tone.

• On multikey radios—an alternating tone.

7.2 Multikey Feature

This feature allows the radio to be equipped with multiple encryption keys. It can support up to two different encryption algorithms simultaneously (e.g., DVP-XL and DES-XL).

• Conventional Multikey — The encryption keys can be tied (strapped), on a one-per-channel

basis. In addition, the radio can have operator-selectable keys, operator-selectable indices, and operator-selectable key erasure. If talkgroups are enabled in conventional, then the encryption keys are strapped to the talkgroups.

• Trunked Multikey — If the radio is used for both conventional and trunked applications, strap

the encryption keys for trunking on a per- talkgroup or announcement group basis. In addition, a different key can be strapped to other features; for example, dynamic regrouping, failsoft, or emergency talkgroup. The radio can have operator-selectable key erasure.

7.3 Select an Encryption Key

You can select an encryption key using either the menu or the keypad.

7.3.1 Use the Menu

To select an encryption key using the menu:

1. Press Right Navigation Button until the display shows “KEY.”

2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button, directly below “KEY.” The display shows the last user-selected and stored encryption key, as well as the available menu selections.

6871619L01-C September 10, 2008

7-2 Encryption: Select an Encryption Index

3. Press Left Navigation Button or Right Navigation Button to scroll through the list of

encryption keys.

NOTE: If you select an erased key, the display alternates between showing the encryption

key and “ERASED KEY.”

4. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below the desired menu.

• PSET = selects the preset or default encryption key.

• SEL = saves the newly selected key and returns to the home display.

5. Press Home Button, the PTT Button, or Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below the ABRT menu to exit this menu.

• If the selected key is erased, the display shows “KEY FAIL” and the radio sounds a

momentary keyfail tone.

• If the selected key is not allowed, the display shows “ILLEGAL KEY” and the radio sounds a

momentary illegal key tone.

7.3.2 Use the Keypad

To select an encryption key using the keypad:

1. Press Right Navigation Button until the display shows “KEY.”

2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below “KEY.” The display shows the last user-selected and

-stored encryption key, as well as the available menu selections.

3. Using the keypad, enter the number of the desired key.

NOTE: If you select an erased key, the display alternates between showing the encryption

key and “ERASED KEY.”

4. Press Left Navigation Button or Right Navigation Button to select from the menu.

• PSET = selects the preset or default encryption key.

• SEL = saves the newly selected key and returns to the home display.

5. Press h, the PTT Button, or Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below the ABRT menu.

• If the selected key is erased, the display shows “KEY FAIL” and the radio sounds a

momentary keyfail tone.

• If the selected key is not allowed, the display shows “ILLEGAL KEY” and the radio sounds a

momentary illegal key tone.

7.4 Select an Encryption Index

This feature lets the user select one or more groups of several encryption keys from among the available keys stored in the radio. For example, the radio could have a group of three keys structured to one index, and another group of three different keys structured to another index. Changing indices makes the radio automatically switch from one set of keys to the other. Every channel to which one of the original keys was tied will now have the equivalent new key instead.

September 10, 2008 6871619L01-C

Encryption: Erase an Encryption Key 7-3

7.4.1 Use the Menu

To select an index using the menu:

1. Press Right Navigation Button until the display shows “INDX.”

2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below “INDX.” The display shows the last user-selected and stored index, as well as the available index menu selections.

3. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below the desired index. The display shows the last user- selected and stored index, as well as the available index menu selections.

4. Choose one of the following:

a. To save the index, press Left Menu Select Button, Middle Menu Select Button, or

Right Menu Select Button directly below “SEL.”

b. To exit this menu without changing the index selection, press Home Button or the PTT

Button.

7.4.2 Use the Keypad

To select an index using the keypad:

1. Press Right Navigation Button until the display shows “INDX.”

2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below “INDX.” The display shows the last user-selected and

-stored index, as well as the available index menu selections.

3. Using the keypad, enter the number of the desired index.

4. Choose one of the following:

a. To save the index, press Left Menu Select Button, Middle Menu Select Button, or

Right Menu Select Button directly below “SEL.”

b. To exit this menu without changing the index selection, press Home Button or the PTT

Button.

7.5 Erase an Encryption Key

This section describes two methods for erasing an encryption key.

7.5.1 Method 1 – Key Zeroization (Multikey Only)

To zeroize an encryption key:

1. Press Right Navigation Button until the display shows “ERAS.”

2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below “ERAS.” The display shows the last user-selected and

-stored encryption key, as well as the available menu selections that are listed in Table 7-1.

3. Choose one of the following:

• If you want to erase all the encryption keys at once, go to section 7.5.2: ”Method 2 – All

Keys Erased” on page 7-4 below.

• If you want to erase a single encryption key, do one of the following:

– Press Left Navigation Button or Right Navigation Button to find the desired key. The

display shows the selected key and the available menu selections shown in Table 7-1.

6871619L01-C September 10, 2008

7-4 Encryption: Erase an Encryption Key

– Using the keypad, enter the location number of the desired key. The display shows the

selected key, as well as the available menu selections shown in Table 7-1.

Table 7-1. Encryption Key Zeroization Options

Selection

ALL Erases all the encryption keys in the radio. The display

shows “ERS ALL KEYS” and “YES” and “NO.”

SNGL Selects the displayed encryption key to be erased.The

display shows “ERS SNGL KEY” and “YES” and “NO.”

ABRT Exits this menu and returns to the home display

NOTE: To exit this menu at any time without erasing the key selection, press Home Button

or the PTT Button.

4. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select Button directly below the desired menu selection.

5. Press Home Button or the PTT Button to exit this menu.

7.5.2 Method 2 – All Keys Erased

To erase all encryption keys at one time:

With the radio on, press and hold the Secure Button (Programmable, Top Left Button) and, while holding this button down, press the Emergency Button (Programmable, Top

Right Orange Button).

NOTE: DO NOT press the Emergency Button (Programmable, Top Right Orange

Button) before pressing the Secure Button (Programmable, Top Left Button)

unless you are in an emergency situation. This sends an emergency alarm.

Action

Before the keys are erased, the display shows “PLEASE WAIT.”

When all the encryption keys have been erased, the display shows “ALL KEYS ERASED.”

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: XTS 4000 Exploded View (Partial) 8-1

Chapter 8 Disassembly/Reassembly Procedures

This chapter provides detailed procedures for disassembling/reassembling XTS 4000 radios. When performing these procedures, refer to “Chapter 10: Exploded Views and Parts Lists” on page 10-1 and the diagrams that accompany the text. Items in parentheses ( ) throughout this chapter refer to item numbers in the exploded view diagrams and their associated parts lists.

8.1 XTS 4000 Exploded View (Partial)

This section contains the XTS 4000 radio partially exploded view and parts list.

NOTES:

• Refer to Figure 8-1 on page 8-2, the Partial Exploded View, and Table 8-1 on page 8-2, the Corresponding Exploded View and Parts List.

• Numbers in parentheses ( ) refer to item numbers in Figure 8-1 and Table 8-1 on page 8-2.

• The Battery Assembly (E) and Antenna Assembly (D) should be removed from the radio before disassembly or reassembly the radio.

6871619L01-C September 10, 2008

8-2 Disassembly/Reassembly Procedures: XTS 4000 Exploded View (Partial)

Figure 8-1. XTS 4000 Partial Exploded View

Table 8-1. Corresponding XTS 4000 Exploded View and Parts List

Item

Number

A Flip Assembly Refer “10.2 Exploded View and Parts List –

Description Exploded View and Parts List

Flip-Front Housing Assemblies” on page 10-3.

B Front Housing

Assembly

C Chassis Assembly Refer “10.3 Exploded View and Parts List –

Refer “10.2 Exploded View and Parts List –

Flip-Front Housing Assemblies” on page 10-3.

Chassis Assembly” on page 10-4.

D Antenna Assembly Refer “10.1 Exploded View and Parts List –

Main Assemblies” on page 10-2.

E Battery Assembly Refer “10.1 Exploded View and Parts List –

Main Assemblies” on page 10-2.

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Required Tools and Supplies 8-3

8.2 Required Tools and Supplies

Table 8-2. Required Tools and Supplies

Tools and Supplies

Anti-static ground kit 0180386A82

Magnetic screwdriver set with bits 0180320B16

Tape, Top and Side Controls Assembly Aid

Black Stick – Hexacon Electric Co. MA-800G

Analog Torque Driver (1-6 in-lbs) Tohnichi 6RTD-A

T3IP, T6IP, and T7IP Torx bits –

Audio Jack Assembly Tool 6671241M01

Tweezers –

Motorola Part

Number

1171742L01

Supplier

Supplier Part

Number

8.3 Fastener Torque Chart

Ta bl e 8 -3 lists the various fasteners by part number and description, followed by the torque values

and the location where used. Torque all fasteners to the recommended value when assembling the radio.

Table 8-3. Fastener Torque Chart

Motorola

Part Number

0371903L01 Flip Assembly Screw (5) 1.5

0371907L01 Antenna Bushing Screw (43)

Keypad Backer Screw (18)

0371711L01 Battery Connector Screw (45) 1.1

0371904L01 Chassis Screw (49) 4.4

Description

Repair Torque

(in-lbf)

2.1

3.1

6871619L01-C September 10, 2008

8-4 Disassembly/Reassembly Procedures: Antenna

8.4 Antenna

This section explains how to attach and remove the antenna.

8.4.1 Attach the Antenna

To attach the antenna:

With the radio turned off, turn the antenna clockwise to attach it to the radio.

8.4.2 Remove the Antenna

To remove the antenna:

With the radio turned off, turn the antenna counter-clockwise to remove it from the radio.

Figure 8-2. Attaching the Antenna

Figure 8-3. Removing the Antenna

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Battery 8-5

8.5 Battery

This section explains how to properly attach and remove the battery.

To avoid a possible explosion:

• DO NOT charge, remove, or attach the battery in an area labeled “hazardous atmosphere.”

• DO NOT discard batteries in a fire.

If the radio is programmed for volatile-key retention, encryption keys will be retained for approximately 30 seconds after battery removal.

NOTE: The Motorola-approved battery shipped with the XTS 4000 radio is uncharged. Prior to using

a new battery, charge it for a minimum of 16 hours to ensure optimum capacity and performance.

8.5.1 Attach the Battery

To attach the battery:

1. With the radio turned off, insert the bottom edge of the battery into the slot at the back of the Main Chassis as shown.

step 2

NOTE: Do not attach the battery without engaging the bottom tabs to prevent damage to the battery

or the radio

2. Rotate the battery toward the radio and press down until the battery clicks into place.

8.5.2 Remove the Battery

step 1

Figure 8-4. Attaching the Battery

To remove the battery:

1. With the radio turned off, press the release button on the top of the battery until the battery releases from the radio.

6871619L01-C September 10, 2008

8-6 Disassembly/Reassembly Procedures: Radio Disassembly

2. Rotate and remove the battery from the radio.

release button

Figure 8-5. Removing the Battery

8.6 Radio Disassembly

This section contains instructions for disassembling the radio. For this section, please refer to

“10.1 Exploded View and Parts List – Main Assemblies” on page 10-2,“10.2 Exploded View and Parts List – Flip-Front Housing Assemblies” on page 10-3 and “10.3 Exploded View and Parts List – Chassis Assembly” on page 10-4.

IMPORTANT:When servicing radio parts

steps of the proper section depending on the location of the specific components location.

To service components in Chassis Assembly (C), refer section 8.6.2 "Disassemble the

Chassis Assembly".

To service components in Front housing Assembly (B), refer section 8.6.3

"Disassemble the Front Housing Assembly".

To service components in Flip assembly (A), separate the flip assembly from Front Housing Assembly (B) by completing steps 1 to10 but skip steps 7-8 in section 8.6.3, then refer section 8.6.4 "Disassemble the Flip Assembly".

Exceptions: CID Bezel (1), Battery Ground redundant Contact (44), Battery

Connector Screw (45), 5Ohm RF Dust Cap Seal (46), Port Seal (47), Audio Jack PC Label (48) and Chassis Screw (49).

†

Completion of ALL the steps in each section is NOT necessary depending on the component to be serviced.

listed in Chapter 10, complete section 8.6.1 followed by the

†

For example: to service the main board, after completing all steps in section 8.6.1, continue step 1-4 in section 8.6.3 to have access till main board level, after that complete the reassemble steps per describe in their respective section in Radio Reassembly.

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Disassembly 8-7

8.6.1 Separate the Flip-Front Housing and Chassis Assemblies

To separate the Flip-Front Housing Assembly (A+B) from the Chassis Assembly (C):

1. Turn off the radio by holding down the Power Button for 3 seconds.

2. Remove the Antenna Assembly (D), Battery Assembly (E) or any accessory connected to the radio.

3. Remove the 5 chassis screws (49) from the back of the radio with a Torx T7 bit driver.

4. Insert the Black Stick (refer “8.2 Required Tools and Supplies” on page 8-3 for part number). into the groove between the Front Housing and the Control Band (20) near the top (opposite of PTT area). Gently tilt to separate the Flip-Front Housing Assembly from the Chassis Assembly.

Black Stick

Figure 8-6. Separating Flip-Front Housing Assembly From Chassis Assembly

5. Lay both sub-assemblies (A+B and C) side by side on the anti-static mat (part of anti-static ground kit. Refer “8.2 Required Tools and Supplies” on page 8-3 for part number). Gently unplug the Keypad Backer Inner Jumper Flex (17) from the Main Board (29). Also gently unplug the CE-UCM Connector Flex (28) from the XTS4000 UCM Board (10) located at the bottom of the Front Housing Assembly (B) as shown in Figure 8-7.

When separating the flexes and small interconnects, care is needed to avoid damage to the interconnect and surrounding on-board components.

6871619L01-C September 10, 2008

8-8 Disassembly/Reassembly Procedures: Radio Disassembly

Figure 8-7. Unplugging Flexes

8.6.2 Disassemble the Chassis Assembly

To disassemble the chassis (C):

1. Gently disconnect the CE-UCM Connector Flex (28) from the Main Board (29).

Figure 8-8. Disconnecting CE-UCM Connector Flex and Lifting Main Board

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Disassembly 8-9

2. Lift up the Main Board (29) from the bottom of the Main Chassis (39) and rotate 90° towards the chassis top side.

Figure 8-9. Rotating Main Board 90° and Unplugging Top Control Inner Jumper Flex

3. Unplug the Top Control Inner Jumper Flex (33) from the top of the Main Board (29).

4. Remove the Main Board (29) and lay it aside. The B Plus Seal (31) may be removed from the B Plus Connector on the back of the Main Board (29).

5. Use the tweezers to remove the center Screw Seal (32) from the Main Chassis (39).

6. Flip open the Audio Jack Dust Cover (22) and the CE Connector Dust Cover (21) from the

Control Band (20).

Removing the Control Band (20) from the Main Chassis (39) without disengaging the dust covers may damage the Control Band.

When removing the control band, make sure the Side and Top Control Flex (40) and the metal dome array mylar is not damage during the disassembly.

6871619L01-C September 10, 2008

8-10 Disassembly/Reassembly Procedures: Radio Disassembly

7. Hold the chassis with the back facing up; push down the Control Band (20) on the PTT side

so that the latches are unlocked from the Main Chassis (39). Gently pull the Control Band side outwards to disengage the Control Band. Rotate the Control Band anti-clockwise along the antenna axis to remove it totally from the Main Chassis (39).

2. Pull gently

1. Push the catches towards the chassis

Figure 8-10. Removing Control Band

8. Separate the Top and Side Controls Buttons (23+24) from the Control Band (20).

9. Rotate the tab behind the Audio Jack Dust Cover (22) 90°. Pull the Audio Jack Dust Cover tab out from the Control Band (20) opening as shown in Figure 8-11. Push the tab behind the CE Connector Dust Cover (21) down. Rotate the tab 90° and pull the dust cover out from the Control Band as shown in Figure 8-12.

Push the tab out from the Control Band

Rotate 90°

Figure 8-11. Removing Audio Jack Dust Cover

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Disassembly 8-11

Push the tab down

Rotate 90°

Push the tab out from the Control

Figure 8-12. Removing CE Dust Cover

10. Gently disengage the snap on Audio Jack Insulator (38). Place the tip of the tweezers at bottom of Insulator ring. With one hand, push the Insulator tab through the chassis hole while simultaneously pressing down and pulling out the Insulator ring with the tweezers. Using the tweezers, grip the sides of the Audio Jack Alignment Sleeve (25) and pull straight out to remove.

Figure 8-13. Removing Audio Jack

11. Use a tweezer to peel off the Audio Jack PC Label (48) and the Gore Membrane (47) from the back of the Main Chassis (39).

12. Unplug the CE-UCM Connector Flex (28) from the Audio Jack Board (26) and push the Audio Jack Board out from the Main Chassis (39) with the help of the Black Stick.

13. Unplug the female connector on the Top Control Inner Jumper Flex (33) from the Side and Top Control Flex (40). Peel off the Side and Top Control Flex (40) from the Main Chassis (39).

NOTE: Once the Side and Top Control Flex (40) is removed, replaced it with a new one.

Locate them accordingly to the top control locator pin on then the side control locating features on the casting.

6871619L01-C September 10, 2008

8-12 Disassembly/Reassembly Procedures: Radio Disassembly

14. Unplug the female connector of the CE-UCM Connector Flex (28) from the CE Connector Board (36) at the bottom of the Main Chassis (39) to remove the CE-UCM Connector Flex.

15. To remove the Bottom CE Retainer (34) from the Main Chassis (39), push the CE Retainer towards the front side of the Main Chassis direction until it stops. Then remove it together with the CE Spacer (35) by directing it away from the bottom of the casting (refer Figure 8-

14). Use the tweezers to peel off the CE Connector Board (36) as shown in Figure 8-15.

Avoid inserting the tweezers into the connector area of the CE Connector Board (36).

Gently push upwards

Direct out from casting

Figure 8-14. Removing CE Retainer and Spacer

Avoid inserting tweezers to the connector area

Figure 8-15. Removing CE Board

16. Loosen the top screw (43) on the Antenna Bushing Assembly (42) with a Torx T6 bit torque driver and remove the Antenna Bushing Assembly.

17. Remove the Battery Connector Screw (45) with a Torx T3 bit torque driver and separate the Battery Ground Redundant Contact (44).

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Disassembly 8-13

8.6.3 Disassemble the Front Housing Assembly

To disassemble the Front Housing Assembly (B):

1. Remove the Main Seal (19) from the Keypad Backer Sub-Assembly (15).

2. Remove the 4 screws from the Keypad Backer Sub-Assembly with a Torx T6 bit.

3. Remove the Keypad Backer Sub-Assembly by gently tilting the bottom part of the backer out from the Front Housing, then tongue out from the top of the Front Housing.

Do not twist or pull the Flip Flex as this might cause permanent damage to the Flip Flex.

Steps 4-6 (Speaker Compartment Seal (13), Main Keypad (12), and UCM Module) should be performed while supporting the keypad backer in the orientation shown in Figure 8-16.

4. Remove the Speaker Compartment Seal (13) from the Keypad Backer Sub-Assembly (15).

5. Remove the Main Keypad (12) from the Front Housing. Gently separate the connection between the Speaker Flex and the UCM Board (10) and remove the UCM Board.

6. Carefully separate the Flip Flex (2) from the Keypad Backer Sub-Assembly (15) by gently working the flat head of the Black Stick around the perimeter of the Flip Flex stiffener. Detach the adhesive area of the Flip Flex from the Front Housing.

Step 4

Step 5

Figure 8-16. Disassemble Speaker Compartment Seal, Main Keyboard and UCM Board

6871619L01-C September 10, 2008

8-14 Disassembly/Reassembly Procedures: Radio Disassembly

7. Separate the Keypad Backer Inner Jumper Flex (17) from the Keypad Backer Sub-Assembly (15) by gently sliding the flat end of the Black Stick under the flex beginning from the side of the flip fold.

Keypad Inner Jumper Flex

Figure 8-17. Separating Keypad Backer Inner Jumper Flex

NOTE: Once the Keypad Backer Inner Jumper Flex (17) and/or Audio Jack Pad (16) are

removed, replaced with new ones. If the Keypad Backer and/or Main Keypad Flex requires servicing, replace with NNTN7100A - Assembly, Keypad Backer.

8. Remove the Audio Jack Pad (16) and Secure Pad (14) as shown in Figure 8-18.

Figure 8-18. Removing Secure Pad

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Disassembly 8-15

9. With the flip in the open position, insert the flat end of the Black Stick between the flip assembly (A) and the Front Housing. With a corner of the Black Stick positioned as shown in

Figure 8-19, gradually increase the gap between the Flip Assembly and Front Housing by

twisting the Black Stick until the Flip Assembly separates.

Do not twist or pull the Flip Flex as this might cause permanent damage to the Flip Flex.

Figure 8-19. Removing Front Housing from Flip Assembly

10. Put the Flip Assembly (A) aside. Remove the Flip Bumper Pad (11) from the Front Housing.

11. Remove each tab of the Flip Stopper Pad (7) as shown in Figure 8-20. Using the flat end of the Black Stick, slide the tab while simultaneously pushing it through the opening in the Front Housing. Then, pull the flip stopper from the side of the front housing to remove the flip

stopper.

Figure 8-20. Removing Tabs from Flip Stopper Pad

6871619L01-C September 10, 2008

8-16 Disassembly/Reassembly Procedures: Radio Disassembly

12. Remove the Microphone Boot (8*) and microphone from the Front Housing by gently lifting the Microphone Boot from the side with the flat end of the Black Stick as shown in

Figure 8-21. Separate the Microphone Boot from the microphone.

Figure 8-21. Removing Microphone Boot and Microphone from Front Housing

8.6.4 Disassemble the Flip Assembly

To disassemble the flip assembly (A):

1. Slowly insert the Audio Jack Assembly Tool (refer “8.2 Required Tools and Supplies” on

page 8-3 for part number) into the Flip Flex opening of the Flip Assembly (A), while

positioning the Flip Flex (2) above the tool as shown in Figure 8-22. Lightly push the tool towards the Hinge (4) to separate the hinge from the Flip Assembly.

Figure 8-22. Separating Hinge from Flip Inner Housing

2. Peel off the Flip Inner Label (6) from the Flip Sub-Assembly (3) with a tweezers. With the CID Bezel Kit (1) facing down, remove the 2 screws with a Torx T6 bit.

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Reassembly 8-17

3. Insert the pointed tip of the Black Stick into one of the screw holes to push out the CID Bezel Kit (1).

Extreme care must be taken during removal of the CID Bezel Kit (1), particularly near the thin ribs adjacent to the CID Display.

4. Insert the flat part of the Black Stick between the CID Bezel Kit (1) and the Flip Sub-Assembly (3), slowly and gently sweep downwards to release the adhesive of the CID Bezel Kit (1) from the Flip Sub-Assembly.

Gently sweep in this direction

5. Remove the CID Bezel Kit (1) from the tongue in area of the Flip Sub-Assembly (3).

6. Use the flat end of the black stick to remove the adhesive between the Flip Flex (2) and outer flip housing and to unplug the Flip Flex from the Display Module flex connector.

NOTE: The Flip Flex cannot be reused after removed. It must be replaced with a brand new part.

7. Gently pull out the Flip Flex (2) from the hinge compartment of the Flip Sub-Assembly (3).

8.7 Radio Reassembly

This section contains instructions for reassembling the radio.

All disassembled interfaces requiring adhesive must have new adhesive applied during reassembly. The adhesive surfaces must be clean and free of all foreign material, including oils and/or any remaining adhesive after disassembly. If necessary, the surfaces may be cleaned using a 0.5% solution of a mild dishwashing detergent in water applied sparingly to the surface, ensuring that no water enters into adjacent openings (connectors or otherwise), cracks, or crevices. Remove the solution and dry the surface using a lintless cloth or tissue. All newly applied adhesive interfaces should be press fit for 10 seconds to ensure sealing capability is retained.

CID Display

Figure 8-23. Removing CID Bezel

6871619L01-C September 10, 2008

8-18 Disassembly/Reassembly Procedures: Radio Reassembly

8.7.1 Reassemble the Flip Assembly

To reassemble the flip assembly (A):

NOTE: Unless the Flip Flex (2) is replaced, otherwise, new adhesives must be applied using material

from the Field Service Kit – Adhesive (NNTN7189_) whenever any adhesive is removed from the Flip Flex.

Item 4 align to these 2 edges

Item 3 align to legend marking & edge

This cut indicate up

Item 5 align to these 2 edges

Adhesive Location – Front View

Item 1 align to these 2 edges

Adhering the Adhesive to Flip Flex – Overview

Item No.

Motorola Part number

Description

1 1171646L01 Adhesive, Flip Flex Seal 2

(Flip)

2 7571858L01 Pad, Conductive Foam

3 1171845L01 Adhesive, Flip Flex

Housing

4 1171857L01 Adhesive, Conductive

5 1171645L01 Adhesive, Flip Flex Seal 1

(Backer)

Figure 8-24. Flip Flex

1. Prepare adhesives surfaces of the Flip Assembly as described in first caution note of Section

“8.7 Radio Reassembly” on page 8-17.

Items 2 align to arrow marking & edge

THIS SIDE UP

Adhering the Adhesive to Flip Flex – Overview

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Reassembly 8-19

2. Carefully insert the Flip Flex (2) into the hinge compartment of the Flip Sub-Assembly (3) as shown in Figure 8-25.Peel off the liner of the adhesive at the new Flip Flex (2) connector area and plug in the Flip Flex to the display module. Press fit for 10 seconds to ensure the adhesive is properly activated.

Figure 8-25. Inserting Flip Flex

3. Get a new CID Bezel Kit (1), remove all the liners of the adhesives.

4. Tongue in the CID Bezel Kit (1) into the Flip Sub-Assembly (3), rotating the screw bosses into the receive holes as shown in Figure 8-26. Press fit for 10 seconds to ensure adhesive functionality.

Figure 8-26. Tongue in CID Bezel into Flip Sub-Assembly

5. With the CID Bezel Kit (1) facing down, assemble the 2 screws near the hinge compartment with a Torx T6 bit at 1.5 ± 0.2 in-lbf.

6. Prepare the Flip Inner Housing label surface as described in the first caution note of Section

“8.7 Radio Reassembly” on page 8-17. Adhere a new Flip Inner Label (6) to the

Flip Sub-Assembly (3), covering the screws.

7. Push the hinge into the opening of the Flip Assembly (A) until it snaps in place.

8.7.2 Reassemble the Front Housing Assembly

To reassemble the Front Housing Assembly (B):

1. Carefully insert each tab of the Flip Stopper Pad (7) into the corresponding openings of the Front Housing. Verify that the stopper is fully seated.

6871619L01-C September 10, 2008

8-20 Disassembly/Reassembly Procedures: Radio Reassembly

2. While holding the Flip Assembly (A), feed the Flip Flex (2) through the top opening of the Front Housing.

3. With the flip in the open position, assemble the Flip Assembly as follows:

Be careful not to pull or pinch the Flip Flex during the assembling process.

a. Guide the Flip Assembly onto the left knuckle of the Front Housing. Ensure the flip flex is

fully inserted in the opening hole of the left knuckle.

b. Gently open a gap on the right knuckle of the Front Housing while simultaneously pushing

the Flip Assembly to engage the Hinge. Simultaneously press on the side of both knuckles and rotate the flip to ensure the hinge is fully inserted into the front housing slot.

4. Peel off the liner of the Flip Flex as shown in Figure 8-27. Rotate the flex into position between the Front Housing alignment tabs. Press fit for 10 seconds to ensure the adhesive is properly activated.

Figure 8-27. Adhere Flip Flex into Front Housing

5. Insert the Microphone Boot (8*) into the Front Housing. Gently push the Microphone into the Microphone Boot. Verify that the Microphone is fully seated.

6. Assemble the Flip Bumper Pad (11) by inserting and fully depressing the tabs into the openings of the Front Housing located in the region between the Keypad and the Speaker Flex compartment.

NOTE: Be careful not to stress the board when plugging the Speaker Flex Connector to the

UCM board (10).

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Disassembly/Reassembly Procedures: Radio Reassembly 8-21

7. Assemble the Main Keypad (12) to the Front Housing. Plug in the Speaker Flex Connector to

the UCM board (10) with the board position as shown in Figure 8-28. Rotate the UCM board (10) into the front housing between the screw bosses and alignment tab.

1. Plug in Connector

2. Rotate

Figure 8-28. Reassemble UCM Board

NOTE: If the Main Keypad Flex and Keypad Backer Sub-Assembly (15) were replaced,

skip step 8 and step 9.

8. Remove the liner of the Keypad Backer Inner Jumper Flex (17). Prepare the Keypad Backer Sub-Assembly (15) surface as discussed in the first caution note of Section “8.7 Radio

Reassembly” on page 8-17. Plug in the connector of the Keypad Backer Inner Jumper Flex

(17) to the Main Keypad flex male connector from the back of Keypad Backer Sub-Assembly. Ensure the flex is fully seated by rubbing over the entire area.

9. Attach the Audio Jack Pad (16) and the Secure Pad (14) to the Keypad Backer SubAssembly (15).

Align to these two side walls when adhering the Secure Pad (14)

Figure 8-29. Attach Secure Pad to Keypad Backer Sub-Assembly

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8-22 Disassembly/Reassembly Procedures: Radio Reassembly

10. Prepare the surface of the Keypad Backer Sub-Assembly (15) as discussed in the first caution note of Section “8.7 Radio Reassembly” on page 8-17. Remove the 2 liners from the connector area of the Flip Flex (2). While holding the Front Housing Assembly (B) in one hand and the Keypad Backer Assembly in the other as shown in Figure 8-30, plug the connector of the Flip Flex to the Keypad Backer Sub-Assembly. Press fit the whole flex surface especially the perimeter for 10 seconds.

Press

Figure 8-30. Reassemble Flip Flex

NOTE: Prior to reassembling the Speaker Compartment and Main Seals, inspect the seals and

sealing surfaces for damage (nicks, cuts, etc.) or dirt.

11. Assemble the Speaker Compartment Seal (13) to the Keypad Backer Sub-Assembly (15). Ensure the seal alignment tabs are properly located and fully seated.

12. With the Flip-Front Housing Assembly (A+B) on a flat surface, tongue in and rotate the Keypad Backer Sub-Assembly assembly into the Front Housing.

NOTE: Be careful when assembling (e.g. DO NOT touch the seal) so that the Speaker Compartment

Seal does not drop off from the Keypad Backer Sub-Assembly (15) resulting in a pinched or improperly assembled seal leakage.

13. With the flip housing of the radio facing down, assemble all 4 screws with a Torx T6 bit torque driver at 3.1 in-lbf in the below sequence.

Figure 8-31. Assemble T6 screws to Front Housing

14. Align and Assemble the Main Seal (19) to the Keypad Backer Sub-Assembly (15).

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Reassembly 8-23

8.7.3 Reassemble the Chassis Assembly

To reassemble the chassis assembly (C):

1. To replace the Top and Side Control Flex, prepare the surface as described in the first caution note of Section “8.7 Radio Reassembly” on page 8-17. Peel off the liner and adhere the flex to the Chassis Assembly (C) by locating it to the top locator pin. Bend the flex 90° and align it to the side control locator features on the Chassis as shown in Figure 8-32. Press fit for 10 seconds.

Press fit this area after assemble to ensure water sealed from the connector

Locating Features

Figure 8-32. Assemble T6 screws to Front Housing

2. Align the Battery Ground Redundant Contact (44) to the Main Chassis (39) and tighten the Battery Connector Screw (45) to hold the connector in place with a Torx T3 bit torque driver at

1.1 in-lbf.

3. Insert tab and rotate to assemble the Antenna Bushing Assembly (42) to the top of the Main Chassis (39). With a Torx T6 bit torque driver at 2.1 in-lbf, tighten the Antenna Bushing Screw (43) on the Antenna Bushing Assembly to secure it in place.

4. Prepare surface as discussed in the first caution note of Section “8.7 Radio Reassembly” on

page 8-17. Adhere the CE connector Adhesive (37) to the Main Chassis (39) bottom

compartment, remove the liner and adhere the CE board to the casting. Press fit for 10 seconds to ensure the adhesive is properly activated. Pre-assemble the CE Spacer (35) to the CE Retainer (34) with the 2 protrusion on the CE Spacer facing the CE Retainer as shown in Figure 8-33, then carefully insert the bottom hook to mate with the chassis. Next, push the retainer down on the Main Chassis (39) to complete the assembly as shown in Figure 8-34.

Protrusions

Figure 8-33. Inserting Spacer to CE Retainer

6871619L01-C September 10, 2008

8-24 Disassembly/Reassembly Procedures: Radio Reassembly

Gently push downwards to engage

Direct into the casting

Figure 8-34. Reassemble CE Retainer and Spacer

5. Prepare the Audio Jack Adhesive (27) surfaces as described in the first caution note of

Section “8.7 Radio Reassembly” on page 8-17. Place the Audio Jack Seal into the audio jack

compartment. Press fit with the black stick for 10 seconds. Assemble the Audio Jack Alignment Sleeve (25) to the Audio Jack Board. Assemble the Audio Jack sub-assemble to the Chassis (C) by resting the Alignment Sleeve fingers on the lip of the Chassis and rotating the sub-assembly into place as shown in Figure 8-35. Press fit for 10 seconds to ensure the adhesive is properly activated.

1. Insert into the chassis

2. Rotate into position

Figure 8-35. Reassemble Flip Flex

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Reassembly 8-25

6. Slide the Audio Jack Insulator (38) by using the Audio Jack Insertion Tool (refer

“8.2 Required Tools and Supplies” on page 8-3 for part number) into the opening of the Chas-

sis until a click sound is heard. Refer Figure 8-36.

Figure 8-36. Slide Audio Jack Insulator into Chassis

7. Position the CE Connector Dust Cover (21) 90° to the Control Band (20) and gently press the tab into the opening of the Control Band. Rotate both sides of the CE Connector Dust Cover 90° and push the CE Connector Dust Cover upwards into position as shown in Figure 8-37.

Be careful not to bend the Control Band (20) when pressing in the CE Connector Dust Cover (21) as this may damage the Control Band.

Insert the CE connector dust cover

Rotate 90°

Push the tab up

to position

Figure 8-37. Reassemble CE Connector Dust Cover

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8-26 Disassembly/Reassembly Procedures: Radio Reassembly

8. Position the Audio Jack Dust Cover (22) 90° to the Control Band (20). Hook and push the long end of the tab into the opening of the Control Band. Simultaneously rotate both sides of the Audio Jack Dust Cover 90°.

Push the tab into the Control Band

Rotate 90°

Figure 8-38. Assemble Audio Jack Dust Cover

9. Position the Top and Side Control Assembly Tape across the button openings of the Control Band as shown in Figure 8-39. Assemble the Top Controls Keypad (24) and Side Controls Keypad (23) to the Control Band (20). Make sure the keypads adhere well to the assembly tape so that they do not drop off during reassembly.

Ensure the CE Connector Dust Cover (21) and Audio Jack Dust Cover (22) are in open positions so that they do not interfere with the side Control Band (20) during installation of the control band.

Figure 8-39. Adhere Assembly Aid

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Reassembly 8-27

NOTE: Be careful not to bend the keypad during the assembly of the Control Band (20). Make sure

while rotating the control band towards the chassis, the protrusion on the retainer is inserted properly into the control band bottom sleeve.

10. Position the Control Band (20) over the Chassis (C) as shown in Figure 8-37 and insert the catches on the antenna side of the Control Band into the corresponding Chassis Openings. Pull then rotate the Control Band towards the Main Chassis (39). Slightly pull the PTT side of the control band away from the chassis and insert the two catches into the chassis opening. Push the catches up into position. Peel off the top and side control assembly aid.

1. Insert catches

11. Gently press the CE Connector Dust Cover (21) and Audio Jack Dust Cover (22) into the closed position.

12. Prepare the adhesive surfaces as described in the first caution note of Section “8.7 Radio

Reassembly” on page 8-17. Insert the CE-UCM Flex through the casting opening beside the

audio jack compartment. Plug in the connector of the CE-UCM Connector Flex (28) to the Audio Jack Board (26) by simultaneously pressing on the flex and on the Audio Jack Alignment Sleeve. Adhere new Gore Membrane (47) and Audio Jack PC Label (48) to the back of the Main Chassis (39).

13. Plug in the connector of the CE-UCM Connector Flex to the CE Connector Board.

2. Rotate towards Main Chassis. Pull to insert the catches.

Figure 8-40. Reassemble Control Band

3. After Inserting catches, Press to locate.

6871619L01-C September 10, 2008

8-28 Disassembly/Reassembly Procedures: Radio Reassembly

14. Plug in the connector of the Top Control Inner Jumper Flex (33) to the Side and Top Control Flex (40).

Avoid any hard contact with the sharp corners of the casting when assembling to avoid damaging the connector and flex

Figure 8-41. Assemble B Plus Seal to B Plus Connector

15. Using a Black Stick, press the Center Screw Seal (32) into position on the Main Chassis (39).

16. Assemble the Thermal Pad (30) and B Plus Seal (31) to the B Plus Connector on the back of the Main Board (29) in the orientation shown.

Thermal Pad

B Plus Seal

Figure 8-42. Assemble B Plus Seal to B Plus Connector

17. Plug the Top Control Inner Jumper Flex (33) to the Main Board (29).

September 10, 2008 6871619L01-C

Disassembly/Reassembly Procedures: Radio Reassembly 8-29

18. While holding the CE-UCM Flex as shown in Figure 8-43 so as to clear the Main Board, rotate the Main Board (29) towards the chassis and into position by aligning the board to the two chassis alignment pins. Check to make sure the battery B-plus seal is not pinched.

Chassis alignment feature

Figure 8-43. Holding CE-UCM Flex

19. Plug the CE-UCM Connector Flex (28) to the Main Board (29).

8.7.4 Assemble the Chassis Assembly to the Flip-Front Housing Assembly

To assemble the chassis sub assembly (C) and Flip-Front Housing Assembly (A+B):

1. Place the Flip-Front Housing Assembly and chassis assembly side by side with the chassis on the right. Plug in the connector of the Keypad Backer Inner Jumper Flex (17) to the Main Board (29) top side. Also plug in the connector on the CE-UCM Connector Flex (28) to the UCM Board (10) located at the bottom of the Flip-Front Housing Assembly as shown in

Figure 8-44.

Figure 8-44. Reassemble Flexes

6871619L01-C September 10, 2008

8-30 Disassembly/Reassembly Procedures: Servicing CID Bezel Only

2. Rotate the chassis assembly towards the Flip-Front Housing Assembly. Snap fit both

assemblies by pressing the 2 snaps on the PTT side and the 2 snaps on the opposite PTT side. Ensure there is no bulging between the Front Housing and the Control Band (20) to confirm that the 4 snaps are properly engaged.

3. With the back of the radio facing upward, assemble the 5 screws with a Torx T7 bit at

4.4 in-lbf.

Figure 8-45. Screws Reassemble Sequence

4. Reassemble the antenna to the chassis by turning it clockwise with hand.

5. Tongue in the battery to the bottom of the chassis and press it towards the casting until it clicks.

6. Power on the radio by pressing the Power Button.

8.8 Servicing CID Bezel Only

8.8.1 Disassemble CID Bezel

Refer steps 2 to 5 of “8.6.4 Disassemble the Flip Assembly” on page 8-16 to disassemble the CID Bezel Kit (1).

8.8.2 Reassemble CID Bezel

Prepare the Flip Sub-Assembly (3) surface as described in the first caution note of Section “8.7

Radio Reassembly” on page 8-17 then continue reassembling by following steps 3 to 6 of “8.7.1 Reassemble the Flip Assembly” on page 8-18.

September 10, 2008 6871619L01-C

Basic Troubleshooting: Power-Up Error Codes 9-1

Chapter 9 Basic Troubleshooting

This section of the manual contains troubleshooting charts and error codes that will help you to isolate a problem. Level one and two troubleshooting will support only radio alignment, programming, battery replacement, and knob replacement, and circuit board replacement.

Component-level service information can be found in the “ASTRO XTS 4000 Portable Radios Detailed Service Manual,” Motorola publication number 68P71620L01.

9.1 Power-Up Error Codes

When the radio is turned on (power-up), the radio performs self-tests to determine if its basic electronics and software are in working order. Problems detected during these tests are presented as error codes on the radio’s display. For non-display radios, the problem will be presented at power-up by a single, low-frequency tone. The radio should be sent to the depot if cycling power and reprogramming the code plug do not solve the problem. The presence of an error should prompt the user that a problem exists and that a service technician should be contacted.

Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user operation; non-fatal errors will not. Use Table 9-1 to aid in understanding particular power-up error code displays.

Table 9-1. Power-Up Error Code Displays

Error Code

01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug

01/12 Security Partition Checksum Non-Fatal Error Send radio to depot

01/20 ABACUS Tune Failure Non-Fatal Error Turn the radio off, then on

01/22 Tuning Codeplug Checksum Non-Fatal Error Send radio to depot

01/81 Host ROM Checksum Fatal Error Send radio to depot

01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug

01/88 External RAM Fatal Error — Note: Not a checksum failure Send radio to depot

01/90 General Hardware Failure Fatal Error Turn the radio off, then on

01/92 Security Partition Checksum Fatal Error Send radio to depot

01/93 FLASHport Authentication Code Failure Send radio to depot

01/98 Internal RAM Fail Fatal Error Send radio to depot

01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot

02/81 DSP ROM Checksum Fatal Error Send radio to depot

Description Corrective Action

02/88 DSP RAM Fatal Error – Note: Not a checksum failure Turn the radio off, then on

02/90 General DSP Hardware Failure (DSP startup message not

received correctly)

6871619L01-C September 10, 2008

Turn the radio off, then on

9-2 Basic Troubleshooting: Operational Error Codes

Table 9-1. Power-Up Error Code Displays (Continued)

Error

Code

09/10 Secure Hardware Error Turn the radio off, then on

09/90 Secure Hardware Fatal Error Turn the radio off, then on

Note: If the corrective action does not fix the failure, send the radio to the depot.

Description Corrective Action

9.2 Operational Error Codes

During radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as error codes on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 9-2 to aid in understanding particular operational error codes.

Table 9-2. Operational Error Code Displays

Error Code Description Corrective Action

FAIL 001 Synthesizer Out-of-Lock 1. Reprogram external codeplug

FAIL 002 Selected Mode/Zone Codeplug

Checksum Error

2. Send radio to depot

Reprogram external codeplug

9.3 Receiver Troubleshooting

Table 9-3 lists the possible causes of, and corrections for, receiver problems.

Table 9-3. Receiver Troubleshooting Chart

Symptom Possible Cause

Radio Dead; Display Does Not Turn On

Radio Dead; Display Turns On

No Receive Audio, or Receiver Does Not Unmute

1. Dead Battery Replace with charged battery

2. Blown Fuse Send radio to depot

3. On/Off Switch

4. Regulators

Main Board Send radio to depot

Programming 1. Does the transmitted signal match the receiver

Correction or Test

(Measurements at Room Temperature)

configuration (PL, DPL, etc.)?

2. With the monitor function enabled, can the radio be unmuted?

September 10, 2008 6871619L01-C

Basic Troubleshooting: Transmitter Troubleshooting 9-3

Table 9-3. Receiver Troubleshooting Chart (Continued)

Symptom Possible Cause

Audio Distorted or Not Loud Enough

RF Sensitivity Poor 1. Synthesizer Not On

Radio Will Not Turn Off Main Board Send radio to depot

Synthesizer Not On Frequency

Frequency

2. Antenna Switch/ Connector

3. Receiver FrontEnd Tuning

9.4 Transmitter Troubleshooting

Table 9-4 lists the possible causes of, and corrections for, transmitter problems.

Table 9-4. Transmitter Troubleshooting Chart

Correction or Test

(Measurements at Room Temperature)

Check synthesizer frequency by measuring the transmitter frequency; realign if off by more than ±1000 Hz

Send radio to depot

Check RF front-end tuning for optimum sensitivity using the tuner

Symptom Possible Cause

No RF Power Out 1. TX Power Level or Frequency Check TX power level and frequency

2. No Injection To Power Amplifier

3. Antenna Switch/Connector

No Modulation; Distorted Modulation

Bad Microphone Sensitivity 1. Check Deviation and

No/Low signaling (PL, DPL, MDC)

Cannot Set Deviation Balance

1. Programming Check deviation and compensation

2. Main Board Send radio to depot

Compensation

2. Microphone Send radio to depot

1. Programming Check programming

2. Main Board Send radio to depot

Main Board Send radio to depot

Correction or Test (Measurements

Taken at Room Temperature)

programming (from tuner)

Send radio to depot

settings using the tuner

Realign if necessary

6871619L01-C September 10, 2008

9-4 Basic Troubleshooting: Encryption Troubleshooting

9.5 Encryption Troubleshooting

Table 9-5 lists the possible causes of, and corrections for, encryption problems.

Table 9-5. Encryption Troubleshooting Chart

Symptom Possible Cause Corrective Action

No “KEYLOAD” on Radio Display When Keyloading Cable is Attached to the Radio Side Connector

Keyloader Displays “FAIL” 1. Wrong Keyloader Type Use correct keyloader

1. Defective Keyload Cable Send radio to depot

2. Defective Radio

type. Refer to Keyloader User Guide for more information

2. Bad Keyloader Try another keyloader

3. Defective Radio Send radio to depot

September 10, 2008 6871619L01-C

Exploded Views and Parts Lists 10-1

Chapter 10 Exploded Views and Parts Lists

This chapter contains exploded views and associated parts lists for the ASTRO XTS 4000 digital portable radios. The following table lists the various exploded views and parts lists for the XTS 4000 radios:

Table 10-1. XTS 4000 Exploded Views and Parts Lists

View Page

Exploded View and Parts List – Main Assemblies 10-2

Exploded View and Parts List – Flip-Front Housing Assemblies

Exploded View and Parts List – Chassis Assembly 10-4

Parts List – Service Kit 10-5

10-3

6871619L01-C September 10, 2008

10-2 Exploded Views and Parts Lists: Exploded View and Parts List – Main Assemblies

10.1 Exploded View and Parts List – Main Assemblies

Table 10-2. Parts List – Main Assemblies

Item No. Motorola Part Number Description

A. Flip Assembly

B. Front Housing Assembly

C. Chassis Assembly

D. Antenna Assembly

NAD6582_ (8571814L02)

or NAD6581_ (8571814L04) or NAD6583_ (8571814L01) or NAE6552_ (8571814L05)

E. Battery Assembly

Battery Pack See Section “A.2 Batteries and Battery Accessories” on page A-1 in “Appendix A: Accessories”

Antenna 136 – 151 MHz (Yellow coded) Antenna 146 – 162 MHz (Black coded) Antenna 162 – 174 MHz (Blue coded) Antenna 380 – 470 MHz (Red coded)

Figure 10-1. Exploded View – Main Assemblies

September 10, 2008 6871619L01-C

Motorola XTS4000 basic service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio.

ATTENTION!

For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site which lists approved accessories: http://www.motorola.com/governmentandenterprise

Manual Revisions

Computer Software Copyrights

Document Copyrights

Disclaimer

Trademarks

Document History

Table of Contents

List of Tables

Related Publications

List of Figures

Commercial Warranty

Limited Warranty

MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

II. General Provisions

III. State Law Rights

IV. How To Get Warranty Service

V. What This Warranty Does Not Cover

VI. Patent And Software Provisions

VII. Governing Law

Model Numbering, Charts, and Specifications

Portable Radio Model Numbering System

ASTRO XTS 4000 VHF Model Chart

ASTRO XTS 4000 UHF Model Chart

Specifications for VHF Radios

Specifications for UHF Range 1 Radios

Chapter 1 Introduction

1.1 Manual Contents

1.2 Notations Used in This Manual

1.3 Radio Description

Chapter 2 Basic Maintenance

2.1 General Maintenance

2.1.1 Inspection

2.1.2 Cleaning

2.2 Handling Precautions

2.3 General Repair Procedures and Techniques

2.3.1 Parts Replacement and Substitution

2.3.2 Rigid Circuit Boards

2.3.3 Chip Components

2.3.4 Shields

Chapter 3 Basic Theory of Operation

3.1 Major Assemblies

3.2 Digital Mode of Operation

3.2.1 Receiving

3.2.2 Transmitting

3.3 Main Board

3.3.1 Transceiver Operation

3.3.2 VOCON Operation

4.1 Recommended Test Equipment

4.2 Service Aids

4.3 Field Programming

Chapter 5 Performance Checks

5.1 Test Equipment Setup

5.2 Display Radio Test Mode

5.2.1 Test Mode Menu

5.2.2 Access the Test Mode

5.2.3 RF Test Mode

5.2.4 CH Test Mode (Control Top and Keypad Test)

5.2.4.1 Control Top Checks

5.2.4.2 Keypad Checks:

5.2.5 RGB Test Mode (Only applicable to Internal Display)

5.2.6 CID Test Mode (Only applicable to External Display)

5.2.7 Vibration Test Mode

5.3 Receiver Performance Checks

5.4 Transmitter Performance Checks

Chapter 6 Radio Alignment Procedures

6.1 Test Setup

6.2 Tuner Main Menu

6.3 Softpot

6.4 Radio Information

6.5 Reference Oscillator Alignment