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XTS4000 Radio Basic Service Manual (129 pgs)

1. NNTN7099_ Flip Front Housing Kit Figure 10 2 Exploded View Flip Front Housing Assemblies Table 10 3 Parts List Flip Front Housing Assemblies 10 3 Item No Motorola Part Number Description A Flip Assembly NNTN7209_ 1 2 Front H on D o o Fb Go 16 17 18 1371710L02 0104024J62 7571858L01 1171645L01 1171646L01 1171845L01 1171857L01 5589594Y02 0371903L01 3371777L01 ousing Assembly 7571739L01 1471714L01 7571741L01 Refer Model Chart on page xvi 7571738L01 7571175L01 3271729L01 7571234M01 7571736L01 0104024J61 1171834L01 0371907L01 19 3271737L01 C Chassis Assembly D Antenna Assembly E Battery NAD6582_ 8571814L02 or NAD6581_ 8571814L04 or NAD6583_ 8571814L01 or NAE6552_ 8571814L05 or NAE6553 _ 85012029001 Assembly Battery Pack Bezel CID Note To replace order NNTN7171_ Field Service Kit CID Bezel Flex Flip Note To replace order NNTN7163_ Field Service Kit Flip Flex Pad Conductive Foam Note Included in NNTN7163_ Field Service Kit Flip Flex if kit is ordered Adhesive Flip Flex Seal 1 Backer Adhesive Flip Flex Seal 2 Flip Adhesive Flip Flex Housing Adhesive Conductive Flip Sub Assembly Note To replace order NNTN7209_ Field Service Kit Flip Assembly Hinge Cam Silent 5 8mm Dia x 5 1mm x 15 6mm Screw
2. 9 2 Basic Troubleshooting Operational Error Codes Table 9 1 Power Up Error Code Displays Continued Description Corrective Action Secure Hardware Error Turn the radio off then on 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 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 Gel Synthesizer Out of Lock 1 Reprogram external codeplug 2 Send radio to depot FAIL Baez Selected Mode Zone Codeplug Reprogram external codeplug Checksum Error 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 Correction or Test ymp Measurements at Room Temperature Radio Dead Display Does Not 1 Dead Battery Replace with charged battery Turn On 2 Blown Fuse Send radio to depot 3 On Off Switch
3. 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 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 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
4. appears Press 8 52 1 appears release 36 6 appears Press 9 57 1 appears release 37 68 appears Press eo appears release 3870 appears Press 53 1 appears release g appears appears release 122 8 appears E appears Press Left Navigation Button 1 appears release Press Right Navigation Button Press Up Navigation Button 1 1 appears release 1 2 appears Press Down Navigation Button 1 appears release 126 8 appears Press Left Menu Select Button appears release 121 8 appears Press Middle Menu Select Button 13271 appears release i H appears Press Right Menu Select Button 13371 appears release 122 8 appears 1 appears release 1 Press Home Button 1 E appears Y appears Press Data Button 13471 appears release i 5 2 5 RGB Test Mode Only applicable to Internal Display To perform the RGB Color Test 1 2 mp m mb oh O Press and release the Emergency Button Top Right Orange button 4 E appears Press any key Crosstalk test patterns appears Press any key White color test appears Press any key Red color horizontal lines appears Press any key until all 13 red color horizontal lines appears Press any key Green color vertical l
5. External CE 8 Accessory Ze onnector Connector 2 Vibrator Main Board Encryption 7 30 Module n Speaker and Microphone 3 SECH 3 Battery Audio jack Figure 3 1 XTS 4000 Overall Block Diagram 3 2 3 2 3 2 1 Basic Theory of Operation Digital Mode of Operation Digital Mode of Operation This section provides an overview of the digital mode receive and transmit theory of operation 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 RX Front End ae A A a 4 Tuneable Tuneable 1st LO Harmonic Antenna Pre Selector Post Selector Filter Switch Filter Filter isi Si XTAL ABACUS III RX Back End Filter 3 RX_SSI_ DATA to VOCON Section MAEPF 27278 A 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 sigma delt
6. digital signal processor code DPL DSP DSP code DTMF Glossary Definition See coder decoder Firmware that contains the unique personality for a system or device A codeplug is programmable and allows changes to system and unit parameters See also firmware A device that encodes or decodes a signal See Customer Programming Software Software with a graphical user interface containing the feature set of an ASTRO radio See also RSS See digital to analog conversion See digital to analog converter A pre defined set of parameters Refers to data that is stored or transmitted as a sequence of discrete symbols from a finite set most commonly this means binary data represented using electronic or electromagnetic signals See also analog Conversion of a digital signal to a voltage that is proportional to the input value See also A D A device that converts digital data into analog signals See also ADC A type of digital communications that utilizes privacy call as well as memory channel and busy channel lock out to enhance communication efficiency A microcontroller specifically designed for performing the mathematics involved in manipulating analog information such as sound that has been converted into a digital form DSP also implies the use of a data compression technique Object code executed by the Digital Signal Processor in an ASTRO subscriber radio The DSP is responsible for computation intensive tas
7. 4 Regulators Radio Dead Display Main Board Send radio to depot Turns On No Receive Audio or Receiver Programming 1 Does the transmitted signal match the receiver Does Not Unmute configuration PL DPL etc 2 With the monitor function enabled can the radio be unmuted Basic Troubleshooting Transmitter Troubleshooting 9 3 Table 9 3 Receiver Troubleshooting Chart Continued Correction or Test Symptom Kene CELEC Measurements at Room Temperature Audio Distorted or Not Loud Synthesizer Not On Check synthesizer frequency by measuring the Enough Frequency transmitter frequency realign if off by more than 1000 Hz RF Sensitivity Poor 1 Synthesizer NotOn Check synthesizer frequency by measuring the Frequency transmitter frequency realign if off by more than 1000 Hz 2 Antenna Switch Send radio to depot Connector 3 Receiver Front Check RF front end tuning for optimum sensitivity End Tuning using the tuner Radio Will Not Turn Off Main Board Send radio to depot 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 mptom Possibl SA Gel Taken at Room Temperature No RF Power Out 1 TX Power Level or Frequency Check TX power level and frequency programming from tuner 2 No Injection To Power Send radio to depot Amplifi
8. For a list of Motorola approved antennas batteries and other accessories visit the following web site which lists approved accessories http www motorolasolutions com governmentandenterprise Manual Revisions Changes which occur after this manual is printed are described in PMRs Publication Manual Revisions These PMRs provide complete replacement pages for all added changed and deleted items To obtain PMRs 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
9. Limited Keypad No Display F Limited Keypad With Display G Full Keypad No Display H Full Keypad With Display J Limited Controls No Display K Limited Controls Basic Display L Limited Controls Limited Display M Rotary Controls Standard Display N Enhanced Controls Enhanced Display P Low Profile No Display Q Low Profile Basic Display R Low Profile Basic Display Full Keypad Position 7 Channel Spacing NO 1 5kHz 5 15kHz 2 6 25kHz 6 20 25kHz 3 10kHz 7 30kHz 4 12 5kHz 9 Variable Programmable OU Wo A N 9 10 11 12 A A Position 12 Unique Model Variations C Cenelec N Standard Package Position 11 Version Version Letter Alpha Major Change Position 10 Feature Level 1 Basic 6 Standard Plus 2 Limited Package 7 Expanded Package 3 Limited Plus 8 Expanded Plus 4 Intermediate 9 Full Feature 5 Standard Package Programmable Position 9 Primary System Type A Conventional B Privacy Plus C Clear SMARTNET D Advanced Conventional Stat Alert E Enhanced Privacy Plus F Nauganet 888 Series G Japan Specialized Mobile Radio JSMR H Multi Channel Access MCA J CoveragePLUS K MPT1327 Public L MPT1327 Private M Radiocom N Tone Signalling P Binary Signalling Q Phonenet W Programmable X Secure Conventional Y Secure SMARTNET MPT Ministry of Posts and Telecommunications Position 8 Prim
10. and exploded views and parts lists 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 AN CAUTION indicates a potentially hazardous situation which if not avoided might result in equipment damage Caution A WARNING indicates a potentially hazardous situation which if not avoided could result in death or injury WARNING DANGER indicates an imminently hazardous situation which if not avoided will result in death or injury 1 3 1 4 Introduction Radio Description 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 matr
11. as well as the available menu selections shown in Table 7 1 Table 7 1 Encryption Key Zeroization Options Menu Selection cuan ALL Erases all the encryption keys in the radio The display shows ERS ALL KEYS and YES and HO Selects the displayed e key to D erased The i display shows L KEW and YES and HO 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 Press Left Menu Select Button Middle Menu Select Button or Right Menu Select Button directly below the desired menu selection 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 Before the keys are erased the display shows FLE When all the encryption keys have been erased the display shows ALL KEYS ERASED Chapter 8 Disassembly Reassembly Procedures 8 1 This chapter provides detailed procedures for disasse
12. closely examine your work for shorts due to solder bridges 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 Posi
13. disassembling 8 16 reassembling 8 18 frequency generation theory of operation 3 4 front end filter alignment 6 13 front end filter alignment UHF 6 13 VHF 6 13 front housing assembly disassembling 8 13 reassembling 8 19 G glossary Glossary 1 H handling precautions 2 1 headsets and earpiece accessories A 2 index encryption selecting with keypad 7 3 selecting with menu 7 3 K key encryption erasing all keys 7 4 key zeroization 7 3 loading 7 1 selecting with keypad 7 2 selecting with menu 7 1 L loading an encryption key 7 1 main board theory of operation 3 3 maintenance cleaning 2 1 inspection 2 1 manual notations 1 1 Index revisions ii model chart numbering system xv UHF xvii VHF xvi model numbering system radio xv multikey conventional 7 1 trunked 7 1 N notations manual 1 1 warning caution and danger 1 1 O ordering replacement parts B 1 oscillator reference 3 4 P parts ordering replacement B 1 performance checks receiver 5 8 test setup 5 1 transmitter 5 10 power amplifier theory of operation 3 4 power up error codes 9 1 precautions handling 2 1 product safety information ii R radio alignment 6 1 basic description 1 2 CID test mode 5 8 control top and keypad test mode 5 6 disassembling chassis assembly 8 8 flip assembly 8 16 front housing assembly 8 13 separating chassis and housing assemblies 8 7 entering display test mode 5 2 exploded view comp
14. order 1171635L01 Audio Jack Adhesive 3271570L01 Port Seal and 3371776L01 Audio Jack PC Label Flex CE UCM Connector XTS 4000 VHF Main Board Pad Thermal and Conductive Seal B plus Screw Seal Flex Top Control Inner Jumper Retainer Bottom CE Spacer CE Board CE Connector with Coating Note To replace order 0104028J13 and NNTN7189_ Field Service Kit Adhesive Adhesive CE Connector Audio Jack Insulator Chassis Main w choform Flex Side amp Top Controls Seal Antenna Bushing Bushing Antenna Assembly 43 0371907L01 44 3971718L01 45 0371711L01 46 3271732L01 47 3271570L01 48 3371776L01 49 0371904L01 50 3371256L01 51 3304791J08 D Antenna Assembly NAD6582_ 8571814L02 or NAD6581_ 8571814L04 or NAD6583_ 8571814L01 or NAE6552_ 8571814L05 or NAE6553_ 85012029001 E Battery Assembly Battery Pack Screw 3MT P965 Obacker Contact Battery Ground Redundant Screw Battery Connector Seal 50hm RF Dust Cap Seal Port Note to replace order 3271570L01 Port Seal and 3371776L01 Audio Jack PC Label Audio Jack PC Label Note to replace order 3271570L01 Port Seal and 3371776L01 Audio Jack PC Label Screw 3MT P964 Ochassis Label Blank Note Not orderable Label FCC Note Not orderable Antenna 136 151 MHz Yellow coded Antenna 146 162 MHz Black coded Antenna 162 174 MHz Blue coded Antenn
15. 8 34 Protrusions Figure 8 33 Inserting Spacer to CE Retainer 8 24 Disassembly Reassembly Procedures Radio Reassembly Gently push downwards to engage 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 SS 1 Insert into the chassis Figure 8 35 Reassemble Flip Flex 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 Chassis 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 upwar
16. 950 mA Receive Current Drain Rated Audio 210 mA Standby Current Drain 89 mA Recommended Battery 630 mAh Li lon NNTN6944_ or 1260 mAh Li lon PMNN4083_ Dimensions H x W x D Radio Only w o battery w o antenna 4 06 x 2 18 x 1 17 103 2 mm x 55 3 mm x 29 6 mm Radio With 630 mAh Li lon NNTN6944_ Only w o antenna 4 06 x 2 18 x 1 36 103 2 mm x 55 3 mm x 34 6 mm Radio With 1260 mAh Li lon PMNN4083_ Only w o antenna 4 06 x 2 18 x 1 58 103 2 mm x 55 3 mm x 40 2 mm Weight w Antenna Less Battery 5 6 oz 160 g With 630 mAh Li lon NNTN6944_ 7 8 oz 220 g With 1260 mAh Li lon PMNN4083_ 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 uV Selectivity 12 5 kHz Channel 63 dB 25 kHz Channel 73 dB Intermodulation 70dB Spurious Rejection 75dB FM Hum and Noise 12 5 kHz Channel 40 dB 25 kHz Channel 45 dB Distortion 2 Digital Sensitivity 1 BER 0 25 uV 5 BER 0 25 pV Selectivity 63 dB Intermodulation 70dB Spurious Rejection 75dB 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 con
17. 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 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 AN Avoid inserting the tweezers into the connector area of the CE Connector Board 36 Caution Gently push upwards Direct out from casting a l N Avoid inserting tweezer lt 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 Disassembly Reassembly Procedures Radio Disa
18. Model Numbering System oocccccnnnoccccccnononoccccnnnnoncccnnnnnn nc cnn cnn rn cn nana rra rr 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 EE 1 1 Ri Manual Contents ecu OS id ls aia 1 1 1 2 Notations Used in This Manual 1 1 1 37 E Lee NR e lee EE 1 2 A AS EE 1 2 Chapter 2 Basic MaintemanCe sccccccceeeeeeeeeeeeeeeneeeseeeeeeaeeeeeeeeeeeees 2 1 21 General Maintenance aeaa a a at tdi tad 2 1 2 2 Handling TEE 2 1 vi Table of Contents 2 3 General Repair Procedures and Technioues tert ntntnn rnnr nn nn 2 2 Chapter 3 Basic Theory of Operation cccccoonnnnncccocononoccnononananonennnnanos 3 1 Sc Major ASMA ra dilata eet art cae 3 1 3 2 Digital MOdeof OperatiON iia a dees ees EEN 3 2 Bids Main BOA MEET 3 3 Chapter 4 Recommended Test Equipment and Service Aids 4 1 4 1 Recommended Test Equipment sssssssksirtrnsersteeetetttttnttnntnne stnn tE EErEE EEESEAS ENESE EEEEEE EEES nanne eE EEEE 4 1 42 SOIVICO AMAS aa a EAA E A A EAE A E A E AEA 4 2 4 3 Feld Progamming EE 4 2 Chapter 5 Performance Checks ccccccceeeeeeeeeeeeeeeeeeeeeeseeaeeeeeeseeeeees 5 1 53 TeshEquipment TT 5 1 9 2 Display Radio Test MOde ennie tomircct titi irreal lat ini Lia 5 2 5 3 Receiver Performance Checks arcera a aE E E EAE Deak KEREN KREE RTE 5 8 5 4 Transmitter Perform
19. Standard Li lon Battery A 3 Carry Accessories A 3 1 Belt Clips NNTN6945 Plastic Belt Clip NNTN6946 _ Leather Belt Clip A 4 Chargers EPNN9229_ XTS4000 Charger US 110V AC EPNN9230_ XTS4000 Charging Cradle EPNN9231_ XTS4000 Charger 12V Vehicular WPLN4114_ Universal Impres Single Unit Charger NOTE Charger requires Battery Adapter PMLN5429_ to charge XTS 4000 batteries A 2 Accessories Surveillance Accessories A 5 Surveillance Accessories A 5 1 Headsets and Earpieces NNTN5006BP Headset Earbud with PTT NNTN5211_ T 2 wire Surveillance Kit NOTE Recommendation settings via CPS e Read the radio setting using CPS e Click Radio Wide and select Tx Audio Control Per Mode NNTN5006BP Disable Digital AGC and set to 3dB Digital Fixed Gain TNNTN5211_ Make sure Digital AGC is selected and Digital Fixed Gain is Odb If it is not Set Digital Fixed Gain to Odb and then enable Digital AGC Radio with NNTNSOO6BP setting while using this Surveillance accessory produces degraded sound quality at high talker level Appendix B Replacement Parts Ordering B 1 B 2 B 3 B 4 Basic Ordering Information When ordering replacement parts or equipment information the complete identification number should be included This applies to all components kits and chassis If the component part number is not known the order should include th
20. and program the corresponding softpot value as the tuned softpot value 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 Rx Front End Filter ee br br bk bk Lee 5 pen Selbst eh Ce KE ER E IO anaa EE race pa pesca eos Figure 6 17 Front End Filter Alignment Screen UHF 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
21. 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 Select an Encryption Key You can select an encryption key using either the menu or the keypad 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 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 E ot 4 Press Left Menu Select Button Middle Menu Select Button or Right Menu Select Button directly below the desired menu e 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 e If the selected key is erased the display shows KEY FAIL and the radio sounds a momentary keyfail tone
22. 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 distrib
23. be used See Figure 6 9 VHF Figure 6 10 UHF on page 6 8 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 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 Radio Alignment Procedures Transmit Power Alignment Table 6 2 Transmit Power Settings Transmit Transmit Power Power Power Level Watts 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 dadaddidi IRIE I gt bk bk Lele Lele bh Figure 6 9 Transmit Power Alignment Screen Typical VHF Figure 6 10 Transmit Power Alignment Screen Typical UHF 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 dist
24. can be done with either the R 2670 Communication Analyzer or the 8901 _ Modulation Analyzer Radio Alignment Procedures Reference Oscillator Alignment 6 5 e 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 e 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 x Frequency Radio Softpot New Softpot MHz Value Value 1739750 396 3 396 0 511 Program All Close PIT Togate TRANSMITTER OFF 173 9750 Help Figure 6 6 Reference Oscillator Alignment Screen VHF 6 6 Radio Alignment Procedures Reference Oscillator Alignment xi Frequency Radio Softpot New Softpot MHz Value Value Iessen 215 p 215 al 0 511 Program All Close EM Togale TRANSMITTER OFF 469 6500 Help Figure 6 7 Reference Oscillator Alignment Screen UHF 2 Click the PTT Toggle button to make the radio transmit The screen indicates whether t
25. circuit providing a digital receiver intermediate frequency IF backend See analog to digital converter See Analog to Digital Digital to Analog and Glue See automatic level control Refers to a continuously variable signal or a circuit or device designed to handle such signals See also digital An integrated circuit designed to be an interface between the radio s DSP which is digital and the analog transmitter and receiver ICs Conversion of an instantaneous dc voltage level to a corresponding digital value See also D A A device that converts analog signals into digital data See also DAC A circuit in the transmit RF path that controls RF power amplifier output provides leveling over frequency and voltage and protects against high VSWR Frequencies allowed for a specific purpose See baseband interface port Synchronous serial interface to the transceiver section used to transfer transmit and receive audio data See ball grid array A type of IC package characterized by solder balls arranged in a grid that are located on the underside of the package Radio accessory connector used for communication with a computer for radio programming and radio servicing Caller ID display Glossary 2 Term CODEC codeplug coder decoder CPS Customer Programming Software D A DAC default digital digital to analog conversion digital to analog converter Digital Private Line digital signal processor
26. kHz 7 Repeat the above process for all frequencies 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 NM This procedure should only be attempted by qualified service technicians Caution 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 2S PE A E HA RF Connector A Z AY gt To Power Supply Y SS 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
27. 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 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 Radio Alignment Procedures Transmit Deviation Balance Alignment Tx Deviation Balance ele bk bk dede Lele Ledo pied eg esc e po es HR e EE pam en El EN EE GN ed Figure 6 12 Transmit Deviation Balance Alignment Screen UHF Click the PTT Tone Low button 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 Measure and record the ac voltage value from the R 2670 analyzer or the deviation value from the 8901_ series analyzer Left click the PTT Tone High button
28. progress and return to normal when the test is done Bit Error Rate x Rix Frequency BER Integration Time 0 36 2 MHz sec H Test Pattern Framed 1011 y Number Of Frames fi Modulation Type C4FM X Continuous Operation No acta Ge Audio Mute Close START STOP Press Start to Start BER Test Help Results BER GT Figure 6 18 Bit Error Rate Screen 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 Transmitter Test Fields This screen contains the following fields e Tx Frequency This field selects the Transmit Frequency directly in MHz e 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 Radio Alignment Procedures Transmitter Test Pattern Transmitter Test Pattern boe mee Figure 6 19 Transmitter Test Pattern Screen VHF Figure 6 20 Transmitter Test Pattern Screen UHF 6 18 Notes Radio Alignment Procedures Chapter 7 Encryption 7 1 7 2 7 3 7 3 1 This c
29. 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 SYSTEM ANALYZER OR COUNTER WATTMETER 30 dB PAD 30 dB PAD RF GENERATOR Set to approx 450mV for Tx AUDIO GENERATOR RECEIVE TEST SET RLN 4460 SINAD METER AC VOLTMETER RS232 XTS4000 Program Measure 80mV for Tx Test Cable NKN1027_ or USB XTS4000 Program Test Cable NKN1029_ TRANSMIT Battery Eliminator with RF connector NNTN7152_ SMA to BNC AUDIO IN TX XTS4000 Radio RF Adaptor COMPUTER Figure 5 1 Performance Checks Test Setup 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 Set Power Supply Monitor Mode Standard Spkr Load Speaker Voltage 7 5 Vdc Receiver Checks PTT OFF center DC On Standby Standby RF Control GEN Output Level 47 dBm Meter Out RX Volt Range 10 Vdc Modulation 1 kHz tone 01 5 kHz deviation Frequency Set to selected radio RX frequency Meter AC Volts Opt Sel ON Current 2 5 Amps Transmitter Checks RF Control MONITOR Frequency Set to s
30. read A module that keeps track of elapsed time even when a computer is turned off Electronic device that amplifies RF signals A receiver separates the audio signal from the RF carrier amplifies it and converts it back to the original sound waves Short term data storage circuits within the microcontroller unit or programmable logic IC Remote transmit receive facility that re transmits received signals in order to improve communications range and coverage conventional operation A conventional radio feature that permits communication through a receive transmit facility which re transmits received signals in order to improve communication range and coverage Glossary Term RESET RF RF PA RIB ROM RPCIC RPT TA RSS RTC RX RX DATA SAP SCI IN Serial Audio CODEC Port Serial Communication Interface Input Line SCI IN Serial Peripheral Interface signal Signal Qualifier mode softpot software software potentiometer spectrum SPI Glossary 7 Definition Reset line an input to the microcontroller that restarts execution See radio frequency See radio frequency power amplifier See Radio Interface Box See read only memory Regulator power control IC See repeater talkaround See Radio Service Software See real time clock Receive Recovered digital data line See Serial Audio CODEC Port Serial Communications Interface Input line SSI to and from the GCAP II IC CODEC used to trans
31. 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 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 T 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 Plug 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 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 Fl
32. 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 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 ak bk bk bk bk Lee EEN jses E am peers Figure 6 13 Transmit Deviation Limit Alignment Screen VHF EELER 11193333 Figure 6 14 Transmit Deviation Limit Alignment Screen UHF 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
33. used for volatile program data memory that does not need to be refreshed DSP interface to peripherals that consists of a clock signal line a frame synchronization signal line and a data line Main control unit of the trunked dispatch system handles ISW and OSW messages to and from subscriber units See ISW and OSW The act of selecting the desired operating system with the system select switch also the name given to this switch A type of dynamic random access memory DRAM package that is commonly used in memory applications A timer that limits the length of a transmission See time out timer Transmitter receiver A device that both transmits and receives analog or digital signals Also abbreviated as XCVR Electronic equipment that generates and amplifies an RF carrier signal modulates the signal and then radiates it into space See thin small outline package Transmit See also Universal Asynchronous Receiver Transmitter Ultra High Frequency A microchip with programming that controls a computer s interface to its attached serial devices An external bus standard that supports data transfer rates of 12 Mbps See Universal Serial Bus See voltage controlled oscillator Glossary Term vector sum excited linear predictive coding VHF VIP VOCON vocoder vocoder controller voice encoder voltage controlled oscillator Glossary 9 Definition A voice encoding technique used in ASTRO dig
34. 1619L01 B Added UHF band Jan 2008 6871619L01 C Added PMNN4083 1260 mAh Li lon Battery Sep 2008 Modified Specifications and Accessories info 6871619L01 D Added in Antenna NAE6553_ 85012029001 380 Oct 2010 470 MHz to Table 10 2 10 3 10 4 8 Appendix A 1 6871619L01 E Update Motorola Solutions Info and rectify pdf Dec 2011 Notes Document History Table of Contents V Table of Contents FORO WOM A o Aaa aAA Ea AEREE a Eia ii Product Safety and RF Exposure Complance ii Manual REVISION TEE ii Computer Software Copyrights neirens a A nono nnn ano nn rn nn nar n cnn nn nan r rr nn rra r cnn rra ii Document Copy cio tE cave det cat ade Sanita ci aid Say eee dee dee E ii BIEN ii Trademarks cti Mc idol diria ii Doc ment HIStory Geesse EES iii Table of Contents a V List f Tables ue EE Ix Commercial Warranty eege ENEE EEN clasica xii Limited Warranty E xii MOTOROLA COMMUNICATION PDRODUICTE xii What This Warranty Covers And For How Long xii Il General Provisions civic dd dai iaa xii IL tere Law RONIS Roa da dida xiii IV How To Get Warranty Service oonncocccnnnncccccnnnnononcnnnonnonnnn non n cnn aran n nn nr nn nn rn arar rr xiii V What This Warranty Does Not Cover xiii VI Patent And Software Provisions oooooococcococcoccoccccncnnccoccnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnarnneninnnanns xiv KARTEN xiv Model Numbering Charts and SpecificationS occcccnnnniccnnnnccooncnnononanos XV Portable Radio
35. 3MT P975 Oflip Label Flip Inner Note Included in kits NNTN7171_ and NNTN7163_ if either kit is ordered Pad Flip Stopper Front Housing Sub Assembly Note to replace kit order NNTN7190_ Service Kit Front Housing and NNTN7189_ Field Service Kit Adhesive Boot Microphone Note included in NNTN7190_ Service Kit Front Housing if kit is ordered Pad Vibrator Note included in XTS 4000 UCM Board kit if kit is ordered XTS 4000 UCM Board Pad Flip Bumper Keypad Main Seal Speaker Compartment Pad Secure Note Included in NNTN7100_ Assembly Keypad Backer if kit is ordered Keypad Backer Sub Assembly Note To replace order NNTN7100_ Assembly Keypad Backer Pad Audio Jack Note Included in NNTN7100_ Assembly Keypad Backer if kit is ordered Flex Keypad Backer Inner Jumper Note Included in NNTN7100_ Assembly Keypad Backer if kit is ordered Adhesive Internal backer Note Included in 0104024J61 Flex Keypad Backer Inner Jumper Screw 3MT P965 Obacker Seal Main Antenna 136 151 MHz Yellow coded Antenna 146 162 MHz Black coded Antenna 162 174 MHz Blue coded Antenna 380 470 MHz Red coded Antenna 380 470 MHz See Section A 2 Batteries and Battery Accessories on page A 1 in Appendix A Accessories Note Items can be ordered individually but they are inclusive in their respective kit if kit is ordered t Items cannot be ordered individ
36. 4 MHz Frequency Stability typical 30 to 60 C 25 C ref Emission typical conducted FM Hum and Noise 12 5 kHz Channel 25 kHz Channel Distortion Modulation Limiting 12 5 kHz Channel 25 kHz Channel Adjacent Channel Power Ratio 12 5 kHz Channel 25 kHz Channel Modulation Fidelity Deviation Carrier Frequency Offset Error Vector Magnitude Symbol Rate Accuracy Adjacent Channel Power Ratio Emissions Designators 1 2 Watts 0 0002 75 dBc 43 dB 48 dB 1 0 2 5 kHz 5 0 kHz 67 dB 78 dB 1750 Hz 0 0002 1 5 0 69 dB 20KOF1E 16KOF3E 11KOF3E 8K10F1D and 8K10F1E Specifications subject to change without notice Notes Measured in ANALOG mode per TIA EIA 603 under nominal conditions Measured in DIGITAL mode per TIA EIA IS 102 CAAA under nominal conditions Model Numbering Charts and Specifications Specifications for UHF Range 1 Radios Specifications for UHF Range 1 Radios All specifications are per Telecommunications Industries Association TIA 603 unless otherwise noted GENERAL xix 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 lon Battery Li lon Battery Voltage Nominal 7 5 Vde Range 6 to 9 Vde Transmit Current Drain Typical
37. A www boonton com or equivalent RF level measurements Power Supply 0 V to 32 V 0Ato20A B8K Precision 1790 www bkprecision com or equivalent Voltage supply 4 2 Recommended Test Equipment and Service Aids Service Aids 42 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 Description Application 0182297115 XTS 4000 Keyload Cable Used to load encryption key into radio Connects to radio s CE connector and key variable loader KVL NKN1027 RS232 Cable Kit Connects radio to RLN 4460 Portable Test Set for radio performance checks and to serial port on personal computer for CPS programming and tuner alignments NKN1029 USB Cable Kit Connects radio to RLN 4460 Portable Test Set for radio performance checks and to Universal Serial Bus USB port on personal computer for CPS programming and tuner alignments NNTN7151 Housing Eliminator Fixture that allows radio s internal board to be mounted exter
38. A 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 Line 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 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 Generator 130 dBm to 10 dBm FM Modulation 0 kHz to 10 kHz Audio Frequency 100 www agilent com Ramsey RSG1000B www ramseyelectronics com or equivalent radios 4 1 Recommended Test Equipment The list of equipment contained in Table 4 1 includes al
39. ARE 8 14 Figure 8 19 Removing Front Housing from Flip ASSeMblY oooococcnnnocococcnnnconnncccnnancnnccnanon cnn r naar o nnn rra 8 15 Figure 8 20 Removing Tabs from Flip Stopper Pad ooocoocccccccccocccocccoccconanonannnnnconncnnnnnnnnnnnnnnnn nn nnnnnnnnnnnnn 8 15 Figure 8 21 Removing Microphone Boot and Microphone from Front HOUSING 8 16 Figure 8 22 Separating Hinge from Flip Inner HOUSING ooooocccccnnnoccccnnnnnoncccnnonnnrc nc na nano cnn nara rn cnn 8 16 Figure 8 23 Removing CID Bezel cnn nora nn cnn nn nan r cnn nn nr AAA 8 17 Figure 3924 Elli dd 8 18 Figore 8 25 Inserting Flip AA is 8 19 Figure 8 26 Tongue in CID Bezel into Flip Gub Aesembiv cnn nar c rn 8 19 List of Figures xi Figure 8 27 Adhere Flip Flex into Front HOUSING coonoocccccnnnccccccccnnconcnccnnnan ono no nano nana rcnnnn nc cnn rnnnn arcano 8 20 Figure 8 28 Reassemble UCM Board 8 21 Figure 8 29 Attach Secure Pad to Keypad Backer Sub ASSEMDIy cooooccccccocooccccccnconncccnonannncncnanannncncnannns 8 21 Figure 8 30 Reassemble Flip Flex EE 8 22 Figure 8 31 Assemble T6 screws to Front HOUSING oooocccccconocnccccconconcnccnannnnnnonanoncnnn nano nn nr rana rra 8 22 Figure 8 32 Assemble T6 screws to Front HOUSING ooooocccccconocccccccononncnccnannnnono nano nc nan cnnna nn narran rra 8 23 Figure 8 33 Inserting Spacer to CE Retainer oconoccccccnnnooccccconconnnccnanannnnnc nano nnnnrcnnnn nn nr ran rn nrrnnnn rara 8 23 Figure 8 34 Reassemb
40. As above lower the As above As above Output level lt 0 35 uV Sensitivity output level until 5 BER 116 dBm is obtained Use test setup shown in Figure 5 1 on page 5 1 Audio Output Mode Proj 25 Std Radio Tuner PTT to OFF Distortion lt 3 0 Distortion RF Control Gen Software notused center Output Level 47 dBm Radio Out of Meter selector to Proj 25 Dev 2 83 kHz TEST MODE Audio PA Code 1011 Hz PAT Select a Spkr Load to Meter Ext Distortion conventional Speaker ASTRO channel Residual Mode Proj 25 Std As above As above Residual Audio Noise Ratio Audio Noise RF Control Gen 45 dB Ratio Output Level 47 dBm Proj 25 Dev 2 83 kHz Code A 1011 Hz PAT B Silence PAT Meter AC Volts 5 8 Performance Checks Receiver Performance Checks Table 5 5 Receiver Tests for ASTRO Conventional Channels Continued Test Name System Analyzer Radio Test Set Comments These tests require a communications system analyzer with the ASTRO 25 test options Performance Checks Transmitter Performance Checks 5 9 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 Set Comments RF Power Mode Proj 25 Std Radio Tuner PTT to continuous VHF 1 2 Watts RF Control Monitor Software not used during UHF1 0 25 2
41. 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 6 16 6 11 6 11 1 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
42. Ener e AE BEE E ER 8 5 Melle RRE e 8 6 ar RadioiReassembl cs ai nt en tia Wa a a EE EE 8 17 88 servicing CID Bezel Only zis A i 8 30 Chapter 9 Basic Troubleshooting oooocccccccononcnccnnencnnnnncononanananennnnnnos 9 1 9 1 PowerUp ErrorGodes ai o na ee eeh 9 1 9 2 Operational Error Codes A 9 2 9 3 Receiver Troubleshoot eerie eE deta dal sieeierad E liad laden iria dirt lied elfo 9 2 9 4 Transmitter Troubleshooting nn DEA E REE EREI KERRE E AEA ARESE R E 9 3 95 Encryption TroubleShOoting neocon is 9 4 Chapter 10 Exploded Views and Parts Lists ccccsssseeeeseeeeeeees 10 1 10 1 Exploded View and Parts List Main Aesemblies 10 2 10 2 Exploded View and Parts List Flip Front Housing Assembltes 10 3 10 3 Exploded View and Parts List Chassis Aesembhy 10 4 10 4 Parts ist Service KE r aaa iat aE lad eae a a a a aeaa 10 5 Appendix A Accessories ooooocccccconnnonnccccccnonnnccnnnnnnannnrrnnnnnnnnrennnrnanannnernnnnnss A 1 A AE aS e E EE Ee A 1 A 2 Batteries and Battery Accessories oooooconnnnnccnnnnnocccccnnnnnncconon non cccnnn nar ncn narran rca rr A 1 Az Carty EE EE sil EE ee enke eege A 1 A e Ee A 1 Ab Surveillance Accessories eee eeeeeeeeeaecaeceeeeeeeeeeeesaacaaaeaaeeeeceeeeeeeeeseseeeececaneeeeeeeees A 2 Appendix B Replacement Parts Ordering c eeesseeeeeeeeeseeeeeeeeeeees B 1 B 1 Basic Ordering Information 2 c c c eeecceeteeeeedeeteeneededeneneesecensebeeedeetseneededeneneece
43. KEY and the radio sounds a e If the selected key is not allowed the display shows IL 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 E S 4 Press Left Navigation Button or Right Navigation Button to select from the menu e 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 e If the selected key is erased the display shows KEY FAIL momentary keyfail tone and the radio sounds a AL KEY and the radio sounds a e If the selected key is not allowed the display shows ILL momentary illegal key tone ZA 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 th
44. Keypad Backer Sub Assembly Press fit the whole flex surface especially the perimeter for 10 seconds O REA A 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 Ibf 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 Disassembly Reassembly Procedures Radio Reassembly 8 23 8 7 3 Reassemble the Chassis Assembly To reassemble the chassis assembly C 1 2 To replace the Top and Side Control Flex prepare the surface as described in the first cau tion note of Section 8 7 Radio Reassembly on page 8 17 Peel off the liner and adhere the flex to the Chassi
45. TM PORTABLE RADIO BASIC SERVICE MANUAL ASTRO XTS 4000 Digital Portable Radios Basic Service Manual MOTOROLA Motorola Solutions Inc 1303 E Algonquin Rd Schaumburg IL 60196 1078 U S A 6871619L01 E 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 NM for safe usage contained in the Product Safety and RF Caution 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
46. UDIO IN TX XTS4000 Radio RF Adaptor COMPUTER Figure 6 1 Radio Alignment Test Setup service personnel Failure to perform alignment procedures properly may result in seriously degraded radio or system performance These radio alignment procedures should only be attempted by qualified Caution 6 2 Radio Alignment Procedures Tuner Main Menu Tuner Main Menu Select Tuner from the START menu To read the radio use the File gt Read Device menu or click on pL Figure 6 2 illustrates how the alignment screens are organized To access a screen aouble click on the desired screen name in the Tuner menu E 123ABC1234 Al x BC1234 Radio Information Transmitter Alignments JA Reference Oscillator A Ts Power High A Tx Power Mid A Tx Power Low JA T Deviation Balance Compensation JA Ts Deviation Limit d A Receiver Alignments JA Front End Filter A Performance Testing JA Bit Error Rate JA Transmitter Test Pattern JA Battery Reading Calibration Figure 6 2 Tuner Software Main Menu Radio Alignment Procedures Softpot 6 3 6 3 Softpot The alignment screens introduce the concept of the softpot an analog SOF Tware controlled POTentiometer used for adjusting all transceiver alignment controls procedure Always left click the Close button on the screen to return to the Main Menu screen before disconnecting the Caution radio Im
47. Watts Meter RF Display Radio Out of measurement TEST MODE Select a conventional ASTRO channel Frequency As above As above As above Error lt 1 0 kHz Error Frequency As above Radio Tuner PTT to OFF Duc Deviation Software center gt 2 543 kHz but Transmitter Test lt 3 110 kHz Pattern screen is Dow required gt 0 841 kHz but High use Symbol lt 1 037 kHz Rate PAT Use test setup shown in Low use Low Symbol Rate P Figure 5 1 on page 5 1 These tests require a communications system analyzer with the ASTRO 25 test options 5 10 Performance Checks Transmitter Performance Checks Notes 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 Battery Eliminator with RF connector NNTN7152_ RF GENERATOR Set to approx 450mV for Tx AUDIO GENERATOR RECEIVE TEST SET RLN 4460 SINAD METER AC VOLTMETER RS232 XTS4000 Program Measure 80mV for Tx Test Cable NKN1027_ or USB XTS4000 Program Test Cable NKN1029_ SMA to BNC A
48. a 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 Basic Theory of Operation Main Board 3 3 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 VCOBIC Buffer Amplifier TX TX Driver Power Module Sensi Mixer reo RX LNA ilter Curre
49. a 380 470 MHz Red coded Antenna 380 470 MHz See Section A 2 Batteries and Battery Accessories on page A 1 in Appendix A Accessories Note T_ Items cannot be ordered individually They are inclusive in the NNTN7189 Field Service Kit Adhesive refer Table 10 5 Service Kit Table on page 10 5 Exploded Views and Parts Lists Parts List Service Kit 10 4 Parts List Service Kit Table 10 5 Service Kit Table Item No Motoro a Description Part Number 0371903L01 Screw 3MT P975 0Flip 3371777L01 Label Flip Inner 7571739L01 Pad Flip Stopper Front Housing Sub Assembly 1171385M01 Lubricant Kit 6 NNTN7100_ Assembly Keypad Backer 7571234M01 Pad Secure Keypad Backer Sub Assembly 7571736L01 Pad Audio Jack 0104024J61 Flex Keypad Backer Inner Jumper Kit 7 NNTN7189_ Field Service Kit Adhesive 1171645L01 Adhesive Flip Flex Seal 1 Backer 1171646L01 Adhesive Flip Flex Seal 2 Flip 1171845L01 Adhesive Flip Flex Housing 1171857L01 Adhesive Conductive 1171636L01 Adhesive CE Connector 1171834L01 Adhesive Internal Backer Item No Motorola Description Part Number Kit 1 NNTN7171_ Field Service Kit CID Bezel 1371710L02 Bezel CID 3371777L01 Label Flip Inner Kit 2 NNTN7163_ Field Service Kit Flip F
50. adio and press down until the battery clicks into place 8 5 2 Remove 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 8 6 8 6 Disassembly Reassembly Procedures Radio Disassembly 2 Rotate and remove the battery from the radio release button Figure 8 5 Removing the Battery 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 listed in Chapter 10 complete section 8 6 1 followed by the 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 t To service components in Front housing Assembly B refer section 8 6 3 Disassemble the Front Housing Assembly t 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 t i Ex
51. aker 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 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 Sub Assembly 15 Align to these two side walls when adhering the Secure Pad 14 Figure 8 29 Attach Secure Pad to Keypad Backer Sub Assembly 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
52. amage during disassembly troubleshooting and repair Handling precautions are mandatory for this radio and are especially important in low humidity conditions 2 2 Basic Maintenance General Repair Procedures and Techniques 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 Caution radio f e The XTS 4000 radio casting has a vent port that allow for pressure 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 2 lvl intct 245 C 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
53. ammable Top Left Button to stop the displays and toggle peta eel RF test mode and the Control Top and Keypad test mode The test mode menu 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 EF test CH test either FGE test or CID ent if the flip is in close poson after powerup and i D temzt e 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 i Co is displayed indicating test frequency 1 Carrier SQuelch mode Go to Section 523 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 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 e Pressing Programmable Keypad Bottom scrolls through and accesses the test environments shown in Tab
54. ance Checks 0ooooniccccccnnnnccccccnoononcncnnnnnnnnnnnnnnnnn conc cnn nn n rra nr nan nn rr rr narran 5 10 Chapter 6 Radio Alignment Procedures cooooomonncccccoconoceccnnnananonennnnanos 6 1 6 1 Ke EE 6 1 0 2 uher Main Mel a A eri 6 2 G23 r SOMDOL eege eg Set dee idol e ele Ate 6 3 e DN le Te Rui e E LTE 6 4 6 5 Reference Oscillator Alignment seriea a Ee A aE EEEE EErEE EEA A EEEN KEERI TEETAR 6 4 6 6 Transmit Power Alignment ersi naea A AAE E E a E 6 7 6 7 Transmit Deviation Balance Alonment nc cnn nar r cra rn 6 9 6 8 Transmit Deviation Limit Alignment nncnnnnnnncccnnnnonacocnnnnononcnncnnnnnnnnnnn nono n nn rra cnn rr rra rra 6 11 6 9 Front End Filter Aligiment iia 6 13 6 10 Bit Error e 6 15 6 11 Transmitter Test Pattern seco ane e E R a aE REGER 6 16 Chapter 7 Encryption ie iaala cisne 7 1 GA LosgdapEnetvptorrkey ee degen Eege EE EE Ee He 7 1 TZ Multikey Feature istectecstcntcccee Agnes egen Ad REEL eta 7 1 AS A SA O 7 1 4 Selectian Encryption plett dee ere li cesta tnd sige aden festa leuzeee 7 2 To Erase an Encryptlom Key ege Meggie idad n 7 3 Chapter 8 Disassembly Reassembly Procedures cceseeeeeees 8 1 8 1 XTS 4000 Exploded View Partial nn nc cnn anar n crac 8 1 8 2 Required Tools and Supplies n00snsnnnnnneneteseeeenetrtttnrrtsstesttttttnnntnntnrestestttrntnnnnneaneertentnnn nenet ent 8 3 8 37 Fastener e E Chami TEE 8 3 Table of Contents vii 8 4 e ET ET 8 4 H Beete a
55. and Canada 1 800 927 2744 The Radio Products and Solutions Organization RPSO was formerly known as the Radio Products Services Division RPSD and or the Accessories and Aftermarket Division AAD Appendix C Motorola Service Centers C 1 C 2 GA GA Servicing Information If a unit requires further complete testing knowledge and or details of component level troubleshooting or service than is customarily performed at the basic level please send the radio to a Motorola Service Center as listed below Motorola Service Center 45D Butterfield Trail El Paso TX 79906 Tel 1 800 227 6772 Motorola Federal Technical Center 4395 Nicole Drive Lanham MD 20706 Tel 1 800 969 6680 Fax 1 800 784 4133 Motorola Canadian Technical Logistics Center Motorola Canada Ltd 8133 Warden Avenue Markham Ontario L6G 1B3 Tel 1 800 543 3222 Fax 1 888 331 9872 or 1 905 948 5970 C 2 Notes Motorola Service Centers Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products Term A D Abacus IC ADC ADDAG ALC analog Analog to Digital Digital to Analog and Glue analog to digital conversion analog to digital converter automatic level control band BBP baseband interface port BGA ball grid array CE Connector CID Definition See analog to digital conversion A custom integrated
56. ary Operation A Conventional Simplex B Conventional Duplex C Trunked Twin Type D Dual Mode Trunked E Dual Mode Trunked Duplex F Trunked Type G Trunked Type II H FDMA Digital Dual Mode J TDMA Digital Dual Mode K Single Sideband L Global Positioning Satellite Capable M Amplitude Companded Sideband ACSB P Programmable FDMA Frequency Division Multiple Access TDMA Time Division Multiple Access 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 Xx NNTN7098 Hardware Tanapa XTS4000 Xx NNTN7101_ Assembly Chassis XTS4000 Xx NNTN7100_ Assembly Keypad Backer XTS4000 Xx NNTN7099 Assembly Flip Front Housing XTS4000 X PMLN5057_ XTS4000 CD UG amp Safety X 6871618L01 XTS4000 User Guide Notes X ltem Included e The model number and sometimes the FLASHcode can be found on the FCC label on the back of the radio e The model number Host code DSP code and sometimes the FLASHcode can be found by putting the radio into the Test Mode e 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 Model Numbering C
57. 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 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
58. ce KI Table tii it a bt da dia 10 5 Related Publications XTS 4000 Digital Portable Radio User Guide ooocccconnnoccccccncconcccconnonccnccnnanoncncnnnan acc ncnnnannncccnnnnns 6871618L01 XTS 4000 Digital Portable Radios Detailed Service Manual 6871620L01 XTS 4000 Digital Portable Radio User Guide CD PMLN5057 Chassis Eli rafe ee BE EE 6871568M01 x List of Figures List of Figures Figure 3 1 XTS 4000 Overall Block Diagram ooooocccccnnnnocccccconoonccncconnonnncncnnnnnnnnnnnnnncnnnnnnnn arc ncn nana nnccnnnns 3 1 Figure 3 2 Receiver Block Diaoram conc ncnn nan nn cnn cnn nr nn rn rra nan nn cr rra nan nnccinns 3 2 Figure 3 3 Transceiver VHF Block Diagram Power and Control Omttted 3 3 Figure 5 1 Performance Checks Test Getup nan n nn cnn anar arc cc nn nana nnccinns 5 1 Figure 6 1 Radio Alignment Test Getun nan n cnc cnn nan nn rc cnn anar nnc nn nnnnnnccnnns 6 1 Figure 6 2 Tuner Software Main Men 6 2 Figure 6 3 Typical Softpot Screen VHF ooocccccnncoccccconononcncnnnnnoncnnnnnnnonnnnnnn nan nnnncnn nan n nn cnn nana nnnnnnnannnnncnnns 6 3 Figure 6 4 Typical Softpot Screen UHF oooccccconnooccccccnononcnncnnnnonnnncnonnnnnncnnnnnnnn cnn naar nnnncn cnn nnncccnnnnnnnninnnns 6 3 Figure 6 5 Radio Information Screen 0 cece erect ee eee ee erie nc nn nan n cnc cnn nar nr nr cnn nn rr rn cnn nn anni 6 4 Figure 6 6 Reference Oscillator Alignment Screen VHF ooonnoccccconnoocnncccnnconnncnonannncncnnnn
59. ceptions CID Bezel 1 Battery Ground redundant Contact 44 Battery Connector Screw 45 50hm RF Dust Cap Seal 46 Port Seal 47 Audio Jack PC Label 48 and Chassis Screw 49 T Completion of ALL the steps in each section is NOT necessary depending on the component to be serviced 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 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 2 Turn off the radio by holding down the Power Button for 3 seconds Remove the Antenna Assembly D Battery Assembly E or any accessory connected to the radio Remove the 5 chassis screws 49 from the back of the radio with a Torx T7 bit driver 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 Lay both sub assembl
60. ceteeesecdertseeeeeenees B 1 BZ Motorola Oldest eka eee eee eee ee B 1 LE Maill ere EE B 1 BA Telephone Orders isi lt atoeet a a ele enee Eed EE ee See B 1 Be Eelere e NN B 2 BiG Parts Identification e eA ele ee ee B 2 B 7 Product Customer Service ET B 2 Appendix C Motorola Service Center s ccccccseeeeeeeeeeeeeeeeeeeeeeeeeeaes C 1 CA Servicing IMO aO ea eo ees Ries ee ea A eae C 1 C2 Motorola Service e ET C 1 C 3 Motorola Federal Technical Center C 1 CA Motorola Canadian Technical Logistics Center C 1 Glossa e EE Glossary 1 Table of Contents SS EEN Index 1 List of Tables List of Tables Table 1 1 Table 2 1 Table 2 2 Table 3 1 Table 4 1 Table 4 2 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 6 1 Table 6 2 Table 7 1 Table 8 1 Table 8 2 Table 8 3 Table 9 1 Table 9 2 Table 9 3 Table 9 4 Table 9 5 Table 10 1 Table 10 2 Table 10 3 Table 10 4 Table 10 5 ASTRO XTS 4000 Basic Features 1 2 Lead Free Solder Wire Part Number st 2 2 Lead Free Solder Paste Part Number ist 2 2 Local Oscillator and First IF Frequencies oooooccccoccccnccccccccccconnnnononnnnncnnnnnnnnnnnnannnn nn n nn nncnncnnn 3 3 Recommended Test Eoumpment ansant ttnn t Ennen nnne ee rren 4 1 DEMIAN EE 4 2 Initial Equipment Control Gettngs cssc eieae aaaea aaae E aeaea i eaaa 5 2 Test Mode Displays o dase A GEEAE E ENEE ce eae eee AEE ATE A 5 3 Test
61. ction 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 voltage controlled oscillator VCO The output of the Abacus Ill 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
62. dex VOCON operation W theory of operation 3 4 warning caution and danger notations 1 1 warranty commercial xii coverage period xii MOTOROLA otorola So 303 East Al OTOROLA he Stylized Sa gt Schaumburg lutions Inc gonquin Road inois 60196 U S A OTO MOTOROLA SOLUTIONS and ogo are trademarks or registered trademarks of Motorola Trademark Holdings LLC and are used under license All other trademarks are the property of their respective owners 2007 2011 December 2011 otorola Solutions Inc All rights reserved 6871619L01 D
63. ds 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 Caution Insert the CE connector dust cover Push the tab up to position Figure 8 37 Reassemble CE Connector Dust Cover 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 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 Dust Cover 22 are in open positions so that they do not interfere with the side Control Band 20 during installation of Caution the control band Ensure the CE Connector Dust Cover 21 and Audio Jack Figure 8 39 Adhere Assembly Aid Disassembly Reassembly Procedures Radio Reassembly 8 27 NOTE Be careful not to bend the keypad during the a
64. ducted 75 dBc FM Hum and Noise 12 5 kHz Channel 40 dB 25 kHz Channel 43 dB Distortion 1 2 Modulation Limiting 12 5 kHz Channel 12 5 kHz 25 kHz Channel 15 0 kHz Adjacent Channel Power Ratio 12 5 kHz Channel 67 dB 25 kHz Channel 75 dB Modulation Fidelity Deviation 1630 Hz lt UHF1 lt 1800 Hz Carrier Frequency Offset 0 0002 Error Vector Magnitude lt 5 Symbol Rate Accuracy 0 Adjacent Channel Power Ratio 67 dB Emissions Designators 20KOF1E 16KOF3E 11KOF3E 8K10F1D and 8K10F1E Specifications subject to change without notice Notes Measured in ANALOG mode per TIA EIA 603 under nominal conditions Measured in DIGITAL mode per TIA EIA IS 102 CAAA under nominal conditions XX Notes Model Numbering Charts and Specifications Chapter 1 Introduction 1 1 1 2 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 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
65. e number of the chassis or kit of which it is a part and sufficient description of the desired component to identify it Motorola Online Motorola Online users can access our online catalog at https www motorola com businessonline To register for online access please call 1 800 422 4210 for U S and Canada Service Centers only International customers can obtain assistance at https www motorola com businessonline Mail Orders Mail orders are only accepted by the US Federal Government Markets Division USFGMD Motorola 7031 Columbia Gateway Drive 3rd Floor Order Processing Columbia MD 21046 U S A Telephone Orders Radio Products and Solutions Organization United States and Canada 7 00 AM to 7 00 PM Central Standard Time Monday through Friday Chicago U S A 1 800 422 4210 1 847 538 8023 United States and Canada U S Federal Government Markets Division USFGMD 1 877 873 4668 8 30 AM to 5 00 PM Eastern Standard Time B 5 B 6 B 7 Replacement Parts Ordering Fax Orders Fax Orders Radio Products and Solutions Organization United States and Canada 1 800 622 6210 1 847 576 3023 United States and Canada USFGMD Federal Government Orders 1 80526 8641 For Parts and Equipment Purchase Orders Parts Identification Radio Products and Solutions Organization United States and Canada 1 800 422 4210 Product Customer Service Radio Products and Solutions Organisation United States
66. elected 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 5 2 1 Test Mode Menu Test Modes available after power up e If flip is Opened RF test gt CH test gt RGB test gt Vibration test e If flip is Closed RF test gt CH test gt CID test gt 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 Within 10 seconds after SELF T succession Performance Checks Display Radio Test Mode T is complete press the Side Button five times in 5 3 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 The literal string indicates the radio has Always 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 hardwa
67. er 3 Antenna Switch Connector No Modulation 1 Programming Check deviation and compensation Distorted Modulation settings using the tuner 2 Main Board Send radio to depot Bad Microphone Sensitivity 1 Check Deviation and Realign if necessary Compensation 2 Microphone Send radio to depot No Low signaling 1 Programming Check programming PL DPL MDC 2 Main Board Send radio to depot Cannot Set Deviation Main Board Send radio to depot Balance 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 EEYLARD on Radio Display When 1 Defective Keyload Cable Send radio to depot Keyloading Cable is Attached to the Radio Side Connector 2 Defective Radio Keyloader Displays FAIL 1 Wrong Keyloader Type Use correct keyloader type Refer to Keyloader User Guide for more information 2 Bad Keyloader Try another keyloader 3 Defective Radio Send radio to depot 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 Part
68. ex 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 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 Ibf Figure 8 45 Screws Reassemble Sequence 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 Beze
69. fer transmit and receive audio data A full duplex receiver transmitter asynchronous serial interface See Serial Communication Interface Input Line How the microcontroller communicates to modules and ICs through the CLOCK and DATA lines An electrically transmitted electromagnetic wave An operating mode in which the radio is muted but still continues to analyze receive data to determine RX signal type See software potentiometer Computer programs procedures rules documentation and data pertaining to the operation of a system A computer adjustable electronic attenuator Frequency range within which radiation has specific characteristics See Serial Peripheral Interface Glossary 8 Term squelch SRAM SRIB SSI Standby mode static RAM Synchronous Serial Interface system central controllers system select thin small outline package time out timer TOT transceiver transmitter TSOP TX UART UHF Universal Asynchronous Receiver Transmitter Universal Serial Bus USB VCO Glossary Definition Muting of audio circuits when received signal levels fall below a pre determined value With carrier squelch all channel activity that exceeds the radio s preset squelch level can be heard See static RAM Smart Radio Interface Box See RIB See Synchronous Serial Interface An operating mode in which the radio is muted but still continues to monitor data A type of memory
70. frequency generation 3 4 local oscillator frequencies 3 3 main board 3 3 major assemblies 3 1 overview 3 1 Index 3 receiver backend 3 4 reference oscillator 3 4 synthesizer 3 4 transceiver XCVR operation 3 3 transmitter power amplifier 3 4 VCO buffer 3 4 VOCON operation components 3 4 tools and supplies needed 8 3 trademark information ii transceiver XCVR operation theory of operation 3 3 transmit deviation balance alignment 6 9 limit alignment 6 11 transmit power alignment 6 7 transmitter ASTRO conventional channel tests 5 10 performance checks 5 10 test pattern 6 16 troubleshooting 9 3 transmitting analog mode 3 3 troubleshooting encryption problems 9 4 introduction 9 1 operational error codes 9 2 power up error codes 9 1 receiver problem chart 9 2 transmitter problem chart 9 3 tuner bit error rate test 6 15 front end filter alignment 6 13 UHF 6 13 VHF 6 13 introduction 6 1 main menu 6 2 radio information screen 6 4 reference oscillator alignment 6 4 test setup 6 1 transmit deviation balance alignment 6 9 transmit deviation limit alignment 6 11 transmit power alignment 6 7 transmitter test pattern 6 16 U UHF front end filter alignment 6 13 model chart xvii V VCO buffer 3 4 VHF front end filter alignment 6 13 model chart xvi vibration test display radio 5 8 view exploded complete chassis assembly 10 4 complete flip assembly 10 2 complete front housing assembly 10 3 partial 8 2 Index 4 In
71. hapter provides procedures for using the encryption capability of your radio The following procedures are outlined e Loading an encryption key e Selecting an encryption key e Selecting an Index Erasing an encryption key 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 0182297115 The display shows EEYLOROTHE 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 e On single key radios a short tone e On multikey radios an alternating tone 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 e 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
72. harts and Specifications ASTRO XTS 4000 UHF Model Chart xvii ASTRO XTS 4000 UHF Model Chart MODEL NUMBER DESCRIPTION H18QCN9PWIAN XTS4000 PORTABLE ASTRO DIGITAL 380 470MHZ 0 25 2W ITEM NUMBER DESCRIPTION Xx NUE3623_ XTS 4000 UHF Tanapa X NUE7350_ XTS 4000 UHF Main Xx NNTN7097_ XTS 4000 UCM Board X NNTN7098_ Hardware Tanapa XTS4000 Xx NNTN7101_ Assembly Chassis XTS4000 X NNTN7100_ Assembly Keypad Backer XTS4000 X NNTN7099_ Assembly Flip Front Housing XTS4000 Xx PMLN5057_ XTS4000 CD UG 4 Safety Xx 6871618L01 XTS4000 User Guide Notes X ltem Included e The model number and sometimes the FLASHcode can be found on the FCC label on the back of the radio e The model number Host code DSP code and sometimes the FLASHcode can be found by putting the radio into the Test Mode e 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 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 TRANSMITTER TYPICAL PERFORMANCE FCC Designation AZ489FT3814 Frequency Ranges 136 151 MHz Subject to Antenna operating 145 166 MHz band See Appendix A Antennas 162 174 MHz Temperature Range Operating 30 C to 60 C Storage 40 C
73. he radio is transmitting 3 Measure the transmit RF frequency with your service monitor 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 Target 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 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 e All power measurements are to be made at the antenna port e Transmit Power alignment is required after replacing or servicing the mainboard L A Jo ZA a RF Connector A LZA 4 SN CSS E gt 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
74. 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 Geta new CID Bezel Kit 1 remove all the liners of the adhesives 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 Ibf 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 8 20 Disassembly Reassembly Procedures Radio Reassembly While holding the Flip Assembly A feed the Flip Flex 2 through the top openi
75. iFrequencies MHZ aii e dd 5 4 Test EnvironMeNtS See Seege e iaa 5 6 Receiver Tests for ASTRO Conventional Channels oonniccccocconoccccnnccnnnnnanannnnanoncnnncnnnnnn 5 8 Transmitter Tests for ASTRO Conventional Channels L ocoococcccccnccccccoconononnncnncnnnnonannnnnnnos 5 10 Reference Oscillator Alignment nn nnno nana rnnnnnnnnar nn rn rr rr 6 6 Transmit Power Settings oooooconnnoncccconnnoccccccnnnonncccnnnann conc na nan nn cnc cnn nn nn cnc cnn nen cnc AEEA 6 8 Encryption Key Zeroization Optons ocn nn non ronca r anno rca rrnnnnn rca 7 4 Corresponding XTS 4000 Exploded View and Parts UIst 8 2 Required Tools and Supplies cccccceceeceeeeeeeecececeeceeeeeeeeeeeeceeecaaaeaecaeeeeeeeeeeseeseecsaceeeeees 8 3 Fastener Torque Chart i srci coria eed id da ANNER Ea Na 8 3 Power Up Error Code Display 9 1 Operational Error Code Displays n0sno0ssnnsnnnneensteeeettnnntrnstrestrerttttrtnnnnnnntentttnnnnnnnn annene enn 9 2 Receiver Troubleshooting Chart 9 2 Transmitter Troubleshooting Chart ooooonnoncccnnnnocccccnonconcccnnnnoncnncnnnnnnnnnnn nana nccnnn ana ncncnnnnnnncnnnns 9 3 Encryption Troubleshooting Chart 9 4 XTS 4000 Exploded Views and Parts Liers 10 1 Parts List Main Assemblies cence eee eeeeeceaeaaeaeceeeeeeeeeeeesenssnnieeeeeeees 10 2 Parts List Flip Front Housing Assemblies ooooncccccnnnocicicinnconncncnnnnoncnnccnnno nan rn canaria rannnnn 10 3 Parts List Chassis Assembhy 10 4 Sen
76. ial 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 Defects or damage from improper testing operation maintenance installation alteration modification or adjustment 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 Product which has had the serial number removed or made illegible Rechargeable batteries if ITON any of the seals on the battery enclosure of cells are broken or show evidence of tampering the damage or defect is caused by charging or using the
77. ies 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 Caution 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 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 a
78. ine appears Press any key until all 13 green color vertical lines appears Press any key Black color test appears Press any key Blue color test appears Performance Checks Receiver Performance Checks 5 2 6 CID Test Mode Only applicable to External Display To perform the CID Test 1 2 3 4 Press and release the Emergency Button Top Right Orange button all pixels are on Press any key Checker box 1 test appears Press any key Checker box 2 test appears Press any key Test co eted appears 5 2 7 Vibration Test Mode To perform the Vibration Test 1 Press and release the Emergency Button Top Right Orange button Press ary key to pr d 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 Mode Proj 25 Std Radio Tuner PTT to OFF BER lt 0 01 BER Floor RF Control Gen Software Bit Error center Use test setup shown in Output Level 47 dBm Rate screen is Figure 5 1 on page 5 Proj 25 Dev 2 83 kHz required 1 Code 1011 Hz PAT Reference
79. ip 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
80. ip stopper from the side of the front housing to remove the flip stopper Figure 8 20 Removing Tabs from Flip Stopper Pad 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 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 NM Extreme care must be taken during removal of the CID Bezel Kit 1 particularly nea
81. ital voice Very High Frequency Vehicle Interface Port See vocoder controller An electronic device for synthesizing speech by implementing a compression algorithm particular to voice See also voice encoder A PC board that contains an ASTRO radio s microcontroller DSP memory audio and power functions and interface support circuitry The DSP based system for digitally processing analog signals and includes the capabilities of performing voice compression algorithms or voice encoding See also vocoder An oscillator in which the frequency of oscillation can be varied by changing a control voltage Glossary 10 Glossary Notes Index Index A Abacus Il theory of operation 3 4 accessories antennas A 1 batteries A 1 belt clips A 1 carry A 1 charger A 1 headsets and earpieces A 2 surveillance A 2 alignment tuner bit error rate test 6 15 front end filter 6 13 UHF 6 13 VHF 6 13 introduction 6 1 main menu 6 2 radio information screen 6 4 reference oscillator 6 4 softpot use 6 3 test setup 6 1 transmit deviation balance 6 9 transmit deviation limit 6 11 transmit power 6 7 transmitter test pattern 6 16 analog mode receiving 3 2 transmitting 3 3 antenna attaching 8 4 removing 8 4 antennas types A 1 assemblies separating 8 7 B battery attaching 8 5 removing 8 5 types A 1 belt clips A 1 bit error rate test 6 15 board CE connector 8 12 8 27 buffer VCO 3 4 C carry accessories belt clip
82. itry is not needed 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 Caution 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 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 d
83. ix 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 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 Chapter 2 Basic Maintenance 2 1 2 2 This chapter describes preventive maintenance and handling precautions Each of these topics provides information vital to the successful operation and maintenance of your radio 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 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 circu
84. ks such as decoding ASTRO signaling See Digital Private Line See also PL See digital signal processor See digital signal processor code See dual tone multi frequency Glossary Term dual tone multi frequency EEPOT EEPROM Electrically Erasable Programmable Read Only Memory FCC firmware FGU flash FLASHcode FLASHport FMR Florida Manual Revision frequency frequency generation unit General Purpose Input Output GPIO Glossary 3 Definition The system used by touch tone telephones DTMF assigns a specific frequency or tone to each key so that it can easily be identified by a microprocessor Electrically Programmable Digital Potentiometer See Electrically Erasable Programmable Read Only Memory A special type of PROM that can be erased by exposing it to an electrical charge An EEPROM retains its contents even when the power is turned off Federal Communications Commission Code executed by an embedded processor such as the Host or DSP in a subscriber radio This type of code is typically resident in non volatile memory and as such is more difficult to change than code executed from RAM See frequency generation unit A non volatile memory device similar to an EEPROM Flash memory can be erased and reprogrammed in blocks instead of one byte at a time A 13 digit code which uniquely identifies the System Software Package and Software Revenue Options that are enabled in a par
85. l 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 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 co
86. l 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 Ce SE SE Model Number Description Characteristics Application Service Can be used as a Aeroflex 2975 Frequency deviation meter and Monitor substitute for items www aeroflex com signal generator for wide range marked with an Motorola R2670 or equivalent troubleshooting and alignment asterisk Digital RMS 100 uV to 300 V Fluke 179 or equivalent AC DC voltage and Multimeter 5 Hz to 1 MHz www fluke com current measurements Audio 10 Mega Ohm voltage measurements Impedance RF Signal 100 MHz to 1 GHz Agilent N5181A Receiver measurements Hz to 10 kHz Oscilloscope 2 Channel Leader LS8050 Waveform measurements 50 MHz Bandwidth www leaderusa com 5 mV div to 20 V div Tektronix TDS1001b www tektronix com or equivalent Power Meter and Sensor 5 Accuracy 100 MHz to 500 MHz 50 Watts Bird 43 Thruline Watt Meter www bird electronic com or equivalent Transmitter power output measurements RF Millivolt Meter 100 mV to 3 V RF 10 kHz to 1 GHz Boonton 92E
87. le 5 4 NOTE Transmit into a load when keying a radio under test Table 5 3 Test Frequencies MHz Test VHF VHF UHF UHF Channel RX TX RX TX 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 F8 463 750 463 7 F9 469 7 469 650 Performance Checks Display Radio Test Mode 5 5 Table 5 4 Test Environments Display Description Function CS Carrier RX unsquelch if carrier detected Squelch TX mic audio TRL Tone RX unsquelch if carrier and tone 192 8 Hz Private Line detected TX mic audio tone 192 8 Hz AST ASTRO RX none TX 1200 Hz tone USO Carrier RX unsquelch always Unsquelch TX mic audio All deviation values are based on deviation tuning of this mode 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 Di
88. le CE Retainer and Spacer coococccccconoccccccnanoncnnnonanoncnccnnnnn ana rc nana nn carr nnnnnrnnrnnnnn 8 24 Figure 8 35 Reassemble Flip FIEX EE 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 Ald oooooononocccconononoconcnnonenonononnnercnn nn cnn rre 8 26 Figure 8 40 Reassemble Control Band 8 27 Figure 8 41 Assemble B Plus Seal to B Plus Connechor cnn nan nncccnnnnns 8 28 Figure 8 42 Assemble B Plus Seal to B Plus Connechor nan n cnc cnn ana ncccnnnnnns 8 28 Figure 8 43 Holding CE UCM FIER re arr aA AAE n EAEE narra 8 29 Figure 9 44 ReassembleFlOXeS ipinia iio AAEE AEE EE DEENEN ERR EAE 8 29 Figure 8 45 Screws Reassemble Sequence sssssessssrisessssrreestntnestinnaessttnnedstntaaeeettannesttinnaasnennnnennna 8 30 Figure 10 1 Exploded View Main Assemblies A 10 2 Figure 10 2 Exploded View Flip Front Housing Assemblies ooooooccccnnnnnnccccnnnconcccccnnnonccccnnnannncccnnnnn 10 3 Figure 10 3 Exploded View Chassis Assembiy cnn o nn n anno rra rn 10 4 xii Commercial Warranty Commercial Warranty Limited Warranty MOTOROLA COMMUNICATION PRODUCTS L What This Warranty Covers And For How Long MOTOROLA SOLUTIONS INC MOTOROLA warrants the MOTOROLA manufactured Communication Products listed below Product against defects in material and workmansh
89. lete chassis assembly 10 4 complete flip assembly 10 2 complete front housing assembly 10 3 partial 8 2 features 1 2 FLASHport feature 1 2 information screen 6 4 model numbering system xv models 1 2 performance checks receiver 5 8 transmitter 5 10 reassembling chassis assembly 8 23 chassis to flip front housing assemblies 8 29 Index flip assembly 8 18 front housing assembly 8 19 RF test mode 5 4 RGB test mode 5 7 test mode menu 5 2 vibration test 5 8 receiver ASTRO conventional channel tests 5 8 backend theory of operation 3 4 performance checks 5 8 troubleshooting 9 2 receiving analog mode 3 2 reference oscillator alignment 6 4 reference oscillator theory of operation 3 4 replacement parts ordering B 1 RF exposure compliance information ii RF test mode display radio 5 4 RGB test mode display radio 5 7 S service aids 4 2 servicing CID bezel 8 30 softpot 6 3 specifications UHF Range 1 radios xix VHF radios xviii surveillance accessories A 2 synthesizer theory of operation 3 4 T terms and definitions Glossary 1 test environments 5 6 test equipment recommended 4 1 test frequencies 5 4 test mode display radio 5 2 test mode menu display radios 5 2 test mode entering display radios 5 2 test setup alignment 6 1 performance checks 5 1 tests receiver ASTRO conventional channels 5 8 transmitter ASTRO conventional channels 5 10 theory of operation Abacus III 3 4 analog mode 3 2 first IF frequencies 3 3
90. lex 1371710L02 Bezel CID 0104024J62 Flex Flip 3371777L01 Label Flip Inner Kit 3 NNTN7209 Field Service Kit Flip Assembly 1371710L02 Bezel CID 0104024J62 Flex Flip Flip Sub Assembly 5589594Y02 Hinge Cam Silent 5 8mm Dia x 5 1mm x 15 6mm 0371903L01 Screw 3MT P975 0F lip 3371777L01 Label Flip Inner 1171385M01 Lubricant Kit 4 NNTN7190_ Service Kit Front Housing Front Housing Sub Assembly 1171385M01 Lubricant Kit 5 NNTN7099 Assembly Flip Front Housing 1371710L02 Bezel CID 0104024J62 Flex Flip Flip Sub Assembly 5589594Y02 Hinge Cam Silent 5 8mm Dia X 5 1mm X 15 6mm 10 5 10 6 Exploded Views and Parts Lists Notes Appendix A Accessories Motorola provides the following approved optional accessories to improve the productivity of the XTS 4000 portable radio For a complete list of Motorola approved antennas batteries and other accessories visit the following web site http www motorolasolutions com governmentandenterprise A 1 Antennas NAD6581_ Antenna 146 162 MHz 1 69 42 8mm Black Coded NAD6582_ Antenna 136 151 MHz 1 89 48 0mm Yellow Coded NAD6583_ Antenna 162 174 MHz 1 49 37 8mm Blue Coded NAE6552_ Antenna 380 470 MHz 1 89 48 0mm Red Coded NAE6553_ Antenna 380 470 MHz 5 52 140 0mm A 2 Batteries and Battery Accessories NNTN6944 630 mAh Standard Li lon Battery PMNN4083 1260 mAh
91. llator 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 NM When keying the radio during a test always transmit into a dummy load Caution Radio Information Figure 6 5 shows a typical Radio Information screen This screen is informational only and cannot be directly changed Radio Information x Model Number PUEDAN UCM Sw Diese Version Serial Number TCBDGOSCH Tuning Hardware 524 R01 09 10 Version Host Version penz DSP Version pesn Figure 6 5 Radio Information Screen 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
92. mbling 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 XTS 4000 Exploded View Partial This section contains the XTS 4000 radio partially exploded view and parts list NOTES e 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 e 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 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 tere Description Exploded View and Parts List Number A Flip Assembly Refer 10 2 Exploded View and Parts List Flip Front Housing Assemblies on page 10 3 B Front Housing Refer 10 2 Exploded View and Parts List Assembly Flip Front Housing Assemblies on page 10 3 C Chassis Assembly Refer 10 3 Exploded View and Parts List Chassis Assembly on page 10 4 D An
93. nally Provides easy access to electronic circuits required for board level troubleshooting NNTN7152 Regulated Battery Eliminator Used in place of battery to connect radio to an external XTS 4000 power supply NNTN7153 SMA Conversion RF Adapter Adapts radio s antenna port to RF cabling of test equipment RLN4460 Portable Test Set Used for radio performance checks Connects to radio s CE connector and allows remote switching and signal injection outputs for test equipment measurements RVN4181 Customer Programming CPS allows customer specific programming of modes and Software CPS and Tuner Software 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 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
94. nd 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 e 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 e 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 7 4 5 Encryption Erase an Encryption Key Using the keypad enter the location number of the desired key The display shows the selected key
95. nd lay it aside The B Plus Seal 31 may be removed from the B Plus Connector on the back of the Main Board 29 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 AN Caution Removing the Control Band 20 from the Main Chassis 39 without disengaging the dust covers may damage the Control Band AN Caution 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 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 41 2 Pull gently UA 1 Push the catches _ towards the chassis NJ Ke Figure 8 10 Removing C
96. ng of the Front Housing With the flip in the open position assemble the Flip Assembly as follows AN Be careful not to pull or pinch the Flip Flex during the assembling process Caution 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 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 Insert the Microphone Boot 8 into the Front Housing Gently push the Microphone into the Microphone Boot Verify that the Microphone is fully seated 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 Disassembly Reassembly Procedures Radio Reassembly 8 21 7 Assemble the Main Keypad 12 to the Front Housing Plug in the Spe
97. nnnnncnn anar nnccnnnns 6 5 Figure 6 7 Reference Oscillator Alignment Screen UHF oooonocccccnoconcncconanoncncnonannnoncncnnnnnnncnnnannnnccnnnns 6 6 Figure 6 8 Battery Eliminator with RF Connector and MA 6 7 Figure 6 9 Transmit Power Alignment Screen Typical VHF 0ococcconnocccccnnnconcnccnnanoncncconanancncnnnnnnncncnnnns 6 8 Figure 6 10 Transmit Power Alignment Screen Typical UHF 0 ce ececeeeceeeeeeeeeeeeeeeeeeseeeeaeeeeteeeaeeees 6 8 Figure 6 11 Transmit Deviation Balance Alignment Screen VHF sssssessrsssessrieseserrrssrrrrrsssrrerressreenns 6 10 Figure 6 12 Transmit Deviation Balance Alignment Screen UHF ceeeeeeeeeeeeeeneeeeeeeeeteeeeeeeeeanees 6 10 Figure 6 13 Transmit Deviation Limit Alignment Screen VHF o oo eee eeeeeeceeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeaees 6 12 Figure 6 14 Transmit Deviation Limit Alignment Screen UHF 00 eee eeeeeeeceeeceeeeeeeeeeeeeeeseeneeeeeeeeeanees 6 12 Figure 6 15 Battery Eliminator with RF Connector and MA 6 13 Figure 6 16 Front End Filter Alignment Screen VE 6 14 Figure 6 17 Front End Filter Alignment Screen UHE ce ceceeceeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeaeeeeeeeenaeeees 6 14 Figure 6 18 Bit Error Rate Green 6 16 Figure 6 19 Transmitter Test Pattern Screen VHF oonccccconncocccccnnnonrnc cinco nono no nn conan rr rana 6 17 Figure 6 20 Transmitter Test Pattern Screen UHF ooooccccconononccccnnnnonnoconn nono n cnn conan nc cnn nar
98. nt ing Pre Selector Filter Antenna Switch MAEPF 27322 0 Figure 3 3 Transceiver VHF Block Diagram Power and Control Omitted Harmonic Filter NX To Antenna 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 3 2 2 Transmitting oscillator as a modulation signal See Figure 3 3 Reference Oscillator L gt ON EPIC Hier FracN 3 VCO A A 1 won DAC LPF VCO ABACUS III lt HH IAN Crystal Filter lt 1 A Sample 2ND Clk LO which transmits the signal under dynamic power control 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 44 85 MHz 73 35 MHz First IF Frequency 3 4 3 3 2 Basic Theory of Operation Main Board The frequency generation fun
99. ntacted 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 Description Corrective Action aisg FLASH ROM Codeplug Checksum Non Fatal Error Reprogram the codeplug Security Partition Checksum Non Fatal Error Send radio to depot Diop ABACUS Tune Failure Non Fatal Error Turn the radio off then on ei zz Tuning Codeplug Checksum Non Fatal Error Send radio to depot Host ROM Checksum Fatal Error Send radio to depot i gz FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug lesa External RAM Fatal Error Note Not a checksum failure Send radio to depot General Hardware Failure Fatal Error Turn the radio off then on Security Partition Checksum Fatal Error Send radio to depot 1 32 FLASHport Authentication Code Failure Send radio to depot Internal RAM Fail Fatal Error Send radio to depot ai Az Tuning Codeplug Checksum Fatal Error Send radio to depot areal DSP ROM Checksum Fatal Error Send radio to depot DSP RAM Fatal Error Note Not a checksum failure Turn the radio off then on received correctly General DSP Hardware Failure DSP startup message not Turn the radio off then on
100. ontrol 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 Figure 8 11 Removing Audio Jack Dust Cover Disassembly Reassembly Procedures Radio Disassembly Push the tab down Rotate 90 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
101. or the part to cool Remove the circuit board and inspect the repair No cleaning should be necessary Chapter 3 Basic Theory of Operation 3 1 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 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 Main Display 130 x 130 dot matrix liquid crystal display LCD CID Display 112 x 32 dot matrix liquid crystal display LCD keypad CE UCM Flex contains vibrator speaker microphone and encryption connector Keypad a 3 x 3 Menu keypad with 4 way navigation button and a 3 x 4 alphanumeric 60 Display Keypad and Earpiece Antenna 16 Controls Ji gt
102. orted 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
103. 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 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 P
104. proper exits from the alignment screens might leave the radio in an improperly configured state and result in seriously degraded radio or system performance f DO NOT switch radios in the middle of any alignment 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 xl Frequency Radio Softpot New Softpot MHz Value Value fi 73 9750 396 _AA AMIA g 396 0 511 Program All Close PTT Togate TRANSMITTER OFF 173 9750 Help Figure 6 3 Typical Softpot Screen VHF x Frequency Radio Softpot New Softpot MHz Value Value 469 6800 js g 215 lt 0 511 Program Al Close PTT Toggle TRANSMITTER OFF 469 6500 Help Figure 6 4 Typical Softpot Screen UHF 6 4 6 4 6 5 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 osci
105. r rn cnnnnnrnnnc 6 17 Figure 8 1 XTS 4000 Partial Exploded View oooooooccccconnooccccccnononccccnnnnnncncnnnnnnnnncnn nano nn ncn nana n nn ncc naaa ncncccnnns 8 2 Figure 8 2 Attaching the Antenna non nn rn cnn nn nn nrn cnn nn n nn rr cnn nnn nn rr nnnnnnnncnnnns 8 4 Figure 8 3 Removing the Antenna cceccscceeceeecceeeedeccceeeeeddaceeeeeedeaaeeeeseaacaeeeedeaccseeseddacaeeeeddenaneenedes 8 4 Figure 8 4 Attaching the Battery EE 8 5 Figure 8 5 Removing the Battery cccceccccccteeeeeeceeeeddeneceeenedeacaeeeedeeneceeeeeencanseteseaceneeeneedcaaseeeeaceneeendes 8 6 Figure 8 6 Separating Flip Front Housing Assembly From Chassis Assembhy 8 7 Figure 8 7 Unplugging Hat EE 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 ooo noooccnnnnnnnccccno 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 EE 8 11 Figure 8 14 Removing CE Retainer and Spacer oociccccccnnnnococcnononononcnnnonononannnnnnnn nn cnn nnnn ronca rn nn nn rra rnnnnnnn 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 lex 8 14 Figure 8 18 Removing Secure Pad seiri aniria aE EAA EARE A EREA AA ET
106. r the thin ribs adjacent to the CID Display Caution 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 Figure 8 23 Removing CID Bezel 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 adhesive applied during reassembly The adhesive surfaces must be clean and free of all foreign material including oils and or any Caution 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
107. re When the radio is secure equipped Encryption Type 1 Type of encryption being used When the radio is secure equipped Encryption Type 2 Type of encryption being used When the radio is secure equipped Model Number The radio s model number as Always programmed in the codeplug Serial Number The radio s serial number as programmed Always in the codeplug ESN Number The radio s Electronic Serial Number as Always programmed in the codeplug ROM Size The memory capacity of the host FLASH Always part FLASH Code The FLASH codes as programmed in the Always codeplug RF Band The radio s RF band as programmed in Always the Tuning codeplug Tuning Codeplug Version of the Tuning codeplug being Always Version used Processor Version Version of the processor 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 HF tes 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 5 4 5 2 3 Performance Checks Display Radio Test Mode 3 Do one of the following e Press the Secure Button Progr
108. ree 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 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 IHH 2 Press Left Menu Select Button Middle Menu Select Button or Right Menu Select Button directly below IHE 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 IHE 2 Press Left Menu Select Button Middle Menu Select Button or Right Menu Select Button directly below IHG The display shows the last user selected a
109. rtz One million cycles per second Used especially as a radio frequency unit Also written as uC A microprocessor that contains RAM and ROM components as well as communications and programming components and peripherals See Master In Slave Out See Master Out Slave In An electronic device that combines several signals for transmission on some shared medium e g a telephone wire See multiplexer Nickel cadmium Nickel metal hydride See over molded pad array carrier A controller configuration that utilizes a microprocessor with extended ROM RAM and EEPROM An electronic device that produces alternating electric current and commonly employs tuned circuits and amplifying components See outbound signaling word See over the air rekeying Data transmitted on the control channel from the central controller to the subscriber unit A Motorola custom IC package distinguished by the presence of solder balls on the bottom pads Allows the dispatcher to remotely reprogram the encryption keys in the radio Power amplifier One way communication that alerts the receiver to retrieve a message A dual core processor that contains an MCU and a DSP in one IC package Printed Circuit Board Also referred to as a PCB A circuit in which an oscillator is kept in phase with a reference usually after passing through a frequency divider See private line tone squelch Glossary 6 Term PLL private line tone sq
110. s A 1 CE connector board 8 12 8 27 charger accessories A 1 chassis and housing 8 7 chassis assembly disassembling 8 8 Index 1 reassembling 8 23 chassis to flip front housing assemblies assemble 8 29 CID bezel servicing 8 30 CID test mode display radio 5 8 cleaning external plastic surfaces 2 1 control top and keypad test mode display radio 5 6 copyrights computer software ii document ii customer service B 2 D disassembly reassembly antenna attaching 8 4 removing 8 4 battery attaching 8 5 removing 8 5 chassis assembly disassembling 8 8 reassembling 8 23 flip assembly disassembling 8 16 reassembling 8 18 front housing assembly disassembling 8 13 reassembling 8 19 introduction 8 1 separating chassis and housing assemblies 8 7 display radio CID test model 5 8 control top and keypad test mode 5 6 entering test mode 5 2 RF test mode 5 4 RGB test mode 5 7 test mode 5 2 test environments 5 6 test frequencies 5 4 test mode menu 5 2 vibration test 5 8 E earpiece and headsets accessories A 2 encryption index selecting with keypad 7 3 selecting with menu 7 3 key erasing all keys 7 4 key zeroization 7 3 selecting with keypad 7 2 selecting with menu 7 1 troubleshooting chart 9 4 error codes operational 9 2 power up 9 1 exploded view Index 2 complete chassis assembly 10 4 flip assembly 10 2 front housing assembly 10 3 partial 8 2 F field programming equipment 4 2 FLASHport 1 2 flip assembly
111. s 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 a mm Press fit this area l after assemble to e ensure water sealed V MA Z from the connector es Locating Features Mr Figure 8 32 Assemble T6 screws to Front Housing 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 Ibf 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 Ibf tighten the Antenna Bushing Screw 43 on the Antenna Bushing Assembly to secure it in place 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
112. s Lists View Page Exploded View and Parts List Main Assemblies 10 2 Exploded View and Parts List Flip Front Housing 10 3 Assemblies Exploded View and Parts List Chassis Assembly 10 4 Parts List Service Kit 10 5 10 2 10 1 Exploded View and Parts List Main Assemblies Figure 10 1 Exploded View Main Assemblies Exploded Views and Parts Lists 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 E Battery Assembly Battery Pack NAD6582_ 8571814L02 or NAD6581_ 8571814L04 or NAD6583_ 8571814L01 or NAE6552_ 8571814L05 or NAE6553_ 85012029001 Antenna 136 151 MHz Yellow coded Antenna 146 162 MHz Black coded Antenna 162 174 MHz Blue coded Antenna 380 470 MHz Red coded Antenna 380 470 MHz See Section A 2 Batteries and Battery Accessories on page A 1 in Appendix A Accessories Exploded Views and Parts Lists Exploded View and Parts List Flip Front Housing Assemblies 10 2 Exploded View and Parts List Flip Front Housing Assemblies
113. splay on page 5 6 5 2 6 CID Test Mode Only applicable to External Display on page 5 7 Release the Emergency Button 3 9 appears which indicates that the Emergency Button is in the open position Your radio is now in the Control Top and Keypad test mode Press the Emergency Button again 371 appears which indicates that the Emergency Button is in the closed position a Press the Upper Volume Rocker 2 1 appears release o appears ER 1 1 appears release Press the Secure Button Programmable Top Left Button 3 1 appears release 3676 appears appears Press Programmable Keypad Button 37 1 appears release 27 8 appears Press Side Button 3 1 appears release 3 Press the PTT Button 1 1 appears release 176 appears E appears 5 6 Performance Checks Display Radio Test Mode 5 2 4 2 Keypad Checks To continue to the keypad checks Press 0 4871 appears release 42 8 appears Press 1 43 1 appears release E appears Press 2 3871 appears release 3g appears ats Press 3 Si 1 appears release appears Press 4 S21 appears release E appears Press 5 S 1 appears release amp appears Press 6 54 1 appears release appears Press 7 3571 appears release 25 8
114. ssembly 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 DM Do not twist or pull the Flip Flex as this might cause permanent damage to the Flip Flex Caution Steps 4 6 Speaker Compartment Seal 13 Main Keypad 12 and UCM Module should be performed while supporting Caution the keypad backer in the orientation shown in Figure 8 16 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 Figure 8 16 Disassemble Speaker Compartment Seal Main Keyboard and UCM Board 8 14 Disassembly Reassembly Procedures Radio Disassembly 7 Separate the Keypad Backer Inner Jumper Flex 17 from the Keypad Backer Sub Assembly 15 by gentl
115. ssembly 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 Al A 2 Rotate towards if Main Chassis Pull to insert the catches y d 3 After Inserting catches Press to locate en N Figure 8 40 Reassemble Control Band 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
116. tenna 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 Disassembly Reassembly Procedures Required Tools and Supplies 8 2 Required Tools and Supplies Table 8 2 Required Tools and Supplies Tools and Supplies er ete Supplier SC Anti static ground kit 0180386A82 Magnetic screwdriver set with bits 0180320B16 Tape Top and Side Controls 1171742L01 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 8 3 Fastener Torque Chart Table 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 Description Repair Torque Part Number H in Ibf 0371903L01 Flip Assembly Screw 5 1 5 0371907L01 Antenna Bushing Screw 43 2 1 Keypad Backer Screw 18 3 1 0371711L01 Battery Connector Screw 45 1 1 0371904L01 Chassis Screw 49 4 4 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 Wi
117. th the radio turned off turn the antenna clockwise to attach it to the radio CdD Figure 8 2 Attaching the Antenna 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 NA Figure 8 3 Removing the Antenna 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 A e DO NOT charge remove or attach the battery in an area labeled hazardous atmosphere WARNING e 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 e after battery removal Caution 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 d Se ZP 1 Figure 8 4 Attaching the Battery 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 r
118. the following table Table 2 1 Lead Free Solder Wire Part Number List Motorola Flux Content Melting Supplier Part e Part Number Alloy Flux Type by Weight Diameter 1088929Y01 95 55n 3 8Ag 0 7Cu RMA Version 2 7 3 2 217C 52171 0 015 1lb spool Table 2 2 Lead Free Solder Paste Part Number List Motorola Part Manufacturer Part Liquid pasi oe 1085674C03 NC SMQ230 900 1000KCPs Type 3 95 a SC 0 7 Cu 217 C Brookfield 5rpm 325 500 9 3 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 Basic Maintenance General Repair Procedures and Techniques 2 3 2 3 2 2 3 3 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
119. 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 ll 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 Commercial Warranty xiii lll 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 ser
120. ticular subscriber radio FLASHcodes are only applicable for radios which are upgradeable through the FLASHport process A Motorola term that describes the ability of a radio to change memory Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to again and again See Florida Manual Revision A publication that provides supplemental information for its parent publication before it is revised and reissued Number of times a complete electromagnetic wave cycle occurs in a fixed unit of time usually one second This unit generates ultra stable low phase noise master clock and other derived synchronization clocks that are distributed throughout the communication network Pins whose function is programmable See General Purpose Input Output Glossary 4 Term host code IC IF IMBE inbound signaling word integrated circuit ISW key variable loader kHz kilohertz KVL LCD LED light emitting diode Lilon liquid crystal display LO low speed handshake LSH Master In Slave Out Master Out Slave In MCU MDC MDI Glossary Definition Object code executed by the host processor in an ASTRO subscriber radio The host is responsible for control oriented tasks such as decoding and responding to user inputs See integrated circuit Intermediate Frequency A sub band voice encoding algorithm used in ASTRO digital voice Data transmitted on the con
121. tion 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 2 4 2 3 4 Shields Basic Maintenance General Repair Procedures and Techniques Removing and replacing shields is recommended to be done with the Air Blower BOSCH GHG 603 or equivalent To remove the shield PATIENTS Place the circuit board in the circuit board holder Add solder paste flux around the base of the shield Position the heat focus head onto the shield Turn on the heater and wait until the shield lifts off the circuit board Once the shield is off turn off the heat and grab the part with a pair of tweezers Remove the circuit board from the circuit board holder To replace the shield 1 2 A E Add solder to the shield if necessary using a micro tipped soldering iron 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 Place the circuit board back in the circuit board holder Place the shield on the circuit board using a pair of tweezers Position the heat focus head over the shield Turn on the heater and wait for the solder to reflow Once complete turn off the heat raise the heat focus head and wait approximately one minute f
122. to 85 C Power Supply Lithium lon Battery Li lon Battery Voltage Nominal 7 5 Vde Range 6 to 9 Vde Transmit Current Drain Typical 950 mA Receive Current Drain Rated Audio 210 mA Standby Current Drain 89 mA Recommended Battery 630 mAh Li lon NNTN6944_ or 1260 mAh Li lon PMNN4083_ Dimensions H x W x D Radio Only w o battery w o antenna 4 06 x 2 18 x 1 17 103 2 mm x 55 3 mm x 29 6 mm Radio With 630 mAh Li lon NNTN6944_ Only w o antenna 4 06 x 2 18 x 1 36 103 2 mm x 55 3 mm x 34 6 mm Radio With 1260 mAh Li lon PMNN4083_ Only w o antenna 4 06 x 2 18 x 1 58 103 2 mm x 55 3 mm x 40 2 mm Weight w Antenna Less Battery 5 6 oz 160 g With 630 mAh Li lon NNTN6944_ 7 8 0z 220 g With 1260 mAh Li lon PMNN4083_ 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 uV Selectivity 12 5 kHz Channel 67 dB 25 kHz Channel 78 dB Intermodulation 75dB Spurious Rejection 75dB FM Hum and Noise 12 5 kHz Channel 45 dB 25 kHz Channel 50 dB Distortion 1 50 Digital Sensitivity 1 BER 0 25 uV 5 BER 0 22 uV Selectivity 63 dB Intermodulation 73dB Spurious Rejection 75dB Residual Audio Noise Ratio silence 65 dB Residual Audio Noise Power mute 65 dBm Distortion 1 00 RF Power 136 17
123. to ensure sealing capability is retained d All disassembled interfaces requiring adhesive must have new 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 1 align to J these 2 edges Item 4 align to these 2 edges This cut indicate up Ee N s y Item 3 align to ge ei legend marking Item 5 align to amp edge these 2 edges Adhesive Location Front View Adhering the Adhesive to Flip Flex Overview Items 2 align to arrow marking amp edge Item Motorola Description AL No Part number UN 1 1171646L01 Adhesive Flip Flex Seal 2 S Flip 2 2 7571858L01 Pad Conductive Foam 1171845L01 Adhesive Flip Flex i i Housing i p E d y 4 1171857L01 Adhesive Conductive a 1171645L01 Adhesive Flip Flex Seal 1 Backer Adhering the Adhesive to Flip Flex Overview 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 Disassembly Reassembly Procedures Radio Reassembly 8 19 2 Carefully insert the Flip Flex 2 into the
124. 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 MOTO MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of Motorola Trademark Holdings LLC and are used under license All other trademarks are the property of their respective owners 2007 2011 by Motorola Solutions Inc All rights reserved Document History The following major changes have been implemented in this manual since the previous edition orientation issues from previous revision Edition Description Date 6871619L01 A Initial edition Mar 2007 687
125. trol channel from a subscriber unit to the central control unit An assembly of interconnected components on a small semiconductor chip usually made of silicon One chip can contain millions of microscopic components and perform many functions See inbound signaling word A device used to load encryption keys into a radio See kilohertz One thousand cycles per second Used especially as a radio frequency unit See key variable loader See liquid crystal display See LED An electronic device that lights up when electricity is passed through it Lithium ion An LCD uses two sheets of polarizing material with a liquid crystal solution between them An electric current passed through the liquid causes the crystals to align so that light cannot pass through them Local oscillator 15baud digital data sent to the radio during trunked operation while receiving audio See low speed handshake SPI data line from a peripheral to the MCU SPI data line from the MCU to a peripheral See microcontroller unit Motorola Digital Communications MCU DSP Interface internal to the Patriot IC Glossary Term MHz Megahertz microcontroller unit MISO MOSI multiplexer MUX NiCd NiMH OMPAC open architecture oscillator OSW OTAR outbound signaling word over molded pad array carrier over the air rekeying PA paging Patriot IC PC Board phase locked loop PL Glossary 5 Definition See Megahe
126. ually They are inclusive in the NNTN7189_ Field Service Kit Adhesive refer Table 10 5 Service Kit Table on page 10 5 10 4 10 3 Exploded View and Parts List Chassis Assembly Figure 10 3 Exploded View Chassis Assembly Exploded Views and Parts Lists Exploded View and Parts List Chassis Assembly Table 10 4 Parts List Chassis Assembly Ite m No Motorola Part Number Description Ite m Motorola Part Number No Description A Flip Assembly B Front Housing Assembly C Chassis Assembly 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37t 38 39 40 41 42 1371131L01 3271734L01 3271733L01 7571176L01 7571179L01 4371778L01 0104024J66 1171635L01 0104028J17 Refer Model Chart on page xvi 7515719H02 3271707L01 3271715L01 0104024J59 4271726L01 4371725L01 0104028J13 1171636L01 1471169M01 2771148L02 0104024J57 3271717L01 4371713L01 Band Control Cover Dust CE Connector Cover Dust Audio Jack Keypad Side controls Keypad Top Controls Audio Jack Alignment Sleeve Board Audio Jack Note to replace order 0104024J66 Audio Jack Board 1171635L01 Audio Jack Adhesive 3271570L01 Port Seal and 3371776L01 Audio Jack PC Label Adhesive Audio Jack Note to replace
127. uelch Programmable Read Only Memory PROM PTT Push to Talk radio frequency radio frequency power amplifier Radio Interface Box Radio Service Software random access memory RAM read only memory real time clock receiver registers repeater repeater talkaround Glossary Definition See phase locked loop A continuous sub audible tone that is transmitted along with the carrier See also DPL A memory chip on which data can be written only once Once data has been written onto a PROM it remains there forever See Programmable Read Only Memory See Push to Talk The switch or button usually located on the left side of the radio which when pressed causes the radio to transmit When the PTT is released the unit returns to receive operation The portion of the electromagnetic spectrum between audio sound and infrared light approximately 10 kHz to 10 GHz Amplifier having one or more active devices to amplify radio signals A service aid used to enable communications between a radio and the programming software DOS based software containing the feature set of an ASTRO radio See also CPS A type of computer memory that can be accessed randomly that is any byte of memory can be accessed without touching the preceding bytes See random access memory A type of computer memory on which data has been prerecorded Once data has been written onto a ROM chip it cannot be removed and can only be
128. ution 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 Model Numbering Charts and Specifications Portable Radio Model Numbering System XV Model Numbering Charts and Specifications Portable Radio Model Numbering System Typical Model Number H 1 8 K C Position 1 2 3 4 5 A A Position 1 Type of Unit H Hand Held Portable Positions 2 amp 3 Model Series 18 XTS 4000 Position 4 Frequency Band A Less than 29 7MHz P 336 to 410MHz B 29 7 to 35 99MHz Q 380 to 470MHz C 36 to 41 99MHz R 438 to 482MHz D 42 to 50MHz S 470 to 520MHz F 66 to 80MHz T Product Specific G 74 to 90MHz U 764 to 870MHz H Product Specific V 825 to 870MHz J 136 to 162MHz W 896 to 941MHz K 146 to 178MHz Y 1 0 to 1 6GHz L 174 to 210MHz Z 1 5 to 2 0GHz M 190 to 235MHz Values given represent range only they are not absolute Position 5 Power Level A 0 to 0 7 Watts B 0 7 to 0 9 Watts C 1 0 to 3 9 Watts D 4 0 to 5 0 Watts E 5 1 to 6 0 Watts F 6 1 to 10 Watts Position 6 Physical Packages gt OZ A RF Modem Operation B Receiver Only C Standard Control No Display D Standard Control With Display E
129. y sliding the flat end of the Black Stick under the flex beginning from the side of the flip fold 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 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 AN Do not twist or pull the Flip Flex as this might cause permanent damage to the Flip Flex Caution 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 fl

XTS4000 Radio Basic Service Manual (129 pgs)

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