ASTRO® XTS® 4000

Digital Portable Radios

Basic Service Manual

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

for safe usage contained in the Product Safety and RF
Exposure booklet enclosed with your radio.

ATTENTION!

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

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

Edition Description Date

6871619L01-A Initial edition Mar. 2007

6871619L01-B Added UHF band Jan. 2008

6871619L01-C Added PMNN4083 1260 mAh Li-Ion Battery. 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 & Appendix A.1

6871619L01-E Update Motorola Solutions Info and rectify pdf Dec. 2011
orientation issues from previous revision
iv Document History

Notes
Table of Contents v

Table of Contents

Foreword .........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ii
Manual Revisions ........................................................................................................................................ii
Computer Software Copyrights ...................................................................................................................ii
Document Copyrights ..................................................................................................................................ii
Disclaimer....................................................................................................................................................ii
Trademarks .................................................................................................................................................ii

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

Table of Contents ...........................................................................................v
List of Tables .................................................................................................ix

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

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

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

Portable Radio Model Numbering System ................................................................................................xv
ASTRO XTS 4000 VHF Model Chart ....................................................................................................... xvi
ASTRO XTS 4000 UHF Model Chart ...................................................................................................... xvii
Specifications for VHF Radios................................................................................................................ xviii
Specifications for UHF Range 1 Radios ................................................................................................... xix

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

1.1 Manual Contents............................................................................................................................ 1-1
1.2 Notations Used in This Manual...................................................................................................... 1-1
1.3 Radio Description .......................................................................................................................... 1-2
1.4 FLASHport® ................................................................................................................................... 1-2

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

2.1 General Maintenance .................................................................................................................... 2-1
2.2 Handling Precautions..................................................................................................................... 2-1
vi Table of Contents

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

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

3.1 Major Assemblies........................................................................................................................... 3-1
3.2 Digital Mode of Operation .............................................................................................................. 3-2
3.3 Main Board..................................................................................................................................... 3-3

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

4.1 Recommended Test Equipment .................................................................................................... 4-1
4.2 Service Aids ................................................................................................................................... 4-2
4.3 Field Programming......................................................................................................................... 4-2

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

5.1 Test Equipment Setup ................................................................................................................... 5-1
5.2 Display Radio Test Mode............................................................................................................... 5-2
5.3 Receiver Performance Checks ...................................................................................................... 5-8
5.4 Transmitter Performance Checks ................................................................................................ 5-10

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

6.1 Test Setup...................................................................................................................................... 6-1
6.2 Tuner Main Menu........................................................................................................................... 6-2
6.3 Softpot............................................................................................................................................ 6-3
6.4 Radio Information........................................................................................................................... 6-4
6.5 Reference Oscillator Alignment ..................................................................................................... 6-4
6.6 Transmit Power Alignment............................................................................................................. 6-7
6.7 Transmit Deviation Balance Alignment .......................................................................................... 6-9
6.8 Transmit Deviation Limit Alignment ............................................................................................. 6-11
6.9 Front End Filter Alignment ........................................................................................................... 6-13
6.10 Bit Error Rate ............................................................................................................................... 6-15
6.11 Transmitter Test Pattern .............................................................................................................. 6-16

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

7.1 Load an Encryption Key................................................................................................................. 7-1
7.2 Multikey Feature ............................................................................................................................ 7-1
7.3 Select an Encryption Key............................................................................................................... 7-1
7.4 Select an Encryption Index ............................................................................................................ 7-2
7.5 Erase an Encryption Key ............................................................................................................... 7-3

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

8.1 XTS 4000 Exploded View (Partial)................................................................................................. 8-1
8.2 Required Tools and Supplies......................................................................................................... 8-3
8.3 Fastener Torque Chart................................................................................................................... 8-3
Table of Contents vii

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

8.5 Battery ........................................................................................................................................... 8-5
8.6 Radio Disassembly ........................................................................................................................ 8-6
8.7 Radio Reassembly....................................................................................................................... 8-17
8.8 Servicing CID Bezel Only ............................................................................................................ 8-30

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

9.1 Power-Up Error Codes .................................................................................................................. 9-1
9.2 Operational Error Codes................................................................................................................ 9-2
9.3 Receiver Troubleshooting.............................................................................................................. 9-2
9.4 Transmitter Troubleshooting.......................................................................................................... 9-3
9.5 Encryption Troubleshooting ........................................................................................................... 9-4

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

10.1 Exploded View and Parts List – Main Assemblies....................................................................... 10-2
10.2 Exploded View and Parts List – Flip-Front Housing Assemblies ................................................. 10-3
10.3 Exploded View and Parts List – Chassis Assembly..................................................................... 10-4
10.4 Parts List – Service Kit................................................................................................................. 10-5

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

A.1 Antennas........................................................................................................................................A-1
A.2 Batteries and Battery Accessories.................................................................................................A-1
A.3 Carry Accessories..........................................................................................................................A-1
A.4 Chargers ........................................................................................................................................A-1
A.5 Surveillance Accessories...............................................................................................................A-2

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

B.1 Basic Ordering Information ............................................................................................................B-1
B.2 Motorola Online .............................................................................................................................B-1
B.3 Mail Orders ....................................................................................................................................B-1
B.4 Telephone Orders..........................................................................................................................B-1
B.5 Fax Orders.....................................................................................................................................B-2
B.6 Parts Identification .........................................................................................................................B-2
B.7 Product Customer Service.............................................................................................................B-2

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

C.1 Servicing Information .....................................................................................................................C-1
C.2 Motorola Service Center ................................................................................................................C-1
C.3 Motorola Federal Technical Center ...............................................................................................C-1
C.4 Motorola Canadian Technical Logistics Center .............................................................................C-1

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

viii Table of Contents

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

List of Tables ix

List of Tables

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

Table 2–1. Lead Free Solder Wire Part Number List.............................................................................. 2-2
Table 2–2. Lead Free Solder Paste Part Number List ............................................................................ 2-2
Table 3–1. Local Oscillator and First IF Frequencies ............................................................................. 3-3
Table 4–1. Recommended Test Equipment............................................................................................ 4-1
Table 4–2. Service Aids .......................................................................................................................... 4-2
Table 5–1. Initial Equipment Control Settings......................................................................................... 5-2
Table 5–2. Test-Mode Displays............................................................................................................... 5-3
Table 5–3. Test Frequencies (MHz)........................................................................................................ 5-4
Table 5–4. Test Environments ................................................................................................................ 5-6
Table 5–5. Receiver Tests for ASTRO Conventional Channels* ............................................................ 5-8
Table 5–6. Transmitter Tests for ASTRO Conventional Channels* ...................................................... 5-10
Table 6–1. Reference Oscillator Alignment ............................................................................................ 6-6
Table 6–2. Transmit Power Settings....................................................................................................... 6-8
Table 7–1. Encryption Key Zeroization Options...................................................................................... 7-4
Table 8–1. Corresponding XTS 4000 Exploded View and Parts List...................................................... 8-2
Table 8–2. Required Tools and Supplies ................................................................................................ 8-3
Table 8–3. Fastener Torque Chart .......................................................................................................... 8-3
Table 9–1. Power-Up Error Code Displays............................................................................................. 9-1
Table 9–2. Operational Error Code Displays .......................................................................................... 9-2
Table 9–3. Receiver Troubleshooting Chart ........................................................................................... 9-2
Table 9–4. Transmitter Troubleshooting Chart ....................................................................................... 9-3
Table 9–5. Encryption Troubleshooting Chart ........................................................................................ 9-4
Table 10–1. XTS 4000 Exploded Views and Parts Lists......................................................................... 10-1
Table 10-2. Parts List – Main Assemblies.............................................................................................. 10-2
Table 10–3. Parts List – Flip-Front Housing Assemblies ........................................................................ 10-3
Table 10–4. Parts List – Chassis Assembly............................................................................................ 10-4
Table 10–5. Service Kit Table ................................................................................................................. 10-5

Related Publications

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

XTS 4000 Digital Portable Radios Detailed Service Manual ...................................................... 6871620L01
XTS 4000 Digital Portable Radio User Guide (CD) .................................................................... PMLN5057_
Chassis Eliminator Leaflet......................................................................................................... 6871568M01
x List of Figures

List of Figures

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

Figure 3–2. Receiver Block Diagram........................................................................................................ 3-2
Figure 3–3. Transceiver (VHF) Block Diagram (Power and Control Omitted).......................................... 3-3
Figure 5–1. Performance Checks Test Setup........................................................................................... 5-1
Figure 6-1. Radio Alignment Test Setup.................................................................................................. 6-1
Figure 6–2. Tuner Software Main Menu ................................................................................................... 6-2
Figure 6–3. Typical Softpot Screen – VHF ............................................................................................... 6-3
Figure 6–4. Typical Softpot Screen – UHF............................................................................................... 6-3
Figure 6–5. Radio Information Screen ..................................................................................................... 6-4
Figure 6–6. Reference Oscillator Alignment Screen – VHF ..................................................................... 6-5
Figure 6–7. Reference Oscillator Alignment Screen – UHF..................................................................... 6-6
Figure 6–8. Battery Eliminator with RF Connector and SMA ................................................................... 6-7
Figure 6–9. Transmit Power Alignment Screen (Typical) – VHF .............................................................. 6-8
Figure 6–10.Transmit Power Alignment Screen (Typical) – UHF.............................................................. 6-8
Figure 6–11. Transmit Deviation Balance Alignment Screen – VHF........................................................ 6-10
Figure 6–12.Transmit Deviation Balance Alignment Screen – UHF ....................................................... 6-10
Figure 6–13.Transmit Deviation Limit Alignment Screen – VHF ............................................................. 6-12
Figure 6–14.Transmit Deviation Limit Alignment Screen – UHF ............................................................. 6-12
Figure 6–15.Battery Eliminator with RF Connector and SMA ................................................................. 6-13
Figure 6–16.Front End Filter Alignment Screen – VHF........................................................................... 6-14
Figure 6–17.Front End Filter Alignment Screen – UHF........................................................................... 6-14
Figure 6–18.Bit Error Rate Screen .......................................................................................................... 6-16
Figure 6–19.Transmitter Test Pattern Screen – VHF .............................................................................. 6-17
Figure 6–20.Transmitter Test Pattern Screen – UHF .............................................................................. 6-17
Figure 8–1. XTS 4000 Partial Exploded View .......................................................................................... 8-2
Figure 8–2. Attaching the Antenna........................................................................................................... 8-4
Figure 8–3. Removing the Antenna ......................................................................................................... 8-4
Figure 8–4. Attaching the Battery............................................................................................................. 8-5
Figure 8–5. Removing the Battery ........................................................................................................... 8-6
Figure 8–6. Separating Flip-Front Housing Assembly From Chassis Assembly...................................... 8-7
Figure 8–7. Unplugging Flexes ................................................................................................................ 8-8
Figure 8–8. Disconnecting CE-UCM Connector Flex and Lifting Main Board.......................................... 8-8
Figure 8–9. Rotating Main Board 90° and Unplugging Top Control Inner Jumper Flex ........................... 8-9
Figure 8–10.Removing Control Band ...................................................................................................... 8-10
Figure 8–11. Removing Audio Jack Dust Cover ...................................................................................... 8-10
Figure 8–12.Removing CE Dust Cover ................................................................................................... 8-11
Figure 8–13.Removing Audio Jack ......................................................................................................... 8-11
Figure 8–14.Removing CE Retainer and Spacer .................................................................................... 8-12
Figure 8–15.Removing CE Board ........................................................................................................... 8-12
Figure 8–16.Disassemble Speaker Compartment Seal, Main Keyboard and UCM Board ..................... 8-13
Figure 8–17.Separating Keypad Backer Inner Jumper Flex ................................................................... 8-14
Figure 8–18.Removing Secure Pad ........................................................................................................ 8-14
Figure 8–19.Removing Front Housing from Flip Assembly..................................................................... 8-15
Figure 8–20.Removing Tabs from Flip Stopper Pad ............................................................................... 8-15
Figure 8–21.Removing Microphone Boot and Microphone from Front Housing ..................................... 8-16
Figure 8–22.Separating Hinge from Flip Inner Housing .......................................................................... 8-16
Figure 8–23.Removing CID Bezel........................................................................................................... 8-17
Figure 8–24.Flip Flex .............................................................................................................................. 8-18
Figure 8–25.Inserting Flip Flex................................................................................................................ 8-19
Figure 8–26.Tongue in CID Bezel into Flip Sub-Assembly...................................................................... 8-19
List of Figures xi

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

Figure 8–28.Reassemble UCM Board .................................................................................................... 8-21
Figure 8–29.Attach Secure Pad to Keypad Backer Sub-Assembly ........................................................ 8-21
Figure 8–30.Reassemble Flip Flex ......................................................................................................... 8-22
Figure 8–31.Assemble T6 screws to Front Housing ............................................................................... 8-22
Figure 8–32.Assemble T6 screws to Front Housing ............................................................................... 8-23
Figure 8–33.Inserting Spacer to CE Retainer ......................................................................................... 8-23
Figure 8–34.Reassemble CE Retainer and Spacer ................................................................................ 8-24
Figure 8–35.Reassemble Flip Flex ......................................................................................................... 8-24
Figure 8–36.Slide Audio Jack Insulator into Chassis .............................................................................. 8-25
Figure 8–37.Reassemble CE Connector Dust Cover ............................................................................. 8-25
Figure 8–38.Assemble Audio Jack Dust Cover....................................................................................... 8-26
Figure 8–39.Adhere Assembly Aid.......................................................................................................... 8-26
Figure 8–40.Reassemble Control Band .................................................................................................. 8-27
Figure 8–41.Assemble B Plus Seal to B Plus Connector........................................................................ 8-28
Figure 8–42.Assemble B Plus Seal to B Plus Connector........................................................................ 8-28
Figure 8–43.Holding CE-UCM Flex......................................................................................................... 8-29
Figure 8–44.Reassemble Flexes ............................................................................................................ 8-29
Figure 8–45.Screws Reassemble Sequence .......................................................................................... 8-30
Figure 10–1.Exploded View – Main Assemblies ..................................................................................... 10-2
Figure 10–2.Exploded View – Flip – Front Housing Assemblies ............................................................ 10-3
Figure 10–3.Exploded View – Chassis Assembly................................................................................... 10-4
xii Commercial Warranty

Commercial Warranty

Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS

I. 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 workmanship
under normal use and service for a period of time from the date of purchase as scheduled below:

ASTRO XTS 4000 Digital Portable Units One (1) Year

Product Accessories One (1) Year

Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.
This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.
MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.

II. General Provisions

This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product.
Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive
remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR
DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE
DISCLAIMED BY LAW.
Commercial Warranty xiii

III. State Law Rights

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.
This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.

IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also call
Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs
(including, without limitation, the addition to the Product of non-Motorola supplied equipment)
which adversely affect performance of the Product or interfere with Motorola's normal
warranty inspection and testing of the Product to verify any warranty claim.
F. Product which has had the serial number removed or made illegible.
G. Rechargeable batteries if:
H. any of the seals on the battery enclosure of cells are broken or show evidence of tampering.
I. the damage or defect is caused by charging or using the battery in equipment or service other
than the Product for which it is specified.
J. Freight costs to the repair depot.
K. A Product which, due to illegal or unauthorized alteration of the software/firmware in the
Product, does not function in accordance with MOTOROLA's published specifications or the
FCC type acceptance labeling in effect for the Product at the time the Product was initially
distributed from MOTOROLA.
L. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
M. Normal and customary wear and tear.
xiv Commercial Warranty

VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:
A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such
claim;
B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its
settlement or compromise; and
C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the
subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to
continue using the Product or parts or to replace or modify the same so that it becomes
noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and
accept its return. The depreciation will be an equal amount per year over the lifetime of the
Product or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.

VII. Governing Law

This Warranty is governed by the laws of the State of Illinois, USA.
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 N 9 P W 9 A N
Position: 1 2 3 4 5 6 7 8 9 10 11 12
Position 1 - Type of Unit
H = Hand-Held Portable

Position 12 -
Positions 2 & 3 - Model Series Unique Model Variations
18 = XTS 4000 C = Cenelec
N = Standard Package
Position 4 - Frequency Band
A = Less than 29.7MHz P = 336 to 410MHz Position 11 - Version
B = 29.7 to 35.99MHz Q = 380 to 470MHz Version Letter (Alpha) - Major Change
C = 36 to 41.99MHz R = 438 to 482MHz
D = 42 to 50MHz S = 470 to 520MHz Position 10 - Feature Level
F = 66 to 80MHz T = Product Specific 1 = Basic 6 = Standard Plus
G = 74 to 90MHz U = 764 to 870MHz 2 = Limited Package 7 = Expanded Package
H = Product Specific V = 825 to 870MHz 3 = Limited Plus 8 = Expanded Plus
J = 136 to 162MHz W = 896 to 941MHz 4 = Intermediate 9 = Full Feature/
K = 146 to 178MHz Y = 1.0 to 1.6GHz 5 = Standard Package Programmable
L = 174 to 210MHz Z = 1.5 to 2.0GHz
M = 190 to 235MHz Position 9 - Primary System Type
Values given represent range only; they are A = Conventional
not absolute. B = Privacy Plus
C = Clear SMARTNET
D = Advanced Conventional Stat-Alert
Position 5 - Power Level E = Enhanced Privacy Plus
A = 0 to 0.7 Watts F = Nauganet 888 Series
B = 0.7 to 0.9 Watts G = Japan Specialized Mobile Radio (JSMR)
C = 1.0 to 3.9 Watts H = Multi-Channel Access (MCA)
D = 4.0 to 5.0 Watts J = CoveragePLUS
E = 5.1 to 6.0 Watts K = MPT1327* - Public
F = 6.1 to 10 Watts L = MPT1327* - Private
M = Radiocom
Position 6 - Physical Packages N = Tone Signalling
A = RF Modem Operation P = Binary Signalling
B = Receiver Only Q = Phonenet
C = Standard Control; No Display W = Programmable
D = Standard Control; With Display X = Secure Conventional
E = Limited Keypad; No Display Y = Secure SMARTNET
F = Limited Keypad; With Display * MPT = Ministry of Posts and Telecommunications
G = Full Keypad; No Display
H = Full Keypad; With Display Position 8 - Primary Operation
J = Limited Controls; No Display A = Conventional/Simplex
K = Limited Controls; Basic Display B = Conventional/Duplex
L = Limited Controls; Limited Display C = Trunked Twin Type
M = Rotary Controls; Standard Display D = Dual Mode Trunked
N = Enhanced Controls; Enhanced Display E = Dual Mode Trunked/Duplex
P = Low Profile; No Display F = Trunked Type I
Q = Low Profile; Basic Display G = Trunked Type II
R = Low Profile; Basic Display, Full Keypad H = FDMA* Digital Dual Mode
J = TDMA** Digital Dual Mode
K = Single Sideband
Position 7 - Channel Spacing
L = Global Positioning Satellite Capable
1 = 5kHz 5 = 15kHz
M = Amplitude Companded Sideband (ACSB)
2 = 6.25kHz 6 = 20/25kHz
P = Programmable
3 = 10kHz 7 = 30kHz
4 = 12.5kHz 9 = Variable/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
X NNTN7098_ Hardware, Tanapa XTS4000
X NNTN7101_ Assembly, Chassis XTS4000
X NNTN7100_ Assembly, Keypad Backer, XTS4000
X NNTN7099_ Assembly, Flip Front Housing, XTS4000
X PMLN5057_ XTS4000 CD UG & Safety
X 6871618L01 XTS4000 User Guide

Notes:
X =Item Included
* • The model number and (sometimes) the FLASHcode can be found on the FCC label on the back of the radio.
• The model number, Host code, DSP code, and (sometimes) the FLASHcode can be found by putting the radio into the Test
Mode.
• The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (NKN1027_ or
NKN1029_) and the CPS to read the radio.
Model Numbering, Charts, and Specifications: ASTRO XTS 4000 UHF Model Chart xvii

ASTRO XTS 4000 UHF Model Chart

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

ITEM NUMBER DESCRIPTION

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

Notes:
X =Item Included
* • The model number and (sometimes) the FLASHcode can be found on the FCC label on the back of the radio.
• The model number, Host code, DSP code, and (sometimes) the FLASHcode can be found by putting the radio into the Test
Mode.
• The model number, Host code, DSP code, and FLASHcode can be found by using the Programming Cable (NKN1027_ or
NKN1029_) and the CPS to read the radio.
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.

RECEIVER TRANSMITTER
GENERAL
(TYPICAL PERFORMANCE) (TYPICAL PERFORMANCE)
FCC Designation: AZ489FT3814 Bandwidth: 38 MHz RF Power:
136–174 MHz: 1–2 Watts
Frequency Ranges: 136–151 MHz,
(Subject to Antenna operating 145–166 MHz, Frequency Stability Frequency Stability (typical)
band - See Appendix A: Antennas)162–174 MHz (-30 to +60°C; 25°C ref.): ±0.0002% (-30 to +60°C; 25°C ref.): ±0.0002%
Temperature Range:
Operating: -30°C to +60°C Rated Audio: 500 mW Emission (typical conducted): -75 dBc
Storage: -40°C to +85°C
Analog Sensitivity* FM Hum and Noise*
Power Supply: Lithium-Ion Battery (Li-Ion) 12 dB SINAD: 0.22 µV 12.5 kHz Channel: -43 dB
25 kHz Channel: -48 dB
Battery Voltage: Selectivity*
Nominal: 7.5 Vdc 12.5 kHz Channel: -67 dB Distortion*: 1.0%
Range: 6 to 9 Vdc 25 kHz Channel: -78 dB
Modulation Limiting*
Transmit Current Drain (Typical): 950 mA Intermodulation*: -75 dB 12.5 kHz Channel: ±2.5 kHz
Receive Current Drain (Rated Audio): 210 mA 25 kHz Channel: ±5.0 kHz
Standby Current Drain: 89 mA Spurious Rejection*: -75 dB
Adjacent Channel Power Ratio*
Recommended Battery: FM Hum and Noise*: 12.5 kHz Channel: -67 dB
630 mAh Li-Ion: NNTN6944_ 12.5 kHz Channel: -45 dB 25 kHz Channel: -78 dB
or 1260 mAh Li-Ion: PMNN4083_ 25 kHz Channel: -50 dB

Dimensions (H x W x D): Distortion*: 1.50%

Radio Only (w/o battery, w/o antenna): Digital Sensitivity** Modulation Fidelity**
4.06" x 2.18" x 1.17" 1% BER: 0.25 µV Deviation: 1750 Hz
(103.2 mm x 55.3 mm x 29.6 mm) 5% BER: 0.22 µV Carrier Frequency Offset: ±0.0002%
Radio With 630 mAh Li-Ion (NNTN6944_) Error Vector Magnitude: 1.5%
Only (w/o antenna): Selectivity**: -63 dB
4.06" x 2.18" x 1.36" Symbol Rate Accuracy**: 0%
(103.2 mm x 55.3 mm x 34.6 mm) Intermodulation**: -73 dB
Radio With 1260 mAh Li-Ion (PMNN4083_) Adjacent Channel Power Ratio**: -69 dB
Only (w/o antenna): Spurious Rejection**: -75 dB
4.06" x 2.18" x 1.58"
(103.2 mm x 55.3 mm x 40.2 mm) Residual Audio Noise Ratio (silence)**: -65 dB
Residual Audio Noise Power (mute)**:
Weight: (w/ Antenna): -65 dBm
Less Battery: 5.6 oz (160 g)
With 630 mAh Li-Ion (NNTN6944_): Distortion**: 1.00%
7.8 oz (220 g)
With 1260 mAh Li-Ion (PMNN4083_): Emissions Designators:
9.9 oz (280 g) 20K0F1E, 16K0F3E, 11K0F3E, 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 xix

Specifications for UHF Range 1 Radios

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

RECEIVER TRANSMITTER
GENERAL
(TYPICAL PERFORMANCE) (TYPICAL PERFORMANCE)
FCC Designation: AZ489FT4881 Bandwidth: 90 MHz RF Power:
380–470 MHz: 0.25–2 Watts
Frequency Ranges: 380–470 MHz
(Subject to Antenna operating Frequency Stability Frequency Stability (typical)
band - See Appendix A: Antennas) (-30 to +60°C; 25°C ref.): ±0.0002% (-30 to +60°C; 25°C ref.): ±0.0002%
Temperature Range:
Operating: -30°C to +60°C Rated Audio: 500 mW Emission (typical conducted): -75 dBc
Storage: -40°C to +85°C
Analog Sensitivity* FM Hum and Noise*
Power Supply: Lithium-Ion Battery (Li-Ion) 12 dB SINAD: 0.25 µV 12.5 kHz Channel: -40 dB
25 kHz Channel: -43 dB
Battery Voltage: Selectivity*
Nominal: 7.5 Vdc 12.5 kHz Channel: -63 dB Distortion*: 1.2%
Range: 6 to 9 Vdc 25 kHz Channel: -73 dB
Modulation Limiting*
Transmit Current Drain (Typical): 950 mA Intermodulation*: -70 dB 12.5 kHz Channel: ±2.5 kHz
Receive Current Drain (Rated Audio): 210 mA 25 kHz Channel: ±5.0 kHz
Standby Current Drain: 89 mA Spurious Rejection*: -75 dB
Adjacent Channel Power Ratio*
Recommended Battery: FM Hum and Noise*: 12.5 kHz Channel: -67 dB
630 mAh Li-Ion: NNTN6944_ 12.5 kHz Channel: -40 dB 25 kHz Channel: -75 dB
or 1260 mAh Li-Ion: PMNN4083_ 25 kHz Channel: -45 dB

Dimensions (H x W x D): Distortion*: 2%

Radio Only (w/o battery, w/o antenna): Digital Sensitivity** Modulation Fidelity**
4.06" x 2.18" x 1.17" 1% BER: 0.25 µV Deviation: 1630 Hz < UHF1 < 1800 Hz
(103.2 mm x 55.3 mm x 29.6 mm) 5% BER: 0.25 µV Carrier Frequency Offset: ±0.0002%
Radio With 630 mAh Li-Ion (NNTN6944_) Error Vector Magnitude: < 5%
Only (w/o antenna): Selectivity**: -63 dB
4.06" x 2.18" x 1.36" Symbol Rate Accuracy**: 0%
(103.2 mm x 55.3 mm x 34.6 mm) Intermodulation**: -70 dB
Radio With 1260 mAh Li-Ion (PMNN4083_) Adjacent Channel Power Ratio**: -67 dB
Only (w/o antenna): Spurious Rejection**: -75 dB
4.06" x 2.18" x 1.58"
(103.2 mm x 55.3 mm x 40.2 mm) Residual Audio Noise Ratio (silence)**: -65 dB
Residual Audio Noise Power (mute)**:
Weight: (w/ Antenna): -53 dBm
Less Battery: 5.6 oz (160 g) Distortion**: 1.00%
With 630 mAh Li-Ion (NNTN6944_):
7.8 oz (220 g)
With 1260 mAh Li-Ion (PMNN4083_): Emissions Designators:
9.9 oz (280 g) 20K0F1E, 16K0F3E, 11K0F3E, 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 Model Numbering, Charts, and Specifications

Notes
Chapter 1 Introduction

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

1.1 Manual Contents

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

1.2 Notations Used in This Manual

Throughout the text in this publication, you will notice the use of note, caution, warning, and danger
notations. These notations are used to emphasize that safety hazards exist, and due care must be
taken and observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.

CAUTION indicates a potentially hazardous situation which, if

not avoided, might result in equipment damage.

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or injury.

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death or
injury.
1-2 Introduction: Radio Description

1.3 Radio Description

The ASTRO XTS 4000 radios are among the most sophisticated two-way radios available. The
radios are available in the VHF (136–174 MHz) and UHF (380–470 MHz) frequency bands.
The ASTRO XTS 4000 radio provides improved voice quality across more coverage area. The digital
process, called embedded signaling, intermixes system signaling information with digital voice,
resulting in improved system reliability and the capability of supporting a multitude of advanced
features.
Table 1–1 describes the basic features of ASTRO XTS 4000 radios.

Table 1–1. ASTRO XTS 4000 Basic Features

Feature XTS4000

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

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

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

3 x 4 Alphanumeric Keypad

Channel Capability 850

Dialing from Prestored List Yes

Programmable Softkeys Yes

1.4 FLASHport®
The ASTRO XTS 4000 radio utilizes Motorola’s FLASHport technology. FLASHport makes it
possible to add software that drives the radio’s capabilities both at the time of purchase and later on.
Previously, changing a radio’s features and capabilities meant significant modifications or buying a
new radio. But now, similar to how a computer can be loaded with different software, the radio’s
features and capabilities can be upgraded with FLASHport software.
Chapter 2 Basic Maintenance

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

2.1 General Maintenance

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

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

2.1.2 Cleaning
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external surfaces of the radio. External surfaces include the housing assembly
and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals
the presence of smudges, grease, and/or grime.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water.

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

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

2.2 Handling Precautions

Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices,
are used in this family of radios. While the attributes of these devices are many, their characteristics
make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges.
Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special
precautions must be taken to prevent device damage during disassembly, troubleshooting, and
repair. Handling precautions are mandatory for this radio, and are especially important in low-
humidity conditions.
2-2 Basic Maintenance: General Repair Procedures and Techniques

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

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

2.3 General Repair Procedures and Techniques

NOTE Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit
boards — examples shown below) were developed and assembled using
environmentally preferred components and solder assembly techniques to comply with
the European Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/
95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/
EC. To maintain product compliance and reliability, use only the Motorola specified parts
in this manual.

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

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

Motorola Flux Content Melting Supplier Part

Alloy Flux Type Diameter Weight
Part Number by Weight Point number

1088929Y01 95.5Sn/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

Viscosity Type Composition & Percent Metal
Number Number Temperature

1085674C03 NC-SMQ230 900–1000KCPs Type 3 (95.5%Sn–3.8%Ag-0.7%Cu) 217°C

Brookfield (5rpm) (-325/+500) 89.3%

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 Rigid Circuit Boards

The family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are not
accessible, some special considerations are required when soldering and unsoldering components.
The through-plated holes may interconnect multiple layers of the printed circuit. Therefore, care
should be exercised to avoid pulling the plated circuit out of the hole.
When soldering near the connector pins:
• avoid accidentally getting solder in the connector.
• be careful not to form solder bridges between the connector pins
• closely examine your work for shorts due to solder bridges.

2.3.3 Chip Components

Use the RLN4062 Hot-Air Repair Station for chip component replacement. Adjust the temperature
control to 390 °C (735 °F), and adjust the airflow to a minimum setting. Airflow can vary due to
component density.
• To remove a chip component:
1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm
(1/8”) above the component to be removed.
2. Begin applying the hot air. Once the solder reflows, remove the component using a pair
of tweezers.
3. Using a solder wick and a soldering iron or a power desoldering station, remove the
excess solder from the pads.
• To replace a chip component using a soldering iron:
1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the
solder pads.
2. Using a pair of tweezers, position the new chip component in place while heating the
fresh solder.
3. Once solder wicks onto the new component, remove the heat from the solder.
4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the
component. If necessary, touch up the first side. All solder joints should be smooth and
shiny.
• To replace a chip component using hot air:
1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.
2. Apply a drop of solder paste flux to each pad.
3. Using a pair of tweezers, position the new component in place.
4. Position the hot-air hand piece approximately 0.3 cm (1/8” ) above the component and
begin applying heat.
5. Once the solder wicks to the component, remove the heat and inspect the repair. All
joints should be smooth and shiny.
2-4 Basic Maintenance: General Repair Procedures and Techniques

2.3.4 Shields
Removing and replacing shields is recommended to be done with the Air Blower,
BOSCH GHG 603 or equivalent.
• To remove the shield:
1. Place the circuit board in the circuit board holder.
2. Add solder paste flux around the base of the shield.
3. Position the heat-focus head onto the shield.
4. Turn on the heater and wait until the shield lifts off the circuit board.
5. Once the shield is off, turn off the heat, and grab the part with a pair of tweezers.
6. Remove the circuit board from the circuit board holder.
• To replace the shield:
1. Add solder to the shield if necessary, using a micro-tipped soldering iron.
2. Next, rub the soldering iron tip along the edge of the shield to smooth out any excess
solder. Use solder wick and a soldering iron to remove excess solder from the solder
pads on the circuit board.
3. Place the circuit board back in the circuit board holder.
4. Place the shield on the circuit board using a pair of tweezers.
5. Position the heat-focus head over the shield.
6. Turn on the heater and wait for the solder to reflow.
7. Once complete, turn off the heat, raise the heat-focus head and wait approximately one
minute for the part to cool.
8. Remove the circuit board and inspect the repair. No cleaning should be necessary.
Chapter 3 Basic Theory of Operation

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

3.1 Major Assemblies

The ASTRO XTS 4000 radio includes the following major connections to the main board
(See Figure 3–1):
• Main Board – contains a dual-core processor which includes both the microcontroller unit
(MCU) and a digital signal processor (DSP) core, the processor’s memory devices, an audio
and power supply support integrated circuit (IC), a digital support IC, and the audio power
amplifier. It also contains all transmit, receive, and frequency generation circuitry, including the
digital receiver back-end IC and the reference oscillator.
• CE-UCM Flex – contains vibrator, speaker, microphone and encryption connector.
• Main Display – 130 x 130 dot matrix, liquid-crystal display (LCD).
• CID Display – 112 x 32 dot matrix, liquid-crystal display (LCD).
• Keypad – a 3 x 3 Menu keypad with 4-way navigation button, and a 3 x 4 alphanumeric
keypad.

60

Display, Keypad and

Earpiece Antenna

16
Controls
J1
J3
External 8
CE
Accessory Connector
Connector

Vibrator
2 Main Board
Encryption 7 30
Module J2
Speaker and
Microphone 3
7.5V
3 3 Battery
Audio jack

Figure 3–1. XTS 4000 Overall Block Diagram

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

3.2 Digital Mode of Operation

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

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

RF Input RX Front End

Tuneable Tuneable 1st LO
Harmonic Antenna Pre-Selector Post-Selector
Filter Switch Filter LNA Filter 1st
Mixer

XTAL ABACUS III - RX Back End

Filter
3
RX_SSI_ DATA
ADC
to VOCON Section

LO CKO

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-
delta, 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

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

TX TX Driver Power
Reference VCOBIC Buffer Amplifier Module
Oscillator

EPIC Loop
Filter Current
FracN Sensing
Antenna
VCO Switch
3
MOD
IN PCIC
DAC LPF
To
VCO Antenna
Harmonic
Filter

ABACUS III
3

Crystal Mixer Post-Selector RX LNA Pre-Selector

Filter Filter Filter

Sample 2ND
Clk LO
MAEPF-27322-O

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

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

3.3 Main Board

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

Table 3–1. Local Oscillator and First IF Frequencies

VHF UHF1

LO Frequency Range 180.85–218.85 MHz 306.65–396.65 MHz

First IF Frequency 44.85 MHz 73.35 MHz

3-4 Basic Theory of Operation: Main Board

The frequency generation function is performed by two ICs - two VCOs, and associated circuitry. The
reference oscillator IC provides a frequency standard to the synthesizer. The fractional-N synthesizer
turns on the two external VCOs and tunes it to RX LO or TX carrier frequency. The VCO buffer
amplifies the signal to the required power level. The synthesizer is controlled by the microcontroller
unit through a serial peripheral interface (SPI) bus. Most of the synthesizer circuitry is enclosed in
rigid metal cans on the transceiver section to reduce interference and microphonic effects.
The receiver back end consists of a bandpass crystal filter, input and output impedance matching
networks, and the digital back-end IC. Final filtering is done digitally in the DSP.
The Abacus III digital back-end IC contains a low-noise amplifier, a mixer, a variable gain amplifier
with integral anti-alias filter, a bandpass, sigma delta, analog-to-digital converter, and a decimation
filter with a programmable decimation factor. The Abacus III also contains an automatic gain control
(AGC) circuit to provide 12 dB of continuous gain adjustments. For the second LO, the Abacus III
has an internal, integer-N frequency synthesizer, and an external, discrete loop filter and voltage-
controlled oscillator (VCO). The output of the Abacus III is digital data on the RX_SSI bus.
The transmitter power amplifier (PA) consists of a driver amplifier IC and a discrete final-stage.
Transmit power is controlled by a power control IC (PCIC) that monitors the currents and adjusts PA
control voltages. The transmitter RF signal then passes through a PIN diode antenna switch and a
low-pass harmonic filter, which connects to the antenna connector.

3.3.2 VOCON Operation

The vocoder and controller (VOCON) circuitry contains the radio's microcontroller unit (Patriot) with
its memory and support circuits, the DSP, its memory devices, and the DSP-support IC, voltage
regulators, audio, and power control circuits. Connected to the VOCON circuitry are the display
circuitry, RF circuitry, keypad circuitry, encryption module, microphone, speaker and vibrator.
The microcontrol unit controls receive/transmit frequencies, power levels, display, and other radio
functions, using either direct logic control or serial communications paths to the devices.The
microcontrol unit executes a stored program located in the FLASH ROM. Data is transferred to and
from memory by the microcontrol unit data bus. The memory location from which data is read, or to
which data is written, is selected by the address lines.
The DSP-support IC is supplied with a 16.8 MHz clock from the RF circuitry. Both the DSP and the
microprocessor have their clocks generated by the DSP-support IC. They can both be adjusted so
that the harmonics do not cause interference with the radio’s receive channel.
The regulator and power-control circuits include 3.3-volt analog, 3.3-volt digital, and 5-volt
regulators. The audio PA is sourced from 7.5V. The regulator’s power-down mode is controlled by
the microcontrol unit, which senses the on/off button.
The DSP performs signalling and voice encoding and decoding, as well as audio filtering and volume
control. This IC performs Private-Line®/Digital Private LineTM (PL/DPL) encode and alert-tone
generation. The IC transmits pre-emphasis on analog signals and applies a low-pass (splatter) filter
to all transmitted signals. It requires a clock on the EXTAL pin. An 8 kHz interrupt signal generated
by the DSP-support IC is also required for functionality. It is programmed using parallel programming
from the microcontrol unit.
The audio CODEC performs analog-to-digital (A/D), and digital-to-analog conversions on audio
signals. The DSP controls squelch, deviation, and executes receiver and transmitter filtering. The
DSP-support IC receives a 2.4 MHz clock, and also receives data, which it formats for the DSP.
Chapter 4 Recommended Test Equipment and Service
Aids

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

4.1 Recommended Test Equipment

The list of equipment contained in Table 4–1 includes all of the standard test equipment required for
servicing two-way portable radios, as well as several unique items designed specifically for servicing
this family of radios. The “Characteristics” column is included so that equivalent equipment may be
substituted; however, when no information is provided in this column, the specific Motorola model
listed is either a unique item or no substitution is recommended.

Table 4–1. Recommended Test Equipment

Motorola
Description Characteristics Application
Model Number

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 µV 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

Generator * -130 dBm to +10 dBm (www.agilent.com),
FM Modulation 0 kHz Ramsey RSG1000B
to 10 kHz (www.ramseyelectronics.com),
Audio Frequency 100 or equivalent
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 5% Accuracy Bird 43 Thruline Watt Meter Transmitter power output
Sensor * 100 MHz to 500 MHz (www.bird-electronic.com) or measurements
50 Watts equivalent

RF Millivolt Meter 100 mV to 3 V RF Boonton 92EA RF level measurements

10 kHz to 1 GHz (www.boonton.com) or
equivalent

Power Supply 0 V to 32 V B&K Precision 1790 Voltage supply

0 A to 20 A (www.bkprecision.com)
or equivalent
4-2 Recommended Test Equipment and Service Aids: Service Aids

4.2 Service Aids

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

Table 4–2. Service Aids

Motorola Part
Description Application
Number

0182297T15 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
externally. 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 features. Tuner software required to perform alignment of
Software 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 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
30 dB PAD
OR COUNTER
TRANSMIT
30 dB PAD WATTMETER

Battery Eliminator with BNC

RF connector NNTN7152_ RF GENERATOR
RECEIVE
Set to approx. 450mV for Tx
SMA to BNC AUDIO IN TX
XTS4000 TEST SET
AUDIO GENERATOR
RF Adaptor
Radio RLN-4460 RX
SINAD METER

AC VOLTMETER

RS232 XTS4000 Program/ Measure 80mV for Tx

Test Cable NKN1027_
or
USB XTS4000 Program/
Test Cable NKN1029_

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
Opt Sel: ON Current: 2.5 Amps
@1.5 kHz deviation
Frequency: Set to selected
radio RX frequency
Meter: AC Volts

Transmitter Checks
RF Control: MONITOR
Frequency: Set to selected
radio TX frequency
Meter: RF Display
Modulation Type: FM
Attenuation: 20 dB

* This Initial Equipment Control Settings is for 12.5 kHz channel

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

5.2 Display Radio Test Mode

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

5.2.1 Test Mode Menu

Test Modes available after power up,
• If flip is Opened:
RF test → CH test → RGB test → Vibration test
• If flip is Closed:
RF test → CH test → CID test → Vibration test

5.2.2 Access the Test Mode

To enter the display radio test mode:
1. Turn the radio on.
NOTE: To access the Test Mode from the external display, close the flip once the radio is power up.
Performance Checks: Display Radio Test Mode 5-3

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

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

Table 5–2. Test-Mode Displays

Name of Display Description Appears

“SERVICE” The literal string indicates the radio has 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 hardware 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, “RF test” is displayed.

To freeze any of the displays, press the Left Navigation Button. To resume
automatic scrolling, press the Right Navigation Button. To rapidly scroll forward
through the displays, continue pressing the Right Navigation Button. You cannot
scroll backwards.
5-4 Performance Checks: Display Radio Test Mode

3. Do one of the following:

• Press the Secure Button (Programmable, Top Left Button) to stop the displays and toggle
between RF test mode and the Control Top and Keypad test mode. The test mode menu
“CH test” is displayed, indicating that you have selected the Control Top and Keypad test
mode. Go to Section “5.2.4 CH Test Mode (Control Top and Keypad Test)” on page 5-5.
NOTE: Each press of the Secure Button will toggle between “RF test”, “CH test”,
either “RGB test” or “CID test “ (only if the flip is in close position after
powerup) and “Vibration test.”
• Press the Emergency Button (Programmable, Top Right Orange Button) to stop the
displays and put the radio into the RF test mode. The test mode menu, “1 CSQ”, is
displayed, indicating test frequency 1, Carrier SQuelch mode. Go to Section “5.2.3 RF Test
Mode” below.
NOTE: Once your radio is in a particular test mode, you must turn off the radio and turn it
back on again to access the other test mode.

5.2.3 RF Test Mode

When the ASTRO XTS 4000 radio is operating in its normal environment, the radio's microcomputer
controls the RF channel selection, transmitter key-up, and receiver muting, according to the
customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or
repair, it must be removed from its normal environment using a special routine, called RF TEST
MODE.
While in RF test mode:
• Each additional press of Side Button advances to the next test channel. (Refer to Table 5–3.)
• Pressing Programmable Keypad Bottom scrolls through and accesses the test environments
shown in Table 5–4.
NOTE: Transmit into a load when keying a radio under test.

Table 5–3. Test Frequencies (MHz)

Test 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

CSQ Carrier RX: unsquelch if carrier detected

Squelch TX: mic audio

TPL 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 *

USQ 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 Display)” on
page 5-6 / “5.2.6 CID Test Mode (Only applicable to External Display)” on page 5-7.)
2. Release the Emergency Button; “3/0” appears, which indicates that the Emergency
Button is in the open position. Your radio is now in the Control Top and Keypad test mode.
3. Press the Emergency Button again; “3/1” appears, which indicates that the Emergency
Button is in the closed position.
4. Press the Upper Volume Rocker; “80/1” appears; release “80/0” appears.
5. Press the Lower Volume Rocker; “81/1” appears; release “81/0” appears.
6. Press the Secure Button (Programmable, Top Left Button); “96/1” appears; release, “96/0”
appears.
7. Press Programmable Keypad Button; “97/1” appears; release, “97/0” appears.
8. Press Side Button; “98/1” appears; release, “98/0” appears.
9. Press the PTT Button; “1/1” appears; release, “1/0” appears.
5-6 Performance Checks: Display Radio Test Mode

5.2.4.2 Keypad Checks:

To continue to the keypad checks:
- Press 0, “48/1” appears; release, “48/0” appears.
- Press 1, “49/1” appears; release, “49/0” appears.
- Press 2, “50/1” appears; release, “50/0” appears.
- Press 3, “51/1” appears; release, “51/0” appears.
- Press 4, “52/1” appears; release, “52/0” appears.
- Press 5, “53/1” appears; release, “53/0” appears.
- Press 6, “54/1” appears; release, “54/0” appears.
- Press 7, “55/1” appears; release, “55/0” appears.
- Press 8, “56/1” appears; release, “56/0” appears.
- Press 9, “57/1” appears; release, “57/0” appears.
- Press *, “58/1” appears; release, “58/0” appears.
- Press #, “59/1” appears; release, “59/0” appears.
- Press Left Navigation Button, “128/1” appears; release, “128/0” appears.
- Press Right Navigation Button, “130/1” appears; release, “130/0” appears.
- Press Up Navigation Button, “135/1” appears; release, “135/0” appears.
- Press Down Navigation Button, “136/1” appears; release, “136/0” appears.
- Press Left Menu Select Button, “131/1” appears; release, “131/0” appears.
- Press Middle Menu Select Button, “132/1” appears; release, “132/0” appears.
- Press Right Menu Select Button “133/1” appears; release, “133/0” appears.
- Press Home Button, “129/1” appears; release, “129/0” appears.
- Press Data Button, “134/1” appears; release, “134/0” appears.

5.2.5 RGB Test Mode (Only applicable to Internal Display)

To perform the RGB Color Test:
1. Press and release the Emergency Button (Top Right Orange button); “4 Border test”
appears.
2. Press any key; Crosstalk test patterns appears.
3. Press any key; White color test appears.
4. Press any key; Red color horizontal lines appears.
5. Press any key until all 13 red color horizontal lines appears.
6. Press any key; Green color vertical line appears.
7. Press any key until all 13 green color vertical lines appears.
8. Press any key; Black color test appears.
9. Press any key; Blue color test appears.
10. Press any key; "Test completed" appears.
Performance Checks: Receiver Performance Checks 5-7

5.2.6 CID Test Mode (Only applicable to External Display)

To perform the CID Test:
1. Press and release the Emergency Button (Top Right Orange button); all pixels are on.
2. Press any key; Checker box 1 test appears.
3. Press any key; Checker box 2 test appears.
4. Press any key; "Test completed" appears.

5.2.7 Vibration Test Mode

To perform the Vibration Test:
1. Press and release the Emergency Button (Top Right Orange button); "Press any key to
proceed" appears.
2. Press any key (except the Power Button); the radio produce the vibration.

5.3 Receiver Performance Checks

CAUTION: Remove any accessory connected to the audio jack before making audio
measurement thru the CE port. The audio level is attenuated when both the CE port
and audio jack are connected.
The following table outline the performance checks for the receiver.

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

Test Name System Analyzer Radio Test Set Comments

Bit Error rate Mode: Proj 25 Std Radio Tuner PTT to OFF BER < 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 As above; lower the As above As above Output level < 0.35 µV
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 < 3.0%
Distortion RF Control: Gen Software not used; (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 Watts
Meter: RF Display Radio: Out of measurement).
TEST MODE;
Select a
conventional
ASTRO channel

Frequency As above As above As above Error ≤ ±1.0 kHz

Error

Frequency As above Radio Tuner PTT to OFF DHIGH

Deviation Software (center) ≥ 2.543 kHz but
(Transmitter Test ≤ 3.110 kHz
Pattern screen) is DLOW
required) ≥ 0.841 kHz but
High use: Symbol ≤ 1.037 kHz
Rate PAT (Use test setup shown in
Low use: Low Figure 5–1, on page 5-1
Symbol Rate P

* 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.
b

SYSTEM ANALYZER
30 dB PAD
OR COUNTER
TRANSMIT
30 dB PAD WATTMETER

Battery Eliminator with BNC

RF connector NNTN7152_ RF GENERATOR
RECEIVE
Set to approx. 450mV for Tx
SMA to BNC AUDIO IN TX
XTS4000 TEST SET
AUDIO GENERATOR
RF Adaptor
Radio RLN-4460 RX
SINAD METER

AC VOLTMETER

RS232 XTS4000 Program/ Measure 80mV for Tx

Test Cable NKN1027_
or
USB XTS4000 Program/
Test Cable NKN1029_

COMPUTER

Figure 6-1. Radio Alignment Test Setup

These radio alignment procedures should only be attempted by qualified

service personnel. Failure to perform alignment procedures properly may
result in seriously degraded radio or system performance.
6-2 Radio Alignment Procedures: Tuner Main Menu

6.2 Tuner Main Menu

Select Tuner from the START menu. To read the radio, use the File › Read Device menu or click on
. Figure 6–2 illustrates how the alignment screens are organized. To access a screen,
double-click on the desired screen name in the Tuner menu.

Figure 6–2. Tuner Software Main Menu

Radio Alignment Procedures: Softpot 6-3

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

DO NOT switch radios in the middle of any alignment

procedure. Always left-click the Close button on the screen to
return to the Main Menu screen before disconnecting the
radio. Improper exits from the alignment screens might leave
the radio in an improperly configured state and result in
seriously degraded radio or system performance.

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

Figure 6–3. Typical Softpot Screen – VHF

Figure 6–4. Typical Softpot Screen – UHF

6-4 Radio Alignment Procedures: Radio Information

Adjusting the softpot value sends information to the radio to increase (or decrease) the voltage in the
corresponding circuit. For example, left-clicking the UP spin button in the New Softpot Value scroll
box on the Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage
across a varactor in the reference oscillator, which increases the frequency.
In ALL cases, the softpot value is just a relative number corresponding to a digital-to-analog (D/A)
generated voltage in the radio.
Perform the following procedures in the sequence indicated.
NOTE: Some of the following screens may vary depending upon the radio under test and the version
of tuner software you are using. Refer to the software’s online help.

When keying the radio during a test, always transmit into a

dummy load.

6.4 Radio Information

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

Figure 6–5. Radio Information Screen

6.5 Reference Oscillator Alignment

Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will
result not only in poor operation, but also in a misaligned radio that will interfere with other users
operating on adjacent channels. For this reason, the reference oscillator should be checked every
time the radio is serviced, or once a year, whichever comes first. The frequency counter used for this
procedure must have a stability of 0.1 ppm (or better).
NOTE: Reference oscillator alignment is required after replacing (or servicing) the mainboard.
This test can be done with either the R-2670 Communication Analyzer or the 8901_ Modulation
Analyzer.
Radio Alignment Procedures: Reference Oscillator Alignment 6-5

• Initial setup using the R-2670 Communication Analyzer:

– RF Control: MONITOR
– B/W: WB
– Freq: CPS frequency under test
– Attenuation: 20dB
– Mon RF in: RF I/O
– Meter: RF Display
– Mode: STD
– Input Level: uV or W
– Display: Bar Graphs
– Squelch: Mid-range or adjust as necessary
• Initial setup using the 8901_ Series Modulation Analyzer:
– Press the green Automatic Operation button on the analyzer.
– Press the FREQ key.
– Type 7.1 followed by SPCL button to set the 8901B_ modulation analyzer for maximum
accuracy.
To align the reference oscillator:
1. Select the Reference Oscillator alignment screen. See Figure 6–6 (VHF) below/ Figure 6–7
(UHF) on page 6-6.

Figure 6–6. Reference Oscillator Alignment Screen – VHF

6-6 Radio Alignment Procedures: Reference Oscillator Alignment

Figure 6–7. Reference Oscillator Alignment Screen – UHF

2. Click the PTT Toggle button to make the radio transmit. The screen indicates whether the
radio is transmitting.
3. Measure the transmit RF frequency with your service monitor.
4. Adjust the reference oscillator’s softpot value until the measured value is as close as possible
to the frequency shown on the screen. See Table 6–1.

Table 6–1. Reference Oscillator Alignment

Band 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.
• All power measurements are to be made at the antenna port.
• Transmit Power alignment is required after replacing (or servicing) the mainboard.

RF Connector

Battery Eliminator

To Power Supply

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

To align transmit power:
1. Select the TX Power (Low, Mid, or High) alignment screen. The screen will indicate the
transmit frequencies to be used. See Figure 6–9 (VHF)/
Figure 6–10 (UHF) on page 6-8.
2. Click the desired frequency field (starting with the highest frequency shown).
3. Click the PTT Toggle button to make the radio transmit. The screen indicates whether the
radio is transmitting.
4. Measure the transmit power of the radio with a service monitor.
5. Adjust the softpot value until the required power, as shown in Table 6–2, is indicated on the
service monitor.
6-8 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.

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 distorted waveforms if
improperly adjusted.
This procedure needs to be performed at multiple frequencies to allow for proper alignment across
the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in
each zone.
NOTE: This alignment is required after replacing (or servicing) the main board.
Proper alignment requires a modulation analyzer or meter with a frequency response to less than
10 Hz modulating frequency. The modulation analyzer settings during this test should be set for
average deviation, a 15 kHz low-pass filter, no de-emphasis, and no high-pass filter, if these settings
are supported.
This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series
Modulation Analyzer. The method of choice is the R-2670 analyzer.
1. Initial setup using the R-2670 Communication Analyzer:
– Connect a BNC cable between the “DEMOD OUT” port and the “VERT/SINAD DIST/DMM
COUNTER IN” port on the R-2670.
– Press the SPF key on the R-2670 to display the “SPECIAL FUNCTIONS MENU.” Move the
cursor to “High Pass,” and select 5 Hz on the soft key menu. Select 20 kHz for the “Low Pass”
setting.
– In the “RF Control” section of the R-2670, enter the frequency displayed on the RSS screen.
Move the cursor to the “B/W” setting and select “WIDE +/- 100 kHz” on the soft key menu.
– Place the R-2670 cursor in the “Display” zone. Select “AC VOLTS” on the soft key menu.
Move the cursor to the “Range” setting and select “AUTO.”
2. Initial setup using the 8901_ Series Modulation Analyzer:
– Press the FM MEASUREMENT button. (The “Error 03-input level too low” indication is
normal until an input signal is applied.)
– Simultaneously press the Peak – and Peak + buttons. Both LEDs on the buttons should light.
– Press the 15 kHz LP filter key.
3. Select the TX Deviation Balance alignment screen. The screen indicates the transmit
frequencies to be used. See Figure 6–11 (VHF)/ Figure 6–12 (UHF) on page 6-10.
4. Click the desired frequency field (starting with the highest frequency shown).
5. Click the PTT Toggle button to make the radio transmit. The screen indicates whether the
radio is transmitting.
6-10 Radio Alignment Procedures: Transmit Deviation Balance Alignment

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

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

6. Click the PTT Tone: Low button.

7. Click the PTT Toggle button on the screen to enable transmission. The screen indicates
whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on
R-2670, or the deviation shown on the 8901_ analyzer, stabilizes.
8. Measure and record the ac voltage value from the R-2670 analyzer or the deviation value
from the 8901_ series analyzer.
9. Left-click the PTT Tone: High button.
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 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.

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

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

4. Click the desired frequency field (starting with the highest frequency shown).
5. Click the PTT Toggle button to make the radio transmit. Wait approximately 5 seconds until
the deviation/voltage displayed on the analyzer stabilizes. The screen indicates whether the
radio is transmitting.
6. Adjust softpot value until the measured deviation is as close as possible to 2.83 kHz.
7. Repeat the above process for all frequencies.
Radio Alignment Procedures: Front End Filter Alignment 6-13

8. Click the Program All button to save the tuned values in the radio.
9. Click the Close button to return to the Transmitter Alignments menu.

6.9 Front End Filter Alignment

This procedure should only be attempted by qualified service technicians.

This alignment procedure adjusts the front end receiver bandpass filters for the best receiver
sensitivity and selectivity. This procedure should be performed for all test frequencies to allow for
proper software interpolation of frequencies between the test frequencies in the band
(see Figure 6–16 (VHF) below/ Figure 6–17(UHF) on page 6-14 ).
NOTE: Rx Front End Filter Alignment is required after replacing (or servicing) the mainboard.

RF Connector

Battery Eliminator

To Power Supply

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

6.9.1 Procedure for VHF/ UHF

To align the VHF/ UHF receiver front end:
1. Click the desired frequency field.
2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency.
3. Start with a softpot value (approximately 10 or 20), increase softpot in ascending order, and
note the RSSI values. The RSSI will reach a peak value and remain stable and then
decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3. Choose the
middle of the peak range and program the corresponding softpot value as the tuned softpot
value.
6-14 Radio Alignment Procedures: Front End Filter Alignment

4. Repeat the above process for all frequencies.

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

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

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

Radio Alignment Procedures: Bit Error Rate 6-15

6.10 Bit Error Rate

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

6.10.1 Bit Error Rate Fields

Set up the R2670 Communication Analyzer as follows:
1. Connect the RF Input port of the radio under test to the RF IN/OUT port of the R2670 Service
Monitor.
2. Set up the R2670 Service Monitor:
– In the Display Zone, select PROJ 25 STD mode and set the meter to RF DISPLAY.
– In the RF Zone, configure the analyzer as follows:

RF Control: Generate
Preset: B/W: NB
Freq: Test frequency (Ex: 136.075 MHz/ 380.075 MHz)
Output Level: -50.0 dBm
Gen RF Out: RF I/O
– In the Audio Zone, select the 1011 Hz PAT code and set the deviation to “PROJ25Dev:
2.83 kHz ~”.
The bit error rate screen contains the following fields:
• Rx Frequency:
This field selects the Receive Frequency directly in MHz.
• Test Pattern:
This field selects the Digital test pattern — TIA. Choices are: Standard Tone Test Pattern
(Framed 1011) and Standard Interface Test Pattern (CCITT V.52).
• Modulation Type:
This field represents the digital modulation type of the incoming signal on which BER is to be
calculated.
• Continuous Operation:
This field allows the user the option to repeat the BER test indefinitely. A selection of Yes will
cause the radio to calculate BER on a continuous basis and update the results on this screen
after each integration time. A selection of No will cause the BER test to execute for only one
sample of the integration time and then update the display.
• Audio:
This field allows the user to select the audio output during a test. Selecting Internal will cause
the radio's built-in speaker to unmute to any signals at the desired frequency which are present
during the test. Selecting External will route the same signal to the radio's accessory connector
audio output. Selecting Mute will disable the audio output.
• BER Integration Time:
This field represents the amount of time over which the Bit Error Rate is to be calculated. The
range is from 0.360 to 91.8 seconds in increments of 0.360 seconds.
6-16 Radio Alignment Procedures: Transmitter Test Pattern

NOTE: When Continuous Operation = Yes, all fields will be grayed out while the test is in progress.
They will be enabled when the STOP button is pressed.

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

Figure 6–18. Bit Error Rate Screen

6.11 Transmitter Test Pattern

The Transmitter Test Pattern test is used to transmit specific test patterns at a desired frequency so
that the user can perform tests on the radio’s transmitter (see Figure 6–19 below/
Figure 6–20 on page 6-17).

6.11.1 Transmitter Test Fields

This screen contains the following fields:
• Tx Frequency:
This field selects the Transmit Frequency directly in MHz.
• Channel Spacing:
This field allows the user to select the desired transmit deviation in kHz.
• Test Pattern Type:
This field represents the type of test pattern which will be transmitted by the radio when PTT
TOGGLE button is pressed.
NOTE: Channel Spacing and Test Pattern Type fields will be grayed out while radio is transmitting.
Radio Alignment Procedures: Transmitter Test Pattern 6-17

Figure 6–19. Transmitter Test Pattern Screen – VHF

Figure 6–20. Transmitter Test Pattern Screen – UHF

6-18 Radio Alignment Procedures

Notes
Chapter 7 Encryption

This chapter provides procedures for using the encryption capability of your radio. The following
procedures are outlined:
• Loading an encryption key
• Selecting an encryption key
• Selecting an Index
• Erasing an encryption key

7.1 Load an Encryption Key

To load an encryption key:
1. Refer to the key-variable loader (KVL) manual for equipment connections and setup.
2. Attach KVL to the bottom connector of the radio using Keyload cable 0182297T15. The
display shows “KEYLOADING.” All other radio functions, except for power down, backlight, and
volume, are locked out.
3. Refer to the KVL manual for how to load the encryption keys into the radio.
4. When the key is loaded successfully, you will hear:
• On single-key radios – a short tone.
• On multikey radios – an alternating tone.

7.2 Multikey Feature

This feature allows the radio to be equipped with multiple encryption keys. It can support up to two
different encryption algorithms simultaneously (e.g., DVP-XL and DES-XL).
• Conventional Multikey – The encryption keys can be tied (strapped), on a one-per-channel
basis. In addition, the radio can have operator-selectable keys, operator-selectable indices, and
operator-selectable key erasure. If talkgroups are enabled in conventional, then the encryption
keys are strapped to the talkgroups.
• Trunked Multikey – If the radio is used for both conventional and trunked applications, strap
the encryption keys for trunking on a per- talkgroup or announcement group basis. In addition,
a different key can be strapped to other features; for example, dynamic regrouping, failsoft, or
emergency talkgroup. The radio can have operator-selectable key erasure.

7.3 Select an Encryption Key

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

7.3.1 Use the Menu

To select an encryption key using the menu:
1. Press Right Navigation Button until the display shows “KEY.”
2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button, directly below “KEY.” The display shows the last user-selected and stored encryption
key, as well as the available menu selections.
7-2 Encryption: Select an Encryption Index

3. Press Left Navigation Button or Right Navigation Button to scroll through the list of
encryption keys.
NOTE: If you select an erased key, the display alternates between showing the encryption
key and “ERASED KEY.”
4. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below the desired menu.
• PSET = selects the preset or default encryption key.
• SEL = saves the newly selected key and returns to the home display.
5. Press Home Button, the PTT Button, or Left Menu Select Button, Middle Menu Select
Button, or Right Menu Select Button directly below the ABRT menu to exit this menu.
• If the selected key is erased, the display shows “KEY FAIL” and the radio sounds a
momentary keyfail tone.
• If the selected key is not allowed, the display shows “ILLEGAL KEY” and the radio sounds a
momentary illegal key tone.

7.3.2 Use the Keypad

To select an encryption key using the keypad:
1. Press Right Navigation Button until the display shows “KEY.”
2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below “KEY.” The display shows the last user-selected and
-stored encryption key, as well as the available menu selections.
3. Using the keypad, enter the number of the desired key.
NOTE: If you select an erased key, the display alternates between showing the encryption
key and “ERASED KEY.”
4. Press Left Navigation Button or Right Navigation Button to select from the menu.
• PSET = selects the preset or default encryption key.
• SEL = saves the newly selected key and returns to the home display.
5. Press h, the PTT Button, or Left Menu Select Button, Middle Menu Select Button, or
Right Menu Select Button directly below the ABRT menu.
• If the selected key is erased, the display shows “KEY FAIL” and the radio sounds a
momentary keyfail tone.
• If the selected key is not allowed, the display shows “ILLEGAL KEY” and the radio sounds a
momentary illegal key tone.

7.4 Select an Encryption Index

This feature lets the user select one or more groups of several encryption keys from among the
available keys stored in the radio. For example, the radio could have a group of three keys structured
to one index, and another group of three different keys structured to another index. Changing indices
makes the radio automatically switch from one set of keys to the other. Every channel to which one
of the original keys was tied will now have the equivalent new key instead.
Encryption: Erase an Encryption Key 7-3

7.4.1 Use the Menu

To select an index using the menu:
1. Press Right Navigation Button until the display shows “INDX.”
2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below “INDX.” The display shows the last user-selected and stored index, as
well as the available index menu selections.
3. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below the desired index. The display shows the last user- selected and -
stored index, as well as the available index menu selections.
4. Choose one of the following:
a. To save the index, press Left Menu Select Button, Middle Menu Select Button, or
Right Menu Select Button directly below “SEL.”
b. To exit this menu without changing the index selection, press Home Button or the PTT
Button.

7.4.2 Use the Keypad

To select an index using the keypad:
1. Press Right Navigation Button until the display shows “INDX.”
2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below “INDX.” The display shows the last user-selected and
-stored index, as well as the available index menu selections.
3. Using the keypad, enter the number of the desired index.
4. Choose one of the following:
a. To save the index, press Left Menu Select Button, Middle Menu Select Button, or
Right Menu Select Button directly below “SEL.”
b. To exit this menu without changing the index selection, press Home Button or the PTT
Button.

7.5 Erase an Encryption Key

This section describes two methods for erasing an encryption key.

7.5.1 Method 1 – Key Zeroization (Multikey Only)

To zeroize an encryption key:
1. Press Right Navigation Button until the display shows “ERAS.”
2. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below “ERAS.” The display shows the last user-selected and
-stored encryption key, as well as the available menu selections that are listed in Table 7–1.
3. Choose one of the following:
• If you want to erase all the encryption keys at once, go to section 7.5.2: ”Method 2 – All
Keys Erased” on page 7-4 below.
• If you want to erase a single encryption key, do one of the following:
– Press Left Navigation Button or Right Navigation Button to find the desired key. The
display shows the selected key and the available menu selections shown in Table 7–1.
7-4 Encryption: Erase an Encryption Key

– Using the keypad, enter the location number of the desired key. The display shows the
selected key, as well as the available menu selections shown in Table 7–1.

Table 7–1. Encryption Key Zeroization Options

Menu
Action
Selection

ALL Erases all the encryption keys in the radio. The display
shows “ERS ALL KEYS” and “YES” and “NO.”

SNGL Selects the displayed encryption key to be erased.The

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

ABRT Exits this menu and returns to the home display

NOTE: To exit this menu at any time without erasing the key selection, press Home Button
or the PTT Button.
4. Press Left Menu Select Button, Middle Menu Select Button, or Right Menu Select
Button directly below the desired menu selection.
5. Press Home Button or the PTT Button to exit this menu.

7.5.2 Method 2 – All Keys Erased

To erase all encryption keys at one time:
With the radio on, press and hold the Secure Button (Programmable, Top Left Button)
and, while holding this button down, press the Emergency Button (Programmable, Top
Right Orange Button).
NOTE: DO NOT press the Emergency Button (Programmable, Top Right Orange
Button) before pressing the Secure Button (Programmable, Top Left Button)
unless you are in an emergency situation. This sends an emergency alarm.
Before the keys are erased, the display shows “PLEASE WAIT.”
When all the encryption keys have been erased, the display shows “ALL KEYS ERASED.”
Chapter 8 Disassembly/Reassembly Procedures

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

8.1 XTS 4000 Exploded View (Partial)

This section contains the XTS 4000 radio partially exploded view and parts list.
NOTES:
• Refer to Figure 8–1 on page 8-2, the Partial Exploded View, and Table 8–1 on page 8-2, the
Corresponding Exploded View and Parts List.
• Numbers in parentheses ( ) refer to item numbers in Figure 8–1 and Table 8–1 on page 8-2.
• The Battery Assembly (E) and Antenna Assembly (D) should be removed from the radio before
disassembly or reassembly the radio.
8-2 Disassembly/Reassembly Procedures: XTS 4000 Exploded View (Partial)

Figure 8–1. XTS 4000 Partial Exploded View

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

Item
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 Antenna Assembly Refer “10.1 Exploded View and Parts List –
Main Assemblies” on page 10-2.
E Battery Assembly Refer “10.1 Exploded View and Parts List –
Main Assemblies” on page 10-2.
Disassembly/Reassembly Procedures: Required Tools and Supplies 8-3

8.2 Required Tools and Supplies

Table 8–2. Required Tools and Supplies

Motorola Part Supplier Part

Tools and Supplies Supplier
Number Number

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 Repair Torque

Description
Part Number (in-lbf)

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

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.

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:

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

If the radio is programmed for volatile-key retention,

encryption keys will be retained for approximately 30 seconds
after battery removal.

NOTE: The Motorola-approved battery shipped with the XTS 4000 radio is uncharged. Prior to using
a new battery, charge it for a minimum of 16 hours to ensure optimum capacity and
performance.

8.5.1 Attach the Battery

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

step 2 step 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 radio 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 Disassembly/Reassembly Procedures: Radio Disassembly

2. Rotate and remove the battery from the radio.

release button

Figure 8–5. Removing the Battery

8.6 Radio Disassembly

This section contains instructions for disassembling the radio. For this section, please refer to
“10.1 Exploded View and Parts List – Main Assemblies” on page 10-2,“10.2 Exploded View and
Parts List – Flip-Front Housing Assemblies” on page 10-3 and “10.3 Exploded View and Parts List –
Chassis Assembly” on page 10-4.

IMPORTANT:When servicing radio parts* 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". †
To service components in Front housing Assembly (B), refer section 8.6.3
"Disassemble the Front Housing Assembly".†
To service components in Flip assembly (A), separate the flip assembly from Front
Housing Assembly (B) by completing steps 1 to10 but skip steps 7-8 in section 8.6.3,
then refer section 8.6.4 "Disassemble the Flip Assembly". †
*
Exceptions: CID Bezel (1), Battery Ground redundant Contact (44), Battery
Connector Screw (45), 5Ohm RF Dust Cap Seal (46), Port Seal (47),
Audio Jack PC Label (48) and Chassis Screw (49).
†
Completion of ALL the steps in each section is NOT necessary depending on the
component to be serviced.
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. Turn off the radio by holding down the Power Button for 3 seconds.
2. Remove the Antenna Assembly (D), Battery Assembly (E) or any accessory connected to the
radio.
3. Remove the 5 chassis screws (49) from the back of the radio with a Torx T7 bit driver.
4. Insert the Black Stick (refer “8.2 Required Tools and Supplies” on page 8-3 for part number).
into the groove between the Front Housing and the Control Band (20) near the top (opposite
of PTT area). Gently tilt to separate the Flip-Front Housing Assembly from the Chassis
Assembly.

Black Stick

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

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

When separating the flexes and small interconnects, care is

needed to avoid damage to the interconnect and surrounding
on-board components.
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) and lay it aside. The B Plus Seal (31) may be removed from the
B Plus Connector on the back of the Main Board (29).
5. Use the tweezers to remove the center Screw Seal (32) from the Main Chassis (39).
6. Flip open the Audio Jack Dust Cover (22) and the CE Connector Dust Cover (21) from the
Control Band (20).

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

When removing the control band, make sure the Side and Top
Control Flex (40) and the metal dome array mylar is not
damage during the disassembly.
8-10 Disassembly/Reassembly Procedures: Radio Disassembly

7. Hold the chassis with the back facing up; push down the Control Band (20) on the PTT side
so that the latches are unlocked from the Main Chassis (39). Gently pull the Control Band
side outwards to disengage the Control Band. Rotate the Control Band anti-clockwise along
the antenna axis to remove it totally from the Main Chassis (39).

2. Pull gently
1. Push the catches
towards the chassis

Figure 8–10. Removing Control Band

8. Separate the Top and Side Controls Buttons (23+24) from the Control Band (20).
9. Rotate the tab behind the Audio Jack Dust Cover (22) 90°. Pull the Audio Jack Dust Cover
tab out from the Control Band (20) opening as shown in Figure 8–11. Push the tab behind the
CE Connector Dust Cover (21) down. Rotate the tab 90° and pull the dust cover out from the
Control Band as shown in Figure 8–12.
.

Push the
tab out from
the Control Band

Rotate 90°

Figure 8–11. Removing Audio Jack Dust Cover

Disassembly/Reassembly Procedures: Radio Disassembly 8-11

Push the tab down

Rotate 90° Push the

tab out from
the Control B

Figure 8–12. Removing CE Dust Cover

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

Figure 8–13. Removing Audio Jack

11. Use a tweezer to peel off the Audio Jack PC Label (48) and the Gore Membrane (47) from the
back of the Main Chassis (39).
12. Unplug the CE-UCM Connector Flex (28) from the Audio Jack Board (26) and push the Audio
Jack Board out from the Main Chassis (39) with the help of the Black Stick.
13. Unplug the female connector on the Top Control Inner Jumper Flex (33) from the Side and
Top Control Flex (40). Peel off the Side and Top Control Flex (40) from the Main Chassis
(39).
NOTE: Once the Side and Top Control Flex (40) is removed, replaced it with a new one.
Locate them accordingly to the top control locator pin on then the side control
locating features on the casting.
8-12 Disassembly/Reassembly Procedures: Radio Disassembly

14. Unplug the female connector of the CE-UCM Connector Flex (28) from the CE Connector
Board (36) at the bottom of the Main Chassis (39) to remove the CE-UCM Connector Flex.
15. To remove the Bottom CE Retainer (34) from the Main Chassis (39), push the CE Retainer
towards the front side of the Main Chassis direction until it stops. Then remove it together with
the CE Spacer (35) by directing it away from the bottom of the casting (refer Figure 8–14).
Use the tweezers to peel off the CE Connector Board (36) as shown in Figure 8–15.

Avoid inserting the tweezers into the connector area of the CE

Connector Board (36).

Gently push upwards

Direct out from

casting

Figure 8–14. Removing CE Retainer and Spacer

Avoid inserting tweezers

to the connector area

Figure 8–15. Removing CE Board

16. Loosen the top screw (43) on the Antenna Bushing Assembly (42) with a Torx T6 bit torque
driver and remove the Antenna Bushing Assembly.
17. Remove the Battery Connector Screw (45) with a Torx T3 bit torque driver and separate the
Battery Ground Redundant Contact (44).
Disassembly/Reassembly Procedures: Radio Disassembly 8-13

8.6.3 Disassemble the Front Housing Assembly

To disassemble the Front Housing Assembly (B):
1. Remove the Main Seal (19) from the Keypad Backer Sub-Assembly (15).
2. Remove the 4 screws from the Keypad Backer Sub-Assembly with a Torx T6 bit.
3. Remove the Keypad Backer Sub-Assembly by gently tilting the bottom part of the backer out
from the Front Housing, then tongue out from the top of the Front Housing.

Do not twist or pull the Flip Flex as this might cause

permanent damage to the Flip Flex.

Steps 4-6 (Speaker Compartment Seal (13), Main Keypad

(12), and UCM Module) should be performed while supporting
the keypad backer in the orientation shown in Figure 8–16.

4. Remove the Speaker Compartment Seal (13) from the Keypad Backer Sub-Assembly (15).
5. Remove the Main Keypad (12) from the Front Housing. Gently separate the connection
between the Speaker Flex and the UCM Board (10) and remove the UCM Board.
6. Carefully separate the Flip Flex (2) from the Keypad Backer Sub-Assembly (15) by gently
working the flat head of the Black Stick around the perimeter of the Flip Flex stiffener. Detach
the adhesive area of the Flip Flex from the Front Housing.

Step 4

Step 5

Figure 8–16. Disassemble Speaker Compartment Seal, Main Keyboard and UCM Board
8-14 Disassembly/Reassembly Procedures: Radio Disassembly

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

Keypad Inner Jumper Flex

Figure 8–17. Separating Keypad Backer Inner Jumper Flex

NOTE: Once the Keypad Backer Inner Jumper Flex (17) and/or Audio Jack Pad (16) are
removed, replaced with new ones. If the Keypad Backer and/or Main Keypad Flex
requires servicing, replace with NNTN7100A - Assembly, Keypad Backer.
8. Remove the Audio Jack Pad (16) and Secure Pad (14) as shown in Figure 8–18.

Figure 8–18. Removing Secure Pad

Disassembly/Reassembly Procedures: Radio Disassembly 8-15

9. With the flip in the open position, insert the flat end of the Black Stick between the flip
assembly (A) and the Front Housing. With a corner of the Black Stick positioned as shown in
Figure 8–19, gradually increase the gap between the Flip Assembly and Front Housing by
twisting the Black Stick until the Flip Assembly separates.

Do not twist or pull the Flip Flex as this might cause

permanent damage to the Flip Flex.

Figure 8–19. Removing Front Housing from Flip Assembly

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

Figure 8–20. Removing Tabs from Flip Stopper Pad

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).

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

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

Gently sweep
in this direction

CID Display

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.

All disassembled interfaces requiring adhesive must have new

adhesive applied during reassembly. The adhesive surfaces must be
clean and free of all foreign material, including oils and/or any
remaining adhesive after disassembly. If necessary, the surfaces
may be cleaned using a 0.5% solution of a mild dishwashing
detergent in water applied sparingly to the surface, ensuring that no
water enters into adjacent openings (connectors or otherwise),
cracks, or crevices. Remove the solution and dry the surface using a
lintless cloth or tissue. All newly applied adhesive interfaces should
be press fit for 10 seconds to ensure sealing capability is retained.
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
1 2 these 2 edges

Item 4 align to
these 2 edges
B
This cut
indicate up

Item 3 align to
legend marking
Item 5 align to & edge
these 2 edges

Adhesive Location – Front View

3
5
4

Adhering the Adhesive to Flip Flex – Overview

Items 2 align to
arrow marking & edge

Item Motorola
Description
No. Part number
THIS SIDE UP

1 1171646L01 Adhesive, Flip Flex Seal 2

(Flip)
2 7571858L01 Pad, Conductive Foam
3 1171845L01 Adhesive, Flip Flex
Housing
4 1171857L01 Adhesive, Conductive
5 1171645L01 Adhesive, Flip Flex Seal 1
(Backer)
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 hinge compartment of the Flip Sub-Assembly (3) as
shown in Figure 8–25.Peel off the liner of the adhesive at the new Flip Flex (2) connector
area and plug in the Flip Flex to the display module. Press fit for 10 seconds to ensure the
adhesive is properly activated.

Figure 8–25. Inserting Flip Flex

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

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

5. With the CID Bezel Kit (1) facing down, assemble the 2 screws near the hinge compartment
with a Torx T6 bit at 1.5 ± 0.2 in-lbf.
6. Prepare the Flip Inner Housing label surface as described in the first caution note of Section
“8.7 Radio Reassembly” on page 8-17. Adhere a new Flip Inner Label (6) to the
Flip Sub-Assembly (3), covering the screws.
7. Push the hinge into the opening of the Flip Assembly (A) until it snaps in place.

8.7.2 Reassemble the Front Housing Assembly

To reassemble the Front Housing Assembly (B):
1. Carefully insert each tab of the Flip Stopper Pad (7) into the corresponding openings of the
Front Housing. Verify that the stopper is fully seated.
8-20 Disassembly/Reassembly Procedures: Radio Reassembly

2. While holding the Flip Assembly (A), feed the Flip Flex (2) through the top opening of the
Front Housing.
3. With the flip in the open position, assemble the Flip Assembly as follows:

Be careful not to pull or pinch the Flip Flex during the

assembling process.

a. Guide the Flip Assembly onto the left knuckle of the Front Housing. Ensure the flip flex is
fully inserted in the opening hole of the left knuckle.
b. Gently open a gap on the right knuckle of the Front Housing while simultaneously pushing
the Flip Assembly to engage the Hinge. Simultaneously press on the side of both knuckles
and rotate the flip to ensure the hinge is fully inserted into the front housing slot.
4. Peel off the liner of the Flip Flex as shown in Figure 8–27. Rotate the flex into position
between the Front Housing alignment tabs. Press fit for 10 seconds to ensure the adhesive is
properly activated.

Figure 8–27. Adhere Flip Flex into Front Housing

5. Insert the Microphone Boot (8*) into the Front Housing. Gently push the Microphone into the
Microphone Boot. Verify that the Microphone is fully seated.
6. Assemble the Flip Bumper Pad (11) by inserting and fully depressing the tabs into the
openings of the Front Housing located in the region between the Keypad and the Speaker
Flex compartment.

NOTE: Be careful not to stress the board when plugging the Speaker Flex Connector to the
UCM board (10).
Disassembly/Reassembly Procedures: Radio Reassembly 8-21

7. Assemble the Main Keypad (12) to the Front Housing. Plug in the Speaker Flex Connector to
the UCM board (10) with the board position as shown in Figure 8–28. Rotate the UCM board
(10) into the front housing between the screw bosses and alignment tab.

2. Rotate
1. Plug in Connector

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 Keypad Backer Sub-Assembly. Press fit the whole flex
surface especially the perimeter for 10 seconds.

Press

Figure 8–30. Reassemble Flip Flex

NOTE: Prior to reassembling the Speaker Compartment and Main Seals, inspect the seals and
sealing surfaces for damage (nicks, cuts, etc.) or dirt.
11. Assemble the Speaker Compartment Seal (13) to the Keypad Backer Sub-Assembly (15).
Ensure the seal alignment tabs are properly located and fully seated.
12. With the Flip-Front Housing Assembly (A+B) on a flat surface, tongue in and rotate the
Keypad Backer Sub-Assembly assembly into the Front Housing.
NOTE: Be careful when assembling (e.g. DO NOT touch the seal) so that the Speaker Compartment
Seal does not drop off from the Keypad Backer Sub-Assembly (15) resulting in a pinched or
improperly assembled seal leakage.
13. With the flip housing of the radio facing down, assemble all 4 screws with a Torx T6 bit torque
driver at 3.1 in-lbf in the below sequence.

1
2

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. 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 Chassis Assembly (C) by locating it to the top locator pin. Bend the flex 90° and
align it to the side control locator features on the Chassis as shown in Figure 8–32. Press fit
for 10 seconds.

Press fit this area

after assemble to
ensure water sealed
from the connector

Locating Features

Figure 8–32. Assemble T6 screws to Front Housing

2. Align the Battery Ground Redundant Contact (44) to the Main Chassis (39) and tighten the
Battery Connector Screw (45) to hold the connector in place with a Torx T3 bit torque driver at
1.1 in-lbf.
3. Insert tab and rotate to assemble the Antenna Bushing Assembly (42) to the top of the Main
Chassis (39). With a Torx T6 bit torque driver at 2.1 in-lbf, tighten the Antenna Bushing Screw
(43) on the Antenna Bushing Assembly to secure it in place.
4. Prepare surface as discussed in the first caution note of Section “8.7 Radio Reassembly” on
page 8-17. Adhere the CE connector Adhesive (37) to the Main Chassis (39) bottom
compartment, remove the liner and adhere the CE board to the casting. Press fit for 10
seconds to ensure the adhesive is properly activated. Pre-assemble the CE Spacer (35) to
the CE Retainer (34) with the 2 protrusion on the CE Spacer facing the CE Retainer as shown
in Figure 8–33, then carefully insert the bottom hook to mate with the chassis. Next, push the
retainer down on the Main Chassis (39) to complete the assembly as shown in Figure 8–34.

Protrusions

Figure 8–33. Inserting Spacer to CE Retainer

8-24 Disassembly/Reassembly Procedures: Radio Reassembly

Gently push downwards

to engage

Direct into the casting

Figure 8–34. Reassemble CE Retainer and Spacer

5. Prepare the Audio Jack Adhesive (27) surfaces as described in the first caution note of
Section “8.7 Radio Reassembly” on page 8-17. Place the Audio Jack Seal into the audio jack
compartment. Press fit with the black stick for 10 seconds. Assemble the Audio Jack
Alignment Sleeve (25) to the Audio Jack Board. Assemble the Audio Jack sub-assemble to
the Chassis (C) by resting the Alignment Sleeve fingers on the lip of the Chassis and rotating
the sub-assembly into place as shown in Figure 8–35. Press fit for 10 seconds to ensure the
adhesive is properly activated.

1. Insert into the chassis

2. Rotate into position

Figure 8–35. Reassemble Flip Flex

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 upwards into position as shown in Figure 8–37.

Be careful not to bend the Control Band (20) when pressing in

the CE Connector Dust Cover (21) as this may damage the
Control Band.

Insert the
CE connector
dust cover

Rotate 90°
Push the tab up
to position

Figure 8–37. Reassemble CE Connector Dust Cover

8-26 Disassembly/Reassembly Procedures: Radio Reassembly

8. Position the Audio Jack Dust Cover (22) 90° to the Control Band (20). Hook and push the
long end of the tab into the opening of the Control Band. Simultaneously rotate both sides of
the Audio Jack Dust Cover 90°.

Push the tab

into the Control
Band

Rotate 90°

Figure 8–38. Assemble Audio Jack Dust Cover

9. Position the Top and Side Control Assembly Tape across the button openings of the Control
Band as shown in Figure 8–39. Assemble the Top Controls Keypad (24) and Side Controls
Keypad (23) to the Control Band (20). Make sure the keypads adhere well to the assembly
tape so that they do not drop off during reassembly.

Ensure the CE Connector Dust Cover (21) and Audio Jack

Dust Cover (22) are in open positions so that they do not
interfere with the side Control Band (20) during installation of
the control band.

Figure 8–39. Adhere Assembly Aid

Disassembly/Reassembly Procedures: Radio Reassembly 8-27

NOTE: Be careful not to bend the keypad during the assembly of the Control Band (20). Make sure
while rotating the control band towards the chassis, the protrusion on the retainer is inserted
properly into the control band bottom sleeve.
10. Position the Control Band (20) over the Chassis (C) as shown in Figure 8–37 and insert the
catches on the antenna side of the Control Band into the corresponding Chassis Openings.
Pull then rotate the Control Band towards the Main Chassis (39). Slightly pull the PTT side of
the control band away from the chassis and insert the two catches into the chassis opening.
Push the catches up into position. Peel off the top and side control assembly aid.

2. Rotate towards 3. After Inserting catches,

Main Chassis. Pull Press to locate.
to insert the catches.

1. Insert catches

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 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).

Avoid any hard

contact with the
sharp corners
of the casting
when assembling
to avoid damaging
the connector and flex

Figure 8–41. Assemble B Plus Seal to B Plus Connector

15. Using a Black Stick, press the Center Screw Seal (32) into position on the Main Chassis (39).
16. Assemble the Thermal Pad (30) and B Plus Seal (31) to the B Plus Connector on the back of
the Main Board (29) in the orientation shown.

Thermal Pad B Plus Seal

Figure 8–42. Assemble B Plus Seal to B Plus Connector

17. Plug the Top Control Inner Jumper Flex (33) to the Main Board (29).
Disassembly/Reassembly Procedures: Radio Reassembly 8-29

18. While holding the CE-UCM Flex as shown in Figure 8–43 so as to clear the Main Board,
rotate the Main Board (29) towards the chassis and into position by aligning the board to the
two chassis alignment pins. Check to make sure the battery B-plus seal is not pinched.

Chassis alignment
feature

Figure 8–43. Holding CE-UCM Flex

19. Plug the CE-UCM Connector Flex (28) to the Main Board (29).

8.7.4 Assemble the Chassis Assembly to the Flip-Front Housing Assembly

To assemble the chassis sub assembly (C) and Flip-Front Housing Assembly (A+B):
1. Place the Flip-Front Housing Assembly and chassis assembly side by side with the chassis
on the right. Plug in the connector of the Keypad Backer Inner Jumper Flex (17) to the Main
Board (29) top side. Also plug in the connector on the CE-UCM Connector Flex (28) to the
UCM Board (10) located at the bottom of the Flip-Front Housing Assembly as shown in
Figure 8–44.

Figure 8–44. Reassemble Flexes

8-30 Disassembly/Reassembly Procedures: Servicing CID Bezel Only

2. Rotate the chassis assembly towards the Flip-Front Housing Assembly. Snap fit both
assemblies by pressing the 2 snaps on the PTT side and the 2 snaps on the opposite PTT
side. Ensure there is no bulging between the Front Housing and the Control Band (20) to
confirm that the 4 snaps are properly engaged.
3. With the back of the radio facing upward, assemble the 5 screws with a Torx T7 bit at
4.4 in-lbf.

1
5

2
4

Figure 8–45. Screws Reassemble Sequence

4. Reassemble the antenna to the chassis by turning it clockwise with hand.

5. Tongue in the battery to the bottom of the chassis and press it towards the casting until it
clicks.
6. Power on the radio by pressing the Power Button.

8.8 Servicing CID Bezel Only

8.8.1 Disassemble CID Bezel
Refer steps 2 to 5 of “8.6.4 Disassemble the Flip Assembly” on page 8-16 to disassemble the CID
Bezel Kit (1).

8.8.2 Reassemble CID Bezel

Prepare the Flip Sub-Assembly (3) surface as described in the first caution note of Section “8.7
Radio Reassembly” on page 8-17 then continue reassembling by following steps 3 to 6 of
“8.7.1 Reassemble the Flip Assembly” on page 8-18.
Chapter 9 Basic Troubleshooting

This section of the manual contains troubleshooting charts and error codes that will help you to
isolate a problem. Level one and two troubleshooting will support only radio alignment,
programming, battery replacement, and knob replacement, and circuit board replacement.
Component-level service information can be found in the “ASTRO XTS 4000 Portable Radios
Detailed Service Manual,” Motorola publication number 68P71620L01.

9.1 Power-Up Error Codes

When the radio is turned on (power-up), the radio performs self-tests to determine if its basic
electronics and software are in working order. Problems detected during these tests are presented
as error codes on the radio’s display. For non-display radios, the problem will be presented at
power-up by a single, low-frequency tone. The radio should be sent to the depot if cycling power and
reprogramming the code plug do not solve the problem. The presence of an error should prompt the
user that a problem exists and that a service technician should be contacted.
Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user operation;
non-fatal errors will not. Use Table 9–1 to aid in understanding particular power-up error code
displays.

Table 9–1. Power-Up Error Code Displays

Error
Description Corrective Action
Code

01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug

01/12 Security Partition Checksum Non-Fatal Error Send radio to depot

01/20 ABACUS Tune Failure Non-Fatal Error Turn the radio off, then on

01/22 Tuning Codeplug Checksum Non-Fatal Error Send radio to depot

01/81 Host ROM Checksum Fatal Error Send radio to depot

01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug

01/88 External RAM Fatal Error – Note: Not a checksum failure Send radio to depot

01/90 General Hardware Failure Fatal Error Turn the radio off, then on

01/92 Security Partition Checksum Fatal Error Send radio to depot

01/93 FLASHport Authentication Code Failure Send radio to depot

01/98 Internal RAM Fail Fatal Error Send radio to depot

01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot

02/81 DSP ROM Checksum Fatal Error Send radio to depot

02/88 DSP RAM Fatal Error – Note: Not a checksum failure Turn the radio off, then on

02/90 General DSP Hardware Failure (DSP startup message not Turn the radio off, then on
received correctly)
9-2 Basic Troubleshooting: Operational Error Codes

Table 9–1. Power-Up Error Code Displays (Continued)

Error
Description Corrective Action
Code

09/10 Secure Hardware Error Turn the radio off, then on

09/90 Secure Hardware Fatal Error Turn the radio off, then on

Note: If the corrective action does not fix the failure, send the radio to the depot.

9.2 Operational Error Codes

During radio operation, the radio performs dynamic tests to determine if the radio is working properly.
Problems detected during these tests are presented as error codes on the radio’s display. The
presence of an error code should prompt a user that a problem exists and that a service technician
should be contacted. Use Table 9–2 to aid in understanding particular operational error codes.

Table 9–2. Operational Error Code Displays

Error Code Description Corrective Action

FAIL 001 Synthesizer Out-of-Lock 1. Reprogram external codeplug

2. Send radio to depot

FAIL 002 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

Correction or Test
Symptom Possible Cause
(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

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 Possible Cause
(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 Not On 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

Symptom Possible Cause
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

Amplifier

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 “KEYLOAD” 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 Parts 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 Exploded Views and Parts Lists: Exploded View and Parts List – Main Assemblies

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

Item No. Motorola Part Number Description

A. Flip Assembly
B. Front Housing Assembly
C. Chassis Assembly
D. Antenna Assembly
NAD6582_ (8571814L02) Antenna 136 – 151 MHz (Yellow coded)
or NAD6581_ (8571814L04) Antenna 146 – 162 MHz (Black coded)
D or NAD6583_ (8571814L01) Antenna 162 – 174 MHz (Blue coded)
or NAE6552_ (8571814L05) Antenna 380 – 470 MHz (Red coded)
or NAE6553_ (85012029001) Antenna 380 – 470 MHz
E. Battery Assembly
Battery Pack See Section “A.2 Batteries and Battery Accessories” on page A-1 in “Appendix A: Accessories”

Figure 10–1. Exploded View – Main Assemblies

Exploded Views and Parts Lists: Exploded View and Parts List – Flip-Front Housing Assemblies 10-3

10.2 Exploded View and Parts List – Flip-Front Housing Assemblies Table 10–3. Parts List – Flip-Front Housing Assemblies
Item No. Motorola Part Number Description
A. Flip Assembly (NNTN7209_)
1 1371710L02 Bezel, CID (Note: To replace, order NNTN7171_: Field Service Kit – CID Bezel)
2 0104024J62 Flex, Flip (Note: To replace, order NNTN7163_: Field Service Kit – Flip Flex)
* 7571858L01 Pad, Conductive Foam (Note: Included in NNTN7163_: Field Service Kit – Flip Flex if kit is
ordered)
† 1171645L01 Adhesive, Flip Flex - Seal 1 (Backer)
† 1171646L01 Adhesive, Flip Flex - Seal 2 (Flip)
†
1171845L01 Adhesive, Flip Flex Housing
†
1171857L01 Adhesive, Conductive
3 – Flip Sub-Assembly (Note: To replace, order NNTN7209_: Field Service Kit – Flip Assembly)

4 5589594Y02 Hinge, Cam, Silent, 5.8mm Dia. x 5.1mm x 15.6mm

D
5 0371903L01 Screw, 3MT-P975-0flip
6 3371777L01 Label, Flip Inner (Note: Included in kits NNTN7171_ and NNTN7163_ if either kit is ordered)

E B. Front Housing Assembly

7 7571739L01 Pad, Flip Stopper
C 8 – Front Housing Sub-Assembly (Note: to replace kit, order NNTN7190_: Service Kit – Front
Housing and NNTN7189_: Field Service Kit – Adhesive)
* 1471714L01 Boot, Microphone (Note: included in NNTN7190_: Service Kit – Front Housing if kit is ordered)
19 9 7571741L01 Pad, Vibrator (Note: included in XTS 4000 UCM Board kit if kit is ordered)
10 Refer Model Chart on page xvi XTS 4000 UCM Board
17
11 7571738L01 Pad, Flip Bumper
15
12 7571175L01 Keypad, Main
13 3271729L01 Seal, Speaker Compartment
12
14 7571234M01 Pad, Secure (Note: Included in NNTN7100_: Assembly, Keypad Backer if kit is ordered)

15 – Keypad Backer Sub-Assembly (Note: To replace, order NNTN7100_: Assembly, Keypad

Backer)
16 7571736L01 Pad, Audio Jack (Note: Included in NNTN7100_: Assembly, Keypad Backer if kit is ordered)
6 7 18 17 0104024J61 Flex, Keypad Backer Inner Jumper (Note: Included in NNTN7100_: Assembly, Keypad Backer if
5 kit is ordered)
16
3 † 1171834L01 Adhesive, Internal backer (Note: Included in 0104024J61: Flex, Keypad Backer Inner Jumper)
14 18 0371907L01 Screw, 3MT-P965-0backer
2
13 19 3271737L01 Seal, Main
11 C. Chassis Assembly
10
9 D. Antenna Assembly
1
NAD6582_ (8571814L02) Antenna 136 – 151 MHz (Yellow coded)
4 or NAD6581_ (8571814L04) Antenna 146 – 162 MHz (Black coded)
8 or NAD6583_ (8571814L01) Antenna 162 – 174 MHz (Blue coded)
or NAE6552_ (8571814L05) Antenna 380 – 470 MHz (Red coded)
or NAE6553_ (85012029001) Antenna 380 – 470 MHz

NNTN7099_: Flip-Front Housing Kit E. Battery Assembly

Battery Pack 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.
†
– Items cannot be ordered individually. They are inclusive in the NNTN7189_: Field Service Kit – Adhesive (refer
Figure 10–2. Exploded View – Flip – Front Housing Assemblies Table 10–5 "Service Kit Table" on page 10-5).
10-4 Exploded Views and Parts Lists: Exploded View and Parts List – Chassis Assembly

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

Ite
Ite m
Motorola Part Number Description
m No
Motorola Part Number Description .
No
. 43 0371907L01 Screw, 3MT-P965-0backer
A. Flip Assembly 44 3971718L01 Contact, Battery Ground
D Redundant
B. Front Housing Assembly
45 0371711L01 Screw, Battery Connector
C. Chassis Assembly
46 3271732L01 Seal, 5ohm RF Dust Cap
20 1371131L01 Band, Control
47 3271570L01 Seal, Port
21 3271734L01 Cover, Dust CE Connector (Note: to replace, order
E
22 3271733L01 Cover, Dust Audio Jack 3271570L01 – Port Seal and
3371776L01 – Audio Jack PC
23 7571176L01 Keypad, Side controls Label)
40 51
43 24 7571179L01 Keypad, Top Controls 48 3371776L01 Audio Jack PC Label
25 4371778L01 Audio Jack Alignment Sleeve (Note: to replace, order
42 50
3271570L01 – Port Seal and
46 26 0104024J66 Board, Audio Jack 3371776L01 – Audio Jack PC
41
(Note: to replace, order Label)
33
0104024J66 – Audio Jack
31 45 Board, 1171635L01– Audio Jack 49 0371904L01 Screw, 3MT-P964-0chassis
30
44 Adhesive, 3271570L01 – Port 50 3371256L01 Label, Blank
Seal and 3371776L01 – Audio (Note: Not orderable)
29 Jack PC Label)
49
51 3304791J08 Label, FCC
24 27 1171635L01 Adhesive, Audio Jack (Note: Not orderable)
32
23 (Note: to replace, order
20
1171635L01 – Audio Jack D. Antenna Assembly
Adhesive, 3271570L01 – Port NAD6582_ (8571814L02) Antenna 136 – 151 MHz
48
39 47
Seal and 3371776L01 – Audio (Yellow coded)
Jack PC Label) or NAD6581_ (8571814L04) Antenna 146 – 162 MHz
28 0104028J17 Flex, CE-UCM Connector (Black coded)
or NAD6583_ (8571814L01) Antenna 162 – 174 MHz
29 Refer Model Chart on XTS 4000 VHF Main Board (Blue coded)
38 page xvi or NAE6552_ (8571814L05) Antenna 380 – 470 MHz
37 30 7515719H02 Pad, Thermal and Conductive (Red coded)
36
or NAE6553_ (85012029001) Antenna 380 – 470 MHz
35
31 3271707L01 Seal, B plus
A 28 E. Battery Assembly
27 32 3271715L01 Screw Seal
26 34 Battery Pack See Section “A.2 Batteries and
33 0104024J59 Flex, Top Control Inner Jumper Battery Accessories” on page A-1 in
25
34 4271726L01 Retainer, Bottom CE “Appendix A: Accessories”

22 35 4371725L01 Spacer, CE Note:

36 0104028J13 Board, CE Connector with †
B
Coating
– Items cannot be ordered individually. They are
21 (Note: To replace, order inclusive in the NNTN7189_: Field Service Kit –
0104028J13 and NNTN7189_: Adhesive (refer Table 10–5 "Service Kit Table" on
Field Service Kit – Adhesive) page 10-5).
37† 1171636L01 Adhesive, CE Connector

38 1471169M01 Audio Jack Insulator

Figure 10–3. Exploded View – Chassis Assembly
39 2771148L02 Chassis, Main w/ choform
40 0104024J57 Flex, Side & Top Controls
41 3271717L01 Seal, Antenna Bushing
42 4371713L01 Bushing, Antenna Assembly
Exploded Views and Parts Lists: Parts List – Service Kit 10-5

10.4 Parts List – Service Kit Motorola

Item No. Description
Part Number
Table 10–5. Service Kit Table
0371903L01 Screw, 3MT-P975-0Flip

Motorola 3371777L01 Label, Flip Inner

Item No. Description
Part Number
7571739L01 Pad, Flip Stopper
Kit 1: NNTN7171_ Field Service Kit – CID Bezel
– Front Housing Sub-Assembly
1371710L02 Bezel, CID
1171385M01 Lubricant
3371777L01 Label, Flip Inner
Kit 6: NNTN7100_ Assembly, Keypad Backer
Kit 2: NNTN7163_ Field Service Kit – Flip Flex
7571234M01 Pad, Secure
1371710L02 Bezel, CID
– Keypad Backer Sub-Assembly
0104024J62 Flex, Flip
7571736L01 Pad, Audio Jack
3371777L01 Label, Flip Inner
0104024J61 Flex, Keypad Backer Inner Jumper
Kit 3: NNTN7209_ Field Service Kit – Flip Assembly
Kit 7: NNTN7189_ Field Service Kit – Adhesive
1371710L02 Bezel, CID
1171645L01 Adhesive, Flip Flex – Seal 1 (Backer)
0104024J62 Flex, Flip
1171646L01 Adhesive, Flip Flex – Seal 2 (Flip)
– Flip Sub-Assembly
1171845L01 Adhesive, Flip Flex Housing
5589594Y02 Hinge, Cam, Silent,
(5.8mm Dia. x 5.1mm x 15.6mm) 1171857L01 Adhesive, Conductive

0371903L01 Screw, 3MT-P975-0Flip 1171636L01 Adhesive, CE Connector

3371777L01 Label, Flip Inner 1171834L01 Adhesive, Internal Backer

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)
10-6 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-Ion Battery
PMNN4083_ 1260 mAh Standard Li-Ion 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_† 2-wire Surveillance Kit

NOTE: Recommendation settings via CPS:

• Read the radio setting using CPS.
• Click Radio Wide and select Tx Audio Control Per Mode.
* NNTN5006BP – Disable Digital AGC and set to +3dB Digital Fixed Gain.
†
NNTN5211_ – Make sure Digital AGC is selected and Digital Fixed Gain is 0db. If it is not,
Set Digital Fixed Gain to 0db and then enable Digital AGC.
Radio with NNTN5006BP setting while using this Surveillance accessory,
produces degraded sound quality at high talker level.
Appendix B Replacement Parts Ordering

B.1 Basic Ordering Information

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

B.2 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

B.3 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.

B.4 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-2 Replacement Parts Ordering: Fax Orders

B.5 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)

B.6 Parts Identification

Radio Products and Solutions Organization*
(United States and Canada)
1-800-422-4210

B.7 Product Customer Service

Radio Products and Solutions Organisation (United States 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 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.

C.2 Motorola Service Center

45D Butterfield Trail
El Paso, TX 79906
Tel: 1-800-227-6772

C.3 Motorola Federal Technical Center

4395 Nicole Drive
Lanham, MD 20706
Tel: 1-800-969-6680
Fax: 1-800-784-4133

C.4 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 Motorola Service Centers

Notes
Glossary Glossary

This glossary contains an alphabetical listing of terms and their definitions that are applicable to
ASTRO portable and mobile subscriber radio products.

Term Definition

A/D See analog-to-digital conversion.

Abacus IC A custom integrated circuit providing a digital receiver intermediate
frequency (IF) backend.
ADC See analog-to-digital converter.
ADDAG See Analog-to-Digital, Digital-to-Analog and Glue.
ALC See automatic level control.
analog Refers to a continuously variable signal or a circuit or device designed
to handle such signals. See also digital.
Analog-to-Digital, An integrated circuit designed to be an interface between the radio’s
Digital-to-Analog DSP, which is digital, and the analog transmitter and receiver ICs.
and Glue
analog-to-digital Conversion of an instantaneous dc voltage level to a corresponding
conversion digital value. See also D/A.
analog-to-digital A device that converts analog signals into digital data. See also DAC.
converter
automatic level A circuit in the transmit RF path that controls RF power amplifier output,
control provides leveling over frequency and voltage, and protects against high
VSWR.
band Frequencies allowed for a specific purpose.
BBP See baseband interface port.
baseband interface Synchronous serial interface to the transceiver section used to transfer
port transmit and receive audio data.
BGA See ball grid array.
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.
CE Connector Radio accessory connector used for communication with a computer for
radio programming and radio servicing.
CID Caller ID display.
Glossary-2 Glossary

Term Definition

CODEC See coder/decoder.

codeplug 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.
coder/decoder A device that encodes or decodes a signal.
CPS See Customer Programming Software.
Customer Software with a graphical user interface containing the feature set of an
Programming ASTRO radio. See also RSS.
Software
D/A See digital-to-analog conversion.
DAC See digital-to-analog converter.
default A pre-defined set of parameters.
digital 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.
digital-to-analog Conversion of a digital signal to a voltage that is proportional to the input
conversion value. See also A/D.
digital-to-analog A device that converts digital data into analog signals. See also ADC.
converter
Digital Private Line A type of digital communications that utilizes privacy call, as well as
memory channel and busy channel lock out to enhance communication
efficiency.
digital signal A microcontroller specifically designed for performing the mathematics
processor 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.
digital signal Object code executed by the Digital Signal Processor in an ASTRO
processor code subscriber radio. The DSP is responsible for computation-intensive
tasks, such as decoding ASTRO signaling.
DPL See Digital Private Line. See also PL.
DSP See digital signal processor.
DSP code See digital signal processor code.
DTMF See dual tone multi-frequency.
Glossary Glossary-3

Term Definition

dual tone multi- The system used by touch-tone telephones. DTMF assigns a specific
frequency frequency, or tone, to each key so that it can easily be identified by a
microprocessor.
EEPOT Electrically Programmable Digital Potentiometer.
EEPROM See Electrically Erasable Programmable Read-Only Memory.
Electrically Erasable A special type of PROM that can be erased by exposing it to an
Programmable electrical charge. An EEPROM retains its contents even when the
Read-Only Memory power is turned off.
FCC Federal Communications Commission.
firmware 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.
FGU See frequency generation unit.
flash 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.
FLASHcode A 13-digit code which uniquely identifies the System Software Package
and Software Revenue Options that are enabled in a particular
subscriber radio. FLASHcodes are only applicable for radios which are
upgradeable through the FLASHport process.
FLASHport 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.
FMR See Florida Manual Revision.
Florida Manual A publication that provides supplemental information for its parent
Revision publication before it is revised and reissued.
frequency Number of times a complete electromagnetic-wave cycle occurs in a
fixed unit of time (usually one second).
frequency This unit generates ultra-stable, low-phase noise master clock and other
generation unit derived synchronization clocks that are distributed throughout the
communication network.
General-Purpose Pins whose function is programmable.
Input/Output
GPIO See General-Purpose Input/Output.
Glossary-4 Glossary

Term Definition

host code 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.
IC See integrated circuit.
IF Intermediate Frequency.
IMBE A sub-band, voice-encoding algorithm used in ASTRO digital voice.
inbound signaling Data transmitted on the control channel from a subscriber unit to the
word central control unit.
integrated circuit 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.
ISW See inbound signaling word.
key-variable loader A device used to load encryption keys into a radio.
kHz See kilohertz.
kilohertz One thousand cycles per second. Used especially as a radio-frequency
unit.
KVL See key-variable loader.
LCD See liquid-crystal display.
LED See LED.
light emitting diode An electronic device that lights up when electricity is passed through it.
LiIon Lithium-ion.
liquid-crystal display 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.
LO Local oscillator.
low-speed 15baud digital data sent to the radio during trunked operation while
handshake receiving audio.
LSH See low-speed handshake.
Master In Slave Out SPI data line from a peripheral to the MCU.
Master Out Slave In SPI data line from the MCU to a peripheral.
MCU See microcontroller unit.
MDC Motorola Digital Communications.
MDI MCU/DSP Interface internal to the Patriot IC.
Glossary Glossary-5

Term Definition

MHz See Megahertz.

Megahertz One million cycles per second. Used especially as a radio-frequency
unit.
microcontroller unit Also written as µC. A microprocessor that contains RAM and ROM
components, as well as communications and programming components
and peripherals.
MISO See Master In Slave Out.
MOSI See Master Out Slave In.
multiplexer An electronic device that combines several signals for transmission on
some shared medium (e.g., a telephone wire).
MUX See multiplexer.
NiCd Nickel-cadmium.
NiMH Nickel-metal-hydride.
OMPAC See over-molded pad-array carrier.
open architecture A controller configuration that utilizes a microprocessor with extended
ROM, RAM, and EEPROM.
oscillator An electronic device that produces alternating electric current and
commonly employs tuned circuits and amplifying components.
OSW See outbound signaling word.
OTAR See over-the-air rekeying.
outbound signaling Data transmitted on the control channel from the central controller to the
word subscriber unit.
over-molded pad- A Motorola custom IC package, distinguished by the presence of solder
array carrier balls on the bottom pads.
over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the
radio.
PA Power amplifier.
paging One-way communication that alerts the receiver to retrieve a message.
Patriot IC A dual-core processor that contains an MCU and a DSP in one IC
package.
PC Board Printed Circuit Board. Also referred to as a PCB.
phase-locked loop A circuit in which an oscillator is kept in phase with a reference, usually
after passing through a frequency divider.
PL See private-line tone squelch.
Glossary-6 Glossary

Term Definition

PLL See phase-locked loop.

private-line tone A continuous sub-audible tone that is transmitted along with the carrier.
squelch See also DPL.
Programmable A memory chip on which data can be written only once. Once data has
Read-Only Memory been written onto a PROM, it remains there forever.
PROM See Programmable Read-Only Memory.
PTT See Push-to-Talk.
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.
radio frequency The portion of the electromagnetic spectrum between audio sound and
infrared light (approximately 10 kHz to 10 GHz).
radio frequency Amplifier having one or more active devices to amplify radio signals.
power amplifier
Radio Interface Box A service aid used to enable communications between a radio and the
programming software.
Radio Service DOS-based software containing the feature set of an ASTRO radio. See
Software also CPS.
random access A type of computer memory that can be accessed randomly; that is, any
memory byte of memory can be accessed without touching the preceding bytes.
RAM See random access memory.
read-only 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 read.
real-time clock A module that keeps track of elapsed time even when a computer is
turned off.
receiver 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.
registers Short-term data-storage circuits within the microcontroller unit or
programmable logic IC.
repeater Remote transmit/receive facility that re-transmits received signals in
order to improve communications range and coverage (conventional
operation).
repeater/talkaround 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 Glossary-7

Term Definition

RESET Reset line: an input to the microcontroller that restarts execution.

RF See radio frequency.
RF PA See radio frequency power amplifier.
RIB See Radio Interface Box.
ROM See read-only memory.
RPCIC Regulator/power control IC.
RPT/TA See repeater/talkaround.
RSS See Radio Service Software.
RTC See real-time clock.
RX Receive.
RX DATA Recovered digital data line.
SAP See Serial Audio CODEC Port.
SCI IN Serial Communications Interface Input line.
Serial Audio CODEC SSI to and from the GCAP II IC CODEC used to transfer transmit and
Port receive audio data.
Serial A full-duplex (receiver/transmitter) asynchronous serial interface.
Communication
Interface Input Line
SCI IN See Serial Communication Interface Input Line.
Serial Peripheral How the microcontroller communicates to modules and ICs through the
Interface CLOCK and DATA lines.
signal An electrically transmitted electromagnetic wave.
Signal Qualifier An operating mode in which the radio is muted, but still continues to
mode analyze receive data to determine RX signal type.
softpot See software potentiometer.
software Computer programs, procedures, rules, documentation, and data
pertaining to the operation of a system.
software A computer-adjustable electronic attenuator.
potentiometer
spectrum Frequency range within which radiation has specific characteristics.
SPI See Serial Peripheral Interface.
Glossary-8 Glossary

Term Definition

squelch 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.
SRAM See static RAM.
SRIB Smart Radio Interface Box. See RIB.
SSI See Synchronous Serial Interface.
Standby mode An operating mode in which the radio is muted but still continues to
monitor data.
static RAM A type of memory used for volatile, program/data memory that does not
need to be refreshed.
Synchronous Serial DSP interface to peripherals that consists of a clock signal line, a frame
Interface synchronization signal line, and a data line.
system central Main control unit of the trunked dispatch system; handles ISW and
controllers OSW messages to and from subscriber units (See ISW and OSW).
system select The act of selecting the desired operating system with the system-select
switch (also, the name given to this switch).
thin small-outline A type of dynamic random-access memory (DRAM) package that is
package commonly used in memory applications.
time-out timer A timer that limits the length of a transmission.
TOT See time-out timer.
transceiver Transmitter-receiver. A device that both transmits and receives analog
or digital signals. Also abbreviated as XCVR.
transmitter Electronic equipment that generates and amplifies an RF carrier signal,
modulates the signal, and then radiates it into space.
TSOP See thin small-outline package.
TX Transmit.
UART See also Universal Asynchronous Receiver Transmitter.
UHF Ultra-High Frequency.
Universal A microchip with programming that controls a computer's interface to its
Asynchronous attached serial devices.
Receiver Transmitter
Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps.
USB See Universal Serial Bus.
VCO See voltage-controlled oscillator.
Glossary Glossary-9

Term Definition

vector sum excited A voice-encoding technique used in ASTRO digital voice.

linear predictive
coding
VHF Very-High Frequency.
VIP Vehicle Interface Port.
VOCON See vocoder/controller.
vocoder An electronic device for synthesizing speech by implementing a
compression algorithm particular to voice. See also voice encoder.
vocoder/controller A PC board that contains an ASTRO radio’s microcontroller, DSP,
memory, audio and power functions, and interface support circuitry.
voice encoder The DSP-based system for digitally processing analog signals, and
includes the capabilities of performing voice compression algorithms or
voice encoding. See also vocoder.
voltage-controlled An oscillator in which the frequency of oscillation can be varied by
oscillator changing a control voltage.
Glossary-10 Glossary

Notes
Index Index-1

Index Index reassembling 8-23

chassis to flip-front housing assemblies
assemble 8-29
CID bezel
A servicing 8-30
CID test mode, display radio 5-8
Abacus III theory of operation 3-4 cleaning external plastic surfaces 2-1
accessories control top and keypad test mode, display radio 5-6
antennas A-1 copyrights
batteries A-1 computer software ii
belt clips A-1 document ii
carry A-1 customer service B-2
charger A-1
headsets and earpieces A-2 D
surveillance A-2
alignment, tuner disassembly/reassembly
bit error rate test 6-15 antenna
front end filter 6-13 attaching 8-4
UHF 6-13 removing 8-4
VHF 6-13 battery
introduction 6-1 attaching 8-5
main menu 6-2 removing 8-5
radio information screen 6-4 chassis assembly
reference oscillator 6-4 disassembling 8-8
softpot use 6-3 reassembling 8-23
test setup 6-1 flip assembly
transmit deviation balance 6-9 disassembling 8-16
transmit deviation limit 6-11 reassembling 8-18
transmit power 6-7 front housing assembly
transmitter test pattern 6-16 disassembling 8-13
analog mode reassembling 8-19
receiving 3-2 introduction 8-1
transmitting 3-3 separating chassis and housing assemblies 8-7
antenna display radio
attaching 8-4 CID test model 5-8
removing 8-4 control top and keypad test mode 5-6
antennas, types A-1 entering test mode 5-2
assemblies RF test mode 5-4
separating 8-7 RGB test mode 5-7
test mode 5-2
B test environments 5-6
test frequencies 5-4
battery test mode menu 5-2
attaching 8-5 vibration test 5-8
removing 8-5
types A-1 E
belt
clips A-1 earpiece and headsets accessories A-2
bit error rate test 6-15 encryption
board index
CE connector 8-12, 8-27 selecting with keypad 7-3
buffer, VCO 3-4 selecting with menu 7-3
key
C erasing
all keys 7-4
carry accessories key zeroization 7-3
belt clips A-1 selecting with keypad 7-2
CE connector selecting with menu 7-1
board 8-12, 8-27 troubleshooting chart 9-4
charger accessories A-1 error codes
chassis and housing 8-7 operational 9-2
chassis assembly power-up 9-1
disassembling 8-8 exploded view
Index-2 Index

complete revisions ii
chassis assembly 10-4 model chart
flip assembly 10-2 numbering system xv
front housing assembly 10-3 UHF xvii
partial 8-2 VHF xvi
model numbering system, radio xv
multikey
F conventional 7-1
trunked 7-1
field programming equipment 4-2
FLASHport 1-2
flip assembly N
disassembling 8-16
reassembling 8-18 notations
frequency generation theory of operation 3-4 manual 1-1
front end filter warning, caution, and danger 1-1
alignment 6-13
front end filter alignment
UHF 6-13 O
VHF 6-13
front housing assembly ordering replacement parts B-1
disassembling 8-13 oscillator, reference 3-4
reassembling 8-19
P
G
parts, ordering replacement B-1
glossary Glossary-1 performance checks
receiver 5-8
test setup 5-1
H transmitter 5-10
power amplifier theory of operation 3-4
handling precautions 2-1 power-up error codes 9-1
headsets and earpiece accessories A-2 precautions, handling 2-1
product safety information ii
I
R
index, encryption
selecting with keypad 7-3 radio
selecting with menu 7-3 alignment 6-1
basic description 1-2
CID test mode 5-8
K control top and keypad test mode 5-6
disassembling
key, encryption chassis assembly 8-8
erasing flip assembly 8-16
all keys 7-4 front housing assembly 8-13
key zeroization 7-3 separating chassis and housing assemblies 8-7
loading 7-1 entering display test mode 5-2
selecting with keypad 7-2 exploded view
selecting with menu 7-1 complete chassis assembly 10-4
complete flip assembly 10-2
L complete front housing assembly 10-3
partial 8-2
loading an encryption key 7-1 features 1-2
FLASHport feature 1-2
information screen 6-4
M model numbering system xv
models 1-2
main board theory of operation 3-3 performance checks
maintenance receiver 5-8
cleaning 2-1 transmitter 5-10
inspection 2-1 reassembling
manual chassis assembly 8-23
notations 1-1 chassis to flip-front housing assemblies 8-29
Index Index-3

flip assembly 8-18 receiver backend 3-4

front housing assembly 8-19 reference oscillator 3-4
RF test mode 5-4 synthesizer 3-4
RGB test mode 5-7 transceiver (XCVR) operation 3-3
test mode menu 5-2 transmitter power amplifier 3-4
vibration test 5-8 VCO buffer 3-4
receiver VOCON operation
ASTRO conventional channel tests 5-8 components 3-4
backend theory of operation 3-4 tools and supplies, needed 8-3
performance checks 5-8 trademark information ii
troubleshooting 9-2 transceiver (XCVR) operation theory of operation 3-3
receiving transmit deviation
analog mode 3-2 balance alignment 6-9
reference oscillator alignment 6-4 limit alignment 6-11
reference oscillator theory of operation 3-4 transmit power alignment 6-7
replacement parts, ordering B-1 transmitter
RF exposure compliance information ii ASTRO conventional channel tests 5-10
RF test mode performance checks 5-10
display radio 5-4 test pattern 6-16
RGB test mode, display radio 5-7 troubleshooting 9-3
transmitting
analog mode 3-3
S troubleshooting
encryption problems 9-4
service aids 4-2 introduction 9-1
servicing operational error codes 9-2
CID bezel 8-30 power-up error codes 9-1
softpot 6-3 receiver problem chart 9-2
specifications transmitter problem chart 9-3
UHF Range 1 radios xix tuner
VHF radios xviii bit error rate test 6-15
surveillance accessories A-2 front end filter alignment 6-13
synthesizer theory of operation 3-4 UHF 6-13
VHF 6-13
T introduction 6-1
main menu 6-2
terms and definitions Glossary-1 radio information screen 6-4
test environments 5-6 reference oscillator alignment 6-4
test equipment test setup 6-1
recommended 4-1 transmit deviation balance alignment 6-9
test frequencies 5-4 transmit deviation limit alignment 6-11
test mode transmit power alignment 6-7
display radio 5-2 transmitter test pattern 6-16
test mode menu
display radios 5-2 U
test mode, entering
display radios 5-2 UHF
test setup front end filter alignment 6-13
alignment 6-1 model chart xvii
performance checks 5-1
tests
receiver V
ASTRO conventional channels 5-8
transmitter VCO
ASTRO conventional channels 5-10 buffer 3-4
theory of operation VHF
Abacus III 3-4 front end filter alignment 6-13
analog mode 3-2 model chart xvi
first IF frequencies 3-3 vibration test, display radio 5-8
frequency generation 3-4 view, exploded
local oscillator frequencies 3-3 complete chassis assembly 10-4
main board 3-3 complete flip assembly 10-2
major assemblies 3-1 complete front housing assembly 10-3
overview 3-1 partial 8-2
Index-4 Index

VOCON operation W
theory of operation 3-4
warning, caution, and danger notations 1-1
warranty
commercial xii
coverage period xii