Aeroflex IFR 4000 User manual

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NAV/COMM Test Set
IFR 4000
Maintenance Manual
Issue-3
T.O. 33A1-3-112-2

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MAINTENANCE MANUAL
NAV/COMM TEST SET
IFR 4000
PUBLISHED BY
Aeroflex
COPYRIGHT ©Aeroflex 2011
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or
otherwise without the prior permission of the publisher.
Reissued Jan 2010
Issue-2 Mar 2010
Issue-3 Sep 2011
10200 West York / Wichita, Kansas 67215 U.S.A. / [phone] / FAX [phone]

MAINTENANCE MANUAL
IFR 4000
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FOR QUALIFIED SERVICE
PERSONNEL ONLY

MAINTENANCE MANUAL
IFR 4000
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MAINTENANCE MANUAL
IFR 4000
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Electromagnetic Compatibility:
For continued EMC compliance, all external cables must be shielded and three meters or less in
length.
Nomenclature Statement:
In this manual, IFR 4000, 4000, Test Set or Unit refers to the IFR 4000 NAV/COMM Test Set.

MAINTENANCE MANUAL
IFR 4000
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MAINTENANCE MANUAL
IFR 4000
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SAFETY FIRST: TO ALL SERVICE PERSONNEL
REFER ALL SERVICING OF UNIT TO QUALIFIED TECHNICAL PERSONNEL.
WARNING: USING THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY THE ACCOMPANYING
DOCUMENTATION MAY IMPAIR THE SAFETY PROTECTION PROVIDED BY THE EQUIPMENT.
CASE, COVER OR PANEL REMOVAL
Opening the Case Assembly exposes the operator to electrical hazards that can result in electrical shock or
equipment damage. Do not operate this Test Set with the Case Assembly open.
SAFETY IDENTIFICATION IN TECHNICAL MANUAL
This manual uses the following terms to draw attention to possible safety hazards that may exist when
operating this equipment.
CAUTION: THIS TERM IDENTIFIES CONDITIONS OR ACTIVITIES THAT, IF IGNORED, CAN RESULT IN
EQUIPMENT OR PROPERTY DAMAGE (E.G., FIRE).
WARNING: THIS TERM IDENTIFIES CONDITIONS OR ACTIVITIES THAT, IF IGNORED, CAN RESULT IN
PERSONAL INJURY OR DEATH.
SAFETY SYMBOLS IN MANUALS AND ON UNITS
CAUTION: Refer to accompanying documents. (This symbol refers to specific CAUTIONS
represented on the unit and clarified in the text.)
AC OR DC TERMINAL: Terminal that may supply or be supplied with AC or DC voltage.
DC TERMINAL: Terminal that may supply or be supplied with DC voltage.
AC TERMINAL: Terminal that may supply or be supplied with AC or alternating voltage.
DANGEROUS VOLTAGE: Indicates electrical shock hazard due to high voltage levels.
EQUIPMENT GROUNDING PRECAUTION
Improper grounding of equipment can result in electrical shock.
USE OF PROBES
Check specifications for the maximum voltage, current and power ratings of any connector on the Test Set
before connecting it with a probe from a terminal device. Be sure the terminal device performs within these
specifications before using it for measurement, to prevent electrical shock or damage to the equipment.
POWER CORDS
Power cords must not be frayed, broken nor expose bare wiring when operating this equipment.
USE RECOMMENDED FUSES ONLY
Use only fuses specifically recommended for the equipment at the specified current and voltage ratings.
WARNING: THE 4000 USES A LITHIUM ION BATTERY PACK. THE FOLLOWING WARNINGS
CONCERNING LITHIUM ION BATTERIES MUST BE HEEDED:
•DO NOT RECHARGE OUTSIDE THE IFR 4000.
•DO NOT CRUSH, INCINERATE OR DISPOSE OF IN NORMAL WASTE.
•DO NOT SHORT CIRCUIT OR FORCE DISCHARGE AS THIS MIGHT CAUSE THE BATTERY
TO VENT, OVERHEAT OR EXPLODE.

MAINTENANCE MANUAL
IFR 4000
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CAUTION: INTEGRATED CIRCUITS AND SOLID STATE DEVICES SUCH AS MOS FETS, ESPECIALLY
CMOS TYPES, ARE SUSCEPTIBLE TO DAMAGE BY ELECTROSTATIC DISCHARGES RECEIVED
FROM IMPROPER HANDLING, THE USE OF UNGROUNDED TOOLS AND IMPROPER STORAGE
AND PACKAGING. ANY MAINTENANCE TO THIS UNIT MUST BE PERFORMED WITH THE
FOLLOWING PRECAUTIONS:
•BEFORE USE IN A CIRCUIT, KEEP ALL LEADS SHORTED TOGETHER EITHER BY THE
USE OF VENDOR-SUPPLIED SHORTING SPRINGS OR BY INSERTING LEADS INTO A
CONDUCTIVE MATERIAL.
•WHEN REMOVING DEVICES FROM THEIR CONTAINERS, GROUND THE HAND BEING
USED WITH A CONDUCTIVE WRISTBAND.
•TIPS OF SOLDERING IRONS AND/OR ANY TOOLS USED MUST BE GROUNDED.
•DEVICES MUST NEVER BE INSERTED INTO NOR REMOVED FROM CIRCUITS WITH
POWER ON.
•PC BOARDS, WHEN TAKEN OUT OF THE SET, MUST BE LAID ON A GROUNDED
CONDUCTIVE MAT OR STORED IN A CONDUCTIVE STORAGE BAG. REMOVE ANY
BUILT-IN POWER SOURCE, SUCH AS A BATTERY, BEFORE LAYING PC BOARDS ON A
CONDUCTIVE MAT OR STORING IN A CONDUCTIVE BAG.
•PC BOARDS, IF BEING SHIPPED TO THE FACTORY FOR REPAIR, MUST BE PACKAGED
IN A CONDUCTIVE BAG AND PLACED IN A WELL-CUSHIONED SHIPPING CONTAINER.
CAUTION
THIS EQUIPMENT CONTAINS PARTS
SENSITIVE TO DAMAGE
BY ELECTROSTATIC DISCHARGE (ESD)
CAUTION: SIGNAL GENERATORS CAN BE A SOURCE OF ELECTROMAGNETIC INTERFERENCE (EMI) TO
COMMUNICATION RECEIVERS. SOME TRANSMITTED SIGNALS CAN CAUSE DISRUPTION
AND INTERFERENCE TO COMMUNICATION SERVICES OUT TO A DISTANCE OF SEVERAL
MILES. USERS OF THIS EQUIPMENT SHOULD SCRUTINIZE ANY OPERATION THAT RESULTS
IN RADIATION OF A SIGNAL (DIRECTLY OR INDIRECTLY) AND ENSURE COMPLIANCE WITH
INSTRUCTIONS IN FAA CIRCULAR AC 170-6C, DATED FEBRUARY 19, 1981.

MAINTENANCE MANUAL
IFR 4000
TABLE OF CONTENTS
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TABLE OF CONTENTS
Title Chapter/Section
Title / Copyright Page
For Qualified Service Personnel Only Page
Statements
Safety Pages
Table of Contents
Introduction
Chapter 2
Section 1 - Servicing 2-1
Section 2 - Troubleshooting 2-2
Section 3 - Disassembly/Reassembly 2-3
Section 4 - Parts List 2-4
Appendix A - Connector Pin-Out Tables
Appendix B - Test Equipment Requirements
Appendix C - Metric/British Imperial Conversion Table with Nautical Distance Conversions
Appendix D - Specifications
Appendix E - Controls, Connectors and Indicators
Appendix F - Abbreviations
Index

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IFR 4000
TABLE OF CONTENTS
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MAINTENANCE MANUAL
IFR 4000
INTRODUCTION
Page 1
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INTRODUCTION
This manual contains the information necessary to test and repair the IFR 4000.
It is strongly recommended that personnel be thoroughly familiar with the contents of this manual
before attempting to perform maintenance on this equipment.
Only qualified personnel should perform maintenance on this equipment.
ORGANIZATION
This manual is divided into the following Chapters and Sections:
CHAPTER 2 - MAINTENANCE
Section 1 - SERVICING (preventive maintenance)
Section 2 - TROUBLESHOOTING (theory of operation, troubleshooting procedures,
calibration/verification, assembly drawings)
Section 3 - DISASSEMBLY/REASSEMBLY
Section 4 - PARTS LIST

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IFR 4000
INTRODUCTION
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MAINTENANCE MANUAL
IFR 4000
2-TABLE OF CONTENTS
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CHAPTER TWO
IFR 4000 NAV/COMM TEST SET
MAINTENANCE MANUAL
TABLE OF CONTENTS
Title Chapter/Section/Subject Page
SECTION 1 - SERVICING 2-1
1. Preventive Maintenance Procedures 2-1-1 1
A. External Cleaning 2-1-1 1
B. Internal Cleaning 2-1-1 1
C. Visual Inspection 2-1-1 2
SECTION 2 - TROUBLESHOOTING 2-2
1. Theory of Operation 2-2-1 1
A. Power Supply Assy 2-2-1 1
B. Multi-Function PCB Assy 2-2-1 5
C. Processor PCB Assy 2-2-1 9
D. RF Assy (7005-5640-400) 2-2-1 11
E. RF Assy (7005-5640-500) 2-2-1 17
2. Troubleshooting Procedures 2-2-2 1
A. Guidelines 2-2-2 1
B. Precautions 2-2-3 2
(1) Safety 2-2-3 2
(2) ESD 2-2-3 2
(3) EMC and Safety Compliance 2-2-3 2
3. Calibration/Verification 2-2-3 1
A. General 2-2-3 1
(1) Calibration/Verification Schedule 2-2-3 2
(2) Controls, Connectors and Indicators 2-2-3 2
(3) Test Record 2-2-3 2
B. Precautions 2-2-3 2
C. Requirements 2-2-3 2
(1) Performance 2-2-3 2
(2) Test Equipment 2-2-3 2
(3) Disassembly 2-2-3 2
(4) Environment 2-2-3 2
D. Verification 2-2-3 3
(1) Self Test 2-2-3 3
(2) RF Accuracy 2-2-3 4
(3) RF Level Accuracy (ANT Connector) 2-2-3 6
(4) RF Level Accuracy (RF I/O Connector) 2-2-3 9
(5) Harmonic and Spurious 2-2-3 12
(6) VSWR (RF I/O and SWR Connectors) 2-2-3 14
(7) Marker Beacon 2-2-3 16
(8) VOR 2-2-3 17
(9) Localizer 2-2-3 20
(10) Glideslope 2-2-3 22
(11) ILS 2-2-3 24
(12) COMM AM 2-2-3 27
(13) COMM FM 2-2-3 28
(14) SELCOM 2-2-3 29
(15) Frequency Counter 2-2-3 30
(16) AM Meter 2-2-3 32
(17) FM Meter 2-2-3 33
(18) SWR Meter 2-2-3 35

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IFR 4000
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Title Chapter/Section/Subject Page
D. Verification (cont)
(19) Power Meter 2-2-3 37
(20) AM Audio - AUX Connector 2-2-3 43
(21) 121.5/243.0 MHz Beacon 2-2-3 44
(22) 406 MHz Beacon 2-2-3 45
(23) SSB Receive 2-2-3 47
(24) SSB Transmit 2-2-3 48
E. Verification Data Sheet 2-2-3 49
F. Alternate Verification Procedures 2-2-3 67
(1) RF Accuracy 2-2-3 67
(2) Marker Beacon 2-2-3 70
(3) VOR 2-2-3 71
(4) Localizer 2-2-3 74
(5) Glideslope 2-2-3 77
(6) ILS 2-2-3 80
G. Alternate Verification Procedures Data Sheet 2-2-3 85
H. Calibration 2-2-3 95
(1) Test Setup 2-2-3 95
(2) Miscellaneous 2-2-3 97
(3) RF Amplitude Levels 2-2-3 99
(4) Modulation 2-2-3 101
4. Assembly Drawings 2-2-4 1
SECTION 3 - DISASSEMBLY/REASSEMBLY 2-3
1. Disassembly 2-3-1 1
A. General 2-3-1 1
B. Preliminary Considerations 2-3-1 1
(1) Tools Required 2-3-1 1
(2) Disassembly Precautions 2-3-1 1
(3) ESD 2-3-1 2
(4) EMC and Safety Compliance 2-3-1 2
C. Procedures 2-3-1 3
(1) Battery 2-3-1 3
(2) Fuse 2-3-1 5
(3) Case Assy 2-3-1 7
(4) Power Supply PCB Assy 2-3-1 9
(5) RF Assy 2-3-1 10
(6) Processor PCB Assy 2-3-1 12
(7) Multi-Function PCB Assy 2-3-1 13
(8) Keypad PCB Assy 2-3-1 15
(9) LCD PCB Assy 2-3-1 16
2. Reassembly 2-3-2 1
A. General 2-3-2 1
B. Preliminary Considerations 2-3-2 1
(1) Tools Required 2-3-2 1
(2) Reassembly Precautions 2-3-2 1
(3) ESD 2-3-2 1
(4) EMC and Safety Compliance 2-3-2 1
C. Procedures 2-3-2 2
(1) Battery 2-3-2 2
(2) Fuse 2-3-2 2
(3) Case Assy 2-3-2 2
(4) Power Supply PCB Assy 2-3-2 2
(5) RF Assy 2-3-2 2
(6) Processor PCB Assy 2-3-2 2
(7) Multi-Function PCB Assy 2-3-2 2
(8) Keypad PCB Assy 2-3-2 2
(9) LCD PCB Assy 2-3-2 2

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IFR 4000
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Title Chapter/Section/Subject Page
SECTION 4 - PARTS LIST 2-4

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IFR 4000
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MAINTENANCE MANUAL
IFR 4000
2-LIST OF ILLUSTRATIONS
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LIST OF ILLUSTRATIONS
Title Chapter/Section/Subject Page
Power Supply PCB Assy Block Diagram 2-2-1 3
Multi-Function PCB Assy Block Diagram 2-2-1 4
Processor PCB Assy Block Diagram 2-2-1 9
RF Assy Block Diagram 2-2-1 15
RF Assy Block Diagram 2-2-1 21
Troubleshooting Table 2-2-2 4
Power Meter Calibration Setup 2-2-3 96
Composite Assy 2-2-4 3
Power Supply PCB Assy 2-2-4 7
Chassis Assy 2-2-4 19
Keypad PCB Assy 2-2-4 21
Processor PCB Assy 2-2-4 25
Multi-Function PCB Assy 2-2-4 35
LCD Assy 2-2-4 48
RF Assy 2-2-4 49

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IFR 4000
2-LIST OF ILLUSTRATIONS
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MAINTENANCE MANUAL
IFR 4000
2-1-1
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SECTION 1 - SERVICING
1. Preventive Maintenance Procedures
Contains routine maintenance instructions for cleaning and inspecting the Test Set.
CAUTION: DISCONNECT POWER FROM TEST SET TO AVOID POSSIBLE DAMAGE TO
ELECTRONIC CIRCUITS.
A. External Cleaning
STEP PROCEDURE
1. Clean front panel and display face with soft lint-free cloth. If dirt is difficult to
remove, dampen cloth with water and mild liquid detergent.
2. Remove grease, fungus and ground-in dirt from surfaces with soft lint-free cloth
dampened (not soaked) with isopropyl alcohol.
3. Remove dust and dirt from connectors with soft-bristled brush.
4. Cover connectors, not in use, with suitable dust cover to prevent tarnishing of
connector contacts.
5. Clean cables with soft lint-free cloth.
6. Paint exposed metal surface to avoid corrosion.
B. Internal Cleaning
CAUTION
THIS EQUIPMENT CONTAINS PARTS
SENSITIVE TO DAMAGE
BY ELECTROSTATIC DISCHARGE (ESD)
CAUTION: DO NOT MOVE COMPONENTS ON CIRCUIT BOARDS OR DISASSEMBLE
CONNECTORS NEEDLESSLY TO AVOID POSSIBLE DAMAGE.
CAUTION: DO NOT OPEN COMPLEX INTERNAL MODULES FOR SOLE PURPOSE OF
CLEANING AND INSPECTION.
Remove dust with hand-controlled dry air jet of 15 psi (1.054 kg/cm2) and wipe internal
chassis parts and frame with soft lint-free cloth moistened with isopropyl alcohol.

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IFR 4000
2-1-1
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C. Visual Inspection
STEP PROCEDURE
1. Inspect Chassis for:
●Tightness of sub-assemblies and chassis mounted connectors.
●Corrosion or damage to metal surfaces.
2. Inspect Capacitors for:
●Loose mounting, deformities or obvious physical damage.
●Leakage or corrosion around leads.
3. Inspect Connectors for:
●Loose or broken parts, cracked insulation and bad contacts.
4. Inspect Circuit Boards for:
●Corrosion or damage to connectors.
●Damage to mounted components including crystals and ICs.
●Freedom from foreign material.
5. Inspect Resistors for:
●Cracked, broken, charred or blistered bodies.
●Loose or corroded soldering connections.
6. Inspect Semiconductors for:
●Cracked, broken, charred or discolored bodies.
●Correct placement and condition of seals around leads.
7. Inspect Wiring for:
●Broken or loose ends and connections.
●Proper dress relative to other chassis parts.
NOTE: Verify wrapped wiring is tight.