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MAINTENANCE MANUAL
BENDIXKING'
KT 76A/78A
ATCRBS TRANSPONDER
MANUAL NUMBER 006-05143-0007
REVISION 7, MARCH, 1999
WARNING
Prior to export of this document, review for export license requirement is need-
ed.
COPYRIGHT NOTICE
Company:__________________________ ;~________ •
Street Address:___________________________________________
City, State:;__________________________________________ ■
AlliedSignal, Inc.
Electronic and Avionics Systems
Attn:Technical Publications
RO. Box 1950
Olathe, Kansas 66051-9930
NO. POSTAGE
NECESSARYIF
MAILED IN THE
UNITED STATES
AlliedSignal, Inc.
Electronic and Avionics Systems
Attn:Technical Publications
P.O.Box 1950
Olathe, Kansas 66051-9930
REVISION HISTORY AND INSTRUCTIONS
PARTNUMBER: 006-05143-0007
Add, delate, or replace pages as indicated below and retain all tabs and dividers. Inserí this
page immediately behind the title page as a record oí revisions.
ITEM ACTION
Add, delete, or replace pages as indicated below and retain all tabs and dividers. Insert this
page immediately behind the title page as a record oí reviSions.
ITEM ACTION
Add, delete, or replace pages as indicated below and retain all tabs and dividers. Inserí this page immediately
behind the title page as a record of revisions. This revisión level of this manual consists oí the following
individual publications:
PAGE ACTION
This is a complete manual revisión. This revisión supersedes all previous revisión manuals.
Sections I, II, and III have been deleted from the Maintenance-Overhaul Manual formal. The Installation Manual, which covers
the same Information, should be placed behind this tab to complete your technical library for each unit. It is reoommended that
the entire Instaliation Manual be removed and replaced when a revisión is issued. The revisión number and date of revisión
are printed on each Installation Manual cover page
^lliedSignal
ELECTRONIC AND AVIONICS SYSTEMS
INSTALLATION MANUAL
BENDIX/KING
KT 76A/78A
ATCRBS
TRANSPONDER
COPYRIGHT NOTICE
SECTION I
GENERAL INFORMATION
SECTION II
INSTALLATION
SECTION III
OPERATION
LIST OF ILLUSTRATIONS
SECTION I
GENERAL INFORMATION
1.1 INTRODUCTION
This manual contains Information relativa to the physical, mechanical, and electrical
characteristics of the AlliedSignal KT 76A/78A. Information relativa to the maintenance, alignment
and procurement of replacement parts may be found in the KT 76A/78A Maintenance/Overhaul
Manual.
SPECIFICATION CHARACTERISTIC
TSO COMPLIANCE: C74b
TSO CATEGORY: KT 76A -DAPBBBXXXXXX Class I
KT 78A -DAPBBBXXXXXX Class II
APPLICABLE DOCUMENTS: TSO C74b RTCA DO-138
TEMPERATURE RANGE: -15 @C to +55 @C for continuous operation
HUMIDITY RANGE: Up to 95% at +50 @C (+122 @F) for 12 hours
WEIGHT: See Figure 2-4
INSTALLATION SPACE: See Figure 2-4
POWER REQUIREMENTS: 14 V, 1.8 A Max., 1.1 A standby
ALTITUDE: KT 76A tested up to 35000 feet, which exceeds
TSO requirements. KT78A up to 15,000 feet.
TRANSMITTER FREQUENCY: 1090 MHz # 3 MHz (with a coax cable
SWR of 1.2 to 1 or less)
TRANSMITTER POWER: KT 76A - 200 W peak mínimum
KT 78A - 113 W peak mínimum
COOLING: Not required, but recommended
SPECIFICATION CHARACTERISTIC
RECEIVER FREQUENCY: 1030 MHz
RECEIVER SENSITIVITY: -74 dBm nominal
-72 dBm mínimum for 90% reply
MODE A CAPABILITY: 4096 identity codes plus SPI pulse
MODE C CAPABILITY: Accepts ARINC altitude digitizer output, reporting
iri 100 foot increments from -1000 feet up to
63,000 feet.
SIDE LOBE SUPPRESSION: 3 pulse
SUPPRESSION IN: Accepts ARINC Bilateral
Ex: (LO < 0.5 V, High > 18V)
KN 63/KDM 706/KTU 709
AlliedSignal Unilateral
Ex: (LO < 0.5 V, High > 8V
KN 62A/KN 64/KNS 80
SECTION II
INSTALLATION
B. Avoid mounting cióse to any external heat source. If this capnot be accomplished, the
following caution must be adhered to.
CAUTION
THE GREATEST SINGLE CONTRIBUTOR TO INCREASED
RELIABILITY OF ALL MODERN DAY AVIONICS IS TO LIMIT THE
MAXIMUM OPERATING TEMPERATURE OF THE INDIVIDUAL
UNITS WHETHER PANEL OR REMOTE MOUNTED. WHILE
MODERN DAY INDIVIDUAL CIRCUIT DESIGNS CONSUME
MUCH LESS ELECTRICAL ENERGY, THE WATTS PER CUBIC
INCH DISSIPATED WITHIN AVIONICS UNITS REMAINS MUCH
THE SAME BECAUSE ÓF THE HIGH DENSITY PACKAGING
TECHNIQUES UTILIZED. CONSEQUENTLY, THE IMPORTANCE
OF PROVIDING AVIONICS STACK COOLING IS ESSENTIAL TO
THE LIFE SPAN OFTHE EQUIPMENT. WHILE EACH INDIVIDUAL
UNIT MAY NOT REQUIRE FORCEO AIR COOLING, THE
COMBINED HEAT LOAD ÓF SEVERAL UNITS OPERATING IN A
TYPICAL AVIONICS STACK WILL SIGNIFICANTLY DEGRADE
THE RELIABILITY OF THE AVIONICS IF PROVISIONS FÓR
STACK COOLING ARE NOT INCORPORATED IN THE INITIAL
INSTALLATION. RECOMMENDATIONS ON STACK COOLING
ARE CONTAINED IN ALLIEDSIGNAL INSTALLATION BULLETIN
#55. FAILURE TO PROVIDE STACK COOLING WILL CERTAINLY
LEAD TO INCREASED AVIONICS MAINTENANCE COSTS AND
MAY VOID THE WARRANTY.
D. Secure the mounting tray P/N 047-03898-0002 to instrument panel per Figure 2-4. The
rearward mounting holes must be attached to a structural member of the airframe by means
of support brackets.
E. Looking at the bottom of unit, make sure the front lobe of the holddown device ¡s in a vertical
position. This can be accomplished by using 3/32” alien wrench through the face píate.
F. Slide unit into tray until front lobe touches mounting tray.
G. Turn alien wrench clockwise until rear lobe engages with the tray slot. Continué turning
wrench clockwise until tight.
CAUTION
DO NOT OVERTIGHTEN LOCKING SCREW.
H. For removal, turn 3/32” alien wrench counterclockwise until unit disengages from tray slot.
Unit may then be removed.
1. Strip each wire 5/32” for contact terminal (P/N 030-01107-0030). (The last two digits
of the contact terminal part number indícate the number of termináis furnished).
3. Using needle nose pliers, fold over each conductor táb ¡n turn, onto the exposed
conductor. When both tabs have been folded, firmly press the tabs against the
conductor.
1. After the contact termináis have been installed on the wiring harness, the contact
termináis can be inserted into the proper location in the connector housing
(P/N 030-01094-0053). The terminal cannot be inserted upside down. Be sure to
push the terminal all the way in, until a click can be felt or heard.
1. Slip the fíat narrow blade of a Molex contact ejector tool, HT-1884
(P/N 047-05099-0001) under the contact on the mating side of the connector. By
turning the connector upside down one can see the blade slide into the stop.
2. When the ejector is slid into place, the locking key of the contact is raised, allowing
the contact to be removed by pulling moderately on the lead.
CRIMP
TERMINAL EXTRACTION
TOOL P/N 047-05099-0001
MOLEX P/N HT-1884
Holding the hand crimpers as shown, ralease the. crimper's ratchet pawl and open by squeezing tightly on the
handles, andthen releasing pressure.
Cióse crimpers until ratchet begins to engage. Then insert terminal into jaws from the back side. (See the
following; Figure 2-1). For 24 to 30 AWG wire, it will be necessary to start the crimp in jaw A and then
complete in jaw B.
Terminal is in the correct position when insulation tabs are flush with outside face of crimp jaws.
Once the terminal is in the correa position, cióse the jaws gently until the terminal is held loosely in place. Push the wire stop down so that it rests
snugly behind the contact portion of the terminal.
Strip off 1/8 inch of the wire insulation and insert the wire through the insulation tabs into the conduaor tabs until the insulation hits the conductor
jaw face or until the conductor touches the wire stop.
Squeeze the handles until the crimp jaws cióse and the ratchet raleases.
Straighten the terminal if necessary, then ralease the plier grips and remove the crimped terminal.
If too much or too little pressure is needed to ralease the crmper's ratchet pawl at the end of the crimp stroke, the tatchet can be easily adjusted. A
spanner wrench provided with the tool can be used to ioosen the lock nut, and rotate the keyed stud dockwise for incteased pressure and
counter-dockwise for decreased pressure. Once the desired pressure has been set, the lock nut must be tightened again. Newer models may have
a screwdriver adjustment.
TO KA 48 ANTENNA
tu
(Q
(!)
ro LBHT TRAY ASSEMBLY
notes:
1. USE PIN 8 FOR 26 VOC 0R PIN 14 FOR 13.75 VDC. DO NOT CONNECT PIN 8 AND PIN 14
TOGETHER. DO NOT CONNECT PIN 8 OR PIN 14 TO THE NON-SWITCHED INPUT ON
PIN I I OF THE KT 76A/78A BECAUSE DAMAGE TO THE ALTITUDE DIGITIZER COULD OCCUR
NOTE 9 CONT. IF PIN 14 IS CONNECTED TO PIN II OF THE KT76A/78A IN A 28VDC AIRCRAFT POWER SYSTEM
WHEN THE TRANSPONDER IS TURNEO OFF. THE VOLTAGE AT PIN II WILL BE APROXIMATELY 28V0C THROUGH
THE SERIES DROPPING RESISTOR CONNECT THE INPUT OF THE ALTITUDE DIGITIZER TOA SWITCHABLE VOLTAGE
2. 14 TO 28 VDC CHANGEOVER KIT. MOUNT ON AIRCRAFT FIREWALL OR OTHER STRUCTURAL
MEMBER AWAY FROM THE AVIONICS STACK.
3. CONNECTOR TERMINAL® NUMBER IS SPECIFIEO ON CONNECTOR.
4. ALL WIRES SHOULO BE *22AWG.
8. ROUTE THE ANTENNA CABLE A8 FAR AS PRACTICAL FROM ANY HARNESS SONOLE. IN
NO CASE SHOULO THE ANTENNA CABLE BE LACEO INTO A HARNESS BUNOLE.
6. CONNECTOR WIRINO FOR LIOHT OIMMERS.
J76A/7BA-------------
PIN 10 7. ACCEPTS POSITIVE GOING SUPPRESSION PULSES. REFER TO KT76A/78 A SERVICE 8ULLETIN-
3REVISED FOR INCORPORARON OF THE SUPPRESSION CIRCUITRY IF THE KT76A IS BELOW S/N 14000
PANEL MOUNTED TRANSPONDER
SELECT SWITCH ANO THE KT 78A IS BELOW 7000.
(KPN 031-0071-00) 8 TO BE USED WITH DIGITIZER RATED AT 31,000 FEET AND ABOVE. THERE IS NO VALID INFORMATION
TRANSPONDER111 SHOWN SELECTED ON THE D4 BELOW 31.000 FEET. NO DAMAGE WILL OCCUR IF D4 IS CONNECTED TO A DIGITIZER
TRANSP0N0ERW2 SHOWN IN STANDBV RATED BELOW 31,000 FEET.
9. EXT SBY WHEN TIED TO GROUND WILL PLACE THAT UNIT IN SBY MODE. KT76A S/N 35,900 AND
(GROUNOING ExTERNAl STANDBV
LINE PLACES UNIT IN STANDBV) ABOVE WITH M0D5 STATUS PROVIDES EXT SBY FUNCTION, S/N 35,899 AND BELOW AND ALL
KT78A UNITS. M005 MAY BE INCORPORATED.
Figure 2-3 DUAL TRANSPONDER INTERCONNECT
(Dwg. No. 155-01363-0000, R-2)
6.3I2
(I6.03)
nr 7S* TA3U
PKBT K9HBKII KCUtt
FIGURE I
NOTES:
2. UNITS- INCHESJCENTIMETERS).
2.7 KA 60 INSTALLATION
Refer to Figure 2-5 and Figure 2-7 for illustrations relating to the KA 60.
A. Peel the backing off the antenna témplate and apply témplate to the aircraft at the desired
mounting location.
B. Drill or cut the proper size holes for mounting the antenna, then remove the témplate.
C. Using the antenna as a stencil, draw a line around the base of the antenna that will come into
contact with the aircraft. Then carefully scrape off the paint within the steneiled area. Lightly
sand the bare metal with fine sandpaper to insure removal of all paint and protective coatings.
D. Sand the inside area of the aircraft where the backing píate will be located to remove the
chromate or other protective finish.
E. Apply Aluminprep No. 33 (P/N 016-01127-0000) following the directions on the container to
cleanse the metal of any residue.
F Apply Alodine No. 1001 (P/N 016-01128-0000) following the directions on the container.
H. Mount the antenna using #8 star washers (P/N 089-08017-0037) and 8-32 nuts
(P/N 089-02148-0032) included with the antenna.
I. RG-142 or equivalent coaxial cable is normally used on installations having a cable run of
ten feet or less. For cable runs from nine to 17.5 feet, use low loss antenna installation kit
(P/N 050-01253-0002).
J. Inspect coaxial cable connector for proper center contact, then fasten it securely to the
antenna.
A. The antenna should be well removed from any projections, the engine(s) and propeller(s).
It should also be well removed from landing gear doors, access doors, or other openings
which will break the ground plañe for the antenna.
B. The antenna should be mounted on a bottom surface of the aircraft and in a vertical position
when the aircraft is in level flight.
D. Avoid mounting the antenna within three (3) feet of the ADF sense antenna or any COMM
antenna and six (6) feet from the transponder to DME antenna.
E. Where practica!, plan the antenna location to keep cable lengths as short as possible, and
avoid Sharp bends in the cable to minimize the VSWR.
H. The antenna should be kept clean. If left dirty (oil covered) the range ofthe Transponder may
be affected.
I. On pressurized aircraft, the antenna should be sealed using RTV (P/N 016-01082-0000)
around the connector and mounting hardware.
J. All antennas should be sealed around the outside for moisture protection.
MOUNTING
HOLE CUTOUT DIAGRAM
NOTE :
DIMENSIONS IN PARENTHESES ( ) ARE IN CENTIMETERS.
■089-05991-0012 (2)
AIRCRAFT FIREWALL OR
STRUCTURAL MEMBER
89-02009-0037 (2)
USING CABLE
P/N 024-00071-0000
'P ECS P/N 311201
KA-60
CDUPLING CONNECTOR
P/N 030-00434-0000
ttj/
P/N 030-00138-0000 KT76A/78A
P/N 024-00051-0060
RG-400
TEFLON
CLAMP SHOULDER TEFLON
WASHER
WASHER INSULATOR
METAL MALE
NUT GASKET SHOULDER CONTACT PLUG BODY
WASHER
1. STRIP RG-142B/U
(P/N 024-00002-0000)
AND PLACE 1” HEAT SHRINK
TUBING (P/N 150-00025-0010)
OVER COAX.
COAX:
CUT. STRIP AND SOLDER 2. SOLDER CENTER CONTACT AND
AS SHOWN. SOLDER INNER SHIELD INSIDE.
SEE NOTE 1.
030-00101 -0002
NOTES:
SECTION III
OPERATION
NOTE
The KT 76A/78A should be turned off before starting aircraft
engine(s).
After being turned on, there is a 45 second delay before the unit becomes functional. This is to
permit the transmitter tube to warm up and stabilize. Usually the function switch will be rotated
to the “standby” position, however, any operativa position will infríate the time delay turn on. Any
time that the function switch is in the “ON” or “ALT’ position the transponder becomes an active
part of the beacon system. It is undesirable from a systems view point to be operating (function
selector in either of these positions) while on the ground, taxiing, or running up at a terminal with
a co-located beacon interrogator. Attention should be paid to the code selected on the control
head. The selected code should be in accordance with instructions for IFR flight or rules applicable
to transponder utilization for VFR flight.
NOTE
Never actívate the transponder with either Code 0000,7700 or 7777
selected on the control head. Code 7700 is selected for
emergencies.
NOTE
Consult the airport/facility directory section of the Airman’s
Information Manual for the location of radar beacons. Air traffic
control radar beacon system (ATCRBS) Description: AIM, Section
I. Radar beacon proceudres: AIM, Section II.
MAINTENANCE/OVERHAUL MANUAL
SECTIOMS IV, V AND VI
^lliedSignal
ELECTRONIC AND AVIONICS SYSTEMS
MAINTENANCE MANUAL
BENDIXKING
KT 76A/78A
ATCRBS
TRANSPONDER
MANUAL NUMBER 006-05143-0006
REVISION 6, NOVEMBER 1996
WARNING
COPYRIGHT NOTICE
SECTIONIV ...
THEORY OF OPÉRÁTÍON
SECTION V
MAINTENANCE
SECTION VI
ILLUSTRATÉD PARTS LIST
LIST OF ILLUSTRATIONS
FIGURE 4-3 COMPOSITE ANTENNA PATTERN OF THE GROUND STATION ............ 4-3
FIGURE 4-6 DITCH DIGGER AND VIDEO SWITCH .... . ................................ 4-6
FIGURE 4-10 DITCH DIGGER AND VIDEO SWITCH WAVEFORMS .............................. 4-14
FIGURE 5-2 KT 76A/78A TROUBLESHOOTING FLOWCHART (S/N < 110,000) ........ 5-13
FIGURE 6-3 KT 76A/78A FINAL ASSEMBLY (S/N < 110,000) .......................................... 6-17
FIGURE 6-4 KT 76A/78A FACE PLATE ASSEMBLY (S/N 2 110,000) ............................ 6-27
FIGURE 6-5 KT 76A/78A FACE PLATE ASSEMBLY (S/N <110,000) .............................. 6-29
FIGURE 6-6 KT 76A/78A FACE PLATE ASSEMBLY (S/N <110,000) ............................... 6-35
FIGURE 6-9 KT 76A/78A MAIN BOARD SCHEMATIC (S/N 2 120,800) ....................... 6-71
FIGURE 6-10 KT 76A/78A MAIN BOARD SCHEMATIC (S/N 2 110,000) ........................ 6-87
FIGURE 6-11 KT76A MAIN BOARD (S/N 40,000 - 109,999) ............ 6-125
FIGURE 6-12 KT 76A MAIN BOARD SCHEMATIC (S/N 40,000 - 109,999) ................ 6-129
FIGURE 6-13 MAIN BOARD KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 -) .. 6-131
FIGURE 6-17 MAIN BOARD KT 76A (S/N 0 - 5899), KT 78A (S/N 0 - 2599) ............ 6-153
FIGURE 6-24 KT 76A CHASSIS ASSY (S/N arf 20,800) ................................ 6-185
FIGURE 6-27 KT 76A PRESELECTOR ASSY (S/N < 110,000) ........................................ 6-205
FIGURE 6-30 KT 76A FINAL ASSEMBLY RFI MOD FILTER ............................................ 6-235
TROUBLESHOOTING AIDS
SECTION IV
THEORY OF OPERATION
4.1 INTRODUCTION
General description oí the KT 76A/78A Transponder and its use in the Air Traffic Control Radar
Beacon System:
The KT 76A/78A Transponder is an integral part of the Air Traffic Control Radar Beacon System
(ATCRBS). In the aircraft, its function is to transmit a coded response to a coded interrogation
transmitteó by an air traffic control ground radar station.
There are two types of radar at each of these ATC ground statiohs. The first, calleó the Primary
Surveillance Radar (PSR), operates on the normal radar principie of receiving energy reflected
from the aircraft under surveillance. The second, calleó the Secondary Surveillance Radar (SSR),
operates on the coded reply from the airborne transponder. Both radars are used in conjunction
to develop the total air traffic situation and to display it on a single radar scope. A typical air traffic
control ground station is shown iri Figure 4-1.
The SSR interrogates the KT 76A/78A ¡n one of two modes. These are referred to as Mode “A”
or Mode “C” interrogations. The type of interrogation is determinad by the spacing between two
pulses transmitted by the SSR on a carrier of 1030 ± 2 MHz. Each interrogation contains a third
pulse at the same frequency which is not transmitted by the SSR but by an omni directional
antenna which is located at the ground radar station. This pulse is transmitted 2 ixsec after the
first pulsetransmitted by the SSR. Mode “A” and Mode “C” interrogation characteristics are shown
in Figure 4-2.
Pl P2 FROM P3
OMNI ANT.
MODE C
I5ps Ips
2l — .2ps
The purpose of P2, the signal from the omni-directional antenna, is to allow the airborne
transponder to determine whether the interrogation carne from the main beam or a si de lobe of
the SSR. If the KT 76A/78A has been interrogated by a side lobe, no reply is generated. A reply
to a side lobe interrogation would give the ground radar operator an erroneous position reading
of the aircraft carrying the transponder. The KT 76A/78A determines by an amplitude comparison
between P1 and P2, if the interrogation is a valid main beam interrogation: If P2 is equal to or larger
then P1, the interrogation is from the side lobe of the SSR. The reason these conditions exist can
be explained with the composite antenna pattern of the ground station as shown in Figure 4-3.
It is seen that the power received from the omni directional antenna is less than the power received
from the main beam but larger than the power received from any of the side lobes of the SSR.
This is why in a main beam interrogation, P1 is larger than P2; and in a side lobe interrogation,
P2 is equal to or larger than P1. The detailed specifications of transponder reply and side lobe
suppression characteristics for the ATCRBS are shown in Figure 4-4.
REPLY
The KT 76A/78A Transponder replies to both the Mode “A” and Mode “C” interrogations with a
coded pulse group on a carrier of 1090 ± 3 MHz. In a Mode “A” reply, the coding of the pulsed
waveform represents an identification number of the plañe carrying the transponder. The
Identification number which will be transmitted is inserted in the transponder by means of the code
switches. This number consists of four octal digits (0-7) which gives the transponder the capability
of 4096 different identification numbers. The coding of a Mode “A” reply can consist of up to fifteen
pulses. Tweive óf these pulses carry the identification number. Two others, called the framing
pulses, come before and after the tweive Information pulses. The last is a special identification
pulse to aid the radar operator. The control head identification numbers and the reply coding
characteristics for the full 15 reply pulses are shown in Figure 4-5.
A B C D
7 7 7 7
FIGURE 4-5A CONTROL HEAD IDENTIFICATION NUMBERS
A Al A2 A4
0 0 0 0
I I 0 0
2 0 I 0
3 I I 0
4 0 0 I
5 I 0 I
6 0 I I
7 I I I
C! Al C2 A2 C4 A4 X Bl DI B2 D2 : B4 D4 F2
~I
L J
The block diagram shows the interconnections of the functional parts of the KT 7W7QK. The
block diagram, as well as the schematics for each section, are located in the back of this manual
and may be folded out and used with the following without flipping pages back and forth.
4.2.1 RF SECTION
Interrogation pulses from the SSR are received at the transponder and are directed through the
Low Pass Filter and Duplexer to the 1030 MHz Bandpass Filter and Mixer. Here, it is mixed with
the Local Oscillator (LO) output and inserted in the IF amplifier. The LO frequency is mixed with
the 1030 MHz received signal, gives an IF frequency of 60 MHz. (70 MHz for serial numbers a
110,000).
4.2.2 IF AMPLIFIER
The IF Amplifier takes a signal input over a dynamic range of 50 dB and compresses the video
output to a dynamic range of 15 dB. This is accomplished by successive detection of the amplified
IF signal. A second input to the IF Amplifier is the output from the Automatic Overload Control
(AOC). This input line reduces the gain of the IF in an overload condition, so that only a specific
portion of the interrogations received causes a reply.
The detected video output from the IF is amplified in the Video Amplifier.
The Noise Suppression Circuit rejects any pulse with a width less than 0.3 seconds. This Circuit
is located inside the LSI for serial numbers a 110,000.
The Ditch Digger and Video Switch circuits function together in comparing the amplitude of P1 and
P2. As explained in 4.1, this is to determine if the interrogation is from the main beam of the radar
or a side lobe. The Ditch Digger produces a linearly rising voltage behind P1 into which P2 falls.
The characteristics of the ditch are such that if P2 > P1 then the Video Switch is triggered by P2,
but if P2 operation of these circuits.
P2<PI
DITCH DITCH
DIGGER DIGGER
0 I- I-
O 0
VIDEO Pl P3 VIDEO P3
SWITCH SWITCH
OUT I- OUT j—
O
(A) CONDITION FOR REPLY (MAIN BEAM) (B) CONDITION FOR'NO REPLY (SIDE LOBE)
For serial numbers & 110,000, P1 is sampled with an analog switch and compared with P2 directly.
The output of the Video Switch is a narrow pulse of about 150 us. The output of the one-shot is
a pulse of about 1 sec for input to the LSI chip. (For serial numbers less than 110,000 only).
The King Transponder LSI chip performs many of the logic and timing functions of the unit. These
inelude the following:
1. The decoding of P1 to P3 spacing for either a Mode “A” (8 us) or Mode “C” (21 usec) reply.
2. Suppression of reply if P2 is present.
3. The encoding of the serial pulse train output for either mode.
4. Insertion of the SPI or ident pulse in the serial output. When the Ident button is pushed, the
Ident pulse is included in all replies for an internally timed period of 23 seconds.
5. When power is first applied, all replies are suppressed for a period of 47 seconds. This
turn-on delay also occurs whenever power is interrupted for more than 5 us.
6. The annunciate output drives the REPLY light. This output goes high for 760 ms whenever
the transponder sends a reply. Additionally, it goes high continuously for the 23 second
period following a low on the Ident input.
7. Mode “C” replies consist of framing pulses only when ALT EÑ is high.
8. When the SiBY pin is low, the chip ignores the serial input line.
4.2.8 CLOCK
The LSI chip timing is derived from a 22.069 MHz. crystal oscillator. This frequeney is divided by
eight to provide a two phase dock at 2.75862 MHz. This divider is reset following an interrogation
to synchronize the reply with the interrogation. For serial numbers a 110,000, the 48 MHz. LO
drives the LSI.
The externa! suppressioh oütput of the LSI chip is a pulse which is output during each reply. These
pulses are averaged and used tosense an overload condition. The receiver is desensitized to limit
the reply rate to approximately 1200 replies per second.
This Circuit switches the reply lamp on and off for each time the ANNUNCIATE line from the LSI
chip goes high. A cockpit light level sensor automatically dims the reply lamp for lower cockpit
lighting levels. Additionally, placing the function switch in the TEST position turns on the REPLY
light.
The modulator takes the coded serial data and switches the transmitter cavity on and off
accordingly. The oscillator RF output passes through the low-pass filter to the antenna where the
power is radiated. The purpose of the low pass filter is to attenuate higher harmonios of the 1090
MHz transmission.
4.3.1 RF SECTION
The complete radio frequency section of the KT 76A/78A is incorporated in a die-cast chassis
assembly. The functions the assembly accomplishes are:
970MHz-
« LOCAL OSCILLATOR
INPUT
L205A
97 0MHz
3ANDPASS
FILTER L205B
MIXER DIODE
L2O5C
L2O5D
1030MHz
BANDPASS
FILTER L2O5E
TRANSMITTER
INPUT
1090MHz
The harmonios of the transmitter output are filtered by means of the 1030 MHz low-pass filter. The
characteristics of this filter are such that the second harmonio of the transmitter frequency (2180
MHz) is attenuated by more than 45 dB. Isolation between the transmitter output and the mixer
diode, as well as receiver front end is accomplished by a 1030 MHz Bandpass Filter. This filter
passes the received signal of 1030 MHz from the antenna to the mixer diode, but greatly
attenuates the transmitter frequency of 1090 MHz. The filter characteristics are shown in
Figure 4.9.
The local osciilator output is filtered by a 970 MHz Bandpass Filter. This filter is used to sepárate
the Local Osciilator (LO) frequency from other harmonios of the frequency multiplier input (LO).
The filtered LO injection and the 1030 MHz signal from the bandpass filter are mixed by CR202,
after passing through appropriate matching networks. The mixed difference frequency is passed
on to the IF while the remaining components are by-passed to ground by C210.
The local osciilator consists of a 138.5714 MHz crystal controlled Cplpitts Osciilator and a X7
varactor multiplication Circuit. The 138.5714 MHz osciilator is in a grounded base configuration.
Frequency control is accomplished by using a crystal (Y201) as a series tuned Circuit in the
emitter-to-collector feedback loop. This accomplishes the desired frequency stability. R201, R202
and R203 are the de biasing elements of Q201. AC isolation of the osciilator from the 9.0 V supply
is accomplished by the low-pass filter C204, L205 and 0201.
Q202 and its associated circuitry function as a buffer amplifier which ¡solates the varactor diode
multiplier from the 138 MHz osciilator stage. The 138.5714 MHz energy coupled from the buffer
is applied to varactor diode CR201. The varactor diode is self-biased by currentflow through R208
during a small portion of the negative swing of each RF eyele. A 2.2 pf capacitor and the inductor
wound on its lead (FL201) series resonate at 970 MHz and allow only the 970 MHz RF component
to be coupled to the bandpass filter.
4.3.3 IF AMPLIFIER
The IF Amplifier in the KT 76A/78A Transponder consists of four stages of amplification. The last
three stages also provide detected video output. all four stages are synchronously tuned and
produce a 5 MHz bandpass characteristic.
L402 and R409 at the IF input form a ground return for.the DC mixer diode current. Inductor L402
functions as a radio frequency choké to découple R409 from the 60 MHz IF input.
The AOC line provides base bias for the first stage and is filtered by C412, R406 and C413. Under
normal interrogation rates, the AOC voltage is at 1.8V. During an overload condition this voltage
decreases to reduce the gain of the first stage. The 9.0V supply lead is RF decoupled by a low-
pass filter consisting of C411, R410, C419, R416, 0424, R421 and 0429.
Filtering of the collector supply for the second stage is accomplished by a low-pass filter consisting
of R413 and 0422. R418 and 0427 provide filtering of the collector supply for the third stage and
R423 and 0432 for the last stage.
The IF input signal is coupled to the first stage by 0414. In the collector Circuit of the first stage
is a resonant tank Circuit consisting of the secondary of T402 and C418. Energy is taken from the
secondary of T402, to provide impedance matching, and coupled to the second stage by 0420.
Across the primary of T402 is a load resistor, R412. The function of this resistor is to lower the Q
of the resonant Circuit, widening the bandpass characteristics.
The collector circuits of the following three stages are identical to the first stage. In addition to
amplifying and providing selectivity, the last three stages detect the IF signal to obtain the video
output. The method of detection is called successive detectión. Overall IF gain is sufficient to
develop large signal and noise amplitudes in CR403, the first detector. The resulting output is
nearly linear and increases until Q407 saturates. The second video detector to contribute to the
output is the base emitter diode of Q407. This video output will increase until Q406 saturates.
At this point, the third detector, the base emitter diodé of Q406, begins to contribute to the detected
video. The fourth detector is the base emitter diode of Q405. The total output is compressed to
ápproximately 3db of video change for each 10db of RF change, over at least a 50db range from
MTL.
0421, 0426, L403, 0431, L404 and C434 accomplish interstage decoupling at the IF signal
frequency, but provide a common output line for the detected video signáis.
The Video Amplifier is used to amplify the video output from the IF amplifier. Power to the Video
Amplifier is obtained from the 14.0 V, 9.0 V, and -6.0 V supplies. The 14V is filtered by the low
pass filter consisting of R429 and C440.
A pulse on the output of the Video Amplifier is translated to TTL logic levels by Q411. When the
collector of Q411 goes low, 0448 discharges through R446. After this time delay, the I403 one-
shot is triggered. The negative-going pulse at I403 pin 1 is inverted by I404D. R437 couples the
output of the Video Amplifier to the ditch Circuit, but when I404 pin 8 is low, the one-shot pulse
therefore allows only the middle portion of the video through to the ditch Circuit, providing rejection
against narrow noise spikes.
The ditch digger and video switch waveforms are shown in Figure 4-10. When a positive video
pulse appears at the emitter of Q413, it chargeS 0438. This charging current flows through CR405
and causes a voltage drop across R436. The idle current through R436 is balanced out in 1201
by the drop across R463. Q412 functions as a constant current sourcé which charges C438 at
a linear rate. 1401 is a high speed differential comparator which translates the low level ditch output
to TTL logic levels.
I404E and I404F and the associated components function as a one-shot multi-vibrator to provide
a constant (nominally one microsecond) pulse at a 9 volt level for input to the LSI chip for decoding.
I 40I
OUTPUT
P2 < Pl
The External Suppression output (I405 pin 13) is applied to the Automatic Overload Control. Q414
is in the OFF State for low reply rates and the output voltage is approximately 3 volts.
The input Circuit integrales the number of replies/s by charging 0437 through R445 during a reply
and discharging 0437 through R444 during the time that the reply gate is low. As the number of
replies/s increases, the average voltage on the base of Q414 will finally reach the full ON State
decréasing the IF bias voltage.
As the bias voltage on the base of the first IF stage is lowered, the gaih of the IF is decreased.
The transponder sensitivity is subsequently lowered to the point that the number of detected
interrogations is limited.
The automatic dim Circuit Controls the amount of voltage on the reply lamp DS301. The light sensor
Controls the base voltage of Q301 and as the light intensity increases on the light sensor, the
voltage is increased at the base of Q301. The reply lamp glows brighter as the emitter voltage of
Q301 increases. A ground is supplied when either the test switch is activated or when Q403 is
turned on by the Annunciate output of the LSI chip.
4.3.9 MODULATOR
The Modulator one-shot (l402)is driven by the Serial Output, pin 3 of I405. The negative going
pulse at pin 3 of I402 triggers a pulse output whose width is determined by R472 and C453. The
Q and Q not outputs are used to drive the transistors Q417 and Q418 in push-pull to provide an
active drive for the modulator transistor, Q419.
The Cavity Oscillator employs a triode vacuum tube to generate the necessary RF Power. Two
manufacturers supply the cavity oscillator used in the KT 76A/78A.
Both the KT 76A/78A have a +1300 volt supply to opérate the RF cavity. The KT 76A has a
mínimum of 200 watts peak power output while the KT 78A has a mínimum of 113 watts peak power
output.
All units have a RF adjustment and require 6.3 volts on the filaments. The transmit frequency is
1090 MHz ±3 MHz.
The oscillator is modulated by Q419 on the cathode and the transmit pulse width is set at 0.45us.
The dock inputs, I405 pins 7 and 8, are the master timing for the transponder LSI chip. The P1
to P3 decodé spacing, as well as the output pulse repetition rate are governed solely by these
inputs.
Q421 and the adjacent circuitry is a single stage 22.069 MHz crystal oscillator. Y401 effectively
grounds the base at the series resonant frequency of the crystal while L406, C461 and C462
resonate on the third overtone.
I406 is a synchronous four stage counter. It is used in this application in a resettable divide-
by-eight mode. This results in a dock frequency of 2.758625 MHz for the LSI chip. Following a
valid decoding of an interrogation, the counter is reset by Q422. This synchronizes the
transponder reply with the asynchronous ground interrogation.
The LSI chip needs a two.phase dock at a nine volt level. I404A, I404B and I404C provide this
inversión and level translation.
The +13.75VDC line voltage is applied to the 9.0 volt regulator through the filter L405, C464, C451
and C410. The Darlington pair, Q415, is'used to regúlate the 9.0 volt output. The zener diode
CR407 serves as a reference voltage (6.2 volts) while R460 adjusts the bias current into the base
of Q416 and in turn the 9.0 volt output. A regulated 5.0 volt output is provided with R458 and
CR414 from the 9.0 volt line.
The DC-DC Converter is pre-regulated by the 9.0 volt line. Power is supplied through the filter,
L401 and C409. The filter isolates the regulated 9.0 volt line from the converter frequency (4KHz
to 5KHz).
The -6.0 volt supply is half wave rectified from one side of the converter by CR415. R478 drops
the voltage from -9.0 volts to -6.2 volts and C449 provides filtering. Transformer T401 has three
windings. Primary power is supplied from the collectors of Q401 and Q402 while the feedback
winding provides the proper voltage and phase to the bases of Q401 and Q402 to sustain
oscillation. The secondary is a single winding, providing 650 volts to the half wave voltage doubler
CR401 and CR402. C401, C402 and C403 provide filtering and voltage doubling while R401
discharges the capacitors by leakage when the converter is turned off.
The power supply is shown on page 1 of the schematic. Q2 switches the AC power on when the
gate is grounded. U23 is a linear regulator which provides 6 volts to the tube heater and also power
some of the RF circuits. U6 is a linear regulator which provides 5 volts to the digital circuits. The
-6 volts is generated by rectifying the 20 kHz signal from the input side of the high voltage
transformer. CR2 is to keep the -6 Volts supply from going positive under fault conditions. Sheet
2 of the schematic shows the high voltage section of the power supply. The Aircraft power is 1 st
preregulated to 9V. This 9V is also used for Receiver circuits after RC filtering. U12-B is a 40 kHz
oscillator which is divided by 2 to produce a 50% duty cycle 20 kHz. Q1 and Q3 drive the
transformer primary in push pulí fashion. The high voltage produced is voltage doubled with C43,
C44, CR7, CR8 and filtered with C45. The resistor ladder network acts as a bleeder load and
also divides down the 1300 volts to compare to a voltage reference. U13 amplifies any error and
applies feedback to the 9V regulator. U6 is a linear regulator that provides +5V for the digital
circuits.
The Local Oscillator is shown on page 3 of the schematic. The 48 MHz oscillator consists of Y1
and Q4. Q5 buffers the signal which is feed to the ASIC. The 48 MHz is squared up with U15-A.
U17-A provides the proper DC bias to the input of U15. The 48 MHz square wave which is rich
in harmonios is feed into a 240 MHz filter to select the 5th harmonio. This signal is amplified U19
and 4th harmonio is selected by filter.FL2. The 960 Mhz signal is amplified to approximately -10
dbm by U22.
4.4.3. RFANDIF
The RF and IF amps are shown on page 4 of the schematic. FL1 is the 1030 MHz preselector.
U20 is the RF amp and supplies approximately 17 db of gain. The signal is goes through an 8 db
pad before being presented to the mixer U21 where it is combined with the 960 MHz LO.. The
output of the mixer is 70 MHz. The signal is filíe red with an LC network before presented to the
IF amplifier. The 5 transistor IF amplifier both amplifies and detects the IF signal. The detected
signal is logarithmic in nature. It is amplified by the video amp cpnsisting of Q18 and Q17. Q14
and Q15 provide the correct bias for the video amp so that the output.of the amplifier is cióse to
ground potential under no-signal conditions.
The output of the video amp is detected with circuits on page 5 of the schematic. Comparator
U14-A switches when the video signal is above approximately .3 volts. U12-D and Q10 increase
this switching threshold voltage if the transmitter is replying at a level exceeding 1400 replies per
second. The height of P2 is compared to height of P1 using a sample and hold Circuit consisting
of switch U16, hold capacitor C93 and comparator U14-B. If the height of P2 is 9 db below P1,
The output of U14-B will be low during P2. If P2 is equal to P1 the U14-B will be high during P2.
The transponder must not reply if P2 is equal to P1.
4.4.5. ASIC
The ASIC contains the digital logic to generate a reply based on the input pulses supplied by the
U14 dual comparator. It makes sure the pulses aré of the proper with and spacing for a legal mode
A or mode C transponder. It takes in parallel altitude lines and front panel switch information. The
4 digit switch code is used for a Mode A reply and the altitude lines are used for mode C. The ASIC
logic is a CMOS ram design and therefore must be loaded on power up by serial EPROM U5. The
ASIC will not load until comparator U4 indicates that the power supply is stable. Q9 supplies the
drive to the cathode of the tube.
The lines listed below are the major ¡nputs, outputs and test outputs of the ASIO.
ASIO Inputs
ASIO Outputs
The altitude and suppression inputs are buffered by comparators on page 7. The high input
impedance offers protection and limits the amount of EMI which can be passed to the outside of
the box. Diode decoupling is used so that the pullups inside the transponder will not be seen by
other aircraft equipment. The external suppression is ACcoupled so that a DC fault condition will
not prevent the Transponder from replying. The switching leve! of the inputs is approximateíy 5
volts.
SECTION V
MAINTENANCE
5.1 GENERAL
Before maintenance of the KT 76A/78A is attempted, a thorough understanding of the Theory of
Operation (Section IV) as well as the Information of semiconductor maintenance is needed. This
material is found in Appendix A. Detailed Information on the various integrated Circuit packages
is also found in this reference.
A. Power Supply
2) Adjust R460 so that 9.0 ±0.1 volts de is obtained at the emitter of Q415.
B. Local Oscillator
NOTE
It oscillator drifts make sure that Y201 is secured to
073-00169-0003 casting.
3) Peak the diode voltage by alternately peaking the coil of FL201, L204, L203 and
L202 to obtain the máximum voltage.
4) Peak L201 by stretching it slowly. Take the highest voltage reached before the
oscillator died (should be between .18 and .33 volts) and subtract .03 volts.
Compress L201 until that voltage is obtained. The final voltage should be between
.15 and .30 volts.
2) Connect the scope probe to TP404. Set the RF level to approximately -50 dBm and
the generator frequency to 1030.0 MHz.
3) Turn L205D CW until it bottoms on the back of the casting. When it bottoms, use a
mínimum of torque to prevent damage to the casting.
4) Observe the pulse peak, P1, at a scope sensitivity of 0.1 volts/cm (including the
scope probe).
6) Turn L205D CCW and use the scope POSITION control to follow the peak of pulse
P1. Tune L205D for a máximum pulse height.
7) After alignment is complete, check the L.O. drive level as outlined in B above.
D. I.F. Alignment
1) Set the RF level to-50 dBm and monitor TP404 with oscilloscope. Set the
interrogation rate to 500/sec.
2) Tune T402, T403, T404 and T405 for máximum video output at TP404.
3) Reduce the RF level to -75 dBm and again tune T402, T403, T404 and T405 for
máximum video output at TP404.
E. Transmitter Adiustments
1) Set the interrogation rate to 500 per second and the transponder code to 0000.
2) Adjust the RF coupling for máximum peak power. Decouple the RF by 10% of this
máximum reading by rotating the RF coupling adjustment CCW.
3) Pulí the line stretcher and note the máximum and mínimum frequency deviation. Set
the HP 8905 wave meter to center of the frequency deviation and pulí the line
stretcher until a peak indication is reached. Without moving thé line stretcher, adjust
the transmit oscillator frequency trim for a 1090 MHz reading. Recheck the
frequency deviation by pulling the line stretcher to see that it is centered about
1090.0 MHz. Check to see that the collector voltage of Q419 does not exceed 140
volts as the line stretcher is pulled (Q9 for serial numbers a 110,000).
4) Adjust R472 so that the first framing pulse is .45 ± .05|is wide (serial numbers <
110,000 only.
2) Set RF amplitude to -20 dbm. Using the gain adjust pot, R165, adjust height of P1
to 4.25 ±.1 volts.
3) Adjust MTL pot, R132 so that the reply rate on the Test Set XPDR Reply % reads
90% ± 3%.
B. Transmitter Adjustments
1) Using the transmitter tube coupling nut and frequency adjust screw, adjust the
transmitter for peak power and a frequency of 1091 ± 1 MHz.
NOTE
If Circulator is INSTALLED, skip step 2. If Circulator is not
INSTALLED, skip step 3.
2) Turn the coupliñg nut counter-clóckwise until one of the following conditions occurs:
NOTE
Decoupling the tube will decrease frequency "pulling” at installation
time.
3) Decrease unit peak power from 1 to 5 percent by turning the coupliñg nut
counter-clockwise.
4) Adjust the Frequency nut to bring back the frequency to 1090.75 ± .1 MHz. Verify
that rise time is between 50 and 100 ns, power is greater than 200 watts, and pulse
width is 450ns ± 70ns. If not, repeat the last two steps until all conditions are met.
5) Connect the unit under test to a line stretcher with a 1.2:1 SWR load. Adjust the
line stretcher through all phase angles and verify the transmitter frequency is not
less than 1087.5 MHz and not more the 1091 Mhz.
5.2.3.1 PURPOSE
The following specifications are the mínimum performance standards which all KT 76A/78A
Transponders must meet.
Ambient room temperature and pressure. Specifications are to be met after a 15 minute warm-up.
The turn on delay shall be less than 60 seconds and the ¡dent time shall be between 15 seconds
and 30 seconds.
The receiver shall reply to 90% of all interrogations at an interrogation signal of between -72 dBm
and -79 dBm. This specification applies to both Mode “A” and Mode “C” interrogations.
The transponder shall reply to greater than 90% of all interrogations from MTL (mínimum trigger
leyel) to -20 dBm.
The transponder shall not reply with greater than a 10% reply efficiency, to any interrogations
whose pulse spacing is greater that ± 1 |is from 8 or 21 ¡as.
The transponder shall not reply to mofe than 1 % of the interrogations when P2 is equal to or greater
than P1 and spaced 2.0 ± 0.15jas from P1. This standard applies from MTL +3 dB to -20 dBm.
The mínimum peak power of the transmitted reply pulses shall be 200 watts for the KT 76A and
114 watts for the KT 78A. This test is perfprmed at a reply rate of 500/sec of code 0000.
The frequency of the reply shall be 1090 ± 3 MHz. With a line stretcher and a 1.2:1 VSWR load
pulling shall be less than 4 MHz total.
The transponder shall provide 4096 codes of reply in Mode “A”. It shall also provide the SPI pulse,
in a Mode “A” reply when the ident feature is initiated. There will be ten (10) pulses available for
Mode UC” operation. These pulses are A1, A2, A4, B1, B2, B4, C1, C2, C4, D4. A ground on each
of the Mode “O” input pins shall cause the córréspondirig pulse to be present in a Mode “C” reply.
The relative spacing of the reply is as follows.
The pulse spacing of any Information pulse must not differ from these spacings by more than ±
0.1 us. The pulse spacing tolerance of any pulse in the reply group with respect to any other pulse
(except the first framing pulse) must be no more than ± 0.15us.
The output pulse width shall be set to .45 ± .07 ps measured at the 50% voltage points on the
detected video of the transmitter reply.
The reply lamp shall be illuminated when the unit replies to an interrogation. The intensity of the
reply lamp shall vary with the ambient light incident upon V301. The reply lamp shall be illuminated
during the period the IDENT pulse is present in Mode “A” replies.
5.2.4.12 FUNCTIONS
The transponder shall not reply when the function switch is in the SBY position. Modé “O” replies
shall consist only offraming pulses when thefunction switch is in the ON position. Mode “A” and/or
Mode “C” data shall be transmitted when the function switch is in the ALT position. The REPLY
light shall be illuminated when the function switch is in the TST position.
With 14 V de applied to pin 2 and ground on pin 3, both panel lamps (DS302 and DS303) shall
be illuminated.
1. Power Supply (+9 ± 0.1; +5 ± 0.25; -6.2 +0.5; -1.3; 1325 ±100) ( )
A ( ) ( )
C ( ) ( )
MTL +3 dB
-60 ______
-50 ______
-40 ______
-30 ______
-20 ______
(KT78A: 113WMin)
9. Reply Spacing ( )
Mode“C”Code ( )
5.3 OVERHAUL
5.3.1 INSPECTION
This section contains instructions to assist in determining by inspection the condition of the KT
76A/78A. Defects resulting from wear, physical damage, deterioration, or other causes can be
found by these inspection procedures. To aid inspection, detailed procedures are arranged in
alphabetical order.
A. Capacitors, Fixed
Inspect capacitors for case damage, body damage, and cracked, broken, or charred
insulation. Check for loose, broken, or corroded terminal studs, lugs, or leads. Inspect for
loose, broken, or improperly soldered connections. On chip caps be especially alert for
hairline cracks in the body and broken terminations.
B. Capacitors, Variable
Inspect trimmers for chipped and cracked bodies, damaged dielectrics and damaged
contacts.
C. Chassis
Inspect the chassis for deformation, dents, punctures, badly worn surfaces, damaged
connectors, damaged fastener devices, loose or missing hardware, component corrosión,
and damage to the finish.
D. Connectors
Inspect connectors for broken parts, and other irregularities. Inspect for cracked or broken
insulation and for contacts that are broken, deformed, or out of alignment. Also, check for
corroded or damaged plating on contacts and for loose, improperly soldered, broken, or
corroded terminal connections.
E. Covers and Shields
Inspect covers and shields for punctures, deep dents, and badly worn surfaces. Also, check
for damaged fastener devices, corrosión and damage to finish.
F. FlexCircuits
Inspect flex circuits for punctures, and badly worn surfaces. Check for broken traces,
especially near the solder contact points.
G. Fuse
Inspect for blown fuse and check for loose solder joints.
H. Insulators
Inspect insulators for evidence of damage, such as broken or chipped edges, burned areas,
and presence of foreign matter.
I. Jacks
Inspect all jacks for corrosión, rust, deformations, íoose or broken parís, cracked insulation,
bad contacts, or other irregularities.
J. Potentiometers
Inspect all potentiometers for evidence of damage or Ioose termináis, cracked insulation or
other irregularities.
K. Resistors, Fixed
Inspect fixed resistors for cracked, broken, blistered, or charred bodies and Ioose, broken,
or improperly soldered connections. On chip resistors be especially alert for hairline cracks
in the body and broken terminations.
L. RF Coils
Inspect all RF coils for broken leads, Ioose mountings, and Ioose, improperly soldered, or
broken terminal connections. Checkfor crushed, scratched, cut or charred windings. Inspect
the windings, leads, termináis and connections for corrosión or physical damage. Check for
physical damage to forms and tuning slug adjustment screws.
M. Terminal Connections soldered
1. Inspect for cold-soldered or resin joints. These joints present a porous or dull, rough
appearance. Check for strength of bond using the points of a tool.
2. Examine the termináis for excess solder, protrusions from the joint, pieces adhering
to adjacent insulation, and particles lodged between joints, conductora, or other
components.
3. Inspect for insufficient solder and unsoldered strands of wire protruding from
conductor at the terminal. Check for insulation that is stripped back too far from the
terminal.
4. Inspect for corrosión at the terminal.
N. Transformers
1. Inspect for signs of excessive heating, physical damage to case, cracked or broken
insulation, and other abnormal conditions.
2. Inspect for corroded, poorly soldered, or Ioose connecting leads or termináis.
O. Wiring/Coaxial Cable
Inspect wiring in chassis for breaks in insulation, conductor breaks, cut or broken lacing and
improper dress in relation to adjacent wiring or chassis.
5.3.2 CLEÁNING
A. Using a clean, lint-free cloth lightly moistened with soao and water only, remove the foreign
matter from the equipment case and unit front panel. Wipe dry using a clean, dry, lint-free
cloth.
B. Using a hand controlled dry air jet (not more than 15 psi), blow the dust from inaccessible
areas. Care should be taken to prevent damage by the air blast.
C. Olean the receptacles and plugs with a hand controlled dry air jet (not more than 25 psi), and
a deán, lint-free cloth lightly moistened with soap and water only, Wipe dry with a olean, dry,
lint-free cloth.
5.3.3 REPAIR
This section describes the procedure along with any special techniques for replacing damaged
or detective components.
A. Connectors
When replacing a connector, refer to the appropriate PC board assembly drawing and follow
the notes to insure corred mounting and mating of each connector.
B. Crystal
Diodes used are Silicon and germanium. Use long nose pliers as a heat sink under normal
soldering conditions. Note the diode polarity before removal.
D. Integrated Circuits
When repairing a wire that has broken from it’s terminal,, remóve all oíd solder and pieces of
wire from the terminal, restrip the wire to the necessary length and resolder thé wire to the
terminal. Replace a damaged wire or coax with one of the same type, size and length.
The unit is disassembled for maintenance and testing purposes by removing the four fíat head
screws on each side that fasten the chassis to the side rails. The faceplate can be removed by
removing the four black fíat screws that fasten it to the side rails.
5.4 TROUBLESHOOTING
This sedion is intended for use as a guide in isolating Circuit malfunctions. The guidance
presentad here and the figures referenced by no means profess to inelude all possible causes of
failure, but are presentad as a guideline to be used in iocating the approximate section of the unit
that has failed. Figure 5-2 is the KT 76A/78A Troubleshooting Flow Chart and is arranged in a
manner that will expedite finding the area of failure. Following are the waveforms that should be
found at various test points in the KT 76A/78A.
TRANSPONDER
NO
FIGURE 5-4 KT 76A/78A ASIC Troubleshooting Flow Chart (S/N > 110,000)
Is I.24VDC YES
present at RIOS,
Check CR7.CR8,
and secondary of
TI
FIGURE 5-5 KT 76A/78A H. V. Power Supply Troubleshooting Flow Chart (S/N a 110,000)
¡ Check U6
and associated
circuitry
BENDIX/KING
KT 76A/78A
TRANSPONDER
I
i
i
KT76A Receiver tróubleshooting Flow Chart
it
t
Is a modulated
Is a 48MHz YES YES YES
Pl, P2 ,P3 signal Is the video signal
present at U21 pin 1 present at TP 5
with RF level set to
-20 dBm
NO NO
NO NO
SWPOS Al A2 A3
0 0 0 0
1 1 0 0
2 1 1 0
3 0 1 0
4 0 1 1
5 1 1 1
6 1 0 1
7 0 0 1
f ■ ■
FIGURE 5-8 KT 76A/78A Switch BoardTroubleshooting Flow Chart (S/N & 110,000)
NO NO
FIGURE 5-9 KT 76A/78A Transmitter Troubleshooting Flow Chart (S/N > 110,000)
RFMTL
CH 1, AC, TP404
dll
RF MTL +20 dB
CH 1, AC.TP404
CH 2, DC, I404 PIN 3
Hffl ' i.'Ad v\' Ch2'' 2.M' V" M I .WOhs' Ch i 7—¿TtfriW 9 oct 1M6
13:12:10
RF MTL +20 dB
CH 1, AC, TP404
CH 2, DC, I403 PIN 1
RFMTL +20 dB
CH 1, AC, TP404
CH 2, AC, Q413 EMITTER
RF MTL +20 dB
CH 1, DC, TP404
CH 2, DC, CR405 ANODE
P2 = P1 -9 dB
RF MTL +20 dB
CH 1, DC, TP404
CH 2, DC, CR405 ANODE
P2 = P1
RF MTL +20 dB
CH 1, DC, TP404
CH 2, DC, 1401 PIN 7
P2 = P1 -9 dB
RF MTL +20 dB
CH 1, DC, TP404
CH 2, DC, 1401 PIN 7
P2 = P1
RF MTL +20 dB
CH 1, DC, TP404
CH 2, DC, I404 PIN 12
P2 = P1 - 9 dB
RF MTL +20 dB
CH 1, DC.TP404
CH 1, DC, TP404
CH 2, DC, TP401
ID CODE 7777 .
CH 1, DC, TP404
CH 2, DC, I406 PIN 1
09:42:37
10:03:38
10:12:00
10:17:16
RF -20dBm
CH 1, DC.TP5
RF MTL
CH 1, DC, TP5
Takenaaas.ocs/g rr 309Acqs
CH 1, DC, U9 PIN 1
i-
I - ci Freq
¡ 1 S.003S4MIU
CH 1, AC, U9 PIN 10
RF -20dBm
CH 1, DC, TP 5
CH 2, AC, U21 PIN 1
RF MTL
CH 1, DC, TP 5
CH 2, AC, Q18 BASE
RF MTL
CH 1, DC.TP5
CH 2, AC, U16PIN6
RF MTL
CH1.DC, TP5
CH 2, AC, U16 PIN 9
RF MTL
CH 1, DC, TP 5
CH 2, DC, U14PIN10
RF MTL + 3dB
CH 1, DC.TP5
CH 2, AC, U14PIN 10
RF -30 dBm
CH 1, DC, Q8 BASE
CH 2, DC, Q7 COLLECTOR
500 prf
CH 1, AC, U1 PIN 4
CH 2, AC, U12PIN 10
C1 Freq
SOO.OOOO Hz
CRí uJ.O(TV'v ioTbmvx Mi.bbms Chi z ov
11:39:09
RFMTL
CH1.DC, TP5
CH 2, DC, TP4
RF MTL
CH 1,DC, TP5
CH 2, DC, TP3
CH 1, DC.TP5
CH 2, DC, TP1
CH 1, DC, TP5
CH 2, DC, TP1
ID CODE 7777
SPI ENABLED
11:51:29
CH 1, DC, TP5
CH 2, DC, U9 PIN 80
ID CODE 7777
SECTION VI
6.1 INTRODUCTION
The lllustrated Parts List (IPL) is a complete list of assemblies and parts required for the unit. The
IPL also provides for the proper Identification of replacement parts. Individual Bills of Material
(BOM) within this IPL are arranged in numerical sequence starting with the top assembly and
continuing with the sub-assemblies. All mechanical parts will be separated from the electrical
parts used on the sub-assembly. Each BOM is followed by the Assembly Drawing and Schematic
Diagram for that assembly.
Parts identified in this IPL by AlliedSignal Part Number meet design specifications for this
equipment and are the recommended replacement parts. Warranty Information concerning
AlliedSignal replacement parts is contained in Service Memo #1 ,P/N 600-08001 -00XX.
This section describes the various ítems that appear on the Bills of Material. A sample BOM is
included in this section as Figure 6-1.
A. BOM Number
The Bill of Material Number appears at the top of the BOM as a 9 or 12-digit number which
is also the AlliedSignal Part Number for the assembly. The BOM Number is followed by the
assembly description and the revisión level of the BOM.
B. Symbol Column
This column contains the Reference Designators of the electrical componente of the
assembly. Mechanical parts are not assigned Reference Designators. The Reference
Designator consists of a letter abbreviation which indicates the type of component followed
by the number assigned to that part (C101, Q101, etc). Common Reference Designator
abbreviations are listed below.
This column contains the AlliedSignal Part Number for each part. Special purpose
999-09999-00XX series part numbers may appear in the BOM and are described below.
The Reference Designator CR401 has been reserved for future use; the assembly
does not currently inelude a CR401.
CR401 is a part of the eléctrica! Circuit but due to assembly or testing requirements ¡s
actually part of a different assembly.
The Reference Designator CR401 is available for future assignment. The assembly
does not currently inelude a CR401.
The Reference Designator CR401 has been previously used for this assembly and
later deleted. It may not be reassigned on this assembly.
D. Description Column
This column coritains the description of each part in the assembly. Common abbreviations
which may appear in this column are listed below.
AL Aluminan MY Mylar
ASSY Assembly PC Polycarbonate
BIFLR Bifilar PF Precisión Film
BOM Bill of Material PP Paper
CAP Capacitor PS Polystrene
CC Carbón Composite QW Quarter Watt
CF Carbón Film RES Resistor
CH Choke S Silicon
CR Ceramic SCR Screw
CRT Cathode Ray Tube SM Silver Mica
DC Disc Ceramic STDF Standoff
DIO Diode SW Switch ■
EL Electrolytic TERM Terminal
EW Eighth Watt TN Tantalum
FC Fixed Composition TST PT Test Point
FERR Ferrite TW Tenth Watt
FLTR Filter U Integrated Circuit
FT Feedthru VA Variable
HV. High Voltage WW Wire Wound
HVXFMR High Voltage XFMR XFMR Transformer
HW Half Watt XSTR Transistor Ceramic
MC Monolithic XTAL Crystal
An ”A” ¡n this column indícales that the part indicated is an assembly. If the P/N and
description reads "200-0XXXX-0099 COMMON BÓM” or "200-XXXX-99 COMMON BOM"
the parís for that assembly are included in the same BOM. The parís breakdown for an
assembly with any other P/N will be found in the BOM with the same number.
This column indicates the Unit of Measure for each parí. Common abbreviations found in this
column are listed below.
Individual flavors of an assembly are identified by the last four digits of the P/N. Part
quantities for each flavor will be indicated under headings numbered 0000 through 9900 as
required. The parís indicated in the 9900 Column are common to all other flavors of the
assembly and are considerad the Common Bill of Material for the assembly.
H. Software Documentation
The documentation of software involves the use of severa) unique types of part numbers.
Thefollowing subsections listthese part numbers with their description. In some cases, some
specific versions of hardware must be used with specific versions of software. Refer to
Appendix S to determine the correct P/N for ordering the corred programmed device. You
will need to know the part number of and the software revisión level of the unit. Appendix
S contains block diagrams for documentad software/hardware configurations. The unit
designator and part numbers are listed in the top box. One level down from that is a box for
the 206-type system software BOM number and boxes for the BOM numbers for all other
hardware assemblies that do not contain any software. The next level are boxes containing
205-type BOM's for assemblies which use software under the system software box. Below
these top BOM boxes are two boxes. One box shows the hardware BOM number and the
other contains a list of Circuit designators and part numbers of individual integrated circuits
used on the Circuit board. The hardware/software configuration diagrams in Appendix S
provide a method to coordínate hardware with software versions and revisión levels.
The last two digits of all software related P/N’s, designated ih the following text as -RN,
indícate the revisión number or level of the related software. This number is incremented with
each revisión of software. For example, -01 is revisión 0, -02 is revisión 1, and so on. When
ordering specific integrated circuits or devices, the applicable 122-XXXXX-XXRN P/N is
used. When ordering a Circuit board which contains software, the applicable
205X-XXXX-XXRN P/N is used. Applicable assembly drawings and schematic diagrams
will then follow in order.
The part number of the unit, typically the 065-, 066- or 071 -top assembly part
number, contains a 206- Item in its bilí of materials. This 206- ítem is the
configuration control mechanism for programmable electronic devices of the unit.
Two different means exist to labél the hardware/software configuration of the unit
depending on the the part number of the unit:
(a) When the part number of the unit is a 9-digit part as representad on the TSO
label, the last 2 digits of the 206-item are the digits of the SOFTware
IDentifi catión tag that appears on the unit.
(b) When the part number of the unit is a 12-digit part as represented on the TSO
label, the last 4 digits of the 206- item are the digits of the SOFTware
MODification tag that appears on the unit. In the example shown on page 7,
the 206- item is flagged with an ”A” in the right hand margin.
The 206- item represénts the collection of all boards in the unit which contain
electronic programmable devices (software). The hardware/software system (206-)
bilí of materials contains two categories of Items:
(a) The part number of the unit label,i.e. the SOFT ID or SOFT MOD tag.
1) In the case of the 9-digit TSOed unit the unit label part number
057-03284-00XX where XX is the last two digits of the 206- number.
2) In the case of the 12-digit TSOed unit the unit label part number is
057-05287-YYYY where YYYY is the last four digits of the 206- number.
This number is also referred to as the software revisión level of the unit.
The software identification tag is illustrated below.
SW ID
01
(b) The 205- hardware/software board assemblies which constitute all the
hardware/software boards which this unit contains. In the example, the item
marked ”B” is the 205- hardware/software board used in the rest of the
example.
205-06616- |0000 |
(b) The software programmable device set assemblies (125-). Each 125-
programmable device set constitutes all the software for a unique
microprocessor on the hardware board. The group of 125- programmable
device sets constitutes all of the software for all Of the microprocessors.
(c) The non-software programmable device set assemblies (126-) which fulfill
software requirements.
In the example, the Ítems marked ”C” in the right margin are all the programmable
device assemblies which fulfill the software requirements.
The hardware board (200-) bilí of materials contains two categories of Items that
relate to programmable devices:
(a) The non-software programmable device sets (126s) that fulfill hardware
requirements. (Items D1 thru D4 in the example).
(b) The references to all of the programmable devices (122-) on to board. These
references resolve device location on the board in that they use the SYMBOL
field of the bilí of materials to specify component location. These 122-numbers
are of the form 122-3XXXX-9999 or 122-0YYYY-9999.
The 122- numbers of the form 122-3XXXX-9999 are used for non-software
programmable devices (126-) that fulfill hardware requirements and therefore these
programmable device sets appear on the hardware board (200-) bilí of materials.
(Items D5 thru D10 in the example).
The 122- numbers of the form 122-0YYYY-9999 are used for both software
programmable devices (125-) (Ítems D12 thru D15 in the example) andnon-software
programmable devices (126-)(item D11 inthe example) that fulfill software
requirements.
These programmable device sets appear on the hardware/software board (205-) bilí
of materials.
The exact programmable device (the resolution of the -9999 in the above Ítems) is
specified by the respective software programmable device set (125-) or the
non-software programmable device set (126-) bilí of materials.
Using the SYMBOL field as specified above would discourage the use of the
SYMBOL field for this purpose in the programmable device sets (125- and 126-) bilí
of materials. This would then permit the specification of the same programmable
device sets in different boards, henee different component designators.
- the Ítems flagged D1 thru D4 in the right margin are non-software programmable
device sets,
- the Ítems flagged D5 thru D10 in the right margin are non-software programmable
device designators that fulfill hardware requirements,
- the item flagged D11 in the right margin is a non-software programmable device
designator that fúifills software requirements,
- the Ítems flagged D12 thru D15 in the right margin are software programmable
device designators that fulfill software requirements,
Figure 6-1, while closely related tó a specific product, does not represent an exact
configuration in use by that product. This exárriple has been modified to clarify
certain points.
BOM NUMBER-^^^
l20S^8B3¿¿^000fi| HST67 I0P/DLP R> 2 MST0067A
DESCRIPTION
066-01062-0000 Rev. BA
066-01062-0001 Rev. 16
066-01062-0002 Rev. BA
066-01062-0010 Rev. AA
066-01062-0099 Rev. 6
SYMBOL EAS PART NBR DESCRIPTION [UOM] -0000 -0001 -0002 -0010 -0099
SYMBOL EAS PART NBR DESCRIPTION [UOM] -0000 -0001 -0002 -0010 -0099
BEÑO SWITCH ARM OF ITEM 1 AS NECESSARY TO FIT SNUGLY AGAINST PUSHBUTTON ITEM 3. "IDENT”
1— PUSHBUTTON MUST OPERATE SATISFACTORILY WHILE NOT BEING LOOSE. -OOOO AND -0002 REQUIRE FINAL
ARM HEIGHT ABOUT 0.47 1NCHES IREFI ABOVE SWITCH BOARD. WHILE -0010 REOUIRES 0.55 INCHES IREFI.
ORIENT FOUR NUMBER WHEELS OF ITEM 5 WITH ”0” IN WINDOW, SELECTOR AT "OFF”. SWITCH MECHANISMS
1—* OF ITEM 1 TO BE ORIENTED WITH NOTCHED FLAT SIDE OF SHAFT OPENING TOWARD TOP.
INSTALL COVER. ITEM 13 TO ITEM 1 BY MATING IT TO ITEM I APPROX1MATELY ONE INCH BACK
L— FROM INSTALLED LOCATION, PUSH DOWN TO MATE ANO SLIDE FORWARD AS FAR AS POSSIBLE
SO SCREWS, ITEM 14, CAN BE INSTALLED.
NOTES:
/í\ BEÑO SWITCH ARM OF ITEM 1 AS NECESSARY TO FIT SNUGLY AGAINST PUSHBUTTON ITEM 3. "IDENT"
—‘ PUSHBUTTON MUST OPERATE SATISFACTOR 1LY WHILE NOT BEING LOOSE. -OOOO AND -0002 REQUIRE FINAL
ARM HEIGHT ABOUT 0.47 1NCHES IREFI ABOVE SWITCH BOARD, WHILE -0010 REOUIRES 0.55 INCHES IREF1.
ORIENT FOUR NUMBER WHEELS OF ITEM 5 WITH "O" IN WINDOW, SELECTOR AT "OFF". SWITCH MECHAN 1SMS
1—1 OF ITEM 1 TO BE 0R1ENTED WITH NOTCHED FLAT SIDE OF 5HAFT 0PEN1NG TOWARD TOP. THIS DRAWING NOT COMPLETE W1THOUT PARTS LIST
ITEM 8 TO BE PLACED ON ITEM 7 IN P0SIT10N TO COMPLETE PART NUMBER AS SHOWN.
066-01062-0000, 066-01062-0002 OR 066-01062-0010
/5\ 1NSTALL COVER, ITEM 13 TO ITEM 1 BY MATING IT TO ITEM 1 APPROXIMATELY ONE INCH BACK
t—1 FROM INSTALLED L0CAT10N, PUSH DOWN TO MATE AND SLIDE FORWARD AS FAR AS POSSIBLE
300056670000R2S1
SO SCREWS. ITEM 14, CAN BE INSTALLED.
V)EW*B-r
SCALE NONE
XN'00
NOTES:
lSSiPI
LAMPS
066-1062-02
088-0136-05
LIGHT FILTER ON THIS
089-06366-0004 (4) LAMP USED ON 066-1062-01
OR ONLY (KT 78A)
089-06310-0004(4)
,Q$
NOTES:
088-0136-05
LIGHT FILTER ON THIS
LAMP USED ON 066-1062-01
ONLY (KT 78A)
q. % *'0?,
NOTES:
088-0136-05
LIGHT FILTER ON THIS
LAMP USED ON 066-1062-01
ONLY (KT 78A)
088-03114-0002
088-00279-0001
088-00279-0002
088-00383-0000
088-00279-0001 (SEE NOTE 41
0R1ENT PUSH-ON
AS SHOWN WHEN
INSTALEING ON
089-02322- 0001 KNOB SHAFTS.
USE TOOL NO. 1089
088-03114-0003
088-00655-0000 088-00690-0001
(SEE NOTE 3) 088-00280-0001 (USED ON -0002 ASSY ONEY)
089 -02322-0000 (5)
INSTALE WITH 047-02431-0011 A
TOOL 1088
078-00055-0000
047-03934-0000
NOTES:
1. ALL NUMBERED WHEELS SET WITH "O" IN WINDOW.
2. FUNCTION SELECTOR WHEEL SET AT OFF POS ITION.
3. ATTACH LENS (088-0655-0000) TO HOLE IN FRONT PANEL
USING SMALL AMOUNT OF ADHES1 VE (016-01131-00001.
4. PA1NT TABS PR0TRUD1NG THRU BACK OF FRONT PANEL
(088-03100-0005), WITH BRUSH1NG LACQUER
I O 16 - O 1039-0000 AFTER THIS PART IS INSTALLED
IN FRONT PLATE.
'b\ ASSEMBLER MAY BEÑO SPRING 078-00055-0000 IF
a NECESSARY TO ENSURE IT MOVES FREELY AND QUIETLY.
'EX ALIGN FILTER "VEE" WITH OPEN1NG ON OCTAGONAL 300020200010R2S1
WHEEL WHEN ÍNSTALEING.
088-03114-0003
088-03100-0005
TANG OVER FLAT SPR1NG
088-00690-0001
088-00280-0001 (USED ON -0002 ASSY ONLY) ARM ON LEFT SI DE
OF BOSS ON WHEEL
047-02431-0000
-078-00055-0000
300020200010R1S1
BENDIX/KING
KT 76A/78A
TRANSPONDER
088-03114-0002 (4)
088-00279-0001
088-00279-0002
088-00383-0000
088-00279-0001 (SEE NOTE 4)
ORIENT PUSH-ON
AS SHOWN WHEN
INSTALE iNG ON
089-02322-0001 (5) KNOB SHAFTS.
USE TOOL NO. 1089
088-03114-0003
088-03100-0002
TANG OVER FLAT SPR1 NG
088-00655-0000
(SEE NOTE 3)
088-00690-0001
088-00280-0001 (USED ON -0002 ASSY ONLY ) ARM ON LEFT 81 DE
089-02322-0000 (5) OF BOSS ON WHEEL
INSTALE W I TH
TOOL 1088 047-02431-0000
078-00055-0000
047-03934-0000 (2)
NOTES"
1. ALL NUMBERED WHEELS SET W1TH ”0" IN WINDOW.
2. FUNCTION SELECTOR WHEEL SET AT OFF POS 1TION.
3. ATTACH LENS (088-0655-0000) TO HOLE IN FRONT PANEL
US1NG SMALL AMOUNT OF ADHESI VE (O 16 - O 1 131 -0000) .
4. PAINT TABS PROTRUDING THRU BACK OF FRONT PANEL
(088-03100-0004), WITH BRUSH1NG LACQUER
(016-01039-0000 AFTER THIS PART IS INSTALLED 3Q0020200010R0S1
IN FRONT PLATE.
088-0692-02 (4)
088-0279-02
RIDGE
088-0279-02
088-0279-01
089-2322 -01(5)
88-0692-03(KT76A S KT76)
88-0692 -05(KT78A)
088-0383-00
(NOTE 5)
057-05700-000I (SEE NOTE 7)
088-0689-02 KT-76A
088-0380-06 KT-78A
088-0655-00 >-088-0689-04 KT-76
(SEE NOTE 4) 088-0690-Oí
088-0280-OI (USED ON-O2 ASS'Y ONLY)
088-0279-01
047-02431-0011 (SEE NOTE 6)
078-0055-00
NOTES:
1. NUMBERED WHEELS SET WITH "O" IN WINDOW. 089-2322-on/r.
ISSSíi K® ,,euRR
047-39s34-0o(9»
“* «ín
2. FUNCTION SELECTOR WHEEL SET AT OFF POSITION.
3. SEE BILL OF MATERIAL 200-02020-0000/0002.
4. ATTACH LENS TO HOLE IN BEZEL USING SMALL
AMOUNT OF ADHESIVE PER KING P/N 016-01131-0000.
5. PAINT TABS PROTRUDING THRU BACK OF FACEPLATE ORIENT PUSH-ON
AS SHOWN WHEN
WITH BRUSHING LACQUER 016-01039-0000 AFTER INSTALLING ON KNOB SHAFTS.
THIS PART IS INSTALLED IN FACEPLATE. USE TOOL NO. 1089
088-0692-02 (4)
088-0279-02
RIDGE
088-0279-02
088-0279-01
088-0383-00
(NOTE 5)
088-0689-02 KT-76A
088-0380-06 KT-78A
088-0655-00 -088-0689-04 KT-76
(SEE NOTE 4) 088-0690-01
■ 088-0280-01 (USED 0N-02 ASSY ONLY)
088-0279-01
047-2431-00 TANG OVER FLAT SPRINGS
notes: 078-0055-00
1. NUMBERED WHEELS SET WITH "O* IN WINDOW.
2. FUNCTION SELECTOR WHEEL SET AT OFF POSITION 047-3934-00(2)
3. SEE BILL OF MATERIAL 200-2020-00/02 089-2322-00(5) (BURR SIDE OUT)
4. ATTACH LENS TO HOLE IN BEZEL USING SMALL instale with TOOL
NUMBER 1088
AMOUNT OF ADHESIVE PER KING P/N 0I6-0II3I-000Q
5. PAINT TABS PROTRUDING THRU BACK OF FACEPLATE
WITH BRUSHING LACQUER 016-1039-00 AFTER THIS RART IS
INSTALLED IN FACEPLATE. ORIENT PUSH-ON
ARM ON LEFT SIDE OF AS SHOWN WHEN
BOSS ON WHEEL INSTALLING ON KNOB SHAFTS.
USE TOOL NO. 1089
088-0692-02 (4)
088-0279-02
RIDGE
088-0279-02
088-0279-01
088-0383-00
(NOTE 5)
088-0689-02 KT-76A
088-0380-06 KT-78A
088-0655-00 *-088-0689-04 KT-76
(SEE NOTE 4) [088-0690-0I
------- [088-0280-OI (USED 0N-02 ASSY ONLY)
088-0279-0I
047-2431-00 TANG OVER FLAT SPRINGS
notes: 078-0055-00
NOTES:
/l\ PRIOR TO POST COATINC 0OTH SIOES 0? P C. BOARD
El THRU E3. J1 THRU J4. TPI THRU TP5, AND ALL SüRFACES
WlTHlN THE FENCED AREA INCLUDING THE OUTSlOE
SÜRFACES OF THE FENCE (THE SEAM SOLOER SURFACE
OF THE FENCE MAY BE COATEO). THICKNESS 002‘- .004*.
@a : 0BB
Sss»0
UASKED OR ASSEMBLEO FOLLOWING POST COAT.
......... njyin——-
8 3fe: e
M /4\ APPLY RTV (ITEM 6) TO HOLO C43. C44. C45. CH7 TOGETHER
>@0: @ L
a
ANO TO FORM A 25" FILLET ON BOTH 80TT0M SIDES OF C45.
JdgSSB |
□9
U«
«239
r22‘ #0
R2Z” S 80 A ñ 1 RES R70 RTr gp gy? 6. PRINTED CIRCUIT ASSEMBLY IDENTIFICATION MUST BE IN
_x
RZZ3 U5 WILL BE INSTALLED WITH SOCKET (ITEM 7).
rZ2b I &H0 Biii @|se|g|rf®®t 9«
rZZS messBk ss&ss§
RZZ6
a . . nagas MTC9 @sea?ñfi .re,o _
r227
rZ3i
WB5H5ss
rZ30
rZZs pRirTTl„ sé... 0
a+.XZ 1------a 0Hg e
RZ32
^®é8é99ÍS8@ „Ennn @b§
®“
8® 22“ @ «_s <sf
gc^B 0g0|? uis 3 .OWSSg 9 0
R
E
n 8I?. ‘
.** XI
nPg&n « » s o-
r* aBHBH HB Hg
C_1 A
MI 12 I
“ “B~.b
9@ɧn6
BB
6
*S^S .|c7ñ>| a O
gfüBBes § u “° H B«O0e§
gt.9 Z
’ 8 g hIb SS QísgHwge^a
A 10 O CM A
la
I »
hhh
o o g
CD nn
oe o
ADD
*DJ DETAIL A
COM D
CNO
CN0 OUTPUT
TOP SlOE:
uu u
CR2. CR4-CR6 INPUT VCC RST VCC
TOP SlOE: CR9-CRI5»
CR17-CR19. CR24 TOP SlOE: TOP SIDE: TOP SIDE: TOP SIDE: TOP SIOE: TOP SlOE: TOP SIDE: TOP SIDE: TOP SlOE:
CR1. CR3, CRI6
CR2 1 CR26 04-05. 010-023 06. 024. Q27-O2B 09 026 U19-U20. U22 U26 01 .' 03
CR22, CR25 CR27
029
REWORK NOTE F. I. REMOVE J2 PlN-19 FROM MAIN 00ARO & Pt PIN-19 FROM SWITCH BOARD
2. RUN MAG WIRE FROM THE POS ITI VE SlOE OF C33 ( AS DESIGNATED BY ARROW) TO NOTES;
THE CONNECTOR P1 PIN-19 ON SWITCH BOARO. TACPAC AS REQUIRED
USE TACPAC 015-011<4-0000 ANO ACCELERATOR 016-01144-0001 AS NEEDED X\ PRIOR TO POST COATINC 90TH SiOES OF P.C, BOARD
REWORK NOTES;
INPUT VCC
TOP SIDE:
TOP SIDE: UI9-U20. U22
TOP SlOE. CR2. CR4-CR6 TOP SIDE: V OUT
CRI. CR3, CRI6 CR9-CRI5 TOP SIDE: 04-05. 07-08 TOP SlOE: TOP SlOE
CR17-CRI9. CR24 CR2I 010-022 06. 023 09 TOP SIDE:
CR20. CR22. CR25
CR26 UI8, U23
CUT PATH
NOTES:
HH 00 00 00 MTG
ALL TESTPOINTS AND REFERENCE DESIGNATORS:
3I5IH f ws PLATEO
WITHIN THE
THROUGH HOLES
FENCED AREA
FOR J2.
INCLUDING
Jl. AND
THE
ALL
OUTSIDE
SURFACES
-------- T3--------
54 33
T3b /2\ THE FOLLOWING AREAS ARE TO RECEIVE .004'-.008' OF
U9
/3\ SWITCH BOARD ASSEMBLY (ITEM 4) TO BE COMPLETELY
O /4\ APPLY RTV (ITEM 6) TO HOLD C43, C44. C45 TOGETHER AND
75 12 -------------MT-&5-------- -------- M+G6----------
________ / TO FORM A .25* FILLET ON 80TH BOTTOM SIDES OF C45.
R
MTG9
98 6. PRINTED CIRCUIT ASSEMBLY IDENTIFICATION MUST BE IN
ACCORDANCE WITH SPEC. 001-01101-0000.
CU6
I oí
RRR
o <j tt
— RR
a o
SCRAPE OFF POSITIVE SIGN INDICATOR ON PC BOARO.
TOP SIDE:
U6 (SEE REWORK NOTE A)
GND OUTPUT
COM
A N/C
nnn input vcc
TOP SIDE: POS NEG S D S
TOP SIDE: CR2, CR4-CR6 TOP SIDE: TOP SIDE:
CR9-CRI5 TOP SIDE: TOP SIDE: Q4-05, 07-08 TOP SIDE: U19-U20, U22
CR1. CR3, CR16
CR17-CR19, CR24 CR2I 01 . Q3 010-022 06. 023
CR2O, CR22, CR25
CR26
TOP SIDE: 300090700000R7S1
UI8. U23
□OÜÜO
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o □ □
□□□□□□□□□□□□oooaaaooo
□ O o o
o M o o o
□
DO o o o
°0 O O
o 00 □ □ □
o O o o
O
O □ □ □□
□ □
1 □
o O
o □ a□o D □ □ oo o□ □□ □ü
O 0000
o □
o □
DDDÜODODDDDDOODOOOODO
□
O O
□ 0000 □ □ □ □ □OOD □ o
o a □ □□ □ o □
o □ □ □ oo o O o
o o 0000
o □
o □ o □
□ □ o o
o
o
□o
□
□ □
□□ ODOQOOO °0°
o 0000000 □ □□
o □ □
□ □ □ □ 00DD00D
o ddddodd
□ □□
o
o
□ □
□□ □□ □ o
O O
o
o □ □□ □ □ 00000000 □
□
□
ODDO □ □□
0°
o o□ 0000
o
o □
D □
□ □
□ □ □ ° 00000000
o
□
□
□ Q
□ □
0°0
□ □
o □ □ o
o □ □ □ □ □ □ □
o □ o □ 2° □ □ □ O □ o □ □
o
o □
□ □
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□
□ □
on □
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□ □ □ □ □□ □ □□
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150-00004-0010 TUBING TFLN 22AWG [IN] 1.2 1.2 1.2 1..2 1.2
MEAT STAKE
NOTES:
FAR 1. ALL COMPONENTS TO BE MOUNTED AS GLOSE TO BOARD
SIDE AS P0SSI8LE . UNLESS OTHERWISE NOTED.
2. Q 415, SEE DETALL. .04 MIN. CLEARANCE BETWEEN TRANS.
LEAOS ANO BOARD SURFACE.
r. OMIT
B. OMIT
9. R458, R477, ANO R487, TO BB SPACED .05 MIN OFF BOARO
SURFACE, WITH R4S8 AND R4B7 BENT TOWARD TO THE
EOOE OF THE BOARD.
10. RM401 TO BE BEND OVER, AS SHOWN ON BOARO, MAX.
HE1GHT .200 INCKES ABOVE BOARD. RM402 1$ TO BEND
OVER TOWARD 1405. THE CLEARANCE BETWEEN U5 AND
RM4O2 SHOULD BE BETWEEN .1 TO .2 INCHES (SEE DETAtL "!")■
SEE DETAIL "G“ It. BEND C 450 ANO C 457 OVER RESISTORS AS SHOWN.
P/N 0I9-7042-0I
WIRING CHART
COLOR LENGTH
REO 1.75 IN.
REO 2.25 N.
BLK
BLU
BRN
1.50 IN.
ORN
GRN
GRY
NOTES:
FAR 1 ALL COMPONENTS TO BE MOUNTED AS GLOSE TO BOARD
S®£ AS POSSBLE . UNLESS OTHERWISE NOTED.
P/N 0I9-7042-0I
WIRING CKART
COLOR LENGTH
RED 1.75 IN.
RED 2.25 K
BLK
BLU
BRN
1 50 IN.
ORN
GRN
GRY
NOTES-
FAR 1. ALL COMPONENTS TO BE MOUNTED AS GLOSE TO BOARD
SIDE AS POSSIBLE . UNLESS OTHERWISE NOTED.
P/N 019-7042-01
WIRtNG CHART
COLOR LENGTH
REO 1 75 N.
RED 2.25 N.
BLK
BLU
8RN
1.50 IN.
CRN
GRN
GRY
FIGURE 6-13 Main Board KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 - )
(Dwg. No. 300-05824-0030 R-16)
NOTES-
TRANSFORMES T40I
P/N 019-7042-01
WIRING CHART
COLOR LENGTH
RED 1.75 ¡N.
RED 225 H
BLK
BLU
BRN
1.50 N.
ORN
GRN
GRY
W:.....
—'■'V— 047-5112-00
DETAIL V
FIGURE 6-13A Main Board KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 - )
(Dwg. No. 300-05824-0030 R-9)
NOTES:
TRANSFORMES T40I
P/N 0I9-7042-01
WIRING CHART
COLOR LENGTH
RED 1.75 IN.
RED 2.25 M
BLK
BLU
BRN
1 50 IN.
ORN
GRN
GRY
?coooooorL 5B„,
“***^ —047-5H2-00
DETAIL "G"
FIGURE 6-13B Main Board KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 - )
(Dwg. No. 300-05824-0030 R-3)
FIGURE 6-14 Main Board Schematic KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 - )
(Dwg. No. 002-00449-0030 R-12)
FIGURE 6-14A Main Board Schematic KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 - )
(Dwg. No. 002-00449-0030 R-8)
FIGURE 6-14B Main Board Schematic KT 76A (S/N 14,000 - 39,999), KT 78A (S/N 7000 - )
(Dwg. No. 002-00449-0030 R-3)
ME*T STAKE
3PLCS | _ _
T40I
A U «05
♦13.75 V 12
SWITCHED
_
9. R 458, R 477, AND R 487. TO BE SPACED05 MIN. OFF BOARO
SURFACE, WITH R 458 AND R 477 BENT TOWARD THE EDGE OF
THE BOARD.
10 RM 401 AND RM402 TOBE BENTUVER.AS WOWN ON BOARD.
090-0296-00(2)
MA3QMUM ®GHT ¿OONCMES ABOVE BOARD.
9-2076-30 —(rtasoi BEÑO C 450 ANO C 457 OVER RESISTORS AS SHOWN.
SEE NOTE 16
019-7042 -OI 12 C 410 MUST BE AT LEAST .700 WCHES FROM FRONT EDGE OF
091-0264-OO
BOARD,FOR SWITCH BOARO SHAFT CLEARANCE.
SEE NOTE B
13. J 401 TO BE SWAGED AND SOLDERED IN PLACE. ALSO SEE
DETAl-B-.
012-1124-02
I. F. FENCE 047-4084-01 SHOULD HAVE A CONTINUOOS SXDER
SEAM AROUND OUTER EDGE TO P.C. BOARO.
SEE NOTE 16 19. LEAVE FLUX INTACT ON ALL SOLDER CONNECTIONS ON SWITCH
BOARD (031-0175-00) DO NOT ALLOW SOLVENT TO COME IN
CONTACT WITH SWITCH BOARD. 00 NOT ATTEMPT TO CLEAN
____ CONTACT SURFACES OR ROTORS OF SWITCHES
TRANSFORMER T40I
P/N 019-7042-01
WIRING CHART
012-1124-01-' TRANSFORMES KIT 047-4084-01 009-5824-21 SEE NOTE 9 SEE NOTE 10 COLOR LENOTH
089 - 2075-30 050-1686-02
RED 1 75 M
(SEE NOTE 18)
089-8109-34 RED 2.25 N.
BLK
BLU
H€AT SMC BRN
SOE 600? 005- I SO IN.
^.200*005 ORN
047-4586-01 GRN
PLACE EDGE OF
SHlELD FLUSH TO GRY
BOARD AND SOLDER
EACH TAB DETAIL 'A‘ THIS PORTON
089-5903-04 C ut nnKr-J PE TAL *8'
DETAL P
TO C40IIREP)
069-6293-0312)
047-4505-01
019-7065—00
7 401
MF)
TRANSfORMER KIT
050-1666-01
(SEE NOTEIS)
FIGURE 6-15 Main Board KT 76A (S/N 5900 - 13,999), KT 78A (S/N 2600 - 6999)
(Dwg. No. 300-05824-0020 R-6)
NOTES:
TRANSFORMEN KIT 17. SPRAY BOTH SttTES OF BOARD WITH PC 101 IN THIS AREA
050-1686-01 BENG CAREFUL NOT TO SPRAY THE SWITCH BOARO CONTACTS
(SEE NOTE 18) AND E 40I.E 402.
SEE NOTE 16
TRANSFORMES T40I
P/N 0I9- 7042-01
WIRING CHART
012—1124—OIJ 047-4084-01 009-5824-21 SEE NOTE 9 SEE NOTE 10 COLOR LENGTH
TRANSFORMER KIT
□89 — 2076—30 050-1686-02 RED 1.75 IN.
(SEE NOTE 18)
89-8109-34 RED 225 H.
BLK
BLU
HEAT SMK BRN
SIDE -600T .005- 150 IN.
£200*005 ORN
GRN
GRY
THIS PORTON.
069 - 5903-04 DETAIL V CLTT HHMJ DETAIL "0'
DETAIL DETAIL *D*
FIGURE 6-15A Main Board KT 76A (S/N 5900 - 13,999), KT 78A (S/N 2600 - 6999)
(Dwg. No. 300-05824-0020 R-4)
SEE NOTE 12 I4V- 2 3. Q 408. Q 409, Q 4K), O 412, Q 414,0 417, Q 418.0 420,Q 421,
P. LITE
0 422, SEE OETAL "C"
TP2 10 8. R 460 SHOULD LAY FLAT ON BOARO SURFACE. RETAN WITH R.TV.
H3.75V II
9. R 458. R 477, AND R 487, TO BE SPACED.05 MN. OFF BOARD
♦I3.75V 12_ SURFACE, WITH R 458 AND R 477 BENT TOWARD THE EDGE OF
-4R436Í— SWITCHEO
THE BOARD.
8109-34 090-0296-00(2) 10. RM 401 ANO RM 402 TO BE BENT OVER,AS SHOWN ON BOARD.
9-2076-30 11. BEÑO C 450 AND C 457 OVER RESISTORS AS SHOWN.
SEE NOTE 16
12. C 410 MUST BE AT LEAST .700 NCHES FROM FRONT EDGE OF
BOARO,FOR SWITCH BOARO SHAFT CLEARANCE.
SEE NOTE o
TO C40I (RED) 13. J 401 TO BE SWAGEO AND SOLDERED N PLACE. ALSO SEE
DETAL "B".
012-1124-02
14. I.F. FENCE 047-4084-01 SHOULD HAVE A CONTINUOOS SOLDER
SEAM AROUND OUTER EDGE TO PC. 80AR0.
019 — 7065—00 15. APPLY 00U8LE S©EO TAPE (P/N 016-1124-00) TO SECURE
t 40t CRYSTAL TO P.C. BOARO.
__iréñ CRN
16. APPLY R.T.V. TO COMPONENTS TO SECURE TO BOARD WHERE
GRT
ORN NOTED.
BLU
TRANSFORMEN KIT 17. SPRAY BOTH S©ES OF BOARD WITH PC. 101 N TWS AREA
050-1686-01 M* BEING CAREFUL NOT TO SPRAY THE SWITCH BOARD CCNTACTS
(SEE NOTEIS) AND E 401,E 402.
SEE NOTE «
TRANSFORMER T40I
P/N 0I9-7042-0I
WIRING CHART
012 -I124 - OI -» 047-4084-01 009-5824-21 SEE NOTE 9 SEE NOTE 10 COLOR LENGTH
TRANSFORMEN KIT
■089 - 2076-30 050-1686-02 RED 1.75 W.
(SEE NOTE 18)
89-8109-34 RED 2.25 N.
BLK
BLU
FIGURE 6-15B Main Board KT 76A (S/N 5900 - 13,999), KT 78A (S/N 2600 - 6999)
(Dwg. No. 300-05824-0020 R-2)
FIGURE 6-16 Main Board Schematic KT 76A (S/N 5900 - 13,999), KT 78A (S/N 2600 - 6999)
(Dwg. No. 002-00449-0020 R-4)
FIGURE 6-16A Main Board Schematic KT 76A (S/N 5900 - 13,999), KT 78A (S/N 2600 - 6999)
(Dwg. No. 002-00449-0020 R-1)
NOTES
089-5903-04
SPRAY BOTH SIDES OF BOARD WITH PC 101 1. BEÑO C450 AND C457 OVER RESISTORS AS SHOWN. HEAT StNK .600 005-
SIOE- -.200 005
IN THIS AREA 8EING CAREFUL NOT TO SPRAY THE SWITCH 2. R460 ANDR472 MUST BE LAIO FLAT TO ALLOW FOR ADJUSTMENT. FCLD GVER AFTER fe’AVc
BOARD CONTACTS AND E40I.E402. SOLOERING AND RETA’N WITH ATV. (USE PREFORM TOOL NG. 943 lEMPLATE J.)
R/C NETWORK 015-0045-00 REPLACES <200-6018-00 AND 015-0023-01) 3. APPLY RTV 016-1082-00 TO COMPONENTS TO SEGURE TO BOARD WHERE NOTED.
OR (200-6018-01 AND 015-0023-01). 4. R458 ANDR477 TO BE BENT TOWARD EDGE OF BOARD. RM40I AND RM402 TO BE BENT OVER AS SHOWN
15. I.F FENCE 047-4084-01 SHOULO HAVE A CONTINUOOS SOLOER SEAM
A ROUND OUTER EDGE TO PC. BOARO
5. J40I TO BE SWAGED ANO SOLDERED IN PLACE. ALSO SEE DETAIL“E.'
6. 0415, SEE OETAIL"A" DETAIL"A"
T
16. C4CI MUST BE Al LEAST .940 INCHES FROM FRONT EDGE OF BOARO FOR 7. REMAINING COMPONENTS TO BE MOUNTED AS CLOSE TO BOARD AS POSSIBLE. SCALE 2/1
SWITCH BOARD SHAFT CLEARANCE. 8. 0420 AND 0422 , SEE OETAIL’B"
17 LEAVE FLUX INTACTON ALL SOLDER CONNECTIONSON SWITCH BOARD (031-0175-00). 9. 0408, 0409, 0410, 0412, 0414, ANO 0421. SEE OETAIL *C.”
DO NOT ALLOW SOLVENT TO COME IN CONTACT WITH SWITCH BD. DO NOT ATTEMPT 10 0404, 0405, 0406,0407, ANO 0411, SEE DETAIL’D"
TO CLEAN CONTACT SURFACE OR ROTORS OF SWITCHES. 11. 0403, 0413, AND 0416, Q4I7, AND 0418, SEE OETAIL " F *
12. 0419, SEE DETAIL’G"
FIGURE 6-17 Main Board KT 76A (S/N O - 5899), KT 78A (S/N O - 2599)
(Dwg. No. 300-05824-0000 R-14)
NOTES
13. SPRAY 8OTH SIDES OF BOARD WITH PC 101 |. BEND C450 AND C457 OVER RESISTORS AS SHOWN. HEAT SINK r*6OO D05-»t p200 005
IN TH1S AREA BEING CAREFUL NOT TO SPRAY THE SWITCH 2. R460 ANDR472 MUST BE LAID FLAT TO ALLOW FOR ADJUSTMENT. FOLO OVER AFTER MAVE SlDE-\
BOARD CONTACTS AND E40I.E402. SOLDERING AND RETAIN WITH RTV. (USE PREFORM TOOL NC. 943 TEMPLATE J.)
i 0415 ~|—
K. R/C NETWORK 015-0045-00 REPLACES (200-6018-^ AND 015-0023-01) 3. APPLY RTV 016-1082-00 TO COMPONENTS TO SECURE TO BOARD WHERE NOTED.
15.
OR (200-6018-01 AND 015-0023-01).
I.E FENCE 047-4084-01 SHOULD HAVE A CONTINUOOS SOLDER SEAN
A ROUND OUTER EDGE TO RC. BOARD.
4.
5.
6.
R458 AN0R477 TO BE BENT TOWARD EDGE OF BOARD. RM40I AND RM4O2 TO BE BENT OVER AS SHOWN.
J40I TO BE SWAGED AND STLDERED IN PLACE . ALSO SEE DETAIL’E."
0415, SEE DETAIL “A" DETAIL’A"
r
7. REMAINING COMPONENTS .‘O BE MOUNTED AS GLOSE TO BOARD AS POSSIBLE. SCALE 2/1
16. C40I MUST BE AT LEAST .940 INCHES FROM FRONT EDGE OF BOARD FOR
SWITCH BOARD SHAFT CLEARANCE. 8.0420 AND 0422, SEE DETAIL’B"
9. 0408, 0409, 0410, 0412, 0414, AND 0421, SEE DETAIL ’C.'
10.0404, 0405, 0406,0407, AND 0411, SEE DETAIL’O."
11. 0403, 0413, AND 0416,0417, AND 0418, SEE DETAIL"F.”
12. 0419, SEE DETAIL“G"
FIGURE 6-17A Main Board KT 76A (S/N O - 5899), KT 78A (S/N O - 2599)
(Dwg. No. 300-05824-0000 R-12)
NOTES
L BEÑO C45O AND C457 OVER RESISTORS AS SHOWN. HEAT SINK f**j600 005->t
SlDE-\ 1 -200 005
2. R460 ANDR472 MUST BE LAID FLAT TO ALLOW FOR AOJUSTMENT.
| I Q4I5 |—
3. APPLY RTV TO COMPONENTS TO SECURE TO BOARD WHERE NOTED.
4 R458 AND R477 TO BE BENT TOWARD EDGE OF BOARO. RM40I AND RM402 TO BE BENT OVER AS SHOWN.
5.
6.
J40I TO BE SWAGED AND SOLOERED IN PLACE. ALSO SEE DETAIL’E.’
Q4I5, SEE DETAIL’A* detail’a"
T
7. REMAINING COMPONENTS TO BE MOUNTED AS CLOSE TO BOARO AS POSSlBLE. SCALE 2/1
S. 0420 AND 0422 , SEE DETAIL’B*
9. 0408, 0409. 04», 0412. AND 0421. SEE DETA>L"C"
10. 0404, 0405, 0406.0407, AND 0411. SEE OETAIL’D.*
11.0403, 0413, 0414. 0416. 0417. AND 0418, SEE DETAIL’F."
12. 0419. SEE DETAIL’G’
13. SPRAY BOTH SIDES OF BOARD WITH PC 101
IN THIS AREA BEING CAREFUL NOT TO SPRAY THE SWITCH
BOARO CONTACTS AND E4OI.E4O2.
FIGURE 6-17B Main Board KT 76A (S/N O - 5899), KT 78A (S/N O - 2599)
(Dwg. No. 300-05824-0000 R-10)
FIGURE 6-18 Main Board Schematic KT 76A (S/N 0 - 5899), KT 78A (S/N 0 - 2599)
(Dwg. No. 002-00449-0000 R-7)
FIGURE 6-18A Main Board Schematic KT 76A (S/N 0 - 5899), KT 78A (S/N 0 - 2599)
(Dwg. No. 002-00449-0000 R-6)
NOTE: ANY FlLL AREAS ON THE TRACE LAYER SHOWN MAY NOT REPRESEN!
FINAL ARTWQRK AS THERMAL RELlEFS MAY NOT BE SHOWN.
TOP SIDE: 01
Page 6-165
FIGURE 6-19 KT 76A Switch Board (S/N =>120,800)
(Dwg. No. 300-09080-0020 R-A), Sheet 2 of 2
NOTES:
REWORK NOTES ) POST C0AT1NG FOR BOTh SlDES OF PC BOARO NOT REG^.REO
A. CUT TRACE AS SHOWN
0 SOLDER LEC OF RESISTOR R4 TO The PAO AS SHOWN WRAP MAGWIRE TO THE 2 PRINTED CIRCUIT ASSEMBLY IDENTIFICATION MUST BE N
OThER LEAO. POSITIONINC CIOSE TO THE BODY OF R4 ANO SOLOCR IN PLACE ACCOROANCE WITh SPEC. 00 I-O H01-0000
TRlM OFF EXCESS LEAD LENGTH OF R4 . SOLDER OTHER END OF MAGWIRE TO
3 LlOUtO STAKE ALL FASTENERS PER SPEC 001-0’060-0003
F£ED THRU AS SHOWN
C USE TACPAC (0I6-CI144-0000) AND ACCELERATOR(OI 6-01I44-0001) AS REOU'RED 4. 02 AND R3 ARE NOT INSTALLED
TRlM THE OThER LEaD CLOSE TO BODY OF R5. AND CONNECT A MAGWIRE
AFTfR SOLDERING IN BOARD. FORM LEADS AS ShOWN V V^EW A-A.
CONNECT OTHER ENO OF MAGWIRE TO THE ENO 0" R4 THAT CONNECTS TO FEEDThR’J. /Cx LOCATE ITEM 7 OVER PHOTO CELL AS SHOWN IN 7 i F A í-A.
vi: w a
NOTE'. ANY FILL ARLAS ON ThE tRACE LAYt’R SHOWN MAY NOT REPRESENT
I' i NAL ARTWORK AS T‘l£RMAL REL'EFS MAY NDT BE SHOWN
TOP S1 DE:
01
□2 (NOT INSTALLED)
SU.Í
su.:
L________ !
20
-0001 -0001
037-0007-01 (2)
047-3965 -01
089-2005-37 (2)
076-0301-11 (2)
012-1002-00
3. 089-8023-30 (2)
150-0003-10 16* REQD FARSIOE
089-5899-05 (2)
SECTION A-A
SOLDER SIDE SEE NOTE 3 047-1102-00
SEE NOTE 6
SEE NOTE 5
SEE NOTE 3
012-1002-00
FARSIDE
088-0275-00
026-0001-00 SOLOER ALL TERMINALS TO PATHS
150-0003-10
012-1002-00
SOLOER IN
PLACE
Ik -L - 150-0003-0
. S30I »--28 PERNOTES
SECTION C-C
089-6293-04 DS302
057-1425-00 .600 DETAIL B
031-0175-00
FORM TERMINAL 134-5005-02 NOTE 7 Td¡5 SEE NOTES 4 B 7
UP TO CLEAR S30I 031-0173-00 033-0051—00(6)
NOTE 7 047-2427-00
033-0051-00 (2)
SWAGE AND SOLDER IN PLACE
NOTES: USE TOOL NO. 1083.
I.SEE BILL OF MATERIAL 200-0381-00 FOR PARTS LISTING.
2. SWITCH ROTORS, BLADES, B CONTACTS TO BE FREE OF SOLDER
AND FOREIGN MATERIAL.
3. FORM INDICATED TERMINALS FLAT TO CLEAR BRACKETS.
4. FOR I4V., 2 JUMPERS AS SHOWN BY SOLIO LINES,
FOR 28V., I JUMPER AS SHOWN BY DASHED LINE,
FORM JUMPERS AS SHOWN IN DETAIL "A* AND PLUG IN-SOLDER
037-0007-01 (2)
047-3965 -01
089-2005-37 (21
076-0301-11 (2)
(—012-1002-00
3, 089-8023-30 (2)
^-150-0003-10 16 * REQD FARSIDE
089- 5899-05 (2)
SECTION A-A
SOLOER SIDE SEE NOTE 3 047-1102-00
SEE NOTE 6
SEE NOTE 5
SEE NOTE 3
012-1002-00
FARSIDE
012-1002-00
SOLDER IN
PLACE
150-000340
PERNOTES
SECTION C-C
089-6293-04 DS302
057-1425-00 .600 DETAIL 8
031-0175-00
FORM TERMINAL 134-5005-02 NOTE 7 ±015 SEE NOTES 4 a 7
UP TO CLEAR S30I—1 031-0173-00 — 033-0051-00(6)
NOTE 7 047-2427-00
033-0051-00 (2)
SWAGE AND SOLDER IN PLACE
NOTES : USE TOOL NO. 1083.
I.SEE BILL OF MATERIAL 200-0381-00 FOR PARTS LISTING.
2. SWITCH ROTORS, BLADES, a CONTACTS TO BE FREE OF SOLDER
AND FOREIGN MATERIAL.
3. FORM INDICATED TERMINALS FLAT TO CLEAR BRACKETS.
4. FOR I4V., 2 JUMPERS AS SHOWN BY SOLID LINES,
FOR 28V., I JUMPER AS SHOWN BY DASHED LINE,
FORM JUMPERS AS SHOWN IN DETAIL "a" AND PLUG IN-SOLOER.
SYMBOL EAS PART NBR DESCRIPTION [UOM] -0000 -0001 -0010 -0020
SYMBOL EAS PART NBR DESCRIPTION [UOM] -0000 -0001 -0010 -0020
NOTES
TO INSTALL FILTER ASSY ITEM 3. SUDE FROM FRONT TO BACK 1NT0 HOLO-OOWNS GROOVES OF ITEM 1.
9\ INSTALL ESO STICKER ITEM 15 IN APPROXIMATE CENTER OF TOP FRAME ITEM 1.
ITEM 4 BOARD ASSEMBL1 ES TO BE SLID INTO HOLD-DOWN GROOVES OF ITEM I FROM THE FRONT.
TO GET THE SWITCH BOARO INTO ITS VERTICAL GROOVES, THE BOX ITEM l NEEDS TO BE "SPRUNG"
APPLY VERY SMALL AMOUNT OF GREASE, ITEM 17. TO 1 LOBE OF EACH SWITCH.
OPEN JUST SL1GHTLY WH1LE THE BOARD ASSY IS PUSHED BACK TO ITS FINAL POSITION.
SOLDER CENTER CONDUCTOR OF COAX ON FILTER ASSY ITEM 3 TO PAD "E2" OF BOARO ITEM 4. BREAK-OUT
SHIELO CABLE OF COAX ANO SOLDER IT TO GROUND PAO BESIDE E2 ON BOARO ITEM 4.
INSTALL CABLE ASSY ITEM 8 TO CAVITY OSCILLATQR ITEM 7, SOLDER1NG WIRES TO TERMINALS AS SHOWN
IN "OETAIL A.” PIN OF CONNECTOR SHOULD ALREAOY BE CLIPPEO TO KEY CONNECTOR TO ITEM 8.
TO INSTALL TUBE RETAINER. ITEM 10, CATCH FI VE TABS INTO SLOTS ON THE
SIDE OF BOX ITEM 1. PLACE THE SCREWS ITEMS 12 INTO THE HOLES OF TUBE RETAINER
AND "SPRING" THEM OOWN OVER TUBE ITEM 7 TO THREAD THEM INTO ITEM 1.
INSTALL WARNING STICKER ITEM II ONTO TUBE RETAINER ITEM 10; BOTTOM EDGE OF STICKER
TO BE APPROXIMATELY EVEN WITH FORWARD EDGE OF TUBE RETAINER; CENTER STICKER ON
PROTRUSION AND WRAP ENOS OF STICKER AROUND EDGES OF TUBE RETAINER IF NECESSARY.
/g\ TO INSTALL F1LTER ASSY ITEM 3. SL1DE FROM FRONT TO BACK 1NTO HOLD-DOWNS GROOVES OF ITEM 1.
/3\ ITEM 4 BOARO ASSEMBLIES TO BE SLID 1NT0 HOLD-DOWN GROOVES OF ITEM I FROM THE FRONT.
4 * TO GET THE SWITCH BOARO INTO ITS VERTICAL GROOVES, THE BOX ITEM I NEEDS TO BE "SPRUNG"
OREN JUST SL1GHTLY WHILE THE BOARO ASSY 1S PUSHED BACK TO ITS FINAL POSITION.
SOLDER CENTER CONDUCTOR OF COAX ON F1LTER ASSY ITEM 3 TO PAO "E2" OF BOARO ITEM 4. BREAK-OUT
ASHIELO CABLE OF COAX ANO SOLDER IT TO GROUND PAD BES IDE E2 ON BOARD ITEM 4.
INSTALL CABLE ASSY ITEM 8 TO CAVITY OSCILLATOR ITEM 7, SOLDER1NG WIRES TO TERMINALS AS SHOWN
IN “DETAIL A." PIN OF CONNECTOR SHOULD ALREADY BE CLIPPED TO KEY CONNECTOR TO ITEM 8.
/s\ SOLDER INDUCTOR ITEM 9 TO SINGLE TERMINAL OF CAVITY OSCILLATOR ITEM 7, OTHER
/g\ INSTALL ESO STICKER ITEM 15 [N APPROXIMATE CENTER OF TOP FRAME ITEM 1.
/io\ APPLY VERY SMALL AMOUNT OF OREASE, ITEM 17. TO 1 LOSE OF EACH SWITCH.
TO GET THE SWiTCH BOARD INTO !TS VERTICAL GROOVES, THE BOX ¡TEM 1 NEEDS TO BE "SPRUNG"
OPEN JUST SLIGHTLY WHILE THE BOARD ASSY JS PUSHED BACK TO ITS FINAL POSITION. DETAIL A
SOLDER CENTER CONDUCTOR OF COAX ON FILTER ASSY ITEM 3 TO PAO "EZ" OF BOARD ITEM 4. BREAK-OUT VIEW FROM BACK OF UN IT
!>[>[>
SHIELD CABLE OF COAX AND SOLDER !T TO GROUND PAD BES IDE E2 ON BOARD ITEM 4.
INSTALL CABLE ASSY ITEM 8 TO CAVITY OSCILLATOR ITEM 7, SOLDER1NG W 1 RES TO TERMINAOS AS SHOWN
IN "DETAIL A." P1N OF CONNECTOR SHOULD ALREADY BE CLIPPED TO KEY CONNECTOR TO ITEM 8.
"SPRING” THEM DOWN OVER TUBE ITEM 7 TO THREAD THEM INTO ¡TEM l.
INSTALO WARNING STICKER ITEM II ONTO SPRING ITEM 10; BOTTOM EDGE OF STICKER
TO BE APPROXJMATELY EVEN WITH FORWARD EDGE OF SPRING; CENTER STICKER ON
PROTRUSION AND WRAP ENDS OF STICKER AROUND EDGES OF SPRING IF NECESSARY.
GREEN------- ""
075-00045-0002—-
(SEE NOTE 4)
L'02(REF)-
089-6293-04(4)------- -
-BRAID
BRAID
VIEW-A-A"
GE. VIOI
(KPN 050-1564-00/02 AND KPN
3. FILAMENT LEAD(S) VIOI AND CATHODE LEAD 050» 1565-00/02).
TO 8E NOT MORE THAN I.5OO INCHES LONG.
4. M0UNT HEATSINK 075-00045-0002 ATRE/W OF 6. TRIM CENTER LEAD OF C204 TO A HEIGHT
SLOT IN CHASSIS TO PROVIDE MAXIMUM OF .150 OR LESS.
CLEARANCE AND MINIMUM LEAD LENGTH
REQUIREMENTS FOR CAVITY ASSEMBLIES.
G.E.VIOI
BOTTOM VIEW
WHITE BRAID
GREEN
BRAID
076-0960-01
WHITE
(SEE NOTE 4)
VIEW-*A-A"
G EVIOI
3 FILAMENT LEAD(S) VIOI AND CATHODE LEAD
TO BE NOT MORE THAN 1500 INCHES LONG.
4.M0UNT HEATSINK 076-0960-01 AT REAR OF
SLOT IN CHASSIS TO PROVIDE MAXIMUM
CLEARANCE ANO MINIMUM LEAD LENGTH
REOUIREMENTS FOR CAVITY ASSEMBLIES.
G E.VIOI
3 FILAMENT LEAD(S) VlOl AND CATHODE LEAD
TO BE NOT MORE THAN 1500 INCHES LONG
4 MOUNT HEATSINK 076-0960-01 AT REAR OF
SLOT IN CHASSIS TO PROVIDE MAXIMUM
CLEARANCE AND MINIMUM LEAD LENGTH
REQUIREMENTS FOR CAVITY ASSEMBLIES.
GREEN
132-5023-00 _
RESISTOR--------
(SUPPLIED WITH
CAVITY -------
KIT)
WHITE BRAID
GREEN
BRAID
076-0960-01
WHITE
(SEE NOTE 4)
VIEW-A-A*
GEVKH
PRESELECTOR
BENDIX/KING
KT 76A/78A
TRANSPONDER
[] -0000
SEE ..
O O 'O O
DETAIL E [I o
° O o oo °l
P20I SEE DETAIL"C
II o • o _ o]
SEE DETAIL A
NOTE
10 O
SOLDER BRAID TO
BRACKET.
l 089-6190-16(5)
057-1250-00 SEE DETAIL"D"
SEE DETAIL"B
047-1693-00
089-6293-03(2) 073-0169-03
10
P202 089-6293-08
SEE DETAIL"F
BRAID SOLDERED TO INSIDE 047-1678-00
WALL. SLOT IN CASTING
MUST NOT BE FILLED WITH
SOLDER.
30-0059-00J20I
106-0001-17C2I5, 090-0104-03,6 PLACES. USE TOOL *196
WRENCH, SPECIAL.
I06-00QI-02C216
I06-000I-0IC2I4
I06-00OI-I7C2II
106-0001-02C2I2
047-4178 -01
106-0008-01C2I0
088-0716-00 090-0104-01
007-6092-00 KEAT STAKE, 2 PLACES.
CR202
DETAIL "A"
PREFORM DIODE
LEAOS IN DIODE
HOLDER
CONNECTOR END
USE TOOL 209
FORM, JIG
NOTES:
I. DETAIL ASSEMBLY INSTRUCTIONS:
A. STRIP THE CONNECTOR END OF THE CABLE AS SHOWN.
B. INSERT THE CABLE INTO THE CONNECTOR UNTIL THE
SHIELD JUST ENTERS THE CONNECTOR.
ALL CORNERS ARE
C. SOLDER THE CENTER CONDUCTOR AND MAKE SURE SOLDER
RIGHT ANGLE BENDS.
FLOWS DOWN INTO CENTER PIN, BUT DOES NOT SHORT
DETAIL"C" OUTER SHELL.
D. CUT OFF EXCESS CENTER CONDUCTOR.
E. BEAD SOLDER THE CABLE SHIELD TO THE CONNECTOR,
TRY TO PREVENT ANY EXCESS WICKING OF SOLDER UP
THE CABLE SHIELD.
ALL
2. DIMENSIONS ARE IN INCHES.
SEE
DETAIL E
089-6293-04(2)
. ip i|i a__ O
089-6293-08
047-2444-01 ______ PB
SEE DETAIL"A
089-6293-10 1----- ©----- — i/------------3----------
NOTE ______
SOLDER BRAID TO
BRACKET
! 1- - - - - - 089-6190-16(5)
057-1250-00
_______ PB
SEE DETAIL"D"
1-----@---------- _
047-1693-00
SEE DETAIL"B _____ inr
089-6293-04(2) 1-elT ------ ------ 073-0169-03
oo _______ B
P202 089-6293-08
SEE DETAIL "F
BRAID SOLDERED TO INSIDE 047-1678-00
WALL. SLOT IN CASTING
MUST NOT BE FILLED WITH
SOLDER.
030-0059-00J201
I06-000I-I7C2I5, 090-0104-03,6 PLACES. USE TOOL *196
WRENCH, SPECIAL.
—106-0001-02C2I6
106-0001-OI C 214
I06-000I-06C2I3
I06-000I-I7C2II
106-0001-02C2I2
047-4178-01
106-0008-01C2I0
088-0716-00 090-0104-01
007-6092-00 HEAT STAKE, 2 PLACES.
CR202 024-0012-01
DETAIL "A"
•-3/I6
PREFORM DIODE «-9/I6 P20I, 030-0091-00,
LEAOS IN DIODE SEE NOTEI.
HOLDER -7/8
CONNECTOR END
7/32-»
detail"e
026-0003-00
.240
6-3/4
024-0012-01
.095
DETAIL "B‘
USE TOOL 209 •3/16
FORM, JIG P202, 030-0091-03,
•-9/I6
SEE NOTE I.
*-7/8—*•—
2TURNS
CONNECTOR END
017-0023-00FL20I DETAIL "F 7/32-H
150-0005-10
NOTES:
.375 I. DETAIL ASSEMBLY INSTRUCTIONS:
.140 A. STRIP THE CONNECTOR END OF THE CABLE AS SHOWN.
B. INSERT THE CABLE INTO THE CONNECTOR UNTIL THE
SHIELD JUST ENTERS THE CONNECTOR.
C. SOLDER THE CENTER CONDUCTOR AND MAKE SURE SOLDER
ALL CORNERS ARE FLOWS DOWN INTO CENTER PIN, BUT DOES NOT SHORT
RIGHT ANGLE BENDS. OUTER SHELL.
DETAIL't" D. CUT OFF EXCESS CENTER CONDUCTOR.
E. BEAD SOLDER THE CABLE SHIELD TO THE CONNECTOR,
TRY TO PREVENT ANY EXCESS WICKING OF SOLDER UP
THE CABLE SHIELD.
2.ALL DIMENSIONS ARE IN INCHES.
DETAIL "A"
PREFORM DIODE
LEADS IN DIODE
HOLDER
SEE
DETAIL E
089-6293-04(2)
089-6293-08
047-2444-01
SEE DETAI L"Á!
089-6293-10
NOTE
SOLDER BRAID TO
BRACKET.
089-6190-16(5)
057-1250-00 SEE DETAIL "D"
SEE DETAIL"B
047-1693-00-
089-6293-04(2) 073-0169-03
P202 089-6293-08
SEE DETAIL"F
BRAID SOLDERED TO INSIDE 047-1678-00
WALL. SLOT IN CASTING
MUST NOT BE FILLED WITH
SOLDER.
30-0059-00 J20I
I06-000I-I7C2I5, 090-0104-03,6 PLACES. USE TOOL *196
WRENCH, SPECIAL.
I06-000I-02C2I6
I06-000I-0IC2I4
106-0001-06C2I3
024-5007-00
I06-OOOI-I7C2II
106-0001-02C2I2
047-4178-01
106-0008-01C2I0
088-0716-00 090-0104-01
007-6045-00 HEAT STAKE. 2 PLACES.
CR202
DETAIL "A"
PREFORM DIODE
LEADS IN DIODE
HOLDER
CONNECTOR END
USE TOOL 209
FORM, JIG
P20I
o o o oo SEE DETAIL"C
O ©
089-6293-08
047-2444-01
SEE DETAIL A
089-6293-10
NOTE
o
SOLDER BRAID TO
BRACKET.
089-6190-16(5)
057-1250-00 SEE DETAIL”D'
SEE DETAlC'B
047-1693-00
089-6293-04(2) 073-0169-03
P202 089-6293-08
SEE DETAIL "F
BRAID SOLDERED TO INSIDE 047-1678-00
WALL. SLOT IN CASTING
MUST NOT BE FILLED WITH
SOLDER.
30-0059-00J20I
I06-000I-I7C2I5, 090-0104-03,6 PLACES. USE TOOL *196
WRENCH, SPECIAL.
I06-000I-02C2I6
I06-000I-0IC2I4
106-0001-06C2I3
024-5007-00
I06-000I-I7C2II
106-0001-02C2I2
-0000
C2I7
C204
L207 NOTES:
L203
L206
R208
C206 C208
C205J (SEE NOTE 2)
C207 L-Q202
R209
R206 C203
R205-' R207
NOTES:
1. DO NOT DISTORT COILS DURING ASS'Y.
2. THERMAL COMPOUND 016-1004-00 TO MAKE GOOD
CONTACT BETWEEN Q20I.Q202 AND METAL PLATE.
3. C2I7 LEADS SHALL BE TO A ABSOLUTE MINIMUM
C2I7
C204
L205
L20I
R204
R20I C20I
C202 L202
R202 C209
R203
047-4022-02
L203
L206
R208
C206 C208
C205J (SEE NOTE
C207 i—Q202
R209
R206 C203
R205- R207
NOTES:
1. DO NOT DISTORT COILS DURING ASS'Y.
2. THERMAL COMPOUND 016-1004-00 TO MAKE GOOD
CONTACT BETWEEN Q20I.Q202 AND METAL PLATE.
3. C2I7 LEADS SHALL BE TO A ABSOLUTE MINIMUM
-0000
Oí1'
RFI MOD FILTER
BENDIX/KING
KT 76A/78A
TRANSPONDER
-0000
-0000
-0000
NOTES =
«n to in m in «o m to _
4. INSERT KEY POLARIZER ,(030-1096-00) BETWEEN PINS 3
AND 4 P50I.
§0 m o o aüüuuti
502 2 2 2 CR503 076- 0012 — 02 ( 2) 5. C502 DOWN FOR MAXIMUM CLEARANCE OF COVER
POSITION.
12
CONPONENT
PC BOARD SIDE
PC
125 BOARD
L 503
m 4-13.75 v (IN)
o>
i C505
s w
CQ N»
R 504
EXT IDENT
o F •VA— F
BENDIX/KING
TRANSPONDER
o> C506
KT 76A/78A
R 505
o> D4C
8 MV- 8
o
w C507
©
00 R506
O C4C
H ■AAA— H
C508
í/j
o
R507
© CIC
3 D -VA- D
tu C509
O
R5O8
B4C
B -AAAr- B
C5I0
ALL RESISTORS TO BE 470 EW
BIC R 510
E -VA- E
C5I2
A4C R 511
J J
C5I3
ALL CAPACIT0RS T0 BE 330 PF
C2C R 513
L MA- L
C5I5
R 514
AIC
M -wv- M
C5I6
14 v P LITE L504
2 2
C 517
L505
28v P LITE
3 3
C 518
GND
GND
A
10
APPENDIX 'A'
BENDIX/KING
APPENDIX A
Paragraph Page
1.1 GENERAL
Due to the wide utilization of semiconductora in this electronic equipment, somewhat different techniques
are necessary in maintenance prpcedures. In solid State circuits,the impedances and resistances encount-
ered are of much lower valúes than those encountered in vacuum-tube circuits. Therefore, a few ohms dis-
crepancy can greatly affect the performance of the equipment. Also, coupling and filter capacitors are
of larger valúes and usually are of the tantalum type. Henee, when measuring valúes of capacitors, an
instrument accurate in the high ranges must be employed. Capacitor polarity must be observed when
measuring resistance. Usually,more accurate measurements can be obtained if the semiconductors are re
moved or disconnected from the Circuit.
Damage to semiconductors by test equipment is usually the result of accidentally applying too much cur-
rent or voltage to the elements. Common causes of damage from test equipment are discussed in the
following paragraphs.
(1) Transformerless Power Supplies. Test equipment with transformerless power supplies is one source
of high current. However, this type of test equipment can be used by employing an isolation
transformer in the AC power line.
(2) Line Filter. It is still possible to damage semiconductors from line current, even though the
test equipment has a power transformer in the power supply, if the test equipment is provided with
a line filter. This filter may function as a voltage divider and apply half voltage to the semi
conductor. To elimínate this condition, connect a ground wire from the chassis of the test equip
ment to the chassis of the equipment under test before making any other connections.
(3) Low-Sensitivity Multimeters. Another cause of semiconductor damage is a multimeter that requires
excessive current to provide adequate indications. Multimeters with sensitivities of less than
20,000 ohms-per-volt should not be used On semiconductors. When in doubt as to the
amount of current supplied by a multimeter, check the multimeter connected in series with the
multimeter leads. If more than one milliampere is drawn on any range, this range cannot be safely
used on small semiconductors.
(4) Power Supply. When using a battery-type power supply, always use fresh batteries of the proper
valué. Make certain that the polarity of the power supply is correct for the equipment under test.
Do not use power supplies having poor voltage regulation.
When measuring voltage or resistance in circuits containing semiconductor devices, remember that these
components are polarity and voltage conscious. Since the valúes of capacitors used in semiconductor
circuits are usually large, time is required to charge these capacitors. Thus, any reading obtained
is subject to error, if sufficient time is not allowed for the capacitor to fully charge. When in
doubt, it may be best in some cases to isolate the components in question and measure them individually.
A transistor checker should be used to properly evalúate transistors. If a transistor testen is not
available, a good multimeter may be used. Make sure that the multimeter meets the requirements outline
in the preceeding paragraph.
(1) PNP Transistor. To check a PNP transistor, connect the positive lead of the multimeter to the
base of the transistor and the negative lead to the emitter. Generally, a resistance reading of
50,000 ohms or more should be obtained. Reconnect the multimeter with the negative lead to the
base. With the positive lead connected to the emitter or collector a resistance valué of 500 ohms
or less should be obtained.
(2) NPN Transistor. Similar tests made on an NPN transistor should produce the following results:
With the negative lead of the multimeter connected to the base of the transistor,the valué of
resistance between the base and the collector or emitter should be high. With the positive lead
of the multimeter connected to the base, the valué of resistance between the base and the collec
tor or emitter should be low. If these results are not obtained, the transistor is probably de
tective and should be replaced.
Page 1-1
BENDIX/KING
APPENDIX A
CAUTIOH
IF A TRANSISTOR IS FOUND TO BE DETECTIVE, MAKE
CERTAIN THAT THE CIRCUIT IS IN GOOD OPERATING
ORDER BEFORE INSTALLING A REPLACEMENT TRANSISTOR.
IF A SHORT CIRCUIT EXISTS IN THE CIRCUIT, PUTTING
IN ANOTHER TRANSISTOR WILL MOST LIKELY RESULT IN
BURNING OUT THE NEW COMPONENT. DO NOT DEPEND
UPON FUSES TO PROTECT TRANSISTORS.
(3) Always check the valué of the bias resistors in series with the various elements. A transistor is
very sensitive to improper bias voltage; therefore, a short or open Circuit in the bias resistance
may damage the transistor.
Never remove or replace a semiconductor with the supply voltage turned on. Transients thus produced may
damage the semiconductor or others remaining in the Circuit. If a semiconductor is to be evaluated in
an external test Circuit, be sure that no more voltage is applied to the semiconductor than normally is
used in the Circuit from which it carne.
(1) Use only a low heat soldering iron when installing or removing soldered-in parts.
(2) When installing or removing a soldered-in semiconductor,grasp the lead to which heat is applied
between the solder joint and the semiconductor with long nosed pliers. This will dissipate some
of the heat that would otherwise conduct into the semiconductor from the soldering iron. Make cer-
tain that all wires soldered to semiconductor termináis have first been properly tinned so that the
necessary connection can be made quickly. Excessive heat will permanently damage a semiconductor.
1.2.1 GENERAL
A knowledge of integrated Circuit fundamentáis is as necessary in testing digital logic circuits involv-
ing I.C.'s as a knowledge of rectificaron fundamentáis is needed to test a power supply.
1.2.2 TERMINOLOGY
(1) A logic State is defined as a high or low level voltage applied to the input or seen at the output
of a device. A high level voltage is called a logic "1". A low level voltage is called a logic
"0". Logic threshold voltage of a device is the input voltage required at an input to change the
output State.
(2) A truth table is a list of input logic States that will yield certain output logic States. A
digital logic element should be thought of as a Circuit element with its output level being either
HI or LO as programmed by the levels present on its inputs. A logic element may be tested by
verifying that it is preforming per the Truth Table of the logic element.
(3) Logic elements which have múltiple inputs and a single output are known as gates. The OR gate
produces a HI output when one OR more of the inputs are HI. With all inputs LO, the output is LO.
The AND gate produces a HI output only when all inputs are HI. When any input is LO the output is
LO. A small circle at the output of a gate on the schematics indicates "negation", which means
that the sense of the gate logic is reversed. An OR gate with negation is called a ÑOR gate and an
AND gate with negation is called a NAND gate. A ÑOR gate produces a LO output when one or more of
the inputs are HI and a NAND gate produces a LO output only when all inputs are HI.
(4) The Flip-Flop logic element is the basic data storage element of digital logic. It has two outputs
that are always at opposite logic levels. That is, when one output is HI the other output is LO.
The Flip-Flop will remain in a particular State until that State is changed by an input signal.
The operation of these Flip-Flops is controlled by the signáis on their inputs and is best under-
stood by a careful study of their Truth Tables. It should be kept in mind that the small circle
on either the input or the output indicates negation. Also, a circle on a dock input indicates
that a HI to LO transition causes the Flip-Flop to function.
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BENDIX/KING
APPENDIX A
(5) Besides the gates and Flip-Flops, two other commonly used logic elements are inverters and expand-
ers. Inverters are merely switching transistors such that if a logic "1" is the input to a device,
a logic "0" will be the output and vice versa. An expanden is a set of parallel switching transis-
tors that depends upon another resistor to provide their supply voltage. General ly .these devices
are used to expand the number of inputs available to a standard gate.
(6) Basic gates, inverters, expanders and Flip-Flops are defined symbolically and functionally in
Figures 1 through 7.
A counter is used to provide one output pulse for every N input pulses. This means F (out) = F (in)/N.
In a programmable counter N /nay be selected from any one of several choices. Programmable counters are
divided into two classifications: reset counters and preset counters. The reset counter uses the prin
cipie that when the counter reaches a fixed load State, it sets to a selected preset State and recycles.
A typical oneshot is shown in Figure 8. When a high pulse is applied to an input this will cause the
output to become low for a preset time and the opposite output to come high for a preset time. The
preset time is determined by the Circuit components associated with expanders.
Ah" R-S (reset-set) Flip-Flop is also used in several instances and is made up of two ÑOR gates inter-
connected together. The interconnection diagram for the monostable Flip-Flop circuit is shown in Figure
7.
As with semiconductors, damage to integrated circuits by test equipment is usually the result of applying
too much current or voltage to the elements. The same precautions as discussed in paragraph 1.1.1 apply
here.
Precise voltage measurements are not needed in testing digital I.C.'s other than to see that the voltage
is a HI or LO level. An oscilloscope is needed where the input levels are of short duration, either HI
or LO. For instance, if a 10 microsecond pulse going from LO to HI was applied to one input of a ÑOR
gate, while the other input stayed LO, the output would go LO for 10 microseconds and then return HI.
This, of course, could not be seen without an oscilloscope.
The minimum high and máximum low levels on the digital logic elements are as follows:
HIGH LOW
+2.10V +0.70V
When checking input and output levels of a logic element under question.it should be remembered that an
input or output may not agree with its truth table because some other component connected to the same
point has shorted to ground or to the supply voltage (Vcc). This is not common when an output of one
element is connected to an input of another. A majority of digital I.C. failures can be grouped into
three categories.
An input or output shorted to ground would be a constant LO and an input or output shorted to Vcc would
be a constant HI.
If an I.C. is known to be detective, the easiest way to remove it is to cut off each of its pins, remove
the case, and then unsolder the remaining pins from the integrated Circuit card one bv one. This method
is prefenrabie to removing the I.C. intact because attempts to remove the I.C. intact may result in
damage to the printed Circuit board.
King Radio Company (KRC) large scale integrated Circuit (LSI) devices are metal oxide semiconductor (MOS)
and complementary metal oxide semiconductor (CMOS) designs that have a very high input impedance. This
feature results in some device damage during handling. The most frequent causes of damage are static
electricity, voltages picked up from measuring devices with large input capacitors, and ungrounded
soldering iron tips. Less frequent causes are bent pins, chipped ceramic around pins, and cracked
packages.
A LSI Puller Package (KPN 050-1671-00) that helps reduce device handling damage has been designed by
King Radio. This package contains an extractor for 28 or 40 pin LSIs that provides excellent control
when installing or removing the device. The extractor snaps securely over the ends of the LSI.
To install a LSI device with the extractor, all pins should be aligned with the socket holes. To remove
a LSI device, the device should be pulled squarely from the socket and immediately inserted into a con
ductivo foam pad that is part of the LSI Puller Package. Several of the conductivo pads have been
included in the package for added convenience. These pads may also be used for médium size integrated
Circuit (MSI) and CMOS devices. It is extremely important to keep all KRC LSI devices in a conductivo
foam pad when transporting from one location to another and to ground or discharge test equipment used
to determine device parameters. Soldering iron tips and instrument probes should be grounded prior to
making contact with a device terminal.
The primary function of the IC is to monitor a serial data line (pin 5) and decide if a pulse train on
that line meets the requirements for a valid interrogation. The pulse train consists of either 2 or 3
pulses. These pulses and their timing characteristics are described in, FAA Document TS0-C74c.
Three decisions may be made about an incoming pulse stream: 1) The interrogation is invalid, 2) The
interrogation may be valid, but the P2 pulse is present in the data stream, and 3) the interrogation is
a valid mode A, or C interrogation. In case (1), the IC completely ignores the pulse(s) and is
immediately ready for further interrogation. In case (2), the IC recognizes the side lobe suppression
(SLS) requirement and makes no reply, as well as ignoring any input pulses for a period of 35 ju seconds.
In case (3), the transponder IC will send a reply. If the interrogation is a mode A type, it will transmit
the data on the Mode A data lines as a serial output bit stream. If the interrogation is a Mode C
interrogation, and Pin 16 is low, it will send the data that is present on the Mode C data lines. If
Pin 16 is high, then only the framing pulses F1 and F2 will be sent.
TABLE I
Secondary Functions
The IC contains several Circuit blocks to perform auxiliary functions. These are explained briefly
below, and timing relationships are detailed later in this document.
Page 1-4
BENDIX/KING
APPENDIX A
The IC will latch a momentary LOW input on Pin 14 for a period of approximately 23 seconds. During this
time, a pulse is added to the serial output stream (Pin 3) for all Mode A replies. Mode C is not affect-
ed in any way. Additionally, the ANNUNCIATE output (Pin 12) will go high for this period.
Power-On-Reset
Whenever power has been interrupted for more than 5 Microseconds, the IC will revert to its initializa-
tion sequence. This clears all internal registers and disables any replies. This period lasts approxi
mately 47 seconds. After this time, the IC will be ready for its normal functions.
Reply Annunciate
As previously stated, the Annunciate Output (Pin 12) will be HIGH for 23 seconds after the Ident input
has been taken LOW. If, however, Ident has not been taken LOW, the annunciate Output will go HIGH for
760 milliseconds every time the IC sends a reply. This will cause the panel lamp to blink as the ground
station beam interrogates the unit. If Ident is taken LOW during this 760 millisecond period, the IC
will go to the SPI mode and Pin 12 will remain HIGH for the 23 Second interval.
STBY (Pin 4) While HIGH, this input allows normal operation. When LOW, the IC ignores the Serial
Input Line.
SER IN (Pin 5) This is the serial input line of the transponder IC. The pulses are Positive-going
signáis, normally at ground potential. Pulse widths must exceed 400 nanoseconds, but may be up
to 1.5 uSec. The IC is sensitive to the leading edge of P3.
0 and 0 (Pins 7 and 8) These are the dock and complemented dock inputs. They have a period of 362.6
nanoseconds.
IDENT (Pin 14) The function of this pin has been described above.
ALT EN (Pin 17) When High, Modes C replies consist of framing pulses only
SER OUT (Pin 3) This pin is the serial output Reply bit-stream. It is normally low, with reply pulses
having width of approximately 360 nanoseconds and a pulse period of 1.45 uSeconds .
SYNC (Pin 11) This pin (Normally Low) is a narrow high pulse which is used to reset the external
dock generator to its initial State. When reset, the dock generator must cause 0 (Pin 8) to
go High, and 0 (Pin 7) to go Low. This output occurs only upon reception of a valid Mode A
or Mode C interrogation and only if Pin 4 is such that a reply will occur.
ANNUN (Pin 12) Described above. Indicates either Ident or Reply Modes.
ESO (Pin 13) This output is a High pulse approximately 35uSec wide which occurs while a reply is
being sent out.
Page 1-5
BENDIX/KING
APPENDIX A
FIGURE I. BUFFER
A Z
Z=A
O O
I I
FIGURE 2. INVERTER
I O
BUFFER INVERTER
1____ 0VoD = I4V oVdd = I4V
J ,_h,Vcc=5V J —oVcc = 5V
XJ VlN OV | I4V Vin OV I I4V
Vin- >0-Vout I OV
Vin- >-Vout Vout OV 15V Vout 5V
H_oVss = GND
oVss = GNO
Page 1-6
BENDIX/KING
APPENDIX A
s R Next Q Q
1 1 0 0
0 1 1 0
0 0 NC NC NC = NO CHANGE
1 0 0 1
Page 1-
BENDIX/KING
APPENDIX A
MR - 1- -16------- vcc
CP - 2- -15------- ------- TC
Po ■ 3- —14------- --------Qo
P1 • 4- —13------- ------- Q1
P2 - 5- — 12------- Q2
P3 - 6- —11------- Q3
CEP 7— -10-------------- CET
GND 8- —9---------------- PE
Page 1-9
BENDIX/KING
APPENDIX A
Q-
NC -
Al -
A2 -
B—
Q -
GND
Page 1-10
BENDIX/KING
APPENDIX A
Page 1-11