army navy air force tm 11-5815-602-24 ee161-dm

army navy air force tm 11-5815-602-24 ee161-dm
ARMY
NAVY
AIR FORCE
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ORGANIZATIONAL,
GENERAL
SUPPORT
TERMINAL,
DIRECT
MAINTENANCE
COMMUNICATIONS
(NSN
SUPPORT,
5815-01-062-8194)
JANUARY
MANUAL
AN/UGC-74A(V)3
DEPARTMENTS OF THE ARMY, THE NAVY, AND THE AIR FORCE
8
AND
1984
SAFETY STEPS TO FOLLOW IF SOMEONE
IS THE VICTIM OF ELECTRICAL SHOCK
DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL
IF POSSIBLE, TURN OFF THE ELECTRICAL POWER
IF YOU CANNOT TURN OFF THE ELECTRICAL
POWER, PULL, PUSH, OR LIFT THE PERSON TO
SAFETY USING A WOODEN POLE OR A ROPE OR
SOME OTHER INSULATING MATERIAL
SEND FOR HELP AS SOON AS POSSIBLE
AFTER THE INJURED PERSON IS FREE OF
CONTACT WITH THE SOURCE OF ELECTRICAL
SHOCK, MOVE THE PERSON A SHORT DISTANCE
AWAY AND IMMEDIATELY START ARTIFICIAL
RESUSCITATION
TM 11-5815-602-24
EE161-DM-MMM-01C/E154UGC74
TO 31W4-2UGC74-2
C1
DEPARTMENTS OF THE ARMY,
THE NAVY, AND THE AIR FORCE
Washington, DC, 1 January 1996
CHANGE
No. 1
Organizational, Direct Support and General Support
Maintenance Manual
TERMINAL, COMMUNICATIONS
AN/UGC-74A(V)3
(NSN 5815-01-062-8194) (EIC: HWS)
TM 11-5815-602-24/EE161-DM-MMM-010/E154UGC74/TO 31W4-2UGC74-2, 8 January 1984, is
changed as follows:
1. Remove old pages and insert new pages as indicated below. New or changed material is indicated by a vertical bar in the
margin of the page. Added or revised illustrations are indicated by a vertical bar in front of the figure caption.
Remove Pages
Insert Pages
A and B
i through iv
1-3 and 1-4
1-9 and 1-10
2-3 and 2-4
2-11 and 2-12
2-19 through 2-26
3-7 and 3-8
None
3-23 and 3-24
3-31 and 3-32
3-71 and 3-72
3-87 and 3-88
3-91 and 4-0
4-9 through 4-14
4-23 and 4-24
4-27 through 4-34
5-5 and 5-6
None
5-9 and 5-10
5-81 and 5-82
5-89 through 5-92
6-17 end 6-18
6-63 through 6-66
None
6-67 end 6-68
6-71 through 6-74
6-83 through 6-86
6-123 and 6-124
6-127 through 6-130
6-135 through 6-140
A-1 and A-2
B-11 and B-12
None
A and B
i through iv
1-3 and 1-4
1-9 and 1-10
2-3 and 2-4
2-11 and 2-12
2-19 through 2-26
3-7 and 3-8
3-8.1 and 3-8.2
3-23 and 3-24
3-31 and 3-32
3-71 and 3-72
3-67 and 3-88
3-91 and 4-0
4-9 through 4-14
4-23 and 4-24
4-27 through 4-34
5-5 and 5-6
5-6.1 and 5-6.2
5-9 and 5-10
5-81 and 5-82
5-89 and 5-90
6-17 and 6-18
6-63 through 6-66
6-66.1 and 6-66.2
6-67 and 6-68
6-71 through 6-74
6-83 through 6-86
6-123 and 6-124
6-127 through 6-130
6-135 through 6-140
A-1 and A-2
6-11 and B-12
D-1 and D-2
2. File this change sheet in front of the publication for reference purposes.
Distribution authorized to US Government agencies and their contractors for official use or for
administrative or operational purposes only. This determination was made on 5 July 1991. Other
requests for this document must be referred to Commander, US Army CommunicationsElectronics Command and Fort Monmouth, ATTN: AMSEL-LC-LM-LT, Fort Monmouth, New
Jersey 07703-5007.
DESTRUCTION NOTICE -- Destroy by any method that will prevent disclosure of contents or
reconstruction of the document.
DISTRIBUTION:
To be distributed in accordance with DA Form 12-51-E, block 7005
requirements for TM 11-5815-602-24.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Never work on electronic equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment and who is competent in administering first aid. When the technicians are
aided by operators, they must be warned about dangerous areas.
Whenever possible, the power supply to the equipment must be shut off before beginning work on the
equipment. Take particular care to ground every capacitor likely to hold a dangerous potential. When working
inside the equipment, after the power has been turned off, always ground every part before touching it.
Be careful not to contact high-voltage connections or 115 volt ac input connections when installing or operating this equipment.
Whenever the nature of the operation permits, keep one hand away from the equipment to reduce the
hazard of current flowing through the body.
For Artificial Respiration, refer to FM 21-11.
A
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Lithium organic batteries or cells are used in this equipment. They are potentially hazardous if
misused or tampered with before, during, or after discharge. The following precautions must be
strictly observed to prevent possible injury to personnel or equipment damage:
DO NOT heat, incinerate, crush, puncture, disassemble, or otherwise
mutilate the batteries.
DO NOT shortcircuit, recharge, or bypass internal fuse.
DO NOT store in equipment during long period of nonuse in excess of 30
days.
TURN OFF the equipment immediately if you detect battery compartment
becoming unduly hot, hear battery cells venting (hissing sound), or smell
irritating sulphur dioxide gas. Remove and dispose of the battery only after it
is cool (30-60 minutes).
Turn spent lithium batteries lacking a discharge switch into the Defense
Reutilization and Marketing Office (DRMO) for disposal. If the lithium battery
is equipped with a discharge switch, use the switch to discharge the battery
completely and discard it as refuse.
B
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
DEPARTMENTS OF THE ARMY,
THE NAVY, AND THE AIR FORCE
Technical Manual
No. 11-5815-602-24
Technical Manual
No. EE161-DM-MMM-010/E154UGC74
Technical Order
No. 31W4-2UGC74-2
Washington, DC, 8 January 1984
Organizational, Direct Support, and General Support Maintenance Manual
TERMINAL COMMUNICATIONS AN/UGC-74A(V)3 (NSN 5815-01-062-8194) (EIC: HWS)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA Form 2028-2 located in back of this manual direct to:
Commander, US Army Communications-Electronics Command and Forth Monmouth, ATTN:
AMSEL-LC-LM-LT, Fort Monmouth, New Jersey 07703-5007.
For Air Force, submit AFTO Form 22 (Technical Order System Publication Improvement Report and
Reply) in accordance with paragraph 6-5, Section Vl, T.O. 00-5-1. Forward direct to prime ALC/MST.
For Navy, mail comments to the Commander, Space and Naval Warfare Systems Command, ATTN:
SPAWAR 8122, Washington, DC, 20363-5100.
In either case, a reply will be furnished direct to you.
PAGE
TABLE OF CONTENTS
CHAPTER
1.
Section I.
Il.
Ill.
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4
1-4
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-0
CHAPTER 2.
Section I.
Il.
Ill.
Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Servicing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
CHAPTER 3.
Section I.
Il.
Ill.
2-1
2-5
2-12
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical, Electronic, and Mechanical Functions. . . . . . . . . .
Test Fixtures, Electrical and Electronic Functions. . .
3-3
3-15
3-53
4-0
CHAPTER 4.
Repair Parts, Special Tools, TMDE and Support Equipment . . . . .
Section I.
Il.
Preventive Maintenance Checks and Services (PMCS). . . . . .
Ill. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV. Maintenance Procedures . . . . . . . . . . . . . . . . . . . .
V. Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
4-1
4-1
4-9
4-14
4-36
This manual, together with, TM 11-5815-602-10, 23 September 1983, supersedes TM 11-5815-602-12,
30 November 1979 including Change 1, 16 March 1981 and TM 11-5815-602-34, 30 November 1979.
EE161-DM-MMM-01C/E154UGC74/ Change 1
i
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
TABLE OF CONTENTS - Continued
CHAPTER 5.
PAGE
5-1
Section I.
Il.
Ill.
IV.
V.
5-3
5-4
5-5
5-12
VI.
VII.
5-37
5-81
5-89
CHAPTER 6.
6-1
Section I.
Il.
Ill.
IV.
V.
VI.
VII.
VIII.
APPENDIX A.
B.
6-3
6-4
6-5
6-29
6-35
6-54
6-87
6-123
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .
MAINTENANCE ALLOCATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Allocation Chart for Communications Terminal
AN/UGC-74A (V) 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ill. Tool and Test Equipment Requirements for Communications
Terminal AN/UGC-74A (V) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV. Remarks . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I.
Il.
C.
Section I.
Il.
D.
A-1
B-1
B-3
B-9
B-13
EXPENDABLE SUPPLIES AND MATERIALS LIST
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expendable Supplies and Materials List . . . . . . . . . . . . . . . . . . . .
C-1
C-2
ERROR MESSAGE LIST
D-1
GLOSSARY
Glossary-1
SUBJECT INDEX
Index-1
ii
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
LIST OF ILLUSTRATIONS
NUMBER
1-1
1-2
1-3
1-4
1-5
1-8
1-7
3-1
3-2
3-3
3-4
3-5
3-5.1
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13(1)
3-13(2)
3-13(3)
3-14
3-15(1)
3-15(2)
3-16(1)
3-16(2)
3-17(1)
3-17(2)
3-18(1)
3-18(2)
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
3-29
PAGE
TITLE
Terminal, Communications AN/UGC-74A (V) 3 . . . . . . . . . . . . . . . . . . .
AN/UGC-74A (V) 3 and KG-30 Interface . . . . . . . . . . . . . . . . . . . . . . . . . .
AN/UGC-74A (V) 3 and KG-84 Interface . . . . . . . . . . . . . . . . . . . . . . . . . .
AN/UGC-74A (V) 3 and KW-7 Interface . . . . . . . . . . . . . . . . . . . . . . . . . .
AN/UGC-74A (V) 3 and KY-57 Interface . . . . . . . . . . . . . . . . . . . . . . . . . .
AN/UGC-74A (V) 3 and MD-522 Interface . . . . . . . . . . . . . . . . . . . . . . . .
AN/UGC-74A (V) 3 and TH-22/TG lnterface . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Components of Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key board Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receive Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing and Print Hammer Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Circuit Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Circuit Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications Circuit Card Assembly. . . . . . . . . . . . . . . . . . . . . . . .
Printer Control Circuit Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relationship Between RAM, ROM and Microprocessor. . . . . . . . . . . .
Key board Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key board Logic Diagram (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . .
Key board Logic Diagram (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . .
Key board Logic Diagram (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . .
Teleprinter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Feed Control System (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . .
Line Feed Control System (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . .
Right-Hand Ribbon Mechanism Circuitry (Sheet 1 of 2) . . . . . . . . . . . .
Right-Hand Ribbon Mechanism Circuitry (Sheet 2 of 2) . . . . . . . . . . . .
Left-Hand Ribbon Mechanism Circuitry (Sheet 1 of 2) . . . . . . . . . . . . .
Left-Hand Ribbon Mechanism Circuitry (Sheet 2 of 2) . . . . . . . . . . . . .
Print Driver (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Hammer Driver (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ul (Hybrid Driver) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dustcover Wiring Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
RX/TX Circuit Card Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Assemblies for Removeable Printer Assembly . . . . . . . . .
Power Connector Key and Pin lndentification . . . . . . . . . . . . . . . . . . . .
Data Connector Key and Pin lndentification . . . . . . . . . . . . . . . . . . . . .
Change 1
1-2
1-7
1-8
1-9
1-10
1-11
1-12
3-2
3-3
3-4
3-5
3-6
3-8
3-8.2
3-9
3-10
3-11
3-12
3-14
3-16
3-17
3-18
3-19
3-22
3-26
3-27
3-28
3-29
3-29
3-30
3-30
3-31
3-31
3-32
3-33
3-35
3-37
3-40
3-41
3-42
3-45
3-89
3-91
iii
TM 11-5815-802-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
LIST OF ILLUSTRATIONS – Continued
NUMBER
PAGE
6- 8
6-10
6-13
6-16
6-28
6-31
6-32
6-38
6-40
6-44
6-48
6-50
6-52
6-55
6-56
6-57
6-58
6-59
6-61
6-63
6-65
6-66
6-67
6-71
6-74
6-79
6-81
6-85
6-86
6-90
6-94
6-98
6-102
6-104
6-105
6-108
6-115
6-117
6-120
6-122
6-125
6-127
6-129
6-132
6-134
6-138
6-140
6-141
6- 1
6- 2
6- 3
6- 4
6- 5
6- 6
6- 7
6- 8(1)
6- 8(2)
6- 9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
6-17
6-18
6-19
6-20
6-21
6-21.1
6-22
6-23
6-24
6-25
6-26
6-27
6-28
6-29
6-30
6-31
6-32
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-40
6-41
6-42
6-43
6-44
6-45
6-46
iv
TITLE
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
NUMBER
FO-1 @)
FO-1 @
FO-2
FO-3
FO-4
FO-5
FO-6
FO-7
FO-8
FO-9 @
FO-9 @
FO-10
FO-11
TITLE
Color Code Marking for Military Standard Capacitors (Sheet 1 of 2)
Color Code Marking for Military Standard Capacitors (Sheet 2 of 2)
Interface Assembly, Schematic Diagram
Power Supply Input, Schematic Diagram
Microprocessor Supply
+5, ±8.6Vdc supply
Drum Motor Supply
+ 18Vdc Constant Current Supply
R41 and R71 Test Connections
AN/UGC-74 Interconnect Diagram (Sheet 1 of 2)
AN/UGC-74 Interconnect Diagram (Sheet 2 of 2)
Power Supply Test Fixture, Schematic Diagram
Drum Motor Simulator Test Fixture, Schematic Diagram
v
TM 11-5815-602-24
EE161-DM-MMM-01O/E154UGC74
LIST OF TABLES
TO 31W4-2UGC74-2
NUMBER
TITLE
Shipment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Power Cables and Fuses.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
Unpacking Terminal AN/UGC-74A (V) 3 . . . . . . . . . . . . . . . . . . . . . . . .
2-3
Installation Instructions for Terminal AN/UGC-74A (V) 3 . . . . . . . . . . .
2-4
Installer’s Local Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
Initial Communication Test With Distant Station . . . . . . . . . . . . . . . . .
2-6
List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Character Code Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
Filter Assembly Test Fixture Wire List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
Hammer Drive Module Test Fixture Wire List . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
Hammer Module Test Fixture Wire List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
Line Feed/Current Control Test Fixture Wire List . . . . . . . . . . . . . . . . . . . . . .
3-6
Power Supply Test FixtureWire List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
Keyswitch Assembly Test Fixture Wire List . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
4-1
Organizational Preventive Maintenance Checks and Services Table .
4-2
Lubrication Schedule (Semi-Annual) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support Troubleshooting Chart .,....... . . . . . . . . . . . . . . . . .
5-1
Interface Assembly Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Power Supply Output Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
6-1
General Support Tools andTest Equipment . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2
Troubleshooting Hammer Driver 3A1A5A2-A3. . . . . . . . . . . . . . . . . . . .
6-3
Troubleshooting Hammer Module 3A1A5A4-A23 . . . . . . . . . . . . . . . . .
6-4
Troubleshooting Motor Drive and Current Control Board Assembly
6-5
3A1A5A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Interface Assembly ±6 Volt = 1 Volt Data Circuits.
6-6
Troubleshooting Interface Assembly 20MA and 60MA DataCircuits.
6-7
Troubleshooting lnterface Assembly Switches . . . . . . . . . . . . . . . . . .
6-8
Interface Assembly Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . .
6-9
Troubleshooting Power Supply (+ 5VA Load Circuit) . . . . . . . . . . . . . .
6-10a
Troubleshooting Power Supply (+ 12V and -5VA Load Circuits) . . . . .
6-10b
Troubleshooting Power Supply (+ 5V and -8.6V Load Circuits . . . . . . .
6-10c
Troubleshooting Power Supply (+ 8.6 Load, Lamp Supply and Line6-10d
Feed Load Circuits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Power Supply (Drum Motor, Backup Battery, and
6-10e
+18V, CCR, CAPVOK Circuits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Filter Assembly (3A1A6FL1) . . . . . . . . . . . . . . . . . . . .
6-11
Troubleshooting Keyboard Keyswitch Assembly (3A2A1) . . . . . . . . . .
6-12
6-13
Interface Test Fixture Interconnections. . . . . . . . . . . . . . . . . . . . . . . . .
Interface Assembly Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . .
6-14
6-15
Selection Values for Resistors R11, R29, R63 . . . . . . . . . . . . . . . . . . . .
6-16
Selection Values for Resistors R41 and R71 . . . . . . . . . . . . . . . . . . . . .
6-17
Programmable Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-18
CharacterCode Matrix Test... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-19
Filter Assembly Test Fixture Wire List . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer DriverModuleTest FixtureWire List. . . . . . . . . . . . . . . . . . . .
6-20
Hammer ModuleTest Fixture Wire List . . . . . . . . . . . . . . . . . . . . . . . . .
6-21
Interface Assembly Test Fixture Test Point Resistance Tests . . . . . .
6-22
Interface Assembly Test Fixture Switch Continuity Tests . . . . . . . . . .
6-23
6-24
Line-Feed/Current Control Test Fixture Input Resistance
Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PowerSupplyTest Fixture Continuity Checks . . . . . . . . . . . . . . . . . .
6-25
6-26
PowerSupplyTest Fixture Resistance Checks . . . . . . . . . . . . . . . . . . .
vi
PAGE
2-1
2-2
2-3
2-6
2-13
2-26
3-2
3-20
3-56
3-60
3-63
3-66
3-73
3-85
4-3
4-21
5-6
5-9
5-10
6-4
6-6
6-7
6-9
6-11
6-14
6-15
6-16
6-17
6-19
6-20
6-21
6-22
6-23
6-25
6-26
6-64
6-69
6-75
6-77
6-78
6-82
6-124
6-126
6-128
6-130
6-131
6-133
6-135
6-135
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
HOW TO USE THIS MANUAL
This manual tells you how to install, perform organizational maintenance, direct support
maintenance, and general support maintenance of Communications Terminal AN/UGC-74A(V)3.
Location of Subjects in Manual
In this manual, paragraphs are numbered sequentially. If you are looking for specific information, use subject index at back of this manual to locate page where topic is described.
For rapid location of required subject, contents of chapter are listed alphabetically on the first
page of each chapter.
Refer to appendix A, REFERENCES, for the complete title of all forms, technical
bulletins, technical manuals and military specifications referenced in this manual.
Refer to GLOSSARY in the back of this manual for a definition of the abbreviations and
unusual terms used in this manual.
Refer to TM 11-5815-602-20P for organizational maintenance repair parts and special tools lists
(RPSTL); refer to TM 11-5815-602-34P for direct support and general support maintenance repair
parts and special tools lists (RPSTL) used with this manual.
Use of Manual for Task Performance
You must familiarize yourself with the entire maintenance procedure before beginning the
maintenance task.
You should also familiarize yourself with the operational capabilities of the terminal in order to
properly perform your maintenance tasks. Refer to the operator’s manual TM 11-5815-602-10 for
this information.
Organizational maintenance personnel should refer to section I in chapter 3 of this
manual for a good understanding of how the major components of the terminal function.
After servicing the equipment, and before returning it to the user, all levels of
maintenance personnel should refer to section III in chapter 2 and perform a complete
operational check of the terminal. This will insure the user receiving a 100 percent serviceable
terminal.
Do not perform maintenance tasks that are assigned to a maintenance level higher than you
are authorized to perform. Chapters 1 through 4 can be used by all levels of maintenance personnel (except operator). Chapter 5 is used by direct and general support personnel only. Chapter 6
is used only by general support personnel.
vii /(viii blank)
TM 11-5815-802-24
EE161-DM-MMM-010O/E154UGC74
TO 31W4-2UGC74-2
CHAPTER 1
INTRODUCTION
PAGE
Section I. GENERAL INFORMATION
Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nomenclature Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . .
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-3
1-3
1-3
1-3
1-3
Section Il. EQUIPMENT DESCRIPTION AND DATA
Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety, Care, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
1-4
1-4
Section III. PRINCIPLES OF OPERATION
Central Processing Unit(CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver/Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
1-5
1-5
1-5
1-5
1-4
1-5
1-5
1-5
1-6
1-1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 1-1. TERMINAL, COMMUNICATIONS AN/UGC-74A(V)3
1-2
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section I. GENERAL INFORMATION
1-1.
SCOPE.
TYPE OF MANUAL: Organizational, Direct Support, and General Support Maintenance
MODEL NUMBER AND EQUIPMENT NAME: AN/UGC-74A(V)3
Communications Terminal
PURPOSE OF EQUIPMENT:
1-2.
Provides a full-duplex, asynchronous (ASCII or Baudot) communications
capability with MlL-STD-188C and normal input keying (NIK) interfaces.
CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS.
Refer to the latest issue of DA Pam 25-30 to determine whether there are new editions, changes or additional
publications pertaining to the equipment.
1-3.
MAINTENANCE FORMS, RECORDS, AND REPORTS
a. Reports of Maintenance and Unsatisfactory Equipment. Department of the Army forms and procedures
used for equipment maintenance will be those prescribed by DA Pam 738-750, as contained in Maintenance
Management Update (Army). Air Force personnel will use AFR 66-1 for maintenance reporting and TO-00-35D54
for unsatisfactory equipment reporting. Navy personnel will report maintenance performed utilizing the
Maintenance Data Collection Subsystem (MDCS) IAW OPNAVINST 4790.2, Vol 3, and unsatisfactory
material/conditions (UR submissions) IAW OPNAVINST 4790-2, Vol 2, Chapter 17.
b. Report of item and Packaging Discrepancies. Fill out and forward SF 364 (Report of Discrepancy (ROD))
as prescribed in AR 735-11-2/DLAR 4140.55/SECNAVlNST 4355.18/AFR 400-54/MCO 4430.3J.
c. Transportation Discrepancy Report (TDR) (SF 361). Fill out and forward Transportation Discrepancy
Report (TDR) (SF 361) as prescribed in AR 55-38/NAVSUPlNST 4610.33C/AFR 75-18/MCO P4610.19D/DLAR
4500.15.
1-4.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
a. Army. If your Terminal, Communications AN/UGC-74A(V)3 needs improvement, let us know. Send us
an EIR. You, the user are the only one who can tell us what you don’t like about your equipment. Let us know
why you don’t like the design or performance, Put it on an SF 368 (Product Quality Deficiency Report). Mail it to
Commander US Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-ED-CFO,
Fort Monmouth, New Jersey 07703-5023. We’ll send you a reply.
b. Air Force. Air Force personnel are encouraged to submit ElR’s in accordance with AFR 900-4.
c. Navy. Navy personnel are encouraged to submit ElR’s through their local Beneficial Suggestion Program.
1-5.
ADMINISTRATIVE STORAGE
Administrative storage of equipment issued to and used by Army activities will have preventive maintenance
performed in accordance with the PMCS charts before storing. When removing the equipment from administrative
storage, the PMCS should be performed to assure operational readiness. Disassembly and repacking of
equipment for shipment or limited storage are covered in chapter 4, section V.
Change 1
1-3
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
1-6.
DESTRUCTION OF ARMY ELECTRONICS MATERIEL
Destruction of Army electronics materiel to prevent enemy use is described in TM 750-244-2.
1-7.
NOMENCLATURE CROSS-REFERENCE
NOTE
Official nomenclature must be used when filling out report forms or looking up technical
manuals.
1-4
COMMON NAME
OFFICIAL NOMENCLATURE
Terminal
Terminal, Communications
AN/UGC-74A(V)3
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INTERFACE
Receives/transmits data in accordance with MIL-STD-188-114; 20/60 milliamp neutral;
NIK for use with TSEC/KW-7.
Communications line in MI L-STD-188-144 is + 6V polar, nonreturn to zero (NRZ) or
conditioned diphase.
These signals are converted to and from internal logic level signals.
RECEIVER/TRANSMITTER
Receiver decodes and converts serial input signals into parallel logic output.
Transmitter encodes and converts parallel logic input levels into serial signals.
Most of these operations are combined into one integrated circuit called a Universal
Synchonous/Asynchonous Receiver/Transmitter (USART).
Operation is possible in ASCII or Baudot at speeds controlled by switch selection.
CENTRAL PROCESSING UNIT (CPU)
Contains timing, microprocessor, scratch pad, random access memory, read only
memory, switch and lamp interface, and baud rate generator.
CONTROLS AND INDICATORS
Provide a man-machine interface, allowing manual inputs/operations and viewing of
system status.
MEMORY
Contains a program instruction read only memory (ROM) of 20K by eight bits each
(20K x 8) and a message storage random access memory (RAM) of 16K by five bits
each (16K x 5) which is a nominal ten pages of 1600 char/page.
PRINT CONTROL
Compares central processing unit’s commands to print commands with
character’s position on print-drum and initiates firing of print hammers.
PRINTING MECHANISM
Provides character/drum positional data to print control and converts electrical
signals to mechanical printing actions.
KEYBOARD
Consists of 63 keys.
59 standard keys required by MIL-STD-1280 (Type 1, Class 1) and four additional
editing keys.
Keyboard is an ASCII keyboard that is also Baudot compatible.
Keyswitches initiate character inputs to central processing unit (CPU).
1-5
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
1-11. SYSTEM APPLICATION
The terminal may be used in the following system configurations:
FULL-DUPLEX - This configuration employs both the terminal transmit and receive
capabilities and provides for simultaneous transmission and reception of data.
HALF-DUPLEX - This configuration utilizes only the terminal’s transmit and receive
capabilities and provides for nonsimultaneous transmission and reception of data.
SECURITY SUBSYSTEM - The block diagram below shows the terminal installed in a
security subsystem interfaced with a control unit, security equipment (send and receive)
and a send and receive signal converter (modem).
SYSTEM INTERFACE - The terminal interfaces with MIL-STD-188-114 compatible devices
such as:
Control Units, Security Equipment:
Modems (Signal Converters):
Telegraphs:
1-6
TSEC/KG-30
TSEC/KG-84
TSEC/KW-7
TSEC/KY-57
MD-522/GRC
TH-22/TG
(fig.
(fig.
(fig.
(fig.
(fig.
(fig.
1-2)
1-3)
1-4)
1-5)
1-6)
1-7)
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
LOW LEVEL INTERFACE
INPUT AND OUTPUT DATA TRANSMISSION ±1/8 CLOCK
PERIOD GATED CLOCK EDGE.
NOTE
lNTERFACE LINES ARE EITHER HIGH SPEED (>200KBPS) OR LOW SPEED
(< 200 KBPS ) AND REQUIRE THE USE OF COAXIAL CABLE AS FOLLOWS:
L O W S P E E D - R G - 6 2 A / A , HIGH SPEED-RG-598/U. THE SIGNAL RETURN
IS PROVIDED BY THE COAX WIRE SHIELDS.
INTERCONNECTIONS DESIGNATED ACCORDING TO AN/UGC-74 WIRING
DIAGRAMS * AN/UGC-74 OPERATE SIMULTANEOUSLY FROM BOTH GATED
REC. CLOCK HI AND RECEIVE CLOCK HI FOR FULL DUPLEX MODE
RECEIVE DATA OUTPUTOR XMT DATA INPUT
GATED REC. CLOCK OR XMT CLOCK
Figure 1-2. AN/UGC-74A(V)3 AN DKG-30 INTERFACE.
1-7
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
NOTE:
1.
ALL UNUSED MIL-STD 188 INPUTS TO THE
KG-84 MUST BE TIED TO THE APPROPRIATE
±6V TIE OFF POINT. (ASSUMED TO BE AVAILABLE
ON KG-84).
Figure 1-3. AN/UGC-74A(V)3 AND KG-84 INTERFACE.
1-8
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 1-4. AN/UGC-74A(V)3 AND KW-7 INTERFACE.
Change 1
1-9
TM 11-5815-602-24
EE161-DM-MMM-010/E154UQC74
TO 31W4-2UGC74-2
Figure 1-5. AN/UGC-74A(V)3 AND KY-57 INTERFACE.
1-10
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 1-6. AN/UGC-74A(V)3 AND MD-522/GRC INTERFACE.
1-11
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 1-7.
1-12
AN/UGC-74A(V)3 AND TH-22/TG INTERFACE.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
STANDARD FORM 368- QUALITY DEFICIENCY REPORT
1-13
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
CHAPTER 2
SERVICE UPON RECEIPT AND INSTALLATION
PAGE
Section I. SERVICE UPON RECEIPT
Packaging Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking Terminal AN/UGC-74A(V)3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Section Il. INSTALLATION INSTRUCTIONS
Assemblage Modification Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section III. PRELIMINARY SERVICING AND ADJUSTMENTS
lnstaller’s Test of Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-0
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section I.
2-1.
SERVICE UPON RECEIPT
PACKAGING DATA
a. TERMINAL. When packaged for shipment the terminal with the ASCII keyboard attached is
secured within its combination case and placed in a fiberboard carton. The fiberboard is sealed
with tape.
Table 2-1. SHIPMENT DIMENSIONS
2-1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
b. ACCESSORIES AND RUNNING SPARES. The copyholer is pocked in the case cover. All running
spares are packaged separately but are shipped with the terminal. The running spares are placed
in a polyshroud bag and sealed, and placed within the terminal shipping container. The fiberboard
tartan is sealed with tape.
NOTE
Data, power, and battery backup cables are not
issued with the equipment and must be ordered
separately.
Table 2-2. POWER CABLES AND FUSES
Power source
Cable
number
Fuse value
F1 and F2
2-2
115 Vac
SM-D-764481
1 1/2 A
230 Vac
SM-D-764482
1 1/2 A
26 Vdc
SM-D-764480
6 1/4 A
12 Vdc
SM-D-915890
2A (F3)
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
2-2. UNPACKING TERMINAL AN/UGC-74A(V)3
Refer to the following table.
Table 2-3. UNPACKING TERMINAL AN/UGC-74A (V) 3
2-3
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 2.3. UNPACKING TERMINAL AN/UGC-74A(V)3 . Continued
ITEM
ACTION
REMARKS
2. Terminal Continued
(4) Inspect for damage that may
have been caused during
shipment.
Report any damage on Form SF 364,
Packaging Improvement Report.
(5) Compare with Packing List.
Be sure shipment is complete.
Report any discrepancies of Form
SF 361. If packing list is not available.
check equipment against Components of End item List (COEIL) in
Appendix B of TM 11-5815-602-10.
Report any shortages in accordance
with AR 735-11.2.
(6) Check for modifications.
Check on front panel near
nomenclature plate for any
modification work order (MWO)
numbers. They will appear ONLY if
unit has been used or reconditioned. Current MWO’S which apply to
Terminal AN/UGC-74A(V)3 are
listed in DA Pam 25-30. Check to
see if all currently applicable
MWO’s have been applied.
Retain carton for storage purposes.
3. Carton
2-4
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section Il.
INSTALLATION
INSTRUCTIONS
2-3. TOOLS AND TEST EQUIPMENT
The tools and test equipment required for the installation of the AN/UGC-74A(V)3 are as
follows:
Item
Multimeter
Model No.
Quantity
AN/USM-223
1
1
TE-50B
Tool Kit
2-4. POWER SOURCES
The availability of at least one of the following fused power sources is required:
115 volts ac ± 15% at any of the following frequencies: 50 Hz ± 5%, 60 Hz ± 5%, or
a.
400 Hz ± 5%.
b. 230 volts ac ± 15% at any of the following frequencies: 50 Hz ± 5%, 60 Hz ± 5%, or
400 Hz ± 5%.
c.
2-5.
+22 to +30 volts dc.
ASSEMBLAGE
MODIFICATION
KITS
Modification kits have been developed for the assemblages listed below. The kits include
cables and all other components necessary to install the system. Refer to DA Pam 310-1 for the
pertinent
MWO
numbers.
a.
Radio
Teletypewriter
b.
Central
c.
Terminal Telegraph AN/TSC-58.
d.
Teletypewriter Central Office AN/MGC-17.
e.
Telegraph Terminal AN/MSC-29.
f.
Radio
Teletypewriter
Set
AN/VSC-2.
g.
Radio
Teletypewriter
Set
AN/VSC-3.
Office
Sets
AN/GRC-122
Teletypewriter
and
AN/GRC-142.
AN/TGC-30.
NOTE
The AN/UGC-74A (V)3 does not provide loop current. The 20 mA and 60
mA current, if required, must be supplied by external equipment.
2-6.
INSTALLATION.
(Initial installation to be performed by 31J or by MWO team only.) Refer to the following table.
2-5
Table 2-4.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
2-6
Table 2-4.
TM
11-5815-602-24
2-7
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 2-4.
2-8
Table 2-4.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
2-9
paragraph 3-22
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 2-4.
2-10
Table 2-4.
2-11
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
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Change 1
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TO 31W4-2UGC74-2
Section Ill.
PRELIMINARY SERVICING AND ADJUSTMENTS
2-7. PRELIMINARY CHECKS
Perform the following preliminary checks before locally testing the terminal:
2-8. INSTALLER’S TEST OF TERMINAL
After the terminal has been installed and the preliminary checks performed, the installer makes
two tests before turning the terminal over to the operator.
Table 2-5. Installer’s Local Test
Table 2-6. Initial Communication Test with Distant Station In the KSR State or Initial
Communication Test with Distant Station in the ICT State.
NOTE
Whether the Initial communication test wiII be
made in the KSR or ICT State wiII depend on the
operating state of the distant station.
If any test fails, refer to troubleshooting tables in chapter 4. Do not proceed with testing
until failure is corrected.
2-12
Table 2-5.
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2-13
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TO 31W4-2UGC74-2
Table 2-5.
2-14
Table 2-5.
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TO 31W4-2UGC74-2
2-15
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TO 31W4-2UGC74-2
2 - 1 6
Table 2-5.
Table 2-5.
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TO 31W4-2UGC74-2
2-17
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2-18
paragraph 4-8
Table 2-5.
Table 2-5.
2-19
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Change 1
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2-20
Table 2-5.
2-21
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Change 1
Change 1
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TO 31W4-2UGC74-2
2-22
Table 2-5.
Table 2-5.
2-23
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Change 1
Change 1
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TO 31W4-2UGC74-2
2-24
Table 2-5.
Table 2-5.
2-25
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Change 1
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TO 31W4-2UGC74-2
2-26
Table 2-6.
Table 2-6.
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TO 31W4-2UGC74-2
2-27
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TO 31W4-2UGC74-2
2 - 2 8
Table 2-6.
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TO 31W4-2UGC74-2
CHAPTER 3
FUNCTIONING
OF
EQUIPMENT
PAGE
Section
I.
FUNCTIONAL
DESCRIPTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
System Electrical Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
System Logic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Section
Il.
ELECTRICAL,
ELECTRONIC
AND
MECHANICAL
FUNCTIONS
Dustcover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3-34
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Keyboard Assembly (3A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Keyboard Operational Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Power Supply Assembly (3A1PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Printer Assembly, Major Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Printer Assembly, Mechanical Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Printer Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Teleprinter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Section Ill. TEST FIXTURES,
ELECTRICAL AND ELECTRONIC FUNCTIONS
Filter Assembly Test Fixture.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3-54
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3-53
Hammer DriverTest Fixture.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Hammer Module Test Fixture.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InterfaceAssemblyTest Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line-Feed/Current Control Test Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PowerSupplyTest Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3-61
. ..3-80
. . 3-64
. . 3-68
Keyswitch Assembly Test Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Powerand DataCables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3-1
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Table 3-1.
LIST
OF
ABBREVIATIONS
Meaning
Abbreviation
TTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transistor-Transistor Logic
Peripheral Interface Adapter
USART . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Synchronous Asynchronous
Electromagnetic Interference
EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver-Transmitter
Radio Frequency Interference
KSR . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyboard Send-Receive
ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read-Only
ICT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCR . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intelligent Communication Terminal
Random Access Memory
Silicon Controlled Rectifier
SCMO . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Control Motor Output
Memory
EMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . E l e c t r o m a g n e t i c P u l s e
DMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . D i r e c t M e m o r y A c c e s s
ETI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E l a p s e d T i m e I n d i c a t o r
Figure 3-1.
3-2
MECHANICAL
COMPONENTS
OF
TERMINAL.
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TO 31W4-2UGC74-2
Section I.
3-1.
FUNCTIONAL
DESCRIPTION
GENERAL
Due to the complexity of the system logic and the utilization of automatic test equipment for
fault isolation and testing, only functional descriptions of the system logic, i.e., CPU (Central
Processing Unit), Printer, Memory, and COMM (Communication) Control are presented. All
other electronic and mechanical functions are presented in sections II and Ill of this chapter.
Abbreviations used in this chapter are presented in table 3-1.
Figure 3-2.
FUNCTIONAL
BLOCK
DIAGRAM
● The keyboard keys actuate the keyswitch assembly which contains logic circuitry to
convert the keyswitch inputs into an eight bit serial data word which is input to the
CPU.
● Interface between the CPU and the rest of the system are by point to point wiring and
data/address buses.
● Address Bus - Set of 16 parallel lines which allow more than 64,000 addresses to be
selected by the CPU.
● Data Bus - Set of eight parallel lines which may send or receive data to or from the interfacing circuit card assembly.
The two data buses interface with the Memory Circuit Card Assembly, the Communications Circuit Card Assembly, and the Print Control Circuit Card Assembly.
3-3
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3-2.
SYSTEM
LOGIC
FUNCTIONS
System logic functions are divided into the following:
Keyboard input
Receive data input
Internal
timing
Internal
processing
Printer control
Line-feed functions
Data transmission
Figure 3-3. KEYBOARD DATA FLOW.
KEYBOARD
INPUT
-
Keyboard logic generates an interrupt request whenever a character is
entered from the keyboard.
Upon receipt of interrupt, CPU circuit card reads first bit of character
from the PIA which generates a keyboard clock pulse.
Clock pulse is sent through PIA to keyboard.
One bit of serial data is then stored in microprocessor accumulator,
Reading second data bit causes generation of a second keyboard clock
pulse.
Third data bit is shifted to PIA.
This process is repeated until all eight bits are loaded into
microprocessor.
Control clock (2400 Hz) is received from clock generator circuitry on
CPU circuit card.
3-4
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TO 31W4-2UGC74-2
Data
is
then
conditioned
for
TTL
processing
by
communications
circuit
card.
Universal synchronous/asynchronous receiver/transmitter (USART) converts serial data to parallel data and places it on data bus.
Figure 3-4.
RECEIVE DATA FLOW.
R E C E I V E D A T A l N P U T - Receive data line interfaces with interface assembly.
Presence of input character is indicated to CPU by an interrupt request
from the USART.
ASCIl/Baudot data is read by microprocessor, converted by CPU to
ASCII and loaded into RAM until 80 characters are read, a carriage
return is read or a 10 second time out occurs.
Code conversions required are dependent upon availability and utilization of memory circuit card.
If data is to be placed into message storage, it is retrieved from scratch
pad memory (RAM), converted to Augmented Baudot and stored in
message storage.
3-5
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Figure 3-5.
INTERNAL
CPU
BLOCK
DIAGRAM
T I M I N G - CPU circuit card contains Process timing circuitry which is driven by a
4.9152 MHz oscillator.
Clock generator produces Phase 1 and Phase 2 clocks:
Control clock
Baud-rate clock
Memory clock
Baud-rate
generator
provides
timing
for
communications
circuit
card.
Direct memory access and refresh control provide an enable to the transmit control
logic and RAM, transferring data from RAM to transmitter.
INTERNAL
P R O C E S S I N G - Data received by PIA on CPU circuit card is read by CPU and stored
in an accumulator.
ROM causes coded data word to be converted into ASCII or Augmented
Baudot depending upon presence or absence of memory.
If memory circuit card is present, Augmented Baudot is used.
Without memory, ASCII is used.
When data is to be printed, it is read from memory, loaded into
microprocessor accumulator and converted to printer compatible code.
In event memory is not present, or terminal is in KSR state, input data is
converted to ASCII, stored in RAM on CPU circuit card, retrieved from
RAM, and converted to printer compatible format.
3-6
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TIMING AND PRINTER CONTROL -
Power supply regulates timing index pulse, which activates print control
card. Data stored in either memory or in CPU RAM is selected to be
printed by CPU. CPU card converts keyboard characters to print codes
which trigger appropriate print hammers.
When POWER switch is turned on, CPU card (A1A1) sends a signal that causes indicator
lamps to be turned on. This signal is also applied to print control (A1A4).
A1A4 sends a signal back to A1A1, which then turns off lamps.
Initial signal from A1A1, and signal from A1A4 are also applied to DC power supply, causing
power supply drum MOTOR control to turn on, thus applying voltage to motor.
Motor causes timing mechanism’s outputs to start pulsating.
A1A4 receives pulse signals from timing mechanism and transfers them to power supply.
Power supply compares timing signal against a reference clock and adjusts signal by
increasing or decreasing voltage to motor.
NOTE
Printing process of AN/UGC-74 differs from that of other
teletypewriters in that AN/UGC-74 can print multiple
characters in various locations at one time using print codes
which represent both the selected character and its
intended location on print drum.
Data stored in CPU accumulator is converted from ASCII or Augmented Baudot (as
appropriate) to a print code, which uniquely identifies character to be printed in terms of print
position on print drum.
Print codes are loaded into 80-column memory, which holds one line of message.
A1A4 continuously checks A1A1 to see if anything needs to be printed.
If printing is to occur, index pulse from timing mechanism sets A1A4 counter to 0.
A1A4 starts counting rows on print drum using pulse generated by timing mechanism. As a
row is counted, A1A4 compares print codes in that row with print codes in 80-column
memory.
When a match occurs, A1A4 selects print hammer to be activated. (If print hammers one or
two are to be used, A1A4 will send a signal to print hammer driver card one. For hammers
three or four, print hammer driver card two receives signal.
Print hammer driver makes a voltage available to selected hammer on all twenty cards.
A1A4 also applies a signal to pin 3 of print hammer card which provides a ground required
for magnet to energize.
Other functions provided by printer control are:
Ribbon lift/drop command
Elapsed time indicator (ETI) control
Constant current control
Audible alarm control
Change 1
3-7
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Figure 3-5.1. TIMING AND PRINT HAMMER ACTIVATION.
3-8
Change 1
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LINE-FEED FUNCTIONS - CPU automatically generates a line-feed command to printer after
eightieth hammer has been fired or a carriage return has been received.
DATA TRANSMISSION - When transmit data command is entered, data to be transmitted is
converted to appropriate ASCII or Baudot code format containing even or
odd parity, and stop bits.
Change 1
3-8.1
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TO 31W4-2UGC74-2
Figure 3-6.
CPU CIRCUIT CARD ASSEMBLY.
CPU Circuit Card Assembly (3A1A1)
The Central Processing Unit (CPU) is the heart of the terminal and performs the following functions:
Clocking/timing generation
Input data processing
Switch and lamp interfaces
Program memory
Scratch pad memory
3-8.2
Change 1
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TO 31W4-2UGC74-2
Figure 3-7. MEMORY CIRCUIT CARD ASSEMBLY.
Memory
●
●
Circuit
Card
Assembly
(3A1A2)
Contains Read-Only Memory (ROM) and Random Access Memory (RAM) for use in
text editing and storage.
The AN/UGC-74A(V)3 can operate without this circuit card, however, message
storage and full editing capabilities are not present and the terminal reverts to the
Keyboard Send Receive (KSR) state.
3-9
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Figure 3-8.
COMMUNICATIONS CIRCUIT CARD ASSEMBLY.
Communications Circuit Card Assembly (3A1A3)
Receive and transmit data interfaces with the terminal through the interface
assembly which interfaces with the communications circuit card. The overall function is to condition input and output data so that it is compatible with its respective
interfaces. This conditioning includes modulation and demodulation for conditioned
diphase data.
Key interface is the Universal Synchronous/Asynchronous Receiver Transmitter
(USART). All data enters and exits through the USART. The USART converts
receiver serial input data to parallel and parallel transmitter output data to
serial.
3-10
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Figure
3-9.
PRINTER
CONTROL
CIRCUIT
CARD
ASSEMBLY.
Printer Control Circuit Card Assembly (3A1A4)
Responds to print commands from the microprocessor on the CPU circuit card. On
command, the print control reads characters from the memory. Each character is
stored in an 80 location print buffer in the CPU RAM memory.
As each of the print drum’s 64 rows pass under the hammers, the 80 locations are
read and the appropriate hammer for each column is commanded to fire when the
character
appears
approximately
1½
characters
before
the
hammer.
The print control, (control circuit) also issues the line feed drive command to the line
feed stepping motor, as well as performing other miscellaneous functions as
follows:
Ribbon-lift
control
Audible alarm drive
External control interface with system logic
Precision timing signal for drum speed control
3-11
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TO 31W4-2UGC74-2
3-12
Figure 3-10.
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TO 31W4-2UGC74-2
Harness Assembly - All system electrical interfaces from the logic circuit card to power
supply, dustcover, and interface assembly, come through the harness assembly.
The harness assembly is composed of the motherboard, dustcover, power supply, and
interface harness.
LEGEND FOR HARNESS ASSEMBLY
KEY
KEY
INTERFACE
INTERFACE
Connector (P5) -
Copy
Switch (S3) -
Transfer
Lens
Parity Reset
Lens Seal -
Abort
Connector (P1) -
Keyboard
Connector (P2) -
Interface
Switch (S4) -
Audible Reset Alarm
Connector (P3) -
Power Supply
Switch (S5) -
Line Feed
Electrical interface
Resistor (R1) -
2.5k Audio Pot
Resistor (R2) -
2.5k Ilium Pot
Switch (S2) Switch (S1) -
Motherboard
-
illumination
Inductor L2
Copy Lamps DS9 and DS10
Assembly
-
Parity
Reset
Parity
Reset
(System)
Connector (P4) -
Inductor L1
PERIPHERAL INTERFACE ADAPTER (PIA)
The principle interface between the logic
circuits
and
the
CPU
is
the
PIA.
The CPU, Printer Control and Communications circuit cards each contain an
MC6820, or equivalent integrated circuit which performs the PIA function.
The PIA may be thought of as a traffic control device, which depending upon
the input control signals, allows data to flow into and out of the circuit.
The peripheral inputs and outputs are discrete lines which interface with only a
single component; i.e., switch, Iampdriver, audible alarm driver, etc.
The logic circuits interface with two sets of bidirectional data buses:
DATA BUS - Functions as input or output lines depending upon control
signal.
ADDRESS BUS - Provides interfaces for process control and data routing
functions.
The bidirectional capabilities are made possible by the use of tri-state logic.
UNIVERSAL SYNCHRONOUS/ASYNCHRONOUS RECEIVER TRANSMITTER (USART)
. External data lines which interface with the terminal carry serial data. Since the terminal processes the data in parallel, a converter must be provided to change the input data from serial to parallel and the output data from parallel to serial.
This task is performed by the USART which is a AMD9551, or equivalent integrated circuit mounted on the Communications circuit card.
TRISTATE LOGIC
Conventional Transistor-Transistor-Logic (TTL) Devices.
uses two states; i.e., logic 1 (+4.75Vdc) and logic 0 (0
- Conventional
to 0.5Vdc).
TTL
Logic
Both these states result in low impedance paths either to ground or to the Vdc
(+5V)
supply.
The interface line between the output device and the input devices is PULLED
toward ground or Vdc supply as required by the output circuit.
The impedance of this type of operation precludes wiring together the outputs of
other drivers which may drive the same logic circuitry.
Therefore, additional interface lines and logic must be provided for these other
drivers.
3-13
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Tristate TTL Devices - Tristate TTL devices utilize the same two logic states as
conventional TTL devices.
However, in addition to the low impedance logic 1 and logic 0, a third state
(high impedance) is provided.
In this state, the output device(s) offer a high impedance to the interface line
which causes it to appear much like an open Circuit.
MICROPROCESSOR
Located on the CPU circuit card.
Controls all internal processing functions and performs the “intelligent” functions of the
terminal.
Directed in process control functions by programmed instructions contained in the ROM
(Read-Only Memory).
READ-ONLY MEMORY (ROM)
Permanently formed memory containing instruction or code conversion tables.
In the CPU, a ROM instructs the microprocessor what to do and when to do it.
In the KEYBOARD, ROM’s translate 16 bit keyswitch code into six bit keyboard code.
In the MEMORY CIRCUIT CARD, ROM’s provide instruction to the CPU for Intelligent
Communication Terminal processing (lCT).
RANDOM ACCESS MEMORY (RAM)
Integrated circuit located on the CPU circuit card.
Microprocessor uses the RAM as a temporary storage device in performing processing
calculations.
Figure 3-11.
3-14
RELATIONSHIP BETWEEN RAM, ROM, AND MICROPROCESSOR.
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Section Il.
ELECTRICAL, ELECTRONIC, AND MECHANICAL FUNCTIONS
3-4. KEYBOARD ASSEMBLY (3A2)
Keyboard assembly is composed of a panel assembly and a keyswitch assembly, which are
mounted
together
in
a
housing
assembly.
Panel assembly:
Contains 63 keys arranged
and Iabelled to meet ASCII,
and Baudot requirements.
Electronics
of
terminal
elec-
tronically translate input from
keyboard into either ASCII or
Baudot mode depending upon
selected operating mode.
Keyswitch assembly:
Keyswitch assembly
contains
logic circuitry to convert
keyswitch inputs into an eight
bit serial data word which is
input to CPU circuit card.
Each key actuates a Honeywell SD Type Hall Effect switch which is mounted immediately below keyboard.
Each keyswitch has a shaft which is mounted within a rubber boot to provide environmental protection.
The shafts come in contact with Plungers on keyswitch assembly, but are not attached to
them.
This allows panel assembly to be removed with removing keyswitch assembly.
Keyboard is optional equipment; without it terminal has only RO capability.
3-15
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3-5.
KEYBOARD
OPERATIONAL
DESCRIPTION
When the terminal keyboard is operated, the keyswitches generate logic “0” output. All the
keyswitches except SHIFT (2 keys), LOC, REPEAT, and CONTROL are wired into an 8 x 8
row/column matrix. The LOC key is an alternate action key. When pressed, it locks in the down
position until a second depression releases it. This key provides the SHIFT LOC function. The
REPEAT key causes the last character entered to be repeated.
Figure 3-12.
KEYBOARD BLOCK DIAGRAM.
(1) The matrix output appears as two 8-bit words. Each 8-bit word represents a row and column address for the respective ROM encoders. The 8 x 8 matrix outputs are normally all a logic 1.
When a keyswitch. other than the LOC/SHIFT. CONTROL, and REPEAT is operated, the two
matrix outputs change from all 1‘s to a single logic 0 and seven logic 1‘s for both the row and
the column outputs. The position of the zeroes provide the row/column address of the operated
switch. The presence of more than one zero in the address indicates that more than one
keyswitch is operated. In such cases the ROM’s (U1 and U3) ignore the address until one of the
keys is released and a legal address is again recognized.
3-16
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-13 (1).
3-17
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-13 (2). KEYBOARD LOGIC DIAGRAM (Sheet 2 of 3).
(2) Having recognized the keyswitch address, the ROM generates a six-bit code representing
the actuated keyswitch. The six bits generated for each key are provided in table 3-2. These six
bits are input to an eight-bit shift register. Both outputs enabled from U1 and U3 become a logic
0 when a keyswitch address is recognized. The presence of a logic 0 of U5 pins 6 and 5 causes a
logic 1 of U5 pin 4. Flip-flop U6 pin 2 is a logic 1 because it is wired to +5V. U6 pin 5 is a logic 0
due to an earlier clear pulse from U5 pin 10. The change of the output on U5 pin 4 from a logic 0
to a 1 causes output of U6 pin 5 to become a logic 1. The logic 1 at U6 pin 5 causes a logic 1 at
U6 pin 12. The output at U6 pin 9 is a logic 0 until U9 pin 8 output changes from a logic 0 to a
logic 1. When this occurs, U4 pin 2 becomes a logic 1. Output U4 pin 5 becomes a logic 1 on the
next change of U9 pin 8 from a logic 0 to a logic 1. When U4 pin 5 is a logic 1, U4 pin 6 is a logic
0 which enables new data to be loaded into shift register U2. The first KYBD CLK steps the first
bit (b 1 ) out of the shift register (U2) and also causes a logic 0 at the output of U5 pin 10. This
logic 0 resets flip-flops U6 and U4 and causes KYBD LD to become a logic 0 again.
3-18
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
F i g u r e 3-13 (3). KEYBOARD LOGIC DIAGRAM (Sheet 3 of 3).
(3) The character in the shift register is shifted bit by bit by the KYBD CLK from the CPU circuit card. With each clock pulse, the data is loaded back into the register so that at the end of
eight clock pulses, the same data is again available. The recycling of the eight bits of data allows
the character to be regenerated with the REPEAT key.
(4) When the REPEAT key is pressed, the logic 0 appears at U5 pin 2. When pin 11 of U8 is a
logic 0, the 12-bit binary counter (U8) divides the 2400 Hz by 512 to produce a positive transition
at pin 14 every 213 ms (4.7 times per second). The logic 1 on U8 pin 14 produces a logic 0 at U7
pin 6 and U5 pin 3. When U5 pin 3 becomes a logic 0, U5 pin 1 becomes a logic 1. The KYBD LD
again becomes a logic 1, resulting in the generation of KYBD CLK. The first KYBD CLK pulse
resets the counter (U8) causing U7 pin 6 to become a logic 1. U5 pin 1 becomes a logic 0 causing
U7 pin 4 to become a logic 0. At the end of 213 ms (nominal), U7 pin 6 again becomes a logic 0. If
the REPEAT keyswitch is still operated, the cycle is again repeated. In any case, the character remains in the register until a new character is input.
3-19
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-2. CHARACTER CODE MATRIX
B8 (control)
0
0
1
1
B7 (shift)
0
1
0
1
Unshifted
b6
b5
b4
b3
b2
b1
controlled
1
1
1
1
1
1
BS
1
1
1
1
1
1
1
1
1
0
1
2
1
1
1
1
0
0
0
3
1
1
1
0
1
1
4
1
1
1
1
0
0
1
0
1
5
6
7
1
BS
!
“
#
&
/
(
)
0
=
8
(
9
)
0
=
1
0
1
1
0
1
1
1
1
0
1
0
0
1
1
1
0
1
0
0
0
—
1
1
0
0
1
1
ESC
ESC
1
1
0
1
1
1
1
1
1
1
0
0
0
0
1
1
0
0
0
1
1
0
0
1
1
0
1
0
1
0
GS
TAB
REV
DCI
ETB
GS
TAB
REV
DC I
ETB
1
0
1
1
0
1
ENQ
0
1
1
0
1
0
0
1
0
1
DC2
0
0
1
0
0
0
1
1
1
1
1
1
1
1
1
1
1
e
E
r
DC4
DC4
t
R
T
0
1
EM
NAK
EM
NAK
i
o
0
0
1
0
1
0
1
FS
I
o
DLE
NUL
FS
Y
u
i
o
1
0
1
US
DEL
H LT
US
DEL
H LT
0
1
SOH
DC3
0
1
EOT
ACK
SOH
DC3
EOT
0
1
BEL
h
j
0
0
1
1
0
0
0
0
0
1
1
1
0
0
0
1
1
0
0
0
1
1
0
0
0
1
1
0
0
1
1
1
1
1
1
1
0
1
1
1
0
0
0
1
0
1
1
0
1
0
1
1
0
0
1
1
0
0
1
0
1
0
0
1
1
1
0
0
1
(
DC2
0
0
0
0
0
(
)
TAB
REV
ENQ
1
1
1
0
0
0
q
w
0
0
1
3
4
)
TAB
REV
Q
W
0
0
0
1
1
1
2
BS
!
“
5
0
1
BS
6
7
1
1
8
9
uncontrolled
Shifted
uncontrolled
&
I
1
0
1
Unshifted
#
$
%
$
%
0
0
1
1
1
3-20
1
1
Shifted
controlled
0
1
0
1
0
DLE
NUL
V/T
FF
;
ACK
BEL
H
J
VT
FF
+
*
P
Y
U
I
o
P
\
@
\
—
1
_
DEL
DEL
H LT
a
s
H LT
d
f
A
s
D
F
9
h
G
H
j
k
J
K
L
+
*
I
;
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-2. CHARACTER CODE MATRIX
- Continued
B8 (control)
0
0
1
1
B7 (shift)
0
1
0
1
Unshifted
Shifted
Unshifted
Shifted
controlled
controlled
uncontrolled
uncontrolled
RS
ˆ
DLL
DLL
SUB
CR
z
CR
z
CAN
ETX
CAN
ETX
x
c
x
SYN
SYN
v
V
STX
SO
m
STX
SO
M
b
n
B
N
m
’
<
’
>
?
D LC
.
/
DLC
M
<
>
?
DLC
LF
LF
LF
Space
Space
Space
b6
b5
b4
b3
b2
b1
0
0
1
1
0
0
1
1
0
0
1
0
0
1
0
0
1
1
CR
CR
0
1
0
0
1
0
SUB
0
0
1
1
0
0
0
0
0
0
1
0
0
0
1
1
1
1
0
0
1
1
1
0
0
1
1
0
1
0
0
0
0
1
1
1
0
0
1
0
1
0
0
1
0
1
0
0
0
0
0
1
1
0
0
0
0
1
0
0
0
0
0
0
0
1
1
1
1
0
1
0
RS
DLL
.
/
DLC
LF
Space
DLL
¬
c
3-21
TM 11-5815-602-24
EE181-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-14.
3-22
TELEPRINTER ASSEMBLY.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
TELEPRINTER ASSEMBLY
PRINTER ASSEMBLY - 3A1
Converts input signals from processing logic circuit cards into printed text.
DUSTCOVER ASSEMBLY - 3A1
Contains system operating controls once mode is selected. Indicators are visually
observable and allow constant monitoring of terminal operation.
(MOTHERBOARD) HARNESS ASSEMBLY - 3A1
Provides access to all inter-related Interfaces between the logic assemblies, power
Supply, and interface assembly.
PROCESSING LOGIC CARD ASSEMBLIES
CPU Circuit Card Assembly - 3A1A1
Memory Circuit Card Assembly - 3A1A2
Expands terminal capacity for editing and storage purposes.
Communications Circuit Card Assembly - 3A1A3
Conditions input/out data making it compatible with respective interfaces,
Print Control Circuit Card Assembly - 3A1A4
Converts electrical signals into print commands.
INTERFACE ASSEMBLY - 3A1A7
The interface assembly serves three functions:
Power mode switching
Mode selection
Data input/output level conversion
FILTER ASSEMBLY - 3A1A6FL1
Converts and filters 115/230 Vac 50/60/400 Hz power to 22-30 Vdc . Also provides EMI
filtering.
CHASSIS ASSEMBLY
Provides easy access for mounting and repair of components.
POWER SUPPLY ASSEMBLY - 3A1PS1
Provides dc power for all functions as required. Also provides battery backup sensing
and switching.
Change 1
3-23
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-7.
3-24
PRINTER ASSEMBLY
MAJOR ELECTRONIC COMPONENTS
TM
11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
MOTOR DRIVE AND CURRENT CONTROL BOARD ASSEMBLY.
This assembly is composed of a line-feed/current controller and a line-feed driver. Assemblies
mount together to make a single component mounted on left hand side of printer assembly.
3-25
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
(1)
Line-Feed
Control
System
Interconnection between controller, line-feed stepping motor and driver as well as circuitry contained on each circuit card is shown below.
Figure 3-15(1). LINE FEED CONTROL SYSTEM (Sheet 1 of 2).
(2) Line-Feed Controller
+22 to +30 Vdc is applied to P1-P and ON/OFF control signal is applied to P1-L. During
periods of time when line-feed function is not required, Pin L is at a logic 0 forcing Q1 to off condition. In turn, base of Q2 rises to between +22 and +30 Vdc causing it to turn off. With Q2 off,
Q3 and Q4 also turn of opening path from +22 to +30 Vdc supply to line-feed stepping motor.
However, when P1-L becomes a logic 1, Q1 turns on, causing voltage at base of Q2 to drop to between 11.4 and 15.5 Vdc. With base of Q2 at between 11.4 and 15.5 Vdc, and emitter at +22 to
+30 Vdc, Q2 turns on. Q2 turning on causes base of Q3 to become between 9.7 and 13.2 Vdc.
Voltage at junction of R3 and R4 drops to between 19.6 and 26.6 Vdc. Voltage at base of Q4 is
now approximately 10% less positive than voltage at P1-P, causing Q4 to be biased on. Diode CR2
and resistors R5 and R6 provide transient protection during field collapse in stepping motor windings. Circuitry associated with P1-H is not used in this application.
3-26
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-15(2). LINE FEED CONTROL SYSTEM (Sheet 2 of 2).
(3) Line-Feed Drivers
Line-feed drivers function as gates allowing current to flow through selected line-feed stepping
motor windings. A logic 1 applied to A0, A1, B0, and B1 causes respective transistors Q1, Q2, Q3,
and Q4 to turn on and provide a low impedance path for +22 to +30 Vdc to ground. Each gate
allows current to flow for 13.3 ms at a time. Diodes are provided across gating transistors to pro
vide suppression of transients created by collasping magnetic fields when gates are switched.
3 - 2 7
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-8.
PRINTER
SUBASSEMBLY
Printer subassembly major electrical and electronic components:
Ribbon-lift mechanisms
Print driver modules
Print hammer modules
RIBBON-LIFT
MECHANISM
The left and right ribbon-lift mechanisms form the left and right hand ends of the printer
subassembly. The electronic components for the left and right ribbon-lift mechanisms are
mounted on the right ribbon-lift mechanism.
Figure 3-16 (1). RIGHT-HAND RIBBON MECHANISM CIRCUITRY (Sheet 1 of 2).
3-28
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-16(2).
RIGHT-HAND RIBBON MECHANISM CIRCUITRY (Sheet 2 of 2).
P1-1 is wired to +18 Vdc. When a ribbon-lift action is required, a logic 1 is applied to P1-6 of
the driver circuit card assembly which causes Q1 to turn on. This provides a path to ground for
the +18 Vdc through the lift solenoid coils. The current through the coils energizes the
mechanical lift mechanism. The drop mechanism is operated through Q2 when a logic 1 is applied to P1-5.
Figure 3-17(1).
LEFT-HAND RIBBON MECHANISM CIRCUITRY (Sheet 1 of 2).
3 - 2 9
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-17(2). L E F T - H A N D
RIBBON
MECHANISM
C l RCUITRY (Sheet 2 of 2).
Figure 3-18(1). PRINT DRIVER (Sheet 1 of 2).
3-30
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Each module contains two print driver circuits supplying +18 Vdc to the print hammer
modules when a print hammer is to be operated. The 4 drivers (two per module) are assigned
respective groups of 20 hammer assemblies. Each hammer assembly contains four hammers.
Figure 3-18(2).
PRINT HAMMER DRIVER (Sheet 2 of 2).
Pins 5 and 6 of P1 are connected to ground. Pins 1 and 3 are connected to +5 Vdc externally,
and pins 11 and 12 are connected to +18 Vdc. Outputs at pins 7, 8, 9, and 10 are connected to
each of the respective hammer driver modules.
Figure 3-19.
HAMMER SYSTEM.
Change 1
3-31
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Since pins 1 and 3 are tied to +5 Vdc when pin 2 is set to a logic 1, the 0, output of U1 Is at
ground potential, creating a voltage divider as +18 Vdc flows through R1 and R2.
The current flow causes the base of Q1 to become less positive than the emitter and causes It
to conduct. The conduction of Q1 properly biases Q2 to the ON condition making the 18 Vdc
available for firing the hammers.
Figure 3-20. UI (HYBRID DRIVER).
The remaining output circuit Is operationally identical to the one previously described and is
applied to one of the remaining groups of 20 hammer modules. The 39 volt Zener diodes CR2 and
CR4 are placed in the circuit to prevent inductive spikes, caused by the collasping field of the
print hammer coil, from damaging circuit components.
3-32
TM 11-5815-602-24
EE181-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
PRINT HAMMER MODULE(S)
Figure 3-21.
Twenty
identical
print
hammer
modules
are
PRINT
HAMMER.
contained
in
the
printer
subassembly.
Each module contains circuitry controlling the operation of four print hammers (fig. 3-19),
P1-3 receives its input from the print control circuit card assembly. Pins 1, 2, 5 and 7 receive
their inputs from the print drivers on circuit card assemblies. Pin 4 is connected to +5 volts and
pins 6 and 8 are circuit ground.
Selection of a print hammer module is accomplished when the output of one of the drivers on
the print hammer driver circuit card assembly is turned on, and an input is received on connector
pin 3. This, in turn, turns on silicon control rectifier (SCR) CR5. Ground is now applied to the
junction
of
the
four
solenoids.
When one of the four print drivers is energized, a +18 Vdc input pulse is received at either connector pin 1, 2, 5, or 7, which energizes the associated print hammer coil. Energizing the coil
pulls in the armature of a print hammer and causes the hammer to strike.
3-33
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ELASPED
TIME
INDICATORS
Two elasped time indicators are mounted on
the top cover of the printer subassembly.
NOTE
Elapsed time meters are installed in
terminals serial numbered 1 through 2000.
The
time
meters
manufacturer
will
starting
be
deleted
with
by
serial
the
number
2001. Time meters will not be replaced in
terminals numbered 1 through 2000.
Right-hand
indicator
records
the
total system operating time (10,000
hour range)
Left-hand indicator records the time that the drum has been in operation (1,000 hour
range)
Both the indicators must be replaced (as part of the cover assembly) when either of
their respective limits is reached.
3-9.
DUSTCOVER
ASSEMBLY
Contains the controls and indicators for operating the terminal. The front cover is shown
schematically on the next page.
Refer to the operator’s manual for description and use of operating controls.
3-34
TM 11-5815-602-24
EE181-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 3-22.
DUSTCOVER
WIRING
SCHEMATIC
DIAGRAM.
3-35
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-10.
INTERFACE
ASSEMBLY
I n t e r f a c e a s s e m b l y c o n t a i n s c i r c u i t r y n e c e s s a r y for interfacing of external data and
power
It
POWER
also
lines
with
contains
internal
internal
system
electronics.
operating
switches.
INTERFACE
Prime power, either ac or dc, enters unit through connector J2 located on rear of interface assembly.
Fuses F1 and F2 on assembly provide protection against drawing excessive current
and are of different values depending upon input power source.
AC input - fuse size is 1½ amperes.
DC input - fuse size is 6¼ amperes.
Backup power which enters through J3 (on rear of assembly) is fused by F3 at 2
amperes.
Switch S1 routes input voltage (except backup) back to J2 where strapping in
mating connector routes voltages to appropriate pins for application to filter
assembly.
Backup power is routed directly from S1 to filter assembly.
3-36
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
RECEIVE
DATA INTERFACE
Two types of input data to terminal may be used.
First type is a neutral current loop of 60 or 20 mA with a maximum voltage of
130 Vdc.
Second type is a standard low level, either inverted or non-inverted data.
Operator selects appropriate mode by setting REC MODE switch (S11) to desired
position.
Protection of input circuitry is provided by resistors RI, R2, R3, and R4 on TB1.
Receive data is converted to TTL level on RX/TX circuit card.
Figure 3-23.
RX/TX CIRCUIT CARD ASSEMBLY.
3-37
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Gate U2 is enabled when either 60 or 20 mA inputs are low. The REC MODE switch provides
this condition when 60 or 20 mA modes are selected. If the standard low level signal modes are
selected, the input to U2 pins 12 and 13 are a logic 1. Input data is fed directly to U4 pins 9 and
10. The output of U4 is fed to U1 pin 11 which is enabled by a logic 1 on U1 pins 9 and 10. The
output of U1 (U1 pin 8) drives U2 pin 4. Since U2 pin 5 is a constant logic 1, the gate U2 is
enabled to pass the data at U2 pin 4 at TTL levels. When the REC MODE switch is in 20 mA,
60 mA or 49V position, U2 pin 11 is a logic 1. The switch also routes the data directly to a diode
bridge. The bridge steers nonpolarized input current through sensing resistor R7 in the 60 mA
mode. The lower combined resistance allows greater current flow through R7/R8 combination
without increasing the voltage across them. When VR1 fires, current flows through the optical
coupler (U3). U3 inputs the data to U2 pin 9. Since U2 pin 10 is a logic 1, data flows from U2
pin 8 to U2 pin 5 and is output from U2 pin 6.
RFI
AND
TRANSIENT
PROTECTION
Within the interface
assembly is an EMI
enclosure containing a
diode circuit card
assembly and filters. The
diodes provide transient
suppression and reduce
conducted interference
on the data lines.
3-38
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
TRANSMIT DATA INTERFACE
T h e t r a n s m i t i n t e r f a c e circuitry functions similarly to the receive except for the
translation levels.
When the XMIT MODE switch is in the 20(mA), 60(mA) or 70(mA) position, U1 pin 6 is
a logic 1. U2 pin 3 is enabled to allow transmitted data to modulate at the Hi level
dc source. The modulation is accomplished by switching Q3 on and off which in
turn causes contacts of K1 to open and the current path to close.
CLOCK
INTERFACES
Clock
interfaces
are performed by
receivers
and
drivers as applicable.
POWER SUPPLY INTERFACE
Input power from the power
supply to the RX/TX circuit card
is ±8.6 Vdc. Both voltages are
regulated to provide +5 Vdc and
–5 Vdc for the transmit and
receive circuitry.
3-39
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3 - 4 0
Figure 3-24.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-11. POWER SUPPLY ASSEMBLY (3A1PS1)
Power supply assembly for terminal is a circuit card assembly located on bottom of chassis
below paper roll.
Figure
3-25.
POWER SUPPLY ASSEMBLY.
Refer to figure 3-24 for the input and output pins and test points of the power supply assembly.
Power supply is described in terms of:
.
.
Input circuitry
Microprocessor
supply
l +5, ±8.6 Vdc circuitry
l Drum motor supply
l +18 Vdc constant current
supply
3-41
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure
3-26.
POWER
SUPPLY
BLOCK
DIAGRAM.
P O W E R S U P P L Y I N P U T C I R C U I T R Y (fig. FO-3.) Ac or dc input power may be applied to the
power supply input circuit. The input power connector A7J2 is wired with pins M and K used for
either ac or dc input. The prime power is switched through S1 on the interface assembly (3A1A7)
and routed back to the A7J2 connector. If the connector is wired for 115 Vac power, pins B, D and
L are strapped together. Pins A, C, and J are also strapped together. The strapping ties the input
power to the appropriate windings of the input transformer (part of 3A1A6FL1). If other than 115
Vac power is supplied, the strapping is as shown.
The rectifier circuit (part of 3A1A6FL1) is a conventional full wave rectifier which is
filtered to produce a +22 to +30 Vdc output. This voltage is used as the primary
source for all power supply circuits.
The backup power indicator drive (U12) is a comparator which drives a lamp driver on
3A1A1 to illuminate the backup lamp on the dustcover whenever the +22 to +30 Vdc
output of the supply drops more than 0.4 volts below the backup power voltage.
The backup power cable supplies +12 Vdc backup power via connector 3A1A7J3. When
prime power is lost, the power supply automatically enables the +12 Vdc battery power
to the microprocessor and memory. The positive side of this dc source is routed through
this third section of 3A1A7S1, fuse 3A1A7F3 to connector 3A1A7J4 pin 8. The negative
side in routed to connector 3A1A7J4 pin 6. The chassis return is routed through pin C of
connector 3A1A7J3.
The backup input voltage is diode ORed with the unregulated +22 to +30 volts dc to
provide the power input to the microprocessor switching regulator.
Voltage limiting is provided to the ±5V, ±8.6V and the motor control circuit controllers
U2 and U4, by limiting resistor R1.
(fig. FO-4.) The microprocessor supply section of the power supply
MICROPROCESSOR SUPPLY
(3A1PS1) provides ±5 Vdc and +12 Vdc for the CPU (3A1A1) and memory circuit card assembly
(3A1A1). The supply is regulated to ±5% by a constant frequency pulse width modulated switching
3-42
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TO 31W4-2UGC74-2
regulator. The regulator (U1) samples the output voltage of the supply and compares it
against a reference voltage. Depending on the results of that comparison, the pass circuit (U5)
turn-on duty cycle is increased or decreased.
The reference voltage is a function of the regulator (U1). Resistors R11, R12 and R13
form a voltage divider which produces a 2.5 Vdc reference voltage for the comparator
(part of U1). The precise value of the voltage is determined by selection of R11.
The comparison voltage is fed back to the comparator through voltage divider R9 and
R10. If the output at J2 pin 13 is less than 5.0 Vdc then the compassion voltage is
lowered below the reference voltage causing U5 to be commanded on. When U5 turns
on, +22 to +30 Vdc is applied to capacitors C15 and C38 through transformer T1. As
C15 and C38 charge, the comparison voltage rises causing U5 to go to the off state.
The sampling of the comparison voltage is at a rate of approximately 25 KHz as determined by R14 and C11.
Pulse width modulation applied to the primary of T1 causes a voltage to be induced in
the secondary which is used to develop the +12 Vdc and the -5 Vdc supply voltages.
Diode VR7, a 5.1 Vdc ±5% zener sets the -5 Vdc supply voltage. The +12 Vdc supply
output voltage is determined by the turns ratio and drive through T1’s primary.
A 25 KHz synchronization output for the +5, ±8,6 Vdc switching regulator is generated
by U1 pin 3 and U1 pin 7.
+ 5 , ± 8 . 6 V d c V O L T A G E R E G U L A T O R (fig. FO-5.) The +5, ±8.6 voltage regulator supplies
regulated power to the keyboard, dustcover assembly, interface assembly, and Logic circuit card
assembly.
The
interface
assembly
3A1A7
utilizes
the
±8.6
volts
exclusively.
This
circuit
functions
in a manner similar to the microprocessor regulator with the exception of the output and the
oscillator. U2 pins 3 and 7 are controlled by the microprocessor oscillator.
The output of the switching regulator pass circuitry (U6) is +8.6 V which is applied to
voltage divider R19 and R20 to produce a 2.5 Vdc nominal comparison voltage. The
reference voltage is generated by R63, R64 and R65. R63 is selected to provide +8.6
Vdc ±0.01 V at J2 pin 8. U11 is a series regulator which reduces the +8.6 V to +5 Vdc
±.25 V at J2 pin 7 under normal load (1.6A). Diode VR9 protects the load circuitry in
case of a Ull failure.
Transformer T2 has a 1:1 turns ratio. Diode CR7 and capacitor C22 produce a -8.6 Vdc
output.
M O T O R C O N T R O L (fig. FO-6.) The motor control circuit provides speed and on/off
control for the dc motor used to drive the print drum and ribbon mechanism of the printer. The
DRUM
operation of the circuit is controlled by the main clock pulses developed by a timing mechanism
which monitors print drum rotation. The motor control circuit operates as follows:
Positive main clock pulses, supplied through pin 19 of connector 3A1PS1J2, are applied
to pin 3 of U10. Resistor R25 assures a level shift from TTL logic high voltages to +5 Vdc
which is supplied by the pulse width controller reference U4 pin 16. Buffer U10 switches
between this reference and ground. At pin 4 of U10 the output is in phase with the
precision 518.4 microsecond speed control motor output (SCMO) pulse. This input occurs 64 times for each full drum revolution.
The dc voltage of the signal at U10 pin 4 is proportional to this drum rate which is
filtered by R26 and C26 and buffered by voltage follower U9. The output of U9 pin 6
drives the regulator controlled error amplifier which compares this voltage to a reference
generated by U4 pin 16 output and resistor dividers R27, R28 and R29. Select resistor
R29 trims this comparison voltage to cancel initial component errors and provide a
motor speed range of approximately ±7.5% with respect to a nominal pulse repetition
period
of
1080
microseconds.
The motor control circuit operates at a nominal frequency of 20 KHz. Timing components C29 and R31 control this frequency. The remainder of the motor control circuit
3-43
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functions similar to the +5, ±8.6 V switching regulator except the output which drives
the print motor at a voltage required to maintain its speed, approximately 9 Vdc ±2 V.
The current sensing resistors R35 and R61 limit the motor current to 4A
±
0.32A.
. A shut down signal under microprocessor control at pin 18 of connector 3A1PS1J2
drives pin 10 of U4 with a logic 1 to turn the motor off and minimize power dissipation
during periods when printing is not active.
+
18
Vdc
CONSTANT
CURRENT
R E G U L A T O R (fig. FO-7.) The constant current regulator main-
tains the printer under a constant load condition to mask printing intelligence during periods of
message traffic and minimizes power consumption when the printer is in a standby condition. Operation of the circuit is controlled by printer logic. The voltage and current sources of this regulator maintains the stored energy of capacitor C1 located in the printer Subassembly Chassis. Capacitor C1
reduces surges caused by printer hammer operation. Circuit operation is as follows:
When the printer is placed into operation by incoming traffic, its logic control circuit
supplies a logical O-input through pin 22 of connector 3A1PS1J2 to the base of transistor
Q4. Transistors Q4 and Q7 are then turned on which biases diodes VR3 and CR11 to provide a 5 Volt dc source across R71 and R41. Select resistors set current driver Q2 and
Q3 to regulate the current at 1.0A
±
0.06A.
The regulated current output restores the loss of charge caused by hammer operation.
When C1 is fully charged to + 18 Vdc nominal, transistor Q5 becomes forward biased into conduction, and permits transistor Q6 to also conduct. As a result, output
current is shunted to ground. For output voltages below 18.1 volts, transistors Q5 and
Q6 are maintained in the off condition.
The output voltage is monitored by comparator circuit U12. The comparator outputs a
print inhibit
sent to the
nominal. If
hibit signal
When
the
signal through pin 25 of connector 3A1 PS1J2. This print inhibit signal is
print control 3A1A4 when the print voltage drops below 16.2 volts dc
the peak print rate exceeds approximately 160 characters per second, the inwill be generated.
printing
function
is
inactive;
i.e.,
between
messages,
the
constant
current
regulator is turned off to minimize power usage by a logic 1 at pin 22 of connector
3A1PS1J2. The print voltage turn-on time delay is minimized by maintaining charge
on the print capacitor while in the inactive state. The charge is maintained through
resistor R62 which supplies current in excess of the leakage and bias currents that
would otherwise discharge the stored 18 Vdc.
3-12 FILTER ASSEMBLY
Filter assembly for terminal includes a power transformer, RFI filter, full wave rectifier and
filter capacitor.
Figure FO-3 shows the filter assembly functioning as part of the power supply input.
FILTER
N E T W O R K . The filter network, consisting of C9 through C14 and inductors L1 and L3, filters
out transient voltages that may exist either on the input or output line. Diodes VR1 and VR2 limit
electromagnetic pulse (EMP) transients being transmitted to the printer through the input power
cable. The filter also includes RFI filters Cl through C7. The output of the filter is applied across
full wave rectifier CR1. It is then filtered by C8 to supply +22 to +30 volts dc to the power supply
assembly
ADDITIONAL
through
connector
FILTERS.
3A1PS1J1.
Additional filtering for the +22 to +30 volts dc input is provided by the dc
filter network in the regulator circuit of the power supply assembly 3A1 PS1. The filter circuit consists
of L1 and L2, and Cl through C4 of this assembly.
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D I S T R I B U T I O N After filtering, the unregulated +22 to +30 volts dc is distributed in the power
supply to the +5, ±8.6 Vdc switching regulator circuit, the microprocessor regulator circuit, the
constant current regulator circuit and the motor control circuit. Additional routing is through J2-30 to
the line feed stepping motor and the ribbon-lift mechanism and lamps. The backup lamp supply
voltage, the +22 to +30 Vdc ORed with backup +12 Vdc, is routed to the BAT lamp through
connector pin J2 pin 1.
3-13.
PRINTER
ASSEMBLY,
MECHANICAL
FUNCTIONS
Below is an exploded view of the printer assembly showing the major mechanical assemblies.
The printer assembly is a removable module containing the majority of the mechanical operating
functions, and consists of the following systems:
Paper-feed
Line-feed
system
system
Printing system
Ribbon-feed
Ribbon-lift
Figure 3-27.
system
system
MECHANICAL ASSEMBLIES FOR REMOVABLE PRINTER ASSEMBLY.
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PAPER-FEED
SYSTEM
The paper-feed system of the printer handles both single and multi-part roll paper.
The system guides the paper from the paper roll through the printing area and out the
printer front cover. The system includes a PAPER-LOW and a PAPER-OUT sensing
mechanism.
PAPER-LOW Mechanism. Consists of a spring-loaded extension arm and a switch. The
extension arm rides the outer circumference of the paper roll. When the paper roll
diameter decreases to the point where the printer is almost out of paper, the lever
operates the switch and the PAPER-LOW lamp lights. It does not stop the printer.
PAPER-OUT Mechanism. Consists of a lever operated switch. Roll paper is secured to
the paper-roll. When the paper supply is about depleted, the paper is drawn tight causing the lever to be pressed. The lever operates the switch generating a drum inhibit
signal which stops the drum and printing.
Refer to TM 11-5815-602-10 for operating instructions and paper supply instructions.
3-46
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LINE FEED SYSTEM
The line-feed mechanism is used to advance the paper one or two line spaces as determined
by the line-feed subcommand. A continuous paper feed is controlled by manually pressing the
LINE-FEED pushbutton on the front panel.
Electronic Line-Feed Control. When a line-feed code is received by the printer, or when
the line-feed pushbutton on the dustcover is pressed, the line-feed stepping motor is
energized. Paper is advanced by a sprocket on the motor shaft which drives a chain on the
upper and lower driven sprockets and an adjustable idler sprocket. The driven sprockets in
turn drive a set of pressure rollers in front of the print drum and another set below the
print drum. The pressure roller assembly in front of the print drum is equipped with two
paper sprockets, one on each side of the printer subassembly, as well as friction rollers.
The friction rollers move the paper when roll-paper is used. The sprockets move the paper
when fanfold paper is used (now discontinued).
NOTE
Sprocket drive feeds (paper sprockets) are installed in terminals serial
numbered 00081A through 03500A. The sprockets will be deleted by the
manufacturer
starting
with
serial
number
03501A.
The pressure roller assembly in front of the print drum is equipped with two paper sprockets,
one on each side of the printer subassembly, as well as friction rollers. The friction rollers
move the paper when roll-paper is used.
3-47
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PRINTING SYSTEM
The major mechanical parts used in printing are the print drum and the solenoid-operated print
hammer modules.
Print Drum. Cylinder with 80 columns of ASCII and Baudot print characters. The cylinder
rotates on the print drum shaft which is supported by ball bearings and is keyed on the dc
motor armature.
3 - 4 8
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TO 31W4-2UGC74-2
Print Hammers. There are 20 print hammer modules contained in the printer
subassembly. Each print hammer module is equipped with a four-hammer mounting
block and compression return springs. Four armatures and coils are radially mounted
around the hammers. The coils are wired to a connector by printed circuits. The hammer
modules are alined to the print drum by slots in the base plate. Each print hammer is
alined with a character column on the print drum. Four adjustment screws, one for each
hammer, are provided on each print hammer assembly for the purpose of adjusting each
of the hammers.
HAMMER
MODULE
3 - 4 9
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TO 31W4-2UGC74-2
RIBBON-FEED SYSTEM
The ribbon-feed system is mounted on the left hand side of the print hammer module frame
and consists of two functional mechanisms; a ribbon-feed mechanism, and a ribbon-reversing
mechanism.
Ribbon-Feed Mechanism. Consists of a drive gear with an eccentric hub, a feed pawl
and a ratchet drive gear.
3-50
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TO 31W4-2UGC74-2
One of the intermediate gears is positioned directly behind the driven gear of
the ribbon-feed mechanism. As the
driven gear rotates, the eccentric hub
changes the drive power to linear motion
of the feed pawl. The feed pawl drives
the ratchet. The ratchet rotates a shaft
on which the two ribbon spools are
mounted. The shaft rotates continuously
as long as the drum motor is on. The ribbon spool that is engaged is determined
by the position of the ribbon-reversing
mechanism.
Ribbon-Reversing Mechanism. Consists of two ribbon sensing levers. one for each
spool, and the ribbon reversing drive dog (detent). The detent is mounted on the ribbon
spool shaft by a pin that permits it to pivot in the vertical direction.
One end of the detent is a knife edge
and the other end contains a magnetic
pin. The ribbon sensing lever of the empty spool forces the detent up, or down,
and permits the magnetic pin on the detent to engage and drive the empty spool
ratchet. Engaged by the detent, the empty spool becomes the driven spool and
the full spool becomes the feed spool.
Instructions for replacing worn or damaged spools are contained in TM 11-5815-602-10.
3-51
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RIBBON-LIFT
SYSTEM
The ribbon-lift system consists of two functional mechanisms, a ribbon-lift mechanism and a
ribbon-drop mechanism. The normal position of the ribbon is below the printed line. The ribbon is
lifted up into position by the ribbon-lift mechanism when data is to be printed. The ribbon is dropped into its normal position when printing stops.
Ribbon-Lift
Mechanism.
Consists of a lift armature,
lift solenoid and ribbon lift
arm
assembly
located
on
each side of the printer
subassembly frame. When
the ribbon-lift solenoids
are energized, the armatures pull in and raise
the
ribbon-lift
arm
assembly to engage the
upper step of the ribbonrelease armature. This
moves the ribbon arms up
to place the ribbon in the
print position.
Ribbon-Drop
Mechanism.
Consists of two release
solenoids and two release
armatures located on each
side of the printer
subassembly frame. When
the release solenoids are
energized, the release armatures pull in and allow
the ribbon arms to drop to
3-52
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Section Ill. TEST FIXTURES,
ELECTRICAL AND ELECTRONIC FUNCTIONS
3-14.
GENERAL
This section provides a detailed electrical and functional description of Terminal
AN/UGC-74A(V)3 Test Fixtures.
Test fixtures are used to test and troubleshoot modules of Terminal AN/UGC-74A(V)3.
Procedures and information are provided below for general support maintenance personnel.
Para
3-15 Test Fixture, Filter Assembly, Honeywell (SM-C-915994)
3-16 Test Fixture, Driver Board, Honeywell (SM-C-915982)
3-17 Test Fixture, Hammer Module, Honeywell (SM-C-915985)
3-18 Test Fixture, PWB (LF/CC) Assembly, Honeywell (SM-C-915988)
3-19 Test Fixture, Power Supply, Honeywell (SM-D-915979)
3-20 Test Fixture, Interface Assembly, Honeywell (SM-D-915991)
3-21
Test
Fixtures
Test
Fixture,
Support
Keyswitch
Assembly,
Honeywell
(SM-C-915997)
Equipment:
Power Cable, 230 Vac, SM-D-764482
Power Cable, 120 Vac, SM-D-764481
Power Cable, 26 Vdc, SM-D-764480
Data Cable, SM-D-915889
3-53
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3-15.
FILTER
ASSEMBLY
Filter
assembly
TEST
test
FIXTURE
fixture
provides
electrical
interconnections
between
input
power
cables and filter assembly.
Also provides output test points for monitoring of output voltage.
Consists of a chassis, four connectors, three fuses, three test points, and one switch.
Test fixture is a passive device which requires no power for its operation.
Input power supplied through connectors J3 and J4 is used by module under test.
Switch S1 (POWER) controls electrical connections between module under test and in.
put power.
Fuses F1 and F2 (1.5A) are provided to protect module from serious damage in event of
a failure.
Since loading is a constant 30 ohms and current does not exceed 1 ampere, the 1.5
ampere fuses in fixture are sufficient for both ac and dc input voltages.
3 - 5 4
TM 11-5815-602-24 .
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TO 31W4-2UGC74-2
Referring to schematic below, connectors J1 and J2 interface directly with connector
cables of filter module.
J1 provides input power interfaces.
J2 provides interfaces between filter module output and load circuitry contained in
test fixture.
. Output from filter module at J2-1, 6 with respect to J2-2, 7 is nominally 30 Vdc.
This output voltage is applied across Cl and RI in fixture to produce a load of 1
ampere. This causes R1 to dissipate 30 watts.
R1 is physically mounted to chassis to dissipate the heat.
Capacitor
Cl
provides
filtering
for
filter
assembly
22-30
Vdc
output
which
in AN/UGC-74A(V)3 is provided by C8.
Voltage is monitored at TP1.
. Output from filter module at J2-5, 9 with respect to J2-2, 7 is dependent upon + 12 Vdc
being supplied from J3.
When applied, +12 Vdc current of 400 mA nominal flows through R2.
Voltage may be measured at TP3 with respect to TP2.
3-55
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Table 3-3. FILTER ASSEMBLY TEST FIXTURE WIRE LIST
Wire No.
From
To
Remarks
1
J1-1
J4-A
22 Gauge Wire
2
J1-2
J4-B
22 Gauge Wire
3
J1-3
J4-C
22 Gauge Wire
4
J2-4
J4-D
22 Gauge Wire
5
J1-5
J4-G
22 Gauge Wire
6
J1-6
J3-B
22 Gauge Wire
Not Used
J1-7*
7
8
J1-8
S1-3
J1-9*
9
20 Gauge Wire
Not Used
10
J2-1
C1(+)
22 Gauge Wire
11
J2-6
C1(+)
22 Gauge Wire
12
TP-1
C1(+)
22 Gauge Wire
13
J2-2
C1(-)
22 Gauge Wire
14
R2-1
C1(-)
22 Gauge Wire
15
TP2
C1(-)
22 Gauge Wire
16
J2-3*
—
Not Used
17
J2-4*
—
Not Used
18
J2-8*
—
Not Used
19
J2-5
TP3
22 Gauge Wire
20
J2-7
TP2
22 Gauge Wire
21
J2-9
TP3
22 Gauge Wire
22
R1-1
TP1
22 Gauge Wire
A
3-56
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TO 31W4-2UGC74-2
Table 3-3. FILTER ASSEMBLY TEST FIXTURE WIRE LIST . Continued
Wire No.
From
To
Remarks
23
R1-2
R2-1
22 Gauge Wire
24
R2-2
TP3
22 Gauge Wire
25
XF1-2
S1-1
20 Gauge Wire
26
XF2-2
S1-2
20 Gauge Wire
27
XF3-2
S1-3
20 Gauge Wire
28
J3-A
XF3-1
20 Gauge Wire
29
J4-L
S1-2
20 Gauge Wire
30
J4-J
S1-1
20 Gauge Wire
31
J4-M
XF1-1
20 Gauge Wire
32
J4-K
XF2-1
20 Gauge Wire
33
J3-B
J4-F
22 Gauge Wire
34
J3-C
E1
22 Gauge Wire
35
J3-D*
—
Not Used
36
J3-E*
—
Not Used
37
J4-H*
—
Not Used
38
TP-4
E-1
22 Gauge Wire
39
TP-4
J4-E
22 Gauge Wire
r
No connection required.
3-57
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TO 31W4-2UGC74-2
3-16. HAMMER DRIVER TEST FIXTURE
Hammer driver test fixture provides power and signal interfaces for hammer driver
module.
Inputs from external + 18V and +5Vdc power supplies and a pulse generator, when
connected to test fixture, provide inputs required by hammer driver module.
No power is required for test fixture itself.
+ 18V and +5Vdc supply voltages for hammer driver module are connected to TP2 and
TP1, respectively.
Return for both supplies is attached to GND (TP6).
Input from pulse generator is attached to SIG IN (TP3).
Outputs are monitored at SIG OUT 1 (TP4) and SIG OUT 2 (TP5).
Switch S1 is used to route generator to input 1 or input 2 hf hammer driver module.
3-58
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+5Vdc input at TP1 is wired
directly to connector J1-1 and 3
for input to module.
+18Vdc input at TP2 is wired
directly to connector J1-11 and
12 for input to module.
Power supply return (GNDTP6) is wired directly to J1-5
and 6.
Terminal E1 is physically
mounted on chassis and provides a common ground for
all fixture components.
Input signal is input to SIG IN terminal (TP3) on fixture and is wired to S1-2 and 5.
When SELECT switch is in IN1 position, wiper ties S1-2 and S1-4 together connecting
J1-2 to SIG IN (TP3).
Switch S1 terminals 1 and 6 are internally connected to each other and wired to ground.
Wiper of S1-3 is connected to S1-6 and causes a ground to be applied to J1-4 disabling
Input 2 to module.
When S1 is placed in IN2 position, SIG IN (TP3) is connected to J1-4 and IN1 (J1-2) is
disabled.
Outputs from module are loaded by resistors R1 and R2.
Module output 1 (J1-9 and 10) is available for monitoring at SIG OUT 1 (TP4).
Module output 2 (J1-7 and 8) may be monitored at SIG OUT 2 (TP5).
3-59
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Table 3-4. HAMMER DRIVER MODULE TEST FIXTURE WIRE LIST
Wire No.
From
To
Remarks
1
J1-1
TP1
22 Gauge Wire
2
J1-2
S1-4
22 Gauge Wire
3
J1-3
TP1
22 Gauge Wire
4
J1-4
S1-3
22 Gauge Wire
5
J1-5
TP6
22 Gauge Wire
6
J1-6
TP6
22 Gauge Wire
7
J1-7
TP5
22 Gauge Wire
8
J1-8
TP5
22 Gauge Wire
9
J1-9
TP4
22 Gauge Wire
10
J1-10
TP4
22 Gauge Wire
11
J1-11
TP2
22 Gauge Wire
12
J1-12
TP2
22 Gauge Wire
13
S1-1
S1-6
22 Gauge Wire
14
S1-6
TP6
22 Gauge Wire
15
S1-2
S1-5
22 Gauge Wire
16
S1-2
TP3
22 Gauge Wire
17
R1-2
R2-2
22 Gauge Wire
18
TP6
E1
22 Gauge Wire
19
R1-2
E1
22 Gauge Wire
20
R1-1
TP4
22 Gauge Wire
21
TP6
E1
22 Gauge Wire
22
R2-1
TP5
22 Gauge Wire
23
R2-2
E1
22 Gauge Wire
1
1
/
3-60
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3-17. HAMMER MODULE TEST FIXTURE
Hammer module test fixture provides a means of selectively activating individual
hammers
to
verify
operation.
As a passive device, it provides an interface between hammer module and supply
voltages.
+5 Vdc, + 18 Vdc and GND interface to fixture is accomplished through three terminals.
Fixture must be connected to +5 V and +18 V power supply to become operational.
Input power is routed directly to four switches.
+5V input power is wired directly to pin 4 of hammer module connector which
energizes +5V circuits on module when it is inserted into fixture.
Capacitor C1 is placed across + 18V supply to provide energy storage for actuating hammers.
3-61
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Switches S1 through S4 control application of + 18Vdc to hammers 1, 2, 3, or 4 respectively.
When switch S1 (HMR1) is ON (closed), + 18V is applied through current limiting resistor
R1 to hammer 1. However, hammer 1 will not actuate until a return path is provided
through CR5 on hammer module.
Control of CR5 on hammer module is function of S5 (CONTROL) on fixture.
When S5 is depressed, a logic 0 is input to pin 3 of hammer module.
A logic 0 causes circuitry on module to drive CR5 into conduction.
3-62
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Table 3-5. HAMMER MODULE TEST FIXTURE WIRE LIST
Wire No.
I
From
I
To
I
Remarks
1
J1-1
R4-1
22 Gauge Wire
2
J1-2
R1-1
22 Gauge Wire
3
J1-3
S5-1
22 Gauge Wire
4
J1-4
TP2
22 Gauge Wire
5
J1-5
R3-1
22 Gauge Wire
6
J1-6
E1
22 Gauge Wire
7
J1-7
R2-1
22 Gauge Wire
8
J1-8
E1
22 Gauge Wire
9
TP3
E1
22 Gauge Wire
10
S5-2
E1
22 Gauge Wire
11
C1(-)
E1
22 Gauge Wire
12
C1(+)
TP-1
22 Gauge Wire
13
S1-1
R1-2
22 Gauge Wire
14
S2-1
R2-2
22 Gauge Wire
15
S3-1
R3-2
22 Gauge Wire
16
S4-1
R4-2
22 Gauge Wire
17
S4-2
S3-2
22 Gauge Wire
18
S3-2
S2-2
22 Gauge Wire
19
S2-2
S1-2
22 Gauge Wire
20
S1-2
TP1
22 Gauge Wire
L
r
3-63
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 3 1 W 4 - 2 U G C 7 4 - 2
3-18. LINE. FEED/CURRENT CONTROL TEST FIXTURE
Line-feed/current control test fixture provides power and signal interfaces for linefeed/current control assembly.
Test points are provided for connecting + 5Vdc supply, + 22Vdc supply, pulse
generator,
and
supply
generator
returns.
Test points are also provided for monitoring input and output signals.
Input +22Vdc at TP1 is routed directly to Iine-feed/current control connector J1-P.
+5Vdc at TP2 is used to produce an input control signal and supply +5Vdc for module
under
3-64
test.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
+5Vdc is divided by R1 and R2 to produce an input voltage of 2.3Vdc at wiper of S3
(CONTROL).
When this switch is closed, voltage is applied to J1-H for actuation of module’s
circuitry.
Resistor R3 provides a pull-up voltage for module circuitry connected to J1-L (CONTROL) when S2-3 (PULSE) is in an CC position.
This pull up voltage causes current control portion of module under test to be
enabled
continuously.
When S2 is placed in LF position, pulse generator is connected to switching circuits of
line-feed/current control module.
Input square wave turns gating transistors on line-feed/current control module on and
off.
Flow of current through these transistors is monitored as a voltage across resistor R4 in
fixture
wiper.
S1B connects R4 to proper gating transistors.
Diode CR1 provides +5Vdc isolation for oscillator when S1 is in OFF position.
3-65
TM 11-5815-602-24
EE161-DM-MMM-010/El154UGC74
TO 31W4-2UGC74-2
Table
3-6.
LINE FEED/CURRENT CONTROL TEST FIXTURE WIRE LIST
Remarks
From
To
1
A1-E3
TP4
22 Gauge Wire
2
A1-E4
TP10
22 Gauge Wire
3
A1-E5
TP4
22 Gauge Wire
Wire No.
I
A1-E6
4
TP9
22 Gauge Wire
n
n
n
5
A1-E7
TP8
22 Gauge Wire
6
A1-E8
S3-2
22 Gauge Wire
7
A1-E9
TP11
22 Gauge Wire
8
A1-E10
S2-3
22 Gauge Wire
9
A1-E11
TP2
22 Gauge Wire
10
A1-E12
TP1
22 Gauge Wire
11
A1-E13
TP15
22 Gauge Wire
12
A1-E14
TP14
22 Gauge Wire
13
A1-E15
TP13
22 Gauge Wire
14
A1-E16
TP12
22 Gauge Wire
15
A1-E17
R4-1
22 Gauge Wire
16
TB1-E18
TB1-E19
22 Gauge Wire
17
TB1-E19
S3-1
22 Gauge Wire
18
TB1-E20
S2-1
22 Gauge Wire
19
TB1-E21
S2-3
22 Gauge Wire
20
TB1-E23
TB1-E25
22 Gauge Wire
21
TB1-E22
E26
22 Gauge Wire
22
TB1-E24
TP5
22 Gauge Wire
I
I
3-66
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-6. LINE FEED/CURRENT CONTROL TEST FIXTURE WIRE LIST - Continued
Wire No.
From
To
Remarks
23
TB1-E23
TP4
22 Gauge Wire
S1-BC
22 Gauge Wire
24
I
R4-2
1
25
S1-B1
TP12
22 Gauge Wire
26
S1-B2
TP13
22 Gauge Wire
27
S1-B3
TP14
22 Gauge Wire
28
S1-B4
TP15
22 Gauge Wire
29
S1-AC
S2-2
22 Gauge Wire
30
S1-A1
TP8
22 Gauge Wire
31
S1-A2
TP9
22 Gauge Wire
32
S1-A3
TP10
22 Gauge Wire
33
S1-A4
TP11
22 Gauge Wire
34
TB1-E21
TP7
35
R4-1
TP6
22 Gauge Wire
36
S3-2
TP3
22 Gauge Wire
37
TB1-E22
TP4
22 Gauge Wire
n
22 Gauge Wire
3-67
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-19. POWER SUPPLY TEST FIXTURE
Provides
following
interfaces
for
AN/UGC-74A(V)3
power
supply
module:
Input power (22-30Vdc)
Battery backup power (+ 12Vdc)
Output loads and controls
Drum motor simulator
Also provides two variable resistors
for use in selecting resistor values on
power supply under test.
INPUT POWER. (fig. FO-10).
+22 to +30 Vdc input power is applied to J2-1, 6 from external power supply to VIN
(TP3) and RTN(TP2).
3-68
TM 11-5815-602-24
EE11-DM-MMM-010E154UGC74
TO 31W4-2UGC74-2
Input current flows through R47 to module under test.
Input current may be measured as a voltage by placing a voltmeter across TP3 (+) and
TP4
(-).
Switch S11A in position 1 enables VIN to be monitored at TP8 and TP9.
BATTERY
BACKUP
POWER.
+12 Vdc battery backup power is applied to J1-5, 9 from a second external supply to
BAT terminal (TP1).
Voltage may be monitored at TP8 and TP9 by placing S11A to position 2 (BAT BU).
OUTPUT
LOADS
AND
CONTROLS.
+5VA output from supply under test enters test fixture at J2-12, 13.
Output is loaded by R2, R3, and R4.
Amount of load is determined by switchs S1 and S2.
When S1 and S2 are both in OFF position, a minimum load condition of 8.25 ohms exests.
When S1 ( +5VA LOAD LO) is turned to ON position, a 4.99 ohm resistor is placed in
parallel with the 8.25 ohms resulting in an effective load of 3.11 ohms.
Placing S2 (+5VA LOAD Hl) to ON position results in maximum load condition of 1.92
ohms by placing an additional 4.99 ohm resistor across R2, R3 combination.
+5VA output voltage is monitored at TP8 and TP9 by placing S11A to position 3.
+ 5VA supply also provides source voltage for DS2.
+ 12VA suply (part of module under test) outputs +12 Vdc at P1-14.
Mating connector J2-14 is wired to switch S3, switch S1 1A, and connector J3-31.
Connector J3 mates with a test fixture circuit card assembly.
3-69
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
J3-31 interconnects with P3-31.
P3-31 is connected to R41 which in turn is connected to R5 and P3-32.
When switch S3 is placed in NORM position, + 12VA current flows through R41 and R5,
and through R6 to RTN on J3-30.
R e s i s t o r s -R 4 1 a n d R 5 p r o v i d e a l o a d f o r + 1 2 V s u p p l y w h e n e v e r s w i t c h i s i n a N O M A X
position.
Placing switch in MAX position causes R41 to be bypassed, the connection J3-33 to be
opened, and R5 to become load resistor for + 12VA supply.
Performance of supply may be monitored at TP8 and TP9 by placing switch S11B
(SELECT) to position 4.
-5VA supply (part of module under test) outputs -5Vdc at P1-15.
Mating connector J2-15 is wired to J3-35 and S11A-5.
+5VB output (from module under test) enters test fixture at J2-7, 26.
+5VB RTN (RTNB) is on J2-4, 5, 6, and 24.
Resistor R10 (15 ohms) is connected across +5VB output.
When +5VB LOAD LO switch (S6) is placed in ON position, R11 (30.1 ohms) is placed in
parallel with R10.
Combination of R10 and R11 produces an effective resistive load of 10.0 ohms.
Placing +5VB LOAD HI switch (S7) to ON position, places R12 (30.1 ohms) in parallel
with R10.
If S6 is in ON position, effective resistive load is 7.5 ohms.
SELECT switch S11, when placed in position 6, connects +5VB output to V OUT (TP9
and TP12) and SCOPE (TP3 and TP11) terminals.
+ 18V output (from module under test) enters test fixture at J2-21.
+ 18V RTN enters at J2-35.
Capacitor C15 is connected across ±18V output and simulates capacitor C2 in AN/UGC74A (V) 3.
Supply output is placed under load by + 18V LOAD switch (S9) to either NORM position,
or MAX position.
When S9 is in NORM position, R15 (27.4 ohms) is placed across C15 and supply output.
Placing S9 to MAX position, removes R15 and places R16 (12 ohms) across output.
When S9 is in the OFF position, both resistors are removed from the output and only
C15 remains in the circuit.
+ 18V output is enabled by a logic 0 at J2.22.
Placing switch S5 (CCR) to ON position, connects a 100-ohm resistor (R43 on circuit card
assembly) across J2-22 and J2-32.
Presence of this resistor produces logic 0 at J2-22.
When + 18V is present, module under test supplies at +5Vdc voltage at J2-25 (CAPVOK).
Voltage is input through J3-36 to a lamp driver (U1-9) on circuit card assembly.
Lamp driver supplies a return path for current to flow through J2-12, 13, DS2, J3-16, R9
(on circuit card assembly) and U1 output.
SELECT switch, when placed in position 9, enables monitoring of + 18V supply voltage
at SCOPE and V OUT terminals.
Lamp Supply output of module under test provides +22 to 30Vdc which enters test fixture at J2-2.
Potentiometer R8 (ILLUM ADJUST) is connected across the 22 to 30Vdc supply.
Wiper of R8 is controlled by test fixture operator and presents to module under test a
variable voltage at J2-36.
This voltage is used by module to control amplitude of lamp supply voltage which is
applied to test fixture at J2-31.
Resistor R13 (40.2 ohms) is load resistor for lamp supply output.
3-70
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
+ 8.6V module under test supplies + 8.6Vdc to J2-8.
Switch S13 (+8.6V LOAD) is wired to J2-8 and load resistors R34, R35, and R36.
Load resistor return (RTN) is provided by J2-5.
When S13 is placed in NORM position, +8.6V load is provided by R35 (44.2 ohms).
Load resistor is switched to R36 (44.2 ohms).
Load resistor is switched to R36 (53.6 ohms) when S13 is placed in MIN position.
When MAX position is selected, R34 provides a load of 30.1 ohms.
Switch S11 (SELECT), when placed in position 12, enables monitoring of + 18Vdc
output of SCOPE and V OUT terminals.
-8.6V module under test supplies -8.6V to J2-20.
Wiper of switch S10 (-8.6V LOAD) is connected to J2-20.
Three loads are selectable:
53.6 ohms
82.50 ohms
115 ohms
When in MAX position, current flows through S10-1 to J3-27.
On circuit card assembly, P3-27 is connected to R17 (53.6 ohms).
Current then flows through R17 to return (RTN P3-24, J2-4).
When S10 is in NORM position, current flow is through R18 (82.5 ohms).
Resistor R19 is used by placing S10 in the MIN position.
-8.6V output is monitored by placing SELECT switch (S11) to position 7.
This connects -8.6V output to V OUT and SCOPE test points.
Line-feed. Module under test outputs a 22-30V line-feed voltage at J2-30.
Output is loaded by R14 (30 ohms) when switch S8 (LF LOAD) is placed to ON position.
Select resistors. Test fixture provides two precision variable resistors which are used to
select resistor values on module under test.
Test leads E1 and E2 are connected to SELECT RESISTOR 1 (R31) which is a 10-turn,
500-ohm potentiometer.
E1 (RED) is connected to wiper (2) and one end (3) of R31.
E2 (BLACK) is connected to terminal 1 of R31.
Capacitor C16 is placed across terminals 1 and 3 of R31 and provides noise filtering.
SELECT RESISTOR 2 (R32) is same type potentiometer as R31.
R32, however, is configured for a three-wire connection and is used to select resistors
used in a voltage divider application on module under test.
E3 (RED) is connected to wiper.
E4 (BLACK) and E5 (YELLOW) are connected to ends 1 and 3, respectively.
DRUM MOTOR SIMULATOR (fig. FO-11).
Drum motor output of the power supply module under test is determined by drum speed.
In order to test this circuit, simulation of drum motor control loop must be provided in
fixture.
U1, 2, 3, and 4 provide this capability.
Power supply under test outputs a voltage which is compared against a reference voltage by
a difference amplifier.
Output of this amplifier is a voltage proportioned to the difference between drum motor
supply output and reference voltage.
3-71
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Voltage-controlled oscillator (VCO) responds to variable input by changing frequency of
its output square wave.
Because output level of VCO is incompatible with one-shot device, a level converter is
provided.
TTL input to one-shot causes it to produce a fixed duration pulse at frequency determined by VCO.
This pulse is returned to power supply under test as signal SCMO.
Output from drum motor supply of module under test is divided by resistors R20 and
R21 (fig. FO-10).
This voltage is applied to J3-6 which, in turn, is applied to U2-4 through resistor R22.
Resistors R23 and R45 adjust reference voltage applied to U2-5.
Resistors R21 and R24 set gain of U2 for unity.
Capacitor C2 defines bandwidth to 1/8thpf or 55.5 Hz.
Capacitor C4 provides noise decoupling to reduce effects of random noise on circuit.
Reference voltage for U2 is provided by CR1, CR2, C1, R45, and R23.
CR1 and CR2 are 6.2V Zener diodes and provide a constant 12.5Vdc across R45,
R23, and C1.
Capacitor C1 eliminates low frequency noise and helps stabilize reference voltage.
Resistor R23 adjusts value of voltage to be used by U2 for its reference and is normally set for 4.1Vdc.
Output of U2 at pin 10 is normally 10 to 12 Vdc with an input voltage of 5Vdc applied to
J3-6.
With +15Vdc applied at junction of C4 and R26, current flows through R26 and R25
causes 13.5Vdc to be input to U3 pin 5.
U3 is a voltage-controlled oscillator (VCO) whose output frequency is a function of value
of the input voltage.
Resistors R27, R28, and capacitor C7 determine center frequency value.
C7 (.022 uf) sets VCO output at approximately 1 kHz.
Resistor R27 is adjustable and is used to set output frequency for 926 Hz.
Capacitor C6 is provided to prevent parasitic oscillations which may occur during
VCO switching.
VCO output is a 5V square wave which switches between +6 and + 11Vdc.
In order for this signal to be used by U4, levels must be converted to TTL.
TTL conversion is accomplished by transistor Q2.
Capacitor C18 and resistor R39 provide dc and load isolation for converter and VCO.
Collecter of Q2 is driven by the VCO and switches between +5V and ground.
Output of Q2 is applied to trigger input of one-shot U4.
Output of U4 is a pulse whose width is determined by values of C19, C11, C46, and R30.
R46 is adjusted to produce a pulse width of 518 usec.
Output at SCMO (J3-12) is a 518 ± 3 usec pulse at an interval of 1080 ± 15 usec.
3-72
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-7. POWER SUPPLY TEST FIXTURE WIRE LIST
Wire No.
From
To
Remarks
1
J2-1
DSI
22 Gauge Wire
2
J2-2
R8-3
22 Gauge Wire
3
J2-4
TB1-5
22 Gauge Wire
4
J2-5
TB1-5
22 Gauge Wire
5
J2-6
TB1-5
22 Gauge Wire
6
J2-24
TB1-5
22 Gauge Wire
7
J2-7
TB1-4
22 Gauge Wire
8
J2-26
TB1-4
22 Gauge Wire
9
J2-10
TB1-6
22 Gauge Wire
10
J2-11
TB1-6
22 Gauge Wire
11
J2-12
TB1-7
22 Gauge Wire
12
J2-13
TB1-7
22 Gauge Wire
13
J2-14
S11-A4
22 Gauge Wire
14
J2-15
S11-A5
22 Gauge Wire
15
J2-16
S11-B11
22 Gauge Wire
16
J2-17
S11-A11
22 Gauge Wire
17
J2-20
S11-A7
22 Gauge Wire
18
J2-21
S11-A9
22 Gauge Wire
19
J2-29
S11-B5
22 Gauge Wire
20
J2-30
S11-A10
22 Gauge Wire
21
J2-31
S11-A8
22 Gauge Wire
I
!
I
3-73
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-7. POWER SUPPLY TEST FIXTURE WIRE LIST - Continued
Wire No.
From
To
Remarks
22
J2-8
S11-A12
22 Gauge Wire
23
J2-32
TB1-8
22 Gauge Wire
24
J2-33
TB1-8
22 Gauge Wire
25
J2-35
TB1-8
22 Gauge Wire
26
J2-18
S4-3
22 Gauge Wire
27
J2-19
TP10
Center Conductor of
Shieided Cable
28
J2-22
J3-22
22 Gauge Wire
29
J2-25
J3-36
22 Gauge Wire
30
J2-28
J3-13
22 Gauge Wire
31
J2-36
R8-2
22 Gauge Wire
32
J2-37
TP13
Shield of Shielded
I
Cable
3-74
33
J1-6
TB1-3
22 Gauge Wire
34
J1-1
TB1-3
22 Gauge Wire
35
J1-5
TB1-1
22 Gauge Wire
36
J1-9
TB1-1
22 Gauge Wire
37
J1-7
S11-B2
22 Gauge Wire
38
J1-2
TB1-2
22 Gauge Wire
39
J3-7
TB1-2
22 Gauge Wire
40
J3-34
TB1-6
22 Gauge Wire
41
J3-30
TB1-6
22 Gauge Wire
42
J3-31
S11-A4
22 Gauge Wire
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-7. POWER SUPPLY TEST FIXTURE WIRE LIST . Continued
Wire No.
From
To
Remarks
43
J3-35
S11-A5
22 Gauge Wire
44
J3-32
S3-3
22 Gauge Wire
45
J3-33
S3-1
22 Gauge Wire
46
J3-23
S5-3
22 Gauge Wire
47
J3-15
DS1-1
22 Gauge Wire
48
J3-16
DS2-2
22 Gauge Wire
49
J3-5
R21-1
22 Gauge Wire
50
J3-6
R21-2
22 Gauge Wire
54
J3-12
TP10
Conductor of
Shielded Cable
55
J3-9
TP13
Shield of Shielded
Cable
I
56
J3-14
TB1-8
22 Gauge Wire
57
J3-24
TB1-5
22 Gauge Wire
58
J3-8
TB1-2
22 Gauge Wire
59
J3-11
TP6
22 Gauge Wire
60
J3-10
TP6
22 Gauge Wire
61
J3-28
TP6
22 Gauge Wire
62
J3-29
TP6
22 Gauge Wire
63
J3-18
TP5
22 Gauge Wire
3-75
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-7. POWER SUPPLY TEST FIXTURE WIRE LIST - Continued
W i r e
N o .
64
66
1
67
I
From
To
I
J3-19
TP5
I
J3-37
TP5
I
22 Gauge Wire
I
J3-1
TP4
I
22 Gauge Wire
I
J3-2
I
TP4
I
Remarks
22 Gauge Wire
22 Gauge Wire
68
J3-20
TP4
22 Gauge Wire
69
TB1-8
S9-2
22 Gauge Wire
70
TB1-8
C1-2
22 Gauge Wire
71
TB1-8
R8-1
22 Gauge Wire
I
I
I
I
I
I
72
I
TB1-8
73
TB1-5
74
TB1-5
I
I
S11-B8
22 Gauge Wire
R1O-1
22 Gauge Wire
75
I
TB1-5
I
R35-1
I
76
I
TB1-6
I
R2-1
I
77
I
I
78
I
TB1-7
I
I
79
I
TB1-7
I
I
80
I
TB1-7
I
3-76
I
22 Gauge Wire
R34-1
I
TB1-6
I
S11-63
R2-2
S1-2
DS2-1
I
22 Gauge Wire
I
22 Gauge Wire
I
22 Gauge Wire
I
22 Gauge Wire
I
22 Gauge Wire
I
22 Gauge Wire
81
TB1-7
S2-2
22 Gauge Wire
82
TB1-7
S11-A3
22 Gauge Wire
83
TB1-2
TP7
22 Gauge Wire
84
TB1-2
TP2
22 Gauge Wire
I
I
I
I
I
I
I
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-7. POWER SUPPLY TEST FIXTURE WIRE LIST
I
Wire No.
- Continued
I
From
I
To
I
Remarks
I
85
I
TB1-2
I
S11-B1
I
22 Gauge Wire
I
86
I
TB1-2
I
TP13
I
22 Gauge Wire
1
87
I
TB1-4
I
R11-1
I
22 Gauge Wire
1
88
I
TB1-4
I
S11-A6
I
89
I
TB1-3
I
R47-2
I
90
I
TB1-3
TP14
22 Gauge Wire
I
91
I
TB1-1
S11-A2
22 Gauge Wire
I
92
I
TP9
TP8
22 Gauge Wire
I
93
I
TP8
S11-AC
22 Gauge Wire
I
94
I
TP12
I
TP11
I
22 Gauge Wire
I
95
I
TP11
1
S11-BC
I
22 Gauge Wire
I
22 Gauge Wire
I
22 Gauge Wire
22 Gauge Wire
96
R21-1
S11-B11
97
S11-B8
S11-B9
22 Gauge Wire
98
S11-B9
S11-B10
22 Gauge Wire
99
S11-B9
R13-1
22 Gauge Wire
100
R13-1
S5-2
22 Gauge Wire
101
I
S11-B10
I
R14-1
I
I
22 Gauge Wire
102
R14-1
S4-2
22 Gauge Wire
103
S11-A4
S3-2
22 Gauge Wire
104
R1O-1
S11-B6
22 Gauge Wire
105
S11-B6
R36-1
22 Gauge Wire
3-77
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
T a b l e 3 - 7 . P O W E R S U P P L Y TEST
From
To
Remarks
106
S11-B6
S11-B7
22 Gauge Wire
107
S11-B7
S6-2
22 Gauge Wire
108
S11-B7
S11-B12
22 Gauge Wire
109
S11-B12
S7-2
22 Gauge Wire
110
R2-1
R3-1
22 Gauge Wire
111
R3-1
R4-1
22 Gauge Wire
112
S11-B3
S11-B4
22 Gauge Wire
113
S11-B4
S11-B5
22 Gauge Wire
114
S11-B1
S11-B2
22 Gauge Wire
115
R21-2
R20-1
22 Gauge Wire
116
S11-A12
S13-2
22 Gauge Wire
117
S11-A11
R20-2
22 Gauge Wire
118
S11-A10
S8-2
22 Gauge Wire
119
S11-A9
R15-1
22 Gauge Wire
120
R15-1
R16-1
22 Gauge Wire
121
R16-1
C15-1
22 Gauge Wire
122
S11-A8
R13-2
22 Gauge Wire
123
S11-A7
S10-2
22 Gauge Wire
124
S11-A6
R12-1
22 Gauge Wire
125
R12-1
R10-2
22 Gauge Wire
126
TP3
S11-A1
22 Gauge Wire
Wire No.
3-78
F I X T U R E WIRE LIST - Continued
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-7. POWER SUPPLY TEST FIXTURE WIRE LIST - Continued
4
Wire No.
From
To
Remarks
127
S11-A1
R47-1
22 Gauge Wire
128
R14-2
S8-3
22 Gauge Wire
129
R16-2
S9-1
22 Gauge Wire
130
R15-2
S9-3
22 Gauge Wire
131
R4-2
S2-1
22 Gauge Wire
132
R3-2
S1-1
22 Gauge Wire
133
R34-2
S13-6
22 Gauge Wire
134
R35-2
S13-4
22 Gauge Wire
135
R36-2
S13-1
22 Gauge Wire
136
R11-2
S6-1
22 Gauge Wire
137
R12-2
S7-1
22 Gauge Wire
138
S10-5
S10-3
22 Gauge Wire
139
S13-5
S13-3
22 Gauge Wire
140
R31-1
E2
141
R31-1
C16-1
22 Gauge Wire (Black)
142
R31-3
C16-2
22 Gauge Wire (Black)
143
R31-3
R31-2
22 Gauge Wire (Red)
144
R31-2
E1
145
R32-3
E5
22 Gauge Wire (Yellow)
146
R32-1
E4
22 Gauge Wire (Red)
147
R32-2
E3
22 Gauge Wire (Black)
\
,
,
22 Gauge Wire (Red)
22 Gauge Wire (Black)
3-79
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-20. INTERFACE ASSEMBLY TEST FIXTURE
Interface assembly test fixture provides an easy means of performing continuity and
functional
3-80
electrical
tests
on
interface
assembly.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
CONTINUITY TESTS
Switch S1 (OHM CHECK) is used along with terminals S1A, S1B, S1C, and S1D to
perform
continuity
tests
of
internal
wiring
of
interface
assembly.
Placing an ohmmeter between
ground terminal (GND) and any
of these four terminals enables
a series of continuity checks to
be made.
Each of 12 terminals of wafer A
of S1 are wired to pins of P2, P3,
and P4.
GND terminal is also wired to
pins of P2, P4, and P5.
By placing S1 in each of its 12
positions, continuity can be read
through the switches, connectors, and harness of interface
assembly which are wired to
wafer A.
. Additional continuity tests can
be performed by moving ohmmeter to terminal 5 (S1B), 6
(S1C), and 7 (S1D) and sequencing through the 12 switch positions.
3-81
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-82
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-21. KEYSWITCH ASSEMBLY TEST FIXTURE
Keyswitch assembly test fixture provides power and input signal interfaces for
keyswitch assembly (SM-D-915636) and keyboard assembly (SM-D-915601).
Input power of +5Vdc is supplied by an external supply and an input signal clock is
supplied by an external pulse generator.
Keyswitch assembly test fixture consists of interface terminals, connecting cable, and
clock control switch.
Input clocks and power are applied to assembly under test through TP1 (SIG IN), TP2
(+5V) and TP12 (GND), respectively.
3-83
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Circuit card assembly
(Al) is mounted in test
fixture and contains
interface
and
control
circuitry.
+5Vdc, supplied
to
test fixture from an
external supply at
TP2,
provides
operating voltage for
test fixture logic circuits as well as
assembly/unit
test (UUT).
under
Interface with circuit
card assembly is via
E4 on the assembly.
UUT interface is
through P1-10.
Return for both power
and signal sources is
TP12.
Return for circuit card
assembly is connected to E7.
UUT return is through
P1-11.
External pulse
generator signal is input at TP1 and enters
circuit card assembly
at E5.
U1 assures a TTL input to UUT at P1-3.
When UUT is connected to test fixture, P-12 is tied to P-11, thus forming a voltage
divider through R7 and R8.
When +5Vdc is applied and UUT connected to fixture, +2.5Vdc may be measured at
PRESENT terminal (TP3),
Resistors R3 and R4 form a voltage divider which supplies 1.5Vdc nominal for CLK REF
input to UUT through P1-2.
TP8 is a monitor test point for this voltage.
Resistors R5 and R6 likewise supply 2400 Hz REF input for UUT through P1-4.
TP9 is a monitor test point for this voltage.
TP6 (Data +) monitors KYBD DATA line from UUT at P1-6.
TP7 (LOGIC +) monitors KYBD LD line from UUT at P1-7.
TP10 (DATA REF) and TP1l (LOGIC REF) monitor voltage in UUT which is similar to
R3/R4 and R5/R6 in fixture.
Control of clock signal for UUT is provided by S1 and U1.
When S1 is not depressed, U1-4 is a logic 0 and U1-10 is a logic 1.
Since a 0 at U1-4 forces U1-6 to a 1, U1-9 is also a logic 1.
This causes U1-8 to be held at a logic 0.
3 - 8 4
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
When S1 is depressed, a logic 0 is placed at U1-10 and a logic 1 is placed at U1-4.
This resets output at U1-8 to a logic 1.
Input at U1-5 becomes a 1 which causes U1-6 to become a logic 0.
This logic 0 causes U1-8 output to remain a logic 1.
When switch (S1) is released, output at U1-8 returns to a logic 0 again.
The purpose of this flip-flop action is to eliminate the effects of “contact bounce” which
is inherent with almost all switches.
Table 3-8. KEYSWITCH ASSEMBLY TEST FIXTURE WIRE LIST
Wire No.
From
To
Remarks
1
P1-1
TP4
22 Gauge Wire
2
A1-E8
TP4
22 Gauge Wire
3
P1-2
TP8
22 Gauge Wire
4
A1-E10
TP8
22 Gauge Wire
5
P1 -3
TP5
22 Gauge Wire
6
A1-E6
TP5
22 Gauge Wire
7
P1 -4
TP9
22 Gauge Wire
8
A1-E11
TP9
22 Gauge Wire
9
P1-5
TP10
22 Gauge Wire
10
P1 -6
TP6
22 Gauge Wire
11
P1 -7
TP7
22 Gauge Wire
12
P1-8
TP11
22 Gauge Wire
13
P1-9
14
P1-10
TP2
22 Gauge Wire
15
A1-E4
TP2
22 Gauge Wire
16
P1-11
TP12
22 Gauge Wire
17
A1-E7
E12
22 Gauge Wire
18
P1-12
A1-E2
22 Gauge Wire
19
TP1
A1-E5
22 Gauge Wire
,
No connection
3-85
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 3-8. KEYSWITCH ASSEMBLY TEST FIXTURE WIRE LIST
- Continued
From
To
Remarks
20
TP3
A1-E1
22 Gauge Wire
21
S1-3
A1-E9
22 Gauge Wire
22
S1-2
E12
22 Gauge Wire
23
S1-1
A1-E3
22 Gauge Wire
24
TP12
E12
22 Gauge Wire
Wire No.
,
3-22. POWER AND DATA CABLES
Tnere
are
tnree
power
cables
and
one
data
cable
W
itch
are
used
to
support
AN/UGC-74(V)3
230 Vac power cable
The 230 Vaq power cable is configured with a prewired connector for mating
with J2 on AN/UGC-74(V)3 or filter assembly test fixture.
Connector is wired to properly interconnect 230 Vac prime power with appropriate winding of power transformer in filter module. Cable is 8 feet long
and is unterminated at the other end.
3-86
testirrg:
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Change 1
3-87
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
3-88
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
The following figure shows the key and pin identification for connector MS 3116F14-12S used
on
the
following
power
cables:
Figure 3-28. POWER CONNECTOR KEY AND PIN IDENTIFICATION.
3-89
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Data cable
Data
cable
provides
an
interface
capability
between
equipments
having
phone
jacks connectors and the transmit and receive lines of AN/UGC-74(V)3.
It is used in conjunction with AN/GGM-15 during interface assembly testing.
3-90
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
The following figure shows the key and pin identification for the data connector used on the
SM-D-915889 data cable.
Figure 3-29.
DATA CONNECTOR KEY AND PIN IDENTIFICATION.
Change 1
3-91
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
CHAPTER 4
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
PAGE
Section I.
REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Common Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Special Tools, TMDE, and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
PMCS Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Records and Reports, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section lll. TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Use of Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Section IV. MAINTENANCE PROCEDURES
Final Inspection Procedures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Organizational Maintenance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Organizational Maintenance Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Organizational Maintenance Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Organizational Maintenance Painting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Organizational Maintenance Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Section V. PREPARATION FOR STORAGE AND SHIPMENT
Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Secure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-0
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section I.
4-1.
COMMON
REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
TOOLS
For all authorized common tools and equipment, refer to the Modified Table of Organization
and Equipment (MTOE) applicable to your unit.
4-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Special tools, TM DE, and support equipment required by Organizational Maintenance personnel
are listed below:
Tool Kit TE-50B
Multimeter AN/USM-223
Loopback plug
Tool, ribbon mechanism adjustment (2 required)
4-3. REPAIR PARTS
Repair parts are listed and illustrated in the repair parts and special tools list in TM 11-5815-602-24P
for organizational maintenance.
Section
4-4.
Il.
PREVENTIVE
MAINTENANCE
CHECKS
AND
SERVICES
(PMCS)
GENERAL
The purpose of scheduled preventive maintenance checks and services (PMCS) is to prevent
trouble, reduce downtime and assure
mains in serviceable condition.
4-5.
RECORDS
AND
that
the
Communications
Terminal
AN/UGC-74A(V)3
re-
REPORTS
Records and reports of preventive maintenance checks and services must be made in accordance with requirements set forth in TM 38-750, The Army Maintenance Management System
(TAMMS). Use your PMCS Table Hem No. column to get the number for the TM ITEM NO. column
of DA Form 2404, Equipment Inspection and Maintenance Worksheet. (Example is shown on page
4-7.)
4-1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-6.
PMCS
TABLE
a. Organizational PMCS table 4-1 can be used to assist in:
SYSTEMATIC CARE - Procedures given in the PMCS table explain the routine,
systematic care and cleaning essential to proper upkeep and operation of the terminal,
TROUBLESHOOTING - To help determine and correct faults.
Reestablishing
service
after
a
shutdown.
b. Routine checks are not listed as PMCS checks. They are checks such as the following:
Cleaning
Dusting
Checking
for
frayed
cables
Storing items not in use
Checking for loose nuts, bolts, and screws
Checking for loose or broken knobs
c. Routine checks are things that you should do anytime you see they must be done. If you
find a routine check like one of those listed in your PMCS table, it was listed because other personnel
reported
problems
with
this
item.
(1) SEQUENCE. Procedures in PMCS table are to be done in order of item number.
(2)
PMCS
table
column
headings
explained:
ITEM NUMBER(S) give the order in which the procedures are to be done. Also,
these item numbers are used to identify individual procedures in the PMCS
table.
ITEM TO BE INSPECTED tells what part or function the procedure will check or
service.
PROCEDURE gives details of what is to be done, the required order for doing
any steps, and results which are acceptable.
NOTES
When equipment is installed or reinstalled, all items in organizational
PMCS table shall be performed. WARNINGS and CAUTIONS about
electrical shock and bodily harm must be observed when performing
PMCS. Refer to WARNING page in front of this manual.
If the terminal MUST be in operation all the time, check and service
those items that can be checked and serviced without disturbing
operation. Make the complete checks and services when the equipment
CAN be shut down.
4-2
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
ATO 31W4-2UGC74-2
Table 4-1.
ORGANIZATIONAL
PREVENTIVE
MAINTENANCE
SEMIANNUAL
CHECKS
AND
SERVICES
TABLE
SCHEDULE
ITEM
ITEM
NO.
1
TO BE
INSPECTED
Printing
PROCEDURES
Using message from self-test, inspect printing for clearness,
even lines and that all characters are printed. Adjust print
hammers as required (refer to para 4-14A). Adjustment to be
performed by 31J only.
2
Gaskets
Check following gaskets for serviceability:
Inspect gaskets for dryness, rips, tears, gouges, or missing
portions. Notify direct support maintenance personnel of any
unserviceable gaskets.
3
Ground
Inspect
ground
connector
for
serviceability
and
cleanliness.
connector
4-3
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 4-1.
ORGANIZATIONAL
PREVENTIVE
SEMIANNUAL
4-4
MAINTENANCE
SCHEDULE
-
CHECKS
Continued
AND
SERVICES
TABLE
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 4-1.
ORGANIZATIONAL
PREVENTIVE
SEMIANNUAL
ITEM
ITEM
TO BE
NO.
INSPECTED
5
MAINTENANCE
SCHEDULE
-
CHECKS
AND
SERVICES
TABLE
Continued
PROCEDURES
Motor
Inspect motor (line-feed) drive chain and sprockets for
(line-feed)
signs of wear or misalinement. Chain should have between
1/16 to 1/8 inch of slack.
drive chain
and
sprocket
Adjust chain tension as required (refer to para 4-14B). If
motor drive (line-feed) sprockets are misalined, make
necessory adjustments. Adjustment to be performed by 31J
only.
6.
Internal
Inspect for loose, bent or cracked controls and switches.
switches
and
controls
Check for smooth operation.
Tighten
any
loose
knobs.
Notify
direct
support
maintenance
of bent or broken controls and switches.
4-5
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 4-1.
ORGANIZATIONAL
PREVENTIVE
SEMIANNUAL
ITEM
ITEM
TO BE
NO.
INSPECTED
7 *
Ribbon-feed
slip clutch
8 *
Ribbonreversing
MAINTENANCE
SCHEDULE.
CHECKS
AND
SERVICES
TABLE
Continued
PROCEDURES
Test ribbon-feed slip clutch in accordance with paragraph
4-14C.
Test ribbon-reversing sensing lever in accordance with
paragraph 4-14D.
sensing
lever
10 *
Ribbonsensing
lever
spring
Test
ribbon-sensing
Ribbonreversing
Test ribbon-reversing
4-14F.
paragraph
lever
spring
tension
in
accordance w i t h
4-14E.
extension
in
accordance
with
paragraph
extension
11
Low-paper
Test low paper alarm switch in accordance with paragraph
alarm
4-14G.
switch
12
Paper exit
bracket
Test paper exit bracket in accordance with paragraph 4-14H.
13 *
Paper out
Test paper out switch in accordance with paragraph 4-14I.
switch
14
Power
linkage
15.
Elasped
time
Test power linkage cable in accordance with paragraph 4-14J.
cable
indicators
Verify number of hours on clasped time meters have not
exceeded maximum meter reading.
If readings have been exceeded, notify direct support
maintenance.
* These test to be performed by 31J only,
Elapsed time meters are installed in terminals serial numbered 1 t h r o u g h
2000. The time meters will be deleted by the manufacturer starting with
serial number 2001. Time meters will not be replaced in terminals
numbered 1 through 2000.
4-6
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
DA FORM 2404, EQUIPMENT INSPECT ION
AND
MAINTENANCE
WORKSHEET.
NOTE
LOCAL COMMAND SOP SHOULD PROVIDE INSTRUCTIONS ON HOW TO
COMPLETE DA FORM 2404 IN ACCORDANCE WITH COMMAND POLICY.
IN ADDITION TM 38.750 (TAMMS) PROVIDES ALL lNFORMATION NEEDED
FOR COMPLETION OF THIS FORM.
4-7/4-8 blank
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section III.
TROUBLESHOOTING
4-7. GENERAL
Troubleshooting at organizational maintenance level requires you to locate any trouble as
quickly as possible.
Once trouble is located, repair it if you are authorized to do so, or determine if a higher
category of maintenance is required. Repairs by organizational maintenance personnel are
limited by tools, test equipment and replacement parts allocated to that level by the
Maintenance Allocation Chart (MAC) in appendix B.
Removal and replacement of any defective units is done by a higher category of
maintenance (direct support).
NOTE
Before using troubleshooting charts, check your work order and talk to
the operator, if possible, for a description of trouble symptom(s).
4-8. USE OF TROUBLESHOOTING CHART
Troubleshooting charts for the terminal are provided in this section. Only those corrective actions which are within the scope of organizational maintenance are listed In these
charts. If these actions do not restore the terminal to normal operation, refer to higher
category of maintenance for corrective action.
No Power Input: If there is no indication of power input (motor does not run, lamps do
not light), and there is a loss of all terminal functions, refer to Troubleshooting Chart
No. 1.
Trouble Indication with Power Input: Refer to Troubleshooting Chart No. 2 and start with
step No. 1 "Self-Test."
a. When a trouble appears, refer to the proper step in the chart for correction of the trouble.
If higher level maintenance is not required, perform the listed adjustment(s), or replace the defective lamp or fuse.
b. If a trouble does not appear during Self-Test, perform the Loopback Test, Troubleshooting
Chart No. 2, step No. 7.
c. If there is a trouble in the battery backup operation, refer to Troubleshooting Chart No. 2,
step No. 8.
d. If a trouble does not appear when operating in other than LO DATA or LO DATA, refer to
Troubleshooting Chart No. 2, step No. 9.
4-9
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ORGANIZATIONAL MAINTENANCE TROUBLESHOOTING CHART NO. 1
STEP
INSTRUCTION
1
Check J1 and J2 cable
connectors
INDICATION
Connectors are
securely fastened
YES
Continue troubleshooting.
x
x
2
Lower dust cover and
check power linkage
cable
Linkage secure and
working properly
4
5
4-10
Disconnect power
cable J2 from terminal
and place Power ON/
OFF switch to OFF.
Extend terminal out on
its slides, locate fuses F1
and F2, remove fuses
and check continuity (less
than 1 ohm) of each fuse.
Continuity
Check cable for operating voltage (115 VAC or
230 VAC) between pins M
and K. Refer to Fig. 3-28.
Operating voltage
present.
Check external power
input circuit (ac or
de), especially fuses,
circuit breakers,
switches and plug
connections.
Change 1
Fasten connectors
securely.
Continue troubleshooting.
x
x
3
REMARKS
NO
x
Adjust linkage as
directed in paragraph
4-14J
Continue troubleshooting.
x
Replace defective
fuses.
Higher maintenance
required.
x
x
Replace power cable
J2 and set Power
ON/OFF switch to ON.
Repair
found;
higher
(direct
trouble if
if not, notify
maintenance
support).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ORGANIZATIONAL MAINTENANCE TROUBLESHOOTING CHART NO. 2
STEP
INSTRUCTION
INDICATION
1
Start Self-Test
(refer to table 2-5,
item 6).
Self-Test starts.
NO
x
x
x
CPU test correct.
x
x
Printer control test
correct.*
*
Memory test correct.
x
x
Communications
correct.
test
x
x
Keyboard test correct.
x
x
2
Check ribbon-feed.
Ribbon feed operates
properly. *
x
*
3
Check ribbon lift/
drop action.
Ribbon lift/drop
operates correctly. *
x
*
REMARKS
Continue troubleshooting.
Check switch settings.
Continue troubleshooting.
Higher level
maintenance required.
Continue troubleshooting.
Higher level maintenance required.
Continue troubleshooting
Higher level
maintenance required.
Continue troubleshooting.
Higher level maintenance required.
Continue troubleshooting.
Higher level
maintenance required.
Continue troubleshooting.
Check ribbon
mechanism adjustment as directed in
para 4-14C, D, E, F
If fault not
corrected, go to
step 5.
Continue troubleshooting
Clean ribbon lift arms
and pivot. If fault not
corrected, higher level
maintenance required.
* If no go, then refer to 31J Teletypewriter Repairman.
Change 1
4-11
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ORGANIZATIONAL MAINTENANCE TROUBLESHOOTING CHART NO. 2- Continued
STEP
4
INSTRUCTION
Using initialization
message check
printing for errors.
INDICATION
Single print position
faulty. *
YES
REMARKS
*
Adjust faulty hammer
as directed in paragraph
4-14A. If fault not corrected, higher level
maintenance required.
x
4 sequential positions
faulty.
Higher level
maintenance required.
Continue troubleshooting.
x
x
Every 4th position
faulty.
Higher level
maintenance required.
Continue troubleshooting.
x
x
All positions faulty.
Higher level
maintenance required.
Continue troubleshooting.
x
x
5
Check line-feed
tension and sprocket
adjustment.
Adjustment required. *
*
x
6
Check paper exit
bracket adjustment.
Adjustment
required.
x
x
7
Start Loopback Test
(refer to table 2-5
item 7).
All operating modes
correct.
x
x
Audio alarm resets.
x
x
* These adjustments to be performed by 31J only.
4-12
Continue trouble shooting.
Perform adjustment
as directed in paragraph
4-14B.
Continue trouble shooting.
Perform adjustment
as directed in paragraph
4-14H.
Continue troubleshooting.
Continue troubleshooting.
Higher level
maintenance required.
Continue troubleshooting.
Higher level
maintenance required.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ORGANIZATIONAL MAINTENANCE TROUBLESHOOTING CHART NO. 2. Continued
STEP
7
INSTRUCTION
Start Loopback Test
- Continued
INDICATION
ABORT test correct.
YES
NO
x
x
Manual line-feed
operates correctly.
x
x
Continuity between
pins R and S of J1
(TRANSFER switch
ON). Open circuit between pins R and S
(TRANSFER switch
OFF). Refer to figure 3 -29,
x
Paper-low switch
operates correctly.
x
Lamp test correct.
x
Continue troubleshooting.
Check for paper-feed
obstruction. If fault not
corrected, higher level
maintenance required.
Higher level
maintenance required.
Continue troubleshooting.
Check paper-low adjustment in accordance with paragraph
4-14G.
Continue troubleshooting.
x
*
x
x
Audio alarm operates
correctly.
Continue troubleshooting.
Higher level
maintenance required.
Continue troubleshooting.
x
Drum motor stops
when paper tension
lever is pressed. *
REMARKS
x
x
Check paper-out adjustment in accordance with paragraph
4-14 I
Continue troubleshooting.
Replace defective
lamps.
Continue troubleshooting.
Higher level
maintenance required.
* This adjustment to be performed by 31J only.
4-13
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
ORGANIZATIONAL MAINTENANCE TROUBLESHOOTING CHART NO. 2- Continued
STEP
8
9
INDICATION
INSTRUCTION
(Optional test if battery backup supply
available)
Using a multimeter,
check battery backup
supply voltage.
Check at TP1 on
power supply.
Voltage acceptable
+ 12 Vdc
If operating in other
than LO DATA
or LO DATA, perform a
Loopback Test looping
signal at a local or
distant patching facility
Improper operation
indicates receive or
transmit fault.
YES
REMARKS
NO
Return terminal to
service.
x
x
x
x
Remove and check
fuse F3. If fuse good,
replace battery. If
battery good, higher
level maintenance required.
Trouble may be
external to terminal,
Higher level
maintenance required.
Section IV. MAINTENANCE PROCEDURES
4-9. GENERAL
This section includes the following maintenance procedures authorized to be performed by
organizational maintenance personnel:
Cleaning (para 4-10)
Painting (para 4-11)
Removal and replacement of fuses in the interface assembly (para 4-12)
Removal and replacement of the PARITY RESET lamp (para 4-12)
Lubrication (para 4-13)
Adjustments (para 4-14)
Final inspection (para 4-15)
4-14
Change 1
4-10.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-15
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-10.
4-16
4-10.
TO
31W4-2UGC74-2
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
4-17
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-11.
4-18
4-12.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-19
TM 11-5815-602-24
TO 31W4-2UGC74-2
4-12.
4-20
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-13. ORGANIZATIONAL MAINTENANCE LUBRICATION INSTRUCTIONS
Refer to removal and replacement procedures in chapter 5 for access to lubrication points where
required.
Table 4-2. LUBRICATION SCHEDULE (SEMI-ANNUAL)
To be performed by 31J only.
ITEM
NO.
ITEM
TO BE
LUBRICATED
LUBRICATION PROCEDURES
1.
Slides
● With a clean, lint-free cloth,
wipe a thin film of grease
(a light, visible coating)
over terminal slides and into
top and bottom grooves of slides.
2..
Paper low
switch
act ivator
arm
● Lubricate paper low arm pivot
with a drop of oil.
NOTE
A drop of oil is the amount of oil retained on a No. 22
gauge wire which has been dipped approximately 1/2
inch into a container of oil (MIL-L-46000).
3.
Ribbon
mechanism
● Place an even coat of grease (MIL-G-23827)
on ribbon mechanism.
(Refer to para
5-10M for
removal of
printer
subassembly)
4-21
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 4.2. LUBRICATION SCHEDULE - Continued
ITEM
NO.
ITEM
TO BE
LUBRICATED
3.
Ribbon
mechanismContinued
LUBRICATION PROCEDURES
● Place a drop of oil on spool
driver dog assembly pivot.
● Using a fine bristle brush,
apply a light coat of oil to
the two sensing lever pivots,
remove any excess oil.
4.
Ribbon
lift and
drop
mechanisms
(Refer to para
5-10M for
removal of
printer
subassembly)
4-22
● Lubricate both left and right ribbon
lift and drop mechanisms.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 4.2. LUBRICATION SCHEDULE . Continued
ITEM
NO.
5.
ITEMS
TO BE
LUBRICATED
Motor
(line-freed)
drive chain
LUBRICATION PROCEDURES
Lightly oil chain using a fine bristle brush; remove excess
oil.
Apply a film of grease to drive motor sprocket using a bristle
brush.
6.
Roll
paper
blocking
levers
4-23
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-14. ORGANIZATIONAL MAINTENANCE ADJUSTMENTS
Organizational maintenance personnel are authorized to make following adjustments to terminal:
These adjustments to be performed by 31J only. (A through F and I)
4-24
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-25
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-26
4-27
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Change 1
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-28
4-29
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Change 1
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-30
4-31
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Change 1
TM 11-5813-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
4-32
4-33
TM 11-5815-802-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Change 1
Change 1
TM 11-5815-802-24
EE161-DM-MMM-010/E154UQC74
TO 31W4-2UQC74-2
4-34
4-15.
TM 11-5815-602-34P
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
table 2-5
4-35
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section V.
PREPARATION FOR STORAGE AND SHIPMENT
4-16. SHUTDOWN
The shutdown procedures for the terminal are as follows:
Print out all stored messages. Any stored messages not printed out will be lost once the
terminal is powered down. (Refer to TM 11-5815-602-10 for procedure in printing out
stored messages.)
● Verify that all messages have been transmitted.
● Place POWER switch in OFF position.
● Perform the AFTER OPERATING checks of the Operator PMCS Table of TM
11-5815-602-10.
●
4-17. SECURE
Secure the terminal as follows:
Loosen the copyholder mounting screw knob in a counterclockwise direction.
Remove the notched end of the copyholder bar from the mounting screw.
Release the hinged sections from the center section by opening the four rotating clips.
Fold the two hinged sections.
Store the copyholder in the front case cover storage compartment.
With power source shut off, disconnect all cables and close rear panel door; secure with
latch.
Attach front case to terminal and secure latches.
4-18.
ADMINISTRATIVE STORAGE
Refer to TM 740-90-1, chapter 10, for the proper siting, preparation and storage procedures.
4-36
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
CHAPTER 5
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
PAGE
Section I.
GENERAL INFORMATION
Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
ContinuityTests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Voltage and Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Section Il.
TOOLS AND EQUIPMENT REQUIRED
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Section lll. TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Interface Assembly Fault Localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
PowerSupplyOutputVoltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Section IV. REMOVAL AND REPLACEMENT
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DrumMotorBrushes . . . . . . . . . . . . . . . . . . . . . . . . . .
Dustcover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyboard Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Hammer Driver Module . . . . . . . . . . . . . . . . . . .
Print Hammer Module . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Processing Logic Circuit Cards . . . . . . . . . . . . . . . . .
Removal and Replacement Procedures . . . . . . . . . .
Ribbon Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section V. DISASSEMBLY AND REASSEMBLY OF TERMINAL,
COMMUNICATIONS AN/UGC-74A(V)3
PAGE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .5-37
Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . .5-56
Disassembly and Reassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Dustcover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 5-60
Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .5-67
Keyboard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-78
Printer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38
Printer Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41
Ribbon Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Section VI. DIRECT SUPPORT MAINTENANCE ADJUSTMENTS
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . ..5-81
Printer Subassembly Alinement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
Ribbon-Feed Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Ribbon Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . 5-85
Ribbon-Lift Mechanism Lift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Ribbon-Lift Mechanism Release Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Timing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . ..5-82
Section VII. DIRECT SUPPORT TEST PROCEDURES
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-89
Terminal Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-89
5-2
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section I. GENERAL INFORMATION
5-1. VOLTAGE AND RESISTANCE MEASUREMENTS
Voltage and resistance measurements, performed by direct support maintenance personnel, are
described in the troubleshooting procedures and should be performed in conjunction with those
procedures. Where applicable, the procedures reference paragraphs, tables and diagrams which
contain the necessary measurement requirements. Unless specified in the procedure, all voltage
measurements are made in terminal using Multimeter AN/USM-223.
5-2. CONTINUITY TESTS
Instructions and data are provided for testing the continuity of wire circuits. Data includes the
location of test points, operation of switches and maximum allowable resistance.
5-3. BENCH TESTING
Direct support bench testing, troubleshooting, and repairing of terminal is as specified by the
Maintenance Allocation Chart (appx B). Detailed procedures are provided in troubleshooting
and maintenance sections of this chapter.
CAUTION
Before applying power to the terminal for the first time, check the value
of fuses F1 and F2. If fuses are 1½A, operate only with ac power. If
fuses are 6¼A, operate with 26Vdc power.
5-3
TM 11-5815-602-24
EE161-DM-MMM-0101E154UGC74
TO 31W4-2UGC74-2
Section II. TOOLS AND EQUIPMENT REQUIRED
NOTE
Refer to the Maintenance Allocation Chart (MAC) in appendix B for the
National Stock Numbers (NSN) of the following tools and test
equipment.
5-4. TOOLS AND TEST EQUIPMENT
Tool Kit TE - 50B
Tool Kit, Electronic Equipment TK-105/G
Multimeter AN/USM-223
5-5. SPECIAL TOOLS
Loopback Plug (SM-B-916000)
Tool, Drum Puller (SM-C-964466)
Remover, Module (SM-B-916003)
Hammer-Drum Spacing Gauge (2)
Pin Extractors M24308/18-1 and MS27534-22VD
Module, CPU (3A1A1)
Module, Memory (3A1A2)
Module, Communications (3A1A3)
Module, Printer Control (3A1A4)
Module, Hammer Driver (3A1A5A1A2-A3)
Module, Hammer (3A1A5A1A4-A23)
Module, MD & CC (3A1A5A3)
Assembly, Interface (3A1A7)
Module, Power Supply (3A1PS1)
5-4
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section Ill. TROUBLESHOOTING
5-6. GENERAL
Troubleshooting at direct support level includes all the troubleshooting techniques outlined
for organizational maintenance (chapter 4, section Ill), and any special or additional techniques
required to isolate a defective assembly.
The systematic troubleshooting procedure, which begins with the operational checks performed at organizational level, must be completed by means of sectionalization and localization
procedures.
●
●
Sectionalization, the first step in troubleshooting, means tracing the trouble to the major
assembly that is responsible for abnormal operation.
Localization, the second step, means tracing the trouble to a particular component
within the major assembly.
5-7. TROUBLESHOOTING CHART
Use the following chart (table 5-1) to sectionalize the trouble to the major assembly. The
chart is indexed by MALFUNCTION/SYMPTOM, and TEST OR PROCEDURE to follow in order
to locate the defective major assembly.
Location of the defective major assembly is done by checking for the correct terminal response
listed in the INDICATION column, and performing the procedures listed in the YES or NO
columns.
5-5
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 5-1. DIRECT SUPPORT TROUBLESHOOTING
MALFUNCTION/SYMPTOM
TEST OR PROCEDURE
INDICATION
YES
NO
NO POWER INDICATION - LOSS OF ALL
TERMINAL FUNCTIONS
Step 1. Check fuses.
Fuses good.
Step 2. Replace power supply assembly
(para 5-11A).
Terminal has . . . . . . . . . . . . .
power (lights
on).
Step 3. Replace filter assembly
(para 5-11G).
Terminal has . . . . . . . . . . . . . . Reinstall
power (lights
original filter
on).
assembly. Go
to general
support
maintenance.
Go to step 2.
Replace
defective fuse.
Reinstall
original power
supply. Go to
step 3.
MOTOR DOES NOT RUN - LIGHTS ON
5-6
Step 1. Check P2J2 for loose connection/
broken pins.
Terminal has . . . . . . . . . . . . .
power.
Go to step 2.
Step 2. Test power supply TP7.
5 VDC or
greater.
Go to step 3.
Step 3. Replace A1A1 and A1A4 cards.
Terminal has . . . . . . . . . . . . .
power.
Reinstall
cards, go to
step 4.
Step 4. Replace power supply.
Terminal has . . . . . . . . . . . . .
power.
Reinstall
power supply.
Go to general
support
maintenance.
Step 5. Test positive terminal of motor for voltage.
5 VDC or
greater.
Go to step 6.
Step 6. Test continuity of positive terminal to
power supply TP7
Low resistance. Go to general
Support
maintenance.
Change 1
Go to step 5.
Go to step 7.
Repair if
accessible or
go to general
support
maintenance. I
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 5-1. DIRECT SUPPORT TROUBLESHOOTING - Continued
MALFUNCTION/SYMPTOM
TEST OR PROCEDURE
INDICATION
YES
Go to step 8.
NO
Go to step 9.
Step 7. Test negative terminal of motor for
voltage.
5 VDC or
greater.
Step 8. Test continuity of J1 pin 12 to the
negative terminal of the motor.
Low resistance. Go to general
support
maintenance.
Step 9. Test motor for mechanical binding.
Motor spins
freely.
Go to step 11.
Go to step 10.
Step 10. Check ribbon mechanism and printer
subassembly adjustments.
Adjustments
proper.
Go to general
support
maintenance.
Adjust
mechanisms.
Step 11. Test continuity between negative and
positive terminal of the motor.
Low resistance.
Go to general.
Support
maintenance.
Go to step 12.
Step 12. Replace brushes.
Terminal has . . . . . . . . . . . . .
power.
Go to step 13.
Step 13. Replace armature.
Terminal has . . . . . . . . . . . . .
power.
Go to general
support
maintenance.
Change 1
Repair if
accessible or
go to general
Support
maintenance.
5-6.1/(5-6.2 blank)
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 5-1.
DIRECT SUPPORT TROUBLESHOOTING - Continued
MALFUNCTION/SYMPTOM
TEST OR PROCEDURE
INDICATION
YES
NO
TERMINAL FAILS SELF-TEST
Step 1. If test No. 1 fails, replace CPU
Al Al board (para 5-11B).
Test
successful.
..........
Reinstall
original circuit
board. Go to
general
support
maintenance.
Step 2. If test No. 2 fails, replace PRINT
A1A4 board.
Test
successful.
..........
Reinstall
original circuit
board. Go to
general
support
maintenance.
Step 3. If test No. 3 fails, replace
MEMORY A1A2 board.
Test
successful.
..........
Reinstall
original circuit
board. Go to
general
support
maintenance.
Step 4. If test No. 4 fails, replace
COMMUNICATIONS A1A3 board.
Test
successful.
..........
Reinstall
original circuit
board. Go to
general
support
maintenance.
Step 1. If all positions faulty, replace both
hammer driver modules (para 5-11D).
Fault
corrected.
..........
Reinstall
original
hammer driver
modules. Go
to general
support
maintenance.
Step 2. If every fourth position faulty, replace appropriate hammer driver module.
Fault
corrected.
..........
Reinstall
original
hammer driver
module. Go to
general
support
maintenance.
IMPROPER OR NO PRINTING
5-7
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 5-1.
DIRECT SUPPORT TROUBLESHOOTING - Continued
MALFUNCTION/SYMPTOM
TEST OR PROCEDURE
INDICATION
YES
NO
Step 3. If four sequential positions faulty,
replace appropriate hammer module (para
5-11E).
Fault
corrected.
..........
Reinstall
original
hammer module.
Go to general
support
maintenance.
Step 4. If single print position faulty, adjust
appropriate hammer on hammer module
(para 4-14A).
Fault
corrected.
..........
Replace
hammer
module. If
fault still not
corrected, go
to general
support
maintenance.
IMPROPER OR NO LINE FEED
Replace motor feed (line-feed) and current
control circuit board (para 5-11F).
Proper line
feed.
Reinstall
original motor
feed and current control
circuit board.
Go to general
support
maintenance.
Step 1. Check for proper control and switch
settings on interface assembly.
Identical
transmitted
and received
message.
Go to step 2.
Step 2. Replace (para 5-11C) or repair
(para 5-13F) interface assembly.
Identical
transmitted
and received
message.
Go to general
support
maintenance.
IMPROPER TRANSMISSION AND
RECEPTION
IMPROPER TRANSMISSION
Replace (para 5-11O) or repair (para 5-13G)
keyboard keyswitch assembly.
5-8
Proper
character or
command is
transmitted
when appropriate key
is pressed.
..........
Go to general
support
maintenance.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-8. INTERFACE ASSEMBLY FAULT LOCALIZATION
Make all continuity tests with the power cable removed.
Fault localization in the interface assembly is limited to faults which can be found by
performing a continuity test as directed in table 5-2.
Failure to detect the fault with this procedure will require forwarding the assembly to
general support.
Refer to paragraph 5-11C for interface assembly removal.
Table 5-2. INTERFACE ASSEMBLY CONTINUITY TEST
Switch
Position
From
To
Resistance (Max)
CLOCK . . . . . . . . . .
in . . . . . . . . . . . . . .
EXT . . . . . . . . . . . . .
KG-30 . . . . . . . . . . . .
+...............
- ...............
s................
J
DIO. . . . . . . . . . . . . . . . .
NRZ . . . . . . . . . . . . .
1...............
2
ASCII. . . . . . . . . . . . . . . . . .
BAUDOT . . . . . . . . .
NORMAL . . . . . . . . .
SELF TEST . . . . . . .
ON . . . . . . . . . . . . . .
OFF . . . . . . . . . . . . .
ON . . . . . . . . . . . . . .
OFF . . . . . . . . . . . . .
ON . . . . . . . . . . . . . .
OFF . . . . . . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J5-40 . . . . . . . .
J2-J . . . . . . . . .
J2-J . . . . . . . . .
J2-L . . . . . . . . .
J2-L . . . . . . . . .
J3-A . . . . . . . .
J3-A . . . . . . . . .
J5-30 . . . . . . . . . .
J5-31 . . . . . . . . . .
J5-30, J5-31 . . . . .
J5-32 . . . . . . . . . .
J5-32 . . . . . . . . . .
J5-35 . . . . . . . . . .
J5-35 . . . . . . . . . .
J5-36 . . . . . . . . . .
J5-36 . . . . . . . . . .
J5-9 . . . . . . . . . . .
J5-10 . . . . . . . . . .
J5-37 . . . . . . . . . .
J5-37. . . . . . . . .
J5-33 . . . . . . . . . .
J5-34 . . . . . . . . . .
J2-M . . . . . . . . . .
J2-M . . . . . . . . . .
J2-K . . . . . . . . . . .
J2-K . . . . . . . . . . .
J4-8 . . . . . . . . . . .
J4-8 . . . . . . . . . . .
1 ohm
1 ohm
open
1 ohm
open
1 ohm
open
1 ohm
open
1 ohm
1 ohm
open
1 ohm
1 ohm
1 ohm
1 ohm
open
1 ohm
open
1 ohm
open
CLOCK +/- . . . . . .
FIGURES S/J . . . . .
SIGNAL . . . . . . . . . .
STOP BITS . . . . . . .
MODE . . . . . . . . . . .
SELF TEST . . . . . . .
POWER . . . . . . . . . .
5-9
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-9. POWER SUPPLY OUTPUT VOLTAGES
The values listed in table 5-3 are for troubleshooting purposes only; they represent
average values. Use Multimeter AN/USM-223 for taking measurements.
CAUTION
Do not short test point jacks to chassis as this could cause equipment
damage.
. Refer to the following figure for location of power supply test points.
Table 5-3. POWER SUPPLY OUTPUT VOLTAGES
Test Point
Normal Voltage*
Test Point Name
1 .......
BU lamp supply . . . . . . . . . . .
2 .......
3 .......
CAP VOK . . . . . . . . . . . . . . . .
CONCURR REG . . . . . . . . . . .
4 .......
5 .......
6 .......
7 ......,
8 .......
9
10. . . . . . . . . . .
+5 V a . . . . . . . . . . . . . . . . . . .
LAMP SUPPLY . . . . . . . . . . . .
-8.6V b . . . . . . . . . . . . . . . . . . .
DRUM MOTOR . . . . . . . . . . . .
+18V . . . . . . . . . . . . . . . . . . .
VIN RTN . . . . . . . . . . . . . . . . .
SHUT DOWN . . . . . . . . . . . . .
11. . . . . . . . . .
ABU . . . . . . . . . . . . . . . . . . . .
12 . . . . . .
13 . . . . . .
14 . . . . . .
15 . . . . . .
16 . . . . .
-5V a . . . . . . . . . . . . . . . . . . . .
SCMO (drum speed) . . . . . . .
22 to 30 V . . . . . . . . . . . . . . . .
+12 V . . . . . . . . . . . . . . . . . . .
+5V b . . . . . . . . . . . . . . . . . . .
+22 to + 32Vdc (normal input)
+ 12Vdc Nominal (battery backup)
+ 4.5Vdc to + 5.5Vdc
+ 2.5Vdc to + 5.5Vdc (not printing)
0 to + 0.5Vdc (printing)
+ 4.75 to + 5.25Vdc
0 to +21.5Vdc (variable by ILLUM control)
-7.95 to -9.25
+5.6 to +11.6Vdc (drum on)
+17 to + 19.6Vdc
o
0 to + 0.5Vdc (motor running)
+ 2.5Vdc to + 5.5Vdc (motor not running)
0 to + 0.6Vdc (battery backup)
+ 3.0Vdc to + 5.0Vdc (not in battery backup)
-4.8Vdc to -5.9Vdc
1080 ±50 us period**
+22 to 32Vdc
+ 10.8Vdc to + 13.2Vdc
+ 4.8V to 5.4Vdc
*All voltages are measured with respect to test point 9.
**Cannot be checked by direct support maintenance.
5-10
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
POWER SUPPLY TEST POINTS
5-11
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section IV. REMOVAL AND REPLACEMENT OF MODULAR ASSEMBLIES
5-10. GENERAL
This section covers removal, replacement and repair of the following terminal components:
A. POWER SUPPLY
B. PROCESSING LOGIC CIRCUIT CARDS
C. INTERFACE ASSEMBLY
D. PRINT HAMMER DRIVER MODULE
E. PRINT HAMMER MODULE
F. LINE-FEED/CURRENT CONTROL CIRCUIT BOARD
G. FILTER ASSEMBLY
H. TIMING MECHANISM
I. DRUM MOTOR BRUSHES
J. DRUM MOTOR
K. PRINTER ASSEMBLY
L. RIBBON MECHANISM
M. PRINTER SUBASSEMBLY
N. KEYBOARD KEYSWITCH ASSEMBLY
O. DUSTCOVER
Procedures listed are for removable modules, components, and assemblies as specified
in Maintenance Allocation Chart (MAC), appendix B, for direct support maintenance.
● Most parts and assemblies of the terminal can be easily reached and replaced without
use of special tools or instructions. Replacement, however, may require special techniques and tools to assure proper operation.
● Tag all wires to be unsoldered, or remove by any other means so as to reduce error in
replacement.
●
Do not attempt any unauthorized repairs on this equipment -- Avoid
personal injury -- BE SAFE. Observe all cautions listed on front page of this
manual.
5-12
5-11.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-13
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-14
C.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-15
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
C.
5-16
D.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-17
TM 11-5815-602-24
EEI 161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-18
E.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-19
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-20
E.
F.
TM 11-5815-602-24
EE161-DM-MMM-01O/E154UGC74
TO 31W4-2UGC74-2
5-21
para 5-11C
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-22
G.
para 5-11C
G.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-23
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-24
H.
paragraph 5-15A
para 5-11K
I.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-25
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-26
I.
para 5-11K
para 5-11I
J.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-27
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-28
J.
para 5-11l
K.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-29
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-30
para 5-11K.
L.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
para 5-11K
5-31
para 5-11K para 5-11L
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-32
M.
para 5-11L
para 5-15F
N.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-33
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-34
para 5-11N
para 5-13E
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-35
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-36
para 5-11N
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section V. DISASSEMBLY AND REASSEMBLY OF TERMINAL, COMMUNICATIONS AN/UGC-74A
5-12. GENERAL
This section contains disassembly and reassembly information for the following assemblies:
A.
B.
C.
D.
E.
F.
G.
PRINTER ASSEMBLY
PRINTER SUBASSEMBLY
RIBBON MECHANISM
CHASSIS ASSEMBLY
DUSTCOVER ASSEMBLY
INTERFACE ASSEMBLY
KEYBOARD ASSEMBLY
Disassembly is performed down to level for direct support maintenance as listed in the
maintenance allocation chart.
5-37
paragraph 5-13C
paragraph 5-11H
paragraph 5-11J
paragraph 5-11L
paragraph 5-13B
paragraph 5-11M
paragraph 5-11K
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-13.
5-38
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
paragraph 4-14B
5-39
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TOt31W4-2UGC74-2
5-40
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-41
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-42
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-43
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-44
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-45
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-46
TM 11-5815-602-24
5-47
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-48
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-49
TM 11-5815-602-24
EE161-DM-MMM-01O/E154UGC74
TO 31W4-2UGC74-2
5-50
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-51
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-52
paragraph 4-14C
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-53
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-54
paragraph 4-14E
paragraph 5-15B
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-55
paragraph 5-11G
para 6-10
paragraph 5-11K
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-56
paragraph 5-11G
para 6-10
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-57
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-58
TM 11-5815-602-24
EE161-DM-MMM-01O/E154UGC74
TO 31W4-2UGC74-2
5-59
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-60
page 5-59
E
page 5-59
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-61
page 5-58
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-62
E.
page 5-58
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-63
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
E.
5-64
E.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-65
page 5-58
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
E.
5-66
F.
para 5-11C
page 5-69
page 5-70
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
5-67
page 5-69
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
F.
5-68
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INTERFACE ASSEMBLY (Sheet 1 of 4)
5-69
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INTERFACE ASSEMBLY (Sheet 2 of 4)
5-70
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO31W4-2UGC74-2
5-71
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INTERFACE ASSEMBLY (Sheet 4 of 4)
5-72
F.
page 5-72
TM 11-5815-602-24
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5-73
pages 5-70, 5-72
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TO 31W4-2UGC74-2
F.
5-74
F.
page 5-72
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TO 31W4-2UGC74-2
5-75
page 5-71
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TO 31W4-2UGC74-2
F.
5-78
F.
page 5-70
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TO 31W4-2UGC74-2
5-77
paragraph 5-110
paragraph 5-110
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TO 31W4-2UGC74-2
G.
5-78
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5-79
page 5-79
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TO 31W4-2UGC74-2
G.
5-80
paragraph 5-110
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TO 31W4-2UGC74-2
Section VI. DIRECT SUPPORT MAINTENANCE ADJUSTMENTS
5-14. GENERAL
This section describes direct support maintenance adjustment procedures for the following:
A.
B.
C.
D.
E.
F.
TIMING
RIBBON-FEED
RIBBON-LIFT MECHANISM RELEASE SOLENOID
RIBBON-LIFT MECHANISM LIFT SOLENOID
RIBBON-HEIGHT
PRINTER SUBASSEMBLY
5-81
Change 1
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TO 31W4-2UGC74-2
5-82
5-15.
B.
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TO 31W4-2UGC74-2
5-83
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TO 31W4-2UGC74-2
B.
5-84
C.
paragraph 5-11M
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TO 31W4-2UGC74-2
para 5-15D
para 5-15E
5-85
D.
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TO 31W4-2UGC74-2
5-86
E.
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TO 31W4-2UGC74-2
5-87
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TO 31W4-2UGC74-2
F.
5-88
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TO 31W4-2UGC74-2
Section VII. DIRECT SUPPORT TEST PROCEDURES
5-16. GENERAL
Perform the terminal test (an overall function test) in the following paragraph to determine if
equipment has been properly repaired and can be returned to stock. This test is a compiIation of
tests from chapter 2 and chapter 4.
5-17. TERMINAL TEST
Preliminary Test
With power off, extend the terminal and connect AN/USM-223 to E1; E2 on the
filter module.
● Measure a resistance greater than 100K to the chassis after an initial capacitor charging
indication.
●
Power Supply Test
● Check power supply outputs (refer to para 5-9).
Self-Test, Loop-Back Test and Battery Back-Up Test
● Refer to table 2-5.
Change 1
5-89/(5-90 blank)
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TO 31W4-2UGC74-2
Line Feed Test
Transmit the composed message.
Activate ABORT switch immediately after the terminal begins line feeding. The terminal
will halt its line-feed function and issue a prompt sequence.
Press the LINE FEED switch on the dustcover. The line-feed function will perform.
TRANSFER Switch Test
Remove loop back plug from connector J1.
With power removed, measure continuity across pins R and S. There will be continuity
with TRANSFER switch at ON position and no continuity with TRANSFER switch at OFF
position.
Memory Test
NOTE
Perform this test only when a battery backup supply and cable are available
to the terminal.
Operate terminal with STATE switch at ICT position and information stored in message
memory.
Remove input power from terminal by disconnecting prime power source from connector
J2.
Reconnect prime power source to connector J2. The terminal will print the Operation
Validation/State Determination message. Check the contents of message memory.
5-91/5-92 blank
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TO 31W4-2UGC74-2
CHAPTER 6
GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
PAGE
Section I. GENERAL INFORMATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
General Support Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Modification WorkOrders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Section ll. TOOLS AND EQUIPMENT
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Required Tools andTest Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SpecializedTest Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Section lll. TROUBLESHOOTING
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Section IV. REMOVAL AND REPLACEMENT OF TERMINAL ASSEMBLIES
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Harness Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Logic Box CoverAssembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Paper-Roll Support Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Section V. DISASSEMBLY AND REASSEMBLY OF TERMINAL COMPONENTS
Filter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Hammer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49
Keyswitch Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Paper-Low Sensing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Printer Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Printer Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43
6-1
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TO 31W4-2UGC74-2
Section VI. GENERAL SUPPORT TESTING PROCEDURES
PAGE
FilterAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Final Test of Communications Terminal AN/UGC74A(V)3. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Hammer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Hammer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
lnterface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Keyboard Keyswitch Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Motor Driver and Current Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Power Supply Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Section VII. TEST FIXTURES DISASSEMBLY AND REASSEMBLY
Disassembly and Reassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Hammer Driver Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Hammer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100
Keyswitch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Line-Feed Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Section VIII. TEST FIXTURE TEST PROCEDURES
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Hammer Driver Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
Hammer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
Keyswitch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139
Line-Feed Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
6-2
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TO 31W4-2UGC74-2
Section I. GENERAL INFORMATION
6-1. GENERAL
This chapter contains information necessary for general suppport personnel to perform
maintenance tasks allocated to general support by the maintenance allocation chart (MAC) in
appendix B. The chapter describes tools and equipment required, procedures for troubleshooting,
removal and replacement, disassembly and reassembly, and testing.
6-2. GENERAL SUPPORT MAINTENANCE PROCEDURES
Maintenance procedures described in lower categories of maintenance (organizational and
direct support), and maintenance procedures in this chapter are all included in general support
maintenance. Testing procedures in this chapter determine acceptability of repaired equipment.
These procedures set forth specific requirements that the repaired equipment must meet before
it is returned to using organization.
6-3. MODIFICATION WORK ORDERS
Performance standards listed in Sections VI and Vlll assume that current modification work
orders (MWO) have been performed. Any MWO’s pertaining to this equipment that may have been
published after the date of this publication will be listed in DA Pam 310-1. MWO’S other than those classified
URGENT shall not be a reason for rejection.
6-3
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TO 31W4-2UGC74-2
Section Il. TOOLS AND EQUIPMENT
6-4. REQUIRED TOOLS AND TEST EQUIPMENT
a. For common tools and equipment, refer to the Modified Table of Organization (MTOE)
applicable to your unit.
b. Table 6-1 contains a list of all tools and test equipment required by general support
maintenance personnel for performance of tasks described in this chapter.
Table 6-1.
GENERAL SUPPORT TOOLS AND TEST EQUIPMENT
Tool Equipment TE-50B
Multimeter AN/USM-223
Loop Back Plug, Honeywell (SM-B-916000)
Oscilloscope AN/USM-281C
Frequency Counter AN/USM-207
Pace Kit
Power Supply PP-2309/U (six each)
Function Generator SG-1133/U (Hewlett-Packard Model 3312A)
Voltmeter, Digital AN/GSM-64B
Tool Kit, Electronic Equipment TK-105/G
Tool, Drum Puller, Honeywell (SM-C-964466)
Test Fixture, Driver Board, Honeywell (SM-C-915982)
Test Fixture, Hammer Module, Honeywell (SM-C-915985)
Test Fixture, PWB (LF/CC) Assembly, Honeywell (SM-C-915988)
Test Fixture, Filter Assembly, Honeywell (SM-C-915994)
Test Fixture, Power Supply, Honeywell (SM-D-915979)
Test Fixture, Interface Assembly, Honeywell (SM-D-915991)
Test Fixture, Keyswitch Assembly, Honeywell (SM-C-915997)
Test Set, Telegraph AN/GGM-15(V)2
Remover, Module, Honeywell (SM-B-916003) (two each)
Power Cable, UGC-74A, 120 Vac (SM-D-764481)
Power Cable, UGC-74A, 230 Vac (SM-D-764482)
Power Cable, UGC-74A, 26 Vdc (SM-D-764480)
Data Cable Assembly (SM-D-915889)
Rolling Punch, Cambion No. 6629
The following are used only at a specialized repair activity (SRA), category L in the
Maintenance Allocation Chart.
Interconnection Device, CPU Circuit Card Assembly
Interconnection Device, MRY Circuit Card Assembly
Interconnection Device, Comm Circuit Card Assembly
Interconnection Device, PRT CTRL Circuit Card Assembly
Test and Repair System, Electronic Equipment AN/MSM-105(V)1
6-4
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TO 31W4-2UGC74-2
6-5. SPECIALIZED TEST EQUIPMENT
Test and Repair System, Electronic Equipment AN/MSM-105(V)1 is located at a designated
Specialized Repair Activity (SRA) and is operated only by skilled personnel trained in its function.
6-6. REPAIR PARTS
Repair parts are listed and illustrated in the repair parts and special tools list TM 11-5815602-34P covering General Support Maintenance for this equipment.
Section Ill. TROUBLESHOOTING
6-7. GENERAL INSTRUCTIONS
General Support troubleshooting procedures in this manual supplement those of Organizational and Direct Support Maintenance for the terminal. The systematic troubleshooting procedures include organizational and direct support sectionalization checks of the complete
system; removal and replacement of components.
6-8. TROUBLESHOOTING PROCEDURES
a. Troubleshooting procedures for modules/assemblies tested at general support card
become part of the test procedures for these modules/assemblies. Assemblies which are not
testable by themselves (i.e., printer assembly, printer subassembly) may be fault isolated using
table 6-2.
CAUTION
Before applying power to the terminal for the first time, check the value
of fuses F1 and F2. If fuses are 1½A, operate only with ac power. If
fuses are 6¼4A, operate only with 26Vdc power.
b. Refer to the following tables and test setups for troubleshooting a defective
module/assembly.
Module/Assembly
Chassis Assembly
Hammer Driver (3A1A5A2-A3)
Hammer Module (3A1A5A4-A23)
Motor Driver and Current Control Board (3A1A5A3)
Interface Assembly (3A1A7)
Power Supply (3A1PS1)
Filter Assembly (3A1A6FL1)
Keyboard Keyswitch Assembly (3A2A1)
Troubleshooting
Table No.
Test Set-Up
Paragraph No.
6-2
6-3
6-4
6-5
6-6,6-7,6-8,6-9
6-10a,b,c,d,e
6-11
6-12
6-23
6-24
6-25
6-26
6-27
6-29
6-30
c. For repair of modules/assemblies, use tools in Pace Kit and Tool Kit, Electronic Equipment
TK-105/G and TE-50/B. Where required, recoat repaired area with conformal coating type UR MIL-I-46058.
d. After repair, repeat the test procedures to verify the repair action.
6-5
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TO 31W4-2UGC74-2
Table 6-2. TROUBLESHOOTING CHASSIS ASSEMBLY
MALFUNCTION/SYMPTOM
TEST PROCEDURE
ASSEMBLY TO BE TESTED
INDICATION
1 PRINT DRUM DOES NOT ROTATE
Replace harness assembly
(refer to para 6-10).
2 RIBBON LIFT/DROP INOPERATIVE
NO
HARNESS ASSEMBLY
Print drum
rotates.
Return to
service.
Troubleshoot
print drum
wiring
(fig. FO-6).
PRINTER SUBASSEMBLY MOTHERBOARD,
HARNESS ASSEMBLY
Step 1- Check continuity from printer
subassembly P1 pin 20 to printer
subassembly motherboard E34; from P1
pin 10 to E38 (refer to fig. 6-9).
Less than
1 ohm.
Go to step 2. Replace (para 5-11M)
or repair (para 6-17)
printer
subassembly.
Step 2- Check continuity from J1-20
to harness assembly XA4-40; from
J1-10 to XA4-41 (refer to fig. 6-7).
Less than
1 ohm.
Return to
service.
3 KEYBOARD INOPERATIVE
Replace harness assembly
(refer to para 6-10).
6-6
YES
Replace
harness
assembly
(refer to
para 6-10).
HARNESS ASSEMBLY
Keyboard
operates.
Return to
service.
Troubleshoot
keyboard
keyswitch assembly
(refer to
table 6-12).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-3. TROUBLESHOOTING HAMMER DRIVER 3A1A5A2-A3 (fig. 6-1)
MALFUNCTION/SYMPTOM
TEST PROCEDURE
INDICATION
YES
NO
NO +18VDC POWER TO HAMMER MODULES
NOTE
Use test setup as directed in paragraph 6-23.
Step 1- With test fixture SELECT switch at
IN 1, connect AN/USM-281 across SIG OUT 1
(pins 9 and 10).
Observe a
60HZ ±10%,
0 to 18V ±5%
square wave
on channel B
of scope.
Go to step 2.
Use scope
and fault
isolate to
failed piece
part.
Step 2- Compare function generator output
on channel A of scope with channel B.
Waveforms
should
coincide
(same frequency and
wave shape).
Go to step 3.
Replace
defective
parts.
Step 3- Place test fixture SELECT switch to
IN 2. Connect AN/USM-281 across SIG OUT 2
(pins 7 and 8).
Observe a
60HZ ±10%,
0 to 18V ±5%
square wave
on channel B
of scope.
Go to step 4.
Use scope
and fault
isolate to
failed piece
part.
Step 4- Compare function generator output
on channel A of scope with channel B.
Waveforms
should
coincide
(same frequency and
wave shape).
Return to
service.
Replace
defective
parts.
6-7
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
FIGURE 6-1.
6-8
PRINT DRIVER MODULE.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-4. TROUBLESHOOTING HAMMER MODULE 3A1A5A4-A23 (fig. 6-2)
MALFUNCTION/SYMPTOM
INDICATION
TEST PROCEDURE
NO
YES
HAMMER MODULE MALFUNCTIONS
NOTE
Use test setup as directed in paragraph 6-24.
Step 1- Place HMR 1 to ON position and
simultaneously press CONTROL pushbutton.
HMR 1 should
move forward
and remain
forward for as
long as both
HMR 1 and
CONTROL are
energized.
This action
Use multisupplies +18
meter and
Vdc to pin 2
isolate fault to
(hammer
failed piece
driver circuit
part.
No. 1) and a
logic control
(ground) to pin
3. Go to step 2.
CAUTION
If troubleshooting requires circuit to be energized for a prolonged period
(more than a few seconds), reduce +18 Vdc to +10 Vdc to prevent heating
of circuitry.
Step 2- Place HMR 2 to ON position and
simultaneously press CONTROL pushbutton
HMR 2 should
move forward
and remain
forward for as
long as both
HMR 2 and
CONTROL are
energized.
+18 Vdc to
pin 7; go to
step 3.
Use multimeter and
isolate fault to
failed piece
part.
Step 3- Place HMR 3 to ON position and
simultaneously press CONTROL pushbutton.
HMR 3 should
move forward
and remain
forward for as
long as both
HMR 3 and
CONTROL are
energized.
+18 Vdcto
pin 5; go to
step 4.
Use multimeter and
isolate fault to
failed piece
part.
Step 4- Place HMR 4 to ON position and
simultaneously press CONTROL pushbutton.
HMR 4 should
move forward
and remain
forward for as
long as both
HMR 4 and
CONTROL are
energized.
+18 Vdc to
pin 1; return
to service-
Use multimeter and
isolate fault to
failed piece
part.
6-9
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-2.
6-10
PRINT HAMMER MODULE.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-5. TROUBLESHOOTING MOTOR DRIVE AND CURRENT CONTROL
BOARD ASSEMBLY 3A1A5A3 (fig. 6-3)
CIRCUIT TO BE TESTED
MALFUNCTION/SYMPTOM
TEST PROCEDURE
INDICATION
NO
YES
CONTROL CIRCUIT
NOTE
Use test setup as directed in paragraph 6-25.
LINE-FEED FUNCTION ABNORMAL
Step 1 - Connect multimeter to CONTROL
test point.
Test fixture
input diode
and bias circuit are working, measure
1.5 Vdc ±5%.
Go to step 2.
Test fixture
defective.
Step 2 - Connect multimeter to LOAD test
point.
Check current
control (CC)
board ability
to switch 22 V
to output load,
measure 22
Vdc ±5%.
Go to step 3.
Current
control board
defective.
Step 3 - Place SURGE CONTROL switch to
ON.
Surge control
circuit cuts
off switching
action in step 2
Measure 4 to
5 Vdc at
LOAD test
point.
Go to step 4.
Surge control
switch
defective.
Step 4 - Return SURGE CONTROL switch to
OFF.
Measure 22
Vdc ±5% at
LOAD test
point.
Go to step 5.
Surge control
switch
defective.
Step 5 - Place PULSE switch to LF.
Routes input
signal (SIG IN)
to pin Q, AO IN
and applies it
to line-feed
board.
22 V peak to
peak ±5%
square wave
at 50 Hz.
Output
available at
AO OUT, go to
step 6.
Line feed
board
defective.
Step 6 - Observe output of channel B of
oscilloscope (AO OUT).
Go to step 7.
Turn off test equipment
and remove Line-Feed/
Current Control Board
assembly from test
fixture. Perform continuity
checks through Q1
(positive lead on P1-Q
and negative lead on
P1-D) and read approximately 621 ±20 ohms.
Reverse leads and read
open. If test fails
isolate fault to piece
part. Refer to fig. 3-15A
and B.
6-11
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-5. TROUBLESHOOTING MOTOR DRIVE AND CURRENT CONTROL
BOARD ASSEMBLY 3A1A5A3 (fig. 6-3) - CONTINUED
CIRCUIT TO BE TESTED
MALFUNCTION/SYMPTOM
TEST PROCEDURE
INDICATION
YES
NO
Step 7- Return LF/CC board assy to test
fixture and compare function generator
output on channel A of oscilloscope with
channel B.
Waveforms
should
coincide
(same
frequency and
waveshape).
Go to step 8.
Use scope
and fault
isolate to
failed piece
part. Refer to
fig. 3-15A and B.
Step 8- Place SELECT switch to A1 (connects a 20-ohm load resistor to A1 OUT).
Measure as in steps 8 and 7 at A1 OUT and
A1 IN.
Indication
same as
step 7.
Go to step 9.
Again turn off test
equipment and
remove LF/CC board
assembly from test
fixture. Perform continuity checks
through Q2 (positive
lead on P1-0 and
negative lead on P1-C)
and read approximately 621 ±20 ohms.
Reverse leads and
read open. If test fails
isolate fault to piece
part. Refer to fig.
3-15A and B.
Step 9 - Place SELECT switch to BO (connects a 20-ohm load resistor to BO OUT).
Measure as in steps 6 and 7 at BO OUT and
BO IN.
Indication
same as
step 7.
Go to step 10. Perform continuity
checks through Q3
(positive lead on P1-K
and negative lead on
P1-B) and read approximately 621 ±20
ohms. Reverse leads
and read open. If test
fails isolate fault to
piece part. Refer to
fig. 3-15A and B.
Step 10 - Place SELECT switch to B1 (connects a 20-ohm load resistor to B1 OUT).
Measure as in steps 6 and 7 at B1 OUT and
B1 IN.
Indication
same as
step 7.
Return to
service.
6-12
Perform continuity
checks through Q4
(positive lead on P1-J
and negative lead on
P1-A) and read approximately 621 ±20
ohms. Reverse leads
and read open. If test
fails isolate fault to
piece part. Refer to
fig. 3-15A and B.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-3.
MOTOR DRIVE AND CURRENT CONTROL BOARD ASSEMBLY.
6-13
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-6. TROUBLESHOOTING INTERFACE ASSEMBLY ± 6 VOLT ± 1 VOLT DATA CIRCUITS
MALFUNCTION/SYMPTOM
TEST PROCEDURE
CIRCUIT TO BE TESTED
INDICATION
NO
YES
± 6V ± 1V DATA CIRCUIT(S)
LOSS OF TRANSMIT OR RECEIVE CAPABILITY
NOTE
Use test setup as directed in paragraph 6-26c(1).
Transmit alternate character bits from
AN/GGM-15 at DATA ± 6V and at speeds between 45.5 baud and 1200 baud. Make the
following checks in RECEIVER CLOCK
circuit: RECEIVER GATED CLOCK circuit:
Output checks Continue
troubleon AN/GGMshooting.
15 analyzer.
J1-G to VR7 to FL7 to S11B to VR2 to E17
to U4, U1, U2 to J5-6
J1-G to VR8 to FL8 to S11C to VR3 to E16
J5-8 to U5 to CR1, CR4 to FL5 to VR5 to J1P
FL6 to VR6 to J1-N
J1-A to VR1 to FL1 to E9 to U4 to J5-4
J1-B to VR2 to FL2 to E8
J5-7 to E2 to U1, U5 to CR13, CR14 to E13 to
S125 to FL9 to VR9 to J1-K
U5 to CR15, CR16 to E14 to S12C to FL10 to J1-L
6-14
Intermediate
points can be
checked with
oscilloscope.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-7. TROUBLESHOOTING INTERFACE ASSEMBLY 20 MA and 60 MA DATA CIRCUITS
MALFUNCTION/SYMPTOM
TEST PROCEDURE
LOSS OF TRANSMIT OR RECEIVE CAPABILITY
CIRCUIT TO BE TESTED
INDICATION
YES
NO
20 MA AND 60 MA DATA CIRCUIT(S)
NOTE
Use test setup as directed in paragraph 6-26c(3).
Step 1Transmit alternate character bits from
AN/GGM-15 at speeds between 45.5 baud
and 75 baud. Make the following checks
with power supplies at 20mA:
Output checks Continue
on AN/GGMtrouble15 analyzer.
shooting.
Intermediate
points can be
checked with
oscilloscope.
Return to
service.
Defective S11
and R8.
J1-G to VR7 to FL7 to S11B to E25 to CR5
to VR1 , U3, Q2, U2 to E20 to J5-6
J1-H to VR8 to FL8 to S11C to E-26 to CR8,
CR7
J5-7 to E2 to U1, U2, U5, Q1, Q3, CR12, K1,
CR13 to E15 to S12B to FL9 to VR9 to J1-K
E12 to S12C to FL10 to VR10 to J1-L
Step 2Repeat procedure in step 1 for
the 60 mA test.
Output checks
on AN//GGM15 analyzer.
6-15
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-8.
fig. 6-4
MALFUNCTION/SYMPTOM
TEST PROCEDURE
INDICATION
YES
NO
INTERFACE ASSEMBLY SWITCH CONTINUITY
Use test setup as directed in paragraph 6-26c(5).
Place OHM CHECK switch to position 1. (This
checks continuity of circuit path from J2-G to
J4-5).
Less than
1 ohm.
Continue
troubleshooting
(table 6-9).
Use multimeter and
fault isolate to
failed piece
part.
NOTE
Table 6-9, Interface Assembly Continuity Checks, shows all 12 positions
and circuit parts that are to be checked. Move the AN/USM-223 to test
points S1B, and then to S1C and finally to S1D.
Figure 6-4.
6-16
SET-UP FOR TESTING INTERFACE ASSEMBLY SWITCHES.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-9. INTERFACE ASSEMBLY CONTINUITY CHECKS
Change 1
6-17
TM 11-5815-802-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-9. INTERFACE ASSEMBLY CONTINUITY CHECKS . CONTINUED
6-18
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-10a. TROUBLESHOOTING POWER SUPPLY (+5VA LOAD CIRCUIT)
CIRCUIT TO BE TESTED
MALFUNCTION/SYMPTOM
TEST PROCEDURE
INDICATION
YES
NO
+5 VA LOAD CIRCUIT
+5 VA LOAD CIRCUIT MALFUNCTIONS
NOTE
Use test setup as directed in paragraph 6-27d.
Step 1- Turn SELECT switch to position 3
(connects VOUT and SCOPE terminal to +5
V(A) output).
+5 Vdc ±5%.
50 mVrms
ripple and
noise
maximum
using AC
function on
DVM.
Go to step 2.
Troubleshoot
+5 VA
regulator
circuit on
microprocessor
supply
(fig. FO-4).
Step 2- Place +5 VA LOAD LO to ON (places
a 10-ohm resistor across +5 V(A) output).
+5 Vdc ±5%.
50mVrms
ripple and
noise
maximum
using AC
function on
DVM.
Go to step 3.
Troubleshoot
+5VA
regulator
circuit on
microprocessor
supply
(fig. FO-4).
Step 3- Place +5 VA LOAD LO to OFF and
place +5 VA LOAD HI to ON (places a 1.5
ohm resistor across +5 V(A) output).
+5 Vdc ±5%.
50 mVrms
ripple and
noise
maximum
using AC
function on
DVM.
Go to step 4.
Step 4- Place +5 VA LOAD LO to ON.
+ 4.3 Vdc
±12%.
Return to
service.
Troubleshoot
+5VA
regulator
circuit on
microprocessor
supply (fig.
FO-4).
Troubleshoot
+5VA
regulator
circuit on
microprocessor
supply
(fig. FO-4).
6-19
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-10b. TROUBLESHOOTING POWER SUPPLY (+12V AND -5VA LOAD CIRCUITS)
MALFUNCTION/SYMPTOM
TEST PROCEDURE
1
2
INDICATION
YES
NO
NOTE
Use test setup as directed in paragraph 6-27d.
+12V LOAD CIRCUIT
+12V LOAD CIRCUIT MALFUNCTIONS
Step 1- Turn SELECT switch to position 4 (connects VOUT and SCOPE terminals to + 12V output).,
+12 Vdc ±5%.
100 mVrms
ripple and
noise
maximum.
Go to step 2.
Step 2- Place +12 V LOAD from OFF
to ON (places a 332-ohm resistor
across +12 V output).
+12 Vdc ±5%.
100 mVrms
ripple and
noise
maximum.
Return to
service.
-5VA LOAD CIRCUIT MALFUNCTIONS
Turn SELECT switch to position 5
(connects VOUT and SCOPE terminals
to –5V(A) output).
6-20
CIRCUIT TO BE TESTED
Troubleshoot
microprocessor
supply
(fig. FO-4).
Troubleshoot
microprocessor
supply
(fig. FO-4).
-5VA LOAD CIRCUIT
–5Vdc ±5%.
40 mVrms
ripple and
noise
maximum.
Return to
service.
Troubleshoot
microprocessor
supply
(fig. FO-4).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-10c. TROUBLESHOOTING POWER SUPPLY (+5VB AND -8.6V LOAD CIRCUITS)
MALFUNCTION/SYMPTOM
TEST PROCEDURE
CIRCUIT TO BE TESTED
YES
INDICATION
NO
NOTE
Use test setup as directed in paragraph 6-27d.
1
2
+5VB LOAD CIRCUIT MALFUNCTIONS
+5VB LOAD CIRCUIT
Step 1- Turn SELECT switch to position 6 (connects VOUT and SCOPE
terminals to + 5V(B) output).
+5Vdc ±5%
15mVRms
ripple and
noise
maximum.
Go to step 2.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
Step 2- Place +5VB LOAD LO to
ON (connects a 2.37-ohm load
across + 5V(B) output).
+5Vdc ±5%
15 mVrms
ripple and
noise
maximum.
Go to step 3.
Troubleshoot
+ 5V, ±8.6V
supply
(fig. FO-5).
Step 3- Place + 5VB LOAD LO to
OFF and place + 5V8 LOAD HI to
ON (connects a 1.7-ohm resistor
across +5V(B) output).
+5Vdc ±5%
15 mVrms
ripple and
noise
maximum.
Go to step 4.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
Step 4- Place +5VB LOAD LO to ON.
+4.0Vdc
±15%.
Return to
service.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
-8.6V LOAD CIRCUIT MALFUNCTIONS
-8.6V LOAD CIRCUIT
Step 1- Turn SELECT switch to position 7 (-8.6V output) and set -8.6V
LOAD switch to position 3 (115-ohm
load across output).
-8.6 Vdc ±5%
85 mVrms
ripple and
noise
maximum.
Go to step 2.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
Step 2- Set -8.6V LOAD to position 2
(82.5-ohm load).
-8.6 Vdc ±5% Go to step 3.
85 mVrms
ripple and
noise
maximum.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
Step 3- Set -8.6V LOAD to position 1
(53.6-ohm load).
-8.6 Vdc ±5%
85 mVrms
ripple and
noise
maximum.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
Return to
service.
6-21
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-10d. TROUBLESHOOTING POWER SUPPLY (+8.6 LOAD, LAMP SUPPLY
AND LINE-FEED LOAD CIRCUITS)
CIRCUIT TO BE TESTED
MALFUNCTION/SYMPTOM
TEST PROCEDURE
YES
INDICATION
NO
NOTE
Use test setup as directed in paragraph 6-27d.
+8.6V LOAD CIRCUIT
1 +8.6V LOAD CIRCUIT MALFUNCTIONS
Step 1- Turn SELECT switch to position
12(+8.6V output) and set +8.6V LOAD
switch to position 3 (53.6-ohm load).
+8.6Vdc ±5%. Go to step 2.
85 mVrms
ripple and
noise
maximum.
Troubleshoot
+ 5V, ±8.6V
supply
(fig. FO-5).
Step 2- Set +8.6V LOAD to position 2
(44.2-ohm load).
+8.6Vdc ±5%. Go to step 3.
85 mVrms
ripple and
noise
maximum.
Troubleshoot
+5V, ±8.6V
supply
(fig. FO-5).
Step 3- Set +8.6V LOAD to position 1
(30.1-ohm load).
+ 8.6Vdc ±5%. Return to
service.
85 mVrms
ripple and
noise
maximum.
Troubleshoot
+ 5V, ±8.6V
supply
(fig. FO-5).
LAMP SUPPLY CIRCUIT
2 LAMP SUPPLY CIRCUIT MALFUNCTIONS
Lamp supply
Turn SELECT switch to position 8
will vary from
(lamp supply). Adjust ILLUM ADJUST
(varies input to Q8 on power supply from 0.0 Vdc ±.2
to 19 Vdc ±2.
0 to 20 Vdc).
3 LINE-FEED LOAD CIRCUIT MALFUNCTIONS
6-22
Return to
service.
Troubleshoot
Q8, R66 and
VR1 (fig. FO-3).
LINE-FEED LOAD CIRCUIT
Step 1- Turn SELECT switch to position
10 (LF output).
+22 to +30
Vdc (pin 30 of
power supply)
at VOUT
terminals.
Go to step 2.
Troubleshoot
power supply
input
(fig. FO-3).
Step 2- Set LF LOAD to ON.
+22 to +30
Vdc (pin 30 of
power supply)
at VOUT
terminals.
Return to
service.
Troubleshoot
power supply
input
(fig. FO-3).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-10e. TROUBLESHOOTING POWER SUPPLY (DRUM MOTOR, BACKUP BATTERY,
AND +18V, CCR, CAPVOK CIRCUITS)
MALFUNCTION/SYMPTOM
TEST PROCEDURE
CIRCUIT TO BE TESTED
INDICATION
YES
NO
NOTE
Use test setup as directed in paragraph 6-27d.
1 DRUM MOTOR CIRCUIT
MALFUNCTIONS
Turn SELECT switch to position 11
(drum motor). Connect AN/USM-281
across SCMO HI and LO (timing
simulator output) and turn DRUM switch
to ON (logic O to DRUM SHUTDOWN).
2 BACKUP BATTERY CIRCUIT
MALFUNCTIONS
DRUM MOTOR CIRCUIT
Timing
simulator
outputs
pulse whose
period is proportional to
drum motor
output, 1080
usec ±50.
Return to
service.
Troubleshoot
drum motor
supply circuit
(fig. FO-6).
BATTERY CIRCUIT
Step 1- Remove VIN lead.
BAT lamp
comes on.
Go to step 2.
Troubleshoot
comparator on
input circuit
(fig. FO-3).
Step 2- Perform test procedures of
Tables 6-10a, b.
Indications
satisfactory.
Go to step 3.
Troubleshoot
comparator on
input circuit
(fig. FO-3).
Step 3- Replace VIN lead.
BAT lamp
goes off.
Return to
service.
Troubleshoot
comparator on
input circuit
(fig. FO-3).
3 +18V, CCR, CAPVOK CIRCUIT
MALFUNCTIONS
+18V, CCR, CAPVOK CIRCUIT
Step 1- Connect AN/USM-223 across
VOUT HI and LO. Set SELECT to
position 9 (+18V print coils). With +18V
LOAD to position 2 (no load), set CCR
to ON (causes power supply circuit card,
pin 22 to become a logic O).
CAP V OK lamp Go to step 2.
comes ON
and VOUT
measures
+18 Vdc ±5%.
Troubleshoot
constant
current supply
(fig. FO-7).
Step 2- Set CCR to OFF (pin 22
becomes a logic 1). Place +18V LOAD
switch to position 1 (27.4 ohms).
CAP V OK lamp Go to step 3.
goes OUT and
VOUT drops
to less than
1 volt dc.
Troubleshoot
constant
current supply
(fig. FO-7).
6-23
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-10e. TROUBLE SHOOTING POWER SUPPLY (DRUM MOTOR, BACKUP BATTERY,
AND +18V, CCR CAPVOK CIRCUITS) - CONTINUED
CIRCUIT TO BE TESTED
MALFUNCTION/SYMPTOM
TEST PROCEDURE
6-24
INDICATION
YES
NO
Step 3- Set CCR to ON.
CAP V OK lamp GO to step 4. Troubleshoot
comes ON
constant
and VOUT
current supply
measures
(fig. FO-7).
+18Vdc ±5%.
Step 4- Place +18V LOAD to
position 3 (12 ohms).
CAP V OK lamp Return to
goes OUT
service.
and VOUT
measures
+12 Vdc ±10%.
Troubleshoot
constant
current supply
(fig. FO-7).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-11. TROUBLESHOOTING FILTER ASSEMBLY (3A1A6FL1)
MALFUNCTION/SYMPTOM
TEST PROCEDURE
ASSEMBLY TO BE TESTED
INDICATION
YES
NO
NOTE
Use test setup as directed in paragraph 6-29d.
FILTER ASSEMBLY
1 120 VAC OPERATION MALFUNCTION
Step 1- Place test fixture POWER switch
to ON. Using AN/USM-223 measure
across 22-30 VDC test point and RTN.
+28 Vdc
±3.5.
Go to step 2.
Troubleshoot
filter
assembly
(fig. FO-3).
Step 2- Use AN/USM-281 to measure
ripple.
750 mVrms
maximum.
Go to step 3.
Step 3- Measure continuity of +12 Vdc
circuitry by measuring from fixture test
point 12 VDC to BAT(J3) pin A. Ensure
that power is disconnected but POWER
switch is ON and fuse F3 is not open.
Less than
1 ohm.
Return to
service.
Troubleshoot
filter
assembly
(fig. FO-3).
Troubleshoot
filter
assembly
(fig. FO-3).
2 230 VAC OPERATION MALFUNCTION
FILTER ASSEMBLY
Repeat procedures in 1.
3 26 VDC OPERATION MALFUNCTION
FILTER ASSEMBLY
Repeat procedures in 1.
6-25
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-12. TROUBLESHOOTING KEYBOARD KEYSWITCH ASSEMBLY (3A2A1) (fig. 6-5)
MALFUNCTION/SYMPTOM
ASSEMBLY TO BE TESTED
TEST PROCEDURE
INDICATION
KEYBOARD KEYSWITCH ASSEMBLY
MALFUNCTIONS
YES
NO
KEYBOARD KEYSWITCH ASSEMBLY
NOTE
Use test setup as directed in paragraph 6-30c.
Step 1- Connect AN/USM-281 to LOGIC
terminal and probe ground to (LOGIC) REF.
Apply +5Vdc ±5% to test fixture by
turning on +5V supply. Press and release
CLOCK CONTROL switch.
Oscilloscope
reads 0 to
+ 0.5Vdc .
Assures
initialization
of logic
circuitry, go to
step 2.
Refer to figure
3-13 for
keyboard logic
diagrams.
Step 2- Connect AN/USM-281 to 2400 Hz
terminal and ground to GND terminal.
Oscilloscope
shows 410
usec nominal
pulse, with a
low logic level
of .4Vdc max
and a high
logic level not
to exceed
5Vdc or be
less than
2.5Vdc.
Go to step 3.
Refer to figure
3-13 for
keyboard logic
diagrams.
Step 3- Connect AN/USM-281 to DATA
terminal and ground to (DATA) REF terminal.
Press and hold a key on keyswitch assembly
that is called out below.
Record logic
level
displayed on
scope (bit 1).
Go to step 4.
Use scope
and fault
isolate to
failed piece
part.
Character Code Matrix
Character Code
b1
b2
b
BS (CTL, SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
E(SHIFT) . . . . . . . . . . . . . . . . . . . . .
FS (SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H (SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Z (SHIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
?..........................................
LF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A ....................................
1
0
1
0
1
0
1
1
0
0
1
1
0
0
1
1
0
1
0
0
1
1
1
1
0
0
0
1
0
0
3
b
4
b
1
0
1
0
1
0
1
0
1
0
NOTE
This procedure causes an 8-bit character to be loaded
and read out one bit at a time.
6-26
5
b6
b7
b8
1
1
0
0
1
1
0
0
0
0
1
1
1
1
0
0
0
0
0
1
1
0
1
1
1
1
1
0
0
0
o
1
1
1
1
1
1
1
1
1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-12. TROUBLESHOOTING KEYBOARD KEYSWITCH ASSEMBLY – CONTINUED
MALFUNCTION/SYMPTOM
TEST PROCEDURE
INDICATION
YES
Step 4- Press and release CLOCK CONTROL
switch on fixture. Key may now be released
because character is stored in the logic.
Record logic
level
displayed on
scope (bit 2).
Go to step 5.
Use scope
and fault
isolate to
failed piece
part.
Step 5- Press and release CLOCK CONTROL
switch.
Record logic
level
displayed on
scope (bit 3).
Go to step 6.
Use scope
and fault
isolate to
failed piece
part.
Step 6- Repeat procedures until bits 4
through 8 have been recorded. Compare eight
readings recorded with the Character Code
Matrix.
Matrix
verified.
Go to step 7
Use scope
and fault
isolate to
failed piece
part.
NO
NOTE
Further use of clock control will allow 8 bit character to be reread providing
that another key has not been pressed. For other codes refer to table 3-2.
Step 7- Test 12 bit counter (U8) by pressing
RPT key. Disconnect oscilloscope leads.
Observe a
210 msec
square wave
at logic
terminals.
Go to step 8.
Use scope
and fault
isolate to
failed piece
part.
Step 8- Using multimeter check PRESENT
test point with respect to GND.
+2.5Vdc ±10%. Go to step 9.
Use scope
and fault
isolate to
failed piece
part.
Step 9- Using multimeter check each REF
terminal with respect to GND.
+ 1.5Vdc ±5%. Return to
service.
Use scope
and fault
isolate to
failed piece
part.
6-27
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-28
Figure 6-5.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section IV. REMOVAL AND REPLACEMENT OF TERMINAL ASSEMBLIES
6-9. GENERAL
This section covers removal and replacement of following components:
HARNESS ASSEMBLY (Motherboard)
PAPER-ROLL SUPPORT ASSEMBLY
LOGIC BOX COVER ASSEMBLY
6-10. HARNESS ASSEMBLY - REMOVAL AND REPLACEMENT
REMOVAL (fig. 6-6)
CAUTION
Do not extend chassis over edge of workbench without securing case to bench.
Extend chassis from its case.
Disconnect power supply from harness assembly and filter module connectors.
Remove power supply assembly as directed in paragraph 5-11A.
Remove interface assembly as directed in paragraph 5-11C.
Release dustcover latches and lower dustcover.
Disconnect printer assembly and printer subassembly harness connectors J1 and J2
from motherboard.
Remove keyboard as directed in paragraph 5-11N.
With keyboard removed, remove screws (21), Iockwashers (2), and nut (1), holding
keyboard connector to dustcover.
NOTE
Mark all wires with appropriate labels. Remove all cable clamps (25) by
removing nuts (28), Iockwashers (27) and flat washers (26).
Remove all rear mounted dustcover lamps and switches.
Unsolder all front mounted lamps and receiver assembly. (Refer to para 5-13E for
instructions on receiver assembly removal).
Remove copy lamps by removing screw (5), Iockwasher (6), and flat washer (7) for each
lamp assembly.
Remove all logic circuit card assemblies (as directed in para 5-11B).
Remove seven screws (18) which secure the motherboard (19) to casting (9).
Unsolder paper low switch terminals (10) and cut five cable ties holding cable to
casting. (Refer to Appx C, item 8.)
Extract motherboard by gently pulling it forward.
Route paper low switch and power supply cables through casting opening as harness is
extracted.
6-29
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
REPLACEMENT (fig. 6-7)
Route paper low switch and power supply cables through casting opening as motherboard is positioned.
Solder paper low switch terminals wires into correct position.
Replace shrink tubing and replace five cable ties holding cable to casting.
Replace seven screws and logic circuit card assemblies.
Replace copy lamps, and solder all front mounted Iamps into position.
Replace rear mounted dustcover lamps and switches.
Replace keyboard connector (12) and keyboard.
Replace printer assembly and printer subassembly.
Replace power supply.
Replace interface assembly.
Apply power and verify terminal is operational.
6-30
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-6.
6-31
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-32
Figure 6-7.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-6. LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Nut
Washer, lock
Connector
Gasket
Screw, pnh
Washer, lock
Washer, flat
Lampholder
Casting
Switch assembly, paper low
Washer, flat
Washer, lock
Screw
Support, paper-roll
Screw, fhd
Washer, flat
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Washer, lock
Screw
Harness, assembly (motherboard)
Cover, logic
Screws, fhd
Washer, flat
Washer, lock
Screw, pnh
Clamp, cable
Washer, flat
Washer, lock
Nut
Washer, flat
Washer, lock
Screw, pnh
Figure 6-7. LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
Copy lamps
Switch (S3)
Switch (S2)
Switch (S1)
Connector (P2)
Connector (P3)
Motherboard
Connector (P4)
9.
10.
11.
12.
13.
14.
15.
16.
Connector (P5)
Lens assembly
Lens seal
Connector (P1)
Switch (S4)
Switch (S5)
Resistor (R1)
Resistor (R2)
6-33
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-11. PAPER-ROLL SUPPORT ASSEMBLY-REMOVAL AND REPLACEMENT
Release side latches and extend
chassis from case.
Remove paper roll.
Remove four mounting screws securing
support assembly to casting.
Remove assembly.
Position assembly on to casting wall.
Apply locking compound (MIL-S-22473)
to threads of mounting screws. (Refer
to appendix C, item 10.)
Replace paper roll and secure terminal
in its case.
6-12.
LOGIC BOX COVER ASSEMBLY-REMOVAL AND REPLACEMENT
Release side latches and extend
chassis from case.
Loosen two fasteners securing cover
across logic box (do not remove
fasteners from cover).
Remove three mounting screws securing
cover assembly to chassis and remove
cover assembly.
Replace three mounting screws.
Secure two fasteners.
Secure terminal in its case.
6-34
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section V. DISASSEMBLY AND REASSEMBLY OF TERMINAL COMPONENTS
6-13. GENERAL
This section covers disassembly and reassembly of the following components:
KEYSWITCH MODULE
PRINTER
PRINTER SUBASSEMBLY
PAPER-LOW SENSING MECHANISM
HAMMER MODULE
INTERFACE ASSEMBLY
FILTER MODULE
6-14. KEYSWITCH MODULE - DISASSEMBLY AND REASSEMBLY
DISASSEMBLY
Remove keyboard as directed in 5-11N.
Remove 24 screws, washers and Iockwashers.
Remove panel assembly, careful to leave sealing ring in place.
Remove keyswitch assembly.
Turn keyswitch assembly over, locate keyswitch module to be replaced.
Unsolder four terminals of switch to be replaced from keyswitch assembly using a
750°F controlled temperature, 1/8 inch chisel tip soldering iron.
When unsoldering terminals, use a solder removal tool to remove all solder from pin
holes in keyswitch assembly.
NOTE
Twenty-one switches are secured to printed circuit card by screws. If
switch to be removed is one of the 21, remove screw securing it to
printed circuit card assembly.
Insert module removal tools at each side of module to restrain the tangs.
With removal tools in position, grip switch module with a pair of pliers and pull
straight out.
6-35
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
REASSEMBLY
When replacing new module take care to orient switch properly. Observe that solder
terminals are through keyswitch assembly prior to snapping in place.
Solder new switch terminals using chisel tip soldering iron.
CAUTION
Solder tip should NEVER be held on terminal for over four seconds.
Clean solder connections with cleaning solvent (refer to Appx C, item 6). Take care not to
contact switch with solvent.
Touch up conformal coating with type UR MIL-1-46058 material (refer to Appx C, item II).
With sealing ring in place, replace panel assembly and keyswitch assembly into housing
assembly and secure with 24 screws, washers and Iockwashers.
Replace keyboard as directed in paragraph 5-11N.
6-15. PRINTER-DISASSEMBLY AND REASSEMBLY (fig. 6-8)
CAUTION
Many of the assemblies in this unit have been precisely alined. Do not
loosen screws holding left vertical wall. All other assemblies are
mounted with reference to this wall (left-hand plate).
NOTE
The following procedures assume complete disassembly. Procedures
may be stopped and reversed at any point where desired assembly has
been removed.
DISASSEMBLY
Remove printer assembly as directed in paragraph 5-11K.
Remove ribbon mechanism as directed in paragraph 5-11L.
Remove printer subassembly as directed in paragraph 5-11M.
Loosen and remove two screws (13) which secure right vertical wall (right-hand plate).
Loosen and remove four screws (73) securing paper trough (63) to right vertical wall.
Loosen and remove screw (56) which secures timing mechanism and remove timing
mechanism (52, 53) by disconnecting A4J1 and A5J1 (50).
Lower upper pressure roller (91) and remove spring (90) on right hand end of upper pressure
roller shaft.
Remove retaining ring (89) securing upper pressure roller to right vertical wall.
Remove retaining ring (70) and slide shaft (64) through right vertical wall.
Remove retaining ring (65) from lever assembly (93).
Gently remove right vertical wall, being careful to secure spring (92).
Remove paper-out switch bracket (5) from right vertical wall.
6-36
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
NOTE
Upper pressure roller assembly remains attached to right vertical wall.
Remove drum motor (35 thru 45) as directed in paragraph 5-11J.
Loosen and remove two screws (58) securing control lever for paper tension release.
Remove four screws which secure paper trough to left vertical wall (26) and remove
paper trough.
Remove Woodruff key (51) (if still in place) from shaft and slide print drum toward right
until it clears left hand wall.
Remove wires from circuit board (108) as follows:
E13 - WHT/RED
E14 - RED
E15 - WHT/GRN
E16 - GRN
E17 - WHT
Remove three screws (117) securing line feed motor (118).
Remove line feed motor.
Remove two gear spurs (57 and 80) by loosening and removing nuts (113 and 114)
securing studs (83 and 84).
REASSEMBLY
NOTE
Refer to DISASSEMBLY for illustration part numbers not referenced.
Replace two spur gears and line-feed motor.
Replace wires on circuit board (108).
Replace print drum and Woodruff key.
Replace paper trough.
Replace two screws (58) securing control lever for paper tension release.
Replace drum motor as directed in paragraph 5-11J.
Replace paper-out switch (15).
Replace right vertical wall.
Replace retaining ring (95) on lever assembly.
Replace shaft (64) through right vertical wall and replace retaining ring (70).
Replace retaining ring (89) that secures upper pressure roller to right vertical wall.
Replace spring (90) on right-hand end of upper pressure roller shaft.
Reconnect A4J1 and A5J1 and replace timing mechanism with screw (56).
Replace four screws (73) securing paper trough to right vertical wall.
Replace two screws (13) which secure right vertical wall.
Replace ribbon mechanism as directed by paragraph 5-11L.
Replace printer subassembly as directed by paragraph 5-11M.
Replace printer assembly as directed by paragraph 5-11K.
6-37
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-38
Figure 6-8(1).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-8. LEGEND (SHEET 1 of 2)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Drum, print
Screw, pnh
Washer, lock
Washer, flat
Bracket
Plate, r.h.
Washer, flat
Washer, spring
Washer, spring
Washer, flat
Screw, pnh
Harness, printer
Screw, pnh
Printer, subassembly
Switch, paper out
Washer, flat
Screw, pnh
Washer, lock
Screw, pnh
Screw, pnh
Spool, ribbon
Ribbon mechanism
Screw, pnh
Plate
Screw, pnh
Plate, I.h.
Motor drive, current control
Strap, retaining
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
Screw, flh
Capacitor (C9)
Clamp
Washer, flat
Washer, lock
Nut
Washer, lock
Screw, pnh
Screw, pnh
Washer, lock
Washer, flat
Housing, drum motor end
Screw, pnh
Washer, flat
Brush
Retainer, brush
Motor, torque
Retainer, bearing
Bearing, ball
Screw, flh
Screw, flh
Connector
Key
Source, timing
Sensor, timing
Washer, flat
Washer, lock
Screw, pnh
6-39
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-40
Figure 6-8(2).
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-8. LEGEND (SHEET 2 of 2)
57. Gear
58. Screw, pnh
59. Washer, lock
60. Washer, flat
61. Washer, flat
62. Ring, retaining
63. Trough, paper
64. Shaft
65. Bearing
66. Ring, retaining
67. Wheel, knurled
68. Washer, flat
69. Nut, lock
70. Ring, retaining
71. Washer, flat
72. Washer, flat
73. Screw, pnh
74. Washer, lock
75. Washer, flat
76. Ring, retaining
77. Ring, retaining
78. Ring, retaining
79. Washer, flat
80. Gear
81. Spring
82. Washer, flat
83. Washer, lock
84. Screw, pnh
85. Screw, pnh
86. Washer, lock
87. Washer, flat
88. Guard, cable
89. Ring, retaining
90. Spring
91. Roller, pressure
92. Spring
93. Washer, flat
94. Ring, retaining
95. Ring, retaining
96. Spring
97. Washer, flat
98. Washer, lock
99. Screw, pnh
100. Screw, pnh
101. Washer, lock
102. Spring
103. Washer, flat
104. Screw, set
105. Ring, retaining
106. Ring, retaining
107. Spring
108. Board, terminal
109. Washer, flat
110. Washer, flat
111, Washer, lock
112. Washer, lock
113. Nut
114. Nut
115. Washer, flat
116. Washer, lock
117. Screw, pnh
118. Motor, line-feed
119. Screw, set
120. Sprocket
121. Washer, flat
122. Screw, pnh
123. Chain, line-feed
124. Bearing
125. Ring, retaining
126. Roller, feed
127. Shaft, idler sprocket
128. Shaft, gear
129. Sprocket, idler
130. Ring, retaining
6-41
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-16. PRINTER HARNESS - DISASSEMBLY AND REASSEMBLY (fig. 6-8)
DISASSEMBLY
Remove printer as directed in paragraph 5-11K.
Unsolder the black and white leads from the drum motor end housing (40).
Unsolder five leads on terminals E13 through E17 on terminal board (108)
(E13-WHT/RED, E14 RED, E15-WHT/GRN, E16-GRN, E17-WHT).
Remove right vertical wall (6) as directed in paragraph 6-15.
Remove LF/CC module (27).
Remove printer subassembly (14) as directed in paragraph 5-11M.
Remove two screws (85) securing the terminal board to the left side wall.
Carefully remove harness assembly (12).
REASSEMBLY
NOTE
Refer to DISASSEMBLY for illustration part numbers not referenced.
Replace harness assembly.
Replace two screws securing terminal board to left side wall.
Replace printer subassembly as directed in paragraph 5-11M.
Replace LF/CC module.
Replace right vertical wall as directed in paragraph 6-15.
Resolder five leads on terminals E13 through E17 on terminal board.
Resolder black and white leads on drum motor end housing.
Replace printer as directed in paragraph 5-11K.
6-42
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-17. PRINTER SUBASSEMBLY-DISASSEMBLY AND REASSEMBLY (fig. 6-9)
DISASSEMBLY OF CABLE ASSEMBLY
Remove printer as directed in paragraph 5-11K.
Remove printer subassembly as directed in paragraph 5-11M.
Remove all modules from printer subassembly as directed in paragraphs 5-11D and E.
Disconnect leads to capacitor C1 (41).
Remove two screws (32) on bottom of clamp (35) and remove C1.
Remove two screws holding bracket (42).
Remove remaining screws from motherboard 3A1A5A1W1A1 (22).
NOTE
Remove cable clamp (52) on terminals Serial No. 1 to 2000.
Disconnect the motherboard two end connectors and lift motherboard from ribbon-lift
mechanism.
REASSEMBLY OF CABLE ASSEMBLY
Install new cable assembly.
Reconnect motherboard to ribbon-lift mechanism.
Secure with cable clamp (52) (Serial No. 1 to 2000).
Connect leads to capacitor C1 and secure capacitor with its bracket,
Secure motherboard into place with screws.
Replace all circuit cards removed.
Reinstall printer subassembly and verify operational capability.
6-43
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-44
Figure 6-9.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-9. LEGEND
1. Cover assembly
2. Washer, flat
3. Washer, lock
4. Screw
5. Plate, retaining
6. Spring
7. Screw
8. Spring, flat
9. Screw
10. Module, hammer drive
11. Hammer module
12. Screw
13. Washer, lock
14. Clamp
15. Screw
16. Washer, lock
17. Clamp
18. Ribbon-lift mechanism
19. Plate, assembly
20. Washer, lock
21. Screw
22. Cable assembly (motherboard)
23. Washer, flat
24. Washer, lock
25. Screw
26. Washer, flat
27. Washer, lock
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Screw
Washer, flat
Washer, lock
Screw
Screw
Washer, lock
Washer, flat
Clamp, capacitor
Washer, lock
Screw
Washer, lock
Washer, lock
Screw
Capacitor
Bracket, capacitor
Screw
Washer, lock
Plate, stop
Screw
Washer, lock
Washer, flat
Screw
Screw
Spring
Clamp, cable
Guide, paper
6-45
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-18. PAPER-LOW SENSING MECHANISM DISASSEMBLY AND REASSEMBLY
DISASSEMBLY
Remove mounting screw and adjusting screw.
Remove bracket assembly from frame.
Remove retaining ring.
Using spring hook (P/O TOOL KIT TE-50B) remove spring end that is secured behind the
large washer on switch.
Slide sensing lever until spring and lever are free.
REASSEMBLY
Position spring and lever into place.
Secure spring behind large washer.
Reattach bracket assembly to frame with mounting screw and adjusting screw.
Secure assembly into place with retaining ring.
Replace paper roll.
Perform adjustment procedures as necessary.
6-19. HAMMER MODULE DISASSEMBLY AND REASSEMBLY (fig. 6-10)
Disassembly of hammer module must be performed with care to avoid damage to
printed circuit wiring and solenoid leads. Use the Pace Kit as required for all unsoldering operations.
CAUTION
Do not allow terminals to heat more than 4 seconds at a time.
6-46
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
SOLENOID CORE
DISASSEMBLY
Remove solder from appropriate terminals on printed circuit (22).
Gently unwrap wires from their respective terminals.
Remove two screws (14) and remove solenoid (12) core.
SOLENOID CORE
REASSEMBLY
PRINTED CIRCUIT
DISASSEMBLY
PRINTED CIRCUIT
REASSEMBLY
Place core (12) into solenoid and secure into position with screw (14).
Wrap wires around their respective terminals and solder into place.
Coat terminals with epoxy (refer to Appendix C, item 12) and allow to
dry.
Realine solenoid as follows:
Select a solenoid armature (8), (10), (25) or (27) which operates a
hammer next to hammer operated by solenoid core which was
replaced.
Place blade end of a common screwdriver between armature end
and appropriate setscrew. (This will force hammer to its maximum
point of travel.)
Loosen screw (14) securing replaced core (12).
Adjust setscrew (2) for solenoid being alined until hammer is
even with adjacent hammer set in its maximum point of travel.
Place a 0.001 “shim” in the gap between core and armature
and manually move core tightly against the “shim”.
Tighten two screws (14) and release core.
Readjust setscrew (2) until it just touches the hammer in rest
position.
Using a .061 inch drill, drill out rivet (18) securing J1 to mounting
plate (1).
Unsolder and remove solenoid leads as described above.
Remove three screws (17).
Remove two screws (20) and guide (19).
Remove printed circuit (22), remove components as required.
Mount printed circuit (22) in place using three screws (17).
Mount guide (19) and secure with screws (20).
Solder solenoid core wires to terminals as follows:
NOTE
Refer to figure 6-2 for terminal identification.
LEAD COLOR
TERMINAL
CORE
TERMINAL
Red
L3
C
G
CORE
L1
LEAD COLOR
Red
L1
Blk
H
L3
Blk
D
L2
Red
E
L4
Red
A
L2
Blk
F
L4
Blk
B
Using a Rolling Punch, Cambion # 6629 replace rivet (18) and
swage in place.
Coat terminals with epoxy (refer to appendix C, item 12) and
allow to dry.
6-47
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-10. HAMMER MODULE ASSEMBLY.
6-48
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-20. INTERFACE ASSEMBLY DISASSEMBLY AND REASSEMBLY (fig. 6-11)
RX/TX CIRCUIT CARD DISASSEMBLY
Remove 12 screws (25), Iockwashers (26), and flat washers (27) securing top cover (24) to
assembly (7).
Remove two screws (21 ), flat washers (20), Iockwashers (31) and nuts (32) holding connector
J2 in place.
Remove two screws (7.1), flat washer (43.3), Iockwasher (43.2) and nut (43.1).
Remove TB1 (11.1).
Remove four screws (28), Iockwashers (29) and flat washers (30) securing diode circuit
and gently lift out.
Remove two screws on back side of interface assembly (7) holding filter board in place.
Remove four screws (14), Iockwashers (13) and flat washers (12) holding RX/TX circuit
card in place.
Gently lift up both the RX/TX circuit card and filter board at the same time.
Tag and unsolder each wire from harness assembly connected on RX/TX circuit card
with terminal number/color code.
Remove RX/TX circuit card.
DIODE CIRCUIT CARD DISASSEMBLY
Remove 12 screws (25), Iockwashers (26) and flat washers (27) securing top cover (24) to
assembly (7).
Remove four screws (28), lock washers (29), and flat washers (30) securing diode circuit
card to assembly (7).
Gently lift diode circuit card until wires on bottom of circuit card are exposed.
Remove diodes as required, using Pace kit.
RX/TX CIRCUIT CARD REASSEMBLY
Resolder wires to respective terminals.
Carefully replace RX/TX circuit card and filter board into original positions.
Secure RX/TX card into position with four screws (14), Iockwashers (13), and flat washers
(12).
Secure filter board with two screws through back side of interface assembly (7).
Replace diode circuit card.
Replace TB1.
Replace connector J2.
Replace top cover.
DIODE CIRCUIT CARD REASSEMBLY
Position diode circuit card into assembly and secure with four screws (28), Iockwashers
(29), and flat washers (30).
Secure top cover into place.
6-49
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-11. INTERFACE ASSEMBLY.
6-50
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TO 31W4-2UGC74-2
Figure 6-11. LEGEND
1. Knob
2. Nut
3. Screw, set
4. Washer, lock
5. Nut
6. Washer, lock
7. Housing, interface
7.1 .Screw, mach, flathead
8. Screw
9. Washer, lock
10. Washer, flat
11. Washer, positioning
11.1. TB1
11.2. Washer, lock
12. Washer, flat
13. Washer, lock
14. Screw
15. Subassembly, interface (A7A1)
16. Bracket
17. Washer, flat
18. Washer, lock
19. Nut
20. Washer, flat
21. Screw
22. Washer, flat
23. Screw
24. Cover, interface
25. Screw
26. Washer, lock
27. Washer, flat
28. Screw
29. Washer, lock
30. Washer, flat
31. Washer, lock
32. Nut
33. Washer, lock
34. Nut
34.1. Nut
34.2. Washer, lock
34.3. Washer, flat
6-21. FILTER MODULE DISASSEMBLY AND REASSEMBLY (fig. 6-12)
DISASSEMBLY
Remove filter module as directed in paragraph 5-11G.
Remove seven screws (43) and two screws (46) securing top cover plate (45) to module
and remove cover plate. Note that two longer screws (46) are used with cable clamps
(49).
Remove transformer T1 (1) as follows:
Remove five screws (36) securing casting (70) to transformer.
Gently lift casting until transformer terminals are accessible.
Unsolder leads from terminals being careful to tag them as they are removed.
Lift casting free of transformer T1.
Remove components as required being sure to note wiring and polarities as required.
REASSEMBLY
Solder leads to their respective terminals.
Replace five screws (36) securing casting to transformer.
Replace top cover and secure onto position with seven screws (43), and two screws (46).
6-51
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TO 31W4-2UGC74-2
6-52
Figure 6-12.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-12. LEGEND
1. Transformer (T1)
2. Nut
3. Washer, lock
4. Washer, flat
5. Inductor (L2)
6. Capacitor (C7)
7. Screw, flh
8. Capacitor (C6)
9. Terminal
10. Capacitor (C5)
11. Terminal lug
12. Band, identification
13. Terminal lug
14. Band, identification
15. Washer, flat
16. Washer, lock
17. Nut
18. Screw, pnh
19, Washer, lock
20. Washer, flat
21. Terminal lug
22. Terminal lug
23. Terminal lug
24. Stand-off (E2)
25. Diode (CR1)
26. Washer, flat
27. Washer, lock
28. Screw, pnh
29. Terminal lug
30. Terminal lug
31. Terminal lug
32. Stand-off (E1)
33. Washer, flat
34. Washer, lock
35. Screw, flh
36. Screw, pnh
37. Inductor (L1)
38. Washer, flat
39. Washer, lock
40. Screw, pnh
41. Washer, flat
42. Washer, lock
43. Screw, pnh
44. Label
45. Cover
46. Screw, pnh
47. Washer, lock
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
Washer, flat
Clamp, cable
Inductor (L3)
Nut
Washer, lock
Washer, flat
Nut
Washer, lock
Washer, flat
Capacitor (C11)
Capacitor (C10)
Capacitor (C9)
Terminal (E4)
Capacitor (C1)
Capacitor (C3)
Capacitor
Diode (VR1)
Diode (VR2)
Screw, pnh
Washer, lock
Washer, flat
Capacitor (C4)
Casting
Screw, pnh
Terminal lug
Washer, flat
Washer, lock
Nut
Clamp, cable
Ferrite bead
Ferrite bead
Washer, lock
Nut
Nut
Washer, lock
Washer, flat
Capacitor (C12)
Capacitor (C2)
Capacitor (C13)
Ferrule, inner
Capacitor (C14)
Band, identification
Band, identification
Mounting plate
Connector (P1)
Connector (P2)
Mounting plate
6-53
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TO 31W4-2UGC74-2
Section VI. GENERAL SUPPORT TESTING PROCEDURES
6-22. GENERAL
Perform tests listed below after performing maintenance on equipment. These tests
determine if equipment has been properly repaired and can be returned to using
organization, or stock.
Repaired equipment must meet requirements given in paragraph 6-31, “Final Test of
Communications Terminal AN/UGC-74A(V)3.”
The following circuit card assemblies are tested and repaired only at a designated
specialized repair activity (SRA) using Test & Repair System, Electronic Equipment
AN/MSM-105(V)1, associated test programs, and interconnection devices.
CPU (3A1A1)
Memory (3A1A2)
Communications (3A1A3)
Printer control (3A1A4)
Test procedures for the following modules and assemblies are explained in detail.
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
6-23
6-24
6-25
6-26
6-27
6-29
6-30
Hammer Driver (3A1A5A2-A3)
Hammer Module (3A1A5A4-A23)
Motor Driver and Current Control Board Assembly (3A1A5A3)
Interface Assembly (3A1A7)
Power Supply (3A1PS1)
Filter Assembly (3A1A6FL1)
Keyboard Keyswitch Assembly (3A2A1)
Power supply adjustments are described in paragraph 6-28.
Final test of the Communications Terminal AN/UGC-74A(V)3 is described in paragraph 6-31.
If a failure is observed in the testing procedure, use the same test setup and refer to
the applicable troubleshooting table in section Ill, “Troubleshooting” to isolate fault
to the failed part(s).
NOTE
Performers of test functions are directed to follow all WARNINGS,
CAUTIONS, and NOTES. “BE SAFE, NOT SORRY.”
6-23. HAMMER DRIVER 3A1A5A2-A3
a. Purpose. The hammer driver provides +18Vdc to the print hammer modules on any one
of four buses. These buses are selected by a logic combination of an enable signal and logic
ground. The enable signal is a TTL (0-5 Volt peak), 60 Hz waveform. The logic circuits on the
module require a +5Vdc source. The hammer driver test fixture is a passive device that provides
the switching, loading and testing capability required to perform piece part maintenance.
b. Test Equipment.
Hammer Driver Module Test Fixture, SM-C-915982.
Power Supply PP-2309/U (2 each)
Function Generator SG-1133/U
Oscilloscope AN/USM-281C
6-54
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TO 31W4-2UGC74-2
c. Test Setup Procedure for Hammer Driver Module (fig. 6-13).
Remove hammer driver as directed in paragraph 5-11D.
Adjust one power supply to +5Vdc ±5%. Turn off and connect to 5V input on test
fixture.
Adjust one power supply to + 18Vdc ±5%. Turn off and connect to 18V input on test
fixture.
NOTE
If power supply being used has current limiting, set limit to greater than 500 mA.
Adjust function generator 60Hz ±10%, 0 to +5V square wave (16.6 msec period).
Turn off and connect to SIG IN input on test fixture.
Adjust channel B on oscilloscope to 1V/DIV and 2mSEC/DIV. Turn off and connect to SIG OUT 1.
Adjust channel A to .5V/DIV and 12mSEC/DIV and connect to SIG IN.
Connect all test equipment grounds to GND on test fixture.
Install hammer driver into test fixture.
Place test fixture SELECT switch to IN 1.
Turn all test equipment on and ensure that outputs are as originally set up.
Figure 6-13.
HAMMER DRIVER MODULE TEST SETUP.
6-55
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TO 31W4-2UGC74-2
d. Test Procedures (fig. 6-14 and 6-15).
1. The test setup causes a 60-Hz signal to be input to pin 2 and a logic ground to pin 4.
2. Observe a 60 Hz ± 10%, 0 to + 18V ±5%, square waveform on channel B of the
oscilloscope (output from pins 9 and 10).
3. Compare the function generator output on channel A of the oscilloscope with channel B.
The waveforms should coincide timewise (same frequency) and have the same wave shape.
4. Place the test fixture SELECT switch to IN 2 (signal input to pin 4 and logic ground to
pin 2).
5. Move the channel B probe to SIG OUT 2 (output from pins 7 and 8) and observe
waveforms as in (2) and (3) above.
6. If a failure is observed in the above steps, refer to Troubleshooting Table No. 6-3 in section Ill for trouble location instructions. Also refer to paragraph 3-16 for hammer driver
test fixture theory of operation.
Figure 6-14.
6-56
PRINT DRIVER SCHEMATIC DIAGRAM.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-15. HYBRID DRIVER (UI).
6-57
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TO 31W4-2UGC74-2
6-24. HAMMER MODULE 3A1A5A4-A23
a. Purpose. Each hammer module contains four print hammers. Each print hammer has an
electrical drive circuit that provides the external electrical impulse which causes a hammer to
move. In the terminal, the hammer driver (3A1A5A2-A3) and print control (3A1A4) provide + 18Vdc
and command control signals to operate the hammer module. The hammer module test fixture
simulates the hammer driver by switching + 18Vdc to a selected hammer and simulates the print
control commands with a control pushbutton switch.
b. Test Equipment.
Hammer Module Test Fixture, SM-C-915985
Power Supply PP-2309/U (2 each)
Multimeter AN/USM-223
c. Test Setup Procedure for Hammer Module (fig. 6-16).
Remove hammer module as directed in paragraph 5-11E.
Adjust one power supply to +5Vdc ±5%. Turn off and connect to 5V input on test
fixture.
Adjust one power supply to + 18Vdc ±5%. Turn off and connect to 18V input on test
fixture.
Connect all test equipment grounds to GND on test fixture.
Install hammer module into test fixture.
Turn all test equipment on and ensure that outputs are as originally set up.
Figure 6-16.
6-58
HAMMER MODULE TEST SETUP.
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TO 31W4-2UGC74-2
d. Test Procedures (fig. 6-17).
Place HMR 1 to the ON position and simultaneously press the CONTROL pushbutton
(See CAUTION). Hammer 1 should move forward and remain forward for as long as both
HMR 1 and CONTROL are energized. This action supplies + 18Vdc to pin 2 (hammer
drive circuit No. 1) and a logic control (ground) to pin 3.
CAUTION
If testing requires the circuit to be energized for a prolonged period (more
than a few seconds), reduce the + 18Vdc to + 10Vdc to prevent heating of
the circuitry.
Repeat the above procedure for hammer 2 (HMR 2, + 18Vdc to pin 7), hammer 3 (HMR 3,
+18Vdc to pin 5) and hammer 4 (HMR 4, +18Vdc to pin 1).
If a failure is observed in the above steps, refer to Troubleshooting Table No. 6-4 in section Ill for trouble location instructions. Also refer to paragraph 3-17 for print hammer
test fixture theory of operation.
Final adjustment of hammer module print quality will be made by the organizational
maintenance technician at the user level.
Figure 6-17.
PRINT HAMMER SCHEMATIC DIAGRAM.
6-59
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TO 31W4-2UGC74-2
6-25. MOTOR DRIVE (LINE FEED) AND CURRENT CONTROL BOARD ASSEMBLY 3A1A5A3
a. Purpose. This board assembly (LF/CC) supplies the operating voltages and current control
to enable and stop the paper (line feed) motor. The four output circuits sequentially control the
motor windings causing this motor to feed the copy paper. The control circuit, which is not used
in the AN/UGC-74A(V)3, cuts off the output signals. The line feed/current control test fixture has a
circuit which checks the control circuitry, a two level rotary selection switch that allows measurement of winding input and output signals, and a load resistor which simulates the motor and a
control circuit.
b. Test Equipment, Tools and Materials.
Line Feed/Current Control Text Fixture, SM-C-915988
Power Supply PP-2309/U (2 each)
Function Generator SG-1133/U
Oscilloscope AN/USM-281C
Multimeter AN/USM-223
c. Test Setup Procedure for Motor Drive (Line Feed)and Current Control Board Assembly
(fig. 6-18).
Remove board assembly as directed in paragraph 5-11 F.
Adjust one power supply to +5Vdc ±5%. Turn off and connect to 5V input on test
fixture.
Adjust one power supply to + 22Vdc ±5%. Turn off and connect to 22V input on test
fixture.
Adjust function generator to 50 Hz, O to +5V square wave (20 msec period). Turn off and
connect to SIG IN input on test fixture.
Adjust channel B on oscilloscope to 5V/DIV and 10 mSEC/DIV. Turn off and connect to
AO OUT.
Adjust channel A to IV/DIV and 10 mSEC/DIV and connect to AO iN.
Connect all test equipment grounds to GND on test fixture.
Install motor drive and current control circuit card assembly into test fixture.
Place test fixture PULSE switch to CC (connects SIG IN to pin L and CONTROL).
Place test fixture SURGE CONTROL switch to OFF (opens circuit to pin H and SURGE
CONTROL (TP)).
Place test fixture SELECT switch to AO (connects 20-ohm load resistor to AO OUT).
Turn all test equipment on and make sure that outputs are as originally setup.
6-60
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TO 31W4-2UGC74-2
Figure 6-18.
MOTOR DRIVE AND CURRENT CONTROL BOARD
ASSEMBLY TEST SETUP.
6-61
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d. Test Procedures (fig. 3-15).
1. Connect the multimeter to CONTROL test point and GND and measure 1.5Vdc ±5%.
This proves that the test fixture input diode and bias circuit are working properly.
2. Connect the multimeter to LOAD test point and measure 22Vdc ±5%. This checks out
the current control board’s (SM-D-766709) ability to control and switch 22Vdc to the output load.
3. Place SURGE CONTROL switch to ON which causes the surge control circuit to cut off
the switching action in (2) above. Measure 4 to 5Vdc at LOAD test point.
4. Return SURGE CONTROL switch to OFF. Measure 22Vdc ±5% at LOAD test point.
5. Place the PULSE switch to LF. This routes the input signal (SIG IN) to pin Q, AO IN applying it to the line-feed board (SM-D-766742). The output of this circuit is available at AO OUT.
6. Measure 22V peak-to-peak ±5% square wave at 50 Hz at AO OUT on channel B of the
oscilloscope. This measurement checks input circuit from pin Q to E1, current control
(CC) jumper to E1 line-feed (LF), through Q1 circuit to E7, E7 (LF) jumper to E7 (CC), E7
to pin D.
7. Compare the function generator output on channel A of the oscilloscope with channel B.
The waveforms should coincide timewise (same frequency) and have the same wave shape.
8. Place the SELECT switch to A1 (connects 20-ohm load resistor to A1 OUT).
9. Remove scope probes from AO OUT and AO IN and connect to A1 OUT and Al IN.
10. Measure as in steps (6) and (7) above. This measurement checks input circuit from pin 0
to E2, E2 (CC) jumper to E2 (LF), through Q2 circuit to E8, E8 (LF) jumper to E8 (CC), E8
to pin C.
11. Place the SELECT switch to BO (connects 20-ohm load resistor to BO OUT).
12. Remove scope probes from A1 OUT and A1 IN and connect to BO OUT and BO IN.
13. Measure as in steps (6) and (7) above. This measurement checks input circuit from pin K
to E3, E3 (CC) jumper to E3 (LF), through Q3 circuit to E9, E9 (LF) jumper to E9 (CC), E9
to pin B.
14. Place the SELECT switch to B1 (connects 20-ohm load resistor to B1 OUT).
15. Remove scope probes from BO OUT and BO IN and connect to B1 OUT and B1 IN.
16. Measure as in steps (6) and (7) above. This measurement checks input circuit from pin J
to E4, E4(CC) jumper to E4(LF), through Q4 circuit to E10, E10(LF) jumper to E10(CC), E10
to pin A.
17. If a failure is observed in the above steps, refer to Troubleshooting Table No. 6-5 in Section Ill for trouble location instructions. Also refer to paragraph 3-18 for motor driver/current control test fixture theory of operation.
6-26. INTERFACE ASSEMBLY 3A1A7
a. Purpose. The interface assembly has three functions: power switching, mode selection
and data input/output level conversion. The prime power is switched on and routed to the filter
assembly. The mode selection is performed by setting rotary and toggle switches to the desired
data mode positions. These data are routed to the CPU communications and print control circuit
card assemblies. The data input and output circuits consist of five circuits which accept and convert a variety of inputs and outputs to the selected formats. The interface assembly test fixture
has input and output jacks which provide direct access to the inputs and outputs of each of the
five data circuits. This provides the capability to check individual circuits or series, and combinations of the five circuits. The test fixture also provides several load resistors to be used in data
circuit testing. The power and mode selection wiring and switches are connected to a four-level
wafer switch and their continuity is easily checked.
6-62
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TO 31W4-2UGC74-2
b. Test Equipment, Tools and Materials.
Interface Assembly Test Fixture, SM-D-915991
Power Supply PP-2309/U (4 each)
Function Generator SG-1133/U
Oscilloscope AN/USM-281C
Multimeter AN/USM-223
Telegraph Test Set AN/GGM-15(V)2
Data cable assembly SM-D-915889
c. Test Setups and Procedures (fig. 6-19).
Remove interface assembly as directed in paragraph 5-11C.
NOTE
Refer to table 6-13 on Interface Test Fixture Interconnections for test point data.
(1) Interface Assembly.
± 6V ± 1V Data Functional Test Setup
Patch as follows:
OUT 1 to IN 2
IN 3 HI to OUT 2 HI to R1
IN 3 LO to OUT 2 LO to R1 (other
OUT 3 to IN 5
OUT 5 HI to R2
OUT 5 LO to R2 (other side)
Connect AN/GGM-15(V)2:
(DATA +6/12) - IN 1 HI/LO
(BRIDGING) - OUT 5 HI/LO
Adjust one power supply to +8.6Vdc
±5%, turn off and connect to +8.6V input on test fixture.
Adjust one power supply to -8.6Vdc
±5%, turn off and connect to -8.6V input on test fixture.
Connect test fixture P1 (to J1) and P5
(to J5) and ground strap (to ground lug)
on interface assembly.
Place interface assembly REC MODE
and XMIT MODE switch to LO DATA.
Turn all test equipment on and ensure
that outputs are as originally setup.
I
Figure 6-19. INTERFACE TEST SETUP,
Change 1
6-63
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TO 31W4-2UGC74-2
Table 6-13. INTERFACE TEST FIXTURE INTERCONNECTIONS
(2) ±6V ±1V Data Test Procedures (fig.6-20)
●
Transmit alternate character bits from the AN/GGM-15 at DATA ±6V and at speeds
between 45.5 baud and 1200 baud. Check the output on the AN/GGM-15 analyzer. lntermediate points can be checked with Oscilloscope AN/USM-281C using interface
assembly schematic, figure FO-2, and RX/TX assembly schematic, paragraph 3-10. This
test checks the following:
1. J1-G to VR7 to FL7 to S11B to E17 to U4, U1, U2 to E-20.
2. J1-H to VR8 to FL8 to S11C to E16 to U4, U1, U2 to E-20.
3. J5-8 to U5 to CR1, CR4 to FL5 to VR5 to J1P.
4. FL6 to VR6 to J1-N.
5. J-1A to VR1 to FL1 to E9 to U4 to J5-4.
6. J1-B to VR2 to FL2 to E8.
7. J5-7 to E2 to U1, U5 to CR9, CR10 to E13 to S12C to FL10 to VR10 to J1-L.
8. U5 to CR11, CR12 to E14 to S12B to FL9 to J1-K.
●
●
6-44
Repeat the above testing substituting the RECEIVER GATED CLOCK circuit for the
RECEIVER CLOCK circuit. Remove test lead F from 0UT3 and connect to OUT4. Remove
test lead E from IN3 LO and connect to IN4 LO. Remove test lead D from IN3 HI and
connect to IN4 H1. This layout now additionally checks J1-D/E to VR3/4 to FL3/4 to
E10/11 to U4 to J5-5.
If a failure is observed in any of the above steps, refer to Troubleshooting Table No. 6-6
in section Ill for trouble location instructions. Also refer to paragraph 3-20 for the interface test fixture theory of operation.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-20. INTERFACE +6V DATA FUNCTIONAL TEST LAYOUT.
(3) Interface Assembly 20 mA and 60 mA Data Functional Test Setup (fig. 6-21).
Remove all leads from test fixture.
Patch as follows:
OUT 1 to IN 5
OUT 5 HI to R4
IN 1 HI to - Power Supply (3)
R3 to + Power Supply (3)
R4 (other side) to + Power Supply (4)
Connect AN/GGM-15(V)2:
(DRY CONTACTS) - HIGH to R3 (other side) common to IN 1 LO
(SERIES) - HIGH to - Power Supply (4) Common to OUT 5 LO
Connect power supplies as shown below:
Adjust power supplies (3) and (4) for 20 mA output; can be measured with voltmeter across R3 and R4.
20 mA = 9.4 VDC.
Verify -8.6V ±5% at -8.6V input on test fixture.
Verify +8.6V +5% at ±8.6V input on test fixture.
Change 1
6-65
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Figure 6-21. 20 mA and 60 mA Data Test Setup.
6-66
Change 1
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TO 31W4-2UGC74-2
Set AN/GGM-15(V)2 Generator SG-860 MESSAGE SELECT switch to “M” MARK HOLD.
Verify that test fixture plug is connected to J1 and plug P5 is connected to J5.
Ensure that ground strap is connected to interface assembly.
Place interface assembly REC MOD switch to 20 MA and XMIT MODE switch to 20.
Turn all test equipment on and ensure that outputs areas originally set up.
(4) 20 mA and 60 mA Data Test Procedures (fig. 6-21.1).
Transmit alternate character bits from the AN/GGM-15 at speeds between 45.5 baud and 75 baud. Check the
output on the AN/GGM-15 analyzer. Intermediate points can be checked with the AN/USM-281C oscilloscope
using interface assembly schematic, figure FO-2 and RX/TX assembly schematic, paragraph 3-10. This test
checks the following:
1. J1-G to VR7 to FL7 to S11B to E25 to CR5 to VR1 , U3, Q2, U2 to E20 to J5-6.
2. J1-H to VR8 to FL8 to S11C to E26 to CR8, CR7.
3. J5-7 to E2 to U1, U2, Q1 to K1, CR13, E15 to S12B to FL9 to VR9 to J1-K.
4. E12 to S12C to FL10 to VR10 to J1-L.
Repeat the above test for 60 mA by readjusting the power supplies to 60 mA. Can be measured with voltmeter
across R3 and R4. 60 mA = 28.2 VDC. Change the REC MODE switch to 60 MA and the XMIT MODE switch
to 60. This check verifies the proper operation of S11 and R8.
If failure is observed on any of the above steps, refer to Troubleshooting Table No. 6-7 in section Ill for trouble
location instructions.
Change 1
6-66.1/(6-66.2 blank)
Figure 6-21.1.
6-67
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Change 1
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TO 31W4-2UGC74-2
(5) Interface Assembly Continuity Checks Test Setup.
Connect test cables P1, 2, 3, 4, 5 and ground strap to the interface assembly.
Connect the AN/USM-223 across the test fixture GND and test point S1A.
(6) Continuity Checks Test Procedures.
CAUTION
All test equipment power must be off. Set AN/USM -223
to measure ohms.
●
●
●
●
6-68
Place the OHM CHECK switch to position 1. The AN/USM-223 should read less than 1
ohm resistance. This checks the continuity of the circuit path from J2-G to J4-5.
Table 6-14 Interface Assembly Continuity Checks, shows all 12 positions and the circuit
parts that are checked.
Checking the next circuits requires moving the AN/USM-223 to test point S1B, and then
to S1C, and finally S1D.
If failure is observed in any of the above steps, refer to Troubleshooting Tables 8-8 and
6-9 in section III for trouble location instructions.
TM 11-5815-602-24
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TO 31W4-2UGC74-2
Table 6-14. INTERFACE ASSEMBLY CONTINUITY CHECKS
6-69
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Table 6-14. INTERFACE ASSEMBLY CONTINUITY CHECKS - Continued
6-27.
POWER SUPPLY 3A1PS1
a. Purpose. The power supply module provides dc power for the AN/UGC-74A(V)3. It converts
28Vdc into ±5Vdc, ±8.6Vdc, + 12Vdc, + 18Vdc and variable 0-22Vdc lamp supply. It also provides battery backup sensing and switching for the terminal.
b. Five Power Supplies are Required for Test.
+26Vdc supply is required to provide 22 to 30 Vdc power input.
+ 12Vdc is required to provide battery backup power.
Three dc power supplies (+5Vdc, + 15Vdc, and – 15Vdc) supply power for circuitry in
power supply test fixture.
c. Test Equipment.
Power Supply Test Fixture, SM-D-915979
Power Supply PP-2309/U (5 each)
Oscilloscope
AN/USM-281C
Digital Voltmeter AN/GSM-64B
d. Test Setup Procedure for Power Supply (fig. 6-22).
Remove power supply module as directed in paragraph 5-11A and remove its plate.
Connect power supply (PS1) to VIN-RTN.
Connect digital voltmeter (DVM) AN/GSM-64B to VOUT HI and LO with SELECT switch to
position 1.
Adjust PS1 for +26 Vdc ±5% as measured on meter.
This supply provides input power for supply under test.
Connect power supply (PS2) to BAT-RTN.
Place SELECT switch to position 2.
Adjust PS2 for +12 Vdc *5% (battery backup power).
Connect power supply (PS3) to +5V and GND and adjust for +5Vdc ±2%. Measure at
+ 5V and GND (test fixture power).
Connect power supply (PS4) to +15 and GND. Measure at + 15V and adjust for+ 15Vdc
±1.0% (test fixture power).
6-70
Figure 6-22.
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TO 31W4-2UGC74-2
6-71
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TO 31W4-2UGC74-2
Connect power supply (PS5) to - 15V and GND. Adjust for - 15V ±1.0% as measured at
- 15V and GND (test fixture power).
Place all power supplies to OFF position.
Install power supply module under test into test fixture.
Place all power supplies to ON position.
Ensure that all input power supply voltages are as originally set.
Reconnect AN/GSM-64B to VOUT HI and LO.
e. + 5V(A) Test Procedures.
With test set up as described in d above, turn SELECT switch to position 3 (connects
VOUT and SCOPE terminals to + 5V(A) output).
Measure + 5Vdc ±5%. Using the AC function on the DVM, measure 50 mVrms ripple and
noise maximum.
Place + 5VA LOAD LO to ON; measure same as above (places a 10-ohm resistor across the
+ 5V(A) output).
Place + 5VA LOAD LO to OFF and place + 5VA LOAD HI to ON (places a 1.5 ohm resistor
across + 5V(A) output). Measure same as above.
Place + 5VA LOAD LO to ON and measure +5.2V ±12%.
Return + 5VA LOAD switches to OFF.
If power supply fails to regulate as described above, refer to Troubleshooting Table No.
6-10a in section Ill for trouble location instructions. Also refer to paragraph 3-19 for the
theory of operation of the power supply test fixture.
f. + 12V Test Procedures.
With test set up as described in d above, turn SELECT switch to position 4 (connects
VOUT and SCOPE terminals to +12 V output).
Measure + 12 Vdc ±5% and 100 mVrms ripple and noise maximum using DVM.
Place + 12V LOAD from OFF to ON and measure same as above (places a 332-ohm resistor
across the + 12V output).
Return + 12V LOAD to OFF position (places 681-ohms across output).
If power supply fails to perform as described above, refer to Troubleshooting Table No.
6-10b in Section Ill for trouble location instructions.
g. - 5V(A) Test Procedures.
With test set up as described in d above, turn SELECT switch to position 5 (connects
VOUT and SCOPE terminals to -5V(A) output).
Measure -5Vdc ±5% and 40 mVrms ripple and noise maximum using DVM.
If power supply fails to perform as described above, refer to Troubleshooting Table No.
6-10b in section Ill for trouble location instructions.
h. + 5V(B) Test Procedures.
With test set up as described in d above, turn SELECT switch to position 6 (connects
VOUT and SCOPE terminals to + 5V(B) output).
Measure + 5Vdc ±5% and 15 mVrms ripple and noise maximum using DVM.
Place + 5VB LOAD LO to ON (connects a 2.37-ohm load across the + 5V(B) output).
Measure same as above.
6-72
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Place +5VB LOAD LO to OFF and place +5VB LOAD HI to ON (connects a 1.7-ohm
resistor across + 5V(B) output). Measure same as above.
Place +5VB LOAD LO to ON. Measure 5.OVdc ±15%. Return +5VB LOAD switches to OFF.
If power supply fails to perform as required, refer to Troubleshooting Table No. 6-10C in
section Ill for trouble location instructions.
i. -8.6V Test Procedures.
With test set up as described in d above, turn SELECT switch to position 7 (-8.6V output) and set -8.6V LOAD switch to position 3 (115-ohm load across output).
Measure -8.6Vdc ±5% and 85 mVrms ripple and noise maximum using DVM.
Change -8.6V LOAD from position 3 to position 2 (82.5-ohm load) and measure same as
above.
Change -8.6V LOAD from position 2 to position 1 (53.6-ohm load) and measure same as
above.
Return -8.6V LOAD switch to position 3.
If power supply fails to perform as required, refer to Troubleshooting Table No. 6-10c in
section Ill for trouble location instructions.
j. + 8.6V Test Procedures.
With test set up as described in d above, turn SELECT switch to position 12 (+8.6V output) and set + 8.6V LOAD switch to position 3 (53.6-ohm load).
Measure +8.6Vdc ±5% with 85 mVrms ripple and noise maximum using DVM.
Change +8.6V LOAD from position 3 to position 2 (44.2-ohm load) and measure same as
above.
Change +8.6V LOAD from position 2 to position 1 (30.1-ohm load) and measure same as
above.
Return +8.6V LOAD switch to position 3.
If power supply fails to perform as required, refer to Troubleshooting Table No. 6-10d in
section Ill for trouble location instructions.
k. Lamp Supply Test Procedure.
With test set up as described in d above, turn SELECT switch to position 8 (lamp
supply).
Adjust ILLUM ADJUST (varies input to Q8 on power supply from 0 to 20 Vdc). Lamp supply will vary from 0.0Vdc ±.2 to 19VDC ±2.
If power supply is not operating properly refer to Troubleshooting Table No. 6-10d in
section Ill for trouble location instructions.
l. Line-Feed Test Procedure.
With test set up as described in d above, turn SELECT switch to position 10 (LF output).
Measure +22 to +30Vdc (pin 30 of power supply) at VOUT terminals,
Change LF LOAD from OFF to ON, measure same as above.
Return LF LOAD switch to OFF.
If power supply fails to perform as required, refer to Troubleshooting Table No. 6-10d in
section Ill for trouble location instructions.
Change 1
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m. Drum Motor Test Procedure.
●
●
●
●
With test set up as described in d above, turn SELECT switch to position 11 (drum-motor).
Connect oscilloscope across SCMO HI and LO (timing simulator output) and turn DRUM
switch to ON (logic 0 to DRUM SHUTDOWN). The timing simulator outputs pulse whose
period is proportional to the drum motor output.
Observe 1080 ±15 usec pulse period on oscilloscope (fig. 6-23).
If power supply fails to perform as required refer to Troubleshooting Table No. 6-10e in
section Ill for trouble location instructions.
NOTE OBSERVE THAT NO TRANSITIONS OCCUR AT LESS THAN
Figure 6-23.
SCMO MEASUREMENT
n. Backup Battery Test Procedure.
Set up as described in d above.
Remove VIN (BAT lamp comes on).
Repeat + 5V(A), 12V, and -5V(A) tests.
Replace VIN (BAT lamp goes off).
If power supply fails to perform as required, refer to Troubleshooting Table No. 6-10e in
section Ill for trouble location instructions.
o. + 18V, CCR, CAP V OK Test Procedure.
●
●
●
●
●
●
●
●
●
●
6-74
Set up as described in d above.
Connect DVM across VOUT HI and LO and turn SELECT switch to position 9 ( + 18V
print coils).
With + 18V LOAD to position 2 (no load), place CCR to ON to cause power supply circuit
card assembly pin 22 to become a logic 0.
Observe that CAP V OK lamp is on and VOUT measures + 18Vdc ±5%.
Switch CCR to OFF (pin 22 becomes a logic 1); there is no effect on output.
Place + 18V LOAD switch to position 1 (27.4 ohms); observe that VOUT drops to less than
one volt dc and CAP V OK lamp goes out.
Place CCR switch to ON; VOUT becomes + 18V ±5% and CAP V OK comes on.
Place + 18V LOAD switch to position 3 (12 ohms). VOUT is approximately + 12Vdc ±10%
and CAP V OK lamp goes out.
Place CCR switch to OFF.
If power suppIy fails to perform as required, refer to Troubleshooting Table No. 6-10e in
section Ill for trouble location instructions.
Change 1
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6-28.
POWER SUPPLY ADJUSTMENTS (fig. 6-22)
a. +5V(A) Adjustment.
Set up power supply test figure configuration as described in paragraph 6-27d and figure
6-22.
Remove power from test fixture by placing each power supply to the OFF position.
Using a pair of diagonal cutters, clip R11 at the resistor body being sure to leave the
leads in the circuit card assembly (refer to fig. FO-8).
Attach SELECT RESISTOR number one test leads to R11 leads.
Set SELECT RESISTOR number one to 500 and place all power supplies to the ON position.
Set +5VA LOAD HI switch to the OFF position and the +5VA LOAD LO switch to ON.
Set + 12V LOAD switch to OFF.
Set SELECT switch to position 3. Connect DVM to VOUT test points on the fixture.
Measure the dc voltage on the meter and adjust SELECT RESISTOR number one as required to cause the output to be +5.02Vdc ±0.01. Note the SELECT RESISTOR
setting and select the closest value of Rll from table 6-15 of Selection Values for
Resistors R11, R29, R63 below.
Set SELECT switch to position 4 and measure + 12V ±5% on the meter.
Set SELECT switch to position 5 and measure -5V ±5% on the meter.
Install selected value of R11.
Table 6-15. SELECTION VALUES FOR RESISTORS R11, R29, R63
Select resistor setting
Resistor
value (ohms)
0020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0274 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0498 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0648 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0730 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0824 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0998 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
40.2
71.5
105
137
174
210
249
287
324
365
412
453
499
6-75
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TO 31W4-2UGC74-2
b. +5V(B) (+8.6V) Adjustment.
Set up as described in a above.
Remove power from test fixture by placing each power supply to the OFF position.
Using a pair of diagonal cutters, clip R63 at the resistor body; be sure to leave the leads
in the circuit card assembly (fig. FO-8).
Attach SELECT RESISTOR number one test leads to R63 leads.
Set SELECT RESISTOR number one to 500 and place all power supplies to the ON position
Set +5VB LOAD HI switch to OFF and +5VB LOAD LO switch to ON.
Set SELECT switch to position 12. Connect meter to VOUT test points on the fixture.
Measure the dc voltage on the meter and adjust SELECTOR RESISTOR number one as
required to cause the output to be +8.6V dc ±0.01. Note the SELECT RESISTOR setting
and select the closest value of R63 from table of Selection Values for Resistors R11, R29,
R63.
Install selected value of R63.
c. Drum Motor Output Adjustment. The drum motor output circuitry is adjusted when the value
of the pulse period is 1080 microseconds.
Set up as described in a above.
Remove power by placing external lower power supply, switches in the OFF position.
Using a pair of diagonal cutters, clip R29 at the resistor’s body leaving the leads attached
to the circuit card assembly. (Refer to fig. FO-8.)
Connect SELECT RESISTOR number one leads across R29.
Apply power by placing all power switches on the external supplies to the ON position.
Connect oscilloscope to SCMO HI and LO and place DRUM switch to ON position.
Observe pulse period and adjust SELECT RESISTOR number one until SCMO is 1080 usec
± 12 (measured from leading edge to middle of jitter in fig. 6-23).
Note setting of SELECT RESISTOR number one and install closest value from table of
Selection Values for Resistors R11, R29, R63.
d. + 18V Constant Current Adjustment.
Remove power from test fixture by placing individual external power supply power switches to the OFF position.
Clip resistors R41 and R71 at the resistor bodies and attach SELECT RESISTOR number
two clips 1, 2, 3 as shown in figure FO-8.
Reapply power to test fixture. Set + 18V LOAD switch to position 1 (normal).
Place CCR switch in the ON position. Set SELECT RESISTOR number two to 10.0. Set
SELECT switch in position 9.
Adjust SELECT RESISTOR number two until CAP V OK lamp goes out. Measure voltage at
VOUT test points, It should be + 16.2V dc ±.45.
Place + 18V LOAD switch to position 3 (max.) and increase SELECT RESISTOR number two
until 12V dc ±.05 is observed on the meter.
Observe reading on SELECT RESISTOR number two dial and select the closest values of
R71 and R41 from table 6-16, “Selection Values for Resistors R41 and R71.”
Install selected resistors R41 and R71.
6-76
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TO 31W4-2UGC74-2
Table 6-16. SELECTION VALUES FOR RESISTORS R41 AND R71
6-77
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6-29. FILTER ASSEMBLY 3A1A6FL1
a. Purpose. The filter assembly converts and filters 115/230Vac, 50/60/400 Hz power to 22-30
Vdc. It also provides EM I filtering of the 26Vdc ±4 and + 12Vdc inputs.
b. Test Equipment and Materials.
Filter Assembly Test Fixture SM-C-915994
Oscilloscope AN/US M-281C
Multimeter AN/USM-223
Power Cable, UGC-74, 120 VAC, SM-D-764481
Power Cable, UGC-74, 230 VAC, SM-D-764482
Power Cable, UGC-74, 26 VDC, SM-D-764480
c. Filter Assembly Test Fixture. The filter assembly test fixture is a device which provides
appropriate interfaces between the input power cabling and the filter assembly. The input power
is provided through the three power cables listed above. Table 6-17 below provides the list of
interconnections-between J4 and J1 on the fixture. The filter output normally is connected to C8
when installed in the AN/UGC-74A(V)3. An equivalent capacitor is part of the fixture and is connected to the output through P2-6 and P2-2. A resistive load is included in the fixture to simulate
the load provided by the power supply 3A1PS1.
Table 6-17. PROGRAMMABLE PLUG CONNECTIONS
CAUTION
Certain filter assembly configurations may have two loose output leads to
C8. If so, tape each lead separately so that they will not short out to each
other or any other object.
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d. Test Setups and Procedures for Filter Assembly (fig. 6-24).
Remove filter assembly as directed in paragraph 5-1 lG.
Connect 120Vac cable (SM-D-766481) to J4 and to a 120Vac source. Connect P1 and P2
(filter) to J1 and J2 (fixture).
Ground filter assembly to test fixture GND.
Place test fixture POWER switch to ON.
Use the AN/USM-223 to measure + 28Vdc ±3.5 across 22-30Vdc test point and RTN.
Use the AN/USM-281C to measure 750 mVrms maximum ripple.
Turn POWER switch to OFF. Remove 120Vac cable and replace with the 230Vac cable
(SM-D-764482). Connect to a 230Vac source.
Repeat above procedures.
Turn POWER switch to OFF. Remove 230Vac cable and replace with the 26Vdc cable
(SM-D-764480). Connect cable to a 26Vdc source.
Repeat above procedures.
Turn POWER switch to OFF and remove the 26Vdc cable from J4. Measure continuity
of + 12Vdc circuitry by measuring from the fixture test point 12Vdc to BAT (J3) pin A.
Be sure the POWER switch in ON and fuse F3 is not open. Read less than 1 ohm from
J3-A to the 12Vdc test point using the AN/USM-223.
NOTE
An alternate method would be to connect a 12Vdc battery backup cable
and source to the fixture and measure +12 volts at the 12Vdc test point.
If a failure is observed in any of the above steps, refer to Troubleshooting Table 6-11
in section III for trouble location instructions. Also refer to paragraph 3-15 for filter
assembly test fixture theory of operation.
Figure 6-24.
FILTER TEST SETUP.
6-79
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TO 31W4-2UGC74-2
6-30. KEYBOARD KEYSWITCH ASSEMBLY
a. Purpose. The keyswitch assembly contains all the electronics and switches used by the
operator in operation of the keyboard. It is tested by verifying that the proper codes are produced
in response to the keyswitch pressed. The test fixture provides clock simulation circuitry to
generate the required clocks for keyswitch assembly operation.
b. Test Equipment and Materials.
Multimeter AN/USM-223
Oscilloscope AN/USM-281C
Power Supply PP-2309/U
Function Generator SG-1133/U
Test Fixture, Keyswitch Assembly, Honeywell (SM-C-915997)
Remover, Module, Honeywell (SM-B-916003)
c. Test Setup Procedures for Keyboard Keyswitch Assembly (fig. 6-25).
Remove the key board keyswitch assembly os directed in paragraph 5-11N.
Adjust power supply for +5Vdc ±0.25; turn power supply OFF.
Connect + 5V power supply to test fixture.
Adjust function generator for 2400 Hz nominal +5V square wave and connect it to SIG IN
connector.
Connect keyswitch assembly to test fixture.
Connect all test equipment to ground.
NOTE
The complete keyboard assembly may also be tested on the fixture.
d. Test Procedures.
Connect multimeter lead to LOGIC terminal and probe ground to REF (LOGIC).
Apply +5Vdc ±5% to the test fixture by turning on the + 5 V supply. Press and release
CLOCK CONTROL switch and verify that the multimeter reads from 0 to +0.5Vdc. This
assures initialization of the logic circuitry.
Set oscilloscope to .1 ms and 1V/DIV.
Connect oscilloscope probe to 2400-Hz terminal and probe ground to GND terminal.
Verify .41 ms sec nominal pulse, with a low logic level of 0.4Vdc max and a high logic level
not to exceed 5Vdc, or be less than 2.5Vdc.
Connect oscilloscope probe to DATA terminal and probe ground to REF(DATA) terminal.
Press and hold a key on the keyswitch assembly that is called out in table 6-18.
6-80
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Figure 6-25.
KEYBOARD KEYSWITCH ASSEMBLY TEST SETUP.
6-81
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Table 6-18. Character Code Matrix Test
NOTE
These procedures cause an 8-bit character to be loaded and read
out one bitatatime.
Record the logic Ievel displayedon the oscilloscope (bit 1). Press and release the
CLOCK CONTROL switch on the fixture. Record the logic level displayed onthe
oscilloscope (bit 2). The key may now be released because the character is stored in the
logic. Press and release the CLOCK CONTROL switch and record the logic level (bit 3).
Repeat until bits 4 through 8 have been recorded.
NOTE
Further use of the clock control will allow the 8 bit character tobe
reread providing that another key hasnot been pressed.
Compare the eight readings above with the codes from table 6-18. For other codes, refer
to table 3-2.
Test the 12 bit counter (U8) by pressing the RPT Key and observing a 210 msec square
wave at the LOGIC terminals. Disconnect oscilloscope leads.
Check for +2.5 Vdc ±10% at PRESENT test point with respect to ground using the
multimeter.
Check for + 1.5 Vdc ±5% with respect to GND at each of the REF terminals.
If a failure is observed in any of the above steps, refer to Troubleshooting Table No. 6-12
in section Ill for trouble location instructions. Also refer to paragraph 3-21 for keyboard
keyswitch test fixture theory of operation.
6-82
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6.31. FINAL TEST OF COMMUNICATIONS TERMINAL AN/UGC-74A(V)3
a. Purpose. The final test of the terminal is performed to verify the terminal’s operational
condition. The terminal’s message transmission and reception capabilities are tested using
the equipment identified in b below.
b. Test Equipment and Materials
Oscilloscope AN/USM-281C
Interface Test Fixture, SM-D-915991
Power Supply PP-2309/U
Function Generator SG-1133/U
Loopback Plug (SM-C-916000)
Power Cable 26 V dc (SM-D-764480)
Power Cable 120 V ac (SM-D-764481)
Power Cable 230 V ac (SM-D-764482)
Battery Backup Cable (SM-D-915890)
c. Test Connections and Conditions.
●
Set interface switches as follows:
Interface Switch
BAUD RATE
ASCII/BAUDOT
PARITY
K30/INT/EXT
XMIT MODE
RCVR MODE
STATE
Setting
ASCII
ODD
INT
LO DATA
LO DATA
ICT
Connect the Ioopback plug to J1.
d. Test Procedure.
Apply power and perform Self-Test as directed in chapter 2 using both internal and external loopbacks.
Repeat above for LO DATA.
Perform Loopback Test (chapter 2). Verify the initialization sequences and the operation of
the following:
MSG RCVD lamp
XMT lamp
Keyboard line feed
Remove Ioopback plug and connect interface test fixture to data connector (J1). Connect
an oscilloscope to 0UT5(HI), Refer to figure 6-26 of test setup.
Set up function generator for 0 to +6 V square wave at 100 Hz (external/clock) and connect to IN3(HI) and IN3(LO). Connect OUT5 to IN1(HI) and (LO).
Connect second oscilloscope channel to OUT2(HI). Using the TTY Command, transmit a
line of E’s observing that data at 0UT5 is being clocked on the positive edge of the clock.
Synchronize the oscilloscope on DATA.
Place CLOCK +/- switch to - and observe that data is transmitted on negative edge of
the clock.
Change 1
6-83
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Remove power by placing POWER switch to OFF.
Set XMIT MODE switch 60 mA and REC MODE switch to 60 mA.
Using the interface assembly test fixture, connect a 26V supply through R3 as shown in
figure 6-27.
Perform Loopback Test as directed in chapter 2.
Remove power by placing POWER switch to OFF.
Connect an external function generator adjusted for 100 Hz, ±6V peak to peak square wave to IN3
HI and IN3 LO. Set CLOCK lNT/EXT/KG-30 to EXT.
Apply power and perform Loopback Test as directed in chapter 2, except that SIGNAL switch shall
be set to NRZ. Observe OUT 5 and IN 2 on an oscilloscope. Data on OUT 5 should be edge
coincident with clocks on IN3.
Set CLOCK lNT/EXT/KG-30 to KG-30 and connect IN3 to IN4.
Perform Loopback Test as directed in chapter 2, except that SIGNAL switch shall be set to NRZ.
Remove power from terminal.
Install 230-Vac cable and connect to 230-Vac source.
Apply power and perform Self-Test.
Remove power and disconnect 230-Vac cable.
Install 6 1/4 Amp fuses in fuseholders F1 and F2.
Connect 26Vdc cable to 26 Vdc source and terminal.
Apply power and perform Self-Test.
If a failure occurs in any of the preceding tests, refer to the troubleshooting tables in section Ill of
this manual. Also, refer to figure FO-9 to check system interconnects. To assist in identifying
capacitor values and ratings, refer to figure FO-1.
6-84
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Figure 6-26. EQUIPMENT SETUP FOR DATA/CLOCK TEST.
Change 1
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Figure 6-27. EQUIPMENT SETUP FOR 26 VOLT SUPPLY TEST.
6-86
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Section VII.
TEST FIXTURES DISASSEMBLY AND REASSEMBLY
6-32. GENERAL
This section describes the disassembly and reassembly of the following test fixtures
used to test the modules and assemblies of the AN/UGC-74A(V)3.
Test Fixture
A.
B.
C.
D.
E.
F.
G.
FILTER ASSEMBLY
HAMMER DRIVER MODULE
HAMMER MODULE
INTERFACE ASSEMBLY
LINE FEED/CURRENT CONTROL
POWER SUPPLY
KEYSWITCH ASSEMBLY
• Use the same care and precautions for the disassembly and reassembly of the test fixtures as used for the terminal components in section V of this chapter.
• Refer to the applicable figure and parts description list for identification and location of
test fixture parts.
• After repair and reassembly of a test fixture, refer to section VIII of this chapter and perform the test procedures required to insure complete repair of the fixture.
6-33. DISASSEMBLY AND REASSEMBLY PROCEDURES
A. FILTER ASSEMBLY TEST FIXTURE DISASSEMBLY AND REASSEMBLY (fig. 6-28).
Remove four screws (8), washers (9) and remove bottom cover (11) from chassis (12).
Removal and Replacement of Switch S1 (72).
• Label and unsolder wires from terminals of switch S1 (72).
Ž Remove nut (47), washer (48).
• Remove switch S1 (72).
Ž Replace switch S1.
• Replace washer (48) and nut (47), tighten into position.
• Replace and solder wires on terminals of S1.
Removal and Replacement of Connector J1 (21).
• Label and disconnect wires from connector J1 (21).
• Remove two screws (17), washers (15) and attaching hardware (18), (19), and (20).
• Remove J1.
• Replace connector J1.
• Replace attaching hardware (18), (19), and (20).
• Place washer (15) and screw (17) into position and secure.
• Replace and connect wires on terminals of J1.
6-87
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Connector J2 (31).
• Label and disconnect wires to connector J2(31).
• Remove two screws (34), washers (32) ond attaching hardware (23), (24) and (25).
• Remove connector J2.
• Replace connector J2.
• Replace attaching hardware (25), (24) and (23).
• Secure into position with washer (32) and screw (34).
• Replace and solder wires on terminals of J2.
Removal and Replacement of Connector J3 (61).
• Label and unsolder wires to connector J3 (61).
• Remove four screws (60) and attaching hardware (62), (63) and (64).
• Remove connector J3.
• Replace connector J3.
• Replace attaching hardware (64), (63) and (62), secure into place with
screws (60).
• Replace and solder wires on terminals of J3.
Removal and Replacement of Connector J4 (71).
• Label and unsolder wires to connector J4.
• Remove four screws (59) and attaching hardware (68), (69) and (70).
• Remove connector J4.
• Replace connector J4.
• Replace attaching hardware (70), (69) and (68), and secure into place with
screws (59).
• Replace and solder wires to terminals of J4.
Removal and Replacement of Fuseholders (13), (14) and (40).
• Label and unsolder fuseholder’s respective wires.
• Remove nut (6) (typical) and washer (7) (typical) on each of the three fuseholders as required.
• Remove fuseholder(s) and washer(s) (39) (typical) as required.
• Replace fuseholder into mounting hole with washer (39) and secure into
place with washer (7) and nut (6).
• Solder respective wires to their terminals.
Removal and Replacement of Capacitor C1 (46).
• Remove capacitor Cl by removing two screws (56), bracket (52) and attaching
hardware (53), (54) and (55).
• Extend capacitor C1 from chassis. Mark and disconnect leads by removing two
screws (44) from C1. Remove C1.
• Replace capacitor C1 by reconnecting leads with two screws (44).
• Replace C1 in chassis, replace bracket (52) over C1 and replace screws (56)
and attaching hardware (53), (54) and (55).
6-88
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Resistors R1 (26) and R2 (38).
● Label and unsolder the leads from the resistors.
● Remove two screws (22) and (33) which attach each resistor to the chassis (12).
● Remove resistors.
● Replace resistors to chassis with screws (22) and (33).
● Resolder leads to resistors.
Removal and Replacement of Test Points (43), (49), (50) and (51).
• Unsolder wires and remove nuts (1) and (2), washers (3) and (4) and spacer (5)
from test points as applicable.
• Remove applicable test point(s) from chassis.
• Replace test point(s) in chassis.
• Replace spacer(s), washer(s) and nut(s) as applicable.
• Resolder wire(s) to applicable test point(s).
NOTE
Refer to table 3-3 for filter assembly wire list, if required.
6-89
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-90
Figure 6-28.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-28. LEGEND
No.
Part Description
No.
Part Description
No.
Part Description
1
Nut
26
Resistor (R1)
51
Test point (TP3)
2
Nut
27
Washer, flat
52
Bracket
3
Washer, lock
28
Washer, lock
53
Washer, flat
4
Washer, flat
29
Nut
54
Washer, lock
5
Spacer
30
Washer, flat
55
Nut
6
Nut
31
Connector (J2)
56
Screw
7
Washer, lock
32
Washer, flat
57
Washer, flat
8
Screw, pnh
33
Screw, pnh
58
Screw, pnh
9
Washer, flat
34
Screw, pnh
59
Screw, pnh
10
Nut, sheet spring U-type 35
Washer, flat
60
Screw, pnh
11
Cover, bottom
36
Washer, flat
61
Connector (J3)
12
Chassis
37
Nut
62
Washer, flat
13
Holder, fuse
38
Resistor (R2)
63
Washer, lock
14
Holder, fuse
39
Washer, flat
64
Nut
15
Washer, flat
40
Holder, fuse socket 65
16
Washer, flat
41
Fuse
66
Washer, lock
17
Screw, pnh
42
Cap, fuse
67
Nut
18
Nut
43
Test point (TP4)
68
Nut
19
Washer, lock
44
Screw
69
Washer
20
Washer, flat
45
Terminal crimp
70
Washer, lock
21
Connector (J1)
Capacitor (C1)
71
Connector (J4)
22
Screw, pnh
46
47
Nut
72
Switch (S1)
23
48
Washer, tab
73
Nut
24
Nut
Washer, lock
49
Test point (TP2)
74
Washer, lock
25
Washer, flat
50
Test point (TP1)
Terminal
6-91
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
B. HAMMER DRIVER TEST FIXTURE DISASSEMBLY AND REASSEMBLY (fig. 6-29).
• Remove four screws (1) and washers (2) which secure bottom cover (3) to test fixture
chassis (11).
Removal and Replacement of Test Points (15) through (20),
• Label and unsolder wire(s) from test point(s) as required.
• Remove test point(s) by removing attaching hardware (4), (5), (6), (7), and (9).
• Position test point(s) into mounting hole and secure with attaching
hardware.
• Solder wires to their respective terminals.
Removal and Replacement of Switch S1 (23).
• Label and disconnect wires from switch S1 (23) by removing six screws (21).
• Remove attaching hardware (31), (32) and remove switch.
• Position S1 into chassis (11) with positioning hardware (24), (25) and (26)
properly oriented to engage alinement hole in chassis.
• With switch properly alined, install attaching hardware (32), (31) so that only 1-2 threads are exposed above the shoulder of nut (31).
• Tighten nut (31) as required to secure switch S1.
• Connect wires to their respective terminals.
Removal and Replacement of Resistor R1 (42) and/or Resistor R2 (49).
• Label and unsolder wires from resistor (42) or (49) as required.
• Remove attaching hardware (44), (45), and (43) or (48), (47), (46) as applicable and
remove resistor(s).
• Position resistor into place and secure with attaching hardware.
• Solder wires to their respective terminals.
Removal and Replacement of Connector Housing (33).
• Remave four screws (34), and attaching hardware (54), (55), and (56).
• Remove housing (33). Remove two screws (39) and attaching hardware (13), (14)
from housing.
• Place housing into position and secure with attaching hardware.
6-92
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Connectors (37) and (38).
•
•
•
•
Removal of connectors (37) and (38) requires housing assembly (33) removal.
Remove two screws (39) and attaching hordware (13), (14) from housing (33).
Grasp connectors (37) and (38) and gently disengage mating pins.
Pins (36) in connector (37) may be removed by depressing the tang holding the
pin(s) in place and gently removing the pin(s).
ž Remove guide rails (35) and (10) by removing attaching hardware (50), (41), (40) or
(51), (52), (53) as applicable.
• Remove grommet (12) and pass it over connector (37).
• Replace grommet.
• Insure that pins in connector (37) are secure by checking tangs.
• Mate connector together.
Ž Position assembly into place and secure with two screws and attaching hardware.
Ž Replace housing assembly (33).
6-93
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-94
Figure 6-29.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-29. LEGEND
No.
Part Description
No.
Part Description
1
Screw
29
Screw
2
Washer, flat
30
Washer, flat
3
Cover, bottom
31
Nut
4
Nut
32
Washer, lock
5
Nut
33
Housing
6
Washer, lock
34
Screw
7
Washer, flat
35
Guide
8
Nut, flat spring, U-type
36
Pin
9
Spacer
37
Connector
10
Guide
38
Connector assembly
11
Chassis
39
Screw
12
Grommet
40
Washer, flat
13
Nut
41
Washer, lock
14
Washer, flat
42
Resistor (RI)
15
Test point (TP2)
43
Washer, flat
16
Test point (TP1)
44
Washer, lock
17
Test point (TP6)
45
Nut
18
Test point (TP3)
46
Washer, flat
19
Test point (TP4)
47
Washer, lock
20
Test point (TP5)
21
Screw
48
49
Screw
Resistor (R2)
22
Terminal
50
Screw, self tapping
23
Switch, toggle (S1)
51
Screw, self tapping
24
Nut
52
Washer, flat
25
Washer, lock
53
Terminal lug
26
Washer, tab
54
Nut
27
Washer, flat
55
Washer, lock
28
Screw
56
Washer, flat
6-95
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
C. HAMMER MODULE TEST FIXTURE DISASSEMBLY AND REASSEMBLY (fig. 6-30).
• Remove screw (1), washer (2) and bottom cover (3) from chassis (13).
Removal and Replacement of Switches S1 (30), S2 (33), S3 (36), and S4 (37)
• Label terminals (28) and remove lockwashers (26) from switch(es) (30), (33), (36),
and (37) as applicable.
Ž Remove nut (20), (23), (25), (48) and washers (17), (19), (21), (49) from appropriate
switch to be removed. Remove switch(es) as required.
• When installing new switch, install nut(s) (29), (32), (35), (38), and
washers (26), (31), (34), (39) before positioning switch in chassis.
• Place switch into chassis and install alinement washer(s) (17), (19), (21) and
(49) to engage alinement hole in chassis.
• Install nut(s) (20), (23), (25), (48) and tighten until 1-2 switch threads extend
beyond the shoulder of nut.
Ž Tighten nut(s) (29), (32), (35) and (38) as required to secure switch.
Removal and Replacement of Switch S5 (4).
• Unsolder and label leads from switch S5 (4).
• Remove nut (12) and remove switch and washer (7).
• Position switch into mounting hole and secure with washer and nut.
• Solder wires to their respective terminals.
Removal and Replacement of Test Point(s) (18), (22) and (24).
• Label and unsolder and remove wires from test point(s) (18), (22) and (24) as
required.
• Remove attaching hardware (5), (6), (8), (9), (11) and remove test point(s).
Ž Position test point(s) into mounting hole and secure with attaching
hardware.
• Solder wires to their respective terminals.
Removal and Replacement of Resistors (59), (60), (61), (68).
• Label and unsolder wires from resistor(s) (59), (60), (61), (68).
• Remove attaching hardware (72), (73), (74), (40), (41); (68), (69), (70), (42), (43); (66),
(64), (63), (45), (46), (67), (65), (62), (44), and (45) respectively, and remove
resistor(s).
• Position resistor(s) into place and secure with attaching hardware.
• Solder wires to their respective terminals.
Removal and Replacement of Capacitor (82).
• Remove capacitor (82) by removing bracket (79) and attaching hardware (75),
(76), (80), (81), (85) in two places.
• Remove capacitor from chassis (13) with leads still attached.
• Remove screws (84) and disconnect leads from capacitor.
• Connect leads to capacitor and secure with screws.
• Position capacitor into chassis.
• Secure into position with attaching hardware.
6-96
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Connector Assembly (55).
• Connector assembly (55) is mounted on a housing (50).
• To remove connector assembly, remove housing attaching hardware (51), (90),
(91), and (92).
• Lift housing from chassis (13) and invert.
• Disconnect connector (54) from connector assembly (55) by gently pulling them
apart.
• Remove two screws (56) and attaching hardware (15), (16) and remove housing
(50).
• Remove guides (52), (78) by removing attaching hardware (77), (58), (57) and (87)
through (89) as appropriate.
• Replace guides and secure with attaching hardware.
• Mate connector with connector assembly.
• Position into chassis assembly.
• Secure housing assembly with attaching hardware.
6-97
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-98
Figure 6-30.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-30. LEGEND
No.
Part Description
No.
Part Description
No.
Part Description
Screw
31
Washer, lock
61
Resistor (R4)
Washer, flat
32
Nut
62
Washer, flat
Cover bottom
33
Switch (S2)
63
Washer, flat
Switch (S5)
34
Washer, lock
64
Washer, lock
5
Nut
35
Nut
65
Washer, lock
6
Nut
36
Switch (S3)
66
Nut
7
Washer, lock
37
Switch (S4)
67
Nut
Washer, lock
38
Nut
68
Resistor (R3)
9
Washer, flat
39
Washer, lock
69
Nut
10
Nut, fiat spring-U-type
40
Washer, flat
70
Washer, lock
11
Spacer
41
Screw
71
Washer, flat
12
Nut
42
Washer, flat
72
Nut
13
Chassis
43
Screw
73
Washer, lock
14
Grommet
44
Washer, flat
74
Washer, flat
15
Washer, flat
45
Screw
75
Screw
16
Nut
46
Screw
76
Washer, flat
17
Washer, tab
47
Washer, flat
77
Screw, self tapping
18
Test point (TP3)
48
Nut
19
Test tab
49
Washer, tab
78
79
Guide
Bracket
20
Nut
50
Housing, connector
80
Washer, flat
21
Washer tab
51
Screw
81
Washer, lock
22
Test point (TP2)
52
Guide
82
Capacitor (C1)
23
Nut
53
Pin, connector
83
Lug, terminal crimp
24
Test point (TP1)
54
Connector
84
Screw
25
Nut
55
Connector assembly
85
Nut
26
Washer, lock
56
Screw
86
Screw
27
Screw
57
Washer, flat
87
Washer, lock
28
Lug terminal crimp
58
Washer, lock
88
Washer, flat
29
Nut
59
Resistor (R1)
89
Terminal lug
30
Switch (S1)
60
Resistor (R2)
90
Nut
91
Washer, lock
92
Washer, flat
1
2
3
4
8
6-99
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
D. INTERFACE ASSEMBLY TEST FIXTURE DISASSEMBLY/REASSEMBLY (figs. 6-31, 6-32, 6-33)
Remove bottom cover.
Removal and Replacement of Switch S1 (1) (fig. 6-31)
● To remove switch S1 (1), first mark each wire soldered to switch to identify
terminal to which it is connected.
● Unsolder and remove each wire.
● Loosen setscrews in knob (28) and remove knob.
● Remove nut (43) and washer (44). Remove switch S1.
• Posit ion’switch into mounting hole in chassis.
• Secure into position with washer and nut.
• Solder wires to their respective terminals.
Removal and Replacement of Test Point(s) (14), (16), (17), (18), (19), (20), (21), (45)
through (50), (52), (54), (56), (58), (59), (61), (62), (63) and (69) (fig. 6-31).
● Prior to removing test points (14), (16), (17),(18),(19), (20), (21), (45) through
(50), (52), (54), (56), (58), (59), (61), (62), (63) and (69) mark each wire to identify
test point(s) from which it was removed.
● Unsolder each wire(s) from each respective test point.
● Remove attaching hardware (6), (7), .(8), (9) and (10) from each test point to be
removed.
• Position test point(s) into mounting hole in chassis and secure with attaching hardware.
• Solder-wire(s) to respective terminals.
Removal and Replacement of Test Points (12), (13), (14), (16), (17), (18), (20) and (21)
(fig. 6-33).
● To remove test point(s) (12), (13), (14), (16), (17), (18), (20), (21), remove resistors
R1 (22), R2 (19), R3 (15) and R4 (6) as required.
● Remove attaching hardware (1) through (5) and (7) through (11) as required and
remove test point(s).
• Mount test point into mounting hole in chassis and secure with attaching
hardware.
• Replace resistor(s) removed (R1, R2, R3 or R4) as required.
Removal and Replacement of Connector Assembly (26) and (27) (fig. 6-31).
● To remove back shell (26) from connector (27), loosen two screws on back shell
clamping the cable.
● Remove two screws (25) and washers (24) along with attaching hardware (22) and
(23).
● Slide back shell toward chassis (15) along the cable.
• With connector in place move back shell along cable to connector.
• Secure into place with attaching hardware and two screws.
6-100
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Connector Assembly (34) and (33) (fig. 6-31).
• To move back shell (34) from connector (33), loosen two screws on back shell
clamping cable.
• Remove the two screws (31), washer (30) and attaching hardware (32) and (29).
Ž Slide back shell toward chassis along the cable.
• With connector in place move back shell along cable toward connector.
• Secure with attaching hardware and two screws.
Removal and Replacement of Connector Assembly (51), (53), and (55) (fig. 6-31).
• Remove two screws and clamp on connector requiring replacement.
• Disassemble connector shell.
• Label and unsolder wires from connector.
• Resolder wires to connector.
Ž Reassemble connector.
• Replace clamp and tighten two screws.
6-101
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-102
Figure 6-31.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-31. LEGEND
No.
Part Description
No.
Part Description
No.
Part Description
1
Switch, rotary (S1)
26
Shell connector
51
Connector, elec.
2
Screw
27
Connector elec.
52
Test point (TP22)
3
Washer, flat
28
Knob, pointer
53
Connector, elec.
4
Cover, Chassis bottom
29
Nut
54
Test point (TP23)
5
Nut, sheet spring U-type
30
Washer, flat
55
Connector, elec.
6
Nut
31
Screw
56
Test point (TP24)
7
Nut
32
Washer, lock, split
57
Clip, electrical
8
Washer, lock
33
Connector, elec.
58
Test point (TP26)
9
Washer, flat
34
Shell connector
59
Test point (TP25)
10
Insulator base
35
Test point (TP12)
60
Grommet, rubber
61
Test point (TP27)
11
Washer, flat
36
Test point (TP8)
12
Screw
37
Test point (TP13)
62
Test point (TP28)
63
Test point (TP30)
13
Grommet, rubber
38
Test point (TP9)
14
Test point (TP1)
39
Test point (TP14)
64
Terminal, lug, solder
15
Chassis-interface assembly
40
Test point (TP10)
65
Terminal, lug, solder
16
Test point (TP2)
41
Test point (TP15)
66
Terminal, lug, solder
17
Test point (TP5)
42
Test point (TP11)
67
Terminal, lug, solder
18
Test point (TP3)
43
Nut
68
Terminal, lug, solder
19
Test point (TP6)
44
Washer, lock
69
Test point (TP29)
20
Test point (TP4)
45
Test point (TP17)
21
Test point (TP7)
46
Test point (TP16)
22
Nut
47
Test point (TP18)
23
Washer, lock, split
48
Test point (TP20)
24
Washer, flat
49
Test point (TP19)
25
Screw
50
Test point (TP21)
6-103
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-32. INTERFACE ASSEMBLY TEST FIXTURE (BOTTOM VIEW ).
6-104
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
No.
Part Description
No.
Part Description
1
Spacer
12
Test point (TP11)
2
Washer, flat
13
Test point (TP15)
3
Washer, lock
14
Test point (TP10)
4
Nut
15
Resistor (R2)
5
Nut
16
Test point (TP14)
6
Resistor (R1)
17
Test point (TP9)
7
Nut
18
Test point (TP13)
8
Nut
19
Resistor (R3)
9
Washer, lock
20
Test point (TP12)
10
Washer, flat
21
Test point (TP8)
11
Spacer
22
Resistor (R4)
Figure 6-33. INTERFACE ASSEMBLY TEST FIXTURE (TEST POINT RESISTORS).
6-105
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
E. LINE-FEED CURRENT CONTROL TEST FIXTURE DISASSEMBLY AND REASSEMBLY (fig. 6-34)
• Remove four screws (5), washers (6) and cover (13).
Removal and Replacement of Test Point(s) (20) through (28), (30) through (35).
Mark and unsolder wire(s) to test points (20) through (28), (30) through (35) as
required.
Remove attaching hardware (8) through (12) from each test point as required.
Position test point(s) into mounting hole and secure with attaching
hardware.
Solder wires to their respective terminals.
Removal and Replacement of Switch S1 (4).
Loosen setscrews and remove knob (29).
Mark and unsolder wires from S1 (4).
Remove nut (36) and washer (37). Remove S1.
Position S1 into mounting hole and secure with nut and washer.
Solder wires to their respective terminals.
Replace nut (36) and washer (37) on S1 threaded shaft.
Replace knob (29) and tighten two setscrews.
Removal and Replacement of Switch S2 (1).
Mark wires on switch S2 (1) and remove them from switch by removing three
screws (76).
Remove nut (38) and tab washer (39) and remove switch S2.
Position hardware (38) and (39) over mounting hole prior to inserting switch.
Once inserted into chassis, switch is alined by installing washer (39) so
that tang on washer mates with alinement hole in chassis.
Nut (38) is then tightened on switch until 1-2 threads appear above shoulder
of nut.
Tighten nut (2) as required to secure switch.
Replace wires on switch with screws (76).
and Replacement of Terminal Board TB1.
Mark and unsolder leads from solder terminals E18 through E25 on TB1 (73).
Remove resistors (67), (68), (69), (74).
Remove screw (65) terminal lug (64) and washer (66).
Remove two screws (70), washers (71) and (72) and terminal board TB1 (73).
Place TB1 into position and secure with attaching hardware.
Replace resistors.
Solder wires to their respective terminals.
6-106
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Printed Circuit Board (59).
Mark and unsolder wire(s) from printed circuit card (59) as reauired.
Remove two screws (44) and washers (45) with attaching hardware (60), (61) and
(62).
Remove connector (49) by unsoldering connector pins and separating connector
from printed circuit board.
Connect connector to printed circuit card and solder pins.
Position into chassis and secure with attaching hardware.
Solder wires to their respective terminals.
Removal and Replacement of Resistor (R4) (55).
Mark and unsolder wires from resistor (55).
Remove two screws (42), washers (43), and attaching hardware (56), (57) and (58).
Remove resistor (55).
Position resistor into place.
Secure with attaching hardware.
Solder leads to their respective terminals.
Removal and Replacement of Switch S3 (53).
Mark and remove two wires by removing two screws (52) from switch (53).
Remove attaching hardware (40), (41) and remove switch.
Install positioning hardware (51) and (50).
Insert switch through mounting hole.
Once inserted into chassis, switch is alined by installing washer (41) so
that tang on washer mates with alinement hole in chassis.
Nut (40) is then tightened on switch until 1-2 threads appear above shoulder
of nut.
Tighten nut (51) as required to secure switch.
Replace wires on switch.
6-107
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-108
Figure 6-34.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-34. LEGEND
No.
Part Description
No.
Part Description
No.
Part Description
1
Switch, toggle (S2)
25
Test point (TP7)
51
Nut
2
Nut
26
Test point (TP3)
52
Screw
3
Washer, lock
27
Test point (TP11)
53
Switch, toggle (S3)
4
Switch, rotary (S1)
28
Test point (TP15)
54
Terminal
5
Screw
29
Knob, pointer
55
Resistor (R4)
6
Washer, flat
30
Test point (TP10)
56
Washer, flat
7
Nut, sheet spring, U-type
31
Test point (TP9)
57
Washer, lock
8
Nut
32
Test point (TP8)
58
Nut
9
Nut
33
Test point (TP14)
59
Printed circuit board
60
Washer, flat
61
Washer, lock
10
Washer, lock
34
Test point (TP13)
11
Washer, flat
35
Test point (TP12)
12
Spacer
36
Nut
62
Nut
63
Washer flat insulating
13
Cover, chassis
37
Washer, lock
14
Chassis
38
Nut
64
Terminal solder
15
Washer, flat
39
Washer, tab
65
Screw
16
Washer, flat
40
Nut
66
Washer, flat
17
Screw
41
Washer, tab
67
Resistor (R3)
18
Deleted
42
Screw
68
Diode (CR1)
19
Screw
43
Washer, flat
69
Resistor (R1)
20
Test point (TP4)
44
Screw
70
Screw
21
Test point (TP2)
45
Washer, flat
71
Washer, lock
22
Test point (TP1)
46
Standoff
72
Washer, flat
23
Test point (TP5)
47
Standoff
73
Terminal board Assy
24
Test point (TP6)
48
Deleted
74
Resistor
49
Connector
75
Terminal, solder lug
50
Washer, lock
76
Screw
6-109
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
F. POWER SUPPLY TEST FIXTURE DISASSEMBLY AND REASSEMBLY (figs. 6-35 and 6-36)
Remove four screws which secure bottom cover to chassis.
NOTE
Use figure 6-35 for location of required component and then refer to
callouts across from instruction.
Removal and Replacement of a Power Resistor
Label and unsolder leads from
resistor terminals 1 and 2.
Remove two screws (1), washer
(2) and attaching hardware (3)
and (4).
Remove resistor (5).
Mount and re-attach hardware
(3) and (4) and tighten screws
(1) into place.
Identify leads and solder
into place.
and Replacement of Potentiometer (typical)
Label and unsolder wires from
potentiometer R31 (20) or R32
(21) as required.
Loosen setscrew (2) and remove
dial (3).
Remove nut (4) and locating
washer (5).
Remove potentiometer (1).
Mount potentiometer and
place into position using
locating washer (5).
Replace nut (4) and
tighten.
Replace dial (3) and
tighten setscrew (2).
Identify wires and solder
into place.
6-110
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Rotary Switch (33).
Label and unsolder leads from rotary
switch.
Loosen setscrew in knob (1) and remove
knob.
Remove nut (2) and lockwasher (3). Remove
switch (4).
Mount switch in position with lockwasher (3) and tighten nut (2).
Replace knob (1) and tighten setscrew.
Identify leads and solder into place.
Removal and Replacement of a Toggle Switch (typical).
Label and unsolder wires from toggle
switch as applicable.
Remove nut (1), lockwasher (2) and
remove switch (3).
Mount switch (3) and replace hardware
(2) and (1); tighten into position.
Identify wires and solder into place.
6-111
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of a Test Point (typical).
● Label and unsolder wire from test
point (1) as required.
● Remove nuts (2), (3), washers (4) and (5)
and spacer (6).
● Remove test point.
● Mount test point into position and
replace hardware (6), (5) and (4).
● Replace nuts (3) and (2) and tighten
into place.
● Solder wire into place.
Removal and Replacement of Capacitor C1.
Label two wires atached to capacitor
C1(1).
Remove two screws connecting wires
to C1.
Remove screws (3) and washer (4)
from attaching hardware (5), (6),
(7), and clamp (8).
Remove capacitor and clamp from
chassis.
Remove capacitor from clamp.
Place capacitor into clamp.
Replace hardware (8), (7), (6),
and (5).
Secure into place with washer
(4) and screw (3).
Replace two screws and connecting
wires.
6-112
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Removal and Replacement of Lamp DS1 Assembly.
Label wires on terminals of lamp
DS1 (1).
Unsolder and remove wires.
Remove nut (2) and washer (3).
Remove DS1 from lens.
Replace lamp assembly into
mounting hole.
Secure into position with
washer (3) and nut (2).
Solder wires to terminals.
Removal and Replacement of LED DS2 Assembly.
● Label and unsolder wires on LED
DS2 (1).
● Unscrew threaded bushing (2).
● Remove sleeve (3).
● Remove DS2.
● Replace lamp assembly into
mounting hole.
● Secure into position with
hardware (3) and (2).
● Identify wires and solder into
place.
6-113
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Printed Wiring Board A1 Removal and Replacement.
• Unplug cable connector from receptacle on printed wiring board A1 (refer
to figure on page 3-69).
Remove four screws (1), lockwashers
(2), flat washer (3) and spacer (5).
Remove printed wiring board (4).
• Replace printed wiring board.
Secure into position with
hardware (5), (3), (2), and (1).
Plug cable connector into
connector on printed wiring
board.
Removal and Replacement of Terminal Block TB1.
● Label and remove all connecting
wires from terminal block TB-1 (1).
● Remove four screws (2), washers (3),
and nuts (4) on each end of block.
● Remove terminal block.
● Position terminal block into
position.
● Secure into place using hardware
(4), (3) and (2).
● Connect all wires to their
appropriate terminals.
Removal and Replacement of Card Mounting Assembly.
• Use figure 6-36 and part description list for removal and disassembly of the
card mounting assembly located on top of the power supply test fixture.
• Reassemble card mounting assembly using figure 6-36 and replace on top
of the power supply test fixture.
6-114
Figure 6-35.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-115
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-35. LEGEND
No.
Part Description
No.
Part Description
1
Printed Wiring Board (A1)
26
Test Point (TP13)
2
Resistor (R21)
27
Test Point (TP10)
3
Resistor (R20)
28
Test Point (TP12)
4
Switch (S1)
29
Test Point (TP9)
5
Test Point (TP3)
30
Test Point (TP11)
6
Switch (S2)
31
Test Point (TP8)
7
Test Point (TP2)
32
Resistor (R47)
8
Resistor (R2)
33
Switch (S11)
9
Test Point (TP1)
34
Resistor (R8)
10
Switch (S3)
35
Resistor (R15)
11
Resistor (R3)
36
Capacitor (C1)
12
Switch (S7)
37
Resistor (R16)
13
Resistor (R4)
38
Switch (S9)
14
Switch (S6)
39
Switch (S10)
15
Resistor (R12)
40
Switch (S13)
16
Resistor (R11)
41
Resistor (R36)
17
Resistor (R20)
42
Resistor (R34)
18
Switch (S4)
43
Resistor (R35)
19
Switch (S5)
44
Test Point (TP7)
20
Potentiometer (R31)
45
LED (DS2)
21
Potentiometer (R32)
46
Test Point (TP6)
22
Resistor (R14)
47
Test Point (TP5)
23
Switch (S8)
48
Lamp (DS1)
24
Resistor (R13)
49
Test Point (TP4)
25
Test Point (TP14)
50
Terminal Block (TB1)
6-116
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-36. POWER SUPPLY TEST FIXTURE (CARD MOUNTING ASSEMBLY).
6-117
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-36. LEGEND
6-118
No.
Part Description
1
Screw
2
Washer, flat
3
Washer, lock
4
Nut
5
Screw
6
Screw
7
Screw
8
Base, card guide
9
Guide, card
10
Mounting block, connector
11
Mounting block, connector
12
Mounting block, connector
13
Mounting block, connector
14
Washer, flat
15
Screw
16
Guide, card
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
G. KEYSWITCH TEST FIXTURE DISASSEMBLY AND REASSEMBLY (figs. 6-37 and 6-38)
Ž Remove four screws (1) washers (2) and cover (3).
Removal and Replacement of Test Point(s) (14) through (17) and (24) through (31).
Label and unsolder wire(s) from test point(s) (14) through (17) and (24) though (31)
as required.
Remove attaching hardware (4), (5), (6), (7), (9) from each test point as required.
Remove test point.
Place test point into mounting hole on chassis and secure with attaching
hardware.
Solder wire(s) to their respective test point(s).
Removal and Replacement of Switch S1 (42).
Label and unsolder wires from each terminal of switch S1.
Remove attaching hardware (32), (33) and remove switch.
When reassembling S1 (42), place S1 in chassis (10) with positioning hardware (40), (41) installed on threaded portion of switch.
Install attaching hardware (32), (33) so that tang in washer (33) is properly
alined with alinement hole in chassis.
Tighten nut (32) until 1-2 threads can be seen above shoulder of nut.
Tighten nut until snug.
Identify wires and solder into place.
Removal and Replacement of Terminal Board TB1 (38).
Remove terminal board TB1 (38) by marking and unsoldering leads from each
terminal E1 through E11.
Remove three screws (37), lockwashers (36), and flat washers (35).
Remove TB1.
Place TB1 into position and secure with flat washers, lockwashers and
screws.
Solder leads to their respective terminals.
6-119
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-120
Figure 6-37.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-37. LEGEND
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part Description
No.
Part Description
Screw
Washer, flat
Cover, chassis
Nut, hex plain
Nut, hex plain
Washer, lock
Washer, flat
Nut, sheet spring U-type
Spacer
Chassis
Washer, flat
Screw, mech. pnh
Grommet
Test point (TP1)
Test point (TP2)
Test point (TP12)
Test point (TP3)
Nut, hex plain
Washer, lock
Washer, flat
Screw, mech. pnh
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Backshell
Connector (P1)
Test point (TP7)
Test point (TP6)
Test point (TP11)
Test point (TP5)
Test point (TP10)
Test point (TP9)
Test point (TP8)
Test point (TP4)
Nut
Washer, tab
Standoff
Washer, flat
Washer, lock
Screw, math. pnh
Circuit card (TB1)
Terminal
Washer, lock
Nut
Switch, pushbutton (S1)
6-121
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-38. KEYBOARD TEST FIXTURE, TB1.
6-122
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Section Vlll. TEST FIXTURE TEST PROCEDURES
6-34. GENERAL
The following test procedures are used to verify proper operation of the respective test fixtures. Because of the simplicity of some of the test fixtures, test procedures may be limited to a
continuity test. Others will require normal electronic maintenance test equipment and procedures.
TEST PROCEDURES
A.
B.
C.
D.
E.
F.
G.
FILTER ASSEMBLY TEST FIXTURE
HAMMER DRIVER MODULE TEST FIXTURE
HAMMER MODULE TEST FIXTURE
INTERFACE ASSEMBLY TEST FIXTURE
LINE-FEED/CURRENT CONTROL TEST FIXTURE
POWER SUPPLY TEST FIXTURE
KEYSWITCH ASSEMBLY TEST FIXTURE
TOOLS REQUIRED FOR TESTS
Nomenclature
Multimeter AN/USM-223
Oscilloscope AN/USM-281C
Power Supply PP-2309/U (6 required)
Frequency Counter AN/USM-207
NOTE
Perform all continuity tests with Multimeter AN/USM-223 unless otherwise
stated. Be sure all input power to test fixture is OFF.
6-35. TEST PROCEDURES
A.
●
●
●
●
●
FILTER ASSEMBLY TEST FIXTURE TEST PROCEDURES (fig. 6-39)
Test fixture provides an interface between the prime power inputs and the filter
assembly. Fuse protection, ON/OFF power control, and test points are provided.
Refer to table 6-19 and filter assembly test fixture schematic and perform continuity
tests of each wire.
Resistance in each case shall be less than 1 ohm.
Connect ohmmeter across TP1 and TP2 and measure 30 ohms ± 5 %.
Connect ohmmeter across TP2 and TP3 and measure 30 ohms± 5 %.
6-123
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-19. FILTER ASSEMBLY TEST FIXTURE WIRE LIST
6-124
Change 1
Figure 6-39.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-125
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
B. HAMMER DRIVER MODULE TEST FIXTURE TEST PROCEDURES (fig. 6-40)
Test fixture provides interface and control signals for the hammer driver module.
Refer to table 6-20 and hammer driver module test fixture schematic and perform continuity tests of each wire.
Place ohmmeter across S1 and measure continuity as follows:
Position IN1 - S1-4 to S1-2 less than 1 ohm
S1-3 to S1-6 less than 1 ohm
Position IN2 - S1-4 to S1-1 less than 1 ohm
S1-3 to S1-5 less than 1 ohm
Place ohmmeter across TP4 to TP6, and TP5 to TP6 and measure 100 ohms ±5%.
Table 6-20. HAMMER DRIVER MODULE TEST FIXTURE WIRE LIST
6-126
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-40.
HAMMER DRIVER TEST FIXTURE, SCHEMATIC DIAGRAM.
6-127
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
C. HAMMER MODULE TEST FIXTURE TEST PROCEDURES (fig. 6-41)
●
●
●
Test fixture provides an interface for input power and control signals required by the
hammer module.
Refer to table 6-21 and hammer module test fixture schematic and perform continuity
test of each wire.
Place ohmmeter across each switch and verify its operation.
Table 6-21.
6-128
Change 1
HAMMER MODULE TEST FIXTURE WIRE LIST
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-41.
HAMMER MODULE TEST FIXTURE. SCHEMATIC DIAGRAM.
Change 1
6-129
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
D. INTERFACE ASSEMBLY TEST FIXTURE TEST PROCEDURES (fig. 6-42)
●
●
●
●
Test fixture provides interconnections between the unit under test and the required
test equipment.
Perform test point resistance tests of each wire in accordance with table 6-22.
Perform switch continuity tests in accordance with table 6-23.
Use interface assembly test fixture schematic during both tests.
Table 6-22. INTERFACE ASSEMBLY TEST FIXTURE TEST POINT RESISTANCE TESTS
6-130
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-23.
INTERFACE ASSEMBLY TEST FIXTURE SWITCH CONTINUITY TESTS
6-131
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure 6-42. INTERFACE ASSEMBLY TEST FIXTURE SCHEMATIC.
6-132
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
E. LINE-FEED/CURRENT CONTROL TEST FIXTURE TEST PROCEDURES (fig. 6-43)
Test fixture provides interconnections between the external test equipment and the Line
Feed/Current Control unit under test. The test fixture also provides input signal selection capability and loads for unit under test outputs.
Refer to table 6-24 and line-feed/current control test fixture schematic and perform continuity tests of each wire.
Table 6-24. LINE-FEED/CURRENT CONTROL TEST FIXTURE INPUT
RESISTANCE MEASUREMENTS
6-133
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-134
Figure 6-43.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
F. POWER SUPPLY TEST FIXTURE TEST PROCEDURES (fig. 6-44)
●
●
●
Test fixture provides interconnections between unit under test and external test
equipment. It also provides simulation and load circuitry for calibration of the unit under
test.
Refer to tables 6-25 and 6-26 and perform continuity and resistance checks as listed.
Refer to power supply test fixture schematic, figure FO-10.
Table 6.25. POWER SUPPLY TEST FIXTURE CONTINUITY CHECKS
Table 6-26.
POWER SUPPLY TEST FIXTURE RESISTANCE CHECKS
Change 1
6-135
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Table 6-26. POWER SUPPLY TEST FIXTURE RESISTANCE CHECKS . Continued
6-136
Change 1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
NOTE
Oscilloscope AN/USM-281C and six power supplies PP-2309/U are required
for the following test procedures:
Set up test fixture supplies as shown in figure 6-44.
Do not insert power supply module SM-D-915606 (power supply for the AN/UGC-74A(V)3).
Place SELECT switch to position 11 (drum motor) and connect a +10 Vdc power supply (place a
jumper between V OUT LOW andGND) to TP9 (+) and TP12 (-).
Turn power supplies on and check voltages.
Touch multimeter leads to TP12 and U2-5 and monitor dc voltage as R23 is adjusted. Adjust R23
for 7 to 8 Vdc as observed on multimeter.
Observe input pin (5) of U3. Readjust R23 for 13.5 Vdc.
Connect frequency counter to U3-3 and GND, and adjust R27 for a frequency count of 925 + 15
HZ. Connect oscilloscope to U3-3 and observe a square wave having a period of 1.08 msec
±.015 ms.
Connect a 1 K ohm, 1/4 W resistor from SCMO HI (TP10) to +5 Vdc (TP6).
Connect an oscilloscope to SCMO HI and SCMO LO and observe output waveform as R46 is
adjusted. Adjust R46 until positive pulse is 518 ±3 usec with a total period of 1080 ±15 usec.
Remove the 1 K ohm, 1/4 W resistor from SCMO HI and TP6.
Remove 10 Vdc from V OUT-LO and V OUT-HI.
Adjust power supply for 15 Vdc.
Place SELECT switch to position 10.
Apply +15 Vdc to J2 pin 1 (+) lead and J2 pin 28 (-) lead on fixture and observe DS1 (BAT) lights
(NOTE: Do not remove GND from V OUT LO to GND).
Remove +15 Vdc from J2 pin 1 and J2 pin 28.
Adjust power supply for +5 Vdc.
Place SELECT switch in position 3.
Apply +5 Vdc to V OUT-HI and V OUT-LO on fixture and observe DS2 (CAP V OK) lights.
In the event of failure in any one of the above steps, refer to theory of operation in chapter 3 of
this manual and troubleshoot as required.
Remove all test equipment and power supply connections to test fixture.
Change 1
6-137
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
6-138
Figure 6-44.
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
G. KEYSWITCH ASSEMBLY TEST FIXTURE TEST PROCEDURES (fig. 6-45 and 6-46)
Test fixture provides signal and power interfaces between the external test equipment
and the keyswitch assembly under test.
NOTE
Oscilloscope AN/USM-281C and Power Supply PP-2309/U are required for
the following test procedures.
Set up the test fixture as shown in figure 6-45 with the exception of the connection to
the keyswitch assembly.
Connect + 5Vdc to + 5V and GND and monitor voltage at TP4 (CLK) with respect to
TP12 (GND).
Observe that voltage changes from GND to 5Vdc whenever CLOCK CONTROL
switch is depressed (oscilloscope connected across TP4).
Connect TP4 (CLK) to TP1 (SIG IN) with a jumper wire and observe that TP5 (2400 Hz)
changes state each time CLK CONTROL switch is depressed.
Also observe that TP5 is inverse of TP4.
Measure 1.5Vdc ±10% at TP8 (CLK REF) and TP9 (2400-Hz REF).
Measure + 5Vdc ±10% at TP3 (PRESENT).
Connect P1-12 to TP12 (ground) and observe TP3 for 2.5Vdc +10%.
In the event of failure in any one of the above steps, refer to keyswitch assembly test
fixture schematic (fig. 6-46), and theory of operation in chapter 3 of this manual and
troubleshoot as required.
Change 1
6-139
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Figure 6-45.
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Figure 6-46.
KEYSWITCH ASSEMBLY TEST FIXTURE, SCHEMATIC DIAGRAM.
6-141/6-142 blank
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APPENDIX A
REFERENCES
A-1. SCOPE
This appendix lists all forms, technical manuals, and miscellaneous publications referenced in
this manual.
A-2. FORMS
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . .
Transportation Discrepancy Repin.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Report of Discrepancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DA Form 2404
SF 361
SF 364
SF 368
A-3. TECHNICAL MANUALS
Operators Manual: Terminal, Communications AN/UGC-74A(V)3
(NSN 5815-01-062-8194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organizational Maintenance Repair Parts and Special Tools Lists for
Terminal, Communications, AN/UGC-74A(V)3 (NSN 5815-01-062-8194)
Direct Support and General Support Maintenance Repair Parts and
Special Tools Lists (Including Depot Maintenance Repair Parts
and Special Tools) for Terminal, Communications, AN/UGC-74A(V)3
(NSN 5815-01-062-8194), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator, Organizational, Direct Support, and General Support
Maintenance Manual Including Repair Parts and Special Tools
Lists: Power Supply PP-2309B/U (NSN 6130-00-752-2215) . . . . . . . . . . . . . . . .
Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual: Signal Generators SG-299/U
(NSN 6625-00-624-3516); SG-299A/U (6625-00-897-0060); SG-299B/U
(6625-00-916-8541); SG-299WU (6625-00-765-6656) and SG-299E/U. . . . .
Operator’s, Organizational, Direct Support and General Support
Maintenance Repair Parts and Special Tools Lists (Including Depot
Maintenance Parts and Special Tools List) for Multimeter,
AN/USM-223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator and Organizational Maintenance Manual (Including Repair Parts
and Special Tools List): Test Sets, Telegraph AN/GGM-15(V)1,
(NSN 6625-00-464-1702) and AN/GGM-15(V)2 (6625-00-442-6131). . . . . .
Operator’s, Organizational, Direct Support, General Support, and Depot
Maintenance Manual: Oscilloscope AN/USM-281A (NSN
6825-00-228-2201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure for Destruction of Electronics Materiel to Prevent Enemy
Use (Electronics Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4.
TM 11-5815-602-10
TM 11-5815-602-20P
TM 11-5815-602-34P
TM 11-6130-245-14-1
TM 11-6625-258-14
TM 11-6625-654-14
TM 11-6625-1668-12
TM 11-6625-1703-15
TM 750-244-2
MISCELLANEOUS PUBLICATIONS
Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . .
The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . .
Painting and Preservation of Supplies Available for Field Use for
Electronics Command Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Instructions for Painting and Preserving Electronics Command
Equipment Including Camouflage Pattern Painting of Electrical
Equipment Shelters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DA PAM 25-30
DA Pam 738-750
SB 11-573
TB 43-0118
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APPENDIX B
MAINTENANCE ALLOCATION
Section I. INTRODUCTION
B-1.
General
This appendix provides o summary of the maintenance operations for the AN/UGC-74A(V)3. It authorizes
categories of maintenance for specific maintenance functions on repairable items and components ond the
tools and equipment required to perform each function. This appendix may be used as an oid in planning
maintenance operations.
B-2. Maintenance Function
Maintenance functions will be limited to and defined as follows:
a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination.
b. Test. To verify serviceability and to detect incipient failure by measuring the mechanical or electrical
characteristics of an item and comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean
(decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air supplies.
d. Adjust. To maintain, within prescribed limits, by bringing into proper or exact position, or by setting
the operating characteristics to the specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
f. Calibrate. To determine and cause corrections to be made or to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any
discrepancy in the accuracy of the instrument being compared.
g. Install. The act of emplacing, seating, or fixing into position an item, part, module (component or
assembly) in a manner to allow the proper functioning of the equipment or system.
h. Rep/ace. The act of substituting a serviceable like type part, subassembly, or module (component or
assembly) for an unserviceable counterpart.
i. Repair. The application of maintenance service (inspect, test, service, adjust, align, calibrate, replace)
or other maintenance actions (welding, grinding, riveting, straightening, facing, remachining, or resurfacing) to restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part,
subassembly, module (component or assembly), end item, or system.
j . Overhaul. That maintenance effort (service/action) necessary to restore an item to a completely serviceable/operational condition as prescribed by maintenance standards (i. e., DMWR) in appropriate
technical publications. Overhaul is normally the highest degree of maintenance performed by the Army.
Overhaul does not normally return an item to like new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment
to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of
materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to
zero those age measurements (hours, miles, etc. ) considered in classifying Army equipment/components.
B-1
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B-3. Column Entries
a. Column 1, Group Number. Column 1 lists group numbers, the purpose of which is to identify components, assemblies, subassemblies, and modules with the next higher assembly.
b. Column 2, Component/Assembly. Column 2 contains the noun names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
c. Column 3, Maintenance Functions. Column 3 lists the functions to be performed on the item listed in
column 2. When items are listed without maintenance functions, it is solely for purpose of having the group
numbers in the MAC and RPSTL coincide.
d. Column 4, Maintenance Category. Column 4 specifies, by the listing of a “work time” figure in the appropriate subcolumn(s), the lowest level of maintenance authorized to perform the function listed in column
3. This figure represents the active time required to perform that maintenance function at the indicated
category of maintenance. If the number or complexity of the tasks within the listed maintenance function
vary at different maintenance categories, appropriate “work time” figures will be shown for each category.
The number of task-hours specified by the “work time” figure represents the average time required to
restore an item (assembly, subassembly, component, module, end item or system) to a serviceable condition
under typical field operating conditions. This time includes preparation time, troubleshooting time, and
quality assurance/quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. Subcolumns of column 4
are as follows:
Operator/Crew
Organizational
Direct Support
General Support
Specialized Repair Activity
Depot
NOTE
If the SRA in your geographical area does not have the capability for the “L”
maintenance functions listed in the MAC, or if there is not SRA in your
geographical area, utilize existing procedures for obtaining depot accomplishment of the “L” maintenance functions,
e. Column 5, Tools and Equipment. Column 5 specifies by code, those common tool sets (not individual
tools) and special tools, test, and support equipment required to perform the designated function.
f. Column 6, Remarks. Column 6 contains an alphabetic code which leads to the remarks in section IV,
Remarks, which is pertainent to the item opposite the particular code.
B-2
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B-4. Tool and Test Equipment Requirements (Sect. III)
a. Tool or Test Equipment Reference Code. The numbers in this column coincide with the numbers used in
the tools and equipment column of the MAC. The numbers indicate the applicable tool or test equipment for
the maintenance functions.
b. Maintenance Category. The codes in this column indicate the maintenance category allocated the tool
or test equipment.
c. Nomenclature. This column lists the noun name and nomenclature of the tools and test equipment required to perform the maintenance functions.
d. National/NATO Stock Number. This column lists the National/NATO stock number of the specific tool
ar test equipment.
e. TOOI Number. This column lists the manufacturer’s part number of the tool followed by the Federal
Supply Code for manufacturers (5-digit) in parentheses.
B-5. Remarks (Sect. IV)
a. Reference Code. This code refers to the appropriate item in section II, column 6.
b. Remarks. This column provides the required explanatory information necessary to clarify items appearing in section II.
B-2.1/(B-2.2 blank)
Section II.
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B-3
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B-4
Section II.
Section II.
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B-6
Section II.
Section II.
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B-7
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B-8
Section II.
Section III.
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B-9
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B-10
Section III.
Section III.
B-11
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B-12
Section III.
Section IV.
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APPENDIX C
EXPENDABLE SUPPLIES AND MATERIALS LIST
Section I.
Introduction
C-1. Scope
This appendix lists expendable supplies and materials you will need to operate and maintain the AN/UGC74A(V)3. These items are authorized to you by CTA 50-970, Expendable Items (Except Medical, Class V,
Repair Parts, and Heraldic Items).
C-2. Explanation of Columns
a. Column 1 — Item Number. This number is assigned to the entry in the listing and is referenced in the
narrative instructions to identify the material (e. g., “Use cleaning compound, item 5, App. D“).
b. Column 2 — Level. This column identifies the lowest level of maintenance that requires the listed
item.
Operator/Crew
Organizational Maintenance
Direct Support Maintenance
General Support Maintenance
c. Column 3 — National Stock Number. This is the National stock number assigned to the item; use it to
request or requisition the item.
d. Column 4 — Description. Indicates the Federal item name and, if required, a description to identify
the item. The last line for each item indicates the part number followed by the Federal Supply Code for
Manufacturer (FSCM) in parentheses, if applicable.
e. Column 5 — Unit of Measure (U/M). Indicates the measure used in performing the actual
maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e. g., ea, in,
pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy
your requirements.
C-1
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Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
C-2
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APPENDIX D
ERROR MESSAGE LIST
Message Number
Message
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GLOSSARY
Section I. ABBREVIATIONS
TTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistor-Transistor Logic
PIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Interface Adapter
USART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Synchronous Asynchronous
Receiver Transmitter
EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Interface
RFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Frequency Interface
KSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Send-Receive
ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read-OnlyMemory
ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intelligent Communication Terminal
RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Random Access Memory
SCA R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silicon Controlled Rectifier
SCMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Control Motor Output
EMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Pulse
DMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Memory Access
ETI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elapsed Time Indicator
Section II.
DEFINITIONS OF UNUSUAL TERMS
ADDRESS - A character or group of characters that identifies a register, aparticular partof
storage, or some other data sourceor destination.
ASCII -American Standard Code for Information Interchange; acode which relates 96 displayed
characters (64 without lower case) and 32 nondisplayed control characters toa sequenceof 7 on
or off choices.
BUFFER -A storage device in which data preassembled temporarily during data transfers. Itis
used to compensate for a difference in the rate of flow of informationor the time occurrence of
events when transferring information from one device to another.
BUS. - 1. A circuit over which data or power is transmitted. Often one which acts as acommon
connection among anumberof Locations (synonymous with trunk). 2. A path over which informs
tion is transferred from any of several sources to any of several destinations. 3. One or more conductors used for transmitting signals or power.
CENTRAL PROCESSING UNIT - A unit of a computer that includes the circuits controlling the interpretation and execution of instructions (synonymous with main frame). Abbreviated CPU.
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GLOSSARY - Continued
CLOCK -1. That specific device or unit designed to time events. 2. A data communications clock
which controls the timing of the sampling of bits received in a data stream.
CLOCK PULSE - A synchronization signal provided by a clock.
DATA PROCESSING - A generic term for all the operations carried out according to precise rules
or procedures.
FLIP FLOP CIRCUIT - An electronic circuit having two stable states, one input line and one output line such that as each successive pulse is received, the output line changes between two
alternative conditions; e.g., high-to-low or off-to-on.
FLIP-FLOP D-D - Stands for delay. A flip flop, the output of which is a function of the input which
appeared one pulse earlier; for example, if a 1 appeared at the input, the output after the next
clock pulse will be a 1.
RADIO FREQUENCY INTERFERENCE (RFI). Interference; i.e., unwanted interference of electromagnetic radiation of radio frequency signals into operating circuits.
REGISTER INPUT BUFFER - A device that receives data from input devices and then transfers it
to internal computer storage.
REGISTER, SHIFT - The computer register capable of shifting data as directed.
REGULATION, LOAD - A deviation from steady-state of the controlled variable when the set point
is fixed. Such an offset resulting from a no-load to a full-load change (or other specified limits) is
often called an offset deviation or droop.
REGULATION, VOLTAGE - A measure of the degree to which an electrical power source maintains its output voltage stability under varying load conditions, with regulation given in percents.
SCRATCH PAD - A useful and informal term referring to or designating a unique internal storage
area, designed to be reserved for intermediate results, various notations, or working area. It is a
quickly erasable main storage.
Glossary-2
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INDEX
SUBJECT
A
Adjustments
Direct Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
General Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Organizational Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Assemblage Modification Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
AudioTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
B
Battery Backup
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25,6-74
Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
C
CPU Circuit Card Assembly (3A1A1)
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Assembly
Disassemblyand Reassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
Circuit Card Assemblies
CPU (3A1A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . .
Communications (3A1A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory (3A1A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MotorDrive(Line Feed)andCurrent Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Control (3A1A4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CommonTools(OrganizationalMaintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications Circuit Card Assembly (3A1A3)
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ContinuityTests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
5-14
5-56
6-5
3-8
3-10
3-9
3-25
3-11
5-14,5-21
4-15
4-1
3-10
5-14
5-3
Index-1
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SUBJECT
INDEX . Continued
PAGE
D
Data Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Data(Receive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Data(Transmit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Direct Support Maintenance
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Disassembly and Reassembly
Direct Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
General Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Test Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Drum Motor
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-74
Drum Motor BrushesRemovaland Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Dustcover Assembly
Disassemblyand Reassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Parity Reset Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
E
Elapsed Time Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Equipment improvement Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Equipment inspection and Maintenance Worksheet(DA Form 2404) . . . . . . . . . . . . . . . . 4-7
F
Filter Assembly
Disassemblyand Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Function . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-44
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-78
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Index-2
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
SUBJECT
INDEX - Continued
PAGE
F
Filter Assembly Test Fixture
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Forms (Maintenance), Recordsand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Final Inspection Procedures (Organizational Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Final Test(General Support Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Functional Description of Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
G
General Support Maintenance
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Disassemblyand ReassemblyofTerminal Components . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Disassemblyand Reassembly ofTest Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Test Procedures forGeneralSupport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Test Procedures forTest Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
H
Hammer Driver
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Hammer Driver Test Fixture
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
Hammer Module
Disassemblyand Reassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Hammer Module Test Fixture
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
Index-3
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INDEX - Continued
SUBJECT
H
Harness Assembly
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
I
initial Communication Testwith Distant Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Tests
Distant Station Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop BackTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PreliminaryChecks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface Assembly
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface Assembly Test Fixture
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
internal Processing oh m........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-26
2-5
2-26
2-13
2-22
2-12
2-18
2-5
5-67,6-49
5-9
3-36
4-19
5-15
6-62
6-14
6-100
3-80
6-130
3-6
3-6
K
Keyboard Assembly (of Keyboard Keyswitch Assembly)
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyboard Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyboard Keyswitch Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Keyswitch Assembly (of Keyboard Keyswitch Assembly)
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyswitch Assembly Test Fixture
Disassemblyand Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index-4
5-78
3-15
3-4
5-33
6-35
6-80
6-26
6-119
3-83
6-139
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INDEX - Continued
PAGE
SUBJECT
L
LampTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Feed Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Feed (Motor Drive) and Current Control Circuit Assembly
see Motor Drive and Current Control Circuit Assembly
Line Feed (Motor Drive) and Current Control Test Fixture
see Motor Drive and Current Control Test Fixture
Local lnstaller’s Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logic Box CoverAssembly Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop BackTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Paper Alarm Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-90
3-7
2-13
1-4
6-34
2-22,5-89
4-31
4-21
M
Maintenance Forms, Records and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Memory Circuit Card Assembly (3A1A2)
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
Modification Work Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Motor Drive (Line Feed) and Current Control Circuit Assembly
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91,6-60
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Motor Drive (Line Feed) and Current Control Test Fixture
Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-133
N
Nomenclature Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
O
Organizational Maintenance
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Index-5
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INDEX - Continued
SUBJECT
PAGE
O
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
P
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Painting . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Paper Exit Bracket Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Paper Low Sensing Mechanism Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . 6-46
Paper Out Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Paper Roll Support Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Paper Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Power Cable Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Power Source (lnstallation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Power Supply Assembly
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10,6-70
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Power Supply Test Fixture
Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Preliminary Checks (lnstallation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Preliminary Test (Direct Support Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3,4-36
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Print Hammer Driver Module
see Hammer Driver
Print Hammer Module
see Hammer Module
Printer Assembly
Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38,6-36
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24,3-45
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Index-6
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INDEX - Continued
SUBJECT
PAGE
P
Printer Control (Logic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Printer Control Circuit Card Assembly (3A1A4)
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Printer Harness Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Printer Subassembly
Alinement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41,6-43
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Processing Logic Card Assemblies
see Circuit Card Assemblies
Q
Quality Deficiency Report (SF 368). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
R
Receive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Records and Reports (Organizational Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal and Replacement
Direct Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
General Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Organizational Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Repair Parts (Organizational Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reporting Equipment Improvement Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Reports and Records (Organizational Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Resistance and Voltag Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Ribbon Mechanism
Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Feed Mechanism Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
Lifts Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Release Solenoid Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Reversing Extension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Reversing Sensing Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Sensing Lever Spring Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Slip Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Index-7
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INDEX - Continued
SUBJECT
PAGE
S
1-4
Safety, Care and Handling
1-3
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Special Tools
Direct Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
General Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Organizational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Storage and Shipment (Preparation for) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3,4-36
System (AN/UGC-74A(V)3)
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Logic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
T
Terminal Test
Test Equipment
see Tools and Test Equipment
Test Fixtures
Disassembly and Reassembly
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures
Direct Support Maintenance . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Support Maintenance . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Mechanism
Adjustment . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and Test Equipment
Direct Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organizational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Direct Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Support Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organizational Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index-8
5-89
6-87
3-53
6-123
5-89
6-54
2-12
6-123
5-82
5-24
5-4
6-4
2-5
4-1
5-91
3-7
5-5
6-5
4-10
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
INDEX - Continued
PAGE
SUBJECT
U
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
V
Voltage and Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
W
Wire List
Filter Assembly Test Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56,6-124
Hammer Driver ModuleTest Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60,6-126
Hammer ModuleTest Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63,6-128
Keyswitch Assembly Test Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Line-Feed/Current Control Test Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Power Supply Test Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Index-9/Index-10 blank
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
FOLDOUT INDEX
FOLDOUT INDEX
FO-1
Color Code Marking for Military Standard Capacitors (Sheet 1 of 2)
FO-1
Color Code Marking for Military Standard Capacitors (Sheet 2 of 2)
FO-2
Interface Assembly, Schematic Diagram
FO-3
Power Supply Input, Schematic Diagram
FO-4
Microprocessor Supply
FO-5
+5, ±8.6Vdc Supply
FO-6
Drum Motor Supply
FO-7
+18Vdc Constant Current Supply
FO-8
R41 and R71 Test Connections
FO-9
AN/UGC-74 Interconnect Diagram (Sheet 1 of 2)
FO-9
AN/UGC-74 Interconnect Diagram (Sheet 2 of 2)
FO-10
Power Supply Test Fixture, Schematic Diagram
FO-11
Drum Motor Simulator Test Fixture, Schematic Diagram
F.O. Index-1/F.O. Index-2 blank
COLOR CODE MARKING FOR MILITARY STANDARD CAPACITORS
TM 11-5815-602-24
TO 31W4-2UGC74-2
GROUP I
TABLE I
GROUP II
TABLE II
TABLE III
GROUP III
Figure FO-1 Color Code Marking for Military Standard Capacitors (Sheet 1 of 2).
TM 11-5815-602-24
TO 31W4-2UGC74-2
TABLE 1
TABLE 2
Figure FO-1
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure FO-2
TM 11-5815-602-24
TO 31W4-2UGC74-2
Figure FO-4
TM 11-5815-602-24
TO 31W4-2UGC74-2
Figure FO-5
TM 11-5815-602-24
TO 31W4-2UGC74-2
Figure FO-6
TM 11-5815-602-24
TO 31W4-2UGC74-2
Figure FO-7
TM 11-5815-602-24
TO 31W4-2UGC74-2
Figure FO-8
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure FO-9
TM 11-5815-602-24
TO 31W4-2UGC74-2
Figure FO-10
TM 11-5815-602-24
EE161-DM-MMM-010/E154UGC74
TO 31W4-2UGC74-2
Figure FO-11
By Order of the Secretaries of the Army, the Navy and the Air Force:
JOHN A. WICKHAM JR.
General, United States Army
Chief of Staff
Official:
ROBERT M. JOYCE
Major General, United States Army
The Adjutant General
G. B. SCHICK, JR.
Rear Admiral, United States Navy
Commander, Naval Electronics
Systems Command
Official:
JAMES P. MULLINS
General, USAF, Commander, Air Force
Logistics Command
CHARLES A. GABRIEL
General, USAF
Chief of Staff
DISTRIBUTION:
To be distributed in accordance with DA Form 12-51A-1,
Organizational Maintenance requirements for AN/UGC-74(V)4.
THE METRIC SYSTEM AND EQUIVALENTS
PIN: 054666-001
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