Maintenance Manual: MANUAL NUMBER 006-15545-0002 REVISION 2, December, 1999
Maintenance Manual: MANUAL NUMBER 006-15545-0002 REVISION 2, December, 1999
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MAINTENANCE MANUAL
KT 76C
ATCRBS
TRANSPONDER
COPYRIGHT NOTICE
SECTION IV
THEORY OF OPERATION
PARAGRAPH PAGE
4.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 CIRCUIT THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.1 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.2 LOCAL OSCILLATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.3 RF AND IF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.4 VIDEO DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.5 ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.6 MICROCONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.7. ALTITUDE AND SUPPRESSION INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.2.8. DISPLAY CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
SECTION V
MAINTENANCE
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 TEST AND ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.1 TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.2 ALIGNMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.3 TEST SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.4 MINIMUM PERFORMANCE UNDER STANDARD CONDITIONS . . . . . . . . . . . . . 5-5
5.3 OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.2 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3.3 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.3.4 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
SECTION VI
ILLUSTRATED PARTS LIST
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Revision Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.4 Sample Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 KT 76C FINAL ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.6 KT 76C BEZEL ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
MMKT76CR2.JA Page i
Rev 2, Dec/1999
BENDIX/KING
KT 76C ATCRBS TRANSPONDER
SECTION VI
ILLUSTRATED PARTS LIST (cont.)
PARAGRAPH PAGE
6.7 KT 76C DISPLAY/BUTTON BD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.8 KT 76C FILTER/HEATSINK ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
6.9 KT 76C SYSTEM SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
6.9 KT 76C MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6.10 KT 76C CIRCULATOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-227
6.11 KT 76C ROTARY SWITCH BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-239
LIST OF ILLUSTRATIONS
FIGURE PAGE
4-1 ATCRBS TRANSMITTER SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2 INTERROGATION CODING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3 COMPOSITE ANTENNA PATTERN OF THE GROUND STATION . . . . . . . . . . . . . . . 4-3
4-4 CONDITION OF REPLY AND SIDE LOBE SUPPRESSION . . . . . . . . . . . . . . . . . . . . 4-3
4-5A CONTROL HEAD IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-5B REPLY CODING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-6 MAIN BOARD/DISPLAY BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-7 SOFTWARE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
5-1 COMPLETE ATC TEST SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-2 KT 76C General Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-3 KT 76C ASIC Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-4 KT 76C Display Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-5 KT 76C High Voltage Power Supply Troubleshooting Flowchart . . . . . . . . . . . . . . . . 5-17
5-6 KT 76C Receiver Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-7 KT 76C Switching Power Supply Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . 5-21
5-8 KT 76C Transmitter Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
6-1 Sample Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-3 Bezel Assembly (-0000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-4 Bezel Assembly (-0010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Page ii MMKT76CR2.JA
Rev 2, Dec/1999
BENDIX/KING
KT 76C ATCRBS TRANSPONDER
TROUBLESHOOTING AIDS
Final Test Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Waveforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Page iv MMKT76CR2.JA
Rev 2, Dec/1999
BENDIX/KING
KT 76C ATCRBS TRANSPONDER
SECTION IV
THEORY OF OPERATION
4.1 INTRODUCTION
General description of the KT 76C Transponder and its use in the Air Traffic Control Radar Beacon
System:
The KT 76C Transponder is an integral part of the Air Traffic Control Beacon System (ATCRBS).
In the aircraft, its function is to transmit a coded response to a coded interrogation transmitted by
an air traffic control ground radar station.
There are two types of radar at each of these ATC ground stations. The first, called the Primary
Surveillance Radar (PSR), operates on the normal radar principle of receiving energy reflected
from the aircraft under surveillance. The second, called the Secondary Surveillance Radar (SSR),
operates on the coded reply from the airborne transponder. Both radars are used in conjunction
to develop the total air traffic situation and to display it on a single radar scope. A typical air traffic
control ground station is shown in Figure 4-1.
The SSR interrogates the KT 76C in one of two modes. These are referred to as Mode “A” or
Mode “C” interrogations. The type of interrogation is determined by the spacing between two puls-
es transmitted by the SSR on a carrier of 1030 ± .2 MHz. Each interrogation contains a third pulse
at the same frequency which is not transmitted by the SSR but by an omni directional antenna
which is located at the ground radar station. This pulse is transmitted 2 µsec after the first pulse
transmitted by the SSR. Mode “A” and Mode “C” interrogation characteristics are shown in Figure
4-2.
The purpose of P2, the signal from the omni-directional antenna, is to allow the airborne transpon-
der to determine whether the interrogation came from the main beam or a side lobe of the SSR.
If the KT 76C has been interrogated by a side lobe, no reply is generated. A reply to a side lobe
interrogation would give the ground radar operator an erroneous position reading of the aircraft
carrying the transponder. The KT 76C determines by an amplitude comparison between P1 and
P2, if the interrogation is a valid main beam interrogation. If P2 is equal to or larger then P1, the
interrogation is from the side lobe of the SSR. The reason these conditions exist can be explained
with the composite antenna pattern of the ground station as shown in Figure 4-3.
It is seen that the power received from the omni directional antenna is less than the power re-
ceived from the main beam but larger than the power received from any of the side lobes of the
SSR. This is why in a main beam interrogation, P1 is larger than P2; and in a side lobe interroga-
tion, P2 is equal to or larger than P1. The detailed specifications of transponder reply and side
lobe suppression characteristics for the ATCRBS are shown in Figure 4-4.
The KT 76C Transponder replies to both the Mode “A” and Mode “C” interrogations with a coded
pulse group on a carrier of 1090 ± 3 MHz. In a Mode “A” reply, the coding of the pulsed waveform
represents an identification number of the plane carrying the transponder. The identification num-
ber which will be transmitted is entered by means of eight push-button switches. This number con-
sists of four octal digits (0-7) which gives the transponder the capability of 4096 different identifi-
cation numbers. The coding of a Mode “A” reply can consist of up to fifteen pulses. Twelve of
these pulses carry the identification number. Two others, called the framing pulses, come before
and after the twelve information pulses. The last is a special identification pulse to aid the radar
operator. The control head identification numbers and the reply coding characteristics for the full
15 reply pulses are shown in Figure 4-5.
Resistor R461 allows Q45 to shut off in the event that the drive from U30 fails with an “open” con-
dition. Resistor R482 and CR43 controls the switching time of Q45, thus aiding in the reduction
of electromagnetic interference.
The current through Q45 is continuously monitored by U30 through R455. The mirror output of
Q45 provides an output current proportional to the total current flowing through the device (typi-
cally 1/2700 of the device current). Resistor R455 provides a current sense voltage which is fed
through the low pass filter comprised of R437 and C211 to U30. The current sense input to U30
will cut-off Q45 if the current flowing through the device becomes excessive. (Typically 15 amps
peak). This current feedback is active for every switching cycle of the power supply.
The voltage spike generated by transformer T3 when Q45 is shut off is clamped by the snubber
network comprised of CR32, CR26, R547, C213, C269, C270, R546, and CR39.
4.2.1.2.4 Post Regulation
A ringing-choke power supply topology provides good output regulation only for the output moni-
tored by the power supply controller. The remaining outputs are loosely regulated and are affect-
ed by total power supply loading, individual output loading, transformer winding resistance and in-
ductance, the switching speed and forward voltage drop across the rectifier diodes, and other par-
asitic effects. An output that is unloaded will tend to float to a very high and potentially destructive
voltage.
4.2.1.2.5 Secondary Supply
The secondary supply is derived from the +11 V output of the primary supply through a +9 V reg-
ulator, U18. Power is applied through the filter C33, L2, and C40. The filter isolates the primary
supply from the secondary supply’s converter frequency of 20 kHz.
4.2.1.2.6 Oscillator Operation
The 40 kHz clock for this supply is generated by U11-B. Flip-flop U2-A divides the 40 kHz clock
by two and creates two 50% duty cycle 20 kHz clock signals. The 20 kHz clock at U2-A pin 5 is
180 degrees out of phase with the 20 kHz clock at U2-A pin 6. The clock signals from U2-A Pin
5 and U2-A Pin 6 drive U32-D and U32-A respectively. R25, R26 and C20 provide a feed back
signal and time constant from Q3 to ensure that Q1 is not turned on at the same time Q3 is on.
Conversely, R17, R18 and C19 provide a feed back signal and time constant from Q1 to ensure
that Q3 is not turned on at the same time Q1 is on. T1 has a split primary that is driven by Q1 and
Q3.
4.2.1.2.7 Output Voltages
The +17 V output is derived from the “flyback” on the primary of T1. It is full-wave rectified by
CR40 and filtered by C275. The +17 V output drives the external suppression circuitry and R543
provides loading during the suppression OFF time.
The secondary supply incorporates a voltage doubler to derive the +1300 V dc required by the
transmitter tube. The 650 V rms output of T1 is doubled by the circuitry consisting of C43, C44,
CR7 and CR8. C45 provides filtering for the +1300 V output.
4.2.1.2.8 Output Regulation
The 1300 V output is divided down by the network consisting of R68 through R75, R104 and R105.
This voltage is compared by U13-A to the reference voltage generated by U35. The voltage gen-
erated by U13-A is used to “steer” the output of U18 to maintain regulation of the +1300 V output.
SECTION V
MAINTENANCE
5.1 GENERAL
Before maintenance of the KT 76C is attempted, a thorough understanding of the Theory of Op-
eration (Section IV) as well as the information of semiconductor maintenance is needed.
5.2 TEST AND ALIGNMENT
5.2.1 TEST EQUIPMENT
The transponder test set-up is shown in Figure 5-1.
2. Connect unit under test to test equipment and apply power to unit.
3. Verify the following power supply voltages are within their specified tolerances.
5.2.2.2. Receiver
2. Set RF amplitude to -20 dBm. Using the gain adjust pot, R165, adjust height of
P1 to 4.25 ± 0.1 volts.
3. Set RF amplitude to a level such that the reply rate is approximately 50%. Ad-
just R571 for maximum reply rate. Repeat until a maximum reply rate is ob-
tained that is less than 100%.
NOTE
R571 alignment applies to units containing main
board (200-09098-0020) only. This alignment does
not apply to units containing main board (200-09098-
0000).
4. Set the RF amplitude to -76 dBm. Adjust the Detector Gain pot, R179 so that
the difference between P1 and P2 is greatest. The actual height of P1 or P3 is
not important for this step.
NOTE
R179 is not planned to be installed at this time so this
step can be ignored if it is not present on the board.
5. Adjust MTL, pot R132 so that the reply rate on the Test Set XPDR Reply %
reads 90% ± 3%.
NOTE
On units containing main board (200-09098-0020), it
may be necessary to desensitize the unit by adjust-
ing R571 to obtain an MTL reading ≥ -77 dBm. This
does not apply to units containing main board (200-
09098-0000).
4. Subject the unit photocell to a 40 Foot Candle light source and turn the unit to
stand by (SBY) mode.
6. Photocell calibration is complete. Turn unit OFF and remove ground from U28
Pin 28.
7. Turn unit on, cover the photocell, and verify the display does not flicker.
5.2.2.4. Transmitter
1. Set the interrogation rate to 500 per second and the transponder code to 0000.
2. Using the transmitter tube coupling nut and frequency adjust screw, adjust the
transmitter for peak power and a frequency of 1090 ±1 MHz.
NOTE
If Circulator is installed, skip step 3. If Circulator is
not installed, skip step 4.
3. Turn the coupling nut counter-clockwise until one of the following conditions oc-
cur:
a) The power drops 15%.
b) The rise time drops to 55ns.
c) The pulse width increases to 520 ns.
NOTE
Decoupling the tube will decrease frequency “pull-
ing” at installation time.
4. Decrease unit peak power from 1 to 5 percent by turning the coupling nut
counter-clockwise.
5. Adjust the frequency nut to bring back the frequency to 1090.00 ± .2 MHz. Verify
that rise time is between 50 and 100 ns, power is greater than 200 watts, and
pulse width is 450 ns ±70 ns. If not, repeat the last two steps until all conditions
are met.
NOTE
For 200-09098-0060 main boards, use R587 for
pulse width adjustment.
6. Connect the unit under test to a line stretcher with a 1.2:1 SWR load. Adjust the
line stretcher through all phase angles and verify the transmitter frequency.
Units without the circulator shall have a frequency pull of 1090.00 ± 3 MHz or
less. Units with the circulator shall have a frequency pull of 1090.00 ± .75 MHz
or less.
7. Pull the line stretcher and note the maximum and minimum frequency deviation.
Set the HP 8905 wave meter to center of the frequency deviation and pull the
line stretcher until a peak indication is reached. Without moving the line stretch-
er, adjust the transmitter oscillator frequency trim for a 1090 MHz reading. Re-
check the frequency deviation by pulling the line stretcher to see that it is cen-
tered about 1090 MHz. Check to see that the drain voltage of Q26 does not ex-
ceed 140 volts as the line stretcher is pulled.
The pulse spacing of any information pulse must not differ from these spacings by more than ±
0.1µs. The pulse spacing tolerance of any pulse in the reply group with respect to any other pulse
(except the first framing pulse) must be no more than ± 0.15µs.
5.2.4.10 OUTPUT PULSE WIDTH
The output pulse width shall be set to .45 ± .07 µs measured at the 50% voltage points on the
detected video of the transmitter reply.
5.2.4.11 REPLY ANNUNCIATOR
The reply annunciator shall be illuminated when the unit replies to an interrogation. The reply an-
nunciator shall be illuminated during the period the IDENT pulse is present in Mode “A” replies.
5.2.4.12 FUNCTIONS
The transponder shall not reply when the function switch is in the SBY position. Mode “C” replies
shall consist only of framing pulses when the function switch is in the ON position. Mode “A” and/
or Mode “C” shall be transmitted when the function switch is in the ALT position. The Display shall
be illuminated when the function switch is in the TST position.
5.2.4.13 PANEL LIGHTING
With 14 V dc applied to pin 2 and ground on pin 3, all panel lamps shall be illuminated.
5.3 OVERHAUL
5.3.1 INSPECTION
This section contains instructions to assist in determining by inspection the condition of the KT
76C. Defects resulting from wear, physical damage, deterioration, or other causes can be found
by these inspection procedures. To aid inspection, detailed procedures are arranged in alphabet-
ical order.
A. Capacitors, Fixed
Inspect capacitors for case damage, body damage, and cracked, broken, or
charred insulation. Check for loose, broken, or corroded terminal studs, lugs,
or leads. Inspect for loose, broken, or improperly soldered connections. On
chip caps be especially alert for hairline cracks in the body and broken termi-
nations.
B. Capacitors, Variable
Inspect trimmers for chipped and cracked bodies, damaged dielectrics and
damaged contacts.
C. Chassis
Inspect the chassis for deformation, dents, punctures, badly worn surfaces,
damaged connectors, damaged fastener devices, loose or missing hardware,
component corrosion, and damage to the finish.
D. Connectors
Inspect connectors for broken parts, and other irregularities. Inspect for
cracked or broken insulation and for contacts that are broken, deformed, or
out of alignment. Also, check for corroded or damaged plating on contacts
and for loose, improperly soldered, broken, or corroded terminal connections.
E. Covers and Shields
Inspect covers and shields for punctures, deep dents, and badly worn surfac-
es. Also, check for damaged fastener devices, corrosion and damage to fin-
ish.
F. Flex Circuits
Inspect flex circuits for punctures, and badly worn surfaces. Check for broken
traces, especially near the solder contact points.
G. Fuse
Inspect for blown fuse and check for loose solder joints.
H. Insulators
Inspect all jacks for corrosion, rust, deformations, loose or broken parts,
cracked insulation, bad contacts, or other irregularities.
J. Potentiometers
Inspect fixed resistors for cracked, broken, blistered, or charred bodies and
loose, broken, or improperly soldered connections. On chip resistors be es-
pecially alert for hairline cracks in the body and broken terminations.
L. RF Coils
Inspect all RF coils for broken leads, loose mountings, and loose, improperly
soldered, or broken terminal connections. Check for crushed, scratched, cut
or charred windings. Inspect the windings, leads, terminals and connections
for corrosion or physical damage. Check for physical damage to forms and
tuning slug adjustment screws.
M. Terminal Connections soldered
1. Inspect for cold-soldered or resin joints. These joints present a porous
or dull, rough appearance. Check for strength of bond using the points
of a tool.
2. Examine the terminals for excess solder, protrusions from the joint, piec-
es adhering to adjacent insulation, and particles lodged between joints,
conductors, or other components.
3. Inspect for insufficient solder and unsoldered strands of wire protruding
from conductor at the terminal. Check for insulation that is stripped back
too far from the terminal.
4. Inspect for corrosion at the terminal.
N. Transformers
1. Inspect for signs of excessive heating, physical damage to case,
cracked or broken insulation, and other abnormal conditions.
2. Inspect for corroded, poorly soldered, or loose connecting leads or ter-
minals.
O. Wiring/Coaxial Cable
Inspect wiring in chassis for breaks in insulation, conductor breaks, cut or bro-
ken lacing and improper dress in relation to adjacent wiring or chassis.
5.3.2 CLEANING
A. Using a clean, lint-free cloth lightly moistened with soap and water only, re-
move the foreign matter from the equipment case and unit front panel. Wipe
dry using a clean, dry, lint-free cloth.
B. Using a hand controlled dry air jet (not more than 15 psi), blow the dust from
inaccessible areas. Care should be taken to prevent damage by the air blast.
C. Clean the receptacles and plugs with a hand controlled dry air jet (not more
than 25 psi), and a clean, lint-free cloth lightly moistened with soap and water
only. Wipe dry with a clean, dry, lint-free cloth.
5.3.3 REPAIR
This section describes the procedure along with any special techniques for replacing damaged or
defective components.
A. Connectors
Diodes used are silicon and germanium. Use long nose pliers as a heat sink
under normal soldering conditions. Note the diode polarity before removal.
D. Integrated Circuits
When repairing a wire that has broken from it’s terminal, remove all old solder
and pieces of wire from the terminal, restrip the wire to the necessary length
and resolder the wire to the terminal. Replace a damaged wire or coax with
one of the same type, size and length.
5.3.4 DISASSEMBLY PROCEDURE
The unit is disassembled for maintenance and testing purposes by removing the two rear cover
assembly screws and the two bottom black screws on the bezel. The faceplate can be removed
by removing the remaining two black flat screws that fasten it to the chassis.
5.4 TROUBLESHOOTING
This section is intended for use as a guide in isolating circuit malfunctions. The guidance present-
ed here and the figures referenced by no means profess to include all possible causes of failure,
but are presented as a guideline to be used in locating the approximate section of the unit that has
failed. Figure 5-2 through 5-7 are the KT 76C Troubleshooting Flow Charts and are arranged in
a manner that will expedite finding the area of failure. Following the Flow Charts are the wave-
forms that should be found at various test points in the KT 76C.
WAVEFORMS
Tek00
RF -30dBm
CH 1, DC, U12 Pin 5
CH 2, DC, U12 Pin 12
Tek01
RF -30dBm
CH 1, DC, U1 Pin 1
Tek02
RF -20dBm
CH 1, AC, U21 Pin 1
Tek03
MTL P2-9
CH 1, DC, TP5
Tek04
RF MTL
CH 1, DC, Base Q18
Tek05
RF MTL
CH 1, DC, U16 Pin 6
Tek06
RF MTL
CH 1, DC, U16 Pin 9
Tek07
RF MTL
CH 1, DC, U16 Pin 12
Tek08
RF MTL +3 dBm
CH 1, DC, U14 Pin 10
CH 2, DC, TP5
Tek09
RF MTL +3 dBm
CH 1, DC, U14 Pin 10
CH 2, DC, U14 Pin 9
Tek10
RF MTL
CH 1, DC, U22 Pin 2
Tek11
RF MTL +3 dBm
500 PRF
CH 1, DC, U11 Pin 10
CH 2, DC, U11 Pin 11
Tek12
RF MTL +3 dBm
1200 PRF
CH 1, DC, U11 Pin 10
CH 2, DC, U11 Pin 11
Tek13
RF MTL
CH 1, DC, TP4
CH 2, DC, TP5
Tek14
RF MTL
CH 1, DC, TP3
CH 2, DC, TP5
Tek15
RF MTL
CH 1, DC, U7, Pin 10
Tek17
RF MTL
SWITCH SET TO TEST
CH 1, DC, U28 Pin 41
CH 2, DC, U28 Pin 30
Tek18
RF MTL +3 dBm
CH 1, DC, TP1
Tek19
RF MTL +3 dBm
SWITCH ALT
CODE 7777
CH 1, DC, TP9
Tek20
CH 1, DC, U11 Pin 1
Tek21
RF -20 dBm
CH 1, DC, TP5
VIDEO ALIGNMENT AT 4.25 VDC
Tek22
UNIT 28V INPUT
RF OFF
SWITCH TEST
CH 1, DC, U28, Pin 4
Tek23
UNIT 14V INPUT
RF OFF
SWITCH TEST
CH 1, DC, U28, Pin 4
Tek24
UNIT 28V INPUT
CH 1, DC, U30, Pin 7
The Illustrated Parts List (IPL) is a complete list of assemblies and parts required for the
unit. The IPL also provides for the proper identification of replacement parts. Individual
parts lists within this IPL are arranged in numerical sequence starting with the top assem-
bly and continuing with the sub-assemblies. All mechanical parts will be separated from
the electrical parts used on the sub-assembly. Each parts list is followed by a component
location drawing.
Parts identified in this IPL by AlliedSignal part number meet design specifications for this
equipment and are the recommended replacement parts. Warranty information concern-
ing AlliedSignal replacement parts is contained in Service Memo #1, P/N 600-08001-
00XX.
Some part numbers may not be currently available. Consult the current AlliedSignal cat-
alog or contact your AlliedSignal representative for equipment availability.
Abbreviation Name
B Motor or Synchro
C Capacitor
CJ Circuit Jumper
CR Diode
DS Lamp
E Voltage or Signal Connect Point
F Fuse
FL Filter
FT Feedthru
I Integrated Circuit
J Jack or Fixed Connector
L Inductor
M Meter
P Plug
Table 1
Abbreviations
Abbreviation Name
Q Transistor
R Resistor
RT Thermistor
S Switch
T Transformer
TP Test Point
U Component Network, Integrated Circuit,
Circuit Assembly
V Photocell/Vacuum Tube
W Waveguide
Y Crystal
Table 1 (Continued)
Abbreviations
Figure 6-1
Sample Parts List
Figure 6-2
Final Assembly S/N ≥ 8700 (Dwg. No. 300-05684-0000 Rev. AH)
Figure 6-2A
Final Assembly S/N ≥ 8200 (Dwg. No. 300-05684-0000 Rev. AF)
Figure 6-2B
Final Assembly S/N ≥ 6600 (Dwg. No. 300-05684-0000 Rev. AE)
Figure 6-2C
Final Assembly (Dwg. No. 300-05684-0000 Rev. 5)
Figure 6-2D
Final Assembly (Dwg. No. 300-05684-0000 Rev. 3)
Figure 6-3
Bezel Assembly (Dwg. No. 300-05679-0000 Rev. 1)
Figure 6-3A
Bezel Assembly (Dwg. No. 300-05679-0000 Rev. 0)
Figure 6-4
Bezel Assembly (Dwg. No. 300-05679-0010 Rev. -)
Figure 6-6
Display Board S/N ≥ 8700 (Dwg. No. 300-09097-0020 Rev. A, Sheet 1 of 2)
Figure 6-6
Display Board S/N ≥ 8700 (Dwg. No. 300-09097-0020 Rev. A, Sheet 2 of 2)
Figure 6-8
Display Board Schematic (Dwg. No. 002-09097-0020 Rev. A, Sheet 1 of 2)
Figure 6-8
Display Board Schematic (Dwg. No. 002-09097-0020 Rev. A, Sheet 2 of 2)
Figure 6-9
Filter/Heatsink Assy. (Dwg. No. 300-05669-0000 Rev. 4)
Figure 6-10
Filter/Heatsink Assy. (Dwg. No. 300-05669-0001 Rev. -)
Figure 6-11
Main Board (Dwg. No. 300-09098-0000 Rev. 5, Sheet 1 of 3)
Figure 6-11
Main Board (Dwg. No. 300-09098-0000 Rev. 5, Sheet 2 of 3)
Figure 6-11
Main Board (Dwg. No. 300-09098-0000 Rev. 5, Sheet 3 of 3)
Figure 6-11A
Main Board (Dwg. No. 300-09098-0000 Rev. 3, Sheet 1 of 3)
Figure 6-11A
Main Board (Dwg. No. 300-09098-0000 Rev. 3, Sheet 2 of 3)
Figure 6-11A
Main Board (Dwg. No. 300-09098-0000 Rev. 3, Sheet 3 of 3)
Figure 6-12
Main Board (Dwg. No. 300-09098-0020 Rev. 3, Sheet 1 of 3)
Figure 6-12
Main Board (Dwg. No. 300-09098-0020 Rev. 3, Sheet 2 of 3)
Figure 6-12
Main Board (Dwg. No. 300-09098-0020 Rev. 3, Sheet 3 of 3)
Figure 6-12A
Main Board (Dwg. No. 300-09098-0020 Rev. 1, Sheet 1 of 2)
Figure 6-12A
Main Board (Dwg. No. 300-09098-0020 Rev. 1, Sheet 2 of 2)
Figure 6-13
Main Board (Dwg. No. 300-09098-0040 Rev. 0, Sheet 1 of 2)
Figure 6-13
Main Board (Dwg. No. 300-09098-0040 Rev. 0, Sheet 2 of 2)
Figure 6-14
Main Board S/N ≥ 8200 (Dwg. No. 300-09098-0060 Rev. -, Sheet 1 of 2)
Figure 6-14
Main Board S/N ≥ 8200 (Dwg. No. 300-09098-0060 Rev. -, Sheet 2 of 2)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 1 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 2 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 3 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 4 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 5 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 6 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 7 of 8)
Figure 6-15
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 6, Sheet 8 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 1 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 2 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 3 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 4 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 5 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 6 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 7 of 8)
Figure 6-15A
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 5, Sheet 8 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 1 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 2 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 3 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 4 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 5 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 6 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 7 of 8)
Figure 6-15B
Main Board Schematic (Dwg. No. 002-09098-0000 Rev. 2, Sheet 8 of 8)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 1 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 2 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 3 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 4 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 5 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 6 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 7 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 8 of 9)
Figure 6-16
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. AB, Sheet 9 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 1 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 2 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 3 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 4 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 5 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 6 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 7 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 8 of 9)
Figure 6-16A
Main Board Schematic (Dwg. No. 002-09098-0020 Rev. 3, Sheet 9 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 1 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 2 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 3 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 4 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 5 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 6 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 7 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 8 of 9)
Figure 6-17
Main Board Schematic (Dwg. No. 002-09098-0040 Rev. 0, Sheet 9 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 1 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 2 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 3 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 4 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 5 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 6 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 7 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 8 of 9)
Figure 6-18
Main Board Schematic (Dwg. No. 002-09098-0060 Rev. A, Sheet 9 of 9)
Figure 6-19
Circular Board S/N ≥ 6600 (Dwg. No. 300-09478-0000 Rev. B, Sheet 1 of 2)
Figure 6-19
Circular Board S/N ≥ 6600 (Dwg. No. 300-09478-0000 Rev. B, Sheet 2 of 2)
Figure 6-20
Circular Board S/N ≥ 6600 (Dwg. No. 300-09478-0010 Rev. A)
Figure 6-21
Circular Board S/N ≥ 6600 (Dwg. No. 300-09478-0091 Rev. B)
Figure 6-22
Circular Board Schematic (Dwg. No. 002-09478-0000 Rev. A)
Figure 6-23
Rotary Switch Board (Dwg. No. 300-09488-0000 Rev. -)
Figure 6-24
Rotary Switch Board Schematic (Dwg. No. 002-09488-0000 Rev. -)
This is a complete reprint. All sections and pages are revised and reformatted.