j. Ensure the air valve 3A11H15 located in rear of equipment rack has closed and shows no signs of excessive wear or damage. 6-44.3 Installation Procedure. WARNING Two men are required to safely lift SRU due to its weight and size. Injury to personnel or damage to equipment may result if the following steps are not carefully followed. a. Lift SRU and slide into equipment rack until properly seated. b. Engage swingbolts 3A11H9 with SRU front panel support hooks H1 and tighten nuts on swingbolts. c. Connect grounding jumper 3A11H17 to SRU front panel stud and tighten wing nut H4. d. Ensure SRU circuit breaker is in OFF position. e. Connect front panel cable assemblies disconnected in procedure 6-44.2.e. Reposition the IRIS spring between the coupling ring and backshell of the connector (remove marker). f. Remove Danger Tag from SRU circuit breaker. g. Set SRU circuit breaker to ON position. h. Attach protective cover 3H1 to cover hooks (3A11H7, H13) on front of Rack 3. Tighten retainer screws. i. Verify proper operation of countermeasures set. j. Return equipment to current readiness condition. 6-45 3A5, HIGH VOLTAGE SEQUENCER, CONTROL INDICATOR, C-10521, REMOVAL AND INSTALLATION. (See figures 7-17 and 7-20.) 6-45.1 Tools and Materials Required. Refer to the applicable procedures to be performed and select the required tools and materials from the following list. a. Maintenance shelf, inboard (PN 928261-1) b. Marker pen, permanent black. c. Pliers, slip joint (electrical connection, multi-joint, conduit nose) d. Tag, Danger (NAVSHIPS 9890/8, red) e. Tape, pressure sensitive adhesive (masking tape) f. Strap, webbed (SRU tie down) g. Screwdriver, flat tip, 8 general purpose. 7-6-447
6-45.2 Removal Procedure. The following procedure assumes maintenance will be performed on this SRU only. Removing primary power from remainder of countermeasures set is not required. a. Loosen retainer screws. Lift protective cover (3H1) from cover hooks (3A11H7, H13) and remove from front of Rack 3. WARNING Voltages capable of causing death are present in this equipment. Injury to personnel or damage to equipment may result if the following steps are not followed carefully. b. Set 3A5 circuit breaker 3A11A1CB1 to OFF position. c. Attach danger tag to 3A5 circuit breaker. d. Verify POWER ON indicator 3A5DS1 is not lit. e. Ensure SRU front panel cable assemblies are correctly identified, using table 6-45 as a guide. If necessary, use adhesive tape and marker pen to mark cables. f. Disconnect front panel cable assemblies listed in table 6-45, using slip joint pliers as required. Push IRIS spring back over backshell. g. Inspect cable connectors and SRU jacks for recessed pins or other damage. h. Disconnect ground jumper 3A11H17 from front panel stud 3A5H9 by loosening wing nut 3A5H19. 3A5 Connector Table 6-45. 3A5, Front Panel Cable Assemblies Cable Assembly Type Connector Cable Destination 3A5J1 3W13 QDISC 3A11A1E5 3A5J2 3W2 QDISC 3A1J2 3A5J3 3W8 QDISC 3A3J2 3A5J4 3W14 QDISC 3A7J2 3A5J5 W70 QDISC 31A1J14 3A5J6 3W15 QDISC 3A9J2 3A5J7 3W5 QDISC 3A2J2 3A5J8 3W11 QDISC 3A2J2 3A5J9 3W16 QDISC 3A8J2 3A5J10 3W17 QDISC 3A10J2 3A5J11 W71 QDISC 21A1J14 3A5J13 W57 QDISC 2A6A1J1 7-6-448
WARNING Two men are required to safely lift SRU due to its weight and size. Injury to personnel or damage to equipment may result if the following steps are not carefully followed. i. Push maintenance shelf into equipment rack holes (below SRU) until properly seated. WARNING SRU will slide from maintenance shelf when ship is rolling/pitching. Injury to personnel and/or damage to equipment may result if SRU is not strapped to maintenance shelf. j. Disengage swingbolts 3A11H9 from SRU support hooks 3A5H12 by loosening nuts on swingbolts. k. Pull SRU approximately 3/4 of the way from equipment rack. l. Lift SRU onto maintenance shelf with each man grasping a front panel bow handle 3A5H3 while supporting the bottom with other hand. m. If necessary due to ship s rolling/pitching, strap SRU to maintenance shelf with webbed strap or move SRU from maintenance shelf to suitable working area if major disassembly is required. CAUTION Rack air flow may be reduced when SRU is removed from rack. Damage to equipment may result from heat build up. n. Ensure both air valves 3A11H5 located in rear of equipment rack have closed and show no signs of excessive wear or damage. o. Return to troubleshooting or alignment/adjustment procedures if further disassembly is not required. p. Move SRU from maintenance shelf to suitable working area if major disassembly is required. q. Refer to paragraph 6-46 for 3A5, SRA and parts removal and installation procedures. 6-45.3 Installation Procedure. The following procedure assumes the SRU was previously moved from the maintenance shelf to a suitable working area. 7-6-449
WARNING Two men are required to safely lift SRU due to its weight and size. Injury to personnel or damage to equipment may result if the following steps are not carefully followed. a. Ensure maintenance shelf is properly seated in equipment rack. b. Set SRU on maintenance shelf in upright position, back towards equipment rack, with each man grasping a front and rear panel handle. c. Slide SRU toward equipment rack until partially overhanging rear of maintenance shelf. d. Lift SRU from maintenance shelf and set on edge of equipment rack, with each man grasping a front panel handle while supporting the bottom with other hand. e. Slide SRU into equipment rack until properly seated. f. Engage swingbolts 3A11H9 with SRU front panel support hooks 3A5H12 and tighten nuts on swingbolts. g. Pull maintenance shelf from equipment rack. h. Connect grounding jumper 3A11H17 to SRU front panel stud 3A5H9 and tighten wing nut 3A5H19. i. Ensure 3A5 circuit breaker 3A11A1CB1 is in OFF position. j. Connect front panel cable assemblies disconnected in procedure 6-45.2.f. Push IRIS spring backover backshell. k. Remove danger tag from 3A5 circuit breaker 3A11A1CB1. l. Set 3A5 circuit breaker to ON position. m. Attach protective cover 3H1 to cover hooks (3A11H7, H13) on front of Rack 3. Tighten retainer screws. n. Verify proper operation of countermeasures set. o. Return equipment to current readiness condition. 6-46 3A5, SRA AND PARTS, REMOVAL AND INSTALLATION. 6-46.1 Tools and Materials Required. Refer to the applicable procedure (see paragraph 6-46.2) to be performed and select the required tools and materials from the following list. a. Adhesive, black, silicon (MIL-A-46146) 7-6-450
b. Brush, paint, 1/2 (2 required) c. Desoldering device, solder wick or solder sucker d. Electrical contact insertion tool (PN MS27495A22D) e. Electrical contact insertion tool (PN MS27534A20) f. Electrical contact removal tool (PN MS27495R22D) g. Electrical contact removal tool (PN MS27534R20) h. Extractor, CCA (mfr 49956, PN 929005-1) i. Heater, gun type, electric j. Insulation sleeving, heat shrinkable, 1/4 k. Key, hex 3/32 l. Key, hex 9/64 m. Knife, putty n. Knife, razor (single edge razor blade) o. Marker pen, permanent black p. Nut driver, 5/16 q. Nut driver, 3/8 r. Pliers, diagonal cutting, standard s. Pliers, narrow nose t. Primer, clear (mfr 49956 PN 570599-2 or mfr 71984 PN 1204) u. Punch, drift, 0.040 v. Rags, wiping, cotton w. Screwdriver, flat tip, 4 general purpose x. Screwdriver, No. 1 Phillips, 8 y. Screwdriver, No. 2 Phillips, 8 z. Screwdriver set, jeweler s aa. ab. Socket, socket wrench, 3/16 with 14 extension, 3/8 drive Solder, tin alloy, rosin core 7-6-451
ac. Soldering iron, pencil tip, 45 watts ad. Solvent, xylene ae. Stripper, wire, AWG 20 af. Tape, pressure sensitive adhesive (masking tape) ag. Tool, crimping, terminal, hand (NSN 5120-00-278-2423) ah. Wrench, open end, 5/16 ai. Wrench, open end, 5/32 aj. Wrench, open end, 7/16 ak. Wrench, open end, 1/2 al. Wrench, open end, 11/16 am. Wrench, socket, 3/8 drive 6-46.2 Procedure Matrix. Use table 6-46 to determine the paragraph number for the removal/ installation procedures to be performed. Parts are listed in reference designation sequence. 6-46.3 3A5H1 and 3A5H11, Top and Bottom Covers. Removal and Installation Procedures. (See figure 6-32.) 7-6-452
Reference Designation 6-46.3.1 Removal Procedure. Table 6-46. 3A5, SRA and Parts, Removal/Installation Procedure Matrix Name/Description Removal Paragraph Installation Paragraph 3A5A2 thru A15 Circuit Card Assemblies 6-46.5.1 6-46.5.2 3A5DS1 Indicator Lamp 6-46.15.1 6-46.15.2 3A5F1, F2 Fuses 6-46.33.1 6-46.33.2 3A5FL1 EMI Filter Assembly 6-46.21.1 6-46.21.2 3A5H1 Top Cover 6-46.3.1 6-46.3.2 3A5H2, H22 Shielding Gasket 6-46.28.1 6-46.28.2 3A5H3, H4 Bow Handle (front)/ferrule 6-46.22.1 6-46.22.2 3A5H5 Back Panel 6-46.11.1 6-46.11.2 3A5H6 Bow Handle (back) 6-46.12.1 6-46.12.2 3A5H7, H8 Sealing Gasket/EMI Filter 6-46.13.1 6-46.13.2 3A5H9 GRound Stud 6-46.16.1 6-46.16.2 3A5H10 CCA Retainer 6-46-4.1 6-46-4.2 3A5H11 Bottom Cover 6-46.3.1 6-46.3.2 3A5H12 Support Hook 6-46.17.1 6-46.17.2 3A5H20 Retainer Ring 6-46.27.1 6-46.27.2 3A5H21 Turnlock Fastener 6-46.27.1 6-46.27.2 3A5H23 Side Panel (left) 6-46.25.1 6-46.25.2 3A5H24 Side Panel (right) 6-46.26.1 6-46.26.2 3A5H25 Front Panel 6-46.18.1 6-46.18.2 3A5H26 Electrical Subassembly Holder 6-46.10.1 6-46.10.2 3A5H27 Electrical Subassembly Holder 6-46.8.1 6-46.8.2 3A5H28 Electrical Subassembly Holder 6-46.9.1 6-46.9.2 3A5H29 Electrical Contact 6-46.32.1 6-46.32.2 3A5J2 thru J13 Electrical Connectors 6-46.29.1 6-46.29.2 3A5J12H1 Protective Cap 6-46.14.1 6-46.14.2 3A5K1 thru K5 Relays 6-46.20.1 6-46.20.2 3A5P1 thru P12 Electrical Connectors 6-46.30.1 6-46.30.2 3A5P13 thru P16 Electrical Connectors 6-46.31.1 6-46.31.2 3A5PS1 Low Voltage Power Supply 6-46.6.1 6-46.6.2 3A5PS2 Low Voltage Power Supply 6-46.7.1 6-46.7.2 3A5S1 thru S80 Toggle Switches 6-46.24.1 6-46.24.2 3A5XDS1 Indicator Lamp Holder 6-46.19.1 6-46.19.2 3A5XF1, XF2 Fuse Holders 6-46.23.1 6-46.23.2 a. Remove SRU from equipment rack, following procedure 6-45.2 CAUTION SRU top and bottom covers have EMI gaskets attached. Damage to the gaskets may result if the following steps are not carefully followed. 7-6-453
Figure 6-32. 3A5, High Voltage Sequencer, Control Indicator, C-10521, Assembly View (Sheet 1 of 3) 7-6-454
Figure 6-32. 3A5, High Voltage Sequencer, Control Indicator, C-10521, Assembly View (Sheet 2 of 3) 7-6-455
Figure 6-32. 3A5, High Voltage Sequencer, Control Indicator, C-10521, Assembly View (Sheet 3 of 3) 7-6-456
b. Loosen twenty-four turnlock fasteners (3A1H21), using 4 flat tip screwdriver. c. Remove top/bottom cover from SRU and place in safe location to protect EMI gasket(s) from damage. 6-46.3.2 Installation Procedure. a. Set top/bottom cover SRU. b. Tighten twenty-four turnlock fasteners (3A1H21) using 4 flat tip screwdriver. c. Install SRU in equipment rack following procedure 6-45.3. 6-46.4 3A5H10, CCA Retainer. Removal and Installation Procedures. (See figure 7-19.) 6-46.4.1 Removal Procedure. a. Remove bottom cover from SRU following procedure 6-46.3.1 b. Loosen, but do not remove, two cross-recessed pan head captive screws attaching retainer to holder (3A5H26), using No. 2 Phillips screwdriver. c. Lift retainer from holder. 6-46.4.2 Installation Procedure. a. Set retainer on holder (3A5H26) and align screw holes. b. Attach retainer to holder with two cross-recessed pan head captive screws, using No. 2 Phillips screwdriver. c. Install bottom cover on SRU following procedure 6-46.3.2 6-46.5 3A5A2 Thru A15, CCAs. Removal and Installation Procedures. (See Figure 7-19.) 6-46.5.1 Removal Procedure. a. Remove CCA retainer following procedure 6-46-4.1. b. Engage pins of CCA extractor tool in holes on both sides of CCA and extractor firmly against CCA holders (2A5H26, H28). c. Squeeze handle of extractor to disengage CCA from interconnecting board jack and pull CCA from holders. 6.46.5.2 Installation Procedure. a. Push CCA into holders (2A5H26, H28) until properly seated b. Install CCA retainer following procedure 6-46-4.2. 7-6-457
6-46.6 3A5PS1, Low Voltage Power Supply. Removal and Installation Procedures. (See figure 6-32, sheet 3.) 6-46.6.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1 b. Loosen 3A5P13 and P14 retaining screws using 4 flat tip screwdriver, and unplug 3A5P13 and P14 from 3A5PS1J1 and J2. c. Loosen six cross-recessed captive screws attaching SRA to holders (3A5H26, H27) and interconnecting board (3A5A18), using No. 2 Phillips screwdriver. d. Pull SRA from holders. 6-46.6.2 Installation Procedure. a. Push SRA into holders (3A5H26, H27) until properly seated. b. Attach SRA to holders and interconnecting board (3A5A18) with six cross-recessed captive screws, using No. 2 Phillips screwdriver. c. Plug 3A5P13 and P14 into 3A5PS1J1 and J2 and tighten retaining screws, using 4 flat tip screwdriver. d. Install top and bottom covers on SRU following procedure 6-46.3.2. 6-46.7 3A5PS2, Low Voltage Power Supply. Removal and Installation Procedures. (See figure 6-32, sheet 3.) 6-46.7.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1 b. Loosen 3A5P15 and P16 retaining screws using 4 flat tip screwdriver, and unplug 3A5P15 and P16 from 3A5PS2J1 and J2. c. Loosen four cross-recessed captive screws attaching SRA to holders (3A5H26, H27) and interconnecting board (3A5A18), using No. 2 Phillips screwdriver. d. Pull SRA from holders. 6-46.7.2 Installation Procedure. a. Push SRA into holders (3A5H26, H27) until properly seated. b. Attach SRA to holders and interconnecting board (3A5A18) with four cross-recessed captive screws, using No. 2 Phillips screwdriver. c. Plug 3A5P15 and P16 into 3A5PS2J1 and J2 and tighten retaining screws using 4 flat tip screwdriver. d. Install top and bottom covers on SRU following procedure 6-26.3.2. 7-6-458
6-46.8 3A5H27, Electrical Subassembly Holder. Removal and Installation Procedures. (See figures 6-32, sheet 3.) 6-46.8.1 Removal Procedure. a. Remove LVPSs following procedures 6-46.6.1 and 6-46.7.1. b. Remove two cross-recessed machine screws attaching holder to interconnecting board (3A5A18), using No. 2 Phillips screwdriver. In some SRUs, these screws are hidden by a wire harness. If necessary, cut cable tie and move wires. c. Remove two recessed hex screws attaching holder to each side panel (3A5H24, H24) using 9/64 hex key. Loosen back panel (3A5H5) to relieve tension on holder, if necessary, using No. 2 Phillips screwdriver. d. Lift holder from SRU. 6-46.8.2 Installation Procedure. a. Set holder in SRU and align screw holes. b. Attach holder to each side panel (3A5H23, H24) with two recessed hex screws, using 9/64 hex key. Tighten back panel (3A5H5) if loosened in 6-46.8.1c., using a No. 2 Phillips screwdriver. c. Attach holder to interconnecting board (3A5A18) with two cross-recessed machine screws, using No. 2 Phillips screwdriver. Install cable tie if removed in procedure 6-46.8.1b. d. Install LVPSs following procedures 6-46.6.2a. through c. and 6-46.7.2. 6-46.9 3A5H28, Electrical Subassembly Holder. Removal and Installation Procedures. (See figure 6-32, sheet 3.) 6-46.9.1 Removal Procedure. a. Removal 3A5A2 thru A15 following procedure 6-46.5.1. b. Remove two cross-recessed machine screws attaching holder to interconnecting board (3A5A18), using No. 2 Phillips screwdriver. In some SRUs, these screws are hidden by a wire harness. If necessary, cut cable tie and move wires. c. Remove two recessed hex screws attaching holder to each side panel (3A5H23, H24), using 9/64 hex key. Loosen front panel (3A5H25) to screwdriver and 7/16 open end wrench. d. Lift holder from SRU. 7-6-459
6-46.9.2 Installation Procedure. a. Set holder in SRU and align screw holes. b. Attach holder to each side panel (3A5H23, H24) with two recessed hex screws, using 9/64 hex key. Tighten front panel (3A5H25) if loosened in 6-46.9.1c., using No. 2 Phillips screwdriver and 7/16 open end wrench. c. Attach holder to interconnecting board (3A5A18) with two cross-recessed machine screws, using No. 2 Phillips screwdriver. Install cable tie if removed in procedure 6-46.9.1b. d. Install 3A5A2 thru A15 following procedure 6-46.5.2. 6-46.10 3A5H26, Electrical Subassembly Holder. Removal and Installation Procedures. (See figure 6-32, sheet 3.) 6-46.10.1 Removal Procedure. a. Remove 3A5A2 thru A15 following procedure 6-46.5.1. b. Remove LVPSs following procedures 6-46.6.1 and 6-46.7.1. c. Remove two cross-recessed machine screws attaching holder to interconnecting board (3A5A18), using No. 2 Phillips screwdriver. In some SRUs, these screws are hidden by a wire harness. If necessary, cut cable tie and move wires. d. Remove two recessed hex screws attaching holder to each side panel (3A5H23, H24), using 9/64 hex key. Loosen back panel (3A5H5) and electrical subassy holder (3A5H27) to relieve tension on holder, if necessary, using No. 2 Phillips screwdriver and 9/64 hex key. e. Lift holder from SRU. 6-46.10.2 Installation Procedure. a. Set holder in SRU and align screw holes. b. Attach holder to each side panel (3A5H23, H24) with two recessed hex screws, using 9/64 hex key. Tighten back panel (3A5H5) and electrical subassy holder (3A5H27) if loosened in 6-46.10.1d., using No. 2 Phillips screwdriver and 9/64 hex key. c. Attach holder to interconnecting board (3A5A18) with two cross-recessed machine screws, using No. 2 Phillips screwdriver. Install cable tie if removed in procedure 6-46.10.1c. d. Install LVPS following procedure 6-46.6.2a. through c. and 6-46.7.2a through c. e. Install 3A5A2 thru A15 following procedure 6-46.5.2. f. Install top cover on SRU following procedure 6-46.3.2. 7-6-460
6-46.11 3A5H5, Back Panel. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.11.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1. b. Remove six cross-recessed pan head screws from back panel, using No. 2 Phillips screwdriver. c. Loosen, but do not remove, six recessed hex screws located through access holes on top inside edge of back panel, using 3/32 hex key. d. Remove back panel from SRU. 6-46.11.2 Installation Procedure. a. Place back panel on rear of SRU and align screw holes. b. Attach back panel to SRU with six cross-recessed pan head screws, using No. 2 Phillips screwdriver. c. Tighten six recessed hex screws located through access holes on top inside edge of back panel, using 3/32 hex key. d. Install top and bottom covers on SRU following procedure 6-46.3.2. 6-46.12 3A5H6, Bow Handle (Back). Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.12.1 Removal Procedure. a. Remove back panel following procedure 6-46.11.1. b. Remove two nuts from handle studs using 3/8 nut driver. c. Pull handle studs through mounting holes in back panel 6-46.12.2 Installation Procedure. a. Push handle studs through mounting holes in back in panel (3A5H5). b. Install two nuts on handle studs and tighten, using 3/8 nut driver. c. Install back panel following procedure 6-46.11.2. 6-46.13 3A5H7 and 3A5H8, Sealing Gasket and EMI Filter. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.13.1 Removal Procedure. a. Remove back panel following procedure 6-26.11.1. 7-6-461
b. Remove eight cross-recessed screws and nuts from EMI filter, using 5/32 open end wrench and No. 1 Phillips screwdriver. c. Remove EMI filter from back panel. d. Remove sealing gasket from EMI filter. 6-46.13.2 Installation Procedure. a. Set sealing gasket on EMI filter. b. Set EMI filter and sealing gasket on back panel (3A5H5) and align screw holes. c. Attach EMI filter to back panel with eight cross-recessed screws and nuts, using 5/32 open end wrench and No. 1 Phillips screwdriver. d. Install back panel following procedure 6-46.11.2. 6-46.14 3A5J12H1. Protective Cap. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.14.1 Removal Procedure. a. Remove bottom cover from SRU following procedure 6-46.3.1. b. Remove cross-recessed pan head screw, washers, and nut attaching protective cap chain to front panel (3A5H25), using No. 1 Phillips screwdriver and 5/32 open end wrench. c. Disconnect protective cap from 3A5J12. 6-46.14.2 Installation Procedure. a. Connect protective cap to 3A5J12. b. Attach protective cap chain to front panel (3A5H25) with cross-recessed pan head screw, washers, and nut, using No. 1 Phillips screwdriver and 5/32 open end wrench. c. Install bottom cover on SRU following procedure 6-46.3.2. 6-46.15 3A5DS1, Indicator Lamp. Removal and Installation Procedures. (See figure 6-32 sheet 2.) 6-46.15.1 Removal Procedure. a. Unscrew locking ring from front of lamp holder (3A5XDS1). b. Pull indicator lamp from lamp holder. 7-6-462
6-46.15.2 Installation Procedure. a. Push indicator lamp into lamp holder (3A5XDS1), ensuring pin contacts are aligned with socket. b. Screw locking ring onto lamp holder. 6-46.16 3A5H9, Ground Stud. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.16.1 Removal Procedure. a. Disconnect grounding jumper (3A11H17) from ground stud by loosening wing nut (3A5H19). b. Unscrew ground stud from front panel (3A5H25), using 7/16 open end wrench. 6-46.16.2 Installation Procedure. a. Screw ground stud into front panel (3A5H25), using 7/16 open end wrench. b. Connect grounding jumper (3A11H17) to ground stud and tighten wing nut (3A5H19). 6-46.17 3A5H12, Support Hook. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.17.1 Removal Procedure. the following procedure assumes that only one support hook will be removed at a time. a. Disengage swingbolt (3A11H9) from support hook by loosening nut on swingbolt. b. Remove two cross-recessed pan head screws attaching support hook to front panel (3A5H25), using No. 2 Phillips screwdriver. 6-46.17.2 Installation Procedure. a. Attach support hook to front panel (3A5H25) with two cross-recessed pan head screws, using No. 2 Phillips screwdriver. b. Engage swingbolt (3A11H9) with support hook and tighten nut on swingbolt. 6-46.18 3A5H25, Front Panel. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.18.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1. b. Unscrew ground stud (3A5H19) from front panel, using 7/16 open end wrench. 7-6-463
c. Remove cross-recessed pan head screw from both support hooks (3A5H12), outer side only, using No. 2 Phillips screwdriver. d. Remove three remaining cross-recessed pan head screws on outer edges of front panel, using No. 2 Phillips screwdriver. e. Loosen, but do not remove, six recessed hex screws located through access holes on top inside edge of front panel, using 3/32 hex key. f. Disconnect protective cap (3A5J12H1) from 3A5J12. g. Remove lamp holder (3A5XDS1) as follows: (1) Unscrew locking ring from front of lamp holder. (2) Pull indicator lamp (3A5DS1) from lamp holder. (3) Loosen, but do not remove, lamp holder clamp nut on rear of front panel, using 1/2 open end wrench. (4) Unscrew retaining ring from front of lamp holder. (5) Pull lamp holder through mounting hole in front panel, from rear. h. Remove four cross-recessed pan head screws attaching 3A5J1 thru J13 to front panel, Using No. 1 Phillips screwdriver. i. Pull each connector through mounting hole in front panel, from rear. j. Identify and mark fuse holder (3A5XF1) connecting wires, using adhesive tape and marker pen. k. Remove heat shrinkable insulation from fuse holder connecting wires, using razor knife. l. Desolder and disconnect wires from fuse holder terminals. m. Remove retaining nut and washer attaching switch (3A5S1) to front panel, using 5/16 nut driver. n. Pull switch through mounting hole in front panel, from rear. o. Identify and mark switch using adhesive tape and marker pen. p. Repeat steps m. thru o. for each remaining switch (3A5S2 through S80). 6-46.18.2 Installation Procedure. a. Remove temporary identification from switch (3A5S80) and push switch through associated mounting hole in front panel (3A5H25), from rear. Ensure ON position of switch is toward top of SRU. b. Attach switch to front panel with retaining nut and wash, using 5/16 nut driver. 7-6-464
c. Repeat steps a. and b. for each remaining switch (3A5S79 thru S1). d. Sleeve wires disconnected in procedure 6-46.18.11., with suitable length of 1/4 heat shrinkable insulation. e. Connect and solder wires disconnected in procedures 6-46.18.1 step 1. to fuse holder terminals. f. Slide heat shrinkable insulation over solder connections and shrink insulation using heat gun. g. Push 3A5J2 through J13 through mounting holes in front panel and attach each with four cross-recessed pan head screws and nut assy, using No. 1 Phillips screwdriver. h. Push 3A5J1 (3AFL1J1) through mounting hole in front panel, from rear, and attach with four cross-recessed pan head screws using No. 1 Phillips screwdriver. i. Connect protective cap (3A5J12H1) to 3A5J12. j. Install lamp holder (3A5XDS1) in front panel as follows: (1) Push lamp holder through mounting hole in front panel, from rear. (2) Screw retaining ring on front of lamp holder, adjusting clamp nut to allow full seating of locking ring. (3) Tighten clamp nut using 1/2 open end wrench. (4) Push indicator lamp (3A5DS1) into lamp holder ensuring pin contacts are aligned with socket. (5) Screw locking ring on front of lamp holder. k. Push front panel against SRU and tighten six recessed hex screws located through access holes on top inside edge of front panel, using 3/32 hex key. l. Attach front panel to side panels (3A5H23, H24) with five cross-recessed pan head screws removed in procedure 6-46.18.lc. and d., using No. 2 Phillips screwdriver. m. Screw ground stud (3A5H9) into front panel and tighten, using 7/16 open end wrench. n. Install top and bottom covers on SRU following procedure 6-46.3.2. 6-46.19 3A5XDS1, Indicator Lamp Holder. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.19.1 Removal Procedure. a. Remove bottom cover from SRU following procedure 6-46.3.1. 7-6-465
b. Unscrew locking ring from front of lamp holder. c. Pull indicator lamp (3A5DS1) from lamp holder. d. Desolder and disconnect wires from lamp holder terminals. e. Loosen, but do not remove, clamp nut on rear of front panel (3A5H25), using 1/2 open end wrench. f. Unscrew retaining ring from front of lamp holder. g. Pull lamp holder through mounting hole in front panel, from rear. 6-46.19.2 Installation Procedure. a. Push lamp holder through mounting hole in front panel (3A5H25), from rear. b. Screw retaining ring on front of lamp holder, adjusting clamp nut to allow full seating of locking ring. c. Tighten clamp nut using 1/2 open end wrench. d. Connect and solder wires disconnected in procedure 6-46.19.1d., to lamp holder terminals. e. Push indicator lamp (3A5DS1) into lamp holder, ensuring pin contacts are aligned with socket. f. Screw locking ring on front of lamp holder. g. Install bottom cover on SRU following procedure 6-46.3.2. 6.46.20 3A5K1 Thru 3A5K5, Relays. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.20.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1 b. Remove heat shrinkable insulation from relay connecting wires using razor knife. c. Identify and mark relay connecting wires using adhesive tape and marker pen. d. Desolder and disconnect wires from relay terminals. e. Remove cross-recessed screws, washers, and nuts attaching relay to interconnecting board (3A5A18), using No. 2 Phillips screwdriver and 3/16 socket mounted on 14 extension. 7-6-466
6-46.20.2 Installation Procedures. a. Place relay on mounting hole in interconnecting board (3A5A18), from bottom, and align screw holes. b. Attach relay to interconnecting board with cross-recessed screws, washers, and nuts, using No. 2 Phillips screwdriver and 3/16 socket mounted on 14 extension. c. Sleeve wires disconnected in procedure 6-46.20.1d., with suitable length of 1/4 heat shrinkable insulation. d. Connect and solder wires to relay terminals. e. Slide heat shrinkable insulation over solder connections and shrink insulation using heat gun. f. Install top and bottom covers on SRU following procedure 6-46.3.2. 6-46.21 3A5FL1, EMI Filter Assembly. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.21.1 Removal Procedure. a. Remove front panel following procedure 6-46.18.1a. through e. b. Remove four cross-recessed pan head screws attaching EMI filter to front panel, using No. 1 Phillips screwdriver. c. Pull EMI filter jack through mounting hole in front panel, from rear. d. Turn filter until wiring is exposed at bottom of front panel. e. Remove heat shrinkable insulation from filter connecting wires using razor knife. f. Identify and mark filter connecting wires using adhesive tape and marker pen. g. Desolder and disconnect wires from filter terminals. 6-46.21.2 Installation Procedure. a. Sleeve wires disconnected in procedure 6-46.21.1g., with suitable length of 1/4 heat shrinkable insulation. b. Connect and solder wires to filter terminals. c. Slide heat shrinkable insulation over solder connections and shrink insulation using heat gun. d. Push EMI filter jack through mounting hole in front panel (3A5H25), from rear, and align screw holes. 7-6-467
e. Attach EMI filter to front panel with four cross-recessed pan head screws, using No. 1 Phillips screwdriver. f. Install front panel following procedure 6-46.18.2k. through n. 6-46.22 3A5H3 and 3A5H4, Bow Handle (Front) and Ferrule. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.22.1 Remove Procedure. a. Remove front panel following procedure 6-43.18.1a. through e. b. Remove two cross-recessed pan head screws from each handle, using No. 2 Phillips screwdriver. c. Slide ferrules from handle. 6-46.22.2 Installation Procedure. a. Slide ferrules onto handle. b. Set handle on front panel (3A5H25) and align screw holes. c. Attach handle to front panel with two cross-recessed pan head screws, using No. 2 Phillips screwdriver. d. Install front panel following procedure 6-46.18.2k. through n. 6-46.23 3A5XF1 and 3A5XF2, Fuse Holders. Removal and Installation Procedures. (See figure 6-32, sheet 2.) NOTE Fuse holder XF2 is designated a spare with no wiring attached. Disregard steps in following procedure which reference wiring and heat shrinkable insulation when XF2 is to be removed/installed. 6-46.23.1 Removal Procedure. a. Remove front panel following procedure 6-46.18.la. through e. b. Remove heat shrinkable insulation from fuse holder terminals using razor knife. c. Desolder and disconnect wires from fuse holder terminals. d. Remove retaining nut from fuse holder using 11/16 open end wrench. e. Pull fuse holder through mounting hole in front panel, from front. 7-6-468
6-46.23.2 Installation Procedure. a. Push fuse holder through mounting hole in front panel (3A5H25), from front. b. Attach fuse holder to front panel with retaining nut and tighten nut, using 11/16 open end wrench. c. Sleeve wires disconnected in procedure 6-46.23.lc., with suitable length of l/4 heat shrinkable insulation. d. Connect and solder wires disconnected in procedure 6-46.23.1c., to fuse holder terminals. e. Slide heat shrinkable insulation over solder connections and shrink insulation using heat gun. f. Install front panel following procedure 6-46.18.2k. through n. 6-46.24 3A5S1 Thru 3A5S80, Toggle Switches. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.24.1 Removal Procedure. a. Remove front panel following procedure 6-46.18.1a. through e. b. Remove retaining nut and washer attaching switch to front panel, using 5/16 nut driver. c. Pull switch through mounting hole in front panel, from rear. d. Identify and mark switch connecting wires using adhesive tape and marker pen. e. Desolder and disconnect wires from switch terminals. 6-46.24.2 Installation Procedure. a. Connect and solder wires disconnected in procedure 6-46.24.1e. to switch terminals. b. Push switch through associated mounting hole in front panel (3A5H25), from rear, ensuring ON position of switch is toward top of SRU. c. Attach switch to front panel with retaining nut and washer, using 5/16 nut driver. d. Install front panel following procedure 6-46.18.2k. through n. 6-46.25 3A5H23, Side Panel (Left). Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.25.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1. 7-6-469
b. Unscrew ground stud (3A5H9) from front panel (3A5H25), using 7/16 open end wrench. c. Remove cross-recessed pan head screw from left support hook (3A5H12), outer side only, using No. 2 Phillips screwdriver. d. Remove remaining cross-recessed pan head screw from left side of front panel, using No. 2 Phillips screwdriver. e. Remove three cross-recessed pan head screws from back panel (3A5H5), using No. 2 Phillips screwdriver. f. Remove six recessed hex screws from side panel, using 9/64 hex key. g. Loosen, but do not remove, six recessed hex screws located through access holes on top inside edge of side panel using 3/32 hex key. h. Pull side panel away from SRU. 6-46.25.2 Installation Procedure. a. Set side panel on SRU and align screw holes. b. Install six recessed hex screws in side panel using 9/64 hex key. c. Install three cross-recessed pan head screws on back panel, using No. 2 Phillips screwdriver. d. Install cross-recessed pan head screw on outer side of left support hook (3A5H12), using No. 2 Phillips screwdriver. e. Screw ground stud (3A5H9) into front panel (3A5H25), using 7/16 open end wrench. f. Install remaining cross-recessed pan head screw on left side of front panel, using No. 2 Phillips screwdriver. g. Tighten six recessed hex screws located through access holes on top inside edge of side panel, using 3/32 hex key. h. Install top and bottom covers on SRU following procedure 6-46.3.2. 6-46.26 3A5H24, Side Panel (Right). Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.26.1 Removal Procedure. a. Remove top and bottom covers from SRU following procedure 6-46.3.1. b. Remove cross-recessed pan head screw from right support hook (3A5H12), outer side only, using No. 2 Phillips screwdriver. c. Remove remaining two cross-recessed pan head screws from right side of front panel (3A5H25), using No. 2 Phillips screwdriver. 7-6-470
d. Remove three cross-recessed pan head screws from back panel 3A5H5, using No. 2 Phillips screwdriver. e. Remove six recessed hex screws from side panel, using 9/64 hex key. f. Loosen but do not remove the six recessed hex screws located through access holes on top inside edge of side panel, using 3/32 hex key. g. Pull side panel away from SRU. 6-46.26.2 Installation Procedures. a. Set side panel on SRU and align screw holes. b. Install six recessed hex screws in side panel, using 9/64 hex key. c. Install three cross-recessed pan head screws on back panel 3A5H5, using No. 2 Phillips screwdriver. d. Install cross-recessed pan head screw on outer side right support hook 3A5H12, using No 2 Phillips screwdriver. e. Install remaining two cross-recessed pan head screws on right side of front panel 3A5H25, using No. 2 Phillips screwdriver. f. Tighten the six recessed hex screws located through access holes on top inside edge of side panel, using 3/32 hex key. g. Install top and bottom covers on SRU, following procedure 6-46.3.2. 6-46.27 3A5H20 and 3A6H21, Retainer Ring and Turnlock Fastener. Removal and Installation Procedures. (See figure 6-30, sheet 1.) 6-46.27.1 Removal Procedure. The following procedure assumes replacement retainer rings are available. Retainer rings may be reused, but recommend replacement. a. Remove top/bottom cover from SRU, following procedure 6-46.3.1. b. Place cover on flat working surface with outer side down. c. Remove retainer ring. d. Pull turnlock fastener through hole in cover. 6-46.27.2 Installation Procedure. a. Push turnlock fastener through hole in cover, from outer side. b. Place cover on flat working surface with outer side down. c. Install lock washer on turnlock fastener, using lock washer installation tool or install retainer ring. d. Install top/bottom cover on SRU, following procedure 6-46.3.2. 7-6-471
6-46.28 3A5H2 and 3A5H22, Shielding Gaskets. Removal and Installation Procedures. (See figure 6-32, sheet 1.) 6-46.28.1 Removal Procedure. a. Remove top/bottom cover from SRU, following procedure 6-43.3.1. b. Pull/scrape gasket from cover, using putty knife as required. 6-46.28.2 Installation Procedure. WARNING Xylene, primer, and adhesive are flammable. Keep away from heat and open flame. Use only with adequate ventilation. a. Clean applicable area of cover with xylene and clean rags. b. Apply primer to applicable area of cover, using 1/2 paint brush. c. Allow primer to dry for two hours at room temperature. d. Apply a thin uniform coat of adhesive onto applicable area of cover (approximately 0.015 maximum thickness), using 1/2 paint brush. e. Set gasket on cover with rubber side down and align holes with turnlock fasteners. f. Press gasket evenly onto cover and wipe off excess adhesive with xylene and clean rags. NOTE The gasket will be bonded to the cover when adhesive curing is complete. Bonding is best accomplished when cover is installed with all twenty-four fasteners. g. Install top/bottom cover on SRU, following procedure 6-46.3.2. 6-46.29 3A5J2 Thru 3A5J13, Electrical Connectors. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.29.1 Removal Procedure. The following procedure assumes replacement connector availability. Do not continue without a replacement connector. a. Remove front panel, following procedure 6-46.18.1a. through e. b. Remove four cross-recessed pan head screws attaching connector to front panel, using No. 1 Phillips screwdriver. c. Pull connector through mounting hole in front panel, from rear. 7-6-472
d. Remove nut assy from rear of connector. e. Remove pin 1 from existing connector, using removal tool MS27495R22D. f. Insert pin 1 in the corresponding socket of replacement connector, using insertion tool MS27495A22D. g. Repeat step e. and f. for each remaining pin in existing connector. 6-46.29.2 Installation Procedure. a. Put nut assy on rear of connector. b. Push connector through mounting hole in front panel (3A5H25), from rear, and align screw holes. c. Attach connector to front panel with four cross-recessed pan head screws and nut assy, using No. 1 Phillips screwdriver. d. Install front panel following procedure 6-46.18.2k. through n. 6-46.30 3A5P1 Thru 3A5P12, Electrical Connectors. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.30.1 Removal Procedure. The following procedure assumes replacement connector availability. Do not continue without a replacement connector. a. Remove front panel following procedure 6-46.18.1a. through e. b. Loosen connector retaining screws using No. 1 Phillips screwdriver, and unplug from interconnecting board (3A5A18) jack. c. Remove two screws and washers from existing connector and install on replacement connector. d. Remove pin 1 from existing connector by carefully pressing spring clip located through access hole on side of connector, using jeweler s screwdriver. e. Push pin 1 into corresponding socket of replacement connector until spring clip is engaged. f. Repeat steps d. and e. for each remaining pin in existing connector. 6-46.30.2 Installation Procedure. a. Plug applicable connector into associated interconnecting board jack (3A5A18J1 thru A18J12) and tighten retaining screws, using No. 1 Phillips screwdriver. b. Install front panel following procedure 6-46.18.2k. through n. 7-6-473
6-46.31 3A5P13 Thru 3A5P16, Electrical Connectors. Removal and Installation Procedures. (See figure 6-32, sheet 3.) 6-46.31.1 Removal Procedure. The following procedure assumes replacement connector availability. Do not continue without a replacement connector. a. Remove top cover from SRU following procedure 6-46.3.1. b. Loosen connector retaining screws, using 4 flat tip screwdriver, and unplug from SRA jack. c. Remove two screws and screw lock clips from existing connector and install on replacement connector. d. Remove pin 1 from existing connector using removal tool MS27534R20 and 0.040 diameter drift punch. e. Insert pin 1 in corresponding socket of replacement connector using insertion tool MS27534A20. f. Repeat steps d. and e. for each remaining pin in existing connector. 6-46.31.2 Installation Procedure. a. Plug connector into SRA jack and tighten retaining screws using 4 flat tip screwdriver. b. Install top cover on SRU following procedure 6-46.3.2. 6-46.32 3A5H29, Electrical Contact. Removal and Installation Procedures. (See figure 6-32, sheet 3.) 6-46.32.1 Removal Procedure. a. Remove top cover from SRU following procedure 6-46.3.1. b. Identify and mark contact wire using adhesive tape and marker pen. c. Pull contact off interconnecting board (3A5A18) pin, using narrow nose pliers, if necessary. d. Cut wire flush to contact using standard diagonal cutting pliers. 6-46.32.2 Installation Procedure. a. Cut away suitable length of insulation using razor knife. b. Crimp contact to wire removed in procedure 6-46.32.1 using hand crimper. c. Push contact on interconnecting board (3A5A18) pin, using narrow nose pliers, if necessary. d. Install top cover on SRU following procedure 6-46.3.2. 7-6-474
6-46.33 3A5F1 and 3A5F2, Fuses. Removal and Installation Procedures. (See figure 6-32, sheet 2.) 6-46.33.1 Removal Procedure. a. Set 3A5 circuit breaker (3A11CB1) to OFF position and tag. b. Remove fuse holder cap from use holder (3A5XF1, XF2) by twisting cap 1/4-turn CCW and pulling out of fuse holder. c. Pull fuse from fuse holder cap. 6-46.33.2 Installation Procedure. a. Push fuse into fuse holder (3A5XF1, XF2) cap. b. Align fuse holder cap tabs with fuse holder slots and push cap into fuse holder until seated. Twist cap 1/4-turn CW. c. Remove tag from 3A5 circuit breaker (3A11CB1) and set breaker to ON position. d. Verify proper operation of countermeasures set. e. Return equipment to current readiness condition. 6-47 3A11, ELECTRICAL EQUIPMENT CABINET, CY-7772A, PARTS REMOVAL AND INSTALLATION. 6-47.1 Tools and Materials Required. Refer to applicable procedures to be performed (see para 6-47.2) and select the required tools/materials from the following list. a. Adhesive, black, silicone (MIL-A-46146) b. Brush, paint, 1/2 (2 required) c. Desoldering device, solder wick or solder sucker d. Electrical contact insertion tool (PN MS27534A16) e. Electrical contact insertion tool (PN MS27495A22D) f. Electrical contact removal tool (PN MS27534R16) g. Electrical contact removal tool (PN MS27495R22D) h. Heater, gun type, electrical i. Insulation sleeving, heat shrinkable, 1/4 j. Insulation sleeving, heat shrinkable, 3/8 k. Knife, putty 7-6-475