TM 11-5810-329-23 SUPERSEDES COPY DATED 11 MARCH 1986 technical manual UNIT AND INTERMEDIATE DIRECT SUPPORT MAINTENANCE for DIGITAL SUBSCRIBER VOICE TERMINAL TSEC/KY-68 (NSN 5810-01-082-8404) and AUXILIARY POWER SUPPLY HYP-71/TSEC (NSN 5810-01-082-8412) Protective marking is in accordance with Paragraph 3-200, exemption 3a, AR 340- 17 EQUIPMENT DESCRIPTION Page 1-5 SERVICE UPON RECEIPT Page 2-1 & 3-1 UNIT PMCS Page 2-11 UNIT TROUBLESHOOTING Page 2-15 UNIT MAINTENANCE PROCEDURES Page 2-16 STORAGE AND SHIPMENT Page 2-23 IDS TROUBLESHOOTING Page 3-5 IDS MAINTENANCE PROCEDURES Page 3-51 Headquarters, Department of the Army, August 1987 FOR OFFICIAL USE ONLY
Transcript
TM 11-5810-329-23
SUPERSEDES COPYDATED 11 MARCH 1986
technical manual
UNIT AND INTERMEDIATE DIRECTSUPPORT MAINTENANCE for
DIGITAL SUBSCRIBERVOICE TERMINAL
TSEC/KY-68(NSN 5810-01-082-8404) and
AUXILIARY POWER SUPPLYHYP-71/TSEC
(NSN 5810-01-082-8412)
Protective marking isin accordance withParagraph 3-200,exemption 3a, AR 340-17
EQUIPMENTDESCRIPTIONPage 1-5
SERVICE UPONRECEIPTPage 2-1 & 3-1
UNITPMCSPage 2-11
UNITTROUBLESHOOTINGPage 2-15
UNIT MAINTENANCEPROCEDURESPage 2-16
STORAGE ANDSHIPMENTPage 2-23
IDSTROUBLESHOOTINGPage 3-5
IDS MAINTENANCEPROCEDURESPage 3-51
Headquarters, Department of the Army, August 1987
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YOUR KY-68 USES 220 VAC OR 115 VAC OR -56 VDC. THISPOWER CAN INJURE YOU. BE CAREFUL NOT TO TOUCH POWERINPUT CONNECTIONS WHEN POWER IS ON.
FOR ARTIFICIAL RESPIRATION OR FLUSHING OF EYES, SEE FM21-11.
USE OF DEMOLITION MATERIALS CAN CAUSE INJURY OR DEATH.GET TO KNOW THE RULES OF FM 5-25.
WHEN USING TRICHLOROTRIFLUOROETHANE MAKE SURE THEAREA IS WELL VENTILATED. ITS FUMES ARE POISONOUS. DONOT USE IT NEAR OPEN FLAMES OR A HOT SURFACE. DO NOTGET IT ON YOUR SKIN.
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SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICALSHOCK
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, ORLIFT THE PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRYROPE OR SOME OTHER INSULATING MATERIAL
SEND FOR HELP AS SOON AS POSSIBLE
AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCEOF ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAYAND, IF REQUIRED, IMMEDIATELY START ARTIFICIAL RESUSCITATION
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STATIC ELECTRICITY
Get To Know It - because when it gets on semiconductor devices it'll ZAP’em for sure. It can certainlyDEGRADE and even DESTROY your Printed Circuit Boards (PCBs). A discharge as low as 100 to 200Volts will zap a PCB, and it can build up to a level of 39,000 Volts. It's created by the contact andseparation of materials. It can be generated by work surfaces floors chairs, clothing, paper, work orderholders, packaging material and personnel. Your body can carry a charge up to 4,000 Volts and you'llnever even know it. Here's what you can generate when you're:
• Walking on a carpet - 12,000 to 39,000 VOLTS• Walking across a floor - 4,000 to 13,000 VOLTS• Working at a bench - 500 to 3,000 VOLTS
See Why You Must Protect Us!!Remember - people, plastics, styrofoam, dust, lint, all carry large chargesof static electricity and must not be allowed to touch sensitivesemiconductor devices. The static charge can even reach us throughtest points. To protect us from getting zapped, proper grounding andhandling is required. Follow these instructions and more of us will beavailable to keep your equipment in service.
1. STORE and TRANSPORT PCBs in conductive materials - not plastic "snow" or plastic trays.2. Do not wear CLOTHING material which can store static electricity, i.e. nylon.3. GROUND yourself using a WRISTSTRAP as shown below, when unpacking, handling and replacing
PCBs or removing equipment cover.
4. If a GROUNDED BENCH AREA is not available always place PCBs on an antistatic surface mat.The known good PCBs must be removed from the protective packing and immediately installed orplaced on the antistatic surface mat. The replaced PCBs must also be placed on the antistaticsurface mat or immediately placed in protective packaging.
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*TM 11-5810-329-23
HEADQUARTERSTechnical Manual DEPARTMENT OF THE ARMYNo. 11-5810-329-23 Washington, D.C. 10 August 1987
UNIT AND INTERMEDIATE DIRECTSUPPORT MAINTENANCE MANUAL
DIGITAL SUBSCRIBER VOICE TERMINALTSEC/KY-68
ANDAUXILIARY POWER SUPPLY HYP-71/TSEC
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way toimprove the procedures, please let us know. Mail your letter or DA Form 2028(Recommended Changes to Publications and Blank Forms) directly to Commander, USArmy Communications Security Logistics Activity, ATTN: SELCL-NMP-TP, FortHuachuca, Arizona 85613-7090. A reply will be furnished to you.
Distribution authorized to U.S. Government agencies only, because thetechnical or operational information is required solely for official use.This determination was made on 1 December 1986. Requests fromoutside the U.S. Government for release of this publication under theForeign Military Sales Program must be made to Commander, U.S.Army Security Assistance Center. ATTN: AMSAC-MI/I, 5001Eisenhower Ave., Alexandria, VA 22333-0001. Requests from outsidethe U.S. Government for release of this publication under the Freedom ofInformation Act must be made to Director. National Security Agency,ATTN: SOS. Fort George G. Meade, MD 20755-6000.
*This manual supersedes TM 11-5810-329-23, dated 11 March 1986
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TABLE OF CONTENTS
HOW TO USE THIS MANUAL ..................................................................................................... v
CHAPTER 1 INTRODUCTION
Section I General Information ............................................................................................. 1-1Section II Equipment Description and Data ........................................................................... 1-5Section III Technical Principles of Operation .......................................................................... 1-9
CHAPTER 2 UNIT MAINTENANCE
Section I Repair Parts, Special Tools, TMDE,and Support Equipment ......................................................................................... 2-1
Section II Service Upon Receipt ........................................................................................... 2-1Section III Preventive Maintenance Checks and
Services (PMCS) ................................................................................................. 2-11Section IV Troubleshooting ................................................................................................... 2-15Section V Maintenance Procedures ...................................................................................... 2-16Section VI Reparation for Storage or Shipment ....................................................................... 2-23
CHAPTER 3 INTERMEDIATE DIRECT SUPPORT MAINTENANCE
Section I Repair Parts, Special Tools, TMDE,and Support Equipment ........................................................................................ 3-1
Section II Service Upon Receipt ........................................................................................... 3-1Section III Troubleshooting ................................................................................................... 3-5Section IV Maintenance Procedures....................................................................................... 3-51
APPENDIX A REFERENCES .................................................................................................... A-1APPENDIX B MAINTENANCE ALLOCATION CHART................................................................ B-1APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND
MATERIALS LIST ................................................................................................ C-1APPENDIX D ST-34 FAULT DICTIONARY ................................................................................ D-1
This manual is broken down into CHAPTERS, SECTIONS, PARAGRAPHS, and APPENDIXES. AnINDEX, placed in the back of the book, is provided to help you find specific tasks or information. AGLOSSARY, also placed in the back of the book, is provided to define terms which may be unfamiliar.
Only main paragraph headings are numbered. Subparagraphs are not numbered, An example is-
2-16. CLEANING
EXTERIOR SURFACE
Remove dust and loose dirt with a soft cloth.
CONNECTORS
Clean all connectors .........................................
and
are given as special reminders for:• Doing your task properly.• Giving additional and special instructions.• Protecting your equipment.• Protecting yourself.
To find SPECIFIC TASKS/INFORMATION, look in the INDEX. Tasks and information are listedalphabetically and refer you to the page number within the book.
Always read through a complete procedure/task before you actually perform the procedure/task.
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CHAPTER 1INTRODUCTION
SECTION I GENERAL INFORMATION
1-1. SCOPE.
TYPE OF MANUAL
Unit and Intermediate Direct Support maintenance.
MODEL NUMBER AND EQUIPMENT NAME
TSEC/KY-68-Digital Subscriber Voice Terminal (also called KY-68 throughout this manual).HYP-71 /TSEC-Auxiliary Power Supply (also called HYP-71 throughout this manual).
PURPOSE OF EQUIPMENT
The KY-68 is used for encrypting/decrypting voice traffic and provides secure digitized data trafficwhen used with various devices. The HYP-71 is used to supply operating power and interfaceconnections.
1-2. MAINTENANCE FORMS AND RECORDS.
Department of the Army forms and procedures used for equipment maintenance will be thoseprescribed by DA PAM 738-750, The Army Maintenance Management System.
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1-3. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE
Destruction of your KY-68, along with keying material and fill devices, will be done as directed by theCOMSEC emergency plan for your unit. If you do not have time to follow the emergency plan, follow theorders of the senior person present. Refer to SB 725-1300-1 and the following paragraphs for destructionprocedures.
In an emergency when you can no longer protectCOMSEC material or move it to a secure place, theKEYING MATERIAL (VARIABLES) MUST BE THEFIRST THING DESTROYED. As time allows, the listbelow gives you the order in which COMSECmaterial must be destroyed.
• SUPERSEDED AND CURRENTLY EFFECTIVE keying material. To includezeroizing your KY-68 and all fill devices in use.
• TOP SECRET multi holder keying material which is to be used within the next 30days.
• SECRET and CONFIDENTIAL multi holder keying material which is to be usedwithin the next 30 days.
• MAINTENANCE MANUALS or at least the pages containing sensitiveinformation.
• CLASSIFIED PRINTED CIRCUIT BOARDS in your KY-68.
• Any remaining classified COMSEC material to include future keying material andthe KY-68.
METHOD OF DESTRUCTION
Your COMMANDER will tell you HOW to destroyyour KY-68 and COMSEC material. If you do nothave time to receive orders from the commander,see the following for possible methods ofdestruction.
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KEYING MATERIAL AND COMSEC DOCUMENTS
Routine destruction methods, such assledge hammers, acetylene torches, etc., can beused.
TSEC/KY-68
Use any means to leave your KY-68 so that it can't be used orrepaired. Remove and destroy the classified parts, such as certainprinted circuit boards. If the classified parts are destroyed, you do nothave to completely destroy your KY-68.
Thermite incendiary hand grenade TH3, AN-M14 may be usedoutside the continental United States. TB 380-41-5, Appendix C.
Incinerators may be used to destroy printed circuit boards. You mayhave to break up the boards after they have been taken from theincinerator.
Acetylene torches, sledge hammers, fire axes, etc. may be used.Printed circuit boards may be destroyed by hacking with an axe andscattering the pieces.
AR 380-40 tells you what you should do after you have destroyed orlost your KY-68.
1-4. PREPARATION FOR STORAGE OR SHIPMENT
COMSEC material will be stored in accordance with TB 380-41-3.
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1-5. OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS
Fill Device General Purpose Tape Reader,KOI-18/TSEC
Fill Device Electronic Transfer Device,KYK-13/TSEC
Fill Device Net Control Device, KYX-15/TSEC
Digital Subscriber TSEC/KY-68Voice Terminal
(DSVT)Hand Set Military Hand Set 350/UHead Set Headset H-349 with M-138G
Microphone
1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONSIf your KY-68 or HYP-71 needs improvement, let us know. Send us an Equipment ImprovementRecommendation. You the user, are the only one who can tell us what you don't like about yourequipment. Let us know why you don't like the design. Put it on an SF 368 (Quality Deficiency Report).Mail it to us at Commander, U.S. Army Communications Security Logistics Activity, ATTN: SELCL-NMP-TP, Fort Huachuca, Arizona 85613-7090.We'll send you a reply.
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SECTION II EQUIPMENT DESCRIPTION AND DATA
1-7. EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
The KY-68 is a single ruggedized unit that:
• Operates as a FULL-DUPLEX or HALF-DUPLEX voice/data subscriber terminal.
• Handles 16 kilobits per second (kb/s) to 32 kb/s traffic.
• Provides secure and non-secure access to switched networks.
• Provides secure access to non-switched networks.
• Can be operated with a COMSEC parent or a COMSEC subordinate switch.
KY-68INPUT VOLTAGE -21 Vdc to -56 VdcCIRCUIT PROTECTION 4,1 amp fuses(dc)
HYP-71INPUT VOLTAGE 115 Vac ± 10%, 45 to
66 Hz, single phase orPOWER REQUIREMENTS 220 Vac + 10%-15%,
45 to 66 Hz, single phas eCIRCUIT PROTECTION 1 ampere circuit
breaker (dc)1/4 ampere circuitbreaker (ac)
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1-9. PHYSICAL DESCRIPTION
The KY-68 consists of
BASE ASSEMBLY
The base contains most of the electronic parts and:
• Has a front cover which lets you get to the ANTI-SPOOF CONTROL and PRINTED CIRCUITBOARDS (PCB). A decal inside this cover shows you the location of the PCBs.
• Its rear contains POWER and EXTENSION connectors, RECEIVE (RCV) and TRANSMIT (XMT)field wire posts and a GROUND (GND) binding post.
• Has four threaded holes on the bottom plate so that unit can be fastened to a surface, if youdesire. Four rubber feet are affixed to the bottom for desk-top use.
• Is internally divided into RED and BLACK compartments.
The RED COMPARTMENT contains PCB for AUDIO, CONTROL LOGIC, and KEYGENERATOR functions.
The BLACK COMPARTMENT contains PCB for the modem and power supply circuits.
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COVER CANOPY
The cover canopy contains the
• Operator's controls and indicators
• Fill and Handset/Headset connectors
• Annunciator
• Handset cradle
• Variable storage battery compartment
The microphone amplifier PCB is mounted inside the cover canopy.
ELECTRICAL PROTECTION
Four fuses, located on PCB E-EUN, protect against over-current. The wire line inputs have internalprotection for lightning, EMP, and dc voltage reversal should the transmit and receive pairs beaccidentally connected to the wrong posts. If these fuses are blown in the PCB E-EUN, the unit must berepaired at Intermediate Direct Support Level.
INTERNAL ADJUSTMENTS
There are three internal adjustments:
• DATA RATE-allows selection of either 16 or 32 kb/s loop data rate.
• OPERATING MODE 1 or 2-allows selection of operating mode.
• EXTERNAL SPOOF CONTROL-enables or disables control of the spoof circuitry.
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HANDSET/HEADSET
Your KY-68 is normally supplied with Military Handset H-350/U.
Headset H-349 with an M-138G microphone may also be used.
1-10. ACCESS AND PHYSICAL SECURITY
The unkeyed (no variables loaded) KY-68 is classifiedCONFIDENTIAL
Refer to the INTRODUCTION in KAM-403( ) /TSEC for further details on classification of the KY-68,other related COMSEC materials and ancillary devices. Physical security requirements for the KY-68 isalso covered.
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SECTION III TECHNICAL PRINCIPLES OF OPERATION
1-11. FUNCTIONAL DESCRIPTION
There are six major functions performed by your KY-68:
• Power distribution.
• Signaling.
• Voice communications.
• Data transfers.
• Remote fill.
• Local fill.
As shown below, there are two ways your KY-68 can be used in a system:
• Through a Circuit Switch (normal mode).
• Directly (back-to-back) with another KY-68 (Sole user mode).
Block diagrams for the six major functions follow. See Chapter 4, KAM-403( )/TSEC for a moredetailed description.
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CHAPTER 2
UNIT MAINTENANCE
SECTION I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
2-1. COMMON TOOLS AND EQUIPMENT
For authorized common tools and equipment refer to the Modified Table of Organization andEquipment (MTOE) applicable to your unit.
2-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
No special tools, TMDE, and support equipment are required for unit maintenance of the KY-68/HYP-71.
2-3. REPAIR PARTS
Repair parts are listed in the repair parts and special tools list (TM 11-5810-329-24P) covering unit,intermediate direct support, and intermediate general support maintenance for the KY-68/HYP-71.
SECTION II SERVICE UPON RECEIPT
2-4. SITE AND SHELTER REQUIREMENTSSite and shelter requirements may be found in the manual for the communications system with which
the KY-68 is used.
2-5. UNPACKING
The KY-68 may be PACKAGED for shipment orshipped in its TRANSIT CASE. When packaged forshipment, the KY-68 and its accessories are packedin individual cartons. All cartons are usually packedin corrugated boxes. The HYP-71 requires nopackaging for shipment.
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KY-68 IN TRANSIT CASE
KY-68 has foam cushion material affixed to inside surfaces of thetransit case to protect unit from shock during transportation.
A manual pressure relief valve (not shown) must be closed whileunit is on ground and opened two turns before air transport.
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HYP-71
The top assembly (cover) has cushion material affixed to itssurfaces to protect unit from shock during transportation. It alsoprovides storage area for connecting cables.
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2-6. CHECKING UNPACKED EQUIPMENT
Inspect the equipment for damage caused during shipment. If damage is found, report the damageon a SF 361, AR 55-38.
Check the equipment against the packing slip to see if the shipment is complete. Report any missingitems as directed in AR 735-11-2.
Check to see if the KY-68 has been modified.
Equipment that has been modified will have the Modification WorkOrder (MWO) number scratched from the modification record label.
Check TB-750-38 for listing of current MWO which apply to the KY-68 and see if they have beenapplied. Apply all URGENT MWOs. Schedule all normal MWOs.
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2-7. INSTALLATION INSTRUCTIONS
Unit level installation action is limited to physically connecting yourKY-68 to your communication system. IF YOUR KY-68 IS PRESETFOR ONE OPERATING MODE OR LOOP RATE AND YOUR SYSTEMREQUIRES THE OTHER, INTERMEDIATE DIRECT SUPPORTMAINTENANCE MUST ASSIST IN THE INSTALLATION.
No special tools, test equipment, or materials are required for installation of the KY-68. All cableconnections are made by hand.
MOUNTING
The HYP-71 is self contained and does not require any specialmounting instructions.
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Your KY-68 may be hard-mounted in some installations. To hard mount:
Mount your KY-68 to desired surface using 8-32machine screws with the threaded holes from which themounting feet were removed
INTERCONNECTING CABLING
Your KY-68 can be powered by either an HYP-71 Auxiliary PowerSupply or the common battery of the switch your KY-68 is operatingwith.
To prevent damage to the E-EUN printed circuit board, in a switchoperation, the RCV and XMIT wirelines must be identified prior toconnecting to the terminals on the KY-68. Wirelines can beidentified by using a multimeter and doing the following steps:
•• Set meter to 200 Vdc Scale.•• Connect (Black) negative lead to ground.•• One at a time, connect (Red) positive lead to the unterminated lines.•• Observe meter reading -
RCV lines should be O VdcXMIT lines should be -21 Vdc to -56 Vdc
•• Once these lines have been metered label them.•• Connect the pair metered at O Vdc to the RCV posts of the KY-68.•• Connect pair metered -21 Vdc to -56 Vdc to the XMIT terminals of the KY-68.
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When operating with a circuit switch, the KY-68 is supplied with upto 300 mA at -56 Vdc. This power can injure you. Do not touch barefield wires when making the following connections.
The four wire field pair must be checked and identified prior tobeing connected to the KY-68 (see page 2-8 for instructions). OnlyCertified Maintenance Personnel at Intermediate Direct SupportLevel are authorized to repair the KY-68 by replacing the fuse(s).
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If you power source is the HYP-71 and your installation uses field cable
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2-8. PRELIMINARY SERVICING AND ADJUSTMENT
No preliminary servicing or adjustment of your KY-68 is required. Should your operation change andyour operating mode, loop rate, or external spoof control need adjustment, have Intermediate DirectSupport maintenance do the work.
SECTION III PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
2-9. GENERAL
Unit preventive maintenance is to be performed quarterly. PMCS should be performed monthly ifyour KY-68 is in stand by (ready for immediate operation) condition. PMCS is not needed if your KY-68 isin limited storage. Maintenance forms and records to be used and maintained are specified inDA PAM 738-750. Perform all checks and services in the sequence listed in the PMCS chart. No tools ortest equipment are needed for Unit PMCS.
Fumes of TRICHLOROTRIFLUOROETHANE are poisonous. Providethorough ventilation whenever you use it; do not breathe the fumes.Do not use near open flame or hot surface.TRICHLOROTRIFLUOROETHANE will not burn, but heat changesthe fumes into a harmful gas. Try not to get it on your skin. Usegloves, sleeves and an apron which solvent cannot penetrate.
ROUTINE CHECKS
Routine checks (such as cleaning, washing, checking for frayed cables, tightening loose nuts, boltsand screws, correct seating of connectors, and completeness of equipment, etc.) are not listed as PMCS.These tasks should be done anytime you see they are needed.
If you find any damage during PMCS, refer to theTROUBLESHOOTING procedures (page 2-15) or MAINTENANCEprocedures ( page 2-16) on how to correct it. If the instructions arenot there, have Intermediate Direct Support correct the problem.
Use the number in the ITEM column of the PMCS table for the TMITEM NO. on DA Form 2404 (Equipment Inspection and MaintenanceWorksheet)
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DA FORM 2404, EQUIPMENT INSPECTION AND MAINTENANCE WORKSHEET.
2-10. PMCS CHART
Perform these checks and services every three months.
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QUARTERLY PMCS CHART
ITEMITEM TO BENO. INSPECTED PROCEDURES
1 Mounting If your KY-68 is hard-mounted,check to see that mounting boltsare firmly in place.
2 Indicators Go off-hook. Check that the RING/BUSY indicator lights and thatNSW indicator flashes.
3 Fill Battery Check that battery is not out ofdate. Date of installation isrecorded on the "BAT INSTLDATE" scratch plate on frontpanel. Battery life is 180 days.Check that there is no indication ofbattery swelling.
4 Groundwire Be sure Power is OFF whenchecking the groundwire. See thatit is free from fungus, rust, andcorrosion and that firm contact ismade with KY-68 ground terminaland earth ground. Clean asrequired.
5 Preservation Check all equipment surfaces forfungus, rust, corrosion. Clean asrequired. Refer to higher level ofmaintenance if painting isrequired.
6 Publications Check DA PAM 310-9 for newapplicable publications. Check TB750-38 for any new applicableMWOs. All URGENT MWOs mustbe applied at once.
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SECTION IV TROUBLESHOOTING
2-11. GENERAL
This section lists problems that may occur during normal operation of your KY-68 or found duringPMCS.
Don't skip over steps. You must follow the steps in the order they are listed.
This section does not list all of the problems that could happen to your KY-68. If a problem is notlisted, or if a problem cannot be fixed by the steps given, notify higher level maintenance or your superior.
Follow the steps when using the troubleshooting table:
• MALFUNCTION-Look here for your problem.
• TEST OR INSPECTION-If you find your problem under MALFUNCTION, this will give you thepossible cause.
• CORRECTIVE ACTION-This will tell you how to possibly correct your problem.
Troubleshooting procedures take for granted that your KY-68 isgetting power. Always check the power source to see that it is ingood working order before you troubleshoot.
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2-12. TROUBLESHOOTING TABLE
MALFUNCTIONTEST OR INSPECTION
CORRECTIVE ACTION
1. Zeroized unit does not initialize properly.
Check to see if fill cable is seated properly.
Remove and reconnect fill cable to KY-68 and fill device.
Perform check operation on variable(s) in fill device(Chapter 2, TM 11-5810-329-10).
Load with a good variable. If trouble persists, replace KY-68.
2. Indicators not lit or flashing and no tone present in handset/headset when you go OFF-HOOK.
Check power source and cable.
Replace power source or cable.
Check wirelines.
Remove wirelines from XMIT and RCV and verify they are labeled and connectedcorrectly. Connect wirelines to proper terminal posts.
SECTION V MAINTENANCE PROCEDURES
No lubrication is required at the Unit maintenance level.
2-13. GENERAL
Unit maintenance of the KY-68 is limited to:
INSPECTION REPLACEMENT• External • KY-68• Visual • Fill battery and cover
Your KY-68 uses 220 Vac or 115 Vac or -56 Vdc. This power caninjure you. Make sure ALL power to the KY-68 has been removedbefore doing the following steps.
CONNECTORS. See that all connectors are properly seated.
CABLES. See that cables are not broken or cracked.
FILL BATTERY. See that battery is not outdated or shows signs of corrosion. Battery life is 180days.
GROUNDING. See that ground terminal is properly connected to ground and that wireline is notbroken or corroded.
EXTERIOR. See that exterior surface is free of dirt, dust, grease, and fungus.
HANDSET/HEADSET. See that unit is properly connected to KY-68 and that push-to-talk switchfunctions properly.
2-15. TESTING
Unit testing is limited to:
• Performing operating procedures of Chapter 2 of TM 11-5810-329-10
• Checking HYP-71 battery for proper voltage
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With a 6-ohm, 30-watt resistor connected between battery terminals 1 (neg) and 4 (pos) check for 10 to12 Vdc
THENConnect the resistor between terminals 2 (neg) and 5 (pos) and check for -10 to -12 Vdc. Replacebattery if less than 10 Vdc is found.
LEGEND1 Connector Latch 7 Connector J1
2 Connector P1 8 Connector J2
3 Battery Cover Captive Screw 9 Connector J3
4 Battery Cover 10 Power Switch
5 Battery 11 MASTER/SLAVE Switch
6 PRI/SEC (Primary/Secondary)Switch
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2-16. CLEANING
Fumes of TRICHLOROTRIFLUOROETHANE are poisonous. Makesure the area is ventilated. Do not use it near open flames or a hotsurface. Do not get it on your skin. Use gloves, sleeves, and anapron which solvent cannot penetrate.
EXTERIOR SURFACE
Remove dust and loose dirt with a soft cloth.Remove grease oil, fungus and ground-in dirt with a cloth dampened with
TRICHLOROTRIFLUOROETHANE.
CONNECTORS
Clean all connectors with a cloth dampened with TRICHLOROTRIFLUOROETHANE. Wipe pincontacts with the same solution. Clean connector contacts the same way using a small brush ortoothpick.
GROUNDWIRE
Check for rust or corrosion and clean as required with a wire brush andTRICHLOROTRIFLUOROETHANE. Coat corrodible parts with a light film of silicone compound.
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2-17. REPLACEMENT
REPLACING KY-68
Check the OPERATE MODE LABEL on your replacement KY-68 tomake sure that the operating mode and loop rate are the same asthe KY-68 being replaced. If needed, have Intermediate DirectSupport make the necessary internal adjustments for your type ofoperation.
When operating with circuit switch the common battery provides upto 300 mA at -56 Vdc. This power can injure you. Be careful not totouch bare wires when disconnecting field wire leads.
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NO SPECIAL INSTRUCTIONS ARE NEEDED FORHOOKING-UP YOUR REPLACEMENT KY-68
REPLACING FILL BATTERY AND COVER
If battery is removed when your KY-68 is powered down, any storedvariables will be lost (zeroized).
Loosen (do not remove) clip screw enough to allow battery to slide out.
Insert replacement battery and secure clip to cover.
Make sure the (+) and (-) signs on the battery, cover, and battery compartment match.
Place battery and cover back into compartment and secure with four captive screws.
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Be careful when disposing the replaced fill battery. BA 1372 is amercury battery and will explode if it is accidentally shorted orplaced in an incinerator. Dispose of battery as specified by localprocedure.
CABLE REPLACEMENT
All cabling used with the KY-68/HYP-71 uses the hand twist-on connectors which require no specialinstruction for replacement.
HANDSET/HEADSET REPLACEMENT
Both the handset and the headset use hand twist connectors. No special instructions are needed forreplacement.
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SECTION VI PREPARATION FOR STORAGE OR SHIPMENT
2-18. SECURITY PROCEDURES
Refer to AR 380-5 and TB 380-41 (series).
2-19. DISASSEMBLY OF EQUIPMENT
When operating with a circuit switch, the KY-68 is supplied with upto 300 mA at -56 Vdc. This power can injure you. Do not touch barefield wires when you are disassembling your KY-68.
Remove and disassemble your KY-68 as shown in paragraph 2-17, page 2-21.
Remove fill battery as shown in paragraph 2-17 page 2-21.
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2-20. REPACKING
Your KY-68/HYP-71 can be shipped and stored in cartons or transit case. See paragraph 2-5, page2-1 (UNPACKING) and perform the procedures in reverse order.
2-21. TYPES OF STORAGE
• Short term (administrative) = 1 to 45 days.All equipment in short term storage must be able to be made ready within 24 hours for use on a mission.Before placing any item in short term storage, perform next schedule PMCS and correct or repair anydeficiencies you find. The storage site should provide required protection from extreme weatherconditions and allow you to reach the equipment for visual inspections or exercises, when applicable.
• Intermediate = 46 to 180 days
• Long term or flyable = no time limit
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CHAPTER 3INTERMEDIATE DIRECT SUPPORT MAINTENANCE
SECTION I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
3-1. COMMON TOOLS AND EQUIPMENTFor authorized common tools and equipment refer to the Modified Table of Organization and
Equipment (MTOE) applicable to your unit.
3-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENTSee Appendix B Maintenance Allocation Chart and TM 11-5810-329-24P for special tools TMDE, and
support equipment available to Intermediate Direct Support Maintenance.
3-3. REPAIR PARTSRepair parts are listed in the repair parts and special tools list (TM 11-5810-329-24P) covering
intermediate direct support and special repair activity maintenance for the equipment.
SECTION II SERVICE UPON RECEIPT
3-4. GENERAL
Refer to Chapter 2, page 2-1 of this manual for the following service upon receipt information.
• Site and shelter requirements (page 2-1)• Unpacking (page 2-1)• Checking unpacked equipment (page 2-6)• Installation instructions (page 2-7)
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3-5. PRELIMINARY SERVICING AND ADJUSTMENTS
Preliminary servicing and adjustments which are required for the installation of your KY-68 consist ofsetting the DATA RATE SWITCH, MODE JUMPER and EXTERNAL SPOOF CONTROL JUMPER for thetype of operation required by your mission.
If the HYP-71 Auxiliary Power Supply is used for your operation, the MASTER/SLAVE switch mustalso be set.
DATA RATE SWITCH
Be sure to record the setting you have made on the operate modelabel.
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MODE AND EXTERNAL SPOOF CONTROL
Static electricity will damage PCBs. So-• Store and transport PCBs in conductive materials not plastic "snow"
or plastic trays.• GROUND yourself before handling PCBs.• Place PCBs on a GROUNDED bench surface or antistatic surface
before handling PCBs.• Do not wear clothing which can store static electricity, i.e., nylon.Refer to front of manual for detailed information
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To select mode 2 operation, connect jumper P3from jack J2 to jack J3
To select mode 1 operation, connect jumper P3from jack J2 to jack J4
To enable external spoof control, connectjumper P2 from jack J5 to jack J6
To disable external spoof control, connectjumper P2 from jack J5 to jack J7
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SECTION III TROUBLESHOOTING
Troubleshooting at the intermediate direct support level consists ofvisual checks, and bench test operational checks.
VISUAL
3-6. TROUBLESHOOTING
Check to see that:
• Mode and Data Rate are set for the assigned on-line operation.
• Anti-spoof control is disabled.
• Correct variables have been loaded and are stored in KY-68.
• Proper power is being used.
• There are no cracked, frayed or broken cables.
• All connectors are tight and firmly in place.
• The fill battery is not outdated.
• The 4-wireline connections are labeled and correctly attached.
TROUBLE ISOLATION TO A DEFECTIVE KY-68
When troubleshooting, always check to see that power is on andcables are properly connected.
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If trouble is in a switch loop, have the switch attendant do a loop around test. Switch diagnostics willtell you which KY-68 is bad.
There are four fuses used in protecting the KY-68 transmit andreceive modems. If trouble occurs when you are in a wireline setup,check fuses (see paragraph 3-7, page 3-56). Also check to becertain the wirelines are labeled and correctly attached (see page 2-8 for instructions).
INTERMEDIATE LEVEL TEST SET ST-34 BENCH TEST/OPERATIONAL CHECKS
A self-test of the ST-34 is required before test of the KY-68 canbegin. When this self-test is made a small amount of ST-34 is notchecked. This means that your KY-68 may cause a NO GO readingon the ST-34 even though it is good. So, if the ST-34 continues toshow your KY-68 as NO GO after all PWAs have been replaced,connect the ST-34 to a KNOWN GOOD KY-68 and repeat the ST-34test.Then, if the KNOWN GOOD KY-68 gives a GO reading you know theST-34 is operating properly and the original KY-68 under test is badand must be sent to higher level maintenance for repair. If theKNOWN GOOD KY-68 gives a NO GO reading, the ST-34 isDEFECTIVE.
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The ST-34 does not check the KY-68 common battery power input Ifthe ST-34 gives a GO reading but the KY-68 does not operate as itshould in a wireline setup, replace the Diphase Modem PCB E-EUN.(See page 3-55).
Connect KY-68, KG-82, and ST-34 as shown
NOTE: USE CABLE ASSEMBLY W2 (ON502465) FOR 220 Vac
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When the front cover is removed the KY-68 is zeroized by thetamper proof switch. To operate the KY-68 with the cover off, thetamper proof switch must be closed.
Static electricity will damage PCBs. So-• Store and transport PCBs in conductive materials not plastic "snow"
or plastic trays.• GROUND yourself before handling PCBs.• Place PCBs on a GROUNDED bench surface or antistatic surface
before handling PCBs.• Do not wear clothing which can store static electricity, i.e., nylon.Refer to front of manual for detailed information
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Make a written record of the position of Jumper P3 (Mode Select)and Jumper P2 (External Spoof Control) so that they can bereturned to their original position when test is over.
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YOU ARE NOW READY TO BEGIN TEST
Throughout the test and at the end of each step, a normal readingwill be given you and should appear in STB display. Should areading other than normal be shown, a fault is indicated. Forexample, if the test step tells you the normal reading is 003 but thedisplay window reads 122 and the NO GO indicator lights, a fault isindicated. Go to the FAULT DICTIONARY (Appendix D) and findfault indication 122. This will tell you which PCB, part, or other unitis defective.
If the KY-68 is operating normally, no faults will be indicated andthe test will end with the STB-34 GO indicator glowing.
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If the FAULT DICTIONARY tells you:
• The fault was due to operator error, you must repeat the test.
• Which component is faulty, replace that component.
• The fault is in PCB E-EUN, check the fuses (page 3-56) beforereplacing the PCB.
BEFORE REPLACING ANY COMPONENT POWER TO THE STP-34MUST BE OFF
If more than one component is shown as defective:• Replace the first part shown, then check to see if fault is corrected.
IF NOT• Put the part just replaced back into KY-68• Replace the next part shown, and check to see if fault is now
corrected
If fault remains uncorrected, continue to replace and check each partshown until trouble is found. If KY-68 does not return to normaloperation after all suggested corrections have been tried, send unit toSRA
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Throughout the test, timing between steps is important. Atthe end of some steps a will appear to tell you how muchtime you have to begin the next step. If you wait too long, the testwill be void and you must start the entire test over again.
Should you have to star the entire test over again, TURN OFF STP-34 POWER then TURN BACK ON. This will zeroize the ancillary KG-82.
Because of the time constraints between some of the steps-RESTPERIODS occur throughout the test. READ AHEAD from one restperiod to the next rest period before trying to run those series ofsteps.
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STEP 1
STEP 2 MUST BE STARTED WITHIN20 SECONDS AFTER 001 IS DISPLAYED
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STEP 2
STEP 3 MUST BE STARTED WITHIN20 SECONDS AFTER 002 IS DISPLAYED
STEP 3
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STEP 4
STEP 5
STEP 6 MUST BE STARTED WITHIN20 SECONDS AFTER 005 IS DISPLAYED
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A display of 004 instead of 005 tells you that the KY-68 under test isstrapped for mode 1 instead of mode 2. See page 3-9 and strapPCB E-EUL for mode 2 and start test over.
STEP 6
You must wait 5 SECONDS after 005 is displayed before youcan start step 6.
A ten second tone indicates bad parity
STEP 7 MUST BE STARTED WITHIN20 SECONDS AFTER 006 IS DISPLAYED
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STEP 7
A ten second tone indicates bad parity.
Test set goes into rest. You are not required to start next stepwithin any specific time.
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STEP 8
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STEP 9
STEP 10 MUST BEGIN WITHIN60 SECONDS AFTER 008 IS DISPLAYED
If the STB-34 DISPLAY shows 346 or 347 check to see if theEXTERNAL SPOOF CONTROL is strapped for DISABLE (Jumper P2connected between J5 and J7 on PCB E-EUL). See page 3-9
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STEP 10
STEP 11 MUST BEGIN WITHIN10 SECONDS AFTER 009 IS DISPLAYED
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STEP 11
STEP 12 MUST BEGIN WITHIN 10 SECONDSAFTER 010 IS DISPLAYED
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STEP 12
Test set goes into rest. You are not required to start next stepwithin a specific time.
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STEP 13
STEP 14
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STEP 15
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Test set goes into rest. You are not required to start next stepwithin a specific time.
STEP 16
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STEP 17 MUST BEGIN WITHIN 20 SECONDS AFTER 006 ISDISPLAYED
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STEP 17
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STEP 18
STEP 19 MUST BEGIN WITHIN 60 SECONDS AFTER 014 ISDISPLAYED
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STEP 19
STEP 20 MUST BEGIN WITHIN 60 SECONDS AFTER 015 ISDISPLAYED
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STEP 20
STEP 21 MUST BEGIN WITHIN 20 SECONDS AFTER016 IS DISPLAYED
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STEP 21
STEP 22 MUST BEGIN WITHIN 20 SECONDS AFTER 017 ISDISPLAYED
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STEP 22
Do not press key until 018 is displayed, but key must be
pressed within 20 seconds after key has been depressed.
Depress key and again talk into handset, vary the audio volume,listen for digit tone change, and observe that display changes to 019.
To complete this step, each key of the keyboard must be tested.
Keys must be pressed, in order, starting with as shown above, then
- - of the first row, then - - - of the second row,
- - - of the third row, and - - and of thebottom row. REMEMBER, do not move to a following key until thedisplay shows a change in number. The proper display number for eachkey is-
After 033 is displayed the STB-34 start indicator will light and KY-68Ring/Busy indicator will remain lit and NSW will flash.
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STEP 23
STEP 24
STEP 25
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STEP 26
STEP 27
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STEP 28
STEP 29 MUST BEGIN WITHIN 10 SECONDS AFTERHANDSET HAS BEEN RETURNED TO CRADLE
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STEP 29
STEP 30
Annunciator ringback will stop and NSW TONE will beheard in handset, NSW indicator will flash.
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STEP 31
STEP 32
A 1/2-second steady MEDIUM A 1/2-second steady HIGHFREQUENCY TONE is heard, FREQUENCY TONE is heard,
followed by the NSW tone. followed by the NSW tone.NSW indicator flashes. NSW indicator flashes.
STEP 33
FORCE CLEAR (low tone 1/2-second on, 1/2-second off) and NSW TONES are heard in handset for 2 or3 seconds. Ring/Busy and NSW indicators go off.
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STEP 34
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STEP 35
STEP 36
You will hear a HIGH FREQUENCY CONSTANT TONE along with theNSW TONE in your headset and the NSW indicator will light.
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STEP 37
STEP 38
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STEP 39
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STEP 40
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STEP 41
STEP 42
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STEP 43
Static electricity will damage PCBs. So-• Store and transport PCBs in conductive
materials not plastic trays.• GROUND yourself before handling PCBs.• Place PCBs on a GROUNDED bench surface or
antistatic surface before handling PCBs.• Do not wear clothing which can store static
electricity, i.e., nylon.Refer to front of manual for detailed information
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STEP 44
STEP 45 MUST BEGIN WITHIN 20 SECONDS AFTER006 IS DISPLAYED
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STEP 45
STEP 46
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STEP 47
STEP 48
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STEP 49
STEP 50
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page 3-7
page 3-9
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STEP 51
TEST END
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SECTION IV INTERMEDIATE DIRECT SUPPORT MAINTENANCE
No lubrication of the KY-68/HYP-71 is required at the IntermediateDirect Support level
3-7. GENERAL
Intermediate Direct Support maintenance is responsible for:
• Assessing the condition of equipment received from a lower level facility
• Performing required repair by replacing plug-in assemblies.
• Forwarding equipment to special repair activities (SRA) when repairs are beyond the scope ofintermediate direct support.
• Fully testing each equipment to verify its operational capabilities before returning to a useractivity.
Intermediate Direct Support maintenance is limited to:
INSPECTION• External• Visual
TESTING• Operational• Bench
REPLACEMENT• PCB's• Front Panel Knobs• Fuses
ADJUSTMENT• Data Rate Switch• Strapping
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3-8. MAINTENANCE PROCEDURES
INSPECTION
Before running any bench checks, check the exterior of theequipment for some obvious fault which requires repair by a SRA.If such a fault is found, stop all intermediate direct supportmaintenance and forward the unit, along with a report of yourfinding, to the SRA. If no fault is found by your external visualinspection, make an interior inspection.
Check that:
IDENTIFICATION AND NAMEPLATES are securely attached and flat against their mating surface.
TOP AND BOTTOM PROTECTIVE COVERS are not bent, dented or distorted and are free of rust,corrosion and any other foreign materials. Make sure that gaskets have a light coating of siliconecompound.
CHASSIS AND FRONT PANEL SURFACES are free of blisters, soft spots and excessive scratchesand that base materials are not exposed.
OPERATING CONTROLS AND CONTROL KNOBS are securely attached and have propermovement and detent action.
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ATTACHING HARDWARE (NUTS, WASHERS, SCREWS, ETC) are present and properly tightened.
CONNECTORS are firmly attached to cable, chassis and front cover. Connector dust covers areintact. Connector pins are straight and free of corrosion and other foreign material. CABLES are free ofcuts, breaks, frays and show no signs of deterioration.
INTERIOR wiring and flexible cables are intact and all areas are free of corrosion and other foreignmaterial.
SUBASSEMBLIES (IN PLACE) are firmly set and visible component parts are intact and free of burnspots, corrosion and other foreign material.
SUBASSEMBLIES (REMOVED) component parts including strap option jumpers appear to be firmlyin place. Conformal coating and etched track are continuous and undamaged (no burn spots), and all arefree of corrosion and foreign material.
MWO's applicable to the KY-68 have been applied and identified on the modification record label
TESTING
Testing at the intermediate direct support level is limited to the ST-34 bench test/operational checksof para 3-6 page 3-6. A checkout of the KY-68 should be made each time it is initially received and afterit is repaired.
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REPLACEMENT
Intermediate Direct Support maintenance is limited to replacing the;• HYP-71• KY-68• KY-68 front panel knobs• KY-68 PCBs
See paragraph 2-17, page 2-20 for replacement of your KY-68.Paragraph 2-17, page 2-23 tells you how to replace the HYP-71.
KY-68 FRONT PANEL KNOBS
The RING VOLUME, AUDIO VOLUME, and FUNCTION SEL knobs are secured by allen screws. Theseare the only knobs authorized for Intermediate Direct Support replacement.
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REPLACING KY-68 PCBs
Static electricity will damage PCBs. So-• Store and transport PCBs in conductive materials
not plastic "snow" or plastic trays.• GROUND yourself before handling PCBs.• Place PCBs on a GROUNDED bench surface or
antistatic surface before handling PCBs.• Do not wear clothing which can store static
electricity, i.e., nylon.Refer to front of manual for detailed information
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KY-68 FUSES
Static electricity will damage PCBs. So-• Store and transport PCBs in conductive materials
not plastic "snow" or plastic trays.• GROUND yourself before handling PCBs.• Place PCBs on a GROUNDED bench surface or
antistatic surface before handling PCBs.• Do not wear clothing which can store static
electricity, i.e., nylon.Refer to front of manual for detailed information
Remove PCB E-EUN as shown on page 3-55The only fuses in the KY-68 are located on the E-EUN PCBPull out the defective fuse
THENPush replacement fuse into contacts
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ADJUSTMENTS
The only adjustments authorized Intermediate Direct Support maintenance consist of:
• Setting KY-68 Data Rate Switch.
• Strapping KY-68 E-EUL for Mode and External Spoof Control .
• Setting HYP-71 MASTER/SLAVE Switch.
These adjustments are described in the Preliminary Servicing and Adjustments paragraph (3-5)pages 3-2 through 3-4.
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APPENDIX AREFERENCES
A-1. INTRODUCTIONFollowing is a list of all forms, Army Regulations, technical bulletins, technical manuals, and maintenancemanuals referenced in this manual.
A-2. FORMS
DA Form 2404 Equipment Inspection and Maintenance Worksheet.
DA Form 2028 Recommended Changes to Publications and BlankForms.
SF 361 Transportation Discrepancy Report.
SF 368 Quality Deficiency Report.
A-3. ARMY REGULATIONS
AR 55-38 Reporting of Transportation Discrepancies in Shipments.
AR 380-5 Security, Department of the Army Information SecurityProgram Regulation.
(C) AR 380-40 Department of the Army Policy for Safeguarding andControlling COMSEC Information (U).
AR 735-11-2 Reporting of Item and Packaging Discrepancies.
A-4. DA PAMPHLETS
(C) DA PAM 310-9 Index of Communications Security (COMSEC)Publications.
DA PAM 738-750 The Army Maintenance Management System (TAMMS).
DA PAM 750-10 Index of Modification Work Orders.
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A-5. TECHNICAL BULLETINS
TB 380-41 (series) Procedures for Safeguarding, Accounting and SupplyControl of COMSEC Materiel.
TB 750-10 Painting, Replating, and Preserving Instructions ForCommunications Security Equipment.
(C) TB 750-38 Alteration of Communications Security Equipment.
A-6. TECHNICAL MANUALS
TM 11-5810-329-10 Operators Manual, TSEC/KY-68 and HYP-71/TSEC.
TM 11-5810-329-24P Organizational, Direct Support, and Specialized RepairActivity Repair Parts and Special Tools List. TSEC/KY-68 and HYP-71/TSEC.
A-7. MAINTENANCE MANUALS
FM 5-25 Explosives and Demolition.
FM 21-11 First Aid for Soldiers.
SB 725-1300-1 Requisition and Issue of Cryptographic Equipment:Destroyer Incendiary; Th 4 M1A2; Grenade, HandIncendiary; Th 3 AN-M4; Document Destroyer,Incendiary ABC-M4.
A-8. OTHER PUBLICATIONS
(C) KAM-403( ) /TSEC Limited Maintenance Manual For TSEC/KY-68 and HYP-71 /TSEC.
(C) KAM-404( ) /TSEC Theory Textbook and Maintenance TroubleshootingManual TSEC/KY-68 and HYP-71/TSEC.
(C) KAO-193/TSEC Operating Instructions for TSEC/KY-68 and HYP-71/TSEC.
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APPENDIX B
MAINTENANCE ALLOCATION CHART
SECTION I INTRODUCTION
B-1. GENERAL
This section provides a general explanation of all maintenance and repair functions authorized atvarious maintenance categories.
The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibilityfor the performance of maintenance functions on the identified end item or component. Performance ofthe maintenance functions on the end item or component will be consistent with the capacities andcapabilities of the designated maintenance categories.
Section III lists the TOOLS AND TEST EQUIPMENT (both special tools and common tool sets)required for each maintenance function as referenced in section II.
Section IV REMARKS contains supplemental instructions and explanatory notes for a particularmaintenance function.
B-2. MAINTENANCE FUNCTIONS
Maintenance functions will be limited to and defined as follows:
INSPECT. To determine the serviceability of an item by comparing its physical, mechanical, and/orelectrical characteristics with established standards through examination (e.g., by sight, sound, or feel).
TEST. To verify serviceability by measuring the mechanical or electrical characteristics of an itemand comparing those characteristics with prescribed standards.
SERVICE. Operations required periodically to keep an item in proper operating condition, i.e., toclean (includes decontamination), preserve, drain, paint, or to replenish fuel, lubricants, chemical fluids, orgases.
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ADJUST. To maintain or regulate, within prescribed limits, by bringing into proper or exact position,or by setting the operating characteristics to specified parameters.
ALIGN. To adjust specified variable elements of an item to bring about optimum or desiredperformance.
CALIBRATE. To determine and cause corrections to be made or to be adjusted on instruments ortest, measuring, and diagnostic equipments used in precision measurement. Consists of comparisons oftwo instruments, one of which is a certified standard of known accuracy, to detect and adjust anydiscrepancy in the accuracy of the instrument being compared.
INSTALL. The act of emplacing, seating, or fixing into position an item part, or module (componentor assembly) in a manner to allow the proper functioning of an equipment or system.
REPLACE. The act of substituting a serviceable like type part, subassembly or module (componentor assembly) for an unserviceable counterpart.
REPAIR. The application of maintenance services, including fault location/troubleshooting,removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troublesand restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a partsubassembly, module (component or assembly), end item or system.
OVERHAUL. That maintenance effort (service/action) prescribed to restore an item to a completelyserviceable/operational condition as required by maintenance standards in appropriate technicalpublications (i.e., CIDOS). Overhaul is normally the highest degree of maintenance performed by theArmy. Overhaul does not normally return an item to like-new condition.
REBUILD. Consists of those services/actions necessary for the restoration of unserviceable equipmentto like-new condition in accordance with original manufacturing standards. Rebuild is the highest degreeof materiel maintenance applied to Army equipment. The rebuild operation includes the act of returningto zero those age measurements (hours/miles, etc.) considered in classifying Armyequipment/components.
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B-3. COLUMN ENTRIES IN THE MAC
COLUMN 1, GROUP NUMBER. Column 1 lists functional group code numbers, the purpose ofwhich is to identify maintenance significant components, assemblies, subassemblies, and modules withthe next higher assembly. End Item group number shall be "00".
COLUMN 2, COMPONENT/ASSEMBLY. Column 2 contains the names of components, assemblies,subassemblies and modules for which maintenance is authorized.
COLUMN 3, MAINTENANCE FUNCTION. Column 3 lists the functions to be performed on the itemlisted in column 2 (For detailed explanation of these functions, see paragraph B-2).
COLUMN 4, MAINTENANCE LEVEL . Column 4 specifies, by the listing of a work-time figure in theappropriate subcolumn(s), the 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 levelof maintenance. If the number or complexity of the tasks within the listed maintenance function vary atdifferent maintenance levels, appropriate work-time figures will be shown for each level. The work-timefigure 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 timeincludes preparation time (including any necessary disassembly/assembly time), troubleshooting/faultlocation time, and quality assurance/quality control time in addition to the time required to perform thespecific tasks identified for the maintenance functions authorized in the MAC.
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The symbol designations for the various maintenance levels are as follows:
C - Operator or Crew
F - Intermediate Direct Support Maintenance
L - Specialized Repair Activity (SRA)
D - Depot Maintenance
COLUMN 5, TOOLS AND EQUIPMENT. Column 5 specifies, by code, those common tool sets (notindividual tools) and special tools, TMDE, and support equipment required to perform the designatedfunction.
COLUMN 6, REMARKS . Column 6 shall, when applicable, contain a letter code, in alphabeticalorder, which shall be keyed to the remarks contained in section IV.
B-4. COLUMN ENTRIES IN TOOLS AND TEST EQUIPMENT REQUIREMENTS, SECTION Ill.
COLUMN 1, REFERENCE CODE. The tool and test equipment reference code correlates with acode used in the MAC, section II, column 5.
COLUMN 2, MAINTENANCE LEVEL . The lowest level of maintenance authorized to use the tool ortest equipment.
COLUMN 3, NOMENCLATURE. Name or identification of the tool or test equipment.
COLUMN 4, NATIONAL STOCK NUMBER. The National Stock Number of the tool or testequipment.
COLUMN 5, TOOL NUMBER. The manufacturer's pat number
B-5. COLUMN ENTRIES IN REMARKS, SECTION IV.
COLUMN 1, REFERENCE CODE. The code that is recorded in column 6, section II.
COLUMN 2, REMARKS . This column lists the information pertinent to the maintenance functionbeing performed as indicated in the MAC, section II.
FOR OFFICIAL USE ONLY
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SECTION II. MAINTENANCE ALLOCATION CHARTFOR THE
KY-68 DIGITAL SUBSCRIBER VOICE TERMINALAND AUXILIARY POWER SUPPLY HYP-71
(4)MAINTENANCE LEVEL (5)
(1) (2) (3) TOOLSGROUP COMPONENT/ MAINTENANCE UNIT INTERMEDIATE Depot AND (6)
NUMBER ASSEMBLY FUNCTION C O F H L D EQPT. REMARKS
03 Cable Assemblies Inspect 0.2 None AON511153, ON511154, Test 0.5 17 LON511155 Repair 1.0 6, 7 K
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SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS FOR THEKY-68 DIGITAL SUBSCRIBER VOICE TERMINAL
AND AUXILIARY POWER SUPPLY HYP-71
TOOL OR TEST MAINTENANCE NOMENCLATURE NATIONAL/NATO TOOL NUMBEREQUIPMENT CATEGORY STOCK NUMBERREF CODE
1 C Flathead Screwdriver 1/4 X 4 Blade 5120-00-222-88522 C Dummy Load for HYP-71 Battery 5905-01-054-5365 RER 75 F6 ROOM3 C Multimeter, Digital 6625-01-139-2512 AN/PSM-454 FLD Intermediate, Level Test Set 5810-01-111-4082 TSEC/ST-345 FLD Loop Key Generator 5810-01-082-8403 TSEC/KG-826 FLD Tool Kit, Electronic 5810-00-610-8177 TK-105 G7 LD Repair Center 4940-01-031-4541 PRC-350 C8 LD Oscilloscope 6625-01-187-7847 AN/USM-4889 LD Audio Oscillator 6625-01-133-6160 SG-1171/U
10 LD Power Supply 6130-00-752-2215 PP 2309 C11 LD Audio Extender BD KY-68/78 0N27385712 L0 Power Adapter KY-68/78 FAB lAW MAMM 404B13 LD Preamplifier Test Cable FAB lAW MAMM 404B14 LD Automatic Test Equipment 5810-01-059-4599 TSEC/ST-51
and Test Head Adapter for PCBE-EUN 5810-01-121-7976 ON273589E-FMQ 5810-01-122-4443 ON300855E-EUL 5810-01-121-4581 ON273583E-EUM 5810-01-122-2095 ON273584
15 LD HYP-71 Test Fixture FAB lAW MAMM 404B16 LD E-FMR Test Fixture FAB lAW MAMM 404B17 LD Multimeter Digital AN/USM 48618 D Power Supply Testers
#1 ON502427#2 ON300685
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SECTION IV. REMARKS FOR THEKY-68 DIGITAL SUBSCRIBER VOICE TERMINAL
AND AUXILIARY POWER SUPPLY HYP-71
REFERENCE REMARKSCODE
A Internal/ExternalB Preventive Maintenance Checks and Services (PMCS)C Limited to End Item ReplacementD OperationalE Bench Test Using TSEC/ST-34F Switches/StrappingG Repair by Replacement of Printed Circuit Board (PCB) and Authorized ComponentsH Repair PCBS and Major SubassembliesI In Compliance with TSEC/KY-68/78 CIDOSJ Test PCBS Using the TSEC/ST-51K Manually Test and RepairL Continuity TestM Limited to HYP-71 ReplacementN Repair by Replacement of BatteriesO Repair by Replacement of Cable Assemblies
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APPENDIX CEXPENDABLE/DURABLE SUPPLIES
AND MATERIALS LIST
C-1. INTRODUCTION
This appendix lists expendable/durable supplies and materials you will need to operate and maintainthe KY-68. These items are authorized you by CTA 50-970, Expendable Items.
C-2. EXPLANATION OF COLUMNS
ITEM NO. This number is referenced in the narrative instructions to identify the material (forexample, "Use cleaning compound, Item 4, App. E").
LEVEL. Shows the lowest level of maintenance that needs the listed item. Enter as applicable:
C - Crew/OperatorO - Unit MaintenanceF - Intermediate Direct Support Maintenance
NATIONAL STOCK NUMBER. Shows the National Stock Number assigned to the item; use it torequest or requisition the item.
DESCRIPTION. Shows Federal item name and, if required a description to identify the item. The lastline for each item indicates the Federal Supply Code for Manufacturer (FSCM) in parentheses followed bythe part number.
UNIT OF MEASURE (U/M). Shows the measure used in performing the actual maintenance function.This measure is shown by a two-letter abbreviation (for example, EA, SH, IN). If the unit of measurediffers from the unit of issue, requisition the lowest unit of issue that will satisfy requirements.
FOR OFFICIAL USE ONLY
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SECTION II EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
(1) (2) (3) (4) (5)NATIONAL
ITEM STOCKNUMBER LEVEL NUMBER DESCRIPTION U/M
1 F 6850-00-177-5094 SILICONE COMPOUND (81349) ozMIL-S-8660
2 C 8309-00-287-3015 CLOTH. COTTON CHEESECLOTH (81348) ydCCC-C-440
3 C 8020-00-224-8010 BRUSH, SOFT BRISTLE (81348) eaH-B-1 18
4 O 6830-00-581-9887 TRICHLOROTRIFLUOROETHANE (81349) ptMIL-C-81302
5 F 8030-00-111-2763 LOCKING COMPOUND ozMIL-S-46163
6 F None TABLE TOP MAT NO ZAP, 20" + 30"SC5203 sh(85670) 2 or equivalent
7 F None WRIST STRAP, CONDUCTIVE BAND, 270 K, pkALLIGATOR SC 1110 (85670) 2 or equivalent
8 F None ZIPPER BAG, NO ZAP 10" - 12"1 pkSC6012 (85670) 2 or equivalent3.
ORZIPPER CUSHION BAG, STATIC FREE(62049) 3 OR EQUIVALENT
1 - Other sizes available
2 - Richmond Division of Dixico Inc. Colton & Opal Sts. Box 1129 Redlands, CA 92373 (714) 794-2111
3 - Sizes will be made to order by. ADE Inc. 1560 E. 96th St. Chicago, Ill 60628 (312) 221-3400
FOR OFFICIAL USE ONLY
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APPENDIX DST-34 FAULT DICTIONARY
A1 = E-EUNA2 = E-FMQ
DICTIONARY A3 = E-EAC/1 PCB TITLETERM A4 = E-EUL
A5 = E-EUM
Probable DefectiveFault Possible KY-68/78 PCB
Indication Operator Error Or Other Part/UnitRING/BUSY indicator EUT FAULT INDICATIONS A4remains illuminated.No sidetone and A3constant whistle ortone in HYX-78.Incorrect KY-68/78 A5, A4, A2tones or displays with005, 006 ST-34indication.Incorrect KY-68/78 A5tones or displays with008 ST-34 indication.No tone with ST-34 A3 handset013 indication.Incorrect KY-68/78 A4, A3tones or displays with033, 053 ST-34indication.Incorrect KY-68/78 A4tones or displays with034 thru 052 ST-34indication.
ST-34 FAULT INDICATIONS101 KG-82 not in alarm KG-82
state.103 Failure to initiate KG-82
variable request.104 Failure to initiate KG-82
variable request.113 A2, A4, A5114 No power to KY-68/78. A1, A4, A2115 A1, A4116 Started with A4
hookswitch up.117 A4118 A1, A4119 A4, A1, A5
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APPENDIX DST-34 FAULT DICTIONARY
Probable DefectiveFault Possible KY-68/78 PCB
Indication Operator Error Or Other Part/UnitST-34 FAULT INDICATIONS
FULL DUPLEX A type of operation which allows two-way talk, messages, or data to bepassed between any two stations at the same time.
HALF DUPLEX (Also INDEPENDENT) A type of operation which allows you to transmitand receive, but not at the same time.
SOLE-USER (Also BACK-TO-BACK) A type of operation which uses two KY-68’sdirectly connected to each other without the use of a circuit switch.
FOR OFFICIAL USE ONLY
GLOSSARY-1
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INDEX
PAGE
A Adjustments:Internal .....................................................................................................................1-7Preliminary ...............................................................................................................2-11, 3-2
B Base Assembly, KY-68 .................................................................................................1-6Battery, Fill, KY-68 .......................................................................................................2-21
C Canopy, Cover .............................................................................................................1-7Case, Transit, KY-68 ....................................................................................................2-4Characteristics, Capabilities, and Features ....................................................................1-5Checking Unpacked Equipment ....................................................................................2-6Cleaning ......................................................................................................................2-19Common Tools and Equipment .....................................................................................2-1, 3-1
D Data Rate Switch .........................................................................................................3-2Description:
Destruction to Prevent Enemy Use ................................................................................2-1, 3-1
E Electrical Protection .....................................................................................................1-7Equipment Characteristics, Capabilities, Features ...........................................................1-5Equipment Improvement Recommendations ..................................................................1-4Equipment Data ...........................................................................................................1-5
F Function Description ....................................................................................................1-9Fill Battery ...................................................................................................................2-21Form DA 2404 .............................................................................................................2-13
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I Inspection:Intermediate Direct Support .......................................................................................3-51Unit ..........................................................................................................................2-17
M Maintenance Forms, Records ........................................................................................1-1Maintenance Procedures:
Intermediate Direct Support .......................................................................................3-52Unit ..........................................................................................................................2-16
P Preliminary Services and Adjustments ...........................................................................2-11, 3-2Preventive Maintenance Checks and Services:
Preparation for Storage and Shipment ...........................................................................2-23Printed Circuit Boards ..................................................................................................3-3, 3-55
R Repacking ....................................................................................................................2-24Repair Parts .................................................................................................................2-1, 3-1Replacing:
Fill Battery .................................................................................................................2-21Fuses .......................................................................................................................3-56Handset ...................................................................................................................2-22Headset ...................................................................................................................2-23HYP-71.....................................................................................................................2-24KY-68 .......................................................................................................................2-20
S Scope .........................................................................................................................1-1Security:
Access and Physical .................................................................................................1-8Procedures ...............................................................................................................2-23
Service Upon Receipt ...................................................................................................2-1, 3-1Site and Shelter Requirements .....................................................................................2-1
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INDEX-1
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S Special Tools, TMDE and Equipment .............................................................................2-1, 3-1Storage, Types of .........................................................................................................2-24Strapping......................................................................................................................3-3ST-34 Bench Test ........................................................................................................3-6
T Tests, Unit ...................................................................................................................2-17Testing, Intermediate Direct Support ..............................................................................3-6TMDE .........................................................................................................................2-1, 3-1Tools and Equipment:
Common ...............................................................................................................2-1, 3-1Special ..................................................................................................................2-1, 3-1
Troubleshooting:Unit .......................................................................................................................2-15Intermediate Direct Support ....................................................................................3-5
Types of Storage ..........................................................................................................2-24
U Unpacking ....................................................................................................................2-1
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TM 11-5810-329-23
By Order of the Secretary of the Army:
CARL E. VUONOGeneral, United States Army
Chief of Staff
Official:
R.L. DILWORTHBrigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-43R, Unit Maintenance requirements for TSEC/KY-68and HYP-71/TSEC.
¶ U. S. GOVERNMENT PRINTING OFFICE : 1994 O - 381-615
