instruction

book

HF-9000 Antenna Couplers

(intermediate maintenance)

Export Control Classification Notice (ECCN) for this document is 7E994.

2013 Rockwell Collins. All rights reserved.

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 September 9, 2013

TO: HOLDERS OF ROCKWELL COLLINS HF-9000 ANTENNA COUPLERS

INTERMEDIATE MAINTENANCE INSTRUCTION BOOK (CPN 523-0777201)

DESCRIPTION OF REVISION NO 6, DATED SEPTEMBER 9, 2013 HIGHLIGHTS

This page shows all pages of the manual that are added or changed. Replace or add the
specified pages of the manual with the new pages supplied.

PAGE NUMBER DESCRIPTION OF REVISION AND REASON FOR CHANGE

List of Effective Pages Revised to reflect current revision.
pages A and B/C
Table of Contents page Revised to reflect current revision.
ii
List of Illustrations page Revised to reflect current revision.
iii
List of Tables page iv Revised to reflect current revision.
1-4 Revised paragraph 1.5.
8-1 thru 8-8 Added new Section 8.

1/2

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 HF-9000 Antenna Couplers

instruction book
(intermediate maintenance)

Printed in the United States of America Rockwell Collins

©2013 Rockwell Collins. All rights reserved. Cedar Rapids, Iowa 52498
523-0777201-602211
2nd Edition, 15 April 2008
(HF-9000_IB_9_SEP_2013) Change 6, 9 September 2013

The document reference is online, please check the correspondence between the online documentation and the printed version.
 LIST OF EFFECTIVE PAGES INSTALL THE NEW CHANGED PAGES. REMOVE REPLACED PAGES.

CAUTION
The material in this manual can possibly change. Before you do maintenance
operations on the equipment included in this manual, make sure that you have a
complete and current manual.

We try to supply manuals that are free of errors, but some can occur. To send data to Rockwell Collins about this manual:
If a problem is found with this manual, you can send the necessary
data to Rockwell Collins. When you report a specified problem, give Rockwell Collins
short instructions. Include the part number, the paragraph or figure 400 Collins Road NE, M/S 153-250
number, and the page number. Cedar Rapids, IA 52498-0001

This manual has 105 pages given in the sequence that follows:
Page *Change Page *Change
No No No No
Front Matter (523-0777201-602211) 2-11 thru 2-13 .............................................. 0
1st Ed – 1 June 1993 2-14 Blank .................................................... 0
2nd Ed – 15 April 2008 2-15 ............................................................... 0
Chg 1 – 1 July 2009 2-16 Blank .................................................... 0
Chg 2 – 30 November 2010 2-17 ............................................................... 0
Chg 3 – 15 March 2011 2-18 Blank .................................................... 0
Chg 4 – 29 September 2011 2-19 ............................................................... 0
Chg 5 – 24 August 2012 2-20 Blank .................................................... 0
Chg 6 – 9 September 2013 2-21 ............................................................... 0
2-22 Blank .................................................... 0

Section 3 Operation
Title .............................................................. 6 3-1 ................................................................. 0
A ................................................................... 6 3-2 Blank ...................................................... 0
B ................................................................... 6
C Blank ........................................................ 1 Section 4 Theory
i ..................................................................... 1 4-1 ................................................................. 0
ii thru iv ....................................................... 6 4-2 ................................................................. 1
v thru viii ..................................................... 0 4-3 ................................................................. 0
4-4 Blank ...................................................... 0
Section 1 Description 4-5 ................................................................. 0
1-1 ................................................................. 5 4-6 ................................................................. 1
1-2 ................................................................. 0 4-7 thru 4-10 ................................................ 0
1-3 ................................................................. 5
1-4 ................................................................. 6 Section 5 Maintenance
1-5 ................................................................. 0 5-1 ................................................................. 2
1-6 ................................................................. 3 5-2 thru 5-3 .................................................. 3
5-4 thru 5-9 .................................................. 0
Section 2 Installation 5-10 Blank .................................................... 0
2-1 thru 2-3 .................................................. 0 5-11 ............................................................... 0
2-4 ................................................................. 3 5-12 Blank .................................................... 0
2-5 ................................................................. 2 5-13 thru 5-14 .............................................. 4
2-6 Blank ...................................................... 0 5-15 ............................................................... 5
2-7 ................................................................. 0 5-16 ............................................................... 4
2-8 Blank ...................................................... 0 5-17 thru 5-20 .............................................. 0
2-9 ................................................................. 0 5-21 ............................................................... 2
2-10 Blank.................................................... 0 5-22 ............................................................... 3

* Zero in this column shows an initial page.

A Change 6

The document reference is online, please check the correspondence between the online documentation and the printed version.
 INSTALL THE NEW CHANGED PAGES. REMOVE REPLACED PAGES.
LIST OF EFFECTIVE PAGES

Page *Change Page *Change

No No No No
5-22A ............................................................ 3
5-22B Blank ................................................. 2
5-23 ............................................................... 0
5-24 thru 5-25 .............................................. 3
5-26 Blank.................................................... 0

Section 6 Parts List

6-1 thru 6-2 .................................................. 1
6-3 thru 6-4 .................................................. 5
6-5 ................................................................. 0
6-6 ................................................................. 1
6-7 ................................................................. 0
6-8 thru 6-9 .................................................. 5
6-10 thru 6-13 .............................................. 2
6-14 Blank.................................................... 1
6-15 thru 6-16 .............................................. 2
6-17 ............................................................... 1
6-18 Blank.................................................... 1

Section 7 Diagrams
7-1 ................................................................. 0
7-2 ................................................................. 1
7-3 ................................................................. 1
7-4 Blank...................................................... 0

Section 8 Options and Accessories

8-1 thru 8-3 Added ...................................... 6
8-4 Blank Added .......................................... 6
8-5 Added ..................................................... 6
8-6 Blank Added .......................................... 6
8-7 Added ..................................................... 6
8-8 Added ..................................................... 6

* Zero in this column shows an initial page.

Change 6 B/C

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 TABLE OF CONTENTS
Subject Page
Section 1 Description
1.1 General ...................................................................................................................................................... 1-1
1.2 Equipment Covered ................................................................................................................................... 1-1
1.3 Equipment Supplied ................................................................................................................................... 1-3
1.4 Accessories ................................................................................................................................................ 1-4
1.5 Options ....................................................................................................................................................... 1-4
1.6 Equipment Specifications ........................................................................................................................... 1-5
1.7 Related Publications .................................................................................................................................. 1-6
Section 2 Installation
2.1 General ...................................................................................................................................................... 2-1
2.2 Unpacking and Inspecting .......................................................................................................................... 2-1
2.3 Preinstallation Check ................................................................................................................................. 2-2
2.4 Cabling ....................................................................................................................................................... 2-2
2.4.1 General ...................................................................................................................................................... 2-2
2.4.2 Shielding and Grounding ........................................................................................................................... 2-2
2.4.3 RF Grounding............................................................................................................................................. 2-3
2.4.4 Fiber-Optic Cabling .................................................................................................................................... 2-3
2.4.5 Lightning Arresters ..................................................................................................................................... 2-4
2.5 Installation Procedures............................................................................................................................... 2-4
2.5.1 Antenna Coupler HF-9040 Installation ....................................................................................................... 2-4
2.5.2 Antenna Coupler HF-9041 or HF-9042 Installation ................................................................................... 2-5
2.5.3 HN Connector Adapter Kit FL-9003 Installation ....................................................................................... 2-11
2.5.4 Wire/Strap Adapter Kit FL-9005 Installation............................................................................................. 2-11
2.5.5 Antenna Connections ............................................................................................................................... 2-11
2.6 Postinstallation Check .............................................................................................................................. 2-11
Section 3 Operation
3.1 General ...................................................................................................................................................... 3-1
3.2 Controls and Indicators .............................................................................................................................. 3-1
Section 4 Theory
4.1 General ...................................................................................................................................................... 4-1
4.2 System Theory ........................................................................................................................................... 4-1
4.2.1 Single System ............................................................................................................................................ 4-1
4.2.2 Dual System ............................................................................................................................................... 4-1
4.3 Functional Theory ...................................................................................................................................... 4-2
4.3.1 Discriminator .............................................................................................................................................. 4-2
4.3.2 RF Tuner .................................................................................................................................................... 4-6
4.3.3 Control ...................................................................................................................................................... 4-10
Section 5 Maintenance
5.1 General ...................................................................................................................................................... 5-1
5.2 Test Equipment And Tools ......................................................................................................................... 5-1
5.3 Preventive Maintenance............................................................................................................................. 5-2
5.4 Testing/Troubleshooting ............................................................................................................................ 5-2
5.4.1 General ...................................................................................................................................................... 5-2
5.4.2 Testing/Troubleshooting Procedures ......................................................................................................... 5-2
5.4.3 Minimum Performance Test ....................................................................................................................... 5-8
5.5 Alignment/Adjustment .............................................................................................................................. 5-18

Change 1 i

The document reference is online, please check the correspondence between the online documentation and the printed version.
 TABLE OF CONTENTS (Cont)
Subject Page
Section 5 Maintenance (cont)
5.6 Disassembly/Assembly ............................................................................................................................ 5-18
5.6.1 Disassembly ............................................................................................................................................. 5-18
5.6.2 Assembly .................................................................................................................................................. 5-21
5.7 Repair .................................................................................................................................................... 5-22A
5.7.1 General..................................................................................................................................................... 5-23
5.7.2 Electrostatic Discharge Sensitive Devices Precautions ........................................................................... 5-23
5.7.3 Postcoat ................................................................................................................................................... 5-25
Section 6 Parts List
6.1 Introduction ................................................................................................................................................ 6-1
6.1.1 General....................................................................................................................................................... 6-1
6.1.2 Group Assembly Parts List......................................................................................................................... 6-1
6.1.3 Numerical Index ......................................................................................................................................... 6-2
6.1.4 Reference Designation Index ..................................................................................................................... 6-2
6.1.5 How To Use This Parts List........................................................................................................................ 6-2
6.1.6 Manufacturer’s Code, Name, and Address ................................................................................................ 6-3
6.1.7 Usable On Codes ....................................................................................................................................... 6-3
6.1.8 Reference Designation Prefixes ................................................................................................................ 6-3
6.1.9 Configuration Identifiers ............................................................................................................................. 6-4
6.2 Group Assembly Parts List......................................................................................................................... 6-5
6.3 Numerical Index ....................................................................................................................................... 6-15
6.4 Reference Designation Index ................................................................................................................... 6-17
Section 7 Diagrams
7.1 Introduction ................................................................................................................................................ 7-1
7.2 Configuration Identifiers ............................................................................................................................. 7-1
7.3 Schematic Changes ................................................................................................................................... 7-1
Section 8 Options and Accessories
8.1 Description ................................................................................................................................................. 8-1
8.2 Installation .................................................................................................................................................. 8-1
8.2.1 Assembly Procedure .................................................................................................................................. 8-1
8.2.2 Disassembly Procedure ............................................................................................................................. 8-2
8.3 Repair ......................................................................................................................................................... 8-2
8.3.1 Test Procedure ........................................................................................................................................... 8-3
8.4 Diagrams .................................................................................................................................................... 8-3

ii Change 6

The document reference is online, please check the correspondence between the online documentation and the printed version.
 LIST OF ILLUSTRATIONS
Figure Page
Section 1 Description
1-1 HF-9000 Antenna Coupler ......................................................................................................................... 1-2
Section 2 Installation
2-1 Antenna Coupler HF-9040, Installation Control Drawing ........................................................................... 2-7
2-2 Antenna Coupler HF-9041 or HF-4042, Installation Control Drawing ....................................................... 2-9
2-3 HN Connector Adapter Kit FL-9003, Installation Diagram ....................................................................... 2-12
2-4 Wire/Strp Adapter Kit FL-9005, Installation Diagram ............................................................................... 2-12
2-5 HF-9000 System (Single) Interconnect Diagram ..................................................................................... 2-13
2-6 HF 9000 System (Dual), Interconnect Diagram ....................................................................................... 2-17
Section 4 Theory
4-1 Single HF-9000 System, Block Diagram.................................................................................................... 4-3
4-2 Dual HF-9000 System, Block Diagram ...................................................................................................... 4-5
4-3 Antenna Coupler, Block Diagram............................................................................................................... 4-7
4-4 Discriminator Output Vs Coupler Input Impedance ................................................................................... 4-8
4-5 Antenna Impedance Translation ................................................................................................................ 4-9
Section 5 Maintenance
5-1 TE-9200 Test Setup Diagram .................................................................................................................... 5-9
5-2 TE-9210 Test Setup Diagram .................................................................................................................. 5-11
5-3 Cover Torque Pattern.............................................................................................................................5-22A
Section 6 Parts List
6-1 HF Antenna Coupler HF-9040, Parts Location Diagram ........................................................................... 6-5
6-2 HF Antenna Coupler HF-9041 and HF-9042, Parts Location Diagram ..................................................... 6-7
6-3 HF Antenna Coupler HF-9040 (With Adapter), Parts Location Diagram ................................................. 6-10
6-4 HF Antenna Coupler HF-9041 (With Adapter), Parts Location Diagram ................................................. 6-12
Section 7 Diagrams
7-1 Antenna Couplers HF-9040/9041/9042, Chassis Interconnect Diagram................................................... 7-2
Section 8 Options and Accessories
8-1 Antenna Adapter FL-9002 Part Locations.................................................................................................. 8-5
8-2 Test Points ................................................................................................................................................. 8-7

Change 6 iii

The document reference is online, please check the correspondence between the online documentation and the printed version.
 LIST OF TABLES
Table Page
Section 1 Description
1-1 Equipment Covered ................................................................................................................................... 1-1
1-2 Equipment Supplied ................................................................................................................................... 1-3
1-3 Options ....................................................................................................................................................... 1-4
1-4 Equipment Specifications ........................................................................................................................... 1-5
1-5 Related Publications .................................................................................................................................. 1-6
Section 4 Theory
4-1 HF-9000 Dual-System Operating States ................................................................................................... 4-5
4-2 HF-9000 Dual-System Logic States ........................................................................................................... 4-6
Section 5 Maintenance
5-1 Test Equipment and Tools ......................................................................................................................... 5-1
5-2 Fault Code Display and Repair Action ....................................................................................................... 5-4
5-3 Minimum Performance Test Procedures ................................................................................................. 5-13
Section 8 Options and Accessories
8-1 Parts List .................................................................................................................................................... 8-3

iv Change 6

The document reference is online, please check the correspondence between the online documentation and the printed version.
 INTRODUCTION

EQUIPMENT PROPERTIES

HF-9000 Antenna Couplers are available for use with virtually any type of antenna. Included are shunt,
whip/open wire, blade, and ground wire/grounded tube antennas. All of the HF-9000 Antenna Couplers
combine light weight and many other features such as:
• Fiber-optic system control bus
-Eliminates multiconductor cables
• Learned preset tuning
-Permits almost instant tuning of frequencies previously tuned by system
• Low primary power requirement
-Reduces overall system power needs

INSTRUCTION BOOK

This instruction book includes all instructions on the basic unit to support intermediate level of maintenance
consisting of card/module replacement and/or chassis repair.

PART NUMBERS

Unless given differently, all part numbers used in this instruction book (external to the parts list) are
Rockwell Collins part numbers (CPNs).

SERVICE BULLETINS/SERVICE INFORMATION LETTERS

Service bulletins (SB) and service information letters (SIL) are written for their specified equipment types.
Refer to the HF-9000 Antenna Couplers book for a list of SBs and SILs that apply to the specified
equipment.
NOTE
Each service bulletin is given number in a sequence for the life of the equipment. Each
service information letter is given a number in sequence that starts at 1 for each calendar
year.
SB/SIL DESCRIPTION ISSUE DATE
Legacy SB/SILs previously incorporated.

The document reference is online, please check the correspondence between the online documentation and the printed version.
introduction

ELECTROSTATIC DISCHARGE SENSITIVE DEVICES PRECAUTIONS

CAUTION

This equipment contains electrostatic discharge sensitive (ESDS) devices. Use special
procedures and materials to prevent equipment damage.
A static electrical charge is produced by friction between, and separation of, dissimilar materials. Potentials
of 1 to 20 kilovolts are commonly generated on the human body or insulated surfaces. Voltages of this
magnitude can produce both immediate and latent failure in electrostatic discharge sensitive (ESDS)
devices.

Transporting circuit card or module subassemblies containing ESDS devices requires that contact with
exposed subassemblies be prevented. Conductive plastic bags, not clear polyvinyl, are suitable for this
purpose. After the subassembly containing ESDS devices is installed in the top level unit, normal handling
of the top level unit is adequate.

SAFETY SUMMARY

These general safety precautions are not related to special procedure and are not shown in other locations in
this document. These are recommended precautions that personnel must know and apply during many
phases of operation and maintenance.

Keep Away From Live Circuits

Personnel must obey all safety precautions. Do not replace components or make adjustments in the
equipment with the high-voltage power supply set to ON. In some conditions when the power control is in
the OFF position, dangerous voltages can occur because of voltages kept by capacitors. To prevent dangerous
shock or injuries, always remove power to the unit. Then remove voltages from components and ground the
circuit before you touch it.

Do Not Service or Adjust Alone

Do maintenance or adjustments on equipment only when a person is there who can supply aid.

Resuscitation

Personnel working with or near high voltages should be familiar with modern methods of resuscitation.
Such information may be obtained from the Bureau of Medicine and Surgery.

vi

The document reference is online, please check the correspondence between the online documentation and the printed version.
 introduction

The warnings and cautions that follow are also shown in some paragraphs of this manual. They are shown
here for added notice.

WARNING

The HF-9000 system contains an RF transmitter which, when operated into an antenna, may
produce electromagnetic fields in close proximity to the antenna that are in excess of
Occupational Safety and Health Administration (OSHA) recommended maximum limits.

Observe the following precautions when handling fiber-optic components:

a. The output from fiber-optic links can cause serious damage to the eye, and glass in the
cable can pierce the skin.

b. Use caution when viewing fiber ends or optical ports under magnification. For further
precautions and information, see ANSI Z136.2-1988.

c. Use caution when viewing an optical port without knowing the optical power level and
the wavelength.

d. Handle bare optical fiber with care. The core end of the fiber is glass that can pierce the
skin and break off. This is hazardous only when terminating a fiber end with a connector
or splice.

e. Potential eye problems result from invisible wavelengths, collimated light, and light
intensity of unknown sources. A general rule, it is always safer and more accurate to use
a meter to measure light output.

f. The HF-9000 fiber-optic system operates at 850 nanometer wavelength with a maximum
output of 200 microwatts into a 200-micrometer optical cable.

Be sure all personnel are clear of the HF antenna when performing radio checks. Do not
touch the RF output terminal on the antenna coupler, the antenna lead-in wire, the
insulated feedthrough, or the antenna itself while the microphone is keyed, while tuning is in
progress, or while the system is in transmit self-test. Serious RF burns can result from direct
contact with the above items when the system is transmitting.

CAUTION

If equipment contains electrostatic discharge sensitive (ESDS) devices, special handling

methods and materials must be used to prevent equipment damage. Refer to paragraph
5.7.2, ESDS devices precautions, before performing maintenance, repair, or disassembly on
the equipment.

Keep protective covers on fiber optic connectors when interconnect cables are not connected.
Dust and moisture on the internal optical lenses of the connectors degrades system
operation.

vii

The document reference is online, please check the correspondence between the online documentation and the printed version.
introduction

CAUTION

Observe the following precautions when installing the system interconnect wiring:

a. Shield and bond all parts of the installation electrical system, such as generators and
ignitions systems.

b. Route connecting cables away from circuits carrying heavy currents, equipment
transmitting pulses, or other sources of interference.

c. Leave slack in cables to permit free sway of equipment in mounts and to avoid breakage
resulting from vibrations.

d. Do not remove protective caps on connectors not used. If caps are misplaced, install new
caps.

e. Clamp all control lines against a metallic structural member, as close to the unit
connector as possible.

f. Never route cabling close to the antenna RF feedline or RF ground return path. If it is
necessary to route control cables within approximately 0.3 m (1 ft) of the RF output or
feed wire, the overall control cable should be shielded. Use a braid (RF shield) around the
entire control cable and ground the ends of the braid to the cable connector shell or to the
metal ground (bulkhead) where the cable leaves the RF environment.

All supporting parts list illustrations that contain ESDS items are shown with the following
symbol. (Either one of the following ESDS symbols may be used, sometimes even both.)

viii

The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 1
DESCRIPTION
1.1 GENERAL
HF-9000 Antenna Couplers, as shown in Figure 1-1, automatically tune and efficiently transfer the RF output of
the receiver-transmitter to the antenna. The antenna couplers tune all frequencies in the hf band within one
second nominally. The learned preset tuning feature of the antenna couplers allows almost instantaneous tuning
on previously-tuned frequencies. The antenna couplers are tuned by vacuum relays that switch inductance and
capacitance in or out to obtain the required impedance at the selected frequency. Equipment covered in this
manual is listed with their attributes in Table 1-1.
1.2 EQUIPMENT COVERED
Table 1-1. Equipment Covered
ALTITUDE
ANTENNA TYPE
TYPE (FT) PART
MIL TYPE NO
NO GROUNDED OPEN NUMBER
SHUNT 55 000 35 000
WIRE/TUBE WIRE/TUBE
HF-9040 X X 622-8113-001 CU-2477/
ARC-217(V)
HF-9040 X X 622-8113-002 None
HF-9040 X X 685-0365-001 None
(note 1)
HF-9040 X X 622-8113-003
HF-9041 X X X 622-8114-001 CU-2478/
ARC-217(V)
HF-9041 X X X 685-0350-001 None
(note 2)
HF-9041 X X X 622-8114-002 None
HF-9041 X X X 685-0350-002 None
(note 3)
HF-9041 X X X 622-8114-020 None
(note 7)
HF-9041 X X X 685-0350-020 None
(note 6, 7)
HF-9042 X X X 622-9405-001 CU-2476/
ARC-217(V)
HF-9042 X X X 622-9405-002 None
(note 4)
HF-9042 X X X 622-9405-003 None
(note 5)
HF-9042 X X X 622-9405-020 CU-2476/
ARC-217(V)
Notes: 1. HF-9040 (622-8113-002) with HN coax connector kit (685-0355-001)
2. HF-9041 (622-8114-001) with grounding ring adapter kit (685-0349-001)
3. HF-9041 (622-8114-002) with grounding ring adapter kit (685-0349-001)
4. HF-9041 (622-9405-001) with grounding ring adapter kit (685-0349-001)
5. Electronic Counter-Counter Measures (ECCM) capable
6. HF-9041 (622-8114-020) with grounding ring adapter kit (685-0349-001)
7. High voltage antenna coupler for antennas having parallel resistance (Rp) exceeding 25 kohms

Change 5 1-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
description

HF-9000 Antenna Coupler

Figure 1-1

1-2

The document reference is online, please check the correspondence between the online documentation and the printed version.
 description

1.3 EQUIPMENT SUPPLIED

Equipment supplied as part of each top level unit is listed in Table 1-2.

Table 1-2. Equipment Supplied

HF-9040 HF-9041 HF-9042

CIRCUIT CARD
CIRCUIT CARD
PART 622-8113-( ) 685-0365 622-8114-( ) 685-0350-( ) 622-9405-( )
NOMENCLATURE
NUMBER
-001 -002 -003 -001 -001 -002 -020 -001 -002 -020 -001 -002 -003 -020

Chassis A1 659-9030-001 X X X X

659-9070-001 X X X X X X

659-9070-002 X X X X

Discriminator A2 659-9043-001 X X X X X X X X X X X X X X

RF tuner A3 659-9031-001 X X X X X X X X

751-7068-001 X X X

751-7068-020 X

659-9031-020 X X

Control A4 687-5075-001 X X X

687-5075-003 X X X X X X

687-5075-004 X X X

687-5075-005 X

687-5075-006 X

External element 659-9052-001 X X X X

A5
659-9052-020 X X

Change 5 1-3

The document reference is online, please check the correspondence between the online documentation and the printed version.
description

1.4 ACCESSORIES

No accessories are available for use with the HF-9000 antenna couplers at this time.

1.5 OPTIONS

Options are listed in Table 1-3. Additional FL-9002 information is given in Section 8 of this manual.

Table 1-3. Options

TYPE NO QTY DESCRIPTION PART NUMBER MIL TYPE NO

HF-9040

MT-9040 1 Mount (rigid) 622-8117-001 None

MT-9040A 1 Mount (shock isolated), low profile 622-8118-001 MT-6790/ARC-217(V)

MT-9040B 1 Mount (shock isolated) 822-0595-001 None

None 1 Mating connector kit 685-0360-002 None

FL-9003 OPT Adapter kit, HN connector* 685-0355-001 None

FL-9005 OPT Adapter kit, wire/strap* 685-0364-001 None

HF-9041/9042 (SINGLE)

MT-9041 1 Mount (rigid) 622-8121-001 None

MT-9041A 1 Mount (shock isolated), low profile 622-8122-001 MT-6792/ARC-217(V)

MT-9041B 1 Mount (shock isolated) 822-0596-001 None

None 1 Mating connector kit 685-0360-002 None

FL-9003 OPT Adapter kit, HN connector* 685-0355-001 None

FL-9005 OPT Adapter kit, wire/strap* 685-0364-001 None

HF-9041 (DUAL)

MT-9042 1 Mount, dual (rigid) 622-8123-001 None

MT-9042A 1 Mount, dual (shock isolated), low 622-8124-001 None

profile
None 2 Mating connector kit 685-0360-002 None
FL-9001 OPT Feedline, RF (CL-601-3A, RJ)* 685-0326-001 None
FL-9002 OPT Feedline, RF (G-IV)* 822-0089-001 None

FL-9006 1 Adapter kit, wire/strap dual mount 988-8095-001 None

None 1 Clamp, feedline 139-0924-010 None
None 2 Adapter kit, grounding ring 685-0349-001 None

*Optional item; use one or the other, not both.

1-4 Change 6

The document reference is online, please check the correspondence between the online documentation and the printed version.
 description

1.6 EQUIPMENT SPECIFICATIONS

Equipment Specifications are listed in Table 1-4

Table 1-4. Equipment Specifications

CHARACTERISTIC SPECIFICATION
Electrical
Input power 28 V DC, 55 W maximum
Duty cycle Receive: continuous
Transmit: The antenna coupler shall be capable of continuous voice
operation over the temperature range of -55 to +71 C (-67 to +160 F). RF
output power may automatically be reduced under some power level and
ambient thermal condition combinations to improve equipment reliability.
During severe thermal stress, the unit disables the transmit function and
provides an indication to the operator to prevent equipment failure.
Input impedance (tuned) 50 ohms nominal
Tuning time New frequency: 1 second nominal, 6 seconds maximum
Learned preset channel: 40 milliseconds nominal
Frequency range 2.0000 to 29.9999 MHz
RF input power 200 W pep and 100 W average, maximum
Tuning power 50 W ±1 dB maximum
Tuning modes Automatic tuning, 99 learned preset channels
Tuning range HF-9040
Grounded tube antenna, 3.35 to 6.10 m (11 to 20 ft)
Grounded wire antenna, 3.05 to 6.10 m (10 to 20 ft)
With AT-9090F tuned monopole antenna, 3.05 to 4.30 m (10 to 14 ft)
HF-9041
Grounded tube antenna, 3.35 to 6.10 m (11 to 20 ft)
Grounded wire antenna, 3.05 to 6.10 m (10 to 20 ft)
Shunt antenna, 2.44 to 3.05 m (8 to 10 ft)
HF-9042
Grounded tube antenna, 3.35 to 6.10 m (11 to 20 ft)
Grounded wire antenna, 3.05 to 6.10 m (10 to 20 ft)
Whip antenna, 5 m (16 ft) minimum length
Open wire or tube, 6.3 m (20 ft) minimum length
Environmental
Temperature -55 to +71 C (-67 to +160 F)
Humidity 95% relative for two 24- hour temperature cycles.

1-5

The document reference is online, please check the correspondence between the online documentation and the printed version.
description

Table 1-4. Equipment Specifications (Cont)

CHARACTERISTIC SPECIFICATION
Altitude HF-9040: 0 to 10 700 m (0 to 35 000 ft)
HF-9041: 0 to 16 800 m (0 to 55 000 ft)
HF-9042: 0 to 16 800 m (0 to 55 000 ft)
Physical HF-9040 HF-9041 HF-9042
Height 19.3 cm (7.6 in) 19.3 cm (7.6 in) 19.3 cm (7.6 in)
Width 9.7 cm (3.8 in) 10.4 cm (4.1 in) 10.4 cm (4.1 in)
Depth 31.7 cm (12.5 in) 36.7 cm (14.5 in) 36.7 cm (14.5 in)
Weight (max) 3.4 kg (7.8 lb) 5.44 kg (12.0 lb) 5.67 kg (12.5 lb)

1.7 RELATED PUBLICATIONS

Related Publications are listed in Table 1-5.

Table 1-5. Related Publications

INSTRUCTION BOOK TITLE PUBLICATION PART NUMBER
HF-9000 High-Frequency Communications System Operator's 523-0774344
Manual
HF-9000 Antenna Couplers Depot Maintenance Instructions 523-0775446
HF-9000 Receiver-Transmitter Intermediate Maintenance 523-0777199
Instruction Book
HF-9000 Radio Set Controls Intermediate Maintenance Instruction 523-0777200
Book
HF-9000 Test Equipment Operation and Maintenance Instruction 523-0775753
Book
RTU-42X0 Radio Tuning Unit Installation Manual 523-0780424
HF Troubleshooting Guide 523-0816266

1-6 Change 3

The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 2
INSTALLATION

2.1 GENERAL

This section provides information and instructions for installing all antenna couplers of the HF-9000 system
and making the system operational. No cooling provisions are required other than providing nominal free
space around the equipment for normal air movement.

WARNING

The HF-9000 system contains an RF transmitter which, when operated into an antenna, may
produce electromagnetic fields in close proximity to the antenna that are in excess of
Occupational Safety and Health Administration (OSHA) recommended maximum limits.

Observe the following precautions when handling fiber-optic components:

a. The output from fiber-optic links can cause serious damage to the eye, and glass in the
cable can pierce the skin.

b. Use caution when viewing fiber ends or optical ports under magnification. For further
precautions and information, see ANSI Z136.2-1988.

c. Use caution when viewing an optical port without knowing the optical power level and
the wavelength.

d. Handle bare optical fiber with care. The core end of the fiber is glass that can pierce the
skin and break off. This is hazardous only when terminating a fiber end with a connector
or splice.

e. Potential eye problems result from invisible wavelengths, collimated light, and light
intensity of unknown sources. A general rule, it is always safer and more accurate to use
a meter to measure light output.

f. The HF-9000 fiber-optic system operates at 850 nanometer wavelength with a maximum
output of 200 microwatts into a 200-micrometer optical cable.

Be sure all personnel are clear of the HF antenna when performing radio checks. Do not
touch the RF output terminal on the antenna coupler, the antenna lead-in wire, the
insulated feedthrough, or the antenna itself while the microphone is keyed, while tuning is in
progress, or while the system is in transmit self-test. Serious RF burns can result from direct
contact with the above items when the system is transmitting.

2.2 UNPACKING AND INSPECTING

Unpack and handle the equipment with care. Check equipment received against the packing list. Examine
each item for evidence of shipping damage. If damage is found, notify the shipper immediately and retain
packing materials.

2-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
installation

CAUTION

If equipment contains electrostatic discharge sensitive (ESDS) devices, special handling

methods and materials must be used to prevent equipment damage. Refer to paragraph
5.7.2, ESDS devices precautions, before performing maintenance, repair, or disassembly on
the equipment.

CAUTION

Keep protective covers on fiber optic connectors when interconnect cables are not connected.
Dust and moisture on the internal optical lenses of the connectors degrades system
operation.
NOTE
It is good practice to save the packing containers and materials for use in future storage or
shipment of the equipment.

2.3 PREINSTALLATION CHECK

The equipment was properly aligned and tested before shipment. Successful completion of the testing and
troubleshooting procedures in the maintenance section of this book verifies the equipment is functioning
within normal limits.

2.4 CABLING

2.4.1 General

RF and fiber optic control cabling is required between units of the HF-9000 system as well as audio cabling
to system audio devices. In addition, RF cabling is required between the antenna coupler and the antenna.
Refer to the HF-9000 system interconnect diagrams, figures 2-5 and 2-6, for to from information. Observe
the precautions listed in paragraphs 2.4.2, 2.4.3, and 2.4.4 when fabricating and installing cables.

2.4.2 Shielding and Grounding

WARNING

Be sure all personnel are clear of the HF antenna when performing radio checks. Do not
touch the RF output terminal on the antenna coupler, the antenna lead in wire, the insulated
feedthrough, or the antenna itself while the microphone is keyed or while tuning is in
progress. Serious RF burns can result from direct contact with the above items when the
system is transmitting.

CAUTION

Observe the following precautions when installing the system interconnect wiring:

a. Shield and bond all parts of the installation electrical system, such as generators and
ignitions systems.

b. Route connecting cables away from circuits carrying heavy currents, equipment
transmitting pulses, or other sources of interference.

2-2

The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

c. Leave slack in cables to permit free sway of equipment in mounts and to avoid breakage
resulting from vibrations.

d. Do not remove protective caps on connectors not used. If caps are misplaced, install new
caps.

e. Clamp all control lines against a metallic structural member, as close to the unit
connector as possible.

f. Never route cabling close to the antenna RF feedline or RF ground return path. If it is
necessary to route control cables within approximately 0.3 m (1 ft) of the RF output or
feed wire, the overall control cable should be shielded. Use a braid (RF shield) around the
entire control cable and ground the ends of the braid to the cable connector shell or to the
metal ground (bulkhead) where the cable leaves the RF environment.

g. Audio input lines are especially critical if an unbalanced input is used. Use twisted-pair,
shielded wire and route audio lines away from 400 Hz power lines or other high current
lines that could induce hum or noise.

h. Space the antenna feedline away from metal (or sharp objects) to avoid high voltage
flashover or arcing. A 50.8 mm (2 in) or larger spacing is required for altitudes of 9150 m
(30 000 ft).

2.4.3 RF Grounding

Proper bonding of all units to an acceptable ground is of prime importance. Special emphasis must be placed
on grounding the coupler and associated mounts.
Each equipment mount must be bonded directly to the ground plane using silver- or tin-plated copper strap,
aluminum strap, or equivalent structure. The length-to-width ratio of strap should not be more than 5 to 1
(that is, a 127-mm (5-in) strap should be a minimum of 25.4 mm (1 in) wide).
Bonding to anodized or painted surfaces is not acceptable for good RF grounds. Surfaces to be bonded should
be sanded free of paint or anodic film and joined using screws with washers to ensure maximum surface
contact over as large an area as possible. Materials should be carefully selected to avoid corrosion due to
dissimilar metals. An electrically-conductive substance should be used on all bare metal surfaces to retard
corrosion.
The ground strap between the antenna coupler and a good ground is the most important ground strap in the
system. It should be run parallel to the antenna feedline and should be bonded as near as possible to the
antenna feedthrough insulator and to the antenna coupler mount as close as possible to the coupler RF
output point. Maximum length-to-width ratio for this strap should not exceed 5 to 1.
Installations using shielded antenna feedlines are not as critical since a good RF return path is provided by
the feedline shield. However, these installations must also have a local ground strap to a nearby good
ground.

2.4.4 Fiber-Optic Cabling

CAUTION

Keep protective covers on fiber-optic connectors when interconnect cables are not connected.
Dust and moisture on the internal optical lenses of the connectors degrades system
operation.

2-3

The document reference is online, please check the correspondence between the online documentation and the printed version.
installation

CAUTION

Do not tie fiber-optic cables tight. Tightly tying fiber-optic cables can deform, kink, or crush
the cables and cause a loss of data or an inoperative HF system.
Proper installation of fiber-optic connectors is essential for reliable system operation. Follow closely the
manufacturer's instructions supplied with the connectors.
After fiber-optic cables have been fabricated, use a fiber-optic test set to measure cable attenuation. (A
recommended unit is the Meson Design MC850/TS-IC-SMA with CPA-SMA power meter adapter or
Photonix Technologies Lanlite PX-C100-SMA 850nm ST LED light source with PX-B100-SMA Dual ST
power meter.) Follow the test equipment manufacturer's instructions for measuring cable attenuation.
Attenuation should not exceed 3.0 dB for each cable.
Ensure the installed fiber optic cables adhere to the cable manufacturers recommended minimum bend
radius.

2.4.5 Lightning Arresters

A compatible lightning arrester should be used in any open wire antenna installation.

2.5 INSTALLATION PROCEDURES

2.5.1 Antenna Coupler HF-9040 Installation

CAUTION

Keep protective covers on fiber-optic connectors when interconnect cables are not connected.
Dust and moisture on the internal optical lenses of the connectors degrades system
operation.

a. Refer to figure 2-1 for outline and mounting dimensions and to HF-9000 system
interconnect diagrams for antenna coupler configuration strapping information.

b. Connect antenna feedline to rear coax connector and slide antenna coupler into MT-9040,
MT-9040A, or MT-9040B mount. Be sure lip on rear of antenna coupler engages hold
down flange on mount.

c. Engage front holddown clamps on mount with clips on antenna coupler (hand tighten
wingnuts).

d. Connect power cable to J1 on front of antenna coupler.

CAUTION

Hand tighten fiber-optic connectors only. Never use a wrench or spanner to tighten. Do not
overtighten safety wire. Most automatic safety-wire pliers exert excessive force on the
connectors. Hand tighten safety wire or use extreme caution when using automatic
safety-wire pliers.

e. Connect fiber-optic cables on J2 (receive) and J3 (transmit) on front of antenna coupler.

Safety-wire as required. Holes for safety wire are provided in the fiber-optic cable plugs.
Use MS20995 CU20 0.020-in copper safety wire.

f. Connect RF coaxial cable to J4 on front of antenna coupler.

2-4 Change 3

The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

2.5.2 Antenna Coupler HF-9041 or HF-9042 Installation

CAUTION

Keep protective covers on fiber-optic connectors when interconnect cables are not connected.
Dust and moisture on the internal optical lenses of the connectors degrades system
operation.

a. Refer to figure 2-2 for outline and mounting dimensions and to HF-9000 system
interconnect diagrams for antenna coupler configuration strapping information.

b. Connect antenna feedline to rear connector and slide antenna coupler into MT-9041,
MT-9041A, or MT-9041B mount. Be sure lip on rear of antenna coupler engages
holddown flange on mount.

c. Engage front holddown clamps on mount with clips on antenna coupler (hand tighten
wing nuts).

d. Connect power cable to J1 on front of antenna coupler.

CAUTION

Hand tighten fiber-optic connectors only. Never use a wrench or spanner to tighten. Do not
overtighten safety wire. Most automatic safety-wire pliers exert excessive force on the
connectors. Hand tighten safety wire or use extreme caution when using automatic safety-
wire pliers.

e. Connect fiber-optic cables on J2 (receive) and J3 (transmit) on front of antenna coupler.

Safety-wire as required. Holes for safety wire are provided in the fiber-optic cable plugs.
Use MS20995 CU20 0.020-in copper safety wire.

f. Connect RF coaxial cable to J4 on front of antenna coupler.

Change 2 2-5/2-6

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

Antenna Coupler HF-9040, Installation Control Drawing

Figure 2-1.

2-7/2-8
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

Antenna Coupler HF-9041 or HF-4042, Installation Control Drawing

Figure 2-2.

2-9/2-10
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

2.5.3 HN Connector Adapter Kit FL-9003 Installation

a. Refer to figure 2-3.

b. Remove four panhead screws (and lockwashers if used) from insulator retaining
plate.

c. Install adapter cup on insulator retaining plate and secure using hardware removed
in step b.

2.5.4 Wire/Strap Adapter Kit FL-9005 Installation

Install wire/strap adapter kit as shown in figure 2-4.

NOTE

Alternate installation should be used when clearance for access to back of antenna
coupler is limited. Be sure to maintain 19 mm (0.75 in) between feedline strap and the
coupler case, and 40 mm (1.5 in) between feedline strap and surrounding aircraft struc-
ture.

2.5.5 Antenna Connections

CAUTION

The RF cable handles high RF voltage and current. Use special care to prevent damage
to connectors. Damaged connectors or cables are susceptible to burning or arcing and
should be repaired or replaced.
Use the RF cable supplied with the antenna to connect the antenna coupler to the antenna. If it is
necessary to replace the RF cable, do not exceed 609.6 mm (24 in) maximum cable length.

2.6 POSTINSTALLATION CHECK

After the HF-9000 system has been installed and all cabling has been checked for proper fabrication and
installation, perform an operational check. Perform the procedures in the operation section to be sure the
system operates properly.

2-11
The document reference is online, please check the correspondence between the online documentation and the printed version.
installation

HN Connector Adapter Kit FL-9003, Installation Diagram

Figure 2-3.

Wire/Strap Adapter Kit FL-9005, Installation Diagram

Figure 2-4.

2-12
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

HF-9000 System (Single) Interconnect Diagram

Figure 2-5. (Sheet 1 of 2)

2-13/2-14
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

HF-9000 System (Single) Interconnect Diagram

Figure 2-5. (Sheet 2)

2-15/2-16
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

HF-9000 System (Dual), Interconnect Diagram

Figure 2-6. (Sheet 1 of 3)

2-17/2-18
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

HF-9000 System (Dual), Interconnect Diagram

Figure 2-6. (Sheet 2)

2-19/2-20
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 installation

HF-9000 System (Dual), Interconnect Diagram

Figure 2-6. (Sheet 3)

2-21/2-22
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 3
OPERATION

3.1 GENERAL
The antenna couplers of the HF-9000 system contain no controls or indicators. For HF-9000 systems
operating from an HF-9010 or HF-9012 radio set control, refer to HF-9000 Radio Set Control Intermediate
Maintenance Manual (523-0777200) for operating instructions. For HF-9000 systems operating from
external control buses (ARINC 429 or MIL-STD-1553B), consult the aircraft manual.

WARNING

The HF-9000 system contains an RF transmitter which, when operated into an antenna, may
produce electromagnetic fields in close proximity to the antenna that are in excess of
Occupational Safety and Health Administration (OSHA) recommended maximum limits.

WARNING

Be sure all personnel are clear of the HF antenna when performing radio checks. Do not
touch the RF output terminal on the antenna coupler, the antenna lead-in wire, the
insulated feedthrough, or the antenna itself while the microphone is keyed, while tuning is in
progress, or while the system is in transmit self-test. Serious RF burns can result from direct
contact with the above items when the system is transmitting.

3.2 CONTROLS AND INDICATORS

The HF-9000 antenna couplers contain no controls and indicators.

3-1/3-2

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 4
THEORY

4.1 GENERAL

This section contains information describing overall operating principles of the HF-9000 antenna couplers on
a functional level.

4.2 SYSTEM THEORY

4.2.1 Single System

As shown in figure 4-1, the single HF-9000 system is composed of a control unit, a receiver transmitter, and
an antenna coupler interconnected by one RF coaxial cable and three fiber optic cables. All control and
status information is transferred serially between units via the fiber optic cables. Transmit and receive RF
signals are supported by the RF coaxial cable.
As shown in figure 4-1, the HF-9040 antenna coupler consists of three major modules: discriminator, RF
tuner, and control. The HF-9041 and HF-9042 antenna couplers have an additional external element to aid
in the tuning of shunt and long wire antennas. The microprocessor in the control module is directed by
software to configure the RF tuner for proper phasing and minimum vswr in response to command signals
from the receiver transmitter and error signals from the discriminator. Tuning data for previously tuned
frequencies is stored by the microprocessor memory and used to minimize future tuning times when that
frequency is used again.

4.2.2 Dual System

As shown in figure 4-2, the dual HF-9000 system is composed of two single systems sharing a common hf
antenna.
In dual-receive operation, both HF-9000 systems can receive using the same antenna with the receive
signals bypassing both antenna couplers. With one of the HF-9000 systems in transmit mode, the other
system is disconnected from the antenna and is unable to receive or transmit. The control unit of the
disconnected system displays MSG 0090, indicating to the operator that this system cannot use the antenna
at this time. If the operator tries to transmit while the other system is transmitting, the control unit displays
MSG 0080, indicating that transmission is not possible while the other system is still transmitting.
NOTE

Receive audio may be heard from the disconnected receiver if the second transmitter is
operating on a nearby frequency.

In order to change back to dual-receive operation from transmit or from receive-through-tuned coupler, the
frequency or emission mode of either control unit must be changed or the 20 second time-out must have
elapsed. This causes both antenna couplers to be bypassed so the received signal is applied directly from the
antenna to both receivers.

4-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
theory

NOTE

Optimum signal reception in a dual system is achieved by momentarily keying the receiving
system to tune the antenna coupler to the received frequency. This also disconnects the
second system from the antenna.

Table 4-1 shows the five possible dual-system operating states. The system can only be in one of the five
states at any one time. Table 4-1 shows each system function for each operating state and each control unit
status display for each operating state.
In the dual-receive state, both receivers are connected to the antenna and the respective antenna coupler
tuning networks are bypassed so the received signals are applied directly to each receiver. Each control unit
display is normal. To reach the dual-receive state, both sides of the dual system must be unkeyed (operating
in receive through coupler 1 or 2) and then either the frequency or emission mode of one of the control units
must be changed.
To reach the transmit state, the PTT key of the desired system must be pushed. The transmit state can be
reached from the dual-receive state or from either of the receive through coupler states. In the transmit
state, the keyed transmitter is connected to the antenna and its control unit display is normal. The opposite
system is disconnected from the antenna and its control unit display shows MSG 0090. Should the opposite
system be keyed, the control unit display changes to MSG 0080, indicating that the other system is still
transmitting. The receive through tuned coupler state is reached only from the respective transmit state.
Unkeying a transmitting system automatically places that system in the receive through tuned coupler
state. The related control unit display is normal. The opposite system is disconnected from the antenna and
its control unit displays MSG 0090. If the opposite system is keyed, the first system control unit display
shows MSG 0090. The receive through tuned coupler state is especially useful when weak or noisy signals
are being received.
Table 4-2 shows the logic level of each system output line for each of the five operating states. The external
element E (J1-N) output indicates when the system is in the transmit state. This output is monitored by the
status A (J1-E) input of the opposite system. The external element F (J1-P) output indicates when the
system is in the dual-receive state. This output is monitored by the status B (J1-F) input of the opposite
system. The external +28 volt (J1-U) output indicates when +28 volt power is applied to the system. This
output is monitored by the dual +28 volt (J1-D) input of the opposite system. When +28 volt power is
removed from one system, the external +28 volt output of that system goes to logic low and the opposite
system reverts to normal single system operation. For this reason, removing power from the faulty half of a
dual system allows the opposite system to operate normally as a single system.

4.3 FUNCTIONAL THEORY

Refer to figure 4-3. The antenna coupler translates the antenna impedance to 50 ohms. This provides an
impedance match for the power amplifier to permit maximum power transfer to the antenna. The antenna
coupler is tuned by vacuum relays that switch RF coils and capacitors in or out of circuits in the RF tuner to
obtain the required impedance at the selected frequency. The relays are controlled by the microprocessor in
response to system control data, learned data, and comparator signals derived from the discriminator
outputs.

4.3.1 Discriminator

Analog DC signals (phasing, loading, resistance, forward power, and reflected power) are produced by the
discriminator based on the phase and magnitude relationship of the RF current and voltage at the network
input. Figure 4-4 shows the relationship of the discriminator signals to the R-X (resistance-reactance) plane.

4-2 Change 1

The document reference is online, please check the correspondence between the online documentation and the printed version.
 theory

Single HF-9000 System, Block Diagram

Figure 4-1

4-3/4-4
The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 theory

Dual HF-9000 System, Block Diagram

Figure 4-2

Table 4-1. HF-9000 Dual-System Operating States.

STATE SUBSYSTEM 1 CONTROL 1 SUBSYSTEM 2 CONTROL 2
DUAL RCV Receive Normal Receive Normal
XMT 1 Transmit Normal Disconnected from an- MSG 0090
tenna MSG 0080*
RTC 1 Receive-through-tuned Normal Disconnected from an- MSG 0090
coupler tenna
XMT 2 Disconnected from an- MSG 0090 Transmit Normal
tenna MSG 0080*
RTC 2 Disconnected from an- MSG 0090 Receive-through-tuned Normal
tenna coupler
*MSG 0080 means opposite subsystem is keyed.

4-5

The document reference is online, please check the correspondence between the online documentation and the printed version.
theory

Table 4-2. HF-9000 Dual-System Logic States.

SUBSYSTEM 1 SUBSYSTEM 2

STATE ELE E ELE F EXT 28 ELE E ELE F EXT 28

J1-N J1-P J1-U J1-N J1-P J1-U
(TX1) (DR1) (PWR1) (TX2) (DR2) (PWR2)
DUAL RCV 1 0 1 1 0 1
XMT 1 0 1 1 1 1 1
RTC 1 1 1 1 1 1 1
XMT 2 1 1 1 0 1 1
RTC 2 1 1 1 1 1 1
OPPOSITE STATUS A STATUS B 28V IN STATUS A STATUS B 28V IN
SYSTEM J1-E J1-F J1-D J1-E J1-F J1-D
INPUT
SUBSYSTEM 2 SUBSYSTEM 1
NOTE
5-volt logic except for J1-U which is 28-volt logic.

If the impedance presented to the discriminator is inductive, the phasing output is positive. Capacitive
impedance produces a negative phasing output. If the impedance magnitude is greater than 60 ohms, the Z
loading signal is positive. An impedance magnitude of less than 60 ohms yields a negative Z loading output.
If the resistive part of the impedance is less than 40 ohms, the R loading output is negative. A resistance
greater than 40 ohms yields a positive R loading output. Positive DC voltage from the forward power sensor
indicates the presence of RF power at the discriminator. A high level positive signal from the reflected power
sensor indicates the coupler is not tuned.
When the coupler is properly tuned and RF is applied, the voltage on the phasing, R and Z loading, and
reflected power lines is near zero, and the forward power analog voltage is positive.

4.3.2 RF Tuner

The RF tuner translates the antenna impedance to 50 ohms by using series and parallel reactive tune
elements. Refer to figure 4-5. As shown on the R X (resistance reactance) plane diagram, a tuning element in
parallel with the antenna impedance (ZA) translates the RF tuner input impedance (ZIN) on a circle tangent
to the origin. The magnitude of ZA determines the circle diameter. A tuning element in series with ZA
translates ZIN on a vertical line of constant resistance. By combining tuning elements in series and parallel,
the RF tuner translates ZA to 50 ohms.
Selection of tuning elements is performed by relays operated by relay drivers on control A4. The relay
drivers are activated by the microprocessor in response to comparator data or data stored from previously
tuned frequencies.

4-6 Change 1
The document reference is online, please check the correspondence between the online documentation and the printed version.
 theory

Antenna Coupler, Block Diagram

Figure 4-3

4-7
The document reference is online, please check the correspondence between the online documentation and the printed version.
theory

Discriminator Output Vs Coupler Input Impedance

Figure 4-4

4-8
The document reference is online, please check the correspondence between the online documentation and the printed version.
 theory

Antenna Impedance Translation

Figure 4-5

4-9
The document reference is online, please check the correspondence between the online documentation and the printed version.
theory

4.3.3 Control

Refer to figure 4-3. Control module functions include serial data communications with the rest of the
system, analog to digital conversion of the DC discriminator outputs, and RF tuner control through relay
drivers. The control module also monitors temperature and overvoltage sensors and supervises the
antenna coupler built in test (BIT) function.
The microprocessor communications controller (MPCC) contains an asynchronous receiver transmitter
(ART) to provide serial data communications between the antenna coupler and the rest of the system
over the fiber optic link. The MPCC has bus interface logic for operation on the microprocessor address
and data buses. External element inputs, comparator outputs, and temperature and pressure sensor
outputs are serviced by 32 parallel I/O ports on the MPCC.
The microprocessor is an 8 bit device. It has an 8 bit bidirectional data bus operating through a bus
transceiver and a 20 bit address bus operating through octal latches. Memories for the system include
one each RAM, EPROM, and EEPROM. The RAM is used for scratch pad and active variable storage.
The EPROM stores the operating program. The EEPROM is used for nonvolatile storage of preset and
learned tuning data. A crystal controlled clock generator provides system timing signals plus power on
and watchdog reset signals for the microprocessor.
Each microprocessor bus cycle consists of at least four clock cycles. During the first cycle, address is
placed on the address/data bus and either memory or I/O operation is indicated. Chip select logic then
enables the chosen device (ie, memory, MPCC, or clock decoder). During the second clock cycle, the
address is removed from the address/data bus and either read or write operation is indicated. For a read
operation, the addressed device places data on the bus to be read by the microprocessor. This includes
system and comparator data from the MPCC, preset tuning data from the EEPROM, and program data
from the EPROM. For a write operation, the microprocessor places data on the bus to be read by the
addressed device. This includes control data to operate the relay drivers, data to be stored in memory,
and status information to be stored by the MPCC for later transmission to the radio system. The read
and write operations are completed during the third and fourth clock cycles.

4-10
The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 5

MAINTENANCE
5.1 GENERAL

The HF-9000 system self test procedures described in this section verify operation of the complete HF-9000
system and provide fault isolation to the functional unit, module, or circuit card.

In the procedures given in this section, all functional units and fiber optic cables are tested. To verify
interface wiring between functional units and aircraft wiring, refer to the interconnect wiring diagrams in
the installation section of this instruction book.

5.2 TEST EQUIPMENT AND TOOLS

Test Equipment and tools are listed in Table 5-1.

Table 5-1. Test Equipment and Tools

ITEM MINIMUM REQUIREMENTS REPRESENTATIVE TYPE

RF load 50-Ω impedance Bird 8164

3-dB attenuator Weinschel 40-3-34
Signal generator 2 to 30 MHz, modulation 1 kHz, sufficient out- Marconi 2018A
put to drive power amplifier to maximum out-
put
Digital multimeter 2K-Ω range Fluke 8050A
Thruline wattmeter Forward, reverse, and VSWR reading; 55-W Bird 4342 with elements 50H
input tolerance and 100H
Antenna simulator Rockwell International
172H-18A Shunt Dummy
Antenna, pn 622-7148-001
Antenna simulator Rockwell International
172H-21A RF Dummy Load,
pn 622-1732-001
System test set Rockwell International
TE-9200, pn 622-9418-001
System test set (alternate, Rockwell International
with same functionality as
TE-9210, pn 822-1429-001
TE-9200 plus ARINC test
(Figure 5-2)
capability)
Power supply 0 to 40 V, 25.0 A (min) Sorenson SRL 40-50
Pressure gauge 0 to 15 psig with a minimum resolution of 0.5 Milton Industries 5901
psig

Change 2 5-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

5.3 PREVENTIVE MAINTENANCE

The HF-9000 antenna couplers require no preventive maintenance.

5.4 TESTING/TROUBLESHOOTING

5.4.1 General

The HF-9000 antenna couplers can be tested in the aircraft or as a complete system in a shop environment.
All tests are performed using the built in test equipment (BITE) self test capabilities of each unit in the
system. The self test establishes minimum performance criteria for the HF-9000 system. The contents of
paragraph 5.4.2.1 (Self Test Fault Code Interpretation) aids the user in fault isolation. Test equipment
required to test the antenna coupler is listed in table 5-1. The HF Troubleshooting Guide, 523-0816266 is a
resource for troubleshooting aircraft problems.

5.4.2 Testing/Troubleshooting Procedures

NOTE
If the antenna coupler is removed from the aircraft or if tuning problems are experienced, it
is recommended that a bond check be performed on the aircraft according to the aircraft bond
check procedure. Refer to Section 2, para 2.4.3.

5.4.2.1 Self Test Fault Code Interpretation

The fault codes that may appear in the FREQ/CHAN display of the control unit and the corresponding repair
actions are listed in table 5-2. The displays are initiated by internal programming, manipulation of front
panel controls, and/or a fault in a system element. The unit codes are as follows: RT = receiver-transmitter,
R = remote control unit, and CU = antenna coupler. Refer to RTU-42X0 manual 523-0780424 for HF
diagnostic information.

5.4.2.2 Receive Self Test

The following steps initiate an HF-9000 system receive self test and verify system operation:

a. Position cursor for OPR function.

b. Use VALUE control to command OPR to display TST.

NOTE
Self test cannot be stopped after OPR displays TST for 3 seconds or more. Turning a knob
after self test has begun may cause a fault to be momentarily displayed but does not affect
final self test results.

c. After a 3 second delay, MODE function displays RT, indicating receiver transmitter self test. The test
should take approximately 10 seconds.

d. On completion of receiver transmitter test, MODE should display CU, indicating antenna coupler self
test. The test should take approximately 3 seconds.

e. On completion of antenna coupler test, MODE should display R, indicating remote control unit self test.
The test should take approximately 2 seconds.

f. On completion of control unit test, the control unit display should be as follows:

5-2 Change 3

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

1. If all units pass receive self test, OPR displays TST and MODE displays OK. Proceed to transmit self
test, paragraph 5.4.2.3.

2. If one or more units fail the receive self test, OPR displays FLT and MODE displays code for
suspected unit (RT for receiver transmitter, CU for antenna coupler, R for remote control unit, FO
for fiber-optic link, or (two blanks) for external failure). The FREQ/CHAN display shows a 4 digit
fault code. To determine if the suspected unit has more than one fault or if more than one unit has
failed, press FREQ/LD switch to sequence through all the identified faults. Refer to table 5-2 for
fault code interpretation.

5.4.2.3 Transmit Self Test

After successful completion of receive self test, initiate transmit self test as follows:

WARNING

Be sure all personnel are clear of the HF-antenna when performing transmit self test. Do not
touch the RF output terminal on the antenna coupler, the antenna lead in wire, the insulated
feedthrough, or the antenna itself while the system is in transmit self test. Serious RF burns
can result from direct contact with the above items when the system is transmitting.

a. Momentarily key microphone or depress PTT key.

b. OPR should continue to display TST and MODE should display TX for approximately 3 seconds.

c. The antenna coupler self test then starts and MODE should display CU. Antenna coupler test should
take approximately 1 second.

NOTE
The control unit was tested during the receive self test. The test is not repeated.

d. On completion of antenna coupler test, control unit display should be as follows:

1. If all units pass the transmit self test, OPR should display TST and MODE should display OK.

2. If one or more units fail the transmit self test, OPR displays FLT or MSG and MODE displays code
for suspected unit (RT, CU, FO, or (two blanks)). The FREQ/CHAN display shows a 4 digit fault
code. To determine if suspected unit has more than one fault or if more than one unit has failed,
press FREQ/LD switch to sequence through all the identified faults. Refer to table 5-2 for fault code
interpretation.

Change 3 5-3

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

Table 5-2. Fault Code Display and Repair Action.

FAULT UNIT MODULE DESCRIPTION REPAIR ACTION

0000 System Not determined None

0010 System Operator error None

0020 System RF stuck on Replace RT or CU

0030 System No RF received Replace RT or CU

0060 System RF overvoltage Check antenna

0070 System Improper dual-system response Replace CU 1 or CU 2

0080 System Other system keyed MSG (dual None

system)

0090 System Receive inhibited MSG (dual sys- None

tem)

1011 RT A1 CPU malfunction Replace module

1012 R A1 Program checksum error Replace module

1012 RT A1 Program checksum error Replace module

1013 R A1 RAM test error Replace module

1014 RT A1 RAM test error Replace module

1015 RT A1 Preset memory storage error Replace module

1021 RT A1 Interrupt control fault Replace module

1031 RT A1 Time base fault Replace module

1032 RT A1 Time fault Replace module

1033 RT A1 Fiber-optic control fault Replace module

1034 RT A1 Synthesizer control fault Replace module

1041 RT A1 Loss of lock interrupt enable fault Replace module

1042 RT A1 DC control interrupt enable fault Replace module

1043 RT A1 RF interlock interrupt enable Replace module

1044 RT A1 PA fault interrupt enable fault Replace module

1045 RT A1 PA fault interrupt enable Replace module

5-4

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

Table 5-2. Fault Code Display and Repair Action. (Cont)

FAULT UNIT MODULE DESCRIPTION REPAIR ACTION

1046 RT A1 PA filter 1 control fault Replace module

1047 RT A1 PA filter 2 control fault Replace module

1048 RT A1 PA filter 3 control fault Replace module

1049 RT A1 PA filter control enable fault Replace module

1050 RT A1 PA low power control fault Replace module

1051 RT A1 PA med power control fault Replace module

1052 RT A1 PA key control fault Replace module

1054 RT A1 Audio mute control fault Replace module

1055 RT A1 Sidetone gate control fault Replace module

1056 RT A1 Tune tone control fault Replace module

1057 RT A1 Speech processor control fault Replace module

1058 RT A1 Voice gate control fault Replace module

1059 RT A1 Data gate control fault Replace module

1060 RT A1 CW gate control fault Replace module

1061 RT A1 CW key control fault Replace module

1062 RT A1 6-dB volume control fault Replace module

1063 RT A1 12-dB volume control fault Replace module

1064 RT A1 24-dB volume control fault Replace module

1065 RT A1 Squelch 1 control fault Replace module

1066 RT A1 Squelch 2 control fault Replace module

1067 RT A1 TIP control fault Replace module

1068 RT A1 Receive enable control fault Replace module

1069 RT A1 Transmit enable control fault Replace module

1070 RT A1 Reserved Replace module

1071 RT A1 Reserved Replace module

5-5

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

Table 5-2. Fault Code Display and Repair Action. (Cont)

FAULT UNIT MODULE DESCRIPTION REPAIR ACTION

1072 RT A1 SSB transmit control fault Replace module

1073 RT A1 RF enable control fault Replace module

1074 RT A1 AGC time constant control fault Replace module

1075 RT A1 SSB filter control fault Replace module

1076 RT A1 SSB audio gate control fault Replace module

1077 RT A1 AM filter control fault Replace module

1078 RT A1 AM audio gate control fault Replace module

1079 RT A1 Carrier reinsertion control fault Replace module

1080 RT A1 Rechannel control fault Replace module

2010 CU A2 No RF received Check rt or system coax

2010 RT A2 Input power loss Check input power

2020 RT A2 Power supply fault Replace module

2030 RT A2 Tone oscillator fault Replace module

3010 CU A3 Tune fault Retune system

3020 CU A3 Overtemperature fault Limit transmit time

3030 CU A3 RF relay fault Replace module

3040 CU A3 High vswr condition Retune system

3110 RT A3A1 Loss of lock fault Replace A3A1 or A6A2 module

3210 RT A3A2 Transmit test fault Replace module

3220 RT A3A2 Receive test fault Replace module

4010 RT A4 1553 control assembly fault Replace module

4011 CU A4 CPU malfunction Replace module

4012 CU A4 Program checksum error Replace module

4013 CU A4 RAM test error Replace module

4015 CU A4 Preset memory storage error Replace module

5-6

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

Table 5-2. Fault Code Display and Repair Action. (Cont)

FAULT UNIT MODULE DESCRIPTION REPAIR ACTION

4016 CU A4 Fiber-optic control fault Replace module

4020 RT A4 ARINC-429 control assembly fault Replace module

5011 RT A5 DC continuity fault Replace module

5012 RT A5 Input voltage/overtemperature Check input power/limit transmit

time

5013 RT A5 RF interlock open Check RF coax

5014 RT A5 Minimum power fault Replace module

5015 RT A5 Power monitor fault Replace module

5016 RT A5 High temperature fault Limit transmit time

9002 CU Fiber-optic data error Check fiber-optic cables and connec-

tors

9002 RT Fiber-optic data error Check fiber-optic cables and connec-

tors

9002 R Fiber-optic data error Check fiber-optic cables and connec-

tors

9003 CU Fiber-optic data error count fault Check fiber-optic cables and connec-
tors

9003 R Fiber-optic data error count fault Check fiber-optic cables and connec-
tors

9003 RT Fiber-optic data error count fault Check fiber-optic cables and connec-
tors

9004 System Invalid data received fault Check fiber-optic cables and connec-
tors

9005 CU No fiber-optic data received Check fiber-optic cables or other

units

9005 R No fiber-optic data received Check fiber-optic cables or other

units

9005 RT No fiber-optic data received Check fiber-optic cables or other

units

5-7

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

5.4.3 Minimum Performance Test

Performance testing includes only testing that can be accomplished using standard test equipment and a
minimum amount of disassembly (removal of covers). This testing includes accessible test points, input and
output voltages, signal levels, and a minimum performance test of the assembled unit.

a. Perform test setup shown in figure 5-1.

b. Set power source to on and adjust power supply for +28. Set test equipment power to on.

c. Perform minimum performance test procedures in table 5-3.

NOTE
If a failure is detected during the tests listed in table 5-3, then those modules which are most
suspect, listed at the beginning of each test, should be replaced.

5-8

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

TE-9200 Test Setup Diagram

Figure 5-1

5-9/5-10

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

TE-9210 Test Setup Diagram

Figure 5-2

5-11/5-12

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

Table 5-3. Minimum Performance Test Procedures

NORMAL IF INDICATION
STEP PROCEDURE
INDICATION IS ABNORMAL

1 TURN-ON TEST

1.1 Connect equipment as shown in figure 5-1,

except do not connect test set cable W4 to
antenna coupler J1. Connect 50-Ω load to
antenna coupler output. Set test set +28
VDC POWER switch to ON.
1.2 Record the current reading on the 28-V DC
power supply.

1.3 Set test set +28 VDC POWER switch to OFF.

Connect the test set cable W4 to antenna
coupler jack J1.

1.4 Set test set CONFIG switches as follows:

A B C
HF-9040 down down down
HF-9041 down up down
HF-9042 down down up
1.5 Set test set +28 VDC POWER switch to ON. Difference is less than
Record the current reading on the 28-V DC 0.5 A.
power supply. Subtract the reading in step
1.2 from the reading in this step.

2 BIT TEST

2.1 Perform self-test procedures and fault anal- All units pass self-test. Remove and replace unit
ysis as presented in paragraphs 5.4.2.1 thru indicated by self-test as
5.4.2.3. faulty.

2.2 Proceed to test 3.

3 50-OHM LOAD TUNING TEST

3.1 Connect equipment as shown in figure 5-1.

Using radio set control, set receiver-trans-
mitter to transmit at 2.0000 MHz, CW, two
power bars indicated (50 W pep).
3.2 Set test set CONFIG switches as follows:
A B C
HF-9040 down down down
HF-9041 down up down
HF-9042 down down up

3.3 Place test set TEST PTT switch to ON. TIP not lighted more
Verify the test set TIP indicator is not light- than 6 seconds.
ed more than 6 seconds

Change 4 5-13

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

Table 5-3 Minimum Performance Test Procedures (Cont)

NORMAL IF INDICATION
STEP PROCEDURE
INDICATION IS ABNORMAL

3 50-OHM LOAD TUNING TEST (Cont)

3.4 Measure the forward power applied to the Not less than 44 W.
antenna coupler input.

3.5 Measure the reflected power at the antenna Not more than 1 W.
coupler input.

3.6 Place test set TEST PTT switch to OFF.

3.7 Repeat steps 3.1 thru 3.6 for frequencies Same as steps 3.2 thru
between 2.0 and 29.9999 MHz in one MHz 3.4.
increments.

4 172H-18A SHUNT LOAD TUNING TEST

4.1 Replace the 50-Ω load shown in test setup

diagram, figure 5-1, with a 172H-18A an-
tenna simulator.
4.2 For HF-9041, use radio set control to set
receiver-transmitter to transmit at 2.0000
MHz, CW, two power bars indicated (50 W
pep).

4.3 For HF-9040 and HF-9042, use radio set

control to set receiver-transmitter to
transmit at 3.0000 MHz, two power bars
indicated (50 W pep).
4.4 Set test set CONFIG switches as follows:
A B C
HF-9040 down down down
HF-9041 down up down
HF-9042 down down down

4.5 Place test set TEST PTT switch to ON. TIP not lighted more
Verify the test set TIP indicator is not light- than 6 seconds.
ed more than 6 seconds.

4.6 Measure the forward power applied to the Not less than 44 W.
antenna coupler input.

4.7 Measure the reflected power at the antenna Not more than 1 W.
coupler input.

4.8 Place test set TEST PTT switch to OFF.

4.9 For HF-9041, repeat steps 4.1, 4.2, and 4.4 Same as steps 4.5 thru
thru 4.8 for frequencies between 2.0 and 4.7.
29.9999 MHz in 1 MHz increments.

5-14 Change 4

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

Table 5-3 Minimum Performance Test Procedures (Cont)

NORMAL IF INDICATION
STEP PROCEDURE
INDICATION IS ABNORMAL

4 172H-18A SHUNT LOAD TUNING TEST (cont)

4.10 For HF-9040 and HF-9042, repeat steps 4.1, Same as steps 4.5 thru
4.3, and 4.4 thru 4.8 for frequencies between 4.7.
3.0 and 29.9999 MHz in 1 MHz increments.

5 172H-21A WHIP LOAD TUNING TEST (FOR HF-9042 ONLY)

5.1 Replace the 50-Ω load shown in test setup

diagram with a 172H-21A antenna simu-
lator. Using radio set control, set receiver-
transmitter to transmit at 2.1000 MHz, CW,
two power bars indicated (50 W pep).

5.2 Set test set CONFIG switches: A and B to TIP indicator is lighted
1, C to 0. Place test set TEST PTT switch to for not more than 6
ON. Verify test set TIP indicator is not seconds.
lighted more than 6 seconds.
5.3 Measure the forward power applied to the Not less than 44 W.
antenna coupler input.

5.4 Measure the reflected power at the antenna Not more than 1 W.
coupler input.
5.5 Place test set TEST PTT switch to OFF.

5.6 Repeat steps 5.1 thru 5.5 for frequencies Same as steps 5.2 thru
between 2.1 and 29.9999 MHz in 1 MHz 5.4.
increments.

6 PRESET TUNING TEST

6.1 Replace the 50-Ω load shown in test setup

diagram with a 172H-18A antenna simu-
lator. Using radio set control, set receiver-
transmitter to transmit at 2.0000 MHz (use
3.0000 MHz for HF-9040 and HF-9042
Only), CW, two power bars indicated (50 W
pep).
6.2 Set test set CONFIG switches as follows:
A B C
HF-9040 down down down
HF-9041 down up down
HF-9042 down down down

6.3 Place test set TEST PTT switch to ON. Wait

until tune cycle is complete, then place test
set TEST PTT switch to OFF.

Change 5 5-15

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

Table 5-3 Minimum Performance Test Procedures (Cont)

NORMAL IF INDICATION
STEP PROCEDURE
INDICATION IS ABNORMAL
6 PRESET TUNING TEST (cont)
6.4 Place test set TEST PTT switch to ON. Coupler does not go
Verify the antenna coupler did not go thru a thru a complete tune
complete tune cycle. cycle.
6.5 Measure the forward power applied to the Not less than 44 W.
antenna coupler input.
6.6 Measure the reflected power at the antenna Not more than 1 W.
coupler input.
6.7 Set test set TEST PTT switch to OFF.
6.8 Repeat steps 6.1 thru 6.6 for frequencies Same as steps 6.2 thru
listed below. 6.4.
Frequency (MHz)
8
14
29.9999

7 HIGH VSWR SENSOR TEST

7.1 Using radio set control, set receiver-

transmitter to transmit at 2.0000 MHz, CW,
two power bars indicated (50 W pep).
7.2 Set test set CONFIG switches as follows:
A B C
HF-9040 down down down
HF-9041 down up down
HF-9042 down down down
7.3 Replace 50 ohm load with 3db attenuator,
unterminated.

7.3.1 Set TE-9200 Test PTT switch to ON or set

TE-9210 PTT switch to KEY.

7.4 Measure the power applied to the antenna Not less than 44 W.
coupler input.
7.5 Measure the vswr at the antenna coupler Vswr approximately
input. 3:1.
7.6 Verify the radio set control indicates a high
vswr condition.
7.7 Place test set TEST PTT switch to OFF.

7.8 Repeat steps 7.1 thru 7.7 using 8 MHz, 14 Same as steps 7.4 and
MHz, and 29.9999 MHz. 7.5.

5-16 Change 4

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

Table 5-3 Minimum Performance Test Procedures (Cont).

NORMAL IF INDICATION
STEP PROCEDURE
INDICATION IS ABNORMAL

8 DUAL-COUPLER TEST (FOR HF-9041 ONLY)

8.1 Set test set STATUS 28V switch to 0. Set test set
STATUS A and B switches to 1.

8.2 Set test set STATUS A switch to 0.

8.3 Verify the radio set control indicates message 090.

8.4 Set test set TEST PTT switch to ON.

8.5 Observe the radio set control indicates a message

080.

8.6 Place test set TEST PTT switch to OFF.

8.7 Set test set STATUS A switch to 1 and STATUS B

switch to 0.

8.8 Verify that test set EXTERNAL ELEMENT F

indicator lights.

8.9 Set test set STATUS A and B switches to 1.

8.10 Verify that test set EXTERNAL ELEMENT F

indicator turns off.

8.11 Set test set TEST PTT switch to ON.

8.12 Verify that test set EXTERNAL ELEMENT E

indicator lights.

8.13 Set test set TEST PTT switch to OFF.

8.14 Verify that test set EXTERNAL ELEMENT E

indicator turns off.

8.15 Jumper test set J1 pin 32 to J1 pin 33.

8.16 Using the radio set control, change the channel

selected. Verify that test set EXTERNAL
ELEMENT F indicator lights.

8.17 Remove jumper installed in step 8.15.

8.18 Using the radio set control, change the channel

selected. Verify the radio set control indicates FLT
070.

5-17

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

Table 5-3 Minimum Performance Test Procedures (Cont).

NORMAL IF INDICATION
STEP PROCEDURE
INDICATION IS ABNORMAL

8 DUAL-COUPLER TEST (FOR HF-9041 ONLY) (cont)

8.19 Set test set STATUS +28V switch to 1. Clear fault

by changing channel selected on radio set control.

8.20 Set test set STATUS A switch to 0 and STATUS B

switch to 1.

8.21 Verify no change in the radio set control indication.

8.22 Set test set STATUS A switch to 1 and STATUS B

switch to 0.

8.23 Verify no change in the radio set control indication.

8.24 Set test set TEST PTT switch to ON.

8.25 Verify the test set EXTERNAL ELEMENT E

indicator lights and EXTERNAL ELEMENT F
indicator is not lit.

8.26 Set test set TEST PTT switch to OFF. Test set
EXTERNAL ELEMENT E indicator turns off and
EXTERNAL ELEMENT F indicator is not lit.

8.27 Using the radio set control, change the channel

selected. Verify the test set EXTERNAL
ELEMENT F indicator lights.

8.28 Set all switches to off. Turn off all test equipment.
Disconnect all equipment.

5.5 ALIGNMENT/ADJUSTMENT

No adjustment of the antenna coupler is recommended at this maintenance level.

5.6 DISASSEMBLY/ASSEMBLY

5.6.1 Disassembly

5.6.1.1 HF-Antenna Coupler HF-9040 Disassembly

a. RF Tuner A3 Removal

5-18

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

1. Refer to parts list, Figure 6-1. Remove left (as viewed from front) side cover (6) by removing 12
screws.

2. Remove 14 screws from RF tuner (8) and one screw from rear RF antenna terminal.

3. Lift RF tuner A3 (8) from chassis (10).

4. Disconnect cable connectors A2P1 and A3P1 and coaxial connector A1W1P1.

b. Discriminator A2 Removal

1. Refer to parts list, Figure 6-1. Remove RF tuner A3 (8) from chassis (10).

2. Remove one screw from terminal A2A1 E1.

3. Remove eight screws from discriminator A2 (9).

c. Control A4 Removal

1. Refer to parts list, Figure 6-1. Remove right (as viewed from front) side cover (6) by removing 12
screws.

2. Remove 11 screws from control A4 (7).

3. Lift control A4 (7) from chassis (10).

4. Unplug cable connectors A1P1, A1A1P1, A2P1, and A3P1.

5.6.1.2 HF-Antenna Coupler HF-9041 Disassembly

a. RF Tuner A3 Removal

1. Refer to parts list, Figure 6-2. Relieve internal pressure by depressing Schrader valve on front of
unit.

2. Remove left (as viewed from front) side cover (6) by removing 16 screws. Be careful when removing
cover to avoid damage to preformed packings (gaskets) and sealing surfaces.

3. Remove 15 screws from RF tuner A3 (9) and unsolder wire from A3E14 to A5K5 C.

4. Lift RF tuner A3 (9) from chassis (14).

5. Disconnect cable connectors A2P1 and A3P1 and coaxial connector A1W1P1.

b. Discriminator A2 Removal

1. Refer to parts list, Figure 6-2. Remove RF tuner A3 (9).

2. Remove one screw from terminal A2A1 E1.

3. Remove eight screws from discriminator A2 (10).

5-19

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

c. External Element A5 Removal

1. Refer to parts list, Figure 6-2. Remove RF tuner A3 (9).

2. Remove five screws from external element A5 (11) and one screw from rear RF antenna terminal.

3. Lift external element A5 (11) from chassis (14).

4. Disconnect cable connector A5P1.

d. Control A4 Removal

1. Refer to parts list, Figure 6-2. Relieve internal pressure by depressing Schrader valve on front of
unit.

2. Remove right (as viewed from front) side cover (6) by removing 12 screws.

3. Remove 11 screws from control A4 (8).

4. Lift control A4 (8) from chassis (14).

5. Unplug cable connectors A1P1, A1A1P1, A2P1, A3P1, and A5P1.

5.6.1.3 HF-Antenna Coupler HF-9042 Disassembly

a. RF Tuner A3 Removal

1. Refer to parts list, Figure 6-2. Relieve internal pressure by depressing Schrader valve on front of
unit.

2. Remove left (as viewed from front) side cover (6) by removing 16 screws. Be careful when removing
cover to avoid damage to preformed packings (gaskets) and sealing surfaces.

3. Remove 15 screws from RF tuner A3 (9) and unsolder wire from A3E14 to A5K5 C.

4. Lift RF tuner A3 (9) from chassis (14).

5. Disconnect cable connectors A2P1 and A3P1 and coaxial connector A1W1P1.

b. Discriminator A2 Removal

1. Refer to parts list, Figure 6-2. Remove RF tuner A3 (9).

2. Remove one screw from terminal A2A1 E1.

3. Remove eight screws from discriminator A2 (10).

c. Control A4 Removal

5-20

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

1. Refer to parts list, Figure 6-2. Relieve internal pressure by depressing Schrader valve on front of
unit.

2. Remove right (as viewed from front) side cover (6) by removing 12 screws.

3. Remove 11 screws from control A4 (8).

4. Lift control A4 (8) from chassis (14).

5. Unplug cable connectors A1P1, A1A1P1, A2P1, and A3P1.

5.6.2 Assembly

CAUTION

If equipment contains electrostatic discharge sensitive (ESDS) devices, special handling

methods and materials must be used to prevent equipment damage. Refer to paragraph
5.7.2, ESDS devices precautions, before performing maintenance on the equipment.

CAUTION

Keep protective covers on fiber optic connectors when interconnect cables are not connected.
Dust and moisture on the internal optical lenses of the connectors degrades system
operation.

5.6.2.1 General

Follow the disassembly steps in reverse order to assemble the units. Be especially careful to maintain correct
screw lengths. Be sure all connectors are properly reinstalled. Refer to paragraph 5.6.2.2 for HF-9041 or HF-
9042 HF-Antenna Coupler Pressurization.

5.6.2.2 HF-Antenna Coupler HF-9041 or HF-9042 Pressurization

a. Clean sealing surfaces on chassis and covers with isopropyl alcohol, CPN 005-2941-100, as required. Be
sure the sealing surfaces are free of nicks or scratches. Clean and inspect preformed packings (gaskets)
with isopropyl alcohol, as required. Replace if damaged.

b. Apply a light, uniform coating of lubricant to preformed packings (Super O Lube, Parker Hannifin
Corporation, CPN 005-1992-010 or equivalent).

c. Align preformed packings with covers and sealing surfaces of unit. Reinstall 16 cover screws.

d. Tighten cover screws progressively to approximately 10.4 kgcm (9 lb.in). Then tighten screws
progressively to 12.7 to 15.0 kgcm (11 to 13 lb.in) using torque pattern shown in Figure 5-3.

NOTE
It is recommended that the unit be re-pressurized to 6 psig +/- 1 psig with dry nitrogen after
being checked, due to the small volume of the unit. Checking the pressure releases a small
amount of nitrogen, and topping off the nitrogen charge is recommended. A certified high

Change 2 5-21

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

accuracy gauge should be used to measure the coupler pressure since standard auto pressure
gauges are inaccurate at lower pressures. Refer to Coupler Pressurization paragraph 5.6.2.3.

e. Pressurize unit through Schrader valve on front to 34.5 to 48.2 kPa (5 to 7 psig) using dry nitrogen or dry
air. Never pressurize the unit to greater than 75.8 kPa (11 psig). The pressurization specification in this
step accounts for pressure variations due to the ambient temperature.

5.6.2.3 Coupler Pressurization

The Rockwell Collins, Inc. HF-9041 and HF-9042 HF Antenna Couplers are sealed units that are
pressurized with dry nitrogen to provide reliable operation at altitudes up to 55,000 ft. These couplers are
sealed and pressurized to:

• Prevent breakdown of the high RF voltages inside the coupler. Most couplers are installed in non-
pressurized areas of the aircraft and therefore must contain their own atmosphere at high altitudes
(>35,000 feet).

• Prevent the ingress of moisture laden air into the coupler during changing temperature & altitude
environmental conditions. Humid air could eventually cause moisture condensation inside the
coupler that could further reduce high voltage standoff capability.

Nominal pressurization of the couplers is 6 pounds per square inch gauge (psig) at sea level at the time of
maintenance service. As long as internal pressure remains positive with respect to ambient sea level
pressure the HF-9041/42 will function properly. As a guideline 1 psig is used as a limit where the HF-
9041/42 should be re-pressurized.

The HF-9041/42 is designed to have a very low leakage rate, however, due to the small internal volume of
the HF-9041, the pressure inside the coupler can decrease over time to below the specified nominal 6 psig.
Additionally, repeated measuring of the pressure can accelerate the effect, as each measurement releases a
small amount of the dry nitrogen from the coupler. If a coupler has a loss of pressure, many operators will
remove the unit and send it in for service. This is unnecessary unless the coupler has a leak rate greater
than 15 micron cu ft/hr. The following procedure is an alternative to allow operators to re-pressurize the HF-
9041 in place when necessary.

The pressure of the HF-9041/42 should be checked at intervals of six months or greater for loss of pressure.
The coupler does not need to be removed from the aircraft if the check and pressurization can be done in-
place. The HF-9041/42 should be at ambient temperature for at least two hours before checking the
pressure. If the pressure measured in the HF-9041/42 is less than 5 psig, but at or above 1 psig, the unit can
be re-pressurized to 6 psig +/- 1 psig. Any unit with less than 1 psig of positive pressure should be removed
from the aircraft and sent to a Rockwell Collins, Inc. Service Center for leak testing and repair. If a leaking
coupler is suspected, the unit can be checked by pressurizing to 6 psig +/- 1 psig and rechecking after 24
hours. If a measurable pressure loss is detected at that time under identical ambient conditions, the unit
should be removed and sent in to a Rockwell Collins, Inc. Service Center for repair.

Use the following procedure to check for leaks when precision leak check equipment is not available.

a. Pressurize the unit to 62 to 76 kPa (9 to 11 psig) of helium.

b. Submerge the unit in water for 2 minutes and check for bubbles exiting the unit.

c. If any leakage is detected (indicated by the presence of bubbles), immediately remove the unit from
water, repair affected area, and repeat steps 1 and 2 until no leakage is detected.

5-22 Change 3

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

d. Thoroughly dry all exterior surfaces of the unit using wipes and compressed air.

e. Hold the pressure relief valve open and evacuate the unit of all helium by filling with dry nitrogen for 30
seconds. Then release the relief valve and pressurize with dry nitrogen to 34.5 to 48.2 kPa (5 to 7 psig).

Cover Torque Pattern

Figure 5-3

5.7 REPAIR

CAUTION

This equipment contains electrostatic discharge sensitive (ESDS) devices. Use special
procedures and materials to prevent equipment damage. Refer to paragraph 5.7.2,
Electrostatic Discharge Sensitive Devices Precautions, before you do maintenance on the
equipment.

Change 3 5-22A/5-22B

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

5.7.1 General

Use standard procedures to remove and replace components or subassemblies attached to the chassis. Make sufficient notes
to put wire locations and leads back to initial positions.

CAUTION

Do not use too much heat when you put solder on solid-state devices or the circuit board. If
you use too much heat, damage can occur to the devices or the copper circuit foil can lift from
the board.

Use standard procedures to remove and replace components on the circuit cards. The paragraphs that follow
give special instructions for ESDS devices, and to remove and replace postcoat on circuit cards.

5.7.2 Electrostatic Discharge Sensitive Devices Precautions

Friction between materials and separation of these materials cause a static electrical charge. Your body or
surfaces with insulation cause voltages of 1 to 20 kilovolts that can cause ESDS devices to become defective.

WARNING

Dry weather (relative humidity less than 30 percent) increases the quantity of static voltage
on a surface. In low-humidity conditions, it is very important to use special procedures with
ESDS devices.

5.7.2.1 ESDS Device Precautions

CAUTION

Do not touch ESDS devices with nylon or other synthetic gloves. This type of material causes
a large quantity of static electricity. Excessive static can build up on this type of material. Do
not touch the leads of ESDS devices.

Before you move ESDS devices, use one of the procedures that follow to put their leads together.

a. Put each device in high-density conductive foam.

b. Put each device in a container with aluminum foil as a cover on the inner surface.
c. Put each device in a storage tube made of aluminum or with a special layer of plastic. Then put a
label on the tube that shows that it is free of static electricity.

5-23

The document reference is online, please check the correspondence between the online documentation and the printed version.
maintenance

The label that follows must show on each part container.

CAUTION

Static electricity can make this component unserviceable. Use only special procedures and
materials with this component.

Protection from static electricity is necessary for ESDS devices until they are installed in a protective
subassembly. If ESDS devices are in subassemblies that do not give sufficient ESDS device protection, they
can also receive static damage.

Use plastic bags that have no effect from static electricity when module subassemblies or circuit boards with
ESDS devices are moved. Do not touch the subassemblies without a correct ground strap attached to your
body. Do not use clear polyvinyl bags. Plastic bags are not necessary when the top-level unit has the
subassemblies installed.

5.7.2.2 ESDS Device Storage

The procedures given in paragraph 5.7.2.1 are satisfactory procedures for storage.

CAUTION

A high-temperature/high-humidity area can cause lead corrosion in a device or assembly.

5.7.2.3 Test of Circuit Cards Containing ESDS Devices

When you do a test on a subassembly with ESDS devices, obey the precautions that follow.

a. Remove power from test fixtures and equipment before you install or remove an ESDS device or
subassembly that contains an ESDS device.
b. Make sure that all test equipment is correctly grounded.
c. Apply a DC power source to the ESDS device or a subassembly that contains an ESDS device before you
apply a signal voltage.
d. Remove signal voltages from the ESDS device or a subassembly that contains an ESDS device before you
remove DC power source.
e. Do not do dielectric strength tests or insulation resistance checks for an ESDS device or subassembly
that contains an ESDS device.

5-24 Change 3

The document reference is online, please check the correspondence between the online documentation and the printed version.
 maintenance

5.7.2.4 ESDS Device Replacement

CAUTION

Place protective containers with ESDS devices on grounded conductive work surfaces.

CAUTION

Use an ionized air blower in the area where you do work on ESDS devices. Do your work in
the path of the ionized air. Operate the air blower for 3 minutes before you touch an ESDS
device to remove static electricity. Wear a grounded wrist strap on bare skin as an
alternative to an ionized air blower.

WARNING

When you use a grounded wrist strap, make sure that no voltages are in the work area.

Obey the precautions that follow when you replace an ESDS device.

a. Ground all solder iron points, special tools, and hand tools.
b. Use only metal hand tools that have no insulation. Put hand tools on a conductive work surface when
you do no use them.
c. Before you install ESDS devices, make sure that their leads touch the conductive work surface to prevent
damage from static electricity.
d. Do not install or remove ESDS devices on a circuit board with the power applied because the voltages
can cause damage.
e. If ESDS device leads are not used, connect them to ground or connect them to the power supply of the
logic circuit.
5.7.3 Postcoat

5.7.3.1 General

Some circuit cards use postcoat to prevent damage from humidity. Remove the postcoat from the repair area
before you do the repair. Then replace the postcoat when the repair is completed.

5.7.3.2 HumiSeal 1B31 Removal

Refer to the procedures given in the newest Rockwell Collins Avionics Standard Shop Practices manual,
Collins part number 523-0768039, local Standard Shop Practices Manual, or The Institute for
Interconnecting and Packaging Electronic Circuits (IPC) standard publications.

5.7.3.3 HumiSeal 1B31 Replacement

Refer to the procedures given in the newest Rockwell Collins Avionics Standard Shop Practices manual,
Collins part number 523-0768039, local Standard Shop Practices Manual, or IPC (known as Association
Connecting Electronics Industries) standard publications.

Change 3 5-25/5-26

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 6
PARTS LIST

6.1 INTRODUCTION

6.1.1 General

The function of this parts list, prepared by Rockwell Collins, Inc. (manufacturer code 13499), is for
identification of parts and how to order parts.
The parts shown in this section meet critical equipment design specifications. Use only part numbers
specified in this parts list as replacement parts.

6.1.2 Group Assembly Parts List

FIG-ITEM Column – Numbers before the first dash refer to section numbers. Numbers after the first dash
refer to figure numbers in the section. Numbers after the second dash are item numbers given in sequence to
agree with numbers on the illustration.
PART NO Column – Shown are the MIL standard or vendor part numbers.
INDENT Column – Items use numbers (1, 2, 3) to show the different levels of the assembly.
DESCRIPTION Column – Use this column to get:
• Part data
• Manufacturer codes (in the absence of a code, the part number is a prime contractor (13499) part)
• Attaching parts (AP)
• Reference to other figures
• Effectivities
Attaching parts are identified by (AP) that follows the part or parts they attach.

Change 1 6-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

Effectivities are identified as follows: Manufacturers Control Number (MCN), 101 and up; Revision Level
Letter (REV LTR), dash (–) is used for initial REV LTR, letter A first change, letter B second change, and up.
One of these identifiers is recorded on each chassis or assembly that can be replaced. Service bulletins are
identified by SB 1, SB 2, and up.
UNITS PER ASSY Column – Quantities specified are for each item number. Letters AR show the selection of
parts “as required”. Letters REF show that the part number is for reference only. The part is assembled in a
different location of the parts list or is non-procurable. A figure is referred to or a note is included in the
description.
USABLE ON CODE Column – Parts used in a group of equipment are shown by a letter code (A, B, C, and
up). When no code is shown, the part is used on all configurations included in the parts list.

6.1.3 Numerical Index

PART NUMBER Column – Part numbers are shown in alphanumeric sequence.

FIG-ITEM Column – Numbers before the first dash refer to section numbers. Numbers after the first dash
refer to figure numbers in the section. Numbers after the second dash are item numbers.
TTL REQ Column – The total quantity of parts or assemblies that are in the group assembly parts list.

6.1.4 Reference Designation Index

REFERENCE DESIGNATION Column – Reference designations are shown in alphanumeric sequence.

FIG-ITEM Column – Numbers before the first dash refer to section numbers. Numbers after the first dash
refer to figure numbers in the section. Numbers after the second dash are item numbers.
PART NUMBER Column – Shown are the MIL standard or vendor part number for each item in the parts
list.

6.1.5 How To Use This Parts List

To find a part number when the assembly that uses the part is known, use the list of illustrations to find the
page number for the assembly. Find the part and its item number on the figure. Then find the item number,
its description, and part number from the group assembly parts list.
To find the figure for a part when the part number is known, refer to the numerical index and find the part
number. Turn to the first figure and item number shown in the index. If the part is not shown, refer to the
other figure numbers given in the numerical index.
To find the figure for a part when the reference designation is known, refer to the reference designation
index and find the reference designation. Turn to the figure and item number shown in the index.

CAUTION

This equipment contains electrostatic discharge sensitive (ESDS) devices. Use special
procedures and materials to prevent equipment damage. Refer to the maintenance section for
the equipment before you do an assembly, disassembly, or repair. The DESCRIPTION
column of the parts list shows (ESDS) for all ESDS items.

The parts list illustrations show ESDS items with the symbol that follows.

6-2 Change 1

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

6.1.6 Manufacturer’s Code, Name, and Address

MFR MANUFACTURER’S NAME MFR MANUFACTURER’S NAME

CODE AND ADDRESS CODE AND ADDRESS
A2203 I B MOORE 77250 ALLIED PRODUCT CORP
648 LACO DR 5700 W ROOSEVELT RD
LEXINGTON KY 40504 CHICAGO, IL 60650-1156

12998 QUALITY NAME PLATE INC 80205 NATIONAL AEROSPACE STANDARDS

P.O. BOX 308 COMMITTEE AEROSPACE INDUSTRIES
EAST GLASTONBURY CT 06025-0308 1250 EYE ST NW
WASHINGTON DC, 20005

13499 ROCKWELL COLLINS 96906 MILITARY STANDARDS

COLLINS AVIONICS AND COMMUNICATIONS PROMULGATED BY MILITARY DEPARTMENTS
350 COLLINS RD NE INDIANAPOLIS, IN
CEDAR RAPIDS, IA 52498

5K923 NRD INC

SUB OF MARK IV INDUSTRIES INC
2937 ALT BLVD N
GRAND ISLAND, NY 14072-1220

6.1.7 Usable On Codes

The following usable on codes are assigned.

USABLE ON CODE UNIT PART NUMBER FIG-ITEM

A 622-8113-001 6-1-
B 622-8113-002 6-1-
C 622-8113-003 6-1-
D 622-8114-001 6-2-
E 622-8114-002 6-2-
F 622-9405-001 6-2-
G 622-9405-002 6-2-
H 685-0350-001 6-4-
J 685-0350-002 6-4-
K 622-9405-003 6-2-
L 622-8114-020 6-2-
M 685-0350-020 6-4-
N 622-9405-020 6-2-
6.1.8 Reference Designation Prefixes

The following are assigned.

PREFIX UNIT PART NUMBER FIG-ITEM

A1 659-9030-001 6-1-10
A1 659-9070-001 6-2-14
A1 659-9070-002 6-2-14
A2 659-9043-001 6-1-9
A2 659-9043-001 6-2-10
A3 659-9031-001 6-1-8
A3 659-9031-001 6-2-9
A3 751-7068-001 6-2-9
A3 659-9031-020 6-2-9

Change 5 6-3

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

PREFIX UNIT PART NUMBER FIG-ITEM

A4 687-5075-001 6-1-7
A4 687-5075-003 6-1-7
A4 687-5075-005 6-1-7
A4 687-5075-001 6-2-8
A4 687-5075-003 6-2-8
A4 687-5075-004 6-2-8
A4 687-5075-006 6-2-8
A5 659-9052-001 6-2-11
A5 659-9052-020 6-2-11

6.1.9 Configuration Identifiers

The following CI/REV LTR were used in compiling this data.

REV LTR UNIT PART NUMBER FIG-ITEM

U 622-8113-001 6-1-
U 622-8113-002 6-1-
U 622-8113-003 6-1-
AF 622-8114-001 6-2-
AF 622-8114-002 6-2-
N 622-9405-001 6-2-
N 622-9405-002 6-2-
N 622-9405-003 6-2-
A 685-0365-001 6-3-
F 685-0350-001 6-4-
F 685-0350-002 6-4-
A 622-8114-020 6-2-
A 685-0350-020 6-4-
- 622-9405-020 6-2-

6-4 Change 5

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

6.2 GROUP ASSEMBLY PARTS LIST

HF Antenna Coupler HF-9040, Parts Location Diagram

Figure 6-1.

6-5

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

I UNITS USABLE
FIG- PART NO N DESCRIPTION PER ON
ITEM D ASSY CODE

6-1- 622-8113-001 1 COUPLER, HF ANTENNA, HF-9040 1 A

- 622-8113-002 1 COUPLER, HF ANTENNA, HF-9040 1 B
- 622-8113-003 1 COUPLER, HF ANTENNA, HF-9040 1 C
-1 642-0407-000 2 PLATE, IDENT 1
-2 685-0363-001 2 PLATE, UNIT MODIFICATION 1
MS51957-2B 2 SCREW,MACHINE SST, 2-56 X 3/16 (96906) 2
343-0669-000 (AP FOR 1, 2)
MS35338-134 2 WASHER,LOCK SST, 0.088 ID X 0.172 OD (96906) 2
310-0275-000 (AP FOR 1, 2)
-3 676-1087-000 2 LABEL (EFF REV LTR F) 1
-4 CEP-16 2 CAP,DUST,CONNECTOR (5K923) 206-0102-250 (EFF REV 1
LTR H)
-5 CEP-08 2 CAP,DUST,CONNECTOR (5K923) 206-0102-060 (EFF REV 1
LTR H)
-6 659-9047-001 2 COVER, SIDE 2
MS51959-27 2 SCREW,MACHINE CRES, 6-32 X 5/16 (96906) 24
342-0061-000 (AP)
- 6A 280-1368-430 2 LABEL,PRESSURE SENS (12998) (EFF REV LTR P) 1
-7 687-5075-001 2 CONTROL (ESDS) A4 1 A
-7 687-5075-003 2 CONTROL (ESDS) A4 1 B
-7 687-5075-005 2 CONTROL (ESDS) A4 1 C
MS51957-27 2 SCREW,MACHINE CRES, 0.138-32 X 0.312IN (96906) 11
343-0168-000 (AP)
MS35338-136 2 WASHER,LOCK SST, 0.141 ID X 0.250 OD (96906) 11
310-0282-000 (AP)
NAS620C6 2 WASHER,FLAT PSVT CRES, 0.143 ID X 0.267 OD 11
(80205) 310-0740-400 (AP)
-8 659-9031-001 2 TUNER, RF A3 1
MS51957-27 2 SCREW,MACHINE CRES, 0.138-32 X 0.312IN (96906) 14
343-0168-000 (AP)
NPBRS0.112-40X0. 2 SCREW,MACHINE NP BRS, 0.112-40 X 0.250IN (77250) 1
0250IN 343-0285-000 (AP)
343-0308-000 2 SCREW,MACHINE NP BRS, 0.164-32 X 0.312IN (AP) 1
MS35338-97 2 WASHER,SPRING CD PL BRZ, 0.115 ID X 0.209 OD 1
(96906) 310-0095-000 (AP)
MS35338-99 2 WASHER,SPRING CD PL BRZ, 0.168 ID X 0.293 OD 1
(96906) 310-0098-000 (AP)
-9 659-9043-001 2 DISCRIMINATOR A2 1
MS51957-15 2 SCREW,MACHINE STL, 4-40 X 3/8 (96906) 8
343-0135-000 (AP)
MS35338-97 2 WASHER,SPRING CD PL BRZ, 0.115 ID X 0.209 OD 8
(96906) 310-0095-000 (AP)
- 10 659-9030-001 2 CHASSIS A1 1

6-6 Change 1

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

HF Antenna Coupler HF-9041 and HF-9042, Parts Location Diagram

Figure 6-2.

6-7

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

I UNITS USABLE
FIG- PART NO N DESCRIPTION PER ON
ITEM D ASSY CODE

6-2- 622-8114-001 1 COUPLER, HF ANTENNA, HF-9041 1 D

- 622-8114-002 1 COUPLER, HF ANTENNA, HF-9041 1 E
- 622-8114-020 1 COUPLER, HF ANTENNA, HF-9041 1 L
- 622-9405-001 1 COUPLER, HF ANTENNA, HF-9042 1 F
- 622-9405-002 1 COUPLER, HF ANTENNA, HF-9042 1 G
- 622-9405-003 1 COUPLER, HF ANTENNA, HF-9042 1 K
- 622-9405-020 1 COUPLER, HF ANTENNA, HF-9042 1 N
-1 642-0406-000 2 PLATE, IDENT 1 D,E,L
-1 676-1217-000 2 PLATE, IDENT 1 F,G,K,N
-2 685-0363-001 2 PLATE, UNIT MODIFICATION 1
MS51957-2B 2 SCREW,MACHINE SST, 2-56 X 3/16 (96906) 343-0669-000 2
(AP FOR 1, 2)
MS35338-134 2 WASHER,LOCK SST, 0.088 ID X 0.172 OD (96906) 2
310-0275-000 (AP FOR 1, 2)
-3 676-1087-000 2 LABEL (EFF REV LTR G) 1 D,E
- 3A 676-1087-000 2 LABEL 1 F,G,K,N
-4 CEC-16 2 CAP,DUST,CONNECTOR (5K923) 206-0102-120 1 D,E
(EFF REV LTR K TO REV LTR L)
-4 CEP-16 2 CAP,DUST,CONNECTOR (5K923) 206-0102-250 1 D,E
(EFF REV LTR L)
-4 CEP-08 2 CAP,DUST,CONNECTOR (5K923) 206-0102-120 1 F,G
(EFF TO REV LTR G)
-4 CEP-16 2 CAP,DUST,CONNECTOR (5K923) 206-0102-250 1 F,G
(EFF REV LTR G)
-4 CEP-16 2 CAP,DUST,CONNECTOR (5K923) 206-0102-250 1 K,L,N
-5 CEP-08 2 CAP,DUST,CONNECTOR (5K923) 206-0102-060 1 D,E
(EFF REV LTR K)
-5 CEP-08 2 CAP,DUST,CONNECTOR (5K923) 206-0102-060 1 F,G,K,L,N
-6 659-9071-001 2 COVER, SIDE 2
MS51957-27 2 SCREW,MACHINE CRES, 0.138-32 X 0.312IN (96906) 32 D,E
343-0168-000 (AP) (EFF TO REV LTR H)
MS51957-28 2 SCREW,MACHINE CRES, 0.138-32 X 0.375IN (96906) 32 D,E
343-0169-000 (AP) (EFF REV LTR H TO REV LTR P)
NAS8101U7 2 SCREW,NON-LOCKING PSVT CRES, 0.1380-32UNJC-3A X 0.44 32 D,E
(80205) (AP) (EFF REV LTR P TO REV LTR W)
MS51957-29 2 SCREW,MACHINE CRES, 0.138-32 X 0.437IN (96906) (AP) 32 D,E
(EFF REV LTR W)
NAS8101U7 2 SCREW,NON-LOCKING PSVT CRES, 0.1380-32UNJC-3A X 0.44 32 F,G,K
(80205) (AP) (EFF TO REV LTR K)
MS51957-29 2 SCREW,MACHINE CRES, 0.138-32 X 0.437IN (96906) (AP) 32 F,G,K
(EFF REV LTR K)
MS51957-29 2 SCREW,MACHINE CRES, 0.138-32 X 0.437IN (96906) (AP) 32 L,N
MS35338-136 2 WASHER,LOCK SST, 0.141 ID X 0.250 OD (96906) 32
310-0282-000 (AP)
NAS620C6 2 WASHER,FLAT PSVT CRES, 0.143 ID X 0.267 OD (80205) 32
310-0740-400 (AP)
- 6A 280-1368-430 2 LABEL,PRESSURE SENS (12998) (EFF REV LTR V) 1 D,E
- 6A 280-1368-430 2 LABEL,PRESSURE SENS (12998) (EFF REV LTR J) 1 F,G,K
- 6A 280-1368-430 2 LABEL,PRESSURE SENS (12998) 1 L,N
-7 300-0015-010 2 PACKING,PREFORMED (A2203) 2
-8 687-5075-001 2 CONTROL (ESDS) A4 1 D
-8 687-5075-003 2 CONTROL (ESDS) A4 1 E,L
-8 687-5075-004 2 CONTROL (ESDS) A4 1 F,G,N
-8 687-5075-006 2 CONTROL (ESDS) A4 1 K
MS51957-27 2 SCREW,MACHINE CRES, 0.138-32 X 0.312IN (96906) 11 D,E
343-0168-000 (AP) (EFF TO REV LTR H)
MS51957-28 2 SCREW,MACHINE CRES, 0.138-32 X 0.375IN (96906) 11 D,E
343-0169-000 (AP) (EFF REV LTR H)
MS51957-28 2 SCREW,MACHINE CRES, 0.138-32 X 0.375IN (96906) 11 F,G,K,L,N
343-0169-000 (AP)
MS35338-136 2 WASHER,LOCK SST, 0.141 ID X 0.250 OD (96906) 11
310-0282-000 (AP)

6-8 Change 5

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

I UNITS USABLE
FIG- PART NO N DESCRIPTION PER ON
ITEM D ASSY CODE

6-2- NAS620C6 2 WASHER,FLAT PSVT CRES, 0.143 ID X 0.267 OD (80205) 11

310-0740-400 (AP)
-9 659-9031-001 2 TUNER, RF A3 1 D,E
-9 659-9031-020 2 TUNER, RF A3 1 L
-9 751-7068-001 2 TUNER, RF A3 1 F,G,K
-9 751-7068-020 2 TUNER, RF A3 1 N
MS51957-27 2 SCREW, MACHINE CRES, 0.138-32 X 0.312IN (96906) 15 D,E
343-0168-000 (AP) (EFF TO REV LTR H)
MS51957-28 2 SCREW, MACHINE CRES, 0.138-32 X 0.375IN (96906) 15 D,E
343-0169-000 (AP) (EFF TO REV LTR H)
MS51957-28 2 SCREW, MACHINE CRES, 0.138-32 X 0.312IN (96906) 15 F,G,K,L,N
343-0168-000 (AP)
NPBRS0.112-40X0. 2 SCREW, MACHINE NP BRS, 0.112-40 X 0.250IN (77250) 1
250IN 343-0285-000 (AP)
343-0308-000 2 SCREW, MACHINE NP BRS, 0.164X32 X 0.312IN (AP) 1
MS35338-136 2 WASHER, LOCK SST, 0.141 ID X 0.250 OD (96906) 10
310-0282-000 (AP)
MS35338-97 2 WASHER, SPRING CD PL BRZ, 0.115 ID X 0.209 OD (96906) 1
310-0095-000 (AP)
MS35338-99 2 WASHER, SPRING CD PL BRZ, 0.168 ID X 0.293 OD (96906) 1
310-0098-000 (AP)
- 10 659-9043-001 2 DISCRIMINATOR A2 1
MS51957-15 2 SCREW, MACHINE STL, 4-40 X 3/8 (96906) 8
343-0135-000 (AP)
MS35338-97 2 WASHER, SPRING CD PL BRZ, 0.115 ID X 0.209 OD (96906) 8
310-0095-000 (AP)
- 11 659-9052-001 2 ELEMENTAL, EXTERNAL A5 1 D,E
- 11 659-9052-020 2 ELEMENTAL, EXTERNAL A5 1 L
MS51957-27 2 SCREW, MACHINE CRES, 0.138-32 X 0.312IN (96906) 5 D,E
343-0168-000 (AP) (EFF TO REV LTR H)
MS51957-28 2 SCREW, MACHINE CRES, 0.138-32 X 0.375IN (96906) 5 D,E
343-0169-000 (AP) (EFF TO REV LTR H)
MS51957-28 2 SCREW, MACHINE CRES, 0.138-32 X 0.375IN (96906) 5 L
343-0169-000 (AP)
MS35338-136 2 WASHER, LOCK SST, 0.141 ID X 0.250 OD (96906) 5 D,E,L
310-0282-000 (AP)
- 12 659-9086-001 2 RING, CONTACT 1 G,K
- 13 MS51957-26B 2 SCREW, MACHINE CRES, 0.138-32UNC-2A X 1/4IN (96906) 4 F,G,K,N
MS35338-136 2 WASHER, LOCK SST, 0.141 ID X 0.250 OD (96906) (AP) 4 F,G,K,N
NAS620C6 2 WASHER, FLAT PSVT CRES, 0.143 ID X 0.267 OD (80205) (AP) 4 F,G,K,N
- 14 659-9070-001 2 CHASSIS A1 1 D,E,L
- 14 659-9070-002 2 CHASSIS A1 1 F,G,K,N

Change 5 6-9

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

HF Antenna Coupler HF-9040 (With Adapter), Parts Location Diagram

Figure 6-3.

6-10 Change 2

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

I UNITS USABLE
FIG- PART NO N DESCRIPTION PER ON
ITEM D ASSY CODE

6-3- 685-0365-001 1 COUPLER, HF ANTENNA, HF-9040 (WITH ADAPTER) 1

-1 622-8113-002 2 COUPLER, HF ANTENNA, HF-9040 (SEE FIG 6-1) 1
-2 752-5172-001 2 DECAL, EQUIPMENT 1
-3 685-0355-001 2 ADAPTER KIT 1
-4 659-9066-001 2 RING, RETAINER-DISC 1
(P/O CHASSIS A1, (CPN 659-9030-001))
-5 MS51957-30 2 SCREW (AP) 4
(P/O CHASSIS A1, (CPN 659-9030-001))

Change 2 6-11

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

HF Antenna Coupler HF-9041 (With Adapter), Parts Location Diagram

Figure 6-4.

6-12 Change 2

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

I UNITS USABLE
FIG- PART NO N DESCRIPTION PER ON
ITEM D ASSY CODE

6-4- 685-0350-001 1 COUPLER, HF ANTENNA, HF-9041 (WITH ADAPTER) 1 H

- 685-0350-002 1 COUPLER, HF ANTENNA, HF-9041 (WITH ADAPTER) 1 J
- 685-0350-020 1 COUPLER, HF ANTENNA, HF-9041 (WITH ADAPTER) 1 M
-1 622-8114-001 2 COUPLER, HF ANTENNA, HF-9041 (SEE FIG 6-2) 1 H
-1 622-8114-002 2 COUPLER, HF ANTENNA, HF-9041 (SEE FIG 6-2) 1 J
-1 622-8114-020 2 COUPLER, HF ANTENNA, HF-9041 (SEE FIG 6-2) 1 M
-2 685-0361-003 2 LABEL 1 H
-2 685-0361-004 2 LABEL 1 J
-2 685-0361-005 2 LABEL 1 M
-3 685-0361-002 2 LABEL 1
-4 659-9086-001 2 RING, CONTACT 1
-5 659-9038-001 2 RETAINER, DISC 4
(P/O CHASSIS A1, (CPN 659-9070-001/659-9070-002))
-6 MS51957-28 2 SCREW (AP) 4
(P/O CHASSIS A1, (CPN 659-9070-001/659-9070-002))
-7 MS35338-136 2 WASHER (AP) 4
(P/O CHASSIS A1, (CPN 659-9070-001/659-9070-002))

Change 2 6-13/6-14

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

6.3 NUMERICAL INDEX

PART NUMBER FIG- TTL PART NUMBER FIG- TTL

ITEM REQ ITEM REQ

CEC-16 6-2-4 1 206-0102-060 6-1-5

CEP-08 6-1-5 6-2-5
6-2-4 6-2-5 3
6-2-5 206-0102-120 6-2-4
6-2-5 4 6-2-4 2
CEP-16 6-1-4 206-0102-250 6-1-4
6-2-4 6-2-4
6-2-4 6-2-4
6-2-4 4 6-2-4 4
MS35338-134 6-1-2 280-1368-430 6-1-6A
6-2-2 4 6-2-6A
MS35338-136 6-1-7 6-2-6A
6-2-6 6-2-6A 4
6-2-8 300-0015-010 6-2-7 2
6-2-9 310-0095-000 6-1-8
6-2-11 6-1-9
6-2-13 6-2-9
6-4-7 77 6-2-10 18
MS35338-97 6-1-8 310-0098-000 6-1-8
6-1-9 6-2-9 2
6-2-9 310-0275-000 6-1-2
6-2-10 18 6-2-2 4
MS35338-99 6-1-8 310-0282-000 6-1-7
6-2-9 2 6-2-6
MS51957-15 6-1-9 6-2-8
6-2-10 16 6-2-9
MS51957-2B 6-1-2 6-2-11 69
6-2-2 4 310-0740-400 6-1-7
MS51957-26B 6-2-13 4 6-2-6
MS51957-27 6-1-7 6-2-8 54
6-1-8 342-0061-000 6-1-6 24
6-2-6 343-0135-000 6-1-9
6-2-8 6-2-10 16
6-2-9 343-0168-000 6-1-7
6-2-11 88 6-1-8
MS51957-28 6-2-6 6-2-6
6-2-8 6-2-8
6-2-8 6-2-9
6-2-9 6-2-9
6-2-9 6-2-11 103
6-2-11 343-0169-000 6-2-6
6-2-11 6-2-8
6-4-6 98 6-2-8
MS51957-29 6-2-6 6-2-9
6-2-6 6-2-11
6-2-6 96 6-2-11 79
MS51957-30 6-3-5 4 343-0285-000 6-1-8
MS51959-27 6-1-6 24 6-2-9 2
NAS620C6 6-1-7 343-0308-000 6-1-8
6-2-6 6-2-9 2
6-2-8 343-0669-000 6-1-2
6-2-13 58 6-2-2 4
NAS8101U7 6-2-6 622-8113-001 6-1- 1
6-2-6 64 622-8113-002 6-1-
NPBRS0.112-40X0.250IN 6-1-8 6-3-1 2
6-2-9 2 622-8113-003 6-1- 1

Change 2 6-15

The document reference is online, please check the correspondence between the online documentation and the printed version.
parts list

PART NUMBER FIG- TTL PART NUMBER FIG- TTL

ITEM REQ ITEM REQ

622-8114-001 6-2- 676-1087-000 6-1-3

6-4-1 2 6-2-3
622-8114-002 6-2- 6-2-3A 3
6-4-1 2 676-1217-000 6-2-1 1
622-8114-020 6-2- 685-0350-001 6-4- 1
6-4-1 2 685-0350-002 6-4- 1
622-9405-001 6-2- 1 685-0350-020 6-4- 1
622-9405-002 6-2- 1 685-0355-001 6-3-3 1
622-9405-003 6-2- 1 685-0361-002 6-4-3 1
642-0406-000 6-2-1 1 685-0361-003 6-4-3 1
642-0407-000 6-1-1 1 685-0361-004 6-4-2 1
659-9030-001 6-1-10 1 685-0361-005 6-4-2 1
659-9031-001 6-1-8 685-0363-001 6-1-2
6-2-9 2 6-2-2 2
659-9031-020 6-2-9 1 685-0365-001 6-3- 1
659-9038-001 6-4-5 1 687-5075-001 6-1-7
659-9043-001 6-1-9 6-2-8 2
6-2-10 2 687-5075-003 6-1-7
659-9047-001 6-1-6 2 6-2-8 2
659-9052-001 6-2-11 1 687-5075-004 6-2-8 1
659-9052-020 6-2-11 1 687-5075-005 6-1-7 1
659-9066-001 6-3-4 1 687-5075-006 6-2-8 1
659-9070-001 6-2-14 1 751-7068-001 6-2-9 1
659-9070-002 6-2-14 1 752-5172-001 6-3-2 1
659-9071-001 6-2-6 2 676-1217-000 6-2-1 1
659-9086-001 6-2-12
6-4-4 2

6-16 Change 2

The document reference is online, please check the correspondence between the online documentation and the printed version.
 parts list

6.4 REFERENCE DESIGNATION INDEX

REFERENCE FIG- REFERENCE FIG-

DESIGNATION ITEM PART NUMBER DESIGNATION ITEM PART NUMBER

A1 6-1-10 659-9030-001 A4 6-1-7 687-5075-001

A1 6-2-14 659-9070-001 A4 6-1-7 687-5075-003
A1 6-2-14 659-9070-002 A4 6-1-7 687-5075-005
A2 6-1-9 659-9043-001 A4 6-2-8 687-5075-001
A2 6-2-10 659-9043-001 A4 6-2-8 687-5075-003
A3 6-1-8 659-9031-001 A4 6-2-8 687-5075-004
A3 6-2-9 659-9031-001 A4 6-2-8 687-5075-006
A3 6-2-9 659-9031-020 A5 6-2-11 659-9052-001
A3 6-2-9 751-7068-001 A5 6-2-11 659-9052-020

Change 1 6-17/6-18

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 7
DIAGRAMS
7.1 GENERAL

The diagrams in this section help in the troubleshooting and maintenance of the equipment.

7.2 CONFIGURATION IDENTIFIERS

The parts list section gives the procedure for identification of changes to the equipment.

7.3 SCHEMATIC CHANGES

Identify electrical changes to the equipment on the applicable schematic diagrams. Revision level changes to
a schematic are identified to a schematic area. These schematic changes are recorded on a schematic
changes page that is shown before the schematic diagram.

7-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
diagrams

SCHEMATIC CHANGES

REVISION DESCRIPTION OF REVISION SERVICE EFFECTIVITY

IDENTIFICATION AND REASON FOR CHANGE BULLETIN

Antenna Couplers HF-9040/9041/9042, Chassis Interconnect Diagram

Figure 7-1 (Sheet 1 of 2)

7-2 Change 1

The document reference is online, please check the correspondence between the online documentation and the printed version.
 diagrams

Antenna Couplers HF-9040/9041/9042, Chassis Interconnect Diagram

Figure 7-1 (Sheet 2)

Change 1 7-3/7-4

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 SECTION 8

ANTENNA ADAPTER FL-9002 (822-0089-001)

8.1 DESCRIPTION

Antenna Adapter FL-9002, part number 822-0089-001, is a part of the hf antenna system which also
includes the antenna coupler and antenna structure. The FL-9002 is used as the RF feedline for HF Antenna
Coupler HF-9041 (dual).

8.2 INSTALLATION

Use the procedures that follow to assemble or disassemble the FL-9002. Refer to Figure 8-1 (in Diagrams
paragraph 8.4) to find part locations for the parts with item numbers in parentheses. When cleaning is
specified, use Toluene (CPN 005-2954-090 or equivalent substitute).

8.2.1. Assembly Procedure

a. Clean any excess material from the base mounting flange (item 2).

b. Install center conductor of electrical lead (item 17) into the semi-rigid RF shield (item 4) using two
slotted disk insulators (item 18, installed from opposite sides). Position these on the convolutions of the
corrugated center conductor of electrical lead (item 17) as shown in Figure 8-1 to hold the center
conductor in the center of the assembly.

c. Position and secure disk insulator (item 19) with two screws (item 20).

d. Liquid stake the threads of special nut (item 5) with thread sealant (005-2028-020).
NOTE
There must be no thread sealant (005-2028-020) or adhesive (005-3167-010) on the flats of
the mating surfaces of coupling nut (item 3) and semi-rigid RF shield (item 4).

e. Use special nut (item 5) to secure the disk insulator (item 7) and retaining ring (item 6) to the center
conductor of electrical lead (item 17).

f. Replace the coupling v-retainer (item 16).

g. Clean the antenna insulator (item 1) and base (item 2), then insert the antenna insulator into the base
using insulator retainer (item 8).

h. Use adhesive (005-3167-010) as liquid stake and sealant between the antenna insulator (item 1) and the
base (item 2). Fill the gap between the antenna insulator and base with the adhesive. Then smooth the
adhesive to create a fillet of .06 inch (1.524 mm) as shown in Figure 8-1. The insulator retainer (item 8)
must be tight enough to prevent rotation of the antenna insulator (item 1).

i. Apply a light coating of adhesive (005-3167-010) to the O-ring (item 9). Mount the O-ring to the antenna
insulator (item 1), then assemble the center conductor electrical lead (item 17) as shown in Figure 8-1.
NOTE
There must be no adhesive (005-3167-010) on the threads of center conductor electrical lead
(item 17).

Change 6 8-1

The document reference is online, please check the correspondence between the online documentation and the printed version.
options and accessories

j. Attach the coupling nut (item 3) to the base (item 2).

k. Install the O-ring (item 10) to the top of antenna insulator (item 1), then attach antenna-PRSD terminal
(item 11).

l. Position antenna-PRSD terminal (item 11) and base (item 2) as shown in View A-A of Figure 8-1. Then
tighten the coupling nut (item 3).

m. Replace the safety wire (item 15) to the coupling nut (item 3).
NOTE
There must be no thread sealant (005-2028-020) or adhesive (005-3167-010) on the flats of
the mating surfaces of coupling nut (item 3) and semi-rigid RF shield (item 4).

8.2.2 Disassembly Procedure

a. Remove antenna-PRSD terminal (item 11).

b. Remove O-ring (item 10).

c. Remove base (item 2).

d. Remove safety wire (item 15) and coupling nut (item 3).

e. Remove antenna insulator (item 1).

NOTE
It may be necessary to remove insulator retainer (item 8) before removing antenna insulator
(item 1).

f. Remove O-ring (item 9).

g. Remove coupling v-retainer (item 16).

h. Remove two screws (item 20).

i. Remove disk insulator (item 19).

j. Remove electrical lead (item 17).

k. Remove two disk insulators (item 18).

l. Remove special nut (item 5).

m. Remove the retaining ring (item 6), then remove disk insulator (item 7).

8.3 REPAIR

Use the procedure that follows to test the FL-9002. Refer to Figure 8-2 (in Diagrams paragraph 8.4) to locate
the test points given in the test procedure. The FL-9002 must pass the test procedure before it can be used.

8-2 Change 6

The document reference is online, please check the correspondence between the online documentation and the printed version.
 options and accessories

8.3.1 Test Procedure

a. Verify continuity of the shield between test point A and test point B (shown in Figure 8-2) is less than
3.0 milliohms.

b. Verify continuity of the center conductor between test point C and test point D (shown in Figure 8-2) is
less than 6.0 milliohms.

8.4 DIAGRAMS

Figure 8-1 shows part locations using item numbers from Installation paragraph 8.2 and Parts List
paragraph 8.5. Test points used in Repair paragraph 8.3 are shown in Figure 8-2. There are no schematic
diagrams for the FL-9002.

Change 6 8-3/8-4

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 options and accessories

FLAT OF ITEM 2
90° ± 5°
FLAT OF ITEM 11

13
14
15
VIEW A-A
A 2
3 12 7 6
8 19
20
10

1
.06 IN 20
11
[1.524 MM] FILLET 4 16
9 18 18

A 17 TPN1951_01

Antenna Adapter FL-9002 Part Locations

Figure 8-1

Change 6 8-5/8-6

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
 options and accessories

Test Points
Figure 8-2

Change 6 8-7

The document reference is online, please check the correspondence between the online documentation and the printed version.
options and accessories

8.5 PARTS LIST

The FL-9002 parts list is given in Table 8-1. For part locations, refer to the item numbers shown in Figure 8-1
(in Diagrams paragraph 8.4).

Table 8-1. Parts List

ITEM DESCRIPTION PART NUMBER QUANTITY
1 Antenna insulator 790-2731-001 1
2 Base 606-9562-001 1
3 Coupling nut 606-9571-001 1
4 RF semi-rigid shield 606-9569-007 1
5 Special nut 606-9568-001 1
6 Retaining ring 606-9570-001 1
7 Disk insulator 606-9567-001 1
8 Insulator retainer 606-9563-001 1
9 O-ring MS9021-016 1
10 O-ring MS28775-018 1
11 Antenna-PRSD terminal 606-9572-001 1
12 Identification plate 676-1247-000 1
13 Machine screw, .086-56 x .12 343-0297-000 1
14 Lug terminal 304-0014-000 1
15 Wire MS20995C32 0.6 ft (0.182 m)
16 Coupling v-retainer 139-0924-010 1
17 Electrical lead 635-4718-003 1
18 Disk insulator 635-4667-001 2
19 Disk insulator 751-2710-001 1
20 Machine screw, .112-40 x .31 343-0286-000 2

8-8 Change 6

The document reference is online, please check the correspondence between the online documentation and the printed version.
The document reference is online, please check the correspondence between the online documentation and the printed version.
523-0777201
 2013, Rockwell Collins,
All Rights Reserved, Printed in USA

The document reference is online, please check the correspondence between the online documentation and the printed version.