TB 11-5820-934-13 DIGITAL TROPOSCATTER TERMINAL ... TRC 170 TROPO/AN TRC...TB 11-5820-934-13 WARNING If a circuit breaker does not stay ON when closed, do not attempt to close it repeatedly

TB 11-5820-934-13

TECHNICAL BULLETIN

EXPANDED CLEANING PROCEDURESDIGITAL TROPOSCATTER

TERMINAL RADIOANITRC-170(V)2 & (V)3

Distribution authorized to US Government agencies and their contractors for official useor for administrative or operational purposes only. This determination was made on 1December 1993. Other requests for this document will be referred to Commander, USArmy Communications-Electrons Command and Fort Monmouth, ATTN.: AMSEL-LC-LM-LT, Fort Monmouth, New Jersey 07703-5007

DESTRUCTION NOTICE- Destroy by any method that will prevent disclosure of contentsor reconstruction of the document

HEADQUARTERS, DEPARTMENT OF THE ARMY

1 FEBRUARY 1996

TM 11-5820-934-13

A

GENERAL HANDLING PROCEDURES FOR ESD ITEMS

USE WRIST GROUND STRAPS OR PERIODICALLY-CHECK CONTINUI’ ANDMANUAL GROUNDING PROCEDURES. RESISTANCE OF GROUNDING SYSTEM.KEEP ESD ITEMS IN PROTECTIVE USE ONLY METALIZED SOLDER SUCKERS. -COVERING WHEN NOT IN USE. HANDLE ESD ITEMS ONLY IN PROTECTEDGROUND ALL ELECTRICAL TOOLS AREASAND TEST EQUIPMENT.

CAUTION

MANUAL GROUNDING PROCEDURE

MAKE CERTAIN EQUIPMENT IS POWERED TOUCH PACKAGE OF REPLACEMENT ESDSDOWN. ITEM TO GROUND BEFORE OPENING.TOUCH GROUND PRIOR TO REMOVING TOUCH GROUND PRIOR TO INSERTINGESD ITEMS. REPLACEMENT ESD ITEMS.

ESD PROTECTIVE PACKAGING AND LABELING

INTIMATE COVERING OF ANTISTATIC MATERIAL WITH AN OUTER WRAP OF EITHER TYPE 1 ALUMINIZEDMATERIAL OR CONDUCTIVE PLASTIC FILM OR HYBRID LAMINATED BAGS HAVING AN INTERIOR OF ANTISTATICMATERIAL WITH AN OUTER LAYER OF METALIZED MATERIAL. LABEL WITH SENSITIVE ELECTRONIC SYMBOLAND CAUTION NOTE, AS ABOVE.

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WARNINGHIGH VOLTAGE

High voltage is used in this equipment. Be careful when working near the interior of the equipment, or nearthe ac power distribution. Observe warning notes in this technical manual and warning decals onequipment. Death on contact can result if safety precautions are not observed.

WARNING

DANGEROUS VOLTAGEis used in the operation of this equipment.

WARNING

DEATH ON CONTACTmay result if personnel fail to observe safety precautions.

WARNING

Never work on electronic equipment unless there is another person nearby who is familiar with theoperation and hazards of the equipment and who is competent in administering first aid. When thetechnician is aided by operators, they must be warned about dangerous areas. Whenever possible, thepower supply to the equipment must be shut off before beginning work on the equipment. Take particularcare to ground every capacitor likely to hold a dangerous potential. When working inside the equipment,after the power has been turned off, always ground every part before touching it.

WARNING

Be careful not to contact high-voltage connections when installing or operating this equipment. Wheneverthe nature of the operation permits, keep one hand away from the equipment to reduce the hazard ofcurrent flowing through vital organs of the body. Do not be misled by the term "low voltage". Potentials aslow as 50 volts can cause death under adverse conditions.

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WARNING

If a circuit breaker does not stay ON when closed, do not attempt to close it repeatedly. That could createan overload situation hazardous to personnel and equipment. Instead, investigate cause of problem.Correct situation before attempting to close the breaker again.

WARNING

COMPRESSED AIRCompressed air shall not be used for cleaning purposes except where reduced to less than 29 pounds persquare inch (psi) and then only with effective chip guarding and personnel protective equipment.Compressed air is dangerous and can cause serious bodily harm if protective means or methods are notobserved to prevent chips or particles (of whatever size) from being blown into the eyes or unbroken skinof the operator or other personnel.

WARNING

Isopropyl Alcohol is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection arerequired. Avoid repeated and prolonged contact. Use only in well ventilated areas. Keep away from openflames or other sources of ignition.

WARNING

The 35-ft. ac power cable weights 35 pounds. It requires two person lift to prevent injury.

WARNING

To prevent possible shock, ground strap must be connected to earth ground before connecting groundstrap to shelters.

WARNING

Do not connect ac power cables until ensuring that all system elements have been properly grounded.Electrical defects in load lines or load equipment can cause death to personnel when contact is made withan ungrounded system.

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WARNING

Do not connect ac power cables until ensuring that commercial MASTER CIRCUIT BREAKER switch is inthe OFF position. Death to personnel can result from contact with load terminals when commercial poweris energized.

WARNING

To prevent injury to personnel when disconnecting ac power cable at the power entry panel, verifyINTERIOR MAIN circuit breakers on the POWER DISTRIBUTION panel remain. ON (up position).

WARNING

To prevent possible shock, ground straps must be disconnected from equipment before disconnectingground strap from earth ground.

WARNING

Do not permit personnel to remain inside shelter during transit. Serious injury can result.

WARNING

To prevent death or serious injury, shut off power at external power source when working in the powerbay. High voltage (120 Volts) is present on the panel and in the bay when external power is applied.

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WARNING

To prevent death or serious injury, do not service power entry panel for a minimum of 30 seconds afterinput power has been shut off.

WARNING

Electronic Surge Arrestor (ESA) contains radioactive material. Use extreme care not to break ESA whilehandling it. Consult qualified medical personnel if you are exposed to broken ESA. for first aid instructions,see TB 43-0116 and AR 755-15. Never place ESA in your pocket. Do not remove ESA from container untilready to use it. Refer to TB 43-0116 and AR 755-15 for instructions on handling, storage, and disposal ofradioactive material.

GENERAL SAFETY INFORMATION

For additional safety information, review TB 385-4 prior to conducting cleaning procedures on thisequipment.

F

TB 11-5820-934-13

Technical Bulletin HEADQUARTERSDEPARTMENT OF THE ARMY

No. 11-5820-934-13 Washington, DC, 1 February 1996

EXPANDED CLEANING PROCEDURESDIGITAL TROPOSCATTER

TERMINAL RADIOAN/TRC-170(V)2 & (V)3

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTSYou can help improve this manual. If you find any mistakes or if you know of a way to improve theprocedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publicationsand Blank Forms), or DA Form 2028-2 located in back of this manual direct to: Commander, US ArmyCommunications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-LM-LT, Fort Monmouth,New Jersey 07703-5007. A reply will be furnished direct to you.

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FOREWORD

The purpose of the Technical Bulletin is to establish standard procedures for the deep cleaning and servicing of theAN/TRC-170(V) Radio Terminal. This Technical Bulletin is for use by unit and direct support maintainers, in conjunctionwith applicable equipment Technical Manuals (TM’s)

The cleaning and service information contained in this Technical Bulletin is official authorization to perform theseprocedures at the applicable organizational and direct support maintenance levels.

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TABLE OF CONTENTS

PARAGRAPH TITLE PAGE

Safety Precautions ............................................................................................................................................. A-FForeword ............................................................................................................................................................ iiTable of Contents ............................................................................................................................................... iiiList of Tables ...................................................................................................................................................... ixList of Illustrations............................................................................................................................................... ix

CHAPTER 1 INTRODUCTION

1-1 Scope ................................................................................................................................................. 1-11-2 Shelter Model Designations ............................................................................................................... 1-11-3 Maintenance Forms, Records, and Report ........................................................................................ 1-21-3.1 Reports of Maintenance and Unsatisfactory Equipment.................................................................... 1-21-3.2 Reporting of Item and Packaging Discrepancies ............................................................................... 1-21-3.3 Transportation Discrepancy Report (TDR) (SF361) .......................................................................... 1-21-4 Consolidated Index of Army Publications........................................................................................... 1-21-5 Reporting Errors and Recommending Improvements ....................................................................... 1-2

CHAPTER 2 DESCRIPTION

Section I. SHELTER COOLING HEATING SYSTEMS .................................................................................... 2-1

Section II. SHELTER AIRFLOW FILTERING AND DISTRIBUTION SYSTEMS ............................................. 2-1

Section III. CONTAMINATED SHELTERS CLEANING ................................................................................... 2-2

2-1 General Information ........................................................................................................................... 2-22-2 Type A Contaminated Shelter ............................................................................................................ 2-22-3 Type B Contaminated Shelter ............................................................................................................ 2-22-4 Type C Contaminated Shelter............................................................................................................ 2-2

Section IV. SHELTER CLEANING AND SERVICE SEQUENCE..................................................................... 2-3

2-5 General information............................................................................................................................ 2-32-6 Pre-Cleaning Procedures................................................................................................................... 2-32-7 Shelter Cleaning and Service Procedures ......................................................................................... 2-42-8 Post-Cleaning Procedures ................................................................................................................. 2-5

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TABLE OF CONTENTS (CONTINUED)


CHAPTER 3 PRE-CLEANING PROCEDURES

Section I. INTRODUCTION ............................................................................................................................... 3-1

3-1 Site Selection ..................................................................................................................................... 3-13-2 Shelter Grounding Procedures........................................................................................................... 3-13-3 AC Commercial Power Connections.................................................................................................. 3-1

Section II. POWER UP PROCEDURES ........................................................................................................... 3-2

3-4 Shelter Component layout.................................................................................................................. 3-13-5 Preliminary Checks ............................................................................................................................ 3-43-6 AC Power Up Procedures .................................................................................................................. 3-43-6.1 Site Commercial AC Power-Up.......................................................................................................... 3-43-6.2 Shelter AC Power-Up......................................................................................................................... 3-4

Section III. LIGHTS AND INDICATORS CHECK ............................................................................................. 3-6

3-7 Component Lights and Indicators Checks ......................................................................................... 3-63-8 Lamp Tests ........................................................................................................................................ 3-6

Section IV. COMPONENT INITIALIZATION AND SELF TEST PROCEDURES ............................................. 3-7

3-9 General Information ........................................................................................................................... 3-73-10 LGM Initialization and Self Test ......................................................................................................... 3-73-11 GM Initialization and Self Test ........................................................................................................... 3-83-12 TGM Initialization Self Test ................................................................................................................ 3-83-13 LSCDM Initialization Self Test............................................................................................................ 3-8

Section V. COMMUNICATION SECURITY EQUIPMENT (COMSEC) AND TRUNKENCRYPTION DEVICE (TED) ....................................................................................................... 3-8

3-14 COMSEC/TED Devices ..................................................................................................................... 3-8

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Section VI. DIAGNOSTIC TESTS..................................................................................................................... 3-9

3-15 General Information ........................................................................................................................... 3-93-16 Loopback Tests.................................................................................................................................. 3-93-16.1 LGM and TGM Loopback Test........................................................................................................... 3-93-16.2 GM Loopback Test............................................................................................................................. 3-93-16.3 LGM Loop Modem Channel Test ....................................................................................................... 3-93-17 Data Orderwire Self-Test ................................................................................................................... 3-103-17.1 Radio Side Data Orderwire (DOW) Self-Test .................................................................................... 3-103-17.2 Cable Side DOW Self Test ................................................................................................................ 3-103-17.3 Receive Signal Level (RSL) Integration Self Test.............................................................................. 3-103-17.4 RF-Amplifier Transmit Subsystems Test ........................................................................................... 3-103-18 Voice Orderwire Control Unit (VOCU) Self Test ................................................................................ 3-11

Section VII. EQUIPMENT SHUTDOWN ........................................................................................................... 3-11

3-19 Shelter Power Shutdown.................................................................................................................... 3-11

Section VIII. PRE-CLEANING PROCEDURES CHECKLIST 3-12

CHAPTER 4 SHELTER CLEANING AND SERVICING

Section I. PERSONNEL REQUIREMENTS ...................................................................................................... 4-1

4-1 General Information ........................................................................................................................... 4-14-2 Team Leader Responsibilities............................................................................................................ 4-14-3 Unit Maintainer Responsibilities ......................................................................................................... 4-14-4 Direct Support Maintainer Responsibilities ........................................................................................ 4-24-5 Electronic Maintenance Shop (EMS) Facility responsibilities............................................................. 4-2

Section II. EQUIPMENT AND MATERIAL REQUIREMENTS.......................................................................... 4-3

4-6 Type A Contaminated Shelter ............................................................................................................ 4-34-7 Type B and C Contaminated Shelters................................................................................................ 4-4

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Section III. SAFETY REQUIREMENTS ............................................................................................................ 4-5

4-8 Noise, Dust, and Eye Protection ........................................................................................................ 4-54-9 Shelter Grounding .............................................................................................................................. 4-54-10 Equipment Lifting Restrictions............................................................................................................ 4-5

Section IV. COMPONENT HANDLING PROCEDURES, VACUUMING AND IONAIR GUN TECHNIQUES ................................................................................................................ 4-6

4-11 Circuit Card Assembly (CCA) Handling ............................................................................................. 4-64-12 Vacuuming Techniques ..................................................................................................................... 4-64-13 Ionizing Air Gun Techniques.............................................................................................................. 4-6

Section V. PRELIMINARY PROCEDURES

4-14 Shelter Components Removed by Unit Maintainer Team..................................................... 4-7

Section VI. PRELIMINARY PROCEDURES CHECKLIST ............................................................................... 4-8

Section VII. TYPE A CONTAMINATED SHELTER CLEANING AND SERVICEPROCEDURES ............................................................................................................................. 4-10

4-15 General Information ........................................................................................................................... 4-104-15.1 In Place Component Cleaning ........................................................................................................... 4-104-15.2 Removed Component Cleaning......................................................................................................... 4-104-15.3 Corrosion Check ................................................................................................................................ 4-114-16 Shelter Component Cleaning............................................................................................................. 4-114-17 Shelter Interior Vacuuming................................................................................................................. 4-124-18 Power Distribution Unit Cleaning........................................................................................................ 4-124-19 Filter Assembly Cleaning and Servicing............................................................................................. 4-134-20 RF Amplifier Cleaning ........................................................................................................................ 4-134-21 Shelter Cooling Fan Cleaning ............................................................................................................ 4-154-22 Miscellaneous Component Cleaning.................................................................................................. 4-164-23 Shelter Final Cleaning........................................................................................................................ 4-164-24 Shelter Components Replacement .................................................................................................... 4-16

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Section VIII. TYPE B AND C CONTAMINATED SHELTER CLEANING ANDSERVICE PROCEDURES........................................................................................................... 4-16

4-25 General Information ........................................................................................................................... 4-164-25.1 CCA Cleaning .................................................................................................................................... 4-164-25.2 In-Place Component Cleaning ........................................................................................................... 4-174-25.3 Removed Component Cleaning......................................................................................................... 4-174-25.4 Component Corrosion Check............................................................................................................. 4-174-26 Surface Cleaning Instructions ............................................................................................................ 4-184-27 CCA Cleaning Instructions ................................................................................................................. 4-184-27.1 Set Up ................................................................................................................................................ 4-184-27.2 Cleaning CCA’s.................................................................................................................................. 4-194-28 Shelter Interior Vacuuming................................................................................................................. 4-194-29 Power Distribution Unit Cleaning........................................................................................................ 4-194-30 Shelter Filter Cleaning and Servicing................................................................................................. 4-194-31 RF Amplifier Cleaning ........................................................................................................................ 4-204-32 Shelter Cooling Fan Cleaning ............................................................................................................ 4-204-33 Miscellaneous Component Cleaning.................................................................................................. 4-204-34 Shelter Final Cleaning........................................................................................................................ 4-204-35 Shelter Components Replacement .................................................................................................... 4-204-36 Shelter Corrosion Check .................................................................................................................... 4-20

CHAPTER 5 POST-CLEANING PROCEDURES

Section I. SET-UP PROCEDURES................................................................................................................... 5-1

5-1 General Information ........................................................................................................................... 5-15-2 Power Cable Connection ................................................................................................................... 5-15-3 Power Up Procedures ........................................................................................................................ 5-15-3.1 General Information ........................................................................................................................... 5-15-3.2 Site Commercial AC Power Up.......................................................................................................... 5-15-3.3 Shelter AC Power Up......................................................................................................................... 5-1

Section II. OPERATIONAL SET-UP ................................................................................................................. 5-2

5-4 General Information ........................................................................................................................... 5-25-5 Component Lights and Indicators Check ........................................................................................... 5-25-5.1 Lights and Indicator Checks............................................................................................................... 5-25-5.2 Lamp Tests ........................................................................................................................................ 5-2

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Section III. INITIALIZATION AND SELF TEST PROCEDURES...................................................................... 5-2

5-6 Component Initialization and Self-Test Procedures........................................................................... 5-25-6.1 LGM Initialization and Self Test ......................................................................................................... 5-25-6.2 GM Initialization and Self Test ........................................................................................................... 5-25-6.3 TGM Initialization Self Test ................................................................................................................ 5-25-6.4 LSCDM Initialization and Self Test..................................................................................................... 5-3

Section IV. COMMUNICATION AND SECURITY EQUIPMENT ...................................................................... 5-3

5-7 Communication Security Equipment (COMSEC) and Trunk EncryptionDevice (TED) Cleaning and Servicing................................................................................................ 5-3

Section V DIAGNOSTIC TESTING................................................................................................................... 5-3

5-8 Diagnostic Tests................................................................................................................................. 5-35-8.1 General Information ........................................................................................................................... 5-35-8.2 LGM and TGM Loopback Test........................................................................................................... 5-35-8.3 GM Loopback Test............................................................................................................................. 5-35-8.4 LGM Loop Modem Channel Test ....................................................................................................... 5-35-9 Data Orderwire Self-Test ................................................................................................................... 5-45-9.1 Radio Side Data Orderwire (DOW) Self-Test .................................................................................... 5-45-9.2 Cable Side DOW Self-Test ................................................................................................................ 5-45-9.3 Received Signal Level (RSL) Integration Self-Test............................................................................ 5-45-9.4 RF-Amplifier Transmit Subsystems Test ........................................................................................... 5-45-10 Voice Orderwire Control Unit (VOCU) Self-Test ................................................................................ 5-4

Section VI. EQUIPMENT SHUTDOWN ............................................................................................................ 5-4

Section VII. POST-CLEANING PROCEDURES CHECKLIST ......................................................................... 5-5

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APPENDIX A SHELTER CLEANING PROCEDURES CHECKLISTS.

A-1 Pre-Cleaning Procedures Checklist ................................................................................................... A-1A-2 Preliminary Procedures Checklist ...................................................................................................... A-1A-3 Post-Cleaning Procedures Checklist ................................................................................................. A-1

LIST OF TABLES

Number Title Page

1-1 Shelter Models Common Names ....................................................................................................... 1-23-1 Shelter Power-Up Procedures ........................................................................................................... 3-53-2 Shelter Components Lights and Indicators Check............................................................................. 3-63-3 Shelter Components Lamp Tests ...................................................................................................... 3-74-1 Equipment and Material Requirements For Type A Contaminated

Shelter Cleaning................................................................................................................................. 4-34-2 Equipment and Material Requirements For Type B and C

Contaminated Shelter Cleaning ......................................................................................................... 4-44-3 Shelter Components Removed By Shelter Team .............................................................................. 4-7

LIST OF ILLUSTRATIONS

FIGURE TITLE PAGE

3-1 AN/TRC-170(V) 2 Shelter Component Layout................................................................................... 3-13-2 AN/TRC-170(V) 3 Shelter Component Layout................................................................................... 3-34-1 AN/TRC-170(V) 2 Shelter Filter Locations......................................................................................... 4-144-2 AN/TRC-170(V) 2 Shelter Filter Locations......................................................................................... 4-14

ix / x (blank)

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CHAPTER 1INTRODUCTION

1-1 SCOPE.

This technical bulletin provides the approved expanded maintenance service and cleaning procedures for all models of theRadio Terminal AN/TRC-170(V) shelters. The cleaning procedures cover both a sand and dirt contaminated, and a sand,dirt, and oil contaminated shelter.

The interval (monthly, bi-monthly, quarterly, semi-annual) between cleaning is based on the degree of sheltercontamination. The expanded maintenance service on specific shelter components is performed at the same time as theshelter is cleaned.

The cleaning and service information contained in this technical bulletin is the official authorization to perform theprocedure at the unit and direct support maintenance levels of maintenance. Before starting the cleaning procedures,personnel should become familiar with the requirements of TB 385-4 "Safety Requirements for Maintenance of Electricaland Electronic Equipment".

NOTE

This technical bulletin IS NOT an authorizationfor requisition or turn-in of shelters.

This technical bulletin DOES NOT establish quantityor types of shelters assigned to units.

This technical bulletin IS NOT an authorizationfor requisition or turn-in of equipment’s.

1-2 SHELTER MODEL DESIGNATIONS.

There are two (2) different models of the AN/TRC-170. The specific models and their assigned common names usedthroughout this technical bulletin are given in Table 1-1. When the information given applies to all models, the commonname is used.

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Table 1-1. Shelter Models Common Names

MODEL COMMON NAMEAN/TRC-170(V)2 RADIO TERMINAL SET (V)2AN/TRC-170A(V)3 RADIO TERMINAL SET (V)3

1-3 MAINTENANCE FORMS, RECORDS, AND REPORTS.

1-3.1 Reports of Maintenance and Unsatisfactory Equipment. Department of the Army forms and procedures used forequipment maintenance will be those prescribed by DA Pam 738-750, as contained in Maintenance Management Update.

1-3.2 Reporting of Item and Packaging Discrepancies. Fill out and forward SF346 (Report of Discrepancy (ROD) asprescribed in AR 735-11-2/DLAR 4140.55/SECNAVINST 4355.18/AFR 400-54/MCO 4430.3J).

1-3.3 Transportation Discrepancy Report (TDR) (SF361). Fill out and forward Transportation Discrepancy Report (TDR)(SF361) as prescribed in AR 55-38/NAVSUPINST 4610.33C/AFR 75-18/MCO P4610.19D/DLAR 4500.15.

1-4 CONSOLIDATED INDEX OF ARMY PUBLICATIONS.

Refer to the latest issue of DA Pam 25-30 to determine whether there are new editions, changes, or additional publicationspertaining to the new equipment.

1-5 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS.

You can help improve this technical bulletin. If you find any mistakes or if you know of a way to improve the procedures,please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DAForm 2028-2 located in back of this manual direct to: Commander, US Army Communications-Electronics Command andFort Monmouth, ATTN: AMSEL-LC-LM-LT, Fort Monmouth, New Jersey 07703-5007. A reply will be furnished direct toyou.

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CHAPTER 2DESCRIPTION

SECTION I. SHELTER COOLING/HEATING SYSTEMS

The AN/TRC-170 shelters are designed to operate in the temperature range from -51 degrees F to 126 degrees F (-46degrees C to +52 degrees C) and in a relative humidity range of 5% to 95%.

The shelter electronic equipment cooling/heating is accomplished by air movement provided by two high speed fanslocated inside the shelter equipment bay. The heater unit provides equipment heating used for start-up under extreme coldweather conditions. The (V)2 exterior roadside contains three (3) each, equipment intake and exhaust filters and one (1)rear door filter. The (V)3 exterior contains two(2) each equipment intake and exhaust filters roadside and one (1) eachequipment intake and exhaust filters curbside and one (1) rear door filter. The front of the shelter contains one (1) eachintake and exhaust filters where an optional Environmental Control Unit (ECU) (air conditioner) can be connected.

SECTION II. SHELTER AIRFLOW FILTERING AND DISTRIBUTION SYSTEMS

The shelter air inlets filter the ambient outside air before it enters the shelter. The filtered air is drawn into the individualcomponents by blowers where it is blown over the components to cool them. The heated air leaves the component throughopenings in the component case. The components that do not have blowers are cooled by the movement of the filteredambient air through the shelter. The heated air is removed from the shelter by the two high speed fans located inside theshelter equipment bay(s).

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SECTION III. CONTAMINATED SHELTERS CLEANING

2-1 GENERAL INFORMATION.

The airflow filtering and distribution system used to cool the shelters, results in dirt and dust accumulation on the shelterinterior, components surfaces, and component circuit card assemblies (CCA’s). This accumulation causes restricted airflow over components and CCA’s resulting in reduced heat dissipation. Vibration of CCA’s during shelter movement canresult in intermittent problems due to dirty card contacts.

The shelter contamination type (A, B, or C) is based upon the environmental conditions at the shelter location. Thedefinition and the method used to clean up the contaminated shelter is given in paragraphs 2-2, 2-3, and 2-4, respectively.

2-2 TYPE A CONTAMINATED SHELTER.

Type A shelter contamination occurs when a shelter is operated in a low humidity dust and dirt environment. A Type Acontaminated shelter is cleaned using vacuum blower and vacuum suction techniques. The shelter interior and componentrack surfaces are suction vacuumed to remove built-up dirt and dust, and is followed by a wipe down using a waterdampened cloth. The component circuit card assemblies (CCA’s) are suction vacuumed to remove dust and dirtaccumulations. Any dust and dirt not removed from a CCA is removed using the three tray bath method used in a Type Bor C CCA cleaning (see paragraph 2-4).

2-3 TYPE B CONTAMINATED SHELTER.

Type B shelter contamination occurs when a shelter is operated in a high humidity dust and dirt environment. A Type Bcontaminated shelter is first vacuumed as described in paragraph 2-2 for a Type A contaminated shelter. Then the sheltersurfaces and component rack surfaces are wiped down with a mild detergent and water solution dampened cloth. TheCCA’s are cleaned by the three tray bath method used in a Type C CCA cleaning (see paragraph 2-4).

2-4 TYPE C CONTAMINATED SHELTER.

Type C shelter contamination occurs when a shelter is operated in an environment heavily laden with residue from burningfuel. Dust and dirt in combination with the burning fuel residue results in a film of fuel residue, dust, and dirt beingdeposited on shelter interior surfaces, air filters, CCA’s, etc. A Type C contaminated shelter cleaning operation uses adetergent solution bath to remove the fuel residue, dust, and dirt from CCA’s and air filters. This solution is also used towash down the components and interior shelter surfaces. The CCA’s and air filters are vacuum blow dried after cleaning inthe detergent solution bath.

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After a CCA is removed from the detergent solution bath, it is placed in a clear water wash to remove the detergentsolution. Finally, it is placed in an alcohol and water solution and then removed to be dried using an ion air gun.

SECTION IV. SHELTER CLEANING AND SERVICE SEQUENCE


The cleaning and servicing of a Type A, B, or C contaminated shelter consists of the following operations, presented in theorder performed:

a. Pre-cleaning procedures (see paragraph 2-6)b. Shelter cleaning and service procedure (see paragraph 2-7)c. Post-cleaning procedure (see paragraph 2-8).

The cleaning and servicing operations are performed by a two (2) person team under supervision of a team leader and aDirect Support (DS) maintainer. The two person cleaning team is responsible for the cleaning of the shelter interior anddesignated shelter components. The DS maintainer is responsible for the cleaning of the Power Distribution Unit 1A1 andthe RF Amplifier components. The team leader is responsible for coordinating the DS maintainer and the team cleaningoperations.

2-6 PRE-CLEANING PROCEDURES.

The pre-cleaning procedures, presented in the order performed is as follows:

a. The shelter is moved to the designated maintenance shop at the direct support facility.

b. The shelter AC power cable is connected between the shelter power entry panel and the outside AC power sourcecommercial power.c. The shelter is powered up and the following operational checks and tests are performed inthe order presented.

1. Components lights and indicators check.2. Shelter components lamp test.3. Initialization and self test.4. Diagnostic tests.

d. The shelter is powered down.e. The shelter AC power cable is disconnected at the power entry panel.f. Compressed air line (no more than 29 psi) is supplied to the shelter area location.

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2-7 PRELIMINARY CLEANING PROCEDURES.

Refer to Section III for the method used to clean a Type A, B, and C contaminated shelter. A typical Type A, B, and Ccontaminated shelter cleaning and service procedure, presented in the order performed by the cleaning team and the DSmaintainer personnel, is as follows:

a. The cleaning team is responsible for removal of designated shelter components and sending them to thedesignated site shop for cleaning and servicing.

b. The cleaning team removes designated shelter components to be cleaned by the team. Also, all miscellaneousitems in the shelter and items in storage cabinets are removed.

c. COMSEC group is notified to remove, clean and service COMSEC/TED equipment.d. The DS maintainer is responsible for removal, cleaning and replacement of designated shelter components and

assists the cleaning team in performing their tasks.e. The cleaning team cleans and services components not removed from the shelter.f. After the final shelter interior wipe down is completed, the cleaned components are reinstalled in the shelter by the

cleaning team.g. COMSEC/TED equipment will be reinstalled by COMSEC group personnel.h. A shelter connector corrosion check is performed.

2-8 POST-CLEANING PROCEDURES.

The post-cleaning procedure, presented in the order performed by the cleaning team is as follows:

a. The site compressed air line is removed from the shelter.b. The shelter AC power cable is connected between the shelter power entry panel and the site AC power source.c. The shelter is powered up and the following operational checks and tests are performed in the order presented:

1. Components lights and Indicators check.2. Shelter components lamp test.3. Initialization and self test.4. Diagnostic tests.

d. The shelter is powered down.e. The shelter AC power cables are disconnected at the power entry panel.

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CHAPTER 3PRE-CLEANING PROCEDURES

SECTION I. INTRODUCTION

3-1 SITE SELECTION.

The shelter must be placed in or adjacent to a Direct Support (DS) facility. This is necessary to have access to the DSfacility air compressor line and the 115V, 1 phase AC power to operate vacuums and trouble lights during shelter cleaning.Shelter components are removed and sent to the DS shop where they are disassembled, cleaned, serviced, andreassembled by DS maintainer personnel.

NOTE

The cleaned shelter components will not be returned to the shelter until after the shelter components notremoved are cleaned and serviced and the shelter interior has been thoroughly cleaned.

3-2 SHELTER GROUND PROCEDURES.

There are three (3) ground rods used with all models. One is used with the power generator unit and two with the shelter.The power entry and signal entry panels must be grounded before connecting power or signal cables. Use earth groundprovided at DS shop to ground shelter and equipment.

3-3 AC POWER CONNECTIONS.

If the shelter is to be operated from the site AC commercial power source, arrange with the direct support facility for powercable and service connections switch. After the AC power connection is completed, indicate on the PRE-CLEANINGPROCEDURES CHECKLIST (refer to Section VIII).

3-4 SHELTER COMPONENT LAYOUT.

Shelter component layout for the AN/TRC-170(V) 2 and AN/TRC-170(V) 3 are detailed in figures 3-1 and 3-2, respectively.

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TB 11-5820-934-13

TRUNK BASEBAND DLED PATCHENCRYPTION PATCH PANEL PANEL

DEVICES

ALARMPOWER DLED MONITOR

DIST VOICEUNIT TRANSMITTER RECEIVER TROPO MODEM ORDERWIRE

AMPLIFIER AMPLIFIER MODULATOR CONTROLCONVERTER CONVERTER UNIT

RF RF AMPLIFIER TRANSMITTERAMPLIFIER AMPLIFIER FREQUENCY

CONVERTER SYNTHESIZER

SURGE RECEIVER TROPO MODEM IF TESTPROTECT AMPLIFIER DEMODULATOR PANEL

FAULT CONVERTERASSY

NOISE HEATERSOURCE ASSY

LOW VOLTAGE LOW VOLTAGE AC TO DCPOWER POWER CONVERTERSUPPLY SUPPLY

ROADSIDE

Figure 3-1. AN/TRC-170(V)2 Shelter Component Layout.

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TB 11-5820-934-13

1 2 3 4

NOISE SOURCEPOWER TROPO MODEM

DISTRIBUTION RF-AMPLIFIER MODULATORUNIT TRANSMIT

AMPLIFIER-CONVERTER

SURGEPROTECTIONFAULT ASSY FREQUENCY

SYNTHESIZER

RECEIVERAMPLIFIER TROPO MODEM

CONVERTERS DEMODULATORI I

I I LOW VOLTAGEI I POWER SUPPLY

ROADSIDE

5 6 7 8

TRUNK BASEBANDENCRYPTION PATCH PANEL

DEVICE DLED PATCHPANEL

DEDICATED LOOPENCRYPTION LOOP GROUP

DEVICES MULTIPLEXER ALARM MONITOR

VOICE ANALOG VOICEGROUP MODEM ORDERWIRE ORDERWIRE UNIT

TRUNK GROUP CONTROL UNITIF TEST PANEL MULTIPLEXER

HEATER ASSY

LOW VOLTAGE LOW-SPEEDPOWER SUPPLY CABLE DRIVER

MODEM

CURBSIDE

Figure 3-2. AN/TRC-170(V)3 Shelter component Layout.

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SECTION II. POWER UP PROCEDURES

3-5 PRELIMINARY CHECKS.

Perform the" following checks prior to applying power to the shelter. After the checks are completed, indicate on PRE-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

a. Check that ground strap is secured to ground stud on power entry panel and tightly connected to earth ground.

b. Check that ground strap(s) are secured to ground stud (s) on signal entry panel(s) and tightly connected to earthground.

c. Check that blower vent covers are open.

d. Set circuit breaker ECU PWR on power entry panel to OFF.

e. Set circuit breaker EXTERIOR MAIN on power entry panel to OFF.

f. Verify that a prime power source has been connected to the PRIME AC POWER connector J1 located on thepower entry panel outside the shelter.

g. Ensure that all circuit breakers on Power Distribution Unit 1A1 are in the OFF position.

3-6 AC POWER UP PROCEDURES.

3-6.1. Site Commercial AC Power-Up. Contact the direct support facility office to arrange for AC power and for cabling toconnect AC power to the shelter.

3-6.2. Shelter AC Power-Up. Perform the shelter AC power-up procedure given in Table 3-1.

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Table 3-1. Shelter Power-Up Procedure

STEP OPERATOR ACTION OBSERVABLE CONDITION1. Verify that a prime power source has been connected to the Prime power and ground are

PRIME AC POWER connector J1 located on the power entry connected.panel outside the shelter.

2. Ensure that all circuit breakers are in the OFF position. Primary circuit breakers are in OFFposition

3. Ensure that all circuit breakers on power distribution unit 1A1 are All circuit breakers on powerin the OFF position. distribution unit are in the OFF position.

4. Turn on prime power at source. Note the frequency (50, 60 or Prime power is on.400 Hz) of prime power.

5. Set the INTERIOR MAIN circuit breaker to the ON position INTERIOR MAIN circuit breaker isin the ON position.

6. Set the LIGHTS circuit breaker to the ON position LIGHTS circuit breaker is in theON position. The shelter lights go on.

NOTE The white shelter lights will turn offIf blackout conditions exist, set LIGHT INTLK OVERRIDE switch when the shelter door is opened.to the NORMAL, position.

7 Set the LIGHT INTLK OVERRIDE switch to the OVERRIDE The shelter lights remain on when theposition shelter door is opened.

CAUTIONVoltage of each phase must agree within ±5 Vac. Do notcontinue if the voltages or frequency are out of tolerance.

8 Set the PHASE SELECT switch to phase A The VOLTMETER indicates 120 ±12Vac. The frequency meters indicates55 + 7 or 400 + 20 Hz.

9. Set the PHASE SELECT switch to phase B. Same as for phase A.10. Set the PHASE SELECT switch to phase C Same as for phase A.11. At locations 6A2 through 6A5, set the POWER-ON/OFF switch to

the ON position.12. On power distribution unit, set DGM GROUP circuit breaker to DGM group POWER indicators are on.

. ON.13. Set LVPS 1/2 circuit breaker (LVPS POWER)to the ON position. LVPS POWER indicator is on.

14. Set FAN PWR CONV 1 and 2 to the ON position. AC to AC, converter INPUT POWERindicator is on.

15. Make sure all exterior air inlets/outlets are open and normalairflow is present at all outlets.

16. If voice orderwire control unit alarm sounds, depress theSUPPI/TEST pushbutton.

17. If FAULT-SUMMARY indicator is on. press FAULT-RESET FAULT SUMMARY Indicator goes off. Switch.

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SECTION III. LIGHTS AND INDICATORS CHECK

3-7 COMPONENT LIGHTS AND INDICATORS CHECKS

After the shelter is powered-up, refer to Table 3-2 and verify that the lights and indicators on the specific component (asapplicable) are functional. If the components light or indicator specified is functional, indicate on PRE-CLEANINGPROCEDURES CHECKLIST (refer to Section VIII). If the components light or indicator specified is not functional, informDS shop when component is delivered for cleaning and servicing.

Table 3-2. Shelter Components Lights and Indicators Check

COMPONENT LIGHT INDICATORPower Distribution Unit 1A1 AC indication

¨ Current meter¨ Frequency meter¨ Voltage meter

Loop Group Multiplexer TD-1235 Power ON lampDigital Data Modem MD-1026 Power ON lampTrunk Group Multiplexer TD-1236 Power ON lampLow Speed Cable Driver Modem MD-1023 Power ON lampLow Voltage Power Supply PP-7904/PP-7905 Power ON lamp

3-8 LAMP TESTS.

The components lamp tests are given in Table 3-3. If the component indicator or lamp is functional, indicate on PRE-CLEANING PROCEDURES CHECKLIST (refer to Section VIIl). If the component indicator or lamp specified is notfunctional, inform DS shop when component is delivered for cleaning and service.

Table 3-3. Shelter Components Lamp Tests

COMPONENT OPERATOR ACTION OBSERVABLE CONDITIONRF Amplifier Depress LAMP TEST toggle switch When Depressed, ALL FAULT LAMPS(AM-7221) located in the BITE Panel. come ON.Loop Group Multiplexer Press ALARM-TEST pushbutton Energizes BITE circuits in a test mode,(TD-1235) All FAULT LAMPS come ON.Digital Data Modem Press ALARM-TEST pushbutton Energizes BITE circuits in a test mode,(MD-1026) All FAULT LAMPS come ON.Trunk Group Multiplexer Press ALARM-TEST pushbutton Energizes BITE circuits in a test mode,(TD-1236) All FAULT LAMPS come ON.Low Speed Cable Driver Press ALARM-TEST pushbutton Energizes BITE circuits in a test mode,Modem (MD-1023) All FAULT LAMPS come ON.

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SECTION IV. COMPONENT INITIALIZATION AND SELF TEST PROCEDURES


The AN/TRC-170 shelter components initialization and self test procedures are as follows:

a. Loop Group Multiplexer (LGM) TD-1235(P)/TTC (see paragraph 3-10).b. Group Modem (GM) MD-1026(V)(P)/G (see paragraph 3-11).c. Trunk Group Multiplexer (TGM) TD-1236/G (see paragraph 3-12).d. Low Speed Cable Driver Modem (LSCDM) MD-1023(V)/G (see paragraph 3-13)

If the result specified in the last step in a procedure does not occur, inform DS shop when component is delivered forcleaning and service. After each procedure has been completed, indicate on PRE-CLEANING PROCEDURESCHECKLIST (refer to Section VIII).

3-10 LGM INITIALIZATION AND SELF TEST.

The LGM initialization and self test is automatically performed each time the LGM is turned on. Proceed as follows:

a. Set POWER ON/OFF switch to OFF.b. Set POWER ON/OFF switch to ON.c. Check that POWER and ALARM - SUMMARY, PWR SPLY, and LOSS OF INPUT lamps come on.d. After 2 seconds, check that ALARM - SUMMARY, PWR SPLY, and LOSS OF INPUT lamps are not lit.

3-11 GM INITIALIZATION AND SELF TEST.

The GM initialization and self test is automatically performed each time the GM is turned on. Proceed as follows:

a. Set POWER ON/OFF switch to OFF.b. Set POWER ON/OFF switch to ON.c. Check that POWER and ALARM - SUMMARY, PWR SPLY, and LOSS OF INPUT lamps come on.d. After 5 seconds, check that ALARM - SUMMARY, PWR SPLY and LOSS OF INPUT lamps are not lit.

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3-12 TGM INITIALIZATION AND SELF TEST.

The TGM initialization and self test is automatically performed each time the TGM is turned on. Proceed as follows:

a. Set POWER ON/OFF switch to OFF.b. Set POWER ON/OFF switch to ON.c. Check that POWER and Alarm Summary, PWR SPLY, and LOSS OF INPUT lamps come ON.d. After 5 seconds, check that ALARM SUMMARY, PWR SLPY and LOSS OF INPUT lamps are NOT lit.

3-13 LSCDM INITIALIZATION AND SELF TEST.

The LSCDM initialization and self test is automatically performed each time the LSCDM is turned on. Proceed as follows:

a. Set POWER ON/OFF switch to OFF.b. Set POWER ON/OFF switch to ONc. Check the POWER and ALARM-SUMMARY, PWR SPLY, and LOSS OFF INPUT lamps come ON.d. After 2 seconds, check that ALARM-SUMMARY, PWR SPLY and LOSS OF INPUT amps are not lit.

SECTION V. COMMUNICATION SECURITY EQUIPMENT (COMSEC) AND TRUNK ENCRYPTION DEVICE (TED)

3-14 COMSEC/TED DEVICES.

Trunk Encryption Devices (TED) and Communication Security Equipment (COMSEC) are to be removed, cleaned,serviced and reinstalled by the COMSEC/TED group personnel. These devices are not part of these cleaning procedures.

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SECTION VI. DIAGNOSTIC TESTS

3-15 GENERAL INFORMATION

The purpose of the pre-cleaning procedure diagnostic tests is to record that there were no existing problems prior to thestart of the deep cleaning operation. The diagnostic tests are as follows:

a. LGM and TGM Loopback Testb. GM Loopback Testc. LGM Loop Modem Channel Testd. Radio Side Data Orderwire (DOW) Self-Teste. Cable DOW Self-Testf. Received Signal Level (RSL) Integration Self-Testg. Voice Orderwire Control Unit (VOCU) Self-Test

3-16 LOOPBACK TESTS.

Confidence testing of CHANNEL TRAFFIC can be performed through simple baseband patching or with the LGM loop testset.

3-16.1 LGM and TGM Loopback Test. This test provides LGM and TGM Loopback Testing through simple basebandpatching. Refer to TM-11-5820-934-13-1-1 (V2), and TM-11-5820-934-13-2-1 (V)3, Chapter 4, Table 4-8 for detailedinstructions. After this test is performed, indicate on the PRE-CLEANING PROCEDURES CHECKLIST (refer to SectionVIII).

3-16-2 GM Loopback Test. This test provides GM Loopback Testing through simple baseband patching Refer to TM-11-5820-934-13-1 -1 (V)2 and TM-11-5820-934-13-2-1 (V)3, Chapter 4, Table 4-41 for detailed instructions. After this test isperformed, indicate on the PRE-CLEANING PROCEDURES CHECKLIST (refer to Section VIII).

3-16.3 LGM Loop Modem Channel Test. This test provides for LGM Loop Modem Channel Testing using the LGM LoopTest Set. Refer to TM-11-5820-934-13-1-1 (V)2 and TM-1 1-5820-934-13-2-1 (V)3, Chapter 4, Table 4-42 for detailedinstructions. After this test is performed, indicate on the PRE-CLEANING PROCEDURES CHECKLIST (refer to SectionVIII).

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3-17 DATA ORDERWIRE SELF TEST.

NOTE

Data orderwire must be patched before performing the following tests. Refer to TM-11-5820-934-13-1-1(V)2 and TM-11-5820-934-13-2-1 (V)3 paragraph 6-10.8 for details. After this test is performed, indicateon the PRE-CLEANING PROCEDURES CHECKLIST (refer to Section VIII)

3-17.1 Radio Side Data Orderwire (DOW) Self-Test. This test provides Radio Side DOW Testing using(IF) LoopbackFunctions and simple baseband patching. Refer to paragraph 6-10.9 for details. After this test is performed, indicate onthe PRE-CLEANING PROCEDURES CHECKLIST (refer to Section VIII)

3-17.2 Cable Side DOW Self-Test. This test provides cable side testing using looping plug and simple basebandpatching. Refer to paragraph 6-10.10 for details. After this test is performed, indicate on the PRE-CLEANINGPROCEDURES CHECKLIST (refer to Section VIII)

3-17.3 Received Signal Level (RSI ) Integration Self-Test. This test indicates a Receiver Signal Level using variablelength antennas for short and long time constant measurements through Receiver Amplifiers 1 and 3. Refer to paragraph6-10.11 for details. After this test is performed, indicate on the PRE-CLEANING PROCEDURES CHECKLIST (refer toSection VIII)

3-17.4 RF Amplifier Transmit Subsystems Test. This test provides for low power transmission into the RF amplifiersdummy load to measure amplifier power and Voltage Standing Wave Ratios (VSWR) levels. Refer to paragraph 6-10.7step (f.) and paragraph 6-10.7 for details. After this test is performed, indicate on the PRE-CLEANING PROCEDURESCHECKLIST (refer to Section VIII)

WARNING

Transmit into DUMMY LOAD ONLY. Klystron operation is not to exceed 10 minutes transmit time intoDUMMY LOAD.

WARNING

To avoid Klystron damage, turn off beam power and allow Klystron to cool for five (5) minutes beforeturning off main circuit breakers

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3-18 VOICE ORDERWIRE CONTROL UNIT (VOCU) SELF TEST

This test sets the Loopback signal through receiver amplifiers 1 through 4 as indicated on the IF test panel. Refer toparagraph 6-10.12 for details. After this test is performed, indicate on the PRE-CLEANING PROCEDURES CHECKLIST(refer to Section VIII)

SECTION VII. EQUIPMENT SHUTDOWN

3-19 SHELTER POWER SHUTDOWN.

After the power shutdown has been completed, indicate on PRE-CLEANING PROCEDURES CHECKLIST (refer toSection VIII). Proceed as follows:

1. Turn off all equipment circuit breakers2. Turn off interior MAIN circuit breakers.3. Turn off commercial power at the source.4. Remove power cable from connector J1 of the power entry panel.

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SECTION VIIl. PRE-CLEANING PROCEDURES CHECKLIST

The purpose of the PRE-CLEANING PROCEDURES CHECKLIST is to provide a hard copy record that the team hasperformed each operational step required in the shelter pre-cleaning procedures. It is the responsibility of the team leaderto obtain a copy of the checklist before starting the shelter cleaning.The top part of the checklist is filled out by the team leader and provides identification data for the shelter being cleanedand the personnel performing the cleaning, as follows:

(1) CORP, BRIGADE, BATTALION, COMPANY. Identification of command units responsible for shelter.(2) SHELTER SERIAL NUMBER. Enter shelter serial number.(3) SHELTER BUMPER NUMBER. Enter shelter bumper number.(4) SHELTER MODEL: Enter check mark as applicable.(5) NAME, RANK. Enter the name and rank of each team member assigned to clean the shelter. Also enter name

and rank of the team leader.

The bottom part of the checklist gives the sequence in which the pre-cleaning procedure operations are performed. Thefirst column, SECTION gives the section in Chapter 3 and the second column, PARAGRAPH gives the paragraph inChapter 3 that covers the step-by-step instructions for the pre-cleaning operation performed. The third column,MAINTAINER ACTION, identifies the specific operation or task performed during the pre-cleaning procedure. the fourthcolumn, CHECK, is where the team leader indicates by entering a check mark, that the specific operation or task has beencompleted by the cleaning team member. If a task fails, list the suspect component into the REMARKS section.

After the cleaning is started, the team leader is responsible for indicating that each operation or task is completed bymaking a check entry in the CHECK column. When the pre-cleaning procedures are completed, the filled-in checklist is tobe saved for record purposes.

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3-13/3-14 (blank)

TB 11-5820-934-13CHAPTER 4

SHELTER CLEANING AND SERVICING

SECTION I. PERSONNEL REQUIREMENTS


The team required to perform a Type A, B, or C shelter cleaning operation consists of four (4) persons; namely, two (2)unit maintainers (MOS 31M), one (1) direct support maintainer (MOS 29V), and one (1) team leader (MOS 31M). Theteam leader oversees and coordinates the work performed by the unit and direct support maintainers and the interfacewith other Electronic Maintenance Shop (EMS) personnel.

4-2 TEAM LEADER RESPONSIBILITIES.

The team leader responsibilities are as follows:

a. Establish interface with the EMS facility personnel to provide the following:1. Time frame for cleaning the shelter.2. Opening of work order for equipment or shelter component parts that may be required.3. Assigned work area for shelter components cleaning and servicing.

b. Provide unit maintainers with copies of the CHECK SHEETS (see Appendix A) and component location diagrams(see Chapter 4).

c. As cleaning procedure tasks and operations are completed, indicate on specific checklists that the task oroperation has been completed.

d. Assemble all checklists and the CHECK SHEET and file for record purposes.e. Provide all materials required during cleaning. (see Tables 4-1 and 4-2).f. Provide technical assistance as required during shelter diagnostic testing.g. Notify COMSEC/TED group personnel to remove, clean and reinstall all COMSEC/TED equipment.

4-3 UNIT MAINTAINER RESPONSIBILITIES.

Unit maintainers are responsible for performing those tasks which fall in their normal areas of responsibility. In addition,the following specific tasks involved in performing a shelter cleaning and servicing operation are also their responsibility:

a. Cleaning of interior shelter surfaces and component racks.b. Shelter filter cleaning and filter replacement.c. Removal and cleaning of specified components.d. Removal and transfer of specific components to the EMS facility for cleaning and servicing (refer to Table 4-3).

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4-4 DIRECT SUPPORT MAINTAINER RESPONSIBILITIES.

The direct support maintainer is responsible for performing those tasks which fall in their normal areas of responsibility. Inaddition, the direct support maintainer will clean, service, remove and replace the Power Distribution Unit 1A1 and RFAmplifier components and will assist the unit maintainer with tasks described in paragraph 4-3.-

NOTE

Do not remove unnecessary hardware such as: slides, hinges, screws etc.

Miscellaneous items must be marked and stored in approved containers to avoid loss or damage.

4-5 ELECTRONIC MAINTENANCE SHOP (EMS) FACILITY RESPONSIBILITIES.

The EMS facility personnel are responsible for performing cleaning and servicing of the following components:

a. Surge Protection Fault Assemblyb. Transmitter Amplifier-Converter Assembly AM-7027c. Dual Frequency Synthesizer SN-53d. Receiver Amplifier-Converter Assembly AM-7026e. Tropo Modem Modulatorf. Tropo Modem Demodulatorg. Low Voltage Power Supply (LVPS) PP-7904/PP-7905h. IF Test Paneli. Noise Sourcej. Loop Group Multiplexer TD-1235k. Digital Data Modem MD-1026I. Trunk Group Multiplexer TD-1236m. Low Speed Cable Driver MD-1023n. Alarm Monitor BZ-250.o. Voice Orderwire Control Unit C-1062p. AC-AC Converterq. Analog Orderwire Unitr. RF Amplifier Front Panel and Components (AM-7221)

1. Klystron Housing and Cooling Ducts2. Fault LED Matrix CCA3. Protect and Metering CCA (A2)4. Control Logic Assembly (A1)5 High Voltage Power Supply (A3)6. Fast Interrupt (FAINT) Assembly (A9)7. Inverter Assemblies (A6-A8)

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SECTION II. EQUIPMENT AND MATERIAL REQUIREMENTS

4-6 TYPE A CONTAMINATED SHELTER.

Refer to Table 4-1 for the cleaning equipment and other material not supplied with the shelter, required to clean a Type Acontaminated shelter. A 115 volt AC electric source (power generator, commercial power, or another shelter) is required tooperate vacuums, box fan, and trouble light. A source of compressed air (no more than 29 psi) is required for cleaningpurposes and to operate air powered vacuums.

Table 4-1. Equipment and Material Requirements For Type A Contaminated Shelter Cleaning

ITEM NSN DESCRIPTION QTY NOTE

1 N/A DISPOSABLE DUST MASK 6 12 4204-00-052-3776 SAFETY GOGGLES 3 23 NA TROUBLE LIGHT 2 34 4204-01-063-4880 WRIST STRAP, ESD APPROVED 3 45 N/A IONIZING AIR GUN, ESD APPROVED 1 56 8020-00-2454522 BRUSH, ESD APPROVED 4 67 5120-00-624-8065 CABLE CONNECTOR PLUG PLIERS 2 28 N/A CCA STORAGE CONTAINER, ESD APPROVED 1 79 FILTERS (see para. 4-19)

10 7939-00-357-7386 CLEANER, DETERGENT, GENERAL AR -11 7920-01-177-3633 WIPING CLOTHS AR -12 N/A SHOP VACUUM INCLUDING BRUSH HEAD AND 2 -

CREVICE TOOL13 N/A CLEAN WATER IN CONTAINERS AR -14 N/A ESD APPROVED VACUUM INCLUDING BRUSH HEAD 2 -

AND CREVICE TOOL15 N/A NOISE PROTECTOR 2 -16 N/A CCA STORAGE BAG, ESD APPROVED AR -17 N/A WINDOW SIZE BOX FAN 1 -18 N/A CCA EXTRACTOR 1 -19 4340-00-542-2048 FULL FACE SHIELD 2 -20 N/A ALL PURPOSE BUCKET ( 3 TO 5 GALLON) 121 N/A LONG HANDLE, HARD BRISTLE SCRUB BRUSH 1

NOTES:1. Obtain additional items by local purchase via normal channels. Must be SHA/NIOSH approved.2. Obtain through normal channels.3. Obtain by local purchase. Trouble light should be a Fluorescent type (with handle) shop light, 12 or 18 inches long.4. Obtain by local purchase through normal supply channels.5. Part of cleaning kit. Available as Top Gun Model, Part No.4002140 from: Simco Co. Inc. 2257 North Penn Road

Hatfield, PA 19440 1-215-822-2171

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6. Wooden handle paint brush. Obtain by local purchase. The paint brush must have a wooden handle with naturalbristles. Do not purchase paint brush with plastic handle or synthetic bristles

7. This item consists of the following component parts:a. Velostat Cover, Part No. 4254Ab. Container, Part No. 4472Ac. Divider, Part No. 4362A

Available through:3M COMPANY, Static Control Systems/3MPO Box 2963, Austin, TX 7876929631-800-328-1368

4-7 TYPE B AND C CONTAMINATED SHELTERS.

Refer to Table 4-1 and Table 4-2 for the cleaning equipment and other material not supplied with the shelter, and arerequired to clean a Type B and C contaminated shelter. The electrical source and compressed air requirements are thesame as described in paragraph 4-6 for a Type A contaminated shelter.

Table 4-2. Equipment and Material Requirements For Type B and C Contaminated Shelter Cleaning

ITEM NSN DESCRIPTION QTY NOTE

1 N/A RUBBER GLOVES 2 PR 1

2 N/A TRAYS 3 2

3 N/A DETERGENT 1 GAL 3

4 6505-00-261-7256 ISOPROPYL ALCOHOL 1 QT 4

5 N/A DEIONIZED (OR DISTILLED) WATER 1 GAL 5

NOTE:1. Obtain by local purchase. Available through:

QRP Inc., PO Box 18141-800-832-3882 (Extension 923)Santa Cruz, CA 9506-18(ORDER BY PART NUMBER 28G-2800)

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2. Obtain by local purchase. Available in most local department/grocery stores or through manufacturer:Rubbermaid Commercial Products2166 Wisconsin Ave, NWWashington DC 200071-202-265-0246(ORDER BY MODEL NUMBER 2951)

3. Obtain by local purchase. Available through:Baxter Heathcare Corp.,Scientific Products Division12110 Waukegan RoadMcGaw Park, IL 60085-6787Call 1-800-942-4591 for local distributor. Order by Part No.C6307-1.

4. Obtain by local purchase. Must be 99% pharmaceutical or reagent grade.5. Obtain by local purchase.

SECTION III. SAFETY REQUIREMENTS

4-8 NOISE, DUST, AND EYE PROTECTION.

When the shop vacuum ((12), Table 4-1) is being used to clean the shelter interior, use the noise protection device ((15),Table 4-1) to prevent hearing damage. Always use a dust mask ( (1), Table 4-1) when using any vacuum. Always usesafety goggles ( (2), Table 4-1) while cleaning to prevent eye damage due to flying dirt particles.

4-9 SHELTER GROUNDING.

Before starting shelter cleaning, check that the shelter is grounded (see Chapter 3, Section II for details). Use onlyapproved braided grounding straps and earth ground.

4-10 EQUIPMENT LIFTING RESTRICTIONS.

Some shelter components require more than one person to lift it. Observe warnings on the component and in this technicalbulletin regarding lifting restrictions.

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SECTION IV. COMPONENT HANDLING PROCEDURES, VACUUMING AND ION GUN TECHNIQUES

4-11 CIRCUIT CARD ASSEMBLY (CCA) HANDLING.

Observe the following precautions when handling CCA’s:

a. Always use an approved anti-static protection device (wrist strap) when handling a CCA.b. Always support the CCA while removing and installing into component nest location. If the CCA is held improperly,

it may bend and crack.c. Always use a card puller to remove a CCA from the nest slot.

4-12 VACUUMING TECHNIQUES.

There are two types of vacuums used in the cleaning of a Type A contaminated shelter. A shop vacuum ((12), Table 4-1)is used for cleaning the interior shelter surfaces and component rack surfaces using a brush and a nozzle attachment tosuction vacuum the dust and dirt. An approved ESD vacuum ((14), Table 4-1) is used to brush vacuum CCA’s and anozzle attachment is used to vacuum the CCA slot connectors and the adjacent slots on the nest motherboard. Whenbrush vacuuming a CCA, use the following techniques:

a. Hold card carefully in one hand at the side edges.b. Touch the brush to the card component side surface and gently move the brush across the surface from top-to-

bottom, in rowsc. Repeat step (b) on the card non-component side surface.d. Run brush across the connector end (both sides) of the card.

4-13 IONIZING AIR GUN TECHNIQUES.

The shop vacuum and the ESD vacuum use suction to remove the dust and dirt. An air compressor driven ionizing air gun((5), Table 4-1) is used to blow bulk dust and dirt from component interiors, card nests and CCA surfaces.

When using the ionizing air gun to blow bulk dust and dirt from CCA’s, backplanes and component interiors, keep the gunnozzle between 1 to 2 inches from the surface being cleaned. Do not allow the nozzle to touch the surface being cleaned.

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SECTION V. PRELIMINARY PROCEDURES

4-14 SHELTER COMPONENTS REMOVED BY UNIT MAINTAINER TEAM.

The shelter team is responsible for removing designated components, all miscellaneous items, and storage cabinet itemsfrom the shelter. As each component is removed, it is the responsibility of the team leader to indicate on thePRELIMINARY PROCEDURES CHECKLIST (refer to Section VI) that the component has been removed from the shelter.Refer to Table 4-3 for the shelter components designated for removal and the applicable TM paragraph containing thecomponent removal, and replacement instructions.

Table 4-3. Shelter Components Removed By Shelter Team

COMPONENT REMOVAL PARAGRAPHTM 11-5820-934-13-1-1

Power distribution assembly 1A1 6-15.1Surge protection fault assembly 6-15.2RF amplifier (1 kW) AM-7221 front panel/upper assembly 6-15.2

Fault LED Matrix bracket and CCA 6-15.5RF Protect and Metering CCA (A2) 6-7.7Klystron cooling ducts and housing 6-7.8Shelter cooling fans 6-7.41

RF amplifier (1 kW) AM-7221 lower assembly 6-7.1Control Logic Assembly (Al) 6-7.2High Voltage Power Supply (A3) 6-7.4Fast Interrupt (FAINT) Assembly (A9) 6-7.5Inverters (A6-A8) 6-7.6

Transmitter amplifier-converter assembly AM-7027 6-7.9Dual frequency synthesizer SN-53 6-7.11Receiver amplifier-converter assembly AM-7026 6-7.10Tropo modem modulator 6-7.12Tropo modem demodulator 6-7.13Low voltage power supply (LVPS) PP-7904/PP-7905 6-7.16IF test panel 6-7.26Heater assembly 6-7.27Noise Source 6-7.29Loop Group Multiplexer TD-1235 6-7.18Digital Data Modem MD-1026 6-7.19Trunk Group Multiplexer TD-1236 6-7.20Low Speed Cable Driver MD-1023 6-7.21Alarm Monitor BZ-250 6-7.24Voice Orderwire Control Unit C-1062 6-7.25AC-AC Converter 6-7.22Analog Voice Orderwire Unit 6-7.28

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SECTION VI. PRELIMINARY PROCEDURES CHECKLIST

The purpose of the PRELIMINARY PROCEDURES CHECKLIST is to provide a hard copy record that the team removedeach specified shelter component and then reinstalled the shelter components during a shelter cleaning operation. It is theresponsibility of the team leader to obtain a copy of the checklist before starting-the shelter cleaning.

The top part of the checklist is filled out by the team leader and provides identification data for the shelter being cleanedand the personnel who performed the cleaning, as follows:

(1) CORP, BRIGADE, BATTALION, COMPANY. Identification of the command responsible for shelter.(2) SHELTER SERIAL NUMBER. Enter shelter serial number.(3) SHELTER BUMPER NUMBER. Enter shelter bumper number.(4) NAME, RANK. Enter the name and rank of the team members assigned to shelter cleaning.

The bottom part of the check list identifies the shelter components. This part of the checklist provides a record of theremoval (OUT column), cleaning (CLEANED column) and the reinstallation (IN column) of the components after theshelter interior have been cleaned.

After the shelter and the removed components are cleaned and reinstalled, it is the responsibility of the team leader toenter a check mark in the appropriate column.

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SECTION VII. TYPE A CONTAMINATED SHELTER CLEANING AND SERVICEPROCEDURES


After all the designated components and miscellaneous items have been removed from the shelter, the team leaderassigns one team member to clean the shelter interior and to service and clean the in place components. The other teammember is responsible for cleaning designated components removed and for transporting those components to the EMSfacility for cleaning, servicing, and when applicable, recertification. The shelter interior and removed components cleaningare performed at the same time.

4-15.1 In Place Component Cleaning. The team member assigned to the shelter interior cleaning operation uses theshop vacuum ((12), Table 4-1) to remove dirt and dust from the interior surfaces and component racks. A typical shelterinterior and in place component cleaning operation consists of the following operations, performed in the order presented:

a. The shelter interior surfaces are suction vacuumed using the shop vacuum to remove bulk dirt and dust from thewalls, ceiling, and floor.

b. Starting at the rear of the shelter, the component rack surfaces are suction vacuumed.c. Dust and dirt is removed from the shelter filter assemblies using a nozzled air hose, suctioned vacuumed then

washed in a detergent and water solution.d. The shelter interior surfaces, component rack surfaces, and component surfaces are wiped down with a clean

water and general purpose detergent ((10), Table 4-1) solution dampened cloth.

4-15.2 Removed Component Cleaning. The team member assigned to clean the removed components uses a nozzledair hose to blow bulk dirt and dust from the component interior and filters. A typical removed component cleaning operationconsists of the following operations, performed in the order presented:

a. Dust and dirt is blown from all component interiors, filters and fan surfaces.b. Interior component surfaces are suction vacuumed using ESD Vacuum ((14),table 4-1)To remove dirt and dust.c. Components and miscellaneous items are wiped down using a damp cloth of clean water and general purpose

detergent, ((10),Table 4-1) solution.

NOTE

After cleaning the components and miscellaneous items they are not returned to the shelter until theshelter is completely cleaned and until directed to do so by the team leader

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4-15.3 Component Corrosion Check. If damage or corrosion is found during component cleaning, notify the Team Leaderand proceed using normal practices to send defective component through normal repair channels. The direct supportmaintainer is responsible for the removal, cleaning, servicing, and replacement of the Power Distribution Unit 1A1 and RF-Amplifier components.

4-16 SHELTER COMPONENT CLEANING.

NOTE

The ESD vacuum ((14),table 4-1) is used for component cleaning, circuit card assembly (CCA) and cardnest cleaning.

To perform the shelter component cleaning operation, proceed as follows:

WARNING

Use protective mask ((1), Table 4-1) and noise protectors ((15), Table 4-1) when performing theVacuuming operation

a. Remove component covers and front panels as required, to expose interior surfaces, card nests, fans, etc.b. Use Ion Air Gun to blow dirt and dust from component interiors, filters and fan surfacesc. Use ESD vacuum with brush attachment to suction vacuum interior and fan surfaces.d. Use crevice attachment to suction vacuum component interior surfaces not accessible with brush attachment.e. Use soft bristle brush ((6), Table 4-1) to loosen dirt and dust not accessible with brush and crevice attachments.

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4-17 SHELTER INTERIOR VACUUMING.

To perform shelter interior vacuuming operation, proceed as follows:

WARNING

Use protective mask ((1), Table 4-1) and noise protectors ((15), Table 4-1) when performing thevacuuming operation.

a. Provide AC power to shelter to operate the box window fan, shop vacuum, and trouble light.b. Use shop vacuum with brush attachment to suction vacuum interior shelter surfaces and component rack

surfaces.c. Use crevice attachment to suction vacuum interior shelter surfaces and component rack surfaces not accessible

using brush attachment.d. Use all purpose cleaning detergent ((10), Table 4-1) dampened cloth to clean heavily soiled surfaces; otherwise

use a water dampened cloth.e. Use Scrub Brush ((21),Table 4-1) and all purpose cleaning detergent ((10), Table 4-1) and water solution to clean

shelter floor.

4-18 POWER DISTRIBUTION UNIT CLEANING.

NOTE

The ESD vacuum ((14),table 4-1) is used for cleaning the Power Distribution Unit, circuit card assemblies(CCA’s) and card nests.

To perform the Power Distribution Unit cleaning, proceed as follows:

WARNING


a. Use brush attachment to suction vacuum interior surfaces and components.b. Use crevice attachment to suction vacuum component surfaces not accessible with brush attachment.c. Use brush attachment and crevice attachment to suction vacuum front panel and circuit breaker panel

components.

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4-19 FILTER ASSEMBLY CLEANING AND SERVICING.

To perform filter cleaning operation, and proceed as follows: Refer to figure 4-1 and figure 4-2 for shelter filter locations.

a. At the air inlets (1,6,7)remove six (6) screws holding the air and EMI filters and remove filters from shelter.b. At the air outlets (3,4,5)remove fourteen (14) screws holding the EMI filters and remove filters from shelter.c. At ECU Filter (2).

1. Loosen two (2) thumbscrews holding the Auxiliary Fan, part number 49956-G-125848-50 and RemoveAuxiliary fan from shelter.

2. Remove four(4) screws holding louvers and remove from shelter.3. Remove sixteen(16) screws holding filter cover plate and remove from shelter.4. Remove twelve(12) screws holding EMI filters and remove from shelter.

d. At Door Filter (8) remove foam door filter by sliding out of door frame.

WARNING

Use protective mask ((1), Table 4-1), safety goggles ((2), Table 4-1), and noise protectors ((15), Table 4-1) when performing shelter filter assembly cleaning

e. Use nozzled air hose to blow dirt and dust from filters.f. Use shop vacuum with brush attachment to suction vacuum dust and dirt from filters.g. wash filters using all purpose bucket ((20), Table 4-1) with water and mild detergent ((10), Table 4-1) solution, and

dry with nozzled air hose.h. From inside of shelter door, use nozzled air hose to blow dirt and dust from honeycomb door filter.I. At outside of shelter door, use shop vacuum with brush attachment to suction vacuum dirt and dust from the door

louvers.j. Wipe down louvers using all purpose cleaning detergent ((10) Table 4-1) solution and water dampened cloth and

dry using nozzled air hose.

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NSN DESCRIPTION QTY FIND#4130-01-158-2877 FILTER, AIR 1 14130-01-157-6551 FILTER, AIR 2 6,75411-01-092-0892 FILTER, FOAM 2 84130-01-158-2876 FILTER, EMI 2 14130-01-158-2875 FILTER, EMI 1 34130-01-157-6548 FILTER, EMI 4 4,5,6,74130-01-157-6547 FILTER, EMI 1 2

FIGURE 4-1. AN/TRC-170(2 SHELTER FILTER LOCATIONS

DESCRIPTION QTY FIND#FILTER 1

9330-00-107-1165 FILTER FOAM AIR 2 2FILTER 3FILTER 4FILTER 5FILTER 6FILTER 7

FIGURE 4-2. AN/TRC-170(V)3 SHELTER FILTER LOCATIONS

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4-20 RF AMPLIFIER CLEANING.

NOTE

The ESD vacuum ((14),table 4-1) is used for cleaning the RF-Amplifier, circuit card assemblies (CCA’s)and card nests.

WARNING


a. Use ESD vacuum with brush attachment to vacuum RF Amplifier interior surfaces and components.b. Use crevice attachment to vacuum component surfaces not accessible with brush attachment.c. Use soft brush ((6), Table 4-1) to loosen dirt and dust not easily accessible with the brush and crevice

attachments.d. Use brush attachment to vacuum EMI filter located in the rear of lower cabinet.e. Using a cloth dampened in a mild detergent solution ((10), Table 4-1) wipe down interior surfaces, then dry with a

dry wiping cloth ((11), Table 4-1).

4-21 SHELTER COOLING FAN CLEANING

To gain access to the two (2) high speed cooling fans, proceed as follows:

a. Model (V)2: Remove the two (2) blank panels located above the RF Amplifier Unit at the top of the equipment bays2 and 3.

b. Model (V)3: Remove the access panels located at the top of the equipment bays 3 and 7.c. Use the ESD vacuum with brush attachment to vacuum fan blades and fan surfaces.d. Use the crevice attachment to vacuum fan surfaces not accessible with the brush attachment.e. Use soft brush ((6), Table 4-1) to loosen dirt and dust not easily accessible with the brush and crevice

attachments.f. Using a cloth dampened in a mild detergent solution ((10),table 4-1) wipe down the fan body and blades then dry

with dry wiping cloth ((11),table 4-1).

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4-22 MISCELLANEOUS COMPONENT CLEANING.

Using a cloth dampened in a mild detergent solution ((10), Table 4-1) wipe down all surfaces on the following:

a. Fluorescent lamps and fixturesb. Power Distribution Unit circuit breakers and front panel surfaces.c. Stowage Items.d. Equipment rack blank panels

4-23 SHELTER FINAL CLEANING.

The final shelter cleaning operation consists of a wiping down of the interior shelter surfaces and the component racksurfaces. Use a water and general purpose cleaner solution ((10), Table 4-1)and wipe dry with dry wiping cloths ((11),Table 4-1).

4-24 SHELTER COMPONENTS REPLACEMENT.

After the shelter final cleaning operation has been completed, the components and miscellaneous items removed forcleaning and servicing are reinstalled. The team leader controls and directs this operation. As each item and componentis installed into the shelter, an entry is made in the applicable shelter PRELIMINARY PROCEDURE CHECKLIST, (refer toSection VI)

SECTION VIII. TYPE B AND C CONTAMINATED SHELTERCLEANING AND SERVICE PROCEDURES


The Type B and C contaminated shelter cleaning and service procedure is performed in the same sequence as describedin Section VII, paragraph 4-16 General Information for a Type A contaminated shelter. In both the Type B and Ccontaminated shelters, the ESD vacuum is used to remove loose dust, sand, and dirt from shelter interior surfaces andcomponent surfaces, etc. These surfaces are then cleaned with a cloth dampened in a detergent solution to remove anysoot and dirt not removed by vacuuming.

4-25.1 CCA Cleaning. The CCA’s are cleaned of soot and dirt using the detergent wash, and alcohol/water dryingmethod. Equipment internal surfaces are suction vacuumed, then cleaned of soot and dirt by the detergent clothdampened wipe down method.

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4-25.2 In-Place Component Cleaning. A typical Type B and C contaminated shelter interior and in-place componentcleaning operation consists of the following operations performed in the order presented:

a. The shelter interior is suction vacuumed using the shop vacuum to remove bulk dirt and dust from the shelterwalls, ceiling, and floor. These surfaces are then wiped down to remove any additional soot and dirt film notremoved by the vacuuming operation.

b. The Power Distribution Unit components, interior surfaces, and back of front panels are suction vacuumed toremove all bulk loose dirt. The components, interior surfaces, and back of front panels are then wiped down toremove soot and dirt not removed by the vacuuming operation.

c. Starting at the rear of the shelter, the component rack surfaces are suction vacuumed, then wiped down to removesoot and dirt not removed by vacuuming operation.

d. The shelter filter assemblies are cleaned using a nozzled air hose, suction vacuumed and then washed in a waterand detergent solution to remove dirt and soot film not removed by the vacuuming operation.

4-25.3 Removed Component Cleaning. The team member assigned to clean the removed components uses an ion airgun to blow bulk dirt and dust from the components interior and filter surfaces. The component interior and filter surfacesare suction vacuumed then wiped down to remove any remaining dirt and soot film not removed by the ion air gun blowingoperation.

4-25.4 Component Corrosion Check. If damage or corrosion is found during component cleaning, notify the Team Leaderand proceed using normal practices to send defective component through normal repair channels. The direct supportmaintainer is responsible for the removal, cleaning, servicing, and replacement of the Power Distribution Unit 1A1 and RF-Amplifier components.

NOTE

After cleaning. Components and miscellaneous items are not returned to the shelter until the shelter iscompletely cleaned and until directed to do so by the team leader.

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4-26 SURFACE CLEANING INSTRUCTIONS.

Clean shelter interior, component interior and exterior surfaces, shelter cooling fans and component rack surfaces asfollows:

a. Wipe surfaces with a clean, low-lint cloth ((11), Table 4-1) dampened in a solution of detergent ((10), Table 4-1)and water.

b. Wipe surfaces with a clean, low-lint cloth dampened with clean water to remove detergent residue.c. Dry surfaces with a clean, low-lint cloth ((11), Table 4-1).

4-27 CCA CLEANING INSTRUCTIONS.

4-27.1 Set Up. Proceed as follows:

a. Establish a work area in the EMS facility with sufficient space for three (3) trays ((2), Table 4-2) and ESDprotective container ((8), Table 4-1).

b. Establish a ground point for operator wrist strap ((4), Table 4-1), grounding mat, and ESD protective container.c. Layout the three trays and fill each as specified:

1. Tray No. 1 contains one (1) gallon of distilled water((5), Table 4-2) and four (4) ounces of detergent ((3), Table4-2) or two (2) gallons of distilled water and eight (8) ounces of detergent (2 to 5% mix).

2. Tray No. 2 contains one (1) gallon of distilled water.

WARNING

Isopropyl Alcohol is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection isrequired. Avoid repeated and prolonged contact. Use only in well ventilated areas. Keep away from openflames or other sources of ignition.

3. Tray No. 3 contains one (1) gallon of distilled water and eight (8) ounces of alcohol ((4), Table 4-2)(15% mix).

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4-27.2 Cleaning CCA’s. Proceed as follows:

a. Place ESD protective container containing CCA’s within an easy reach near the cleaning trays.b. Ground ESD protective container by placing on ESD mat or by attaching ground strap.c. Attach maintainer ESD wrist strap and put on Gloves ((1),table 4-2)d. Remove CCA’s one at a time and proceed as follows:

1. Immerse CCA in Tray No. 1 and GENTLY wipe all surfaces with soft brush ((6),Table 4-1). Lift CCA out of trayand let excess detergent drain back into tray.

2. Immerse CCA in Tray No. 2 and GENTLY wipe all surfaces with a second soft brush to remove detergentresidue. Lift out of tray and let excess water drain back into tray.

3. Immerse CCA in Tray No. 3 and then lift out of solution. Repeat several times. Lift out of tray and let excesssolution drain back into tray.

NOTE

If available, use ionized air gun to blow excess water from CCA after removal from Tray No. 3. Use low airpressure (25 psi) and be sure to keep nozzle 6 to 8 inches away from CCA surface.

4-28 SHELTER INTERIOR VACUUMING.

Refer to Section VII, paragraph 4-18 and Section VIII, paragraph 4-26 for the shelter interior cleaning vacuuming andsurface cleaning instructions, respectively.

4-29 POWER DISTRIBUTION UNIT CLEANING.

Refer to Section VII, paragraph 4-19 and Section VIII paragraph 4-26 for the Power Distribution Unit cleaning vacuuming,and surface cleaning instructions, respectively.

4-30 SHELTER FILTER CLEANING AND SERVICING.

Refer to Section VII, paragraph 4-20 and Section VIIl, paragraph 4-26 for the shelter filter cleaning and surface cleaninginstructions, respectively.

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4-31 RF AMPLIFIER CLEANING

Refer to Section VII paragraph 4-21, and paragraph 4-26 for the RF Amplifier cleaning and surface cleaning instructions,respectively.

4-32 SHELTER COOLING FAN CLEANING.

Refer to Section VIII, paragraph 4-22 and Section VII paragraph 4-26 for the shelter cooling fan cleaning and surfacecleaning instructions, respectively.

4-33 MISCELLANEOUS COMPONENT CLEANING.

Refer to Section VII paragraph 4-23 and Section VIII paragraph 4-26 for the miscellaneous component cleaning andsurface cleaning instructions, respectively.

4-34 SHELTER FINAL CLEANING.

Refer to Section VII paragraph 4-24 and Section Vll paragraph 4-26 for the shelter final cleaning and surface cleaninginstructions, respectively.

4-35 SHELTER COMPONENTS REPLACEMENT.

After the shelter final interior cleaning has been completed, the components and miscellaneous items removed forcleaning and servicing are reinstalled. The team leader controls and directs the operation. As each component isreinstalled into the shelter, a check mark entry is made in the PRELIMINARY PROCEDURES CHECKLIST. (refer toSection VI).

4-36 SHELTER CORROSION CHECK

This visual check is performed to verify that external cable connectors do not show signs of corrosion which can causedegraded shelter operation. Refer to TM 11-5820-934-13-1-1 (V)2 and TM 11-5820-934-13-2-1 (/)3, table 6-8, PreventiveMaintenance Checks and Services for details and corrective action.

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CHAPTER 5POST-CLEANING PROCEDURES

SECTION I. SETUP PROCEDURES


The post-cleaning setup procedures consists of the following operations presented in the order performed:

a. Power Cable Connection (see paragraph 5-2).b. Power Up Procedures (see paragraph 5-3).c. Components Lights and Indicators Check (see paragraph 5-5).

5-2 POWER CABLE CONNECTION.

Refer to Chapter 3, Section I for shelter grounding and AC power connection. After this has been completed, indicate onPOST-CLEANING PROCEDURES CHECKLIST (refer to Section VIl).

5-3 POWER UP PROCEDURES.

5-3.1 General Information. The power up procedures consists of the following operations presented in the orderperformed

a. Site commercial AC Power Up (see paragraph 5.3.2).b. Shelter AC Power Up (see paragraph 5.3.3).

5-3.2 Site Commercial AC Power Up. Refer to Chapter 3, Section II, paragraph 3-5.1 for the power up procedure. Afterthe procedure is completed, indicate on the POST-CLEANING PROCEDURES CHECKLIST(refer to Section VII).

5-3.3 Shelter AC Power Up. Refer to Chapter 3, Section II, paragraph 3-5.2 for the power up procedure. After theprocedure is completed, indicate on the POST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

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SECTION II. OPERATIONAL SET-UP


The operational setup consists of the following, presented in the order performed:

a. Component Light and Indicators Check(see paragraph 5-5)b. Component Initialization and Self Tests (see paragraph 5-6).c. Diagnostic Tests (see paragraph 5-8).

5-5 COMPONENT LIGHTS AND INDICATORS CHECK.

5-5.1 Lights and Indicator Checks. Refer to Chapter 3, Section III, Table 3-2 and perform the lights and indicators checkspecified. After this check is completed, Indicate on the POST-CLEANING PROCEDURES CHECKLIST (refer to SectionVII).

5-5.2 Lamp Tests. Refer to Chapter 3, Section III, Table 3-3 and perform the shelter components lamp tests specified.After this test has been completed, Indicate on the POST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

SECTION III. INITIALIZATION AND SELF TEST PROCEDURES

5-6 COMPONENT INITIALIZATION AND SELF TEST PROCEDURES.

The self test procedures consists of the following, presented in the order performed

a. Loop Group Multiplexer (LGM) TD-1235(P)/TCC (see paragraph 5-6.1).b. Group Modem (GM) MD-1026(V)(P)/G (see paragraph 5-6.2).c. Trunk Group Multiplexer (TGM) TD-1236/G (see paragraph 5-6.3).d. Low Speed Cable Driver Modem (LSCDM) MD-1023(V)/G (see paragraph 5-6.4)

5-6.1 LGM Initialization and Self Test. Refer to Chapter 3, Section IV, paragraph 3-10 for the LGM initialization and selftest procedure. After this test has been completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer toSection VII).

5-6.2 GM Initialization and Self Test. Refer to Chapter 3, Section IV, paragraph 3-11 for the GM initialization and self testprocedure. After this test has been completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer toSection VII).

5-6.3 TGM Initialization Self Test. Refer to Chapter 3, Section IV, paragraph 3-12 for the TGM self test procedure. Afterthis test has been completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

5-6.4 LSCDM Initialization and Self Test. Refer to Chapter 3, Section IV, paragraph 3-13 for the TGM self testprocedure. After this procedure has been completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer toSection VII).

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SECTION IV. COMMUNICATION AND SECURITY EQUIPMENT

5-7 COMMUNICATION SECURITY EQUIPMENT (COMSEC) AND TRUNKENCRYPTION DEVICE (TED) CLEANING AND SERVICING.

Refer to Chapter 3, Section V, Paragraph 3-14 for COMSEC/TED removal, cleaning servicing and reinstallation. After thishas been completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

SECTION V. DIAGNOSTIC TESTING

5-8 DIAGNOSTIC TESTS.

5-8.1 General Information. The post cleaning procedures diagnostic tests consists of the following checks performed inthe order presented:

a. LGM AND TGM LOOPBACK TESTb. GM LOOPBACK TESTc. LGM LOOP MODEM CHANNEL TESTd. RADIO SIDE DATA ORDERWIRE (DOW) SELF-TESTe. CABLE SIDE DOW SELF-TESTf: RECEIVED SIGNAL LEVEL (RSL) INTEGRATION SELF-TESTg. RF AMPLIFIER TRANSMIT SUBSYSTEMS TESTh. VOICE ORDERWIRE CONTROL UNIT (VOCU) SELF-TEST

5-8.2 LGM and TGM Loopback Test. Refer to Chapter 3, Section VI, paragraph 3-15.1 for the LGM and TGM LoopbackTest Procedure. After this check is completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer toSection VII).

5-8.3 GM Loopback Test. Refer to Chapter 3, Section VI, paragraph 3-15.2 for the GM Loopback Test procedure. Afterthis test is completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

5-8.4 LGM Loop Modem Channel Test. Refer to Chapter 3, Section VI, paragraph 3-15.3 for the LGM Loop ModemChannel Test procedure. After this check is completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (referto Section VII).

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5-9 DATA ORDERWIRE SELF TEST.

Refer to Chapter 3, Section V1, paragraph 3-16 for the DOW Self Test procedure. After this test is completed, indicate onPOST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

5-9.1 Radio Side Data Orderwire (DOW) Self-Test. Refer to Chapter 3, Section VI, paragraph 3-16.1 for the Radio SideDOW Self Test procedure. After this test is completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (referto Section VII).

5-9.2 Cable Side DOW Self-Test. Refer to Chapter 3, Section VI, paragraph 3-16.2 for the Cable Side DOW Self Testprocedure. After this test is completed, indicate on POST-CLEANING PROCEDURES CHECKLIST (refer to Section Vi).

5-9.3 Received Signal Level (RSL) Integration Self-Test. Refer to Chapter 3, Section VI, paragraph 3-16.3 for the RSLIntegration Self Test procedure. After this test is completed, indicate on POST-CLEANING PROCEDURES CHECKLIST(refer to Section VII).

5-9.4 RF Amplifier transmit subsystems test. Refer to Chapter 3, Section VI, paragraph 3-16.4 for the RF AmplifierTransmit Subsystems Test procedure. After this test is completed, indicate on POST-CLEANING PROCEDURESCHECKLIST (refer to Section VII).

5-10 VOICE ORDERWIRE CONTROL UNIT (VOCU) SELF TEST.

Refer to Chapter 3, Section VI, paragraph 3-17 for the VOCU Self Test procedure. After this check is completed, indicateon POST-CLEANING PROCEDURES CHECKLIST (refer to Section VII).

SECTION VI. EQUIPMENT SHUTDOWN

The post cleaning shelter shutdown consists of the shelter power down procedure. Refer to Chapter 3, Section VI,paragraph 3-19. After the shelter power down procedure is performed, indicate on POST-CLEANING PROCEDURESCHECKLIST (refer to Section VII).

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SECTION VII. POST-CLEANING PROCEDURES CHECKLIST

The purpose of the POST-CLEANING PROCEDURES CHECKLIST is to provide a hard copy record that the team hasperformed each operational step required in the shelter post-cleaning procedures. It is the responsibility of the team leaderto obtain a copy of the checklist before starting the post-cleaning procedures.

The top part of the checklist is filled in by the team leader to provide identification data for the shelter being cleaned andthe personnel performing the cleaning, as follows:

(1) CORP, BRIGADE, BATTALION, COMPANY. Identification of command units responsible for shelter.(2) SHELTER SERIAL NUMBER. Enter shelter serial number.(3) SHELTER BUMPER NUMBER. Enter shelter bumper number.(4) SHELTER MODEL: Enter check mark as applicable.(5) NAME, RANK. Enter the name and rank of each team member assigned to clean the shelter. Also enter name

and rank of the team leader.

The bottom part of the checklist gives the sequence in which the post-cleaning procedure is performed. The first column,SECTION gives the section in Chapter 5 and the second column, PARAGRAPH gives the paragraph in Chapter 5 thatcovers the step-by-step instructions to be performed. The third column, MAINTAINER ACTION, identifies the specificprocedure or task performed during the post-cleaning procedure. The fourth column, CHECK, is where the team leaderindicates, by entering a check mark, that each specific operation or task has been performed and completed by themaintainer.

The completed post cleaning procedures checklist is to be saved for record purposes.

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5-7/5-8 (blank)

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APPENDIX A

SHELTER CLEANING PROCEDURES CHECKLISTS.

A-1 PRE-CLEANING PROCEDURES CHECKLIST.

The purpose and column heading descriptions for the PRE-CLEANING PROCEDURES CHECKLIST are given in Chapter3, Section VIII. A reproducible blank checklist is provided on page A-3.

A-2 PRELIMINARY PROCEDURES CHECKLIST.

The purpose and column heading descriptions for the PRELIMINARY PROCEDURES CHECKLIST are given in Chapter 4Section VI. A reproducible blank checklist is provided on page A-5.

A-3 POST-CLEANING PROCEDURES CHECKLIST.

The purpose and column heading descriptions for the POST-CLEANING PROCEDURES CHECKLIST are given inChapter 5, Section VII. A reproducible blank checklist is provided on pages A-7 and A-8.

A-1/A-2 (BLANK)

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PRE-CLEANING PROCEDURES CHECKLIST

A-3/A-4 (BLANK)

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PRELIMINARY PROCEDURES CHECKLIST

A-5/A-6 (BLANK)

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POST-CLEANING PROCEDURES CHECKLIST

A-7

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A-8

PIN: 074543-000

Documents

TB 11-5820-934-13 DIGITAL TROPOSCATTER TERMINAL ... TRC 170 TROPO/AN TRC...TB 11-5820-934-13 WARNING If a circuit breaker does not stay ON when closed, do not attempt to close it repeatedly