Kac 1052 Maintenance Manual

COMPONENT MAINTENANCE MANUAL
KAC 1052
Antenna Coupler
MANUAL NUMBER 006-15640-0001

REVISION 1 JANUARY, 2004
WARNING
Prior to export of this document, review for export license requirement is needed.
COPYRIGHT NOTICE
2003, 2004 Honeywell International Inc.
Reproduction of this publication or any portion thereof by any means without the express
written permission of Honeywell is prohibited. For further information contact the Manager
of Technical Publications, Honeywell, Olathe, KS 66061. Telephone: (913) 712-0400.
N
______________________________________________________________________
Honeywell
Aerospace Electronic Systems
23500 West 105th Street
Olathe, Kansas 66061
Component Maintenance Manual

with illustrated parts list
KAC 1052 Antenna Coupler
Part No. Manufacturer

064-01074-0101 Honeywell
PAGE T-1
23-10-07 Jan/2004
PRINTED IN U.S.A PUB. NO. 006-15640-0001
N
NOTE
IF ANY UNUSUAL OR SPECIAL SERVICE PROBLEMS ARISE,

CONTACT HONEYWELL CUSTOMER SUPPORT DEPARTMENT.
PROPRIETARY NOTICE
This document contains proprietary information and

such information may not be disclosed to others for any
purpose, nor used for manufacturing purposes without
written permission from Honeywell.
PAGE T-2
23-10-07 Jan/2004
PRINTED IN U.S.A PUB. NO. 006-15640-0001
N
KAC 1052 Antenna Coupler / Part No. 064-01074-0101
TRANSMITTAL INFORMATION
TO HOLDERS OF: HOLDERS OF COMPONENT MAINTENANCE MANUAL,

PUB. NO. 006-15640-0000, KAC 1052 ANTENNA COUPLER
(PART NO. 064-01074-0101).
REVISION NO. 001, DATED Jan/2004
Revision History
Table of Revisions
Revision No. Revision Date Date Put in Manual By
1 Jan/2004 (full revison of manual)
Highlights
This revision contains these changes:
Table of Highlights
Task/Page Description of Change Effectivity
(various) Corrected clerical errors.
PAGE TI-1
23-10-07 Jan/2004
Use or disclosure of information on this page is subject to the restrictions in the proprietary notice of this document.
N
Task/Page Description of Change Effectivity
PAGE TI-2
23-10-07 Jan/2004
N
RECORD OF REVISIONS
For each revision, put the revised pages in your manual and discard the superseded
pages. Write the revision number and date, the date put in the manual, and the
incorporator’s initials in the applicable columns on the Record of Revisions.
Revision Revision Date Put Revision Revision Date Put

Number Date In Manual By Number Date In Manual By
1 01/04 (full rev.)
PAGE RR-1
23-10-07 Jan/2004
N
Revision Revision Date Put Revision Revision Date Put

Number Date In Manual By Number Date In Manual By
PAGE RR-2
23-10-07 Jan/2004
N
RECORD OF TEMPORARY REVISIONS
Instructions on each page of a temporary revision tell you where to put the pages in your
manual. Remove temporary revision pages only when discard instructions are given. For
each temporary revision, put the applicable data in the record columns on this page.
Temp Rev. No. Status Task Location
PAGE RTR-1
23-10-07 Jan/2004
N
Temp Rev. No. Status Task Location
PAGE RTR-2
23-10-07 Jan/2004
N
SERVICE BULLETIN LIST
The following Service Bulletins have been incorporated in this manual.
Manual Manual
ATA Revision Revision
Coverage
Number Number Date
PAGE SBL-1
23-10-07 Jan/2004
N
Manual Manual
ATA Revision Revision
Coverage
Number Number Date
PAGE SBL-2
23-10-07 Jan/2004
N
LIST OF EFFECTIVE PAGES
SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE

Title Introduction
T-1 Jan/2004 INTRO-1 Jan/2004
T-2 Jan/2004 INTRO-2 Jan/2004
Transmittal Information INTRO-3 Jan/2004
TI-1 Jan/2004 INTRO-4 Jan/2004
TI-2 Jan/2004 INTRO-5 Jan/2004
Record of Revisions INTRO-6 Blank
RR-1 Jan/2004 Description and Operation
RR-2 Jan/2004 1 Jan/2004
Record of Temporary Revisions 2 Jan/2004
RTR-1 Jan/2004 3 Jan/2004
RTR-2 Jan/2004 4 Jan/2004
Service Bulletin List 5 Jan/2004
SBL-1 Jan/2004 6 Jan/2004
SBL-2 Jan/2004 7 Jan/2004
List of Effective Pages 8 Blank
LEP-1 Jan/2004 F 9 Jan/2004
LEP-2 Jan/2004 10 Blank
LEP-3 Jan/2004 11 Jan/2004
LEP-4 Blank 12 Jan/2004
Table of Contents 13 Jan/2004
TOC-1 Jan/2004 14 Jan/2004
TOC-2 Jan/2004 15 Jan/2004
TOC-3 Jan/2004 16 Blank
TOC-4 Jan/2004 F 17 Jan/2004
List of Figures 18 Blank
LOF-1 Jan/2004 F 19 Jan/2004
LOF-2 Blank 20 Blank
List of Tables 21 Jan/2004
LOT-1 Jan/2004 22 Jan/2004
LOT-2 Blank 23 Jan/2004
24 Jan/2004
25 Jan/2004
26 Jan/2004
27 Jan/2004
indicates a changed, added, or deleted page

J
F indicates a right foldout page with a blank back
LF indicates a left foldout page with a blank front.
PAGE LEP-1
23-10-07 Jan/2004
N

Description and Operation (cont) Repair
28 Jan/2004 6001 Jan/2004
29 Jan/2004 6002 Jan/2004
30 Jan/2004 Assembly
Testing and Fault Isolation 7001 Jan/2004
1001 Jan/2004 7002 Jan/2004
1002 Jan/2004 7003 Jan/2004
1003 Jan/2004 7004 Jan/2004
1004 Jan/2004 7005 Jan/2004
1005 Jan/2004 7006 Jan/2004
1006 Jan/2004 7007 Jan/2004
1007 Jan/2004 7008 Blank
1008 Jan/2004 Fits and Clearances
1009 Jan/2004 8001 Jan/2004
1010 Jan/2004 8002 Blank
Schematics and Wiring Diagrams Special Tools, Fixtures, and Equipment
2001 Jan/2004 9001 Jan/2004
2002 Blank 9002 Jan/2004
Disassembly F 9003 Jan/2004
3001 Jan/2004 9004 Blank
3002 Jan/2004 Special Procedures
3003 Jan/2004 11001 Jan/2004
3004 Blank 11002 Blank
Cleaning Removal
4001 Jan/2004 12001 Jan/2004
4002 Jan/2004 12002 Blank
4003 Jan/2004 Installation
4004 Jan/2004 13001 Jan/2004
4005 Jan/2004 13002 Blank
4006 Blank Servicing
Check 14001 Jan/2004
5001 Jan/2004 14002 Jan/2004
5002 Jan/2004 Storage
15001 Jan/2004
15002 Blank

J
PAGE LEP-2
23-10-07 Jan/2004
N

Rework
16001 Jan/2004
16002 Blank
Illustrated Parts List
10001 Jan/2004
10002 Jan/2004
10003 Jan/2004
10004 Blank
F 10005 Jan/2004
10006 Blank
F 10007 Jan/2004
10008 Blank

J
PAGE LEP-3
23-10-07 Jan/2004
N
Blank Page

J
PAGE LEP-4
23-10-07 Jan/2004
TABLE OF CONTENTS
DESCRIPTON PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. How to Use This Manual (Task 23-10-06-99C-801-A01) . . . . . . . . . . . . . . . . . . . . 1
A. General Information (Subtask 23-10-06-99F-001-A01) . . . . . . . . . . . . . . . . . . . 1
B. Acronyms (Subtask 23-10-06-99F-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Physical Description (Task 23-10-87-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. General (Subtask 23-10-07-87-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Packaging (Subtask 23-10-07-87-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(1) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
C. Chassis (Subtask 23-10-07-87-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Switches and Knobs (Subtask 23-10-07-87-004-A01) . . . . . . . . . . . . . . . . . . . . 7
E. Connector (Subtask 23-10-07-87-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(1) RF Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
(2) P10521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
(3) P10522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
F. Cooling (Subtask 23-10-07-87-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
G. Internal Connections (Subtask 23-10-07-87-007-A01) . . . . . . . . . . . . . . . . . . . 7
H. Major Subassemblies (Subtask 23-10-07-87-008-A01) . . . . . . . . . . . . . . . . . . 11
(1) PS and Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
(2) CPLR Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
(3) Sensor and Relay Drive Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .11
(4) Shunt Capacitor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
(5) Series Capacitor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
(6) Coil Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2. Functional Description (Task 23-10-07-87-802-A01) . . . . . . . . . . . . . . . . . . . . . . 12
A. General (Subtask 23-10-07-87-009-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Theory of Operation (Subtask 23-10-07-87-010-A01) . . . . . . . . . . . . . . . . . . . 12
(1) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
(2) RF Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
(3) Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
(4) Bridging Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
(5) CPLR Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
(6)Power Supply and Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
(7) Interface Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. How to Use (Task 23-10-07-99C-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
A. General (Subtask 23-10-07-99F-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Test Philosophy (Task 23-10-07-75-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 1001
A. Airplane Fault Isolation (Subtask 23-10-07-94-001-A01) . . . . . . . . . . . . . . . 1001
PAGE TOC-1
23-10-07 Jan/2004
TABLE OF CONTENTS (cont)
DESCRIPTON PAGE
3. Procedure (Task 23-10-06-75-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

A. Shop Fault Isolation (Subtask 23-10-07-81-001-A01) . . . . . . . . . . . . . . . . . 1001
B. Bench-Test Harness Return to Service Test Solution
(Subtask 23-10-07-75-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
(1) Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004
(2) Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004
(3) Antenna Coupler Tuning Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004
(4) High-SWR Retune Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1007
(5) Bridging Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1007
C. KPA 1052 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009
4. Automatic Test Requirements (Task 23-10-07-75-803-A01) . . . . . . . . . . . . . . 1009
A. General (Subtask 23-10-07-75-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009
B. Equipment and Materials (Subtask 23-10-07-75-005-A01) . . . . . . . . . . . . . 1009
C. HF ATE System Test Solution (Subtask 23-10-07-75-006-A01) . . . . . . . . . 1009
SCHEMATICS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
1. Task (Task 23-10-07-99C-803-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
A. General (subtask 23-10-07-99F-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
2. Equipment and Materials (Task 23-10-07-94-802-A01) . . . . . . . . . . . . . . . . . . 3001
3. Procedure (Task 23-10-07-03-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
(1) Side Plates (2) MPBC36547A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002
(2) Series Cap Board (26) MDLW11386D . . . . . . . . . . . . . . . . . . . . . . . . . .3002
(3) Shunt Cap Board (25) MDLW11385F . . . . . . . . . . . . . . . . . . . . . . . . . . .3002
(4) Coil Board (27) MDLW11390E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002
(5) Sensor and Relay Drive Board (24) MDCW10907D . . . . . . . . . . . . . . . .3003
(6) Shields (29) MPSC30332A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3003
(7) CPLR Control Board (23) MDLW11428 . . . . . . . . . . . . . . . . . . . . . . . . .3003
(8) Power Supply and Interface Board (22) MDBW10546B . . . . . . . . . . . . .3003
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
1. Task (Task 23-10-06-99C-804-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
3. Procedure (Task 23-10-06-16-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4002
(1) Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
(2) Cleaning Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
(3) Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
(4) Chassis, wired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4004
(5) Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
PAGE TOC-2
23-10-07 Jan/2004
DESCRIPTON PAGE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
1. Task (Task 23-10-07-99C-805-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
3. Procedure (Task 23-10-07-21-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
(1) Structural Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001
(2) Electrical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
1. Task (Task 23-10-06-99C-806-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
2. Equipment and Material (Task 23-10-06-94-805-A01) . . . . . . . . . . . . . . . . . . . 6001
3. Procedure (Task 23-10-06-35-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
(1) General Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
(2) Detailed Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
1. Task (Task 23-10-07-99C-807-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
B. Staking Compounds, Sealants, Thermal Compounds,
and Lubricants to be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
(Subtask 23-10-07-99F-011-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
C. Screw and Nut Torque Values (Subtask 23-10-07-99F-012-A01) . . . . . . . . 7002
A General (Subtask 23-10-07-94-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7003
3. Procedure (Task 23-10-07-43-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7003
(1) PS and Interface Board (22) MDBW10546B . . . . . . . . . . . . . . . . . . . . .7003
(2) CPLR Control Board (23) MDLW11428 . . . . . . . . . . . . . . . . . . . . . . . . .7004
(3) Shield Assembly (29) MPSC30332A . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
(4) Sensor and Relay Drive Board (24) MDCW10907D . . . . . . . . . . . . . . . .7004
(5) Coil Board (27) MDLW11390E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
(6) Shunt Cap Board (25) MDLW11385F . . . . . . . . . . . . . . . . . . . . . . . . . . .7005
(7) Series Cap Board (26) MDLW11386D . . . . . . . . . . . . . . . . . . . . . . . . . .7005
(8) Side Plates (2) MPBC36547A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7005
B. Pressurization (Task 23-10-07-43-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . 7006
1. Pressurization with dry nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7006
2. Pressurization with dry air pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7007
FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
PAGE TOC-3
23-10-07 Jan/2004
DESCRIPTON PAGE
SPECIAL TOOLS, FIXTURES AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 9001

1. Task (Task 23-10-06-99C-808-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
2. Return to Service Testing (Task 23-10-06-94-807-A01) . . . . . . . . . . . . . . . . . . 9001
SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12001
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13001
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14001
STORAGE (INCLUDING TRANSPORTATION) . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
1. Storage (Task 23-10-06-55-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
A. Storage After Assembly (Subtask 23-10-06-55-001-A01) . . . . . . . . . . . . . 15001
REWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001
ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
1. Introduction (Task 23-10-07-99C-809-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
A. General (Subtask 23-10-07-99F-014-A01) . . . . . . . . . . . . . . . . . . . . . . . . 10001
B. Parts Listing (Subtask 23-10-07-99F-015-A01) . . . . . . . . . . . . . . . . . . . . . 10001
(1) FIND NO. Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001
(2) PART NUMBER Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001
(3) DESCRIPTION Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001
(4) QTY Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001
PAGE TOC-4
23-10-07 Jan/2004
LIST OF FIGURES
DESCRIPTION PAGE
Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01) . . . . . . . . . . . . . 1

Figure 2 KAC 1052 Subassembly Locations (Task 23-10-07-99B-802-A01) . . . . . . . 6
Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01) . . . . . . . . . . 9
Figure 4 Simplified Block Diagram (Task 23-10-07-99B-804-A01) . . . . . . . . . . . . . . 13
Figure 5 Matching Network Element Selection (Task 23-10-07-99B-805-A01) . . . . . 14
Figure 6 RF Matching Network (Task 23-10-07-99B-806-A01) . . . . . . . . . . . . . . . . . 15
Figure 7 Impedance Sensors Block Diagram (Task 23-10-07-99B-807-A01) . . . . . . 21
Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01) . . . . . . . . 23
Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01) . . . . . . . . . . . 24
Figure 10 Power Supply and Interface Block Diagram
(Task 23-10-07-99B-810-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 11 PS and Interface Surge Protection Circuits
(Task 23-10-07-99B-811-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01) . . . . . . . . . . . . 1005
Figure 1002 KAC 1052 Bridging Amplifier Test Setup
(Task 23-10-07-99B-813-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008
Figure 7001 Side Plate Installation (Task 23-10-07-99B-814-A01) . . . . . . . . . . . . 7006
Figure 9001 HF ATE System (Task 23-10-06-99B-815-A01) . . . . . . . . . . . . . . . . 9002
Figure 9002 KHF 1050 System Bench-Test Harness
(Task 23-10-06-99B-816-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003
Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) . . . . . . . 1005
Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) . . . . . . . 1007
PAGE LOF-1
23-10-07 Jan/2004
(Blank Page)
PAGE LOF-2
23-10-07 Jan/2004
LIST OF TABLES
DESCRIPTION PAGE
Table INTRO-1. Acronyms (Task 23-10-07-99A-801-A01) . . . . . . . . . . . . . . . . . . . . . . 5

Table 1 Leading Particulars (Task 23-10-07-99A-803-A01) . . . . . . . . . . . . . . . . . . . . 3
Table 2 KAC 1052 Subassemblies (Task 23-10-07-99A-804-A01) . . . . . . . . . . . . . . . 5
Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01) . . . . . . . . . . . . . . . . . . 17
Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01) . . . . . . 29
Table 5 Interface Signal Description J10522 (Task 23-10-07-99A-807-A01) . . . . . . 30
Table 1001 KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01) . . . . . . . . . . 1002
Table 1002 KAC 1052 Pressure Indication (Task 23-10-07-99A-809-A01) . . . . . . 1003
Table 4001 Recommended Cleaning Materials (Task 23-10-07-99A-810-A01) . . 4002
Table 7001 Sealants, Staking Compounds, Thermal Compounds,
and Lubricants (Task 23-10-07--99A-809-A01) . . . . . . . . . . . . . . . . 7002
Table 7002 Typical Screw and Nut Torque Values
(Task 23-10-07-99A-810-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002
Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01) . . . . . . . . . . . . . 10002
PAGE LOT-1
23-10-07 Jan/2004
(Blank Page)
PAGE LOT-2
23-10-07 Jan/2004
N
KRX 1052 Antenna Coupler / Part No. 064-01074-0101
INTRODUCTION
1. How to Use This Manual (Task 23-10-06-99C-801-A01)
A. General Information (Subtask 23-10-06-99F-001-A01)
(1) This publication is written to the Air Transport Association of America (ATA)
Spec 2200 and will be revised as necessary to show current information.
(2) All front matter consists of a title page that displays the equipment name and
part number, and the ATA and document numbers assigned to the manual, a
“RECORD OF REVISIONS” page for recording revision incorporation, a
“RECORD OF TEMPORARY REVISIONS” page for recording temporary
revision (yellow page) insertion prior to formal revision, a “SERVICE BULLETIN
LIST”that includes a brief description of the reason for the bulletin, and the date
that Service Bulletin information was incorporated into the manual, a “TABLE
OF CONTENTS”, a “LIST OF FIGURES” and a “LIST OF TABLES”.
(3) “DESCRIPTION AND OPERATION” section contains an equipment illustration,

table of leading particulars, a general description, and a theory of operation for
the electronic assemblies to assist in understanding the circuitry for fault
isolation purposes.
(4) “TESTING AND FAULT ISOLATION” section contains a functional test to

enable maintenance personnel to assess the operational condition of the
equipment, calibration procedures for electronic or mechanical adjustment as
necessary, troubleshooting guide to assist in fault isolation, and complete
electrical wiring and schematic diagrams.
(5) “SCHEMATICS AND WIRING DIAGRAMS” section contains complete

electrical wiring and schematic diagrams.
(6) “DISASSEMBLY” section contains procedures for disassembling the

equipment to the part replacement level. Complete overhaul procedures are not
provided. Specific procedures are intended to be a supplement to, and are
correlated to, the Illustrated Parts List (IPL).
(7) “CLEANING” section contains general cleaning procedures, which should be

observed during repair and/or part replacement where applicable.
(8) “CHECK” section contains general areas to visually observe during

disassembly and assembly to assure that equipment operational standards are
met.
PAGE INTRO-1
23-10-07 Jan/2004
N
(9) “REPAIR” section contains specific instructions for repairing areas of the
equipment not specifically covered in the “ASSEMBLY” section.
(10)“ASSEMBLY” section contains all specific instructions necessary for part

replacement and to supplement the IPL. Special instructions for use of
adhesives, wires, heat sink compounds, etc., not covered in the IPL, are
included. Special assembly sequence requirements, as applicable, are
provided.
(11)“FITS AND CLEARANCES” section contains a list of dimensional values,

torques, etc., if required during assembly. These parameters are also specified
in the “ASSEMBLY” section where applicable.
(12)“SPECIAL TOOLS, FIXTURES AND EQUIPMENT” section contains a list of all

equipment required to perform procedures specified in the other manual
sections.
(13)“STORAGE (INCLUDING TRANSPORTATION)” section contains storage and

transportation instructions.
(14)“ILLUSTRATED PARTS LIST” section contains illustrations and parts lists for
all equipment assemblies, subassemblies and components. The illustrations
and parts lists are item-number keyed for location of parts, and list quantities,
part numbers, and part descriptions. An introduction to the IPL relates how it is
used, definitions used, equipment designators and alphanumerical indices for
parts.
PAGE INTRO-2
23-10-07 Jan/2004
N
B. Acronyms (Subtask 23-10-06-99F-002-A01)
TERM DEFINITION
ACP Antenna Coupler (or equivalent test panel)

ADLP Airborne Data Link Processor
AGC Automatic Gain Control
ALC Automatic Level Control
AME Amplitude Modulated Equivalent
ASCII American Standard Code for Information Interchange
ATE Automatic Test Equipment
A3A Single sideband reduced carrier voice emission (R3E)
A3H Single sideband full carrier emission (H3E, H3D)
A3J Single sideband suppressed carrier emission (J3E, J3D)
BCD Binary Coded Decimal
BIT Built-In Test
BITE Built-In Test Equipment
BNC RF connector type
BPS Bits Per Second
°C Celcius
CCITT Consultive Committee for International Telegraphy and Telephony (ITU)
CMC Central Maintenance Computer
CMU Communication Management Unit
COM Communication
COMM Communication
CW Continuous Wave (unmodulated)
dB Decibels
dBc Decibels relative to carrier
dBm Decibels relative to 1 mW
DSP Digital Signal Processor
PAGE INTRO-3
23-10-07 Jan/2004
N
TERM DEFINITION
EMI ElectroMagnetic Interference

Fc carrier Frequency
FM Frequency Modulated
GHz Gigahertz (109)
HF High Frequency (2-30 MHz)
HFDL High Frequency Data Link
Hg Mercury (chemical element)
HIRF High Intensity Radiated Field
H3D Single sideband full carrier data emission
H3E Single sideband full carrier voice emission (formerly A3H)
ICAO International Civil Aviation Organization
IF Intermediate Frequency
ITU International Telecommunications Union
IMD Inter Modulation Distortion
j The square root of -1
J3D Single sideband suppressed carrier data emission
J3E Single sideband suppressed carrier data emission (formerly A3J)
°K Kelvin
KBPS KiloBits Per Second
KHz Kilohertz (103)
KPN King Part Number
LSB Least Significant Bit
LSB Lower SideBand emission
MCDU Mode Control Display Unit
MHz Megahertz (106)
mic microphone
PAGE INTRO-4
23-10-07 Jan/2004
N
TERM DEFINITION
MPS Minimum Performance Standard

MSB Most Significant Bit
NLT Not Less Than
NMT Not More Than
PEP Peak Envelope Power
pF Picofarad (10-12)
PC Personal Computer
PTT Push To Talk (or Transmit)
PTT German Post, Telephone and Telegraph Authority
RAM Random Access Memory
RF Radio Frequency
R3E Single sideband reduced carrier voice emission (formerly A3A)
RX/EX Receiver/Exciter
SDI Source/Destination Identifier
SBH Syllabic squelch for a high signal environment
SBL Syllabic squelch for a low signal environment
SELCAL Selective Calling
SINAD Signal including noise and distortion
SQH Signal to noise squelch for a high noise environment
SQL Signal strength squelch for a low noise and high signal environment
SSB Single Sideband
µH Microhenry (10-6)
USB Upper Sideband emission
VRMS Root Means Square Voltage
VSWR Voltage Standing Wave Ratio
W Watt
Table INTRO-1. Acronyms (Task 23-10-07-99A-801-A01)
PAGE INTRO-5
23-10-07 Jan/2004
N
(Blank Page)
PAGE INTRO-6
23-10-07 Jan/2004
N
Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01)

Dwg. No. SDNFC5037L
PAGE 9
23-10-07 Jan/2004
N
(Blank Page)
PAGE 10
23-10-07 Jan/2004
N
DESCRIPTION AND OPERATION
1. Physical Description (Task 23-10-87-801-A01)
A. General (Subtask 23-10-07-87-001-A01)
(1) The KAC 1052 Antenna Coupler automatically tunes the 50 ohm coaxial output
of the 200 Watt PEP Transmitter Power Amplifier to the aircraft antenna
impedance for each of the operating frequencies actually used by the KHF 1050
System (also known as Primus HF 1050). The network configurations for each
tune are stored in non-volatile memory so that once the KAC 1052 is tuned in
to the aircraft antenna and particular operating frequency, it will remember that
tune. In the event that the antenna impedance changes, the KAC 1052 will
retune to the new impedance. An additional use of the coupler is to provide a
good signal from the antenna to the KRX 1053 in the receive mode.
Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01)
PAGE 1
23-10-07 Jan/2004
N
Each tune that is remembered is also utilized on other nearby frequencies. For
example, the tuning values determined at 6550.0 kHz will be utilized from
6547.4 kHz through 6553.8 kHz. If a frequency is selected beyond this range,
the KAC 1052 will find a new tune. In general, the same tune will be used over
a range of 0.1% of the operating frequency. At an operating frequency of 3000.0
kHz, the same tune will be used over a range of approximately 3 kHz. At 22000
kHz, the same tune will be used over a range of approximately 22 kHz.
A variety of tuning networks are available in the KAC 1052, to allow the antenna
coupler to match most commonly used aircraft HF antennas. Sensor circuitry
and a CPU (microprocessor) internal to the KAC 1052 guide the antenna
coupler to selection of a network that provides a complementary match for the
impedance of the antenna. The same CPU circuitry communicates with the
KRX 1053 Receiver/Exciter and the KPA 1052 Power Amplifier. The KAC 1052
also provides a communication path between the KRX 1053 and the KPA 1052.
With some antenna configurations, high RF voltages can be developed at

certain operating frequencies. In order to prevent this high voltage from arcing
over internally at high altitudes, the KAC 1052 is pressurized with nitrogen. In
the event that nitrogen should leak out of the coupler, the KAC 1052 first
generates a low pressure warning message that is sent to the controller. An
additional drop in pressure will result in a low pressure fault condition, which will
force the output power of the KHF 1050 system to be reduced to 50 W until
pressure is restored.
The KAC 1052 antenna coupler has an internal bridging amplifier that is used
in receive mode when the antenna is not tuned. The bridging amplifier is also
used in a dual configuration.
In a KHF 1050 dual-system configuration, both systems share one antenna. If

the two systems are tuned to different frequencies, the strongest reception is
normally realized on the primary system (which is defined as the last system to
have transmitted) because the antenna is tuned to that frequency. The
secondary system (the opposite system from the primary system) will generally
realize somewhat weaker reception. To help minimize the effects of this weaker
reception, the bridging amplifier built into the KAC 1052 is automatically
switched in to help amplify the signal received by the secondary system.
Also in a dual-system configuration, when the primary system is transmitting,

the connections to the antenna in the secondary system are opened up. As a
result, reception on the secondary system is disabled.
PAGE 2
23-10-07 Jan/2004
N
The KHF 1050 does not require any external accessories for dual-system
operation, other than a specifically fabricated coaxial cable to allow
interconnection of the two KAC 1052 Antenna Couplers to the antenna.
Six printed circuit assemblies are used in the KAC 1052. The matching
networks reside on three printed circuit assemblies; the Shunt Cap Board, the
Series Cap Board and the Coil Board. A Sensor and Relay Driver Board
monitors the impedance of the network and provides relay drive current. The
Coupler Control Board contains the CPU that controls the operation of the KAC
1052 and the KPA 1052. Interface circuitry to the KPA 1052 and KRX 1053 is
located on the PS and Interface Board, along with the KAC 1052 power supply.
The mechanical configuration of the KAC 1052 Antenna Coupler is mainly

composed of chassis assembly, two side plates, shield assembly and mounting
brackets.
An HN connector on the back of the unit provides for connection to an antenna,

while connectors for interface with the rest of the KHF 1050 system are on the
front of the unit.
CHARACTERISTIC DESCRIPTION
Overall Dimensions 13.6 L x 4.75 W x 7.24 H in. 434 cu. in.

Weight (approximate) 16.4 lbs.
Temperature Range:
• Operating -55°C to +70°C
• Storage (See “STORAGE (INCLUDING
TRANSPORTATION)”)
Altitude: +55,000 ft.
Power Requirements: +27.5Vdc @ 3A
Connectors: 37 Pin (J10521) and 9 Pin (J10522) D-Subs
Table 1 Leading Particulars (Task 23-10-07-99A-803-A01)

(sheet 1 of 2)
PAGE 3
23-10-07 Jan/2004
N
CHARACTERISTIC DESCRIPTION
TSO: C31d, C32d,

DO-160D Env. cat .
[A2F2X]BAB[RS]EXXXXXA[BZ]A[BZ]A[TT]L[A3E3]XAA
Applicable Document: RTCA DO-160D, DO-163

FCC Part 80, 87 and 90
Power Capability: 200 Watts PEP.

VSWR: Less than 1.5:1 typical, 3:1 maximum
Antenna Tuning Time: 50 msec (nominal) for previously tuned freq.
2 to 10 sec (nominal) if not previously tuned.
Antenna Matching Capability:
• Wire Antenna: Grounded Wire Antenna:
• 10-25 feet grounded (55,000 ft max
ALT)
• 25-30 feet may be grounded or
ungrounded (30,000 ft max ALT if
ungrounded)
NOTE: Altitude limits not applicable if
KAC 1052 is mounted in a
pressurized environment.
Internal protection: High SWR due to change in antenna
impedance will force a retune. An internal
bleeder resister provides a static discharge
path to ground.
Should the coupler not be able to tune the

antenna at a given frequency, a tune fault
will result after the coupler has attempted
different network configurations to tune the
antenna.
Table 1 Leading Particulars (Task 23-10-07-99A-803-A01)

(sheet 2 of 2)
PAGE 4
23-10-07 Jan/2004
N
B. Packaging (Subtask 23-10-07-87-002-A01)
(1) General
Two side panels attach to a welded chassis assembly. Seals between the side
panels and the chassis maintain the internal pressure. Removal of the side
panels allows access to the printed circuit assemblies.
Internal to the KAC 1052 is a shield assembly consisting of a shield cap, shield
plate and two supports. This shield isolates the microprocessor circuitry from
the matching network RF circuitry. The shield assembly is located between the
Coupler Control Assembly and the Sensor and Relay Driver Assembly.
Brackets attached to each end of the KAC 1052 allow for mounting the unit to
a mounting tray in the aircraft.
A 37-pin D-shell connector is located on the front of the unit to allow for
interfacing with the rest of the KHF 1050 system. The front of the KAC 1052
also includes a BNC connector for connection to the KPA 1052, and a 9-pin
D-shell connector that is used for ground maintenance purposes.
Both a fill valve and a pressure relief valve are also located on the front panel.
On the rear of the unit is an HN connector for connection to the antenna, and a
ground post. Additionally, a vent plug is mounted on the rear of the KAC 1052
to enable the purging of air from the unit as it is pressurized.
The KPA 1052 amplifies the KTR 1053 exciter output to 200 Watts PEP or 50
Watts of carrier power in AM. This amplified signal is routed through the KAC
1052, which matches the various impedances of the antenna to the 50 ohm
output of the transmitter. The received signals, from the antenna, pass through
the antenna coupler to the KTR 1053.
Nomenclature Item Number Part No.
Power Supply and Interface Board 22 DEXX-CBL-103

Coupler Controller Board 23 DHXX-CDC-1083B
Sensor and Relay Drive Board 24 DHXX-CCN-338
Shunt Capacitor Board 25 DHXX-CSC-590B
Series Capacitor Board 26 DHXX-CSC-591B
Coil Board 27 DHXX-CSC-592B
Table 2 KAC 1052 Subassemblies (Task 23-10-07-99A-804-A01)
PAGE 5
23-10-07 Jan/2004
N
Figure 2 KAC 1052 Subassembly Locations (Task 23-10-07-99B-802-A01)
PAGE 6
23-10-07 Jan/2004
N
C. Chassis (Subtask 23-10-07-87-003-A01)
(1) The chassis assembly serves as a support for the printed circuit boards. All
connectors used for external interface also mount to the chassis. The Shunt
Cap Board, Series Cap Board and Coil Board mount directly to tabs on the
chassis, whereas the Sensor and Relay Driver Board, Coupler Control Board
and the PS and Interface Board mount to the chassis assembly via standoffs.
The side panels, as well as all connectors and valves that penetrate the chassis
assembly, are sealed to retain the nitrogen pressure inside the unit. A ground
stud is pressed into the chassis assembly to provide a return path for antenna
RF current.
D. Switches and Knobs (Subtask 23-10-07-87-004-A01)
(1) The KAC 1052 does not contain any switches or knobs.
E. Connector (Subtask 23-10-07-87-005-A01)
(1) RF Output Connector
The HN-type RF output connector, for connection to the antenna, is on the rear
surface of the antenna coupler.
(2) P10521
A 37-pin D-shell connector, P10521, is located on the front of the unit to allow
for interfacing with the rest of the KHF 1050 system. DC power, along with serial
and parallel interfaces to the KRX 1053 and KPA 1052, connect to this
connector.
(3) P10522
A 9-pin D-shell connector is located on the front of the unit to allow for
interfacing with shop maintenance computers and test functions.
F. Cooling (Subtask 23-10-07-87-006-A01)
(1) No forced air cooling is required for this Unit.
G. Internal Connections (Subtask 23-10-07-87-007-A01)
(1) See “Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01)”.
PAGE 7
23-10-07 Jan/2004
N
(Blank Page)
PAGE 8
23-10-07 Jan/2004
N
H. Major Subassemblies (Subtask 23-10-07-87-008-A01)
(1) PS and Interface Board Assembly
The PS and Interface card is located at the front panel and composed of a
power supply switching circuit, voltage regulators, voltage-current convertor for
APC, RS422 interface driver and surge protection for interface signals.
The card supplies 28V, 12V and 5V DC power to all circuit cards and has all
interface connectors to communicate with other LRUs.
(2) CPLR Control Board Assembly
The Coupler Control Card is located between the PS and Interface card and the
Shield Assembly and composed of a CPU, CPLD, EEPROM, analog interface,
RS232 interface driver, reference voltage generator, pressure sensor,
temperature sensor and voltage monitor. The card administers all operations to
be needed and monitoring the state of the Unit.
(3) Sensor and Relay Drive Board Assembly
The Sensor and Relay Drive Card is located between the Shield Assembly and
three matching network boards, and composed of an impedance sensor. This
card includes the RF power level detector, 3dB attenuator, relay driver, bridge
amplifier and some of the relays for RF network determination. The card detects
input impedance and provides them to the Coupler Control, converts serial
relay signals to parallel relay signals and amplifies received signals and
provides to the RX/EX.
(4) Shunt Capacitor Board Assembly
The Shunt Capacitor Board card is located between the Series Capacitor
Board and the Coil Board card and composed of shunt capacitors and relays
constituting the RF networks, arrestor and discharging resistor.
(5) Series Capacitor Board Assembly
The Series Capacitor Board card is located at the right side of the unit and
composed of series capacitors and relays constituting the RF networks. The
capacitors are sometimes connected as shunt capacitor arm of the RF
networks.
PAGE 11
23-10-07 Jan/2004
N
(6) Coil Board Assembly
The Coil Board card is located at left side of the unit and composed of inductors
and relays constituting the RF networks. The inductors are connected as shunt
inductor arm or series inductor arm of the RF networks.
2. Functional Description (Task 23-10-07-87-802-A01)
(1) This section gives the functional description and block diagrams for the KAC
1052. Each subsection tells about the function of the shop-replaceable units
and how they interrelate to each other. The functional operations described in
this chapter refer to the KAC 1052 in the test environment, not on the aircraft.
This section provides the information required to effectively perform fault
isolation at the shop-replaceable unit level. The shop technician should be
familiar with the systems that interface with the KAC 1052 as well as the signal
flow from circuit card assembly to circuit card assembly in order to effectively
achieve this level of maintenance.
B. Theory of Operation (Subtask 23-10-07-87-010-A01)
(1) General
The KAC 1052 Antenna Coupler is a component of a KHF 1050 Radio

Communications System.
It receives 200W PEP HF signals from the KPA Power Amplifier (PA) and feeds
the power to an aircraft antenna through its impedance transformation
networks. Received signals from the antenna pass through the KAC 1052 and
KPA 1052 Power Amplifier (PA) to the KRX 1053 Receiver/Exciter (RX/EX).
The Unit is normally installed near an antenna inside the aircraft fuselage.
Placement within close proximity to the antenna is important in the reduction of
feed line loss.
In order to prevent high-voltage arcing at high altitudes, the unit is filled with
nitrogen and keeps its internal pressure consistent.
PAGE 12
23-10-07 Jan/2004
N
Figure 4 Simplified Block Diagram (Task 23-10-07-99B-804-A01)
PAGE 13
23-10-07 Jan/2004
N
(2) RF Networks
The RF matching circuit of the unit is composed of three circuit branches; shunt
capacitor, series capacitor and inductor circuit. Each branch has a dedicated
card; Shunt Capacitor Board, Series Capacitor Board and Coil Board.
Each branch is composed of 12 to 13 elements that are combination of

capacitors or inductors and switching relays. The element values are designed
to provide both sufficient resolution at the upper limit frequency and wide
coverage range at the lower limit frequency. Each capacitor or inductor is
connected and disconnected by relays.
“Figure 5 Matching Network Element Selection (Task 23-10-07-99B-805-A01)”

shows the way in which inductor and capacitor elements are switched in and
out by relays. The values of these elements increase in a binary manner.
For example, if the capacitance value of C101 is 1, the relative capacitance

value of C102, C103 will be 2 and 4. Combined inductance or combined
capacitance of each branch is the sum of all applied elements in that branch.
Figure 5 Matching Network Element Selection (Task 23-10-07-99B-805-A01)
Refer to “Figure 6 RF Matching Network (Task 23-10-07-99B-806-A01)”.
The Shunt Cap Board has 13 shunt capacitor elements that can be connected
in parallel. It also contains three relays that are used to determine the network.
The maximum capacitance is approximately 5600 pF.
PAGE 14
23-10-07 Jan/2004
N
Up to 13 capacitors can be connected in parallel on the Series Cap Board to
provide the series capacitor elements for the tuning network. This board also
has three network determining relays. The maximum capacitance is
approximately 1500 pF.
The Coil Board has 12 inductor elements that can be connected in series. It also
contains three relays that are used to determine the network type. The
maximum inductance is approximately 48 uH.
Figure 6 RF Matching Network (Task 23-10-07-99B-806-A01)
The unit has many circuit configurations that enable wide matching impedance
range. Combinations of network determination relays set the circuit
configuration. Available circuit configurations are listed in “Table 3 Circuit
Configurations (Task 23-10-07-99A-805-A01)”. The unit tries to set the most
efficient circuit among these configurations during tuning sequence.
PAGE 15
23-10-07 Jan/2004
N
(Blank Page)
PAGE 16
23-10-07 Jan/2004
N
No. Circuit Schematic Ls on Lp on LC on LH1 LH2 LHSR Cin on Cs on1 Cs on2 C1p Cp in Cp out Note
1 Cp-Cs O O O O O O
2 Cs-Cp O O O O O O
3 Cp-Ls O X X X O O
4 Ls-Cp O X X X O
5 Cs-Pl O O O O O
6 Cp-Cs-Lp O X X X O O O O
Note: O = relay on X = either relay on or off, depending on inductor value Blank = relay open
Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01)

(sheet 1 of 2)
PAGE 17
23-10-07 Jan/2004
N
(Blank Page)
PAGE 18
23-10-07 Jan/2004
N
No. Circuit Schematic Ls on Lp on LC on LH1 LH2 LHSR Cin on Cs on1 Cs on2 C1p Cp in Cp out Notes
7 Lp-Cs-Cp O O O O O O
8 Clp-Ls-C3p O X X X O O O O
9 Ls-Cp-Cs O O O O O
10 Cp-Ls-Cs O O O O O
11 Ls-Cs-Cp O O O O
12 THRU O O O O O
Note: O = relay on X = either relay on or off, depending on inductor value Blank = relay open
Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01)

(sheet 2 of 2)
PAGE 19
23-10-07 Jan/2004
N
(Blank Page)
PAGE 20
23-10-07 Jan/2004
N
(3) Sensors
The KAC 1052 has the following sensors; impedance sensors, pressure
sensor, temperature sensor and power supply voltage sensor. The impedance
sensors are located on the Sensor & Relay Drive. The other sensors are
located on the Coupler Control Board. The impedance sensors are divided into
magnitude detector, phase detector, angle detector, resistance (R) detector,
conductance (G) detector and VSWR detector.
“Figure 7 Impedance Sensors Block Diagram (Task 23-10-07-99B-807-A01)”

shows the block diagram of the impedance sensors on the Sensor & Relay
Drive Board.
Figure 7 Impedance Sensors Block Diagram (Task 23-10-07-99B-807-A01)
The magnitude (Zin) detector measures the magnitude of line impedance. The
detector compares the magnitude of line voltage with that of current. If
magnitude of line voltage is smaller than line current (impedance is less than
50 Ohms), the signal Zin<Zo will be low.
The phase detector monitors the phase of line impedance. The detector detects
phase difference between line voltage and current. If line voltage lags line
current (impedance is capacitive), the signal PH<0 will be low.
PAGE 21
23-10-07 Jan/2004
N
The angle detector generates DC voltage proportional to the phase difference
between line voltage and line current. The signal has no polarity and it will be
5Vdc at maximum phase difference of 90 degrees.
The resistance detector measures the magnitude of real part line impedance.
The detector compares the sum of the line voltage and current with the
magnitude of the line voltage. If the real part of line impedance is smaller than
50 Ohms, the signal Rin<Zo will be low.
The conductance detector determines the magnitude of real part line

admittance (conductance). The detector compares the sum of the line voltage
and current with the magnitude of the line current. If the line conductance is
smaller than 1/50 Siemens, the signal Gin>Go will be high.
The VSWR detector detects forward voltage (Vf) and reflected voltage (Vr) of
line. Each voltage is compared to each other to generate VSWR signals on the
CPLR Control card. The signal Vf is also used to generate PWR ON and PWR
Hi signals. The PWR ON signal informs the CPU that RF power level is valid
and enables tuning operation. The PWR Hi signal informs the CPU that RF
power level is too high to tune and enables detune detection.
The pressure sensor detects internal absolute pressure of the unit. The device
U42 outputs differential DC voltage Vo+ and Vo- proportional to the pressure
followed by the high input impedance differential amplifier composed of U43
and U44A. The gain of the differential amplifier is designed such that the output
voltage will be approximately 4Vdc with 30-psi pressures. This voltage is
provided to CPU and converted digital value to detect pressure-warning level.
The comparator U44B detects the low-pressure alarm and informs CPU via
CPLD as PRESS ALM. The alarm level is set to approximately 11.9 psia.
The temperature sensor detects internal temperature of the unit. The device
R428 varies its resistance in response to temperature and shunt resistors R426
and R427 linearize the resistance. The output voltage of the amplifier U45A is
approximately proportional to absolute temperature and will be approximately
2Vdc at 400 degrees K. This voltage is provided to the CPU and converted to
a digital value to compensate the pressure value at room temperature.
The power supply voltage monitor observes the combined voltage of 12Vdc
and 5Vdc used in the unit. The combined voltage is provided to the CPU and
converted digital value. If the 12Vdc and /or 5Vdc have failed, the CPU detects
power supply alarm.
PAGE 22
23-10-07 Jan/2004
N
(4) Bridging Amplifier
The Bridging Amplifier is mounted on the Sensor Relay Drive Board. This
amplifier is activated under three conditions:
• In the event the KAC 1052 has not been tuned up on the receive frequency
• During dual-system operation (in the secondary system)
• When the KHF 1050 system is first turned on, before any transmission is
made
When activated, the amplifier amplifies the received signal from the antenna
and provides the signal to the KRX 1053 Receiver/Exciter via the KPA 1052
Power Amplifier.
“Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01)”

shows a block diagram of the Bridging Amplifier. The amplifier is composed of
single NPN transistor and transformer used for feedback circuit. The
impedance matching transformer is inserted at its input circuit to convert the
impedance from 50 Ohm to about 400 Ohm. The approximate gain of the
amplifier is 9 to 12 dB at the frequency range from 2 to 30MHz.
The internal oscillator and output level detector are incorporated to detect the
failure of the amplifier. The frequency of the oscillator is approximately 4MHz.
To protect the amplifier, the input circuit is connected to ground and the output
is connected to an internal 50 Ohm resistor during transmission on the KHF
1050 system.
Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01)
PAGE 23
23-10-07 Jan/2004
N
(5) CPLR Control
The CPLR CONTROL is composed of CPU, CPLD, EEPROM, analog

interface, RS232C interface driver, reference voltage generator, pressure
sensor, temperature sensor and voltage sensor. The card administers all
operations and monitoring of the state of the unit.
“Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01)” shows

the block diagram of the card.
Functions of this card are as follows:
• Serial communication with RX/EX

• Observation of the discrete signals from RX/EX
• Setting of operation mode of PA according to frequency and emission mode
• Observation of the PA alarm
• ON-OFF control of relays for the RF matching network
• Observation of impedance signals fed from SENSOR & RLY DRV card
• Measurement and observation of pressure, temperature and power supply
voltage
• Storing, restoring and initializing the tuning parameters in the EEPROM
• Serial communication with external PC via RS-232C port
• Execution Built-In-Test (BIT), reporting and recording of the results of BIT
Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01)
PAGE 24
23-10-07 Jan/2004
N
CPU U1 performs a main role in the unit. It is the highly efficient single chip
microcomputer, which makes the 32-bit H8/300H a core and integrates the
peripheral functions needed for system configuration. The H8/300H operates
in a 32-bit configuration and is capable of 16Mbytes linear address area.
The integrated peripheral functions in the device is composed of 128kbytes

ROM, 4kbytes RAM, 16-bit and 8-bit timers, programmable pattern controller
(TPC), watch dog timer (WDT), 3-channel serial communication interfaces
(SCI), 10-bit A/D converter, D/A converter, I/O ports, DMA controller etc. The
CPU has the flexibility to change its configuration and operation mode. The
CPU has seven operation modes that change address and data bus widths.
The ROM on this card has 128kbyte flash ROM that enables it to be
reprogrammed. The operating frequency is approximately 20MHz. External
address and data buses are not used.
CPLD U2 is a programmable logic device that enables users to rewrite the

hardware configuration. In this card the CPLD is applied to interface between
the CPU and other card or other LRUs.
EEPROM U5 is the non-volatile memory and has the capacity of 32kbytes. The
device is directly connected with the CPU. The device stores tuning
parameters, strap information, some of the latest tuning failure results and BIT
results. The recorded data can be read by maintenance software via RS-232C
port J10522. Some failures are reported to the RX/EX.
All analog signals are fed to the CPU and converted from analog voltages to
digital data by and internal 10-bit A/D converter. The converter has 8-port
channels selected by time division. The following signals are input to the
converter via analog switched U29 to U31:
• Forward power voltage fed from SENSOR & RLY DRV: Vf

• Reflected power voltage fed from SENSOR & RLY DRV: Vr
• Magnitude of RF input voltage (only during tuning operation): Vin
• Magnitude of RF input current (only during tuning operation): Iin
• Absolute Kelvin temperature: Temp
• Magnitude of phase difference between RF voltage and current (only during
tuning operation): Angle
• Absolute internal air pressure: Press
• Combined voltage of 12V and 5V regulated power supply: Vcc
• Output level of bridge amplifier: V-BRDG
• RF peak voltage of internal 50 Ohm resistor on the SENSOR & RLY DRV:
Vdum
PAGE 25
23-10-07 Jan/2004
N
These signals are used to determine the tuning algorithm and failures detection
of pressure, power supply voltage, bridge amplifier and sensor.
RS-232C interface driver IC U6 converts bi-directionally between differential

signals and TTL level signals. The TTL signals are provided to the CPU via the
CPLD.
Reference voltage generator U4 generates a stable 5Vdc required by the CPU

for A/D converting.
Pressure sensors, temperature sensors and the voltage monitor are described
in Paragraph 2.B.“(3) Sensors”.
Connector J16 is a port for programming the CPLD with dedicated cables and
parallel port of a PC.
Connector J17 is a port for programming the CPU with dedicated cables and
writer and serial port of a PC.
Connector J18 is a port for debugging software operation of the CPU and direct
monitoring the state of relays at the factory.
(6)Power Supply and Interface
The PS & Interface card is composed of power supply switching circuit, voltage
regulators, voltage-current converter for APC, RS422 interface driver and surge
protection for interface signals. The card supplies 28V, 12V and 5V DC power
to all cards and has all interface connectors to communicate with other LRUs.
The power supply switching circuit is comprised of a controller IC U51, a
switching N-channel FET Q2, a resistor for detecting excessive current, an
overvoltage detector, an undervoltage detector and PWR CONT controller.
If the PWR CONT pin is grounded, the FET Q1 will turn off. And if the voltage
of U51-1 is over about 1.25Vdc, the FET Q2 will turn on. As a result, 28Vdc
power will be supplied to relays and regulator ICs U52 and U53 that are used
by CPLR CONTROL card and SENSOR & RLY DRV card. The power-on
voltage is determined by a voltage divider comprised of R43 and R44.
PAGE 26
23-10-07 Jan/2004
N
Figure 10 Power Supply and Interface Block Diagram (Task 23-10-07-99B-810-A01)
If the voltage at U51-5 is above approximately 1.25Vdc, the FET Q2 will turn off
to protect internal circuit devices from damage due to excessive voltage. The
threshold voltage is set to 36 to 38Vdc by series connected Zener diodes CR83
and CR84. This pin is also used for determining the time interval caused by an
over-current trip. The time interval is determined to approximately 180 mSec by
timing capacitors C48 and C49.
Resistor R45 detects excessive load current. If the current is over 4.5 to 5.1
ADC, U51 shuts off FET Q51. Then U51 will try to turn Q2 on at approximately
180 mSec intervals until the cause of current trip is removed. Two voltage
regulator ICs U52 and U53 generate regulated 12 Vdc and 5 Vdc each. Output
voltage of 12 Vdc is determined by a voltage divider comprised of R51, R52 and
R53.
PAGE 27
23-10-07 Jan/2004
N
The output voltage is controlled by the voltage across U52-2 and U52-3 which
is approximately 1.2 Vdc. As a result, the output voltage is approximately 12
Vdc.
The voltage-current converter for the automatic power control (APC) is

comprised of a rail-to-rail operational amplifier, IC U63, and an NPN transistor,
Q3. The circuit converts the forward power voltage Vf fed from SENSOR & RLY
DRV to direct current for the APC feedback system during tuning operation of
the unit. The output current is proportional to 2-Vf. For example, If Vf is 0V, the
output current is approximately 20 mA. If Vf is approximately 2 Vdc, the current
is nearly 0 mA. In the event the APC line between the KAC 1052 and the KPA
0152 is broken, the power amplifier will default to minimum output power. This
system will protect both the PA and the antenna coupler from excessive RF
output power during tuning operation.
RS-422 interface driver IC U61 converts between differential signals and TTL
level signals in a bi-directional manner. The TTL signals are provided to CPU
on the CPLR CONTROL card.
Opto-coupler interfaces are adopted for all discrete input signals (excluding
RS-422 receiving signal and PWR CONT signal) to isolate internal circuits from
aircraft noise.
All discrete output signals from the CPLR CONTROL card are fed to the KRX
1053 and KPA 1052 via this card.
All discrete input and output pins are protected against induced surge voltage
by inserting series resistors and shunt surge absorbers (Silicon Transient
Voltage Suppressor: TVS) excluding primary power input. “Figure 11 PS and
Interface Surge Protection Circuits (Task 23-10-07-99B-811-A01)” shows three
kinds of surge protection circuits adopted on this card.
Figure 11 PS and Interface Surge Protection Circuits (Task 23-10-07-99B-811-A01)

PAGE 28
23-10-07 Jan/2004
N
This card has two interface connectors that are directly mounted for interfacing
with external devices. Sub-D connector J10521 is used for communication with
the RX/EX and PA, and J10522 is used for connecting to the serial port of an
external PC.
(7) Interface Signal Descriptions
The discrete interface signals of CONTROL connector J10521 are described in

“Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01)”,
and those of TEST connector J10522 are described in “Table 5 Interface Signal
Description J10522 (Task 23-10-07-99A-807-A01)”.
Pin Signal Name Source/Dest I/O Description Properties
20 PRI PWR External Input +27.5 Vdc Primary Power Power In
1 PRI PWR RTN External N/A Primary Power Return GND
21 PWR CNT External Input Power ON/OFF Control Low in active
2 PWR CNT RTN External N/A Power ON/OFF Control Return GND
11 RC COM RX/EX Input RX/EX Input Common +15V
27 MATCH ON RX/EX Input Matching Circuit ON Low in active
28 BRDG ON RX/EX Input Bridge Amplifier ON High in active
30 BFRD KEY RX/EX Input Buffered Key ON Low in active
33 PA BFRD KEY PA Output Buffered Key ON Low in active
36 PC COM PA Input PA Input Common +15V
34 PA ALM #1 PA Input PA Alarm Signal #1 High in active
35 PA ALM #2 PA Input PA Alarm Signal #2 High in active
3 STRAP A External Input Antenna Type Strap A Low in active
22 STRAP B External Input Antenna Type Strap B Low in active
4 STRAP COM External Input Strap Common GND
23 SPARE N/A I/O Spare Interface Port Low in active
29 CR COM RX/EX Output RX/EX Output Common +12V
10 TUNE FAIL RX/EX Output Tune Fail Signal High in active
12 TUNE REQ RX/EX Output Tune Request Signal High in active
9 EXTR INHB RX/EX Output RX/EX TX Inhibit High in active
Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01)

(sheet 1 of 2)
PAGE 29
23-10-07 Jan/2004
N
32 CP COM PA Output PA Output Common +12V
15 PA INHB PA Output PA TX Inhibit High in active
16 PA SI PA Output PA Mode Serial Data High in active
17 PA SCK PA Output PA Mode Serial Clock High in active
18 PA RCK PA Output PA Mode Serial Strobe High in active
19 PA ALM RST PA Output PA Mode Rest Low in active
6 RCA RX/EX Input Serial Receive Data + RS-422 +
24 RCB RX/EX Input Serial Receive Data - RS-422 -
7 CRA RX/EX Output Serial Send Data + RS-422 +
25 CRB RX/EX Output Serial Send Data - RS-422 -
8 BUS COM RX/EX N/A RS-422 BUS Common GND
14 APC H PA Output APC Feedback + Current loop
37 APC L PA Output APC Feedback - Current loop return
26 EXTR COM RX/EX N/A Exciter Common GND
5 FG N/A N/A Frame Ground GND

(sheet 2 of 2)
3 TEST TXD External PC Output Serial Send Data + RS-232C
2 TEST RXD External PC Input Serial Receive Data RS-232C
5 TEST COM External PC N/A Test Common GND
9 LEAK WRN INH External Input Air Leak Warning Inhibition Low in active
7 PRESS External Output Absolute Pressure Level Analog Voltage
4 GND N/A N/A Ground GND
PAGE 30
23-10-07 Jan/2004
N
TESTING AND FAULT ISOLATION
1. How to Use (Task 23-10-07-99C-802-A01)
A. General (Subtask 23-10-07-99F-005-A01)
(1) This section describes procedures for testing and fault isolation of the KAC
1052 Coupler.
(2) Equivalent materials and equipment to the items listed in the Return to Service
testing options are permitted. It is the responsibility of the user to find equivalent
part numbers.
(3) The KAC 1052 can be tested as part of a KHF 1050 system using a bench-test
harness or as a stand-alone unit with a properly configured HF Automated Test
Equipment (ATE) System. Paragraph 3.B.“B. Bench-Test Harness Return to
Service Test Solution (Subtask 23-10-07-75-001-A01)” for the bench-test
harness procedure and to Paragraph 4.“C. HF ATE System Test Solution
(Subtask 23-10-07-75-006-A01)” for the ATE system procedure.
2. Test Philosophy (Task 23-10-07-75-801-A01)
A. Airplane Fault Isolation (Subtask 23-10-07-94-001-A01)
(1) The test philosophy for the KAC 1052 is to test and fault isolate to the defective
circuit card assembly or other authorized subassembly in accordance with this
manual. The line mechanic should remove the KAC 1052 only when the unit is
not operating properly.
3. Procedure (Task 23-10-06-75-802-A01)
A. Shop Fault Isolation (Subtask 23-10-07-81-001-A01)
The KAC 1052 contains six printed circuit boards. The information in “Table 1001
KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01)” and “Table 1002 KAC
1052 Pressure Indication (Task 23-10-07-99A-809-A01)” can be used to assist in
troubleshooting the antenna coupler to the card level. Due to the complexity of the
KAC 1052, it may be necessary to return the unit to the factory for troubleshooting
on computer-based equipment.
PAGE 1001
23-10-07 Jan/2004
N
Symptom Primary Cause/Action Alternate Cause/Action
Unit totally inoperative Check to see if PWR Defective PS Interface

CONT line is less than 1 Board or CPU Board
Vdc
Pressure Fail or Pressure Low pressure in the KAC CPU Board is defective.
Warning annunciation on 1052. See Note 2 in “Table
the controller 1002 KAC 1052 Pressure
Indication (Task
23-10-07-99A-809-A01)”).
CPLR Fail annunciation on PS Interface Board is CPU Board is defective.
the controller defective or PWR CONT
line is not low.
Coupler fails to find a tune Sensor Board is defective Defective Coil, Shunt Cap
on any frequency or antenna connection is or Series Cap Board.
bad.
Coupler fails to find a tune Defective Coil, Shunt Cap Sensor Board is defective.
on a narrow band of or Series Cap Board.
frequencies
Coupler finds a tune, but Defective Coil, Shunt Cap A loose connection exists
then retunes when making or Series Cap Board. or arching is occurring at
a transmission. the HN connector, feedline
or antenna simulator.
Less than 6 dB of drop Sensor Board is defective. KAC 1052 has previously
when bridging amplifier is been tuned to this
disengaged frequency or a nearby
frequency.
Table 1001 KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01)
PAGE 1002
23-10-07 Jan/2004
N
Pressure Indication Meaning Corrective Action
No warning or failure Normal condition. Pressure is Check pressure on an annual

indication greater than 8 pounds per basis (See Note 1).
square inch (psi).
Pressure Warning The pressure has been Service the KAC 1052 in the
reduced below 8 psi. No near future to check for leaks
performance degradation will and repressurize the unit.
be observed. Continued
operation may result in a
pressure failure.
Pressure Fail The pressure has been Service the KAC 1052
reduced to a level at which immediately. Performance is
arching could occur inside the reduced in this failure mode.
antenna coupler at a 200 W
power level. The system will
automatically reduce the
power to 50 W, regardless of
the power level setting
selected by the pilot.
Note 1: When measured at room temperature, the pressure should be between 8 and
10 psi (66-69 kPa gauge). If below 8 psi, add Nitrogen to bring the pressure up to 8 to
10 psi.
Note 2: With the KAC 1052 vented to the atmosphere at standard sea-level pressure,
a Pressure Warning will be realized. A Pressure Fail will occur only at pressures below
standard sea-level pressure.
Table 1002 KAC 1052 Pressure Indication (Task 23-10-07-99A-809-A01)
PAGE 1003
23-10-07 Jan/2004
N
B. Bench-Test Harness Return to Service Test Solution (Subtask
23-10-07-75-001-A01)
(1) Equipment Required
The following equipment is required for manually bench testing the KAC 1052:
• 28 Vdc power supply capable of 30 A

• Multimeter
• 50 Ohm load (30 dB attenuator) with a 100 W minimum power rating
• Low-power 30 dB attenuator (1.2 W minimum)
• Antenna simulator - or 4 each 50 Ohm, 25 W loads. (See Paragraph 3.B.“(2)
Preliminary Setup” for load configuration).
• SWR/Wattmeter capable of average reading and peak reading functions,
2-30 MHz.
• KHF 1050 System bench-test harness. “Figure 9002 KHF 1050 System
Bench-Test Harness (Task 23-10-06-99B-816-A01)”.
• Functional KPA 1052, KRX 1053 and controller
(2) Preliminary Setup
Connect the KAC 1052 to a functioning KPA 1052, KRX 1053 and an ARINC
429 controller such as the PS440. “Figure 1001 KAC 1052 Test Setup (Task
23-10-07-99B-812-A01)” for a suitable bench-test setup. If an antenna
simulator representative of the antenna type used on the aircraft is available,
connect the simulator to J10528. As an alternative, the following can be used.
• Honeywell KTS 157 Antenna Simulator

• 4 each 50 Ohm, 25 W loads; connected in parallel with short interconnects;
then connected to the KAC 1052 with approximately 10 feet (3 m) of 50 Ohm
coax (RG 214, or equivalent).
Set the power supply to between 27.5 and 28.0 Vdc
(3) Antenna Coupler Tuning Tests
(a) Perform Preliminary Setup per Paragraph 3.B.“(2) Preliminary Setup” in this
section. Ensure that J10528 is terminated into an appropriate antenna
simulator.
(b) Turn the KHF 1050 system on and set the frequency to 2.1 MHz, AM mode.
If a KTS 157 Antenna Simulator is being used, set the switch to position 1.
PAGE 1004
23-10-07 Jan/2004
N
Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01)
(c) Momentarily key the transmitter with the PTT switch. The antenna coupler
will begin the tuning sequence. During the tuning sequence, relay switching
sounds will be heard inside the KAC 1052. The controller will also indicate
that the antenna coupler is in the tuning process.
Note: If the antenna coupler has already been tuned up into this load at
this operating frequency (or into a load of similar impedance), the
antenna coupler will not retune. If this is the case, skip to step (f).
(d) Observe the power on the Wattmeter in the AVERAGE reading mode. This
will typically be 10 to 20 W, with up to 50 W possible.
PAGE 1005
23-10-07 Jan/2004
N
(e) As the antenna coupler is tuning, observe that the SWR reading is 2:1 or
less. It is normal for the SWR to vary as the antenna coupler tunes the load.
(f) After the tuning sequence has completed, key the microphone with no
modulation and observe the SWR. The SWR should be less than or equal
to 2.5:1. (On most frequencies, the SWR will be 1.5:1 or less.)
Measured SWR at 2.1 MHz: __________
Note: If using a KTS 157 antenna simulator, limit the transmissions to a

25% duty cycle to prevent overheating the antenna simulator. Limit
maximum transmission time to 20 seconds.
Note: The length of time it takes to tune the antenna will vary with
operating frequency and antenna impedance. Tuning times of 1 to
30 seconds may be observed.
Note: Differences in SWR meter and wattmeter calibration may result in

SWR and power readings somewhat different from those specified.
(g) Briefly speak into the microphone, and ensure that the SWR remains
constant.
(h) When not speaking, observe that unmodulated AM power is typically 50 W.
Measured power at 2.1 MHz: __________.
(i) Change the operating frequency to 10.1000 MHz. Repeat steps (c) through
(h). (If using a KTS 157 Antenna Simulator, set the switch to position 3.)
(j) Change the operating frequency to 29.9 MHz. Repeat steps (c) through (h).
(If using a KTS 157 Antenna Simulator, set the switch to position 8.)
(k) Change the operating frequency to any other desired test frequency.
Repeat steps (c) through (h).
(l) Return to an operating frequency of 2.1 MHz. (If using a KTS 157 Antenna
Simulator, set the switch to position 1.)
(m)Key the microphone. The KAC 1052 should not retune this time. The SWR
and power should be the same as, or similar to, that noted in steps (f) and
(h) at 2.1 MHz.
PAGE 1006
23-10-07 Jan/2004
N
(4) High-SWR Retune Test
(a) Perform the Preliminary Setup in Paragraph 3.B.“(2) Preliminary Setup” and
Antenna Coupler Tuning Tests in Paragraph 3.B.“(3) Antenna Coupler
Tuning Tests” in this section.
(b) Remove the KAC 1052 RF output, J10528, from the antenna simulator and
connect J10528 to the 50 Ohm dummy load.
(c) Set the frequency to 2.1 MHz, AM mode.
(d) Momentarily key the transmitter with the PTT switch. The antenna coupler
should sense that the load has changed and again begin its tuning
sequence. During the tuning sequence, relay switching sounds will be heard
inside the KAC 1052. The controller will also indicate that the antenna
coupler is in the tuning process.
NOTE: With some particular load impedance and frequency combinations,

it is possible that the SWR will not exceed approximately 3:1 when
changing from the antenna simulator to the 50 Ω load. Under such
conditions, a retune will not occur.
(e) After the tuning sequence has completed, key the microphone with no
modulation and observe that the SWR is less than or equal to 2.5:1.
(5) Bridging Amplifier
(a) Connect the equipment as shown in the Bridging Amplifier Test Setup,
“Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01)”. Ensure
that there is 60 dB of attenuation between KAC 1052 J10528 and the RF
signal generator output.
(b) Turn the KHF 1050 system on and set the frequency to one that the KAC
1052 has not been previously tuned up on, such as 10.200 MHz, USB voice
mode. (This activates the bridging amplifier in the KAC 1052).
(c) Tune the RF signal generator to 10.201 MHz with no modulation. Set the
level to –60 dBm
(d) Monitor the Receiver/Sidetone audio level on a distortion analyzer or an

oscilloscope with the volume control set to mid range.
Measured Level: __________________ VAC.
PAGE 1007
23-10-07 Jan/2004
N
Figure 1002 KAC 1052 Bridging Amplifier Test Setup (Task 23-10-07-99B-813-A01)
(e) Momentarily key the PTT switch to tune the KAC 1052 into the attenuator.
This deactivates the bridging amplifier.
(f) When the KAC 1052 has completed the tuning, note the Receiver/Sidetone
audio level.
Measured Level: __________________ VAC.
PAGE 1008
23-10-07 Jan/2004
N
(g) The level in step (f) should be at least 6 dB lower (one-half the voltage or
less) than that noted in step (d).
Note: If the Bridging Amplifier Test is repeated, it is important to select a

frequency that has not previously been tuned by the KAC 1052 in
order to activate the bridging amplifier. Change the frequency at
least 100 kHz from any previously tuned frequency.
C. KPA 1052 Adjustments
The KAC 1052 does not contain any field adjustments. All adjustments are to be
made in the factory.
4. Automatic Test Requirements (Task 23-10-07-75-803-A01)
(1) This section contains information pertaining to the automated test solution for
the KAC 1052 Coupler.
B. Equipment and Materials (Subtask 23-10-07-75-005-A01)
(1) Equipment and materials required to functionally test the KAC 1052 on the HF
ATE System are contained in the following:
• HF ATE System, Part No. 071-05558-0001

• KAC 1052 Test Sequence Software, Part No. 731-00804-XXXX
C. HF ATE System Test Solution (Subtask 23-10-07-75-006-A01)
(1) HF ATE System Test Procedures
(a) Attach the HF ATE System test cable connector marked J10521 to the INT
connector (J10521) of the KAC 1052 to be tested.
(b) Connect the HF ATE System test cable connector marked J10522 to the
Control Connector (J10522) of the KAC 1052 to be tested.
(c) Connect the HN output of the KAC 1052 to the HF ATE Antenna Simulator.
(d) Apply power to the HF ATE System.
(e) Execute the KAC 1052 Test Sequence Software.
PAGE 1009
23-10-07 Jan/2004
N
(f Following on screen instructions, enter operator name and password and
UUT serial number.
(g) After the test sequence screen opens, select the option TEST UUT.
(h) Return to service testing will automatically execute.
PAGE 1010
23-10-07 Jan/2004
N
SCHEMATICS AND WIRING DIAGRAMS
This pageblock is not applicable to this CMM.
PAGE 2001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 2002
23-10-07 Jan/2004
N
DISASSEMBLY
1. Task (Task 23-10-07-99C-803-A01)
A. General (subtask 23-10-07-99F-006-A01)
(1) Use these procedures to remove parts from the KAC 1052 to do the cleaning,
checks, repair, and replacement of parts as necessary. References to the
“ILLUSTRATED PARTS LIST” (IPL) show you where to find the parts to
remove. The applicable figure number in the IPL is given in each primary
paragraph and does not change until specified differently.
(2) Before disassembly, use “TESTING AND FAULT ISOLATION” to examine the
condition of the KAC 1052 or to find the most probable cause of malfunctions.
Do this to prevent disassembly that is not necessary. Do only those procedures
of disassembly that are necessary to remove defective parts and to correct
malfunctions.
(3) As an aid for assembly, tag the items that are disconnected to show where the
connections were made. Include data on any special conditions of a connection
such as the polarity and the position of the items.
2. Equipment and Materials (Task 23-10-07-94-802-A01)
(1) Common shop tools and best-established shop practices are used to
disassemble the KAC 1052. Refer to “Figure 10001 KAC 1052 Final Assembly
(Task 23-10-07-99B-816-A01)” to aid in disassembly.
3. Procedure (Task 23-10-07-03-801-A01)
CAUTION: THE KAC 1052 HAS COMPONENTS THAT ELECTROSTATIC

DISCHARGE MAY DAMAGE. REFER TO THE INSTRUCTIONS IN
THE REPAIR CHAPTER WHEN YOU MOVE OR DISASSEMBLE
THE KAC 1052.
CAUTION: THE KAC 1052 IS A PRESSURIZED UNIT. BEFORE DISASSEMBLY

RELIEVE THE PRESSURE BY DEPRESSING THE SCHRADER
VALVE (12). FINISH RELIEVING THE PRESSURE BY REMOVING
VENT PLUG (13).
PAGE 3001
23-10-07 Jan/2004
N
Arrange all subassemblies and the associated hardware in specific areas to aid in
reassembly.
(1) Side Plates (2) MPBC36547A
Remove both side plates by removing 76 NA3x16Sus Screws (50). Carefully

pop the side plates up and away from the chassis (1) to prevent rupturing the
O-ring seals. (36)
(2) Series Cap Board (26) MDLW11386D
Remove the series cap board (CSC-591B) by removing the 8 NC3x10BS

screws (57) securing the series cap board to the chassis (1). Slide the series
cap board to the rear disconnecting it from the sensor and relay drive board
(24). Remove the series cap board from the chassis (1).
(3) Shunt Cap Board (25) MDLW11385F
Remove the Shunt Cap Board (CSC-590B) by removing NC3x10BS screws

(57) securing the Shunt Cap B board to the chassis (1). Remove the short
standoff (near the unit HN connector) from the Shunt Cap Board. Remove the
long standoff (near the long resistor on the rear of the board), which goes
through the Shunt Cap Board, from the Coil Board. If provided, remove the long
standoff near the lower front of the board, which goes through the Shunt Cap
Board, from the Coil Board. (Early production units will not have this standoff.)
Remove the W2 antenna wire (58) NC3x6Bs from the Shunt Board, freeing the
board from the antenna wire. Slide the Shunt Cap Board to the rear,
disconnecting it from the Sensor and Relay Drive Board (24) and lift it up and
out of the chassis (1).
(4) Coil Board (27) MDLW11390E
Remove the coil board (CSC-592B) from the left side of the unit by removing 9
NC3x10BS screws (57) securing the board to the chassis. If the Series Cap
Board and Shunt Cap Board have not been removed, remove three additional
NC3x10BS screws attaching the Coil Board to the standoffs. (Early production
units have only two standoff screws.) Slide the coil board to the rear,
disconnecting it from the Sensor and Relay Drive board (24), and lift it up and
out of the chassis (1).
PAGE 3002
23-10-07 Jan/2004
N
(5) Sensor and Relay Drive Board (24) MDCW10907D
Remove the sensor and relay drive board (CNN-338) by removing the 4
NC3x6BS screws (58) securing the board to the standoffs (34) of the coupler
control board (23). Remove the sensor relay board board by separating the
bayonet pins from the CPLR control board connector. Remove the sensor and
relay drive board from the chassis (1).
(6) Shields (29) MPSC30332A
Remove the 4 standoffs (34) securing the Shields to the CPLR control board
(23). Dislodge the RF Collar from the BNC housing which will allow the shields
to be removed as an assembly.
(7) CPLR Control Board (23) MDLW11428
Remove the CPLR control board (CDC-1083B) by removing the 4 Shield

standoffs (33). Remove the CPLR control board by separating the bayonet pins
from the power supply and interface connector. Remove the CPLR control
board from the chassis.
(8) Power Supply and Interface Board (22) MDBW10546B
Remove the PS and Interface board (CBL-103) by removing the 4 standoffs

(32) securing the PS and Interface board to the front of the chassis (1) and 1
NC3x6Bs screw (58) from TP4 . Remove 8 S3x8 Sus screws (55) from J10521
and J10522 securing the connectors to the front of the chassis (1). Remove the
PS and Interface board from the chassis (1) ensuring that the gaskets (15) &
(16) do not tear as they will need to hold pressure upon reassembly.
PAGE 3003
23-10-07 Jan/2004
N
(Blank Page)
PAGE 3004
23-10-07 Jan/2004
N
KAC 1052 Coupler / Part No. 064-01074-0101
CLEANING
1. Task (Task 23-10-06-99C-804-A01)
(1) This section contains information pertaining to the cleaning of subassemblies

in the KAC 1052.
WARNING: GOGGLES MUST BE WORN WHEN USING PRESSURIZED

AIR TO BLOW DUST AND DIRT FROM EQUIPMENT. ALL
PERSONNEL SHOULD BE CLEARED FROM THE IMMEDIATE
AREA.
WARNING: OPERATIONS INVOLVING THE USE OF A CLEANING

SOLVENT SHOULD BE PERFORMED UNDER A VENTILATED
HOOD. AVOID BREATHING SOLVENT VAPOR AND FUMES.
AVOID CONTINUOUS CONTACT WITH THE SOLVENT.
(1) “Table 4001 Recommended Cleaning Materials (Task 23-10-07-99A-810-A01)”

lists the recommended cleaning agents to be used during overhaul of the KAC
1052.
NOTE: Equivalent substitutes may be used as cleaning agents.
(2) In this section, “air jet” refers to a hand-operated air nozzle supplied with clean,
dry, compressed air at a maximum of 28 pounds of force per square inch (psi).
PAGE 4001
23-10-07 Jan/2004
Use or disclosure of information on this page is subject to the restrictions in the proprietary noticeof this document.
N
Type Used to Clean / Description
Denatured Alcohol Exterior Surfaces

Isopropyl Alcohol Interior Surfaces
Lintless Tissue Kimberly-Clark Kimwipes ( or equivalent)
Cloth, Lint-Free Cotton Various
Brush, Flat Various, fiber bristles
Brush, Round Various, fiber bristles
Table 4001 Recommended Cleaning Materials (Task 23-10-07-99A-810-A01)
3. Procedure (Task 23-10-06-16-801-A01)
WARNING: THE KAC 1052 HAS COMPONENTS THAT ELECTROSTATIC

THE KAC 1052.
(1) Exterior Surfaces
(a) Wipe exterior of the KAC 1052 with a lint-free cloth dampened with
denatured alcohol.
(b) If necessary, open any blocked ventilation holes by first saturating the
debris clogging the apertures with denatured alcohol and then blowing the
loosened material out with an air jet.
(c) Clean connectors as outlined in Paragraph 3.A.“(2) Cleaning Connectors”.
(2) Cleaning Connectors
CAUTION: DO NOT PERMIT SOLVENT TO RUN INTO SLEEVES OR

CONDUIT THAT COVERS WIRES CONNECTED TO INSERT
TERMINALS.
(a) Wipe dust and dirt from bodies
PAGE 4002
23-10-07 Jan/2004
N
(b) Wipe parts dry with a clean, dry, lint-free cloth.
(c) Remove dirt and lubricant from the connector inserts, insulation and
terminals, using a small soft-bristled brush moistened with solvent.
(d) Dry the inserts with an air jet.
(3) Modules
CAUTION: HONEYWELL RECOMMENDS ISOPROPYL ALCOHOL AS A

SAFE CLEANING SOLVENT FOR PRINTED CIRCUIT BOARDS
CONTAINING ALUMINUM ELECTROLYTIC CAPACITORS.
SOLVENTS WHICH MAY BE USED ARE AS FOLLOWS:
SAFE SOLVENTS
Isopropyl Alcohol
Methyl Alcohol
Butyl Alcohol
Propyl Alcohol
Ethyl Alcohol
Calgonite™ (Detergent)
Xylene
CAUTION: PRINTED CIRCUIT BOARDS CONTAINING ALUMINUM

ELECTROLYTIC CAPACITORS SHALL NOT BE CLEANED WITH
THE FOLLOWING SOLVENTS:
UNSAFE SOLVENTS
Freon TF, TMC
Trichloroethane
Carbon Tetrachloride
ALL™ (Detergent)
Chloroform
Methylene Chloride
Trichloroethylene
CAUTION: ULTRASONIC CLEANING CAN DAMAGE CERTAIN PARTS AND

SHOULD GENERALLY BE AVOIDED.
PAGE 4003
23-10-07 Jan/2004
N
(a) Modules containing resistor, capacitors, inductors, transformers and other
wired parts should be cleaned as follows:
(1) With a soft-bristled brush and an air jet, remove large dust and dirt
particles from all surfaces, including parts and wiring.
(2) Any dirt or dust that cannot be removed in this manner should be
removed with a brush (not synthetic bristle) saturated with an approved
solvent. Remove any excess solvent with a clean, dry air jet.
(3) Remove flux residue, metallic chips, or solder balls with the approved
solvent.
NOTE: Solvents may be physically applied in several ways, such as

agitation, spraying, brushing and vapor degreasing. The
cleaning solvents and methods used should have no
deleterious effect on the parts, connections and materials being
used.
(b) If sensitive components are being used, spray is recommended. Uniformity

of solvent spray flow should be maximized and wait time between soldering
and cleaning should be minimized.
(4) Chassis, wired
CAUTION: AVOID AIR BLASTING SMALL COILS, LEADS AND OTHER

DELICATE PARTS BY HOLDING AIR JET NOZZLE TOO CLOSE.
USE BRUSHES CAREFULLY ON DELICATE PARTS.
NOTE: When necessary to disturb dress of wiring and cables, note the
positions before disturbing and restore to proper dress after cleaning.
(a) Clean chassis containing terminal boards, resistor and capacitor

assemblies, RF coils, switches, sockets, inductors, transformers and other
wire parts as follows:
(1) Clean printed circuit boards (modules) as outlined in Paragraph 3.A.“(3)

Modules”.
(2) Blow dust from surface, holes and recesses using an air jet.
(3) With minimum disturbance to wiring, clean connectors as outlined in

Paragraph 3.A.“(2) Cleaning Connectors”
PAGE 4004
23-10-07 Jan/2004
N
(4) Finish cleaning chassis by wiping finished surfaces with a lint-free cloth
moistened with solvent.
(5) Dry with a clean, dry, lint-free cloth.
(6) When thoroughly clean, touch up any minor damage to finish.
(7) Protect chassis from dust, moisture and damage pending inspection.
(5) Covers
(a) Side covers and chassis should be cleaned as follows:
(1) Remove surface grease with a lint-free cloth.
(2) Blow dust from surface, holes and recesses using an air jet.
(3) If necessary, scrub with a solvent until clean. Work over all surfaces and
into all holes and recesses with a suitable nonmetallic brush.
(4) Position the cleaned part to dry so solvent is not trapped in holes or
recesses. Use an air jet to blow out any trapped solvent.
(5) When thoroughly clean, touch up any minor damage to the finish.
PAGE 4005
23-10-07 Jan/2004
N
(Blank Page)
PAGE 4006
23-10-07 Jan/2004
N
CHECK
1. Task (Task 23-10-07-99C-805-A01)
(1) Perform checks of the KAC 1052 Coupler to determine the condition of its
physical, mechanical, and electrical properties. These properties are compared
to established standards.
(2) Visual checks make sure the parts of the KAC 1052 are serviceable and show
no signs of wear, damage, or possible failure.
(3) During disassembly, assembly or repair, use Paragraph “3. Procedure (Task
23-10-07-21-801-A01)” to find the condition of the KAC 1052.
(1) Common shop tools and best established shop practices are used to perform
the checks in this subheading.
3. Procedure (Task 23-10-07-21-801-A01)
(1) Structural Checks
(a) Make sure the KAC 1052 is clean and has no dirt, chips, solder splashes, or
other unwanted materials such as excess grease or oil. The component
leads must be free from grease, dirt, paint, mold flash, and other
contaminants.
(b) Make sure all parts are installed or attached correctly. Check for damaged,
loose, or missing parts.
(c) Check for bent or damaged connector pins.
(d) Check threads on applicable parts for burrs or cross-threads (connectors,

frames, and heat sink brackets, etc.).
(e) Check the metal parts for corrosion, rust, or other structural damage.
PAGE 5001
23-10-07 Jan/2004
N
(f) Check that no pinholes, pits, or other voids are found at joints and
connection points or where circuit lines change direction abruptly.
(2) Electrical Checks
(a) Check that solder is properly applied and connections are secure. Solder
joints must be tight and free from scratches, roughness, sharp edges,
dullness, bridging, or blistering. Solder joints must show evidence of wetting
(molten solder adhering and flowing on a metallic surface to a smooth, even
coating) and bonding where the solder blends to the soldered surface
forming a small contact angle.
(b) Check for signs of arcing, especially around the HN connector (J10528) and
the Coil Board, Shunt Cap Board and Series Cap Board.
(c) Check the electrical components for cracks, corrosion, discoloration, or

burned, overheated areas.
(d) Check for heat or solvent damaged to components and markings.
(e) Check for broken or disconnected bus wires. Bus wires found in this
condition must be replaced.
(f) Check leadwires for breaks or brittleness.
PAGE 5002
23-10-07 Jan/2004
N
REPAIR
1. Task (Task 23-10-06-99C-806-A01)
(1) Use these procedures to correct problems that are identified during the
procedures in “CHECK” and “TESTING AND FAULT ISOLATION”. Repair of
the KAC 1052 is done to replace or repair subassemblies, to replace defective
parts and wires and to correctly attach loose wires. Repair of the subassemblies
is usually done to replace defective parts.
(2) Refer to “ASSEMBLY” and “DISASSEMBLY” for removal and installation

instructions. Do only those procedures of disassembly that are necessary to
make repairs. When new parts are necessary, refer to the “ILLUSTRATED
PARTS LIST” for the correct part numbers, quantities and hardware that is
attached.
2. Equipment and Material (Task 23-10-06-94-805-A01)
WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE

MANUFACTURERS MATERIAL SAFETY DATA SHEETS FOR
DATA ON PERSONAL PROTECTION. SOME MATERIAL CAN BE
DANGEROUS.
(1) Crocus cloth, grade 4/0 - optional source
(2) Isopropyl alcohol (99%) - optional source
NOTE: Equivalent alternatives are permitted for equipment and materials in

this list.
3. Procedure (Task 23-10-06-35-801-A01)
CAUTION: THIS EQUIPMENT IS SENSITIVE TO DAMAGE BY

ELECTROSTATIC DISCHARGE.
THIS EQUIPMENT CONTAINS MOISTURE SENSITIVE PARTS.

SPECIAL PROCEDURES ARE REQUIRED
PAGE 6001
23-10-07 Jan/2004
N
(1) General Repair Procedures
(a) Straighten warped or bent cover surface.
(b) Straighten any bent pins in connectors.
(c) Replace screws, nuts and bolts that are stripped or have other damage.
NOTE: Before you repair electrical connections, note the color code and
routing of lead wires. Use the lead wire you removed to measure
for replacement.
(d) Repair defective wiring.
(2) Detailed Repair Procedures
(a) Replace broken or disconnected wires.
(b) Replace damaged or defective switches.
PAGE 6002
23-10-07 Jan/2004
N
ASSEMBLY
1. Task (Task 23-10-07-99C-807-A01)
(1) This section provides information for assembly of the KAC 1052. The assembly
procedure is to be followed after the unit has been disassembled for repair,
modification by a Service Bulletin, cleaning, or inspection.
WARNING: REMOVE ALL POWER FROM THE UNIT BEFORE ASSEMBLY

OF ANY MODULE. BESIDES BEING DANGEROUS TO LIFE,
VOLTAGE TRANSIENTS CAN CAUSE CONSIDERABLE
DAMAGE TO THE EQUIPMENT.
CAUTION: EXERCISE EXTREME CARE WHEN RECONNECTING

MULTI-PIN CONNECTORS. ENSURE THAT CONNECTORS
ARE NOT DAMAGED BY MISALIGNMENT OF THE PINS.
B. Staking Compounds, Sealants, Thermal Compounds, and Lubricants to be Used

(Subtask 23-10-07-99F-011-A01)
(1) “Table 7001 Sealants, Staking Compounds, Thermal Compounds, and

Lubricants (Task 23-10-07--99A-809-A01)” lists the staking compounds,
sealants, and thermal compounds to be applied during assembly. Points of
application are referenced on the drawings in the “ILLUSTRATED PARTS
LIST”(IPL).
CAUTION: THREAD LOCKING SEALANTS MAY TEND TO SOFTEN OR

CRAZE VINYL, CELLULOSIC, STYRENE, ABS, POLY
CARBONATE, AND METHACRYLATE PLASTICS.
NOTE: Equivalent substitutes may be used for sealants, staking compounds,

thermal compounds, and lubricants listed in “Table 7001 Sealants,
Staking Compounds, Thermal Compounds, and Lubricants (Task
23-10-07--99A-809-A01)”.
PAGE 7001
23-10-07 Jan/2004
N
Place Representative Honeywell Qty

Used Type Part Number Used
Screw Threads Locktite 425 016-01412-0000 (as required)

Side Plates Dow Corning HV Grease 005-02133-0075 (as required)
Table 7001 Sealants, Staking Compounds, Thermal Compounds, and Lubricants

(Task 23-10-07--99A-809-A01)
C. Screw and Nut Torque Values (Subtask 23-10-07-99F-012-A01)
(1) “Table 7002 Typical Screw and Nut Torque Values (Task
23-10-07-99A-810-A01)” lists typical torque values to be observed when
screws and nuts are tightened during assembly of the unit.
Table 7002 Typical Screw and Nut Torque Values (Task 23-10-07-99A-810-A01)
PAGE 7002
23-10-07 Jan/2004
N
A General (Subtask 23-10-07-94-006-A01)
(1) Common shop tools and best-established shop practices are used to assemble
the KAC 1052. Refer to “Figure 10001 KAC 1052 Final Assembly (Task
23-10-07-99B-816-A01)” to aid in assembly.
3. Procedure (Task 23-10-07-43-801-A01)
CAUTION: THE KAC 1052 HAS COMPONENTS THAT ELECTROSTATIC

THE KAC 1052.
CAUTION: ALL SEALING SURFACES MUST BE CLEAN OF ALL FOREIGN

MATERIAL.
NOTE: APPLY LOCKTITE 425 TO ALL SCREWS BEFORE INSERTION.
Assembly of the KAC 1052 should be the reverse of disassembly but will include
added precautions and requirements. These procedures will begin at complete
disassembly and work toward total assembly. For any partial disassembly for
repair, this procedure may be begin at the last board removed.
(1) PS and Interface Board (22) MDBW10546B
Apply grease (Dow Corning 3452) between the chassis assembly gaskets (15)
and (16) and the Sub-D 37 pin (J10521) and Sub-D 9 pin (J10522) connectors.
Insert the PS and Interface Board (CBL-103),. Secure by inserting 8 S3x8 Sus
screws (55). Torque the screws to 6.5 ± 0.1 in-lb. Repeat torquing screws (55)
three times in sequence, or until screws no longer rotate when 6.5 +/- 0.1 in-lb
is applied.
Ensure that the 4 spacers (31) are in place and install the 4 standoffs (32)
securing the board to the chassis (1). Install 1 NC3x6Bs screw (58) at TP4.
PAGE 7003
23-10-07 Jan/2004
N
(2) CPLR Control Board (23) MDLW11428
Carefully install the CPLR control board (CDC-1083B) into the chassis (1),
aligning the bayonet pins with the connector on the PS and interface board (22).
Squeeze the connector together assuring proper pin contact. Install the 4
standoffs (33) securing the board to the PS and Interface board.
(3) Shield Assembly (29) MPSC30332A
Install the shield assembly into the chassis (1). Press the RF Collar into the
BNC housing . This is a pressure fit. ensure that it seated completely. Align the
standoff and screw holes.
When the shield cap (29) can not be inserted in the front panel, apply a
lubricant. Install the 4 standoffs (34) to secure the shield assembly to the
standoffs from the CPLR control board (23).
(4) Sensor and Relay Drive Board (24) MDCW10907D
Carefully install the Sensor and RLY DRV board (CNN-338) into the chassis,
aligning the bayonet pins with the connector on the CPLR control board (23).
Squeeze the connector together assuring proper pin contact. The sensor and
relay drive board should be aligned with the 4 standoffs (34) from the shield
assembly (29). Install 4 NC3x6BS screws (58) to secure the board to the shield
assembly standoffs (34).
(5) Coil Board (27) MDLW11390E
Insert the Coil board (CSC-592B) into the chassis (1) on the left side,
maintaining proper orientation to align the connector to the pins on the Sensor
and RLY DRV board (24).
Push the coil board forward seating the connector against the Sensor RLY DRV
board (24). The chassis standoffs will now be aligned. Install 9 NC3x10BS
screws (57) securing the board to the chassis (1).
If the Coil Board was removed without removing the Series Cap Board and
Shunt Cap Board, install three additional NC3x10BS screws attaching the Coil
Board to the standoffs. (Early production units have only two standoff screws.)
PAGE 7004
23-10-07 Jan/2004
N
(6) Shunt Cap Board (25) MDLW11385F
Insert the Shunt Cap board (CSC-590B) on the right side, maintaining proper
orientation to align the connector to the pins on the Sensor RLY DRV board
(24). Push the shunt cap board forward seating the connector against the
Sensor RLY DRV board (24). The chassis standoffs are now aligned. Install 10
NC3x10BS screws (57) securing the shunt cap board to the chassis (1).
Install one long standoff through the hole in the Shunt Cap Board near the long
resistor on the rear of the board and attach it to the Coil Board (27) with 1
NC3x10BS screw (57).
If provided, also install one long standoff through the hole in the Shunt Cap
Board near the lower front of the board near the unit HN connector (P10528)
and attach it to the Coil Board (27) with 1 NC3x10BS screw (57).
Install the standoff on the shunt cap board near the unit HF connector (J10528).
Attach the RF antenna wire to W2 by securing it with 1 NC3x6Bs screw (58).
(7) Series Cap Board (26) MDLW11386D
Install the Series cap board (CSC-591B) on the right side after the Shunt Cap
Board (25), maintaining proper orientation to align the connector to the pins on
the Sensor RLY DRV board (24). Push the series cap board forward seating the
connector against the sensor RLY DRV board (24). All standoffs are now
aligned. Install 8 NC3x10BS screws (57) securing the series cap board to the
chassis (1).
(8) Side Plates (2) MPBC36547A
Clean and degrease sealing surfaces on chassis (1). Clean and degrease
o-ring groove in side plate (2). Apply a thin uniform film of Dow Corning High
Vacuum Grease to sealing surfaces on chassis (1) and o-ring groove in side
plate (2). Place side plate (2) on a flat surface and place o-ring (8) in groove.
Carefully lower chassis (1) onto side plate (2). Turn chassis/side plate (1/2)
over, being careful not to allow side plate (2) to slip. (It is helpful to partially
install two side plate screws () prior to turning assembly over.) Install the six
side plate screws (50) shown in “Figure 7001 Side Plate Installation (Task
23-10-07-99B-814-A01)” and tighten them 1/2 to 1 turn at a time until all are
fully seated. Install the remaining side plate screws (50) and torque to 4.7 +/-
0.5 in-lb. Repeat torquing all side plate screws (50) two times in sequence, or
until screws no longer rotate when 4.7 +/- 0.5 in-lb is applied. Repeat this
procedure for the other side plate (2).
PAGE 7005
23-10-07 Jan/2004
N
.
Figure 7001 Side Plate Installation (Task 23-10-07-99B-814-A01)
B. Pressurization (Task 23-10-07-43-002-A01)
(1) Pressurization with dry nitrogen.
When assembly is complete, ensure that the Schrader valve (12) core is tightly
seated in the charging valve.
(a) Set the regulator on the dry nitrogen source to 15 PSI (103.43 kPa) and
attach the filling hose to the charging valve.
(b) Remove the vent plug (13) on the back of the unit, if installed.
(c) Open the nitrogen tank valve to purge the air in the KAC 1052 tube.
(d) After about 30 seconds, turn the nitrogen tank valve off.
(e) Apply grease to the vent plug seal (13) and install. Torque to 3.7 ± .1 in-lb
(do not overtighten and rupture the fiber washer ).
(f) Set the regulator on the dry nitrogen source to 10 PSI. Recharge the unit
with dry nitrogen to 9 ± .5 PSI. See Notes on “Figure 10001 KAC 1052 Final
Assembly (Task 23-10-07-99B-816-A01)”.
(g) Apply grease to the Schrader valve cap and install. Torque to 5 ± 0.5 in-lb.
PAGE 7006
23-10-07 Jan/2004
N
CAUTION: DO NOT OPERATE THE KAC 1052 IN AN AIRCRAFT
WITHOUT CHARGING THE UNIT AND MAKING CERTAIN
THERE ARE NO NITROGEN LEAKS.
(2) Pressurization with dry air pump.
CAUTION: PRESSURIZATION WITH A DRY AIR PUMP SHOULD ONLY BE

DONE WHEN DRY NITROGEN IS NOT AVAILABLE. PURGING
AND RE-PRESSURIZATION WITH NITROGEN SHOULD BE
DONE AT THE EARLIEST OPPORTUNITY.
(a) Remove the valve cap from the KAC 1052 charging valve. Make sure the
valve core is tightly seated in the charging valve (12). Remove the vent plug
(13).
(b) Attach dry air pump to the charging valve and purge the air within the
coupler by pumping for about 30 seconds.
(c) Apply grease (Dow Corning 3452) to vent plug (13) and install . Torque to
3.7 ± .1 in-lb (do not overtighten and rupture the fiber washer ).
(d) Using dry air pump, pressurize the coupler to 9 ± .5 PSI. (See notes on
“Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01)”)
(e) After re-pressurization has been performed, the final test procedure should
be accomplished before returning the unit to service.
PAGE 7007
23-10-07 Jan/2004
N
(Blank Page)
PAGE 7008
23-10-07 Jan/2004
N
KAC 1052 Antenna Coupler / Part No. 064-01074-0000.
FITS AND CLEARANCES
This pageblock is not applicable to this CMM.
PAGE 8001
23-10-07 Jan/2004
N
KAC 1052 Antenna Coupler / Part No. 064-01074-0000.
(Blank Page)
PAGE 8002
23-10-07 Jan/2004
N
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. Task (Task 23-10-06-99C-808-A01)
(1) This section contains the special tools, fixtures, and equipment necessary to
support the KPA 1052 in a maintenance facility.
2. Return to Service Testing (Task 23-10-06-94-807-A01)
(1) The KPA 1052 may be tested as a stand-alone unit with a properly configured
HF ATE (Automated Test Equipment) System or as part of a KHF 1050 system
using a bench-test harness. Refer to Paragraph 3.“B. Bench-Test Harness
Return to Service Test Solution (Subtask 23-10-07-75-001-A01)” in TESTING
AND FAULT ISOLATION for the bench-test harness procedure, and to
Paragraph 4.“C. HF ATE System Test Solution (Subtask
23-10-07-75-006-A01)” in TESTING AND FAULT ISOLATION for the ATE
System procedure.
(2) The following special tools, fixtures, and equipment are required to functionally
test the KPA 1052 using Automated Test Equipment (ATE).
• HF ATE System - P/N 071-05558-0001

See “Figure 9001 HF ATE System (Task 23-10-06-99B-815-A01)”.
• KHF 1050 System Bench-Test Harness
See “Figure 9002 KHF 1050 System Bench-Test Harness (Task
23-10-06-99B-816-A01)”.
PAGE 9001
23-10-07 Jan/2004
N
Figure 9001 HF ATE System (Task 23-10-06-99B-815-A01)
PAGE 9002
23-10-07 Jan/2004
N
Figure 9002 KHF 1050 System Bench-Test Harness (Task 23-10-06-99B-816-A01)
PAGE 9003
23-10-07 Jan/2004
N
(Blank Page)
PAGE 9004
23-10-07 Jan/2004
N
SPECIAL PROCEDURES
This pageblock is not applicable to this CMM
PAGE 11001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 11002
23-10-07 Jan/2004
N
REMOVAL
PAGE 12001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 12002
23-10-07 Jan/2004
N
INSTALLATION
PAGE 13001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 13002
23-10-07 Jan/2004
N
SERVICING
PAGE 14001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 14002
23-10-07 Jan/2004
N
STORAGE (INCLUDING TRANSPORTATION)
1. Storage (Task 23-10-06-55-801-A01)
A. Storage After Assembly (Subtask 23-10-06-55-001-A01)
(1) If units are to be stored for 7 days or less, perform the Short-Term Storage
procedures of Paragraph 1.A.“(2) Short-Term Storage”. If units are to be stored
for up to 6 months, perform the Temporary Storage procedures of Paragraph
1.A.“(3) Temporary Storage”. If it is anticipated that units will be stored for
longer than 6 months, perform the procedures of Paragraph 1.A.“(4) Extended
Storage”.
(2) Short-Term Storage
(a) Store away from vibration and shock.
(b) Storage temperature range shall not exceed -55° to +85°C (-67° to +185°F).
(3) Temporary Storage
(a) Place equipment in a waterproof plastic bag.
(b) Put a packet of silica gel or other desiccant in the bag.
(c) Seal open end of plastic bag.
(d) Store away from vibration and shock.
(e) Storage temperature range shall not exceed -55° to +70°C (-67° to +158°F).
(4) Extended Storage
(a) Place the unit in a waterproof plastic bag.
(b) Put a packet of silica gel or other desiccant in the bag.
(c) Seal open end of plastic bag.
(d) Store away from vibration and shock.
(e) Storage temperature range shall not exceed -55° to +70°C (-67° to +158°F).
Humidity shall not exceed 95 percent (%), noncondensing.
PAGE 15001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 15002
23-10-07 Jan/2004
N
KAC 1052 Antenna Coupler / Part No. 064-01074-0000. 0001, 0101
REWORK
PAGE 16001
23-10-07 Jan/2004
N
(Blank Page)
PAGE 16002
23-10-07 Jan/2004
N
ILLUSTRATED PARTS LIST
1. Introduction (Task 23-10-07-99C-809-A01)
This Illustrated Parts List is a complete list of assemblies and parts for the KAC
1052 Antenna Coupler. Reference “Table 10001 KAC 1052 Coupler (Task
23-10-07-99A-811-A01)” and “Figure 10001 KAC 1052 Final Assembly (Task
23-10-07-99B-816-A01)”.
Periodically the Illustrated Parts List is revised to cover additions, deletions, or

changes to the equipment. These revisions are indicated by an R placed to the
right of each revised line and apply to the current revision only.
B. Parts Listing (Subtask 23-10-07-99F-015-A01)
(1) FIND NO. Column
This column lists the find number as shown in the assembly drawing.
(2) PART NUMBER Column
In this column are listed Honeywell part numbers for each part and assembly.
(3) DESCRIPTION Column
This column identifies each part and assembly by verbal description.
(4) QTY Column
The total quantity of parts or assemblies required at each location is listed in

this column.
PAGE 10001
23-10-07 Jan/2004
N
NUMERICAL INDEX
FIND PART
DESCRIPTION QTY
NO. NUMBER
1 MPBC36866 PRINTED CHASSIS ASSEMBLY 1
2 MPBC36547A SIDE PLAT ASSEMBLY 2
4 MTB364529 FRONT BRACKET 1
5 MTB364530 REAR BRACKET 1
7 MPXL30173 PRESSURE RELIEF VALVE 1
8 MPPK30976 O-RING 1
12 MPXL30174 AIR VALVE 1
13 MPTG31242 VENT PLUG 1
15 MPPK30974A GASKET 37 PIN 1
16 MPPK30975A GASKET 9 PIN 1
17 MTT309136 GASKET 1
18 MTL316688 GROUND STUD 1
19 MTL316711 WASHER 1
20 MPTG31273 NUT SELF LOCKING 1
22 MDBW10546B PS & INTERFACE BOARD 1
23 MDLW11428 CPLR CONTROL BOARD 1
24 MDCW10907D SENSOR & RLY DRV BOARD 1
25 MDLW11385F SHUNT CAP BOARD 1
26 MDLW11386D SERIES CAP BOARD 1
27 MDLW11390E COIL BOARD 1
29 MPSC30332A SHIELD 1
31 MTL316690 SPACER-1 4
32 MTL316693 STANDOFF-5 4
Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01)

(sheet 1 of 2)
PAGE 10002
23-10-07 Jan/2004
N
FIND PART
DESCRIPTION QTY
NO. NUMBER
35 MPNN40129 DISCERNMENT LABEL 1
36 MPPK30920 O-RING 2
37 MTT308482A COVER 1
38 MPNN40379A WARNING LABEL 2
39 MPNN39853 NAME PLATE 1
40 MPNN39854A S/N TAG 1
41 MPNN39856 DECAL, CAUTION 1
42 MPNN39857 DECAL WARRANTY SEAL 1
44 MPNN40026 SOFTWARE MOD. TAG 1
45 BSPT01253C CRIMP-STYLE TERMINAL R1.25-3 1
46 BSPT02033C CRIMP-STYLE TERMINAL 2-S3.3 1
47 BSPT05503C CRIMP-STYLE TERMINAL 5.5-S3 1
48 MPNN40639 LABEL 1
49 MPTG31330 CAPTIVE PANEL SCREW 2
50 BRTG03582 SCREW ASSY. NA3X16SUS 76
51 BRTG03577 SCREW ASSY. NA3X8SUS 16
52 MPTG31300 HEX. NUT NO.6-32UNC BS 1
53 BRTG01619 WASHER M3.5BS 2
54 BRTG00345 SPRING LOCK WASHER SW3.5 1
55 BRTG00531 SCREW S3X8SUS 8
57 BSNC03010B SCREW ASSY. NC3X10BS 28
58 BSNC03006B SCREW ASSY. NC3X6BS 6
59 BSSW03000S SPRING LOCK WASHER SW3 14
Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01)

(sheet 2 of 2)
PAGE 10003
23-10-07 Jan/2004
N
(Blank Page)
PAGE 10004
23-10-07 Jan/2004
N
Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01)

(Sheet 1 of 2)
PAGE 10005
23-10-07 Jan/2004
N
(Blank Page)
PAGE 10006
23-10-07 Jan/2004
N
Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01)

(sheet 2 of 2)
PAGE 10007
23-10-07 Jan/2004
N
(Blank Page)
PAGE 10008
23-10-07 Jan/2004

Kac 1052 Maintenance Manual

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Kac 1052 Maintenance Manual

Încărcat de

Drepturi de autor:

Formate disponibile

COMPONENT MAINTENANCE MANUAL

MANUAL NUMBER 006-15640-0001

Component Maintenance Manual

KAC 1052 Antenna Coupler

Part No. Manufacturer

IF ANY UNUSUAL OR SPECIAL SERVICE PROBLEMS ARISE,

This document contains proprietary information and

TO HOLDERS OF: HOLDERS OF COMPONENT MAINTENANCE MANUAL,

REVISION NO. 001, DATED Jan/2004

Revision No. Revision Date Date Put in Manual By

1 Jan/2004 (full revison of manual)

This revision contains these changes:

Task/Page Description of Change Effectivity

(various) Corrected clerical errors.

Task/Page Description of Change Effectivity

Revision Revision Date Put Revision Revision Date Put

1 01/04 (full rev.)

Revision Revision Date Put Revision Revision Date Put

Temp Rev. No. Status Task Location

Temp Rev. No. Status Task Location

The following Service Bulletins have been incorporated in this manual.

LIST OF EFFECTIVE PAGES

SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE

indicates a changed, added, or deleted page

LIST OF EFFECTIVE PAGES

SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE

indicates a changed, added, or deleted page

LIST OF EFFECTIVE PAGES

SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE

indicates a changed, added, or deleted page

LIST OF EFFECTIVE PAGES

SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE

indicates a changed, added, or deleted page

3. Procedure (Task 23-10-06-75-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

SPECIAL TOOLS, FIXTURES AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 9001

Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01) . . . . . . . . . . . . . 1

Table INTRO-1. Acronyms (Task 23-10-07-99A-801-A01) . . . . . . . . . . . . . . . . . . . . . . 5

1. How to Use This Manual (Task 23-10-06-99C-801-A01)

A. General Information (Subtask 23-10-06-99F-001-A01)

(3) “DESCRIPTION AND OPERATION” section contains an equipment illustration,

(4) “TESTING AND FAULT ISOLATION” section contains a functional test to

(5) “SCHEMATICS AND WIRING DIAGRAMS” section contains complete

(6) “DISASSEMBLY” section contains procedures for disassembling the

(7) “CLEANING” section contains general cleaning procedures, which should be

(8) “CHECK” section contains general areas to visually observe during

(10)“ASSEMBLY” section contains all specific instructions necessary for part

(11)“FITS AND CLEARANCES” section contains a list of dimensional values,

(12)“SPECIAL TOOLS, FIXTURES AND EQUIPMENT” section contains a list of all

(13)“STORAGE (INCLUDING TRANSPORTATION)” section contains storage and

ACP Antenna Coupler (or equivalent test panel)

EMI ElectroMagnetic Interference

MPS Minimum Performance Standard

Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01)

1. Physical Description (Task 23-10-87-801-A01)

A. General (Subtask 23-10-07-87-001-A01)

Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01)

With some antenna configurations, high RF voltages can be developed at

In a KHF 1050 dual-system configuration, both systems share one antenna. If

Also in a dual-system configuration, when the primary system is transmitting,

The mechanical configuration of the KAC 1052 Antenna Coupler is mainly

An HN connector on the back of the unit provides for connection to an antenna,

Overall Dimensions 13.6 L x 4.75 W x 7.24 H in. 434 cu. in.

Table 1 Leading Particulars (Task 23-10-07-99A-803-A01)