AT&T 540 Series Setup guide

BELL
SYSTEM PRACTICES
AT
&TCo
Standard
SECTION
502-500-120
Issue
4,
Decemb
er 1
975
TELEPHONE
SETS
540, 560, 1
560,
AND
2560
SERIES
COMMON
INSTALLATION
AND
MAINTENANCE
INFORMATION
1. GENERAL
1.01 This
sec
tion contains common in
sta
ll
at
ion
and
maintenance information
on
4·
and
6-button key telephone sets.
1.02 This section is reissued
to
add information
on
the
563H
BM
,
564
HLM, 565GKM, HKM,
LK~f
.
566~1DM,
568HAAM, 569NBM, 2563HBM,
2564HLM, 2565GKM, HKM, LKM, and 2568
HAAJ\I
(modular) telephone sets.
1.03
Wh
en
installing
or
re
pai
ring
any telephone
set,
nll
connections should be checked for
tightne
ss
in order to prevent troub
le
re
port
s.
2.
INSTALLATION
Keys
2.
01
The
636-type key (Fig.
1)
has
a
te
rminal
board
arrangement
to accommodate matching
cord terminal
wafers,
so
that
any
line connected
to
the
set
can be interchanged readily to
appea
r
on any five line pickup keys. See
F'
ig. 2
and
3
for terminal d
es
ignations
on
the
6a6A
and
6HGB,
respectively.
2.
02
Lamps associated
wi
th the buttons may have
co
mmon
or
individual grounds. Sec
sect
ions
covering
co
nnections
of
individual telephone
sets
for lamp connections.
2.03 Certain pickup
buttons
on 4· and 6-button
sets
are
ar
ranged for conversion
to
signaling.
To convert., remove
t811
218924• (P-12A892)
sc
r
ew
detail (Fig.
1)
and make necessat·y wiring changes.
Table
A
shows key
and
associated t.elephone
sets
with convertible buttons.
2.04
Un
u
se
d
butto
n
s,
ei
the
t· r
ound
ot· s
qua
t·c
sty
le, may be blocked with an • 8
1
121
8585•
---
....:::0..
8112
1
8924
OR
P·I
2A892
SC
R
EW
DETAIL
fig
. 1
-63
6A
Ke
y,
Bottom
View
(P
-1
2A858) blocking ring. In
sert
as
shown
in
Fig.
4.
La.mF Ret
ai
11
er
2.05
In
early telephone sel.'l equipped with a
63
6A
or
B
ke
y,
the
GlA
lamp c
ont
act
sprin
gs
arc
suceptib
lc to loMing their tension. An adjun
ct
840362347 lamp r
et
ainer (Fig.
5)
is available and
can be in
sta
lled
between
the
spring
contacts
of
the lamps. The retainer must be ordered sepa
rat
e
ly
as D-180557
Kit
of
Pat'ts.
Exclusion
Switch
Assem
b
ly
Note:
When exclusion
featu
re is provided
the
A25B conn
ector
cable
must
be used.
2.06
The
ii
ll
5-
fl
nd
1565-Lype
Le
l
ephone
~eLs
manu
l'
acLu
t·ed
prior
to M
ay
1967 provided
an
excl u
~>ion
plun
gc
t· in the
housing.
Oth
e
t·
NOTICE
Not for u"'!
or
disclosure outside
the
R~ll
System except under written
al,'Tl'<'mcnt
Printed
in
U.S.A.
Pag
e 1

SECTION
502-500-120
tTABLE
A.
PICKUP
BUTTON
CONVERSION
KEY
TEl.
SETS
CONVERTIBLE
BUTTONS
2565GK*
2565GKM
636B
1565GK*
PPPPsPsPs
565GK*
565GKM
2565HK
*
2565HKM
2-564HL*
2564HLM
2563HB
*
2563HBM
1565HK
*
636A
1564HK
* HPPPsPsPs
1564HL
*
1563HB
*
565HK*
565HKM
564HL
*
564HLM
563HB*
563HBM
2565LK
*
2565LKM
589AJ
1565LK
* HPPPPsC
565LK
*
565LKM
589AN 566MD* HPPPPL
566MDM
589Y
*
564HK
* HPPPsPsPs
589L
566MB* HPPPPL
589K
*
565L
A/
LB* HPPPsPsPs
565LD
*
589J
* 565GA/GB* PPPPsPsPs
565H
A/
HB
*
589H
565HD* HPPPsPsPs
564HA/HB*
564HD
588B 544BA/BB* HPPPs
545BA/BB*
*M
D.
Page
2
0
gg
B
El
0
~~~~~--~~~~
g
~
BEl
EJ
El
gg
El
El
0
gg
El
El
0
Fig.
2-Terminal
Baard
for
the
636A
and
589Y
Key
co
mp
onen
ts
of
the exclusion
asse
mbly were part
of
a D-
17
9935
Ki
t
of
Par
ts. C
urr
e
nt
manufact
ur
ed
sets no longer include the plun
ge
r
in
the housing.
The plun
ger
is n
ow
in
cluded
in
the
D-1
79935
Ki
t
of
Pa
r
ts
(o
rdered separately and f
ie
ld
installed
).
2.
07
Compone
nts
of
the D-179935
Kit
of
Pa
rts
are:
•
t
803448
59
~
(P-344859) brack
et
e
t
80340560
~
(P-340560) spring
• t 8
01
809229• (P-180922) screw
• t 81
255
11
82
• (P·25E11
8)
exclusion switch
e t 811416130• (P-14A613) exclusion plunger

0
gg
El
El
0
g g
El
El
El
El
g g
E5
E'l
0
gg
E5 E5
0
Fig.
3-Terminal
Baard
far
the
6368
Key
Fig.
4-
.811218585
(P-1
2A858
)
Blocking
Ring,
Installed.
2.08
In
stall
ex
clusion
kit
as
follows:
(1)
Insert
the
•803448596• (P-344859} b
ra
cket
into the two T slots
pr
ecut
in
th
e line switch
hrack
et
(
Fi
g.
6).
636
-
TYPE
KEY
ISS
4, SECTION
502
-
500-120
~840362347
LA
MP
RETA
IN
ER
Fig.
5-lnstalling
D-180S57 Kit
of
Parts
(2)
Tighten
the
•801809229• (P-180922)
screw
which holds
the
bracket
in
the
T
slots
.
(3)
Mo
unt
the exclusion switch assembly on the
bracket
(Fig.
6)
and
fasten
in
place
using
the
•
80:~40560
4
•
(P·a40560)
spring
.
(4)
Remove the •8113fi9538• (P-13F953) pl
unger
from
the
left
!;ide
of
the
Lelephone
set
housing
and
r
eplace
it
with
Lhe
•81141G
l30
•
(P
-
14AG
1
3)
ex
clusion p
lunger
.
R
ep
la
ce
th e
tel
eph
one
s
et
housing
bef
o
re
mak
ing
any
tests. The
}lousing
serves
to
01·ient
the
exc
lusi
on
sw
itch
and
tilts
th
e s
pring
pile-
up
so
that
it
will
not
short
to
th
e
bracket.
2.09
Th
e
exc
lusion
sw
itch
assemb
ly
must
meet
the following requirements:
(a) 'l'he exclus
ion
plun
ge
r should
rem
ain
in
the
oriented position
when
pulled
up
to
the
full
extent
of
its stroke.
It
should hold
in
position
when
50 grams
of
fo•·ce
or
less
ar
e
app
li
ed
to
the
center
of
the
plunger.
Page
3

SEC
TI
ON
502-500-120
Fig. 6- D-1
79935
Ex
clu
sion
Kit
, Installed
(b) The pl
unger
should release from
its
upper
(locked) position wben the handset is dropped
from
a
distance of 1/
4-in
ch above the plunger.
2.10
The t81255118
2f
(P-25Ell8) exclusion switch
asse
mbly
ter
minates
in
individual and
waf
er
st
rip spade-tipped
co
ndu
ctor
s Wig. 7). This allows
adaption
of
the exclusion
feature
to
any
one
of
lhe pickup buttons.
2.11
Exclusion switch connections
ar
e found
in
sect
ions covering the appropriate telephone
set.
Page 4
Buzz
ers
2.12
A
KS-8109
L2
or
equivale
nt
buzzer may be
mounted
to
the
Hl
-
type
ring
er
bracket
(Fig. 8).
2.13 A
second buzzer can be
in
stalled on
a
70-type
brac
ket
(orde
t·
ed
separate
ly) mo
unted
on
top
of
the Hl-type ringer
coil
in
nonexclusion switch
equipped sets.
2.14
A
KS
-2
041
9L1 buzz
er
(10
volt
AC
onl
y)
may
be mounted
in
any
conve
ni
e
nt
lo
cation (screw
must
be provided).
ln
current
production
565
-
and 2565-type
sets
(exce
pt
the
GK),
this buzzer is

Fig.
7-t8
12
551182
(P
-25£
11
8)
Exdu
sion
Switcht
1<5·6109,
L2
OR EOUIV4LENT
Fig.
8-location
of
KS-8
109l2
Buzzer
ISS
4,
SECT
ION
502-500-120
furni
shed
from
the
factory
and
mounted
on
th
e
l
eft
dial mounting
bracket
scre
w.
Mounting
Cords
2.15
:Mounting co
rds
on 54(}-type
and
earlier models
of
the 560-type telephone sets have spade-tipped
leads
and
te
rmin
ate
at
44A connecting blocks.
2.16
Plug-ended mounting co
rds
terminate
at
66E3
or
66E4
connecting
blocks
or
connect
to
A20B
or
A25R connect01·
cab
les. A
B20A
or
B25A
connector cable
ca
n
be
u
se
d to
exte
nd mounting
cords
where
a
t>
lu
g is
ne
ede
d on
the
eq
uipment
end.
2
.17
The
set
ends
of
mounting
cord co
nduct
ors
are
furni
shed with individual spade tips
or
wafers
for
terminating
on 588-, 589·, or 636-type
keys (Fig.
9,
10,
and
ll).
2.18
Terminating methods
are
shown
in
sections
covering connecting blocks.
Ri11
ger
2
.19
The
ringers
may
be
connected
as
individual
line
ring
er
or
common audible signals. R
efer
to the
Serv
ice
sect
ion
for
the appropriate telephone
set
connections.
2.
20
Current
production models
are
manufactur
ed
equipped
with
a C4B
or
HlB
(one-coil)
t·i
ng
e
rs.
Th
ese
ring
ers
can
a l
so
be
used
as
maint
enance repl
acements
for
the
C4A
and
H
lA
ringers.
When wiring
changes
are
necessary r
efer
to
the
Servi
ce
sect
ton
for
the
app
t·
opriate telephone
set.
2.21
Volume
cont
rol
cams
project
through
th
e
base
of
the
telephone
set
when
equipped
with C4A, B,
or
Hl-type ringers, and through the
lower
left
side
of
the
hous
ing
on
te
l
epho
ne
sets
equipped with
NlA
ringer
s.
2.
22
Volume is adjustable
to
loud, so
ft
,
and
off
by
eithet· type volume control ringer.
2
..
23
For
ring
er
cutoff
on
sets
with volume control
cams, remove hou
sing
and
move
the
detent
spring
from
its slot
and
rotate
the cum to the
off
position.
Pag
e 5

SECT
ION
502-500-
120
2.
24
For ringer cutoff on sets with
vo
lume control
arms,
it
is
not
necessary
to
remove
the
housing. Rotate and exert
pressure
on
the
arm
to
overcome
lhe
detent
action
to
reach
the
off
position.
Vo
lum
e c
ontrol
lever
dete
nt
act
ion
of
c
urr
e
nt
N-type
ring
ers
ha
s b
ee
n
i
mproved
by
msking
it
more
diffi
c
ult
to
insdverte
.IJtly
operat
e
th
e c
ontrol
le
ver
to
the
off
position
.
Termi
nal
S
trip
s
2.
25
The
589Y
and
636A
use
~
1
4
3
1
983
S.
(P-43A983)
terminal board (Fig.
2).
The
636B
uses the
~
1445400
S.
(P
-44E400)
terminal board (Fig.
3).
2.
26
Additional termi
na
l for connecting auxiliary
equipment
in
6-
butt
on sets m
ust
be
or
dered
se
par
ate
ly as fo
ll
ows:
• 589-type keys r e
quir
e an • 8
11
353
1.35
•
(P
-13
E313)
te
rminal
st
r
ip.
•
636-type
keys
requir
e
an
•812559623•
(P
-25
E962)
terminal
str
ip.
2.
27
These auxiliary terminal strips are attached
to the line switch bracket
as
shown
in
Fig.
6.
T
O
U
C
H
-
T
O
N
~
Di
al
2.
28
The 1560 a
nd
2560 s
eri
es telephone
sets
have
25
-type 10-bu
tto
n and
85-
type 1
2-
button
TOU
CH-
TONE dials, respectivel
y.
2.29
These
di
als
mu
st be connected so the green
dial lead
is
positive (
+)
and the orange-bl
ac
k
lead
is
negative
(-
).
2.
30
After completing installation, check the dial
operation
on each line using
the
central
of
fi
ces dial
lest
circuits. Refer to the appropriate
dial section
in
Division 5
01.
Hand
sets
2.31 When s
peci
al conditions e
xi
st the •
GS
A-type
or
Gl5A
ha
ndset• may be re
pl
aced
by
the
fo
ll
o
wi
ng:
•
G6A
R
(MD)
or
G6B
hand
set
for impaired
hearing
Pag
e 6
• G7
AR
handset for weak speech
•
GSA
or
GSB
handset for noisy locations
Polarit
y
Gu
ar
d
2.32
Polarity
guards
sh
ould
be
in
sta
ll
ed in
TO
UC
H-TONE sets only when specified by
local instruction for end-to-end
sig
naling when
batte
ry
and ground reversals are en
cou
ntered.
2.33
Mount the •819040528• (P-
90D
05
2)
guard
assembly
to
the r
ig
ht
di
al mounting br
ac
k
et
as shown
in
Fig. 1
2.
Fig.
9-Nonslotted
Wafer
S
tr
ip
End
af
M
ou
ntin
g
Card,
Early
Type
2.
34
A
po
larity guard c
an
no
t be mounted in a
l
!i63
or
25
63
sems
telep
hon
e set.
I
P2Lamps
2.35
The 1P2 key telephone system requires the
use of a dual envelope lamp (KS-
20673)
on
PI
CTUREPHONE® lines to indicate w
het
h
er
an
audio or v
id
eo ca
ll
is be
in
g
pr
ocessed.
2.
36
The same pair
of
wires is used to control
the K
S-2
0
67
3 lamp
as
is used for the 51A
la
mp.
The
vo
ltages a
t·
e under the control
of
the
PICTUREPHON8 l
in
e c
ir
cuit. The lamp is
in
serted
so th
at
th
e
wh
ile lamp
is
ill
uminated on
au
dio ca
ll
s
(
-1
0
vo
lt DC from the
li
ne circui
t)
and the red
lamp on video calls (
+
10
volt DC fr
om
the line

circuit). This
test
should be made by the installer
before fully inserting the lamp.
Speakerphone
Note:
When speakerphone feature
is
provided
the
A25B
connector cable should be used.
2.37
In nonspeakerphone installations, it
is
necessary
to disconnect the speakerphone leads
(V-G,
G-V
, V-BR, BR-V,
V-S
, and
S-V)
when these
sets
are multipled with other sets providing speakerphone.
3. MAINTENANCE
Components
3.01
Maintenance of handsets, dials, and ringers
are
outlined
in
sections
covering
these
components.
Removing
and
Replacing
Housing
3.02
Sets without exclusion:
•
To
remove housing, loosen captive screws
in
base of
set
. Lift housing up and toward
front of set.
• To replace housing, guide lower
front
of
housing over pushbuttons, align housing with
base of
set
, and gently press housing into
place. Tighten captive screws
in
base
of
set
.
3.03 Sets with exclusion:
•
To
remove housing, pull up exclusion plunger
to its operated position, loosen captive screws
in
base
of
se
t,
and
lift
housing
up
and
toward the front of set.
•
To
replace housing, guide lower front portion
of housing over pushbuttons, align housing
with base of set, and gently press housing
in
place.
•
Depress
exclusion
plunger
. With
slight
pressure it should snap into its unoperated
position.
• Operate exclusion plunger several times to
insure
proper operation. Tighten captive
screws
in
base of set.
ISS
4,
SECTION
502-500-120
Exclusion
Switch
3.04
Perform
no
field maintenance on exclusion
switch
and
plunger
other
than
cleaning
contacts with a
265C
tool.
3.05 Replace
set
or exclusion switch assembly if
any
of
the
following
exclusion
switch
requirements cannot be met:
• Exclusion
plunger
should
remain
in
the
operated
position when pulled up to the
full extent of its stroke.
• The
plunger
sho
uld
return
to
the
fully
depressed position when handset
is
replaced.
•
With
housing
removed,
normally
closed
contacts of the exclusion switch should have
perceptible follow when operated manually.
• With
housing
removed, open contacts
of
the exclusion switch shou
ld
have minimum
separation of 1/64-inch; gauge
by
eye.
Mounting
Cords
3.06
Replace mounting cords of early manufacture
(Fig.
9)
as follow
s:
(1)
Remove dial from its mounting bracket.
(2)
Remove terminal screws.
(3)
Disconnect spade-tipped conductors and wafer
sections.
(4)
Disengage cord stay hook from right leg of
dial mounting bracket.
3.07
Mounting cords of late manufacture feature
a slotted wafer strip (Fig.
10)
to facilitate
replacement.
3.08
Still later manufactured cords, designed for
use with 636-type key assemblies,
feature
slotted
wafer
sections for each line appearance
(Fig.
11).
This allows easy
arrangement
of lines
to pickup buttons.
t
No
field
maintenance
should
be
performed
on
the
pllll{
end
of
plug-ended
mounting
cords.
Page
7

SECTION 502-500-120
I NSUL ATED SPAOE TIPS
Fig. 10-Siotted Wafer Strip End of Mounting Cord,
Later Type .
Fig.
11 - Mounting Cord Used W i th 636-Type Key
Page 8
Fig.
12---819040528 (P-900052) Guard Assembly ,
In
sta ll ed.
Lam ps and Pushbutt ons
3.09 Replace cracked pushbuttons or coll ars.
Remove accumulated dirt or film from lamps,
co llars, and pushbuttons with a water dampened
cloth.
DO NOT USE SOL VENTS OF ANY
KIND. If cl ean ing does no t correct binding of
pushbuttons, replace button and collar assembly.
3.10 To replace defective lamp:
(1) Remove dial from mounting bracket.
(2) Carefully lift lamp from socket with KS - 6320
orange stick.
(3) Align larnp co u tacL ;;uriaces wheu placiug
new lamp in socket.
(4) Remou nt dial.
3.11 The button and coll ar assembly should be
carefully aligned to avoid interference wi
th
removal or replacement of housing.
Loose Number Card Retainers
3. 12 Current production TOUCH-TONE sets are
equipped with •812558039• (P-25£803) and
•802695619• (P-269561) card retainers, which cannot
be adjusted.

3.13
If
the
.S
1255785
S.
(P-25E785)
(MD)
number
card retainer becomes soloose on the faceplate
that
the number card
or
key designation strip s
lip
s,
it
can be tightened as follows:
(1)
Remove faceplate from set.
(2)
Remove card retainer from faceplate.
(3)
Bend the four
arms
of the retainer so
that
more
pr
essure will be applied to the number
ca
rd and designa
tion
strip.
The
bends s
hould
be made approximately 1/2-inch in from the tabs
on
the
ends
of
th
e arms and in the oppos
it
e
direction from the factory
bent
tabs.
(4)
In
st
all the
card
r
etaine
r on
the
facepl
ate
and insert the number card and key designation
st
rip.
(5)
Install faceplate on telephone set.
Note:
If
adjusting the arms
of
the r
eta
in
er
does not
result
in
suff
ici
ent
holding powet·,
replace
th
e number card retainer.
589·
and
636-Type K
eys
3.14
Field maintenance of the 589· and 636-type
keys (Fig.
1,
13, and
14)
consi
st
of:
• Adjusting contacts with a
363
tool.
• Cleaning contacts with a
265C
tool.
• Replacing loose or missing damper
studs
"VVith
•
811818590
• (P·18A859) vibration daruper
sleeves (Fi
g.
14).
Later
589-type keys do
not require this vibra
Lion
damper.
3.15
Contact
fo
llow and
sepa
ration is
obta
ined
by using a 363 tool
at
a point adjacent to
contact
sp
ring pile-up (Fig. 14). When adjusting
springs:
• There should be a minimum spring clearance
of
1/64
-inch
bet
ween
contact
sprin
gs
and
those parts of the key which
do
not make
co
ntact
with springs (Fig.
14).
•
No
rmally open contacts should make
wi
th
perceptible follow on locking keys before
key plun
ge
r assumes locked position.
ISS 4, SECTION
502-500-
1
20
K
EY
CODE
NO.
BASEP
LATE
CO
IL SPRING LATCH
BAR
Fig.
13-589-Type
Key
, Top View
MIN
CLEARANCE
BETWEEN
SPRINGS 116'1
INCH
811818590
( P
18A859
) VIBRATION
D
AMPER
SLEEVE
Fig.
14-589-
T
ype
Key
, Bottom
View
3.16
Replace
set
if
the
following r
equ
i1·ements
cannot be m
et
:
•
Wh
en
depressed
, locking pl
unger
should
rel
ease
any previously locked plunger on
its downstro
ke
.
•
Wh
en any pushbutton plunger is released
fr
om
its operated position, it should return
with a snap
to
its nonoperated position.
Page
9

SECTION 502-500-120
• An operated key plunger should not release
during downstroke
of
hold button.
• An operated key plunger should release from
i
ts
operated position on the upstroke
of
the
hold button.
• A turnbutton operated plunger, when rotated
90
degree
s clockwise, should maintain its
operated position.
•
When
rotated
counterclockwise
from
its
operated position, it should be self-restoring
the
last
30
degrees
of
r
otat
ion.
241-Type
Amplifier
3.17
Used
in
telephone
sets
with he
adset
jacks
to
amp
lif
y
the
o
utput
of
the
h
eadset
transmitter.
NO
FIELD
MAINTENANCE
SHOULD
BE
A1TEMPTED
ON
241-TYPE
AMPLIFIERS.
3.18
The
24
1A
"Series II"
(MD)
or
241B
amplifier
must
be used on a
ll
563HB (
MD
), HBM,
1563HB (MD), 2563HB (MD),
and
HBM se
ts
to
Page
10
10 Pages
eliminate mechanical interference with the exc
lu
sion
plunger.
3.19
Replace a 241-type amplifier if it
is
suspected
of
being defect
iv
e (as evidenced
by
poor
or
no
transmission).
TOUCH-TONE
Dial
3.20
Check line polarity if
no
tones are h
ea
rd
in
the receiver when a button
is
depressed.
ft
The
25-
and
35-type
dial
will
function
only
when
the
green
dial
lead
is
positive
(
+)
and
when
the
orange-black
lead
is
negative
(
-).
3.21
A ha
nd
test
set
connected to line
ter
minations
can be used to
test
for defective dials.
ft
Do
not
attemptrepairofTOUCH-TONE
dials
in
the
field.
Replace
defective
dials.