Honeywell XK516D1 User manual

Honeywell
I.B. 1516A Page T-1/T-2
May 5/97
Rev. 3: Oct 25/02
23-12-01
Component Maintenance Manual
XK516D1 HF Transceiver
Part Number
964-0452-001
964-0452-002
964-0452-011
964-0452-012
964-0452-022
DOCUMENT NO. 012-0693-001
Honeywell CAGE Code 97896

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page RR-1/RR-2
Oct 25/02
23-12-01
RECORD OF REVISIONS
REV. INSERTION BY
NO. DATE
REV. INSERTION BY
NO. DATE
REV. INSERTION BY
NO. DATE
1 Mar 30/01 HON
2 Sep 5/01 HON
3 Oct 25/02 HON
Retain this record in the front of the manual or chapter. Upon receipt of revisions, insert revised
pages in the manual, and enter revision number, date inserted, and initials.

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page TR-1/TR-2
Oct 25/02
23-12-01
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV. NO.
ISSUE
DATE
INSERTION
DATE / BY
INCORPORATION
DATE
23-01 Jul 15/97 Mar 30/01
23-02 Nov 7/01 Oct 25-02
23-03 Feb 5/02 Oct 25-02
23-04 Mar 26/02 Oct 25-02
23-05 Jul 26/02 Oct 25-02
INCORPORATION DATE is the date of the CMM revision that incorporates TR information.

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B.1516A Page SB-1
Sep 5/01
23-12-01
SERVICE BULLETIN LIST
SERVICE BULLETIN
NUMBER
DATE
INCORPORATED DESCRIPTION
964-0452-00X-23-1
(012-0693-101)
Mar 30/01 Corrects for anomalous behavior observed during
power interrupts between 4 and 250ms duration.
SW Ver. 1.50; HW Mod 10.
964-0452-00X-23-2
(012-0693-102)
Mar 30/01 Corrects for anomalous behavior observed during
testing at Airbus. Refer to EPRs 00001, 00002,
and 00003. SW Ver. 1.60; HW Mod 14.
964-0452-00X-23-3
(012-0693-103)
Mar 30/01 Eliminates problems encountered with the existing
Controller D module, and provides more reliable
XK516D1 Transceiver operation. HW Mod 22.
964-0452-00X-23-4
(012-0693-104)
Mar 30/01 Eliminates problems encountered with the
ON/OFF module, and provides more reliable
XK516D1 Transceiver operation. HW Mod 15.
964-0452-0XX-23-5
(012-0693-105)
Mar 30/01 Changes made in the upgraded software: Added
bit with Air/Ground status information to ARINC
429 Word Label 270 broadcast to ACARS MU and
Radio Control Panel. HFDL SW Mod 3.
964-0452-0XX-23-6
(012-0693-106)
Mar 30/01 Changes made in the upgraded software: Correct-
ed erroneous LRU Fault indication when Trans-
ceiver is in Data mode and on the ground, and the
Radio Control Panel input to the Radio is missing
or not available on both frequency select ports.
HFDL SW Mod 4.
964-0452-00X-23-7
(012-0693-107)
Mar 30/01 Eliminates problems encountered with the existing
Receiver/Exciter module, and provides more reli-
able XK516D1 Transceiver operation. HW Mod 13.
964-0452-00X-23-8
(012-0693-108)
Mar 30/01 Eliminates problems encountered during vibration
testing, and provides more reliable XK516D1
Transceiver operation. HW Mod 11.
964-0452-00X-23-9
(012-0693-109)
Mar 30/01 Converting the HF Transceivers to the new Part
Numbers will correct potential HF system lockup
conditions, resulting from unreliable HF Transceiv-
er/Coupler control communications in installations
with high EMI conditions.
964-0452-00X-23-10
(012-0693-110)
Mar 30/01 Corrects potential HF system lockup conditions,
resulting from unreliable HF Transceiver/Coupler
control communications in installations with high
EMI conditions. The software upgrade sets the co-
axial interface to Coupler, as the default, in the
Transceiver Control software. SW Ver. 1.70; HW
Mod 16.
964-0452-00X-23-11
(012-0693-111)
Mar 30/01 Reduces potential HF Transceiver susceptibility to
false PTT activation caused by keying of other au-
dio components. HW Mod 18.
964-0452-00X-23-12
(012-0693-112)
Mar 30/01 Corrects for spurious signals on SELCAL output
caused by ringing in SELCAL output stage. Cor-
rects for intermodulation distortion in the RF spec-
trum in the internal HFDL data mode. HW Mod 19.

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
1I.B.1516A Page SB-2
Sep 5/01
23-12-01
964-0452-0XX-23-13
(012-0693-113)
Mar 30/01 The HFDR Software Mod 6 version contains cus-
tomer requested Red label changes to be used for
flight testing. HFDL SW Mod 6.
964-0452-0XX-23-14
(012-0693-114)
Mar 30/01 Converts the Transceivers to the production ver-
sion of PN 964-0452-012, which are HFDL Soft-
ware Mod 8.
964-0452-022-23-15
(012-0693-115)
Mar 30/01 Converts HF Transceivers with Honeywell propri-
etary HF Data Link (HFDL) protocol (PN
964-0452-022) to HF Transceivers, using the in-
dustry standard ARINC 635 HFDL protocol (PN
964-0452-012). HFDL SW Mod 8.
964-0452-00X-23-16
(012-0693-116)
Mar 30/01 Changes the default date mode of operation of the
-0X2 Transceivers when both TP7G and MP2D
are grounded to Internal HFDL Data Mode instead
of defaulting to External Data Mode. This change
does not affect the voice mode of operation of any
of the radios. HW Mods 21 and 22.
964-0452-012-23-17
(012-0693-117)
Mar 30/01 Changes the Airborne Datalink Processor (ADP)
software to add the capability to display the ADP
and High Frequency Modem (HFM) software part
numbers on the ACARS/MCDU system and to fix
minor problems identified during testing of HFDL
Software Mod 8. HFDL SW Mod 9.
964-0452-00X-23-18
(012-0693-118)
Mar 30/01 Reverts back to Software Version 1.70. Software
Version 1.80 introduced problems with sidetone
suppression during transmit operation. SW Ver.
1.70; HW Mod 22.
964-0452-012-23-19
(012-0693-119)
Mar 30/01 Incorporates changes to the Airborne Datalink Pro-
cessor (ADP) software requested by ARINC to
prevent the HFDL System from logging on to a
ground station when the ICAO address input from
the MODE-S transponder is missing, and readjusts
the data rate thresholds. HFDL SW Mod 10.
964-0452-0XX-23-20
(012-0693-120)
Mar 30/01 Allows the HF Transceivers and Control Panel to
be powered up in any sequence. Currently, the
"HFDR INSTALLED" discrete output of the HF Da-
ta Radio (or DOUT0 Spare Discrete OUT of A2
ADP board) is grounded on power up under soft-
ware control. The "HFDR INSTALLED" discrete
needs to be grounded on the A2 ADP board even
when power is OFF. HW Mod 23.
964-0452-022-21
(012-0693-121)
Mar 30/01 Incorporates changes to the Airborne Datalink Pro-
cessor (ADP) software to reduce/eliminate nui-
sance HFDR Faults (Fault Code 39) caused by in-
put power transients. HFDL SW Mod 5.
964-0452-012-23-22
(012-0693-122)
Mar 30/01 Incorporates minor changes to the Airborne
Datalink Processor (ADP) software requested by
ARINC to ensure that the Maximum Uplink Data
Rate recommended by the avionics to the HFDL
ground stations is a minimum of 300bps. HFDL
SW Mod 11.
SERVICE BULLETIN
NUMBER
DATE
INCORPORATED DESCRIPTION

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page SB-3/SB-4
Oct 25/02
23-12-01
964-0452-0XX-23-23
(012-0693-123)
Mar 30/01 Upgrades Transceiver to be capable of operation
in HF Datalink (HFDL) mode per ARINC 753 and
635, as well as the HF Voice Radio (HFVR) capa-
bilities. Control SW Ver. 1.70; HFDL HW Mod 11.
964-0452-00X-23-24
(012-0693-124)
Mar 30/01 Corrects for nuisance CMC input fault reporting.
SW Ver. 2.00; HW Mod 27.
964-0452-00X-23-25
(012-0693-125)
Mar 30/01 Allows the ARINC 429 interface between the HF
Transceiver and a CMU or ATSU to operate reli-
ably at high-speed. Also improves susceptibility of
the Transceiver to short power interrupts of 10 to
40ms when operating in data mode. Mod 28.
964-0452-00X-23-26
(012-0693-126)
Mar 30/01 Incorporates minor changes to Airborne Datalink
Processor (ADP) software to improve data mode
operation during short power interrupts, and to en-
able high-speed 429 interface to the ATSU. HFDL
SW Mod 12.
964-0452-0XX-23-27
(012-0693-127)
Mar 30/01 Converts the Airborne Datalink Processor (ADP)
CCA, A2, from either Part No. 722-4134-006 to
722-4134-008 or from Part No. 722-4134-007 to
722-4134-009. The modification consists of remov-
ing IC sockets XU6 and XU23. Mod 31.
964-0452-0XX-23-28
(012-0693-128)
Oct 25/02 Replaces the EMC Filter, A7, Part No. 300-1096-
001 (R&S Part No. 6030.2251.02, Mod 4 or lower)
with EMC Filter, A7, Part No. 300-1096-002 (R&S
Part No. 6030.2251.02, Mod 5). HW Mod 33.
964-0452-0XX-23-29
(012-0693-129)
Oct 25/02 Replaces EPROM set, Part No. 6030.2151.00 Ver-
sion 2.00 or lower, with Version 2.20 on Controller
D, A8. HW Mod 34.
964-0452-0XX-23-30
(012-0693-130)
Oct 25/02 Instructions to upload upgraded HFDL software via
a Portable Data Loader while on the bench. HW
Mod 13.
SERVICE BULLETIN
NUMBER
DATE
INCORPORATED DESCRIPTION

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page LEP-1
Oct 25/02
23-12-01
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Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page LEP-2
Oct 25/02
23-12-01
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Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page LEP-3
Oct 25/02
23-12-01
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Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B. 1516A Page LEP-4
Oct 25/02
23-12-01
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Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B.1516A Page TC-1
Oct 25/02
23-12-01
TABLE OF CONTENTS
TITLE PAGE
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Purpose of Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Operation of HF Data Radio (HFDR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Operation of XK516D1 in Voice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Simplified Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. Detailed Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TESTING AND FAULT ISOLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3. Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4. Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5. Automated Test Equipment (ATE) Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A. Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B. ATP Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
C. CFDS Software Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6. HF Transceiver Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7. HF Transceiver ATP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8. Test Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9. Fault Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
B. Methods of Fault Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
C. Fault Isolation Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
D. BITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
E. Manually-Initiated Test/Power Up Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.4
F. Basic Voltage Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.5
G. Transceiver Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.6
H. Procedure to Verify Failed Frequency with the CFDS Function . . . . . . . . . . . . . . . . . . 122.7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
1I.B.1516A Page TC-2
Mar 30/01
23-12-01
TITLE PAGE
2. Disassembly Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
3. XK516D1 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
2. Transceiver Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
A. Cleaning the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
B. Cleaning the Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
C. Modules and Circuit Card Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
D. Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
E. Machined metal Parts or Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
F. Miscellaneous Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
G. Nonmetallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
2. General Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
3. Specific Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
A. Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
B. Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
C. Covers and Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
D. Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
E. Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
F. Modules and CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
G. Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
2. Circuit Card Assemblies (CCA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
3. Conformal Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
B. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
4. Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
5. Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
6. Painted Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
7. Transceiver Special Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603
ASSEMBLY (INCLUDING STORAGE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701
2. Transceiver Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B.1516A Page TC-3
Mar 30/01
23-12-01
TITLE PAGE
A. Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
B. Motherboard, A6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
C. EMC Filter, A7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
D. Power Supply, A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
E. Power Amplifier, A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
F. Receiver/Exciter Module, A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
G. Airborne Data Link Processor, A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
H. LED Board, A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
I. Interface D, A9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
J. Controller D, A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
K. HF Modem CCA, A10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
L. Chassis Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
M. Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
N. Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
3. Storage After Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
A. Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
B. Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
3. Equipment Designator Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
4. Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
5. Manufacturers’ Codes, Names, and Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
MANUFACTURERS’ CODES, NAMES, AND ADDRESSES . . . . . . . . . . . . . . . . . . . 1003
EQUIPMENT DESIGNATOR INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
NUMERICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
1I.B.1516A Page TC-4
Mar 30/01
23-12-01
LIST OF ILLUSTRATIONS
FIGURE DESCRIPTION PAGE
1 XK516D1 HF Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transceiver Front Panel and Rear Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Interconnect Diagram, HF Voice/Data Radio System . . . . . . . . . . . . . . . . . . . . . . 5
4 Transceiver Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Interconnect Diagram (Simplified), Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Block Diagram, Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Functional Diagram, Receiver/transmitter, A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Block Diagram, ADP, A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Connector Pin Assignments, ADP, A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 Block Diagram, HF Modem, A10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11 Connector Pin Assignments, HF Modem, A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12 Block Diagram, Synthesizer Loop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
13 Block Diagram, Synthesizer Loop 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14 Frequency Range Corresponding Data Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15 Gate Arrays Register Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
16 Synthesizer D6 Divider Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
17 Block Diagram, Receiver Analog Front-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
18 Block Diagram, Transceiver AF/Digital Section. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
19 Block Diagram, Exciter Analog Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
20 Block Diagram, Power Amplifier Board, A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
21 Block Diagram, Amplifier Board, A31A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
22 Block Diagram, Amplifier Control, A33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
23 Block Diagram, Harmonic Filter, A32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
24 Block Diagram, Controller Voice, A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
25 Assignment of Chip Select Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
26 Connection of an ASCII Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
27 Format of an ARINC Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
28 Minimum Interval between two ARINC Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
29 Assignment of ARINC Level to TTL Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
30 Linking Diagram of TTL Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
31 Block Diagram, ARINC Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
32 Level of Differential Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
33 Block Diagram, ARINC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
34 Block Diagram, ARINC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
35 Block Diagram, Regulator Board, A41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B.1516A Page TC-5
Oct 25/02
23-12-01
36 Block Diagram, Filter Board, A71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
101 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
102 Transceiver Main Menu (ABD0048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
103 Transceiver LRU Identification Menu (ABD0048) . . . . . . . . . . . . . . . . . . . . . . . . 118
104 Transceiver Last Leg Report with No Fault Indicated . . . . . . . . . . . . . . . . . . . . . 118
105 Transceiver Last Leg Report with Failures Detected. . . . . . . . . . . . . . . . . . . . . . 119
106 Previous Leg Report with Failure Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
107 Transceiver Ground Report with No Fault Detected . . . . . . . . . . . . . . . . . . . . . . 120
108 Previous Ground Report with Failure Detected . . . . . . . . . . . . . . . . . . . . . . . . . . 121
109 Transceiver Troubleshooting with No Fault Detected . . . . . . . . . . . . . . . . . . . . . 122
110 Transceiver Troubleshooting Data Menu with Failure Detected . . . . . . . . . . . . . 122
111 Transceiver Ground Scanning Menu with No Fault Detected . . . . . . . . . . . . . .122.1
112 Transceiver Ground Scanning Menu with Failure Detected . . . . . . . . . . . . . . .122.2
113 Table of Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.3
114 Table of Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4
115 Transceiver Test Menu with No Fault Detected . . . . . . . . . . . . . . . . . . . . . . . .122.5
116 Transceiver Test Menu with Failure Detected . . . . . . . . . . . . . . . . . . . . . . . . . .122.5
117 Basic Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.6
117A Sample Test Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.8
118 Transceiver Fault Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.19
119 Schematic, XK516D1 400W HF Transceiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
120 Schematic, Receiver/Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
121 Schematic, RF Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
122 Schematic, IF Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
123 Schematic, Subsynthesizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
124 Schematic, On Off Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
125 Schematic, Airborne Datalink Processor, A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
126 Schematic, HF Modem, A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.19
127 Schematic, Power Amplifier, A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.35
128 Schematic, Amplifier Board, A31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.39
129 Schematic, Harmonic Filter, A32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.51
130 Schematic, Amplifier Control, A33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.65
131 Schematic, Power Supply, A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.79
132 Schematic, Regulator Board, A41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.83
133 Schematic, Mains Filter, A42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.95
134 Schematic, LED Board, A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.99
135 Schematic, Motherboard, A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.101
FIGURE DESCRIPTION PAGE

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
1I.B.1516A Page TC-6
Oct 25/02
23-12-01
FIGURE DESCRIPTION PAGE
136 Schematic, EMC Filter, A7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.123
137 Schematic, Controller D, A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.161
138 Schematic, Interface D, A9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198.177
401 Cleaning Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
601 Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
701 Assembly Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
901 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
IPL 1 XK516D1 400W HF Transceiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B.1516A Page INTRO-1
Mar 30/01
23-12-01
INTRODUCTION
This manual was prepared by Honeywell according to ATA Specification No. 100.
The 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, and a List of Illustrations.
DESCRIPTION AND OPERATION section contains an equipment illustration, table of leading
particulars, a general description, and a description of operation for electronic assemblies, to assist
in understanding the equipment for fault isolation purposes.
TESTING AND TROUBLESHOOTING section contains tests to enable maintenance personnel to
assess the operational condition of the equipment, a troubleshooting guide to assist in fault
isolation, and schematics.
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 with the Illustrated Parts List (IPL).
CLEANING section contains general cleaning procedures, which should be observed during repair
and part replacement where applicable.
CHECK section contains general areas to visually observe during disassembly and assembly to
assure that equipment operational standards are met.
REPAIR section contains specific instructions for repairing areas of the equipment not specifically
covered in the ASSEMBLY section.
ASSEMBLY section contains all specific instructions necessary for part replacement and to
supplement the IPL.
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.
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT section contains a list of all special equipment
required to perform procedures specified in the other manual sections.
ILLUSTRATED PARTS LIST (IPL) 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.

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
1I.B.1516A Page INTRO-2
Mar 30/01
23-12-01
ABBREVIATIONS AND ACRONYMS
A/D Analog-to-Digital
AC Alternating Current
ACARS Aircraft Communications Addressing and Reporting System
ADP Airborne Datalink Processor
AF Audio Frequency
AGC Automatic Gain Control
AM Amplitude Modulation
AMPL Amplifier
ARINC Aeronautical Radio, Inc.
ATA Air Transport Association
ATE Automatic Test Equipment
ATP Acceptance Test Procedure
BIT Built-In Test
BITE Built-In Test Equipment
BP Bottom Plug
CCelsius
CCA Circuit Card Assembly(ies)
CFDS Central Fault Display System
CMC Central Maintenance Computer
CMU Communications Management Unit
CPLR Coupler
D/A Digital-to-Analog
dB Decibel
dBm Decibel with respect to 1 milliwatt
DC Direct Current
DDS Direct Signal Synthesis
DM Data Module
DMM Digital Multimeter
DOD-HDBK Department of Defense Handbook
DOS Disk Operating System
EMC Electromagnetic Compatibility
EMF Electromotive Force
EEPROM Electrically Erasable Programmable Read Only Memory
EPROM Electrically Programmable Read Only Memory
F Fahrenheit
FAA Federal Aviation Administration

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
I.B.1516A Page INTRO-3
Mar 30/01
23-12-01
Fig. Figure
GND Ground
GSE Ground Support Equipment
HF High Frequency
HFDL High Frequency Data Link
HFDR High Frequency Data Radio
HFM High Frequency Modem
HFVR High Frequency Voice Radio
Hg Mercury
Hz Hertz
IF Intermediate Frequency
kHz kilohertz
kBps kilobits per second
LED Light Emitting Diode
LRU Line Replaceable Unit
MCU Modular Concept Unit
MHz Megahertz
MIL-STD Military Standard
MP Middle Plug
MS Windows Microsoft Windows
mV millivolt
nm Nanometer
PC Personal Computer
PLL Phase-locked Loop
PROM Programmable Read Only Memory
PTT Push-to-Talk
PWB Printed Wiring Board
Ref. Reference
RF Radio Frequency
RTCA Radio Technical Commission for Aeronautics
RX Receive
SSB Single Sideband
TDMA Time Division Multiple Access
TP Test Point or Top Plug
TX Transmit
UTC Universal Time Coordinated
VVolt
VAC Volts Alternating Current

Honeywell
COMPONENT MAINTENANCE MANUAL
PART NUMBER 964-0452
1I.B.1516A Page INTRO-4
Mar 30/01
23-12-01
VCO Voltage-controlled Oscillator
VDC Volts Direct Current
WWatt
XCVR Transceiver