____sommurications AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100 COCKPIT VOICE RECORDER (CVR) MODELS A100, A100A CVR CONTROL UNITS MODELS A150, A151, A152, A151B, A152B CVR MIC MODULES MODELS A55, A55B RECORDER PART NUMBERS 93A100—( ) SOLID STATE MEMORY MODEL KIT 938SMK CONTROL UNIT PART NUMBERS 93A151-( ) 93A152-( ) MIC MODULES PART NUMBERS 93A055-{ ) COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST P/N: 165E0101—00 IN ACCORDANCE WITH FAA TSO—C84 AND ARINC CHARACTERISTIC NO. 557 23-70-01 Rov 3: Mar 04® ________communications____ AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100. ALOD/A100A Cockpit Voice Recorder A151, A518, A152, and A152B Control Units ‘A180 Microphone Preampliiier Module ‘ASS and ASSB Microphones ‘93SSMK Solid State Memory Module Kit PIN: 185E0101—00 Rovision 3: Mar 04 The recorder products/software are being exported from the United States in accordance with the Export Adminis- tration Regulations ECCN 40994, No License Required. Diversion contrary to U.S. law is prohibited. In accor- dance with U.S. Law (31 CFR Part 746, and Supplement No.1 to Part 774, and CFR Part 550) resate/re-export or transfer to the countries identified thorein is prohibited without the prior written consent of the U.S, Department of Commerce. This manual contains date sensitive information. To verify the latest revision level of this manual, visit our document download site at htto:/iwww.L—3ar.net. @Copyright 2004 by L-3 Communications. All rights reserved. No part of this manual may be repro- duced or utilized in any form or by any means, electronic ‘or mechanical, including photecopying, recording, or by information storage and retrieval system, without permis- sion in writing. Inquiries should be addressed to: L-3 Communications Aviation Recorders Publications Vendor Code: 06141 P.O. Box 3041 Sarasota, Florida 34230 Phone: (941) 371-0811 FAX: (941) 377-5591 23-70-01munication: AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL A100, A100A om, CAUTION x 4 THE CONTENTS CAN \ J BE DAMAGED BY t STATIC ELECTRICITY PROPER HANDLING REQUIRED GENERAL This product and related documentation must be reviewed for familiarization with safety markings and instructions before operation. This instrument was constructed in an ESD (electro-static discharge) protected environ- ment. This is because most of the semiconductor devices used in this instrument are susceptible to damage by static discharge Depending on the magnitude of the charge, device substrates can be punctured or de- stroyed by contact or mere proximity of a static charge. The results can cause degrada- tion of device performance, early failure, or immediate destruction. These charges are generated in numerous ways such as simple contact, separation of materials, and normal motions of persons ‘ing with static sensitive devices. When handling or servicing equipment coniaining static sensitive devices, adequate precautions mist be taken to prevent device damage or destruction. Only those who are thoroughly familiar with industry accepted techniques for handling static sensitive devices should attempt fo service circultry with these devices. In ail instances, measures must be taken to prevent static charge build-up on work sur- faces and persons handling the devices. BEFORE APPLYING POWER Verify that the product is set fo match the available line voltage and the correct fuse fs installed. Servicing instructions are for use by service~‘rained personnel only. To avoid dangerous electric Shock, do not perform any servicing unless qualified to do so. Adjustments described in the manual are performed with power supplied to the instru- ‘ment while protective covers are removed. Energy available at many points may, if con- tacted, result in personal injury. 23-70-01 nev: nts'04mmunicat AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100A THIS PAGE IS INTENTIONALLY LEFT BLANK. 23—70—01 rev Mr 08AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘Al00, A004 SERVICE BULLETIN LIST cvn DATE INCORPORATED ‘BULLETINNO, DATE ISSUED SUBJECT IN. MANUAL 101 Revt May 5/66 ‘A152 Control Unit Rewiring June 1/84 102 Rev 1 May 5/66 Relocation of Shiold Wire A151, A152C.U. June 1/84 103 Oct, 5768 Hard Mounting (CVR} June 1/84 104 Oct, 5/65 Heat Sink June 1/84 105 Oct. 5/66 Replacement cf Crash Protection Screws June 1/84 106 Oot. 5/68 A70 Time Courter Power Rating June 1/84 107 Oct. 16766 Crowning of Drive Motor Shaft June 1/84 108 Jan. 26167 Installation of Mod. No, Plate June 1/84 109 Rev. 1 Jan. 10/67 ‘Control Unit Field Conversion Kit June 1/84 110 Oct. 23/67 Mod. of 83G0A84 Tesi tone Gen, June 1/84 114 Rev.4 Oct. 23/67 Mod. of 930023 Monitor Amp. Assy. June 1/84 112 Rew. Oct, 23/67 Mod, of 300425 Test Tone Gen. dune 1/84 113 Jan, 26767 ‘Mod, of 8300823 Monitor Amp L1 June 1/84 114 Feb, 15/67 Rev. to O/H Requirements June 1/84 115 Feb. 15/67 Deactivation of Phone Jack June 1/84 116 Mar. 18167 LD, as to Last O74 June 1/84 417 Mar. 15/67 A140 Inverter Mod. June 1/84 118 Apr. 15/67 Allernaie Motor Source June 1/84 119 ‘Apr. 18/67 ‘A140 Inverter Mod. June 1/84 120 Jun 1469 Installation of Wire Guide PIN 800-487 dune 1/84 321 Oct. 1469 Special Mod. June 1/84 122 Sept. 3070 Now Bridge Assomblios June 1/84 123 Sepl. 30/70 Mad, 8900~A25 Test Tone Gen. June 1/84 124 Deo. 15770 ‘General Mode! Identification June 1/84 125 Sept. 20/72 Test Tone Gen, Board Beta Selection June 1/84 425 Fw. 1 June 1/73 Test Tone Gen Board Trans. Replacement June 1/84 128 June 1173 Addition of RF Fier Capacitor to Bulk June 1/84 Erase Assy, PIN 9300824 ser June 1774 Addition of RF Filter Capacitor to Blas Gen. June 1/84 Assy, PIN 9300421 128 ly 1774 Adgition of Filer Capacitor to Bulk Erase Jane 1/84 Asey.. PIN 8300-124 and 9300424 Rev. M 129 dan. 15/75 Deletion of Motor Heat Obiitecate Sink, June 1/84 PIN 8300-447 to units with PIN 9300—218—1 June 1/64 only 130 Mar, 1775 Replacement of Fitter Capacitor, June 1/84 PIN 8800-2581 with P/N 9300—258-3 431 Aug. 15/75 Replacement at Fier Capacitor, June 1/84 PIN 9800489 in P/N 980022 Assy. 23-70-01 musovr BULLETINNO. DATE ISSUED 31 Rev. 1 132 133 194 195 136 197 138 139 ata iat 142 143 144 145 146: 147 ana. ‘A148 Rew. 1 149 180 150 Rev. 1 15 152 153 +54 AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL Dec. 1/75 Sept. 1/77 Dec. 1/7 May 18/78 May 15/78 Mar, 15/79 Jun, 18/79 Jun, 30/79, ul. 1779 Deo.10/78 Jun. 30/80 Aug. 8/80 Oct. 20/80 Feb. 10/81 Mar. 1/84 Mar. 15/81 Feb. 15/82 Jun, 19/82 ‘Aug. 10/82 Jun, 30/82 Jun, 30/82 ‘Aug. 10/82 ‘Aug. 30/84 Mar. 30/86 Apr. 186 ‘Aug. 1487 FAIRCHILD MODEL A100, A1008, SERVICE BULLETIN LIST (continued) DATE INCORPORATED SUBJECT Change Filter Capacitor trom P/N 9300-459 10 9300-459-1 on P/N 930022 Assy. ‘Transistor Change on AG21 Board New Splicing Tape and Procedure Addition of Timer Bd. Assy. P/N 9300A098 Adeition of Underwater Locating Device to CVR Model Aco Replacement of Battery in Underwater Device Installation of Motor Heat Sink Addition of Retlective Tape to Recorder Modification of Mic. Pre—Amp ‘Alert Bulletin Check for Omission of Thermal Assy. Introduction of Precision Bridge Assy. Modification cf Control Units Mic. Pro—Amp Obiiterate Moa. 4 Modification of 152B and 1818 Gontro! Units Assy, Procedure Capstan Assy, P/N 93004028 ‘Addition of Mic. Jumper Wices Modification cf Control Unit Model 1528 PIN 934152—20 Modification to Capstan Shaft and Capstan Bearings Alert Bulletin — Modification to ‘9200802302 Bd. Assy. Correction to Schematic FSB A148 Introduction ct Altemate Drive Motor, PIN 9300-21802 Introduction ef Underwater Locating Device Installation Kit for Modo! A100 Recorders Correction t9 $8150 Modification cf Control Unit Modols A151B and A152B Addition of Capacitors for Edge Track Head Biasing, Models A100 and A100A ‘Moulfication of Meter Resistor on Monitor ‘Ampilier, PIN $200-A023-04 Insulation Assembly Advisory IN. MANUAL June 1/84 June 1/84 June 1/84 June +184 June 1184 June 1184 June 1/84 June 1/84 June 1/84 June 1/84 dune 1/84 dune 1/84 June 1/84 June 1/84 June 184 June 1/84 June 1/84 June 1/84 June 1/84 June 1/84 June 1/84 June 1/84 June 1/84 Feb. 15/90 Feb. 18/90 Fob, 15/90 23-70-01 Service Buletin List Page 2 Rev 1: Mar 93cv BULLETIN NO. 155 156 187 188 159 160 161 162 163, 163 Rev. 1 163 Rev. 2 164 165 166 167 AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILE MODEL ‘A100, AL0OA SERVICE BULLETIN LIST (continued) DATE INCORPORATED. DATEISSUED. Aug. 90/87 Feb.15/88 Mar, 15/68 Sep, 20/88 Aug. 15/69 Oct. 180 sul, 15/91 Jun. 13/91 Dee, 20/98 May 1/96 Jun. 19/96 Nov. 15/93 Apr. 04/98 Feb, 01/97 Mar, 21/00 SUBJECT SN MANUAL Introduction of Drive Motor P/N 9300-218-03 Feb. 15/90 to replace P/Ns 900-218-901 and 300-218-02 Introduction of New Type Hads, Reel, and Tape Assembly Modification to Precision Bridge Assy, PIN 9900-125-02 Introduction of New Type Erase Head for Non-Procision Bridge Assy. Introduetion of New Type Underwater Locating Device with Six Year Battery Modiication te GVR Gable Assembly P/N 89008016; to use printed circuit Board in place of exsting connector; no P/N change Introduction of New Type Power Supply PwA Introduction of 8800A140-02 AC/DC Inverter Introduction of Solid—State Memory Kit (PIN: 99-SS-MK) MOD-DOT #29 Correction to FSB 163, Correction to FSB 163 — Retained Parts, Page 9. ‘tomate Supplier for Underwater Locator Beacon (Datasonics) Introduction of new Underwater Locator Beacon (Dukene PIN: DK120) Modification of Solid-State Memory Kit PIN 93-SS—UK, only for MOD—DOT #29 Units Introcuction of new Reel & Tape Assy. PIN: 88400 Fob, 15/90 Feb. 15/90 Fob. 15/90 Feb, 15/90 May 1/91 May 191 May 1191 TBS ~ Rev. 08 TBS ~ Rev. 03 TBS — Rev. 03, TBS ~ Rev. 03, TBS — Rev. 03 TAS — Rev. 03 TSS — Rev. 03, 23—70—01 ‘Service Bulletin List Page 3 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A104 THIS PAGE INTENTIONALLY LEFT BLANK. 23-70-01 series Bun ts Wey 1791AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, MOOA RECORD OF REVISIONS REV. INSERTION [BY |REV. INSERTION [BY REV. |INSERTION BY NO. |DATE NO, |DATE No [DATE oF Mares | OM @ Jul 8 cM 03 Mar.o# | GW ae Pago 1 Rev. 3: Mar 04AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, 100A THIS PAGE INTENTIONALLY LEFT BLANK 23-—70—01 Record of Revisions Page 2 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A RECORD OF CHANGES REVISION | DATE OF CHANGE ‘COMMENTS May 1191 Relssue May 1/97 Tmplemented FSB 160, 161, 162, & 163, Also modified IPL in accordance with ATA~Spec 200, Mar 83 Rov. t Tar 83 Corrected numerical index. Also implemented miscellaneaus corrections, ul 83) Rov. 2 Jul 93 Included data on preFSB127 bias oscillaior board. Also included piece parts for recorder assembly moter, pin $300—218—x« Mar 04 Rov.3 Mar 04 Introduction of new Datasonies ULB. pin: ELP-362D per FSB159. Cianfication of }28Vdec input configurations for CV Record ers, (see IPL Fig2}. Updated Section 100, Testing & Troubleshooting. Updated IPL to feflect latest revisions. Updated Overhaul re- guirements. 23-—70—01 Record of Changes Paget Rev: Mar 08AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘At00, 1004 THIS PAGE INTENTIONALLY LEFT BLANK 23—70—-01 core of anges Page? May 191AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILC MODEL A100, 100A LIST OF EFFECTIVE PAGES Section Page Date Title Page i Mar 04 i Mar 04 i Mar 04 v Mar 04 Service Bulletin List 1 Mar 04 2 Mar 93 3 Mar 04 4 May 181 Record of Revisions Revs 4 Mar 04 2 May 1191 Record of Changes Rov3 4 Mar 04 May 81 Mar 04 2 Mar 04 3 Mar 04 4 Mae 04 Re.3 5 Mar 04 Ret 6 Mar 93 Table of Contents Revs 1 Mar 04 Revd 2 Mar 04 Reva 3 Mar 04 Rev.2 4 sul 93 Reva 8 Mar 04 Revt 6 Mar ¢3 Revd 7 Mar 04 Ret 8 Mar $3 Rows 9 Mar 04 Rev.3 10 Mar 04 Introduction Res 1 Mar 04 Rev3 2 Mar 04 Revs 3 Mar 04 Revs 4 Mar 04 Revs 5 Mar 04 Revd 8 Mar 04 Revs 7 Mar 04 Reva 8 Mar 04 Description and Operation Rev.3 ft Mar 04 Alt Section Page Date Rev. 2 Mar 04 Rev.3 3 Mar 04 Revs 4 Mar 04 Rev3 5 Mar oa 8 May 1/01 7 May 1/91 Revd 8 Mar 04 9 May 1/91 10 May 1/91 " May 119 Rew. 12 Mar 04 Revd 13 mar 04 Rev'd 14 Mar 04 18 May 1/91 Revd 18 Mar 04 Rev.3 17 Mar 04 8 May 119% 19 May 101 Rev.3 20 Mar 04 Rev. 24 Mar 04 2 May 1/91 2 May 1/91 24 May 119% 25 May 1194 26 May 1/94 Testing and Troubleshooting Rev. 101 Mar 04 Rev 3 102 Mar 04 Rew. 103 Mar O4 Rev.3 104 Mar 04 Rov.3 105 Mar 04 Rev.3 105 Mar 04 Rev.2 107 Mar 04 Rev.3 108 Mar 04 Rev.3 109 Mar 04 Rev. 110 Mac 04 Revs itt Mar 04 Rev. 112 Mar 04 Rov. 113 Mar 04 Revd 114 Mar 04 Rev. 115 Mar 04 Rev3 116 Mar 04 Rev.3 117 Mar 04 Rev 118. Mar 04 23-70-01 Page 1 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, Ai00A Section Page Date Section Page Date Testing and Troubleshooting (cont,) Rev. 164 Mar 04 Re. 3 19 Mar 04 Rows 165 Mar 04 Rev.3 120 Mar 04 Revs 166 Mar 0+ Rev 3 121 Mar 04 Disassembly Rev.3 122 Mar 04 Rov.3 301 Mar 08 Rev.3 125 Mar 04 Rev. 302 Mar 04 Rev.3 124 Mar 04 Rev.3 725 Mar 04 Reva 303 Mar 04 ev sul 93 Rev. 126 Mar 04 Rew Rev.3 127 Mar 04 ev. 308 Mar 04 Revs 128 Mar o4 Rev.3 506 Mar 04 Rov.3 129 Mar 04 307 May 1/91 Re. 3 190 Mar 04 308 May 191 Rov. 3131 Mar 04 309 May 1/91 Rev.3 732 Mar 04 310 May 1/91 Rov. 3 133 Mar 04 an Mey 191 maa eM a Mya Revd 135 Mar 4 lean Rev.3 136 Mar 04 Cleaning Rev.3 137 Mar 04 ot May 191 Rev.3 138, Mar 04 02 May 181 Rev.3 138 Mar 04 Check Rev.3 140 Nar oA Rev.3 501 wer 04 nr fos soe er Rev.3 143 Mar 04 Rev. 3503 Mar 04 Rev.3 144 Mar 04 Rev. 504 Mar 04 Rev. 145 Mar 04, Repair Revs 46 Mar 04 cot May ver Rows 147 Mar 04 02 Mey 81 Revs 148 Mar 04 60s Mayer Revs 149 iar 04 Rev.3 150 Mar 04 $04 May 1/01 Rev.3 151 Mar 04 Rev.3 605 Mar 04 Revs tse Mar 04 Rev.3 606 Mar a4 Revs 153 Mar 08 07 May 1199 Rev.3 154 Mar 04 608 May 1/91 Rev.3 155 Mar 04 a09 May 1/91 Rev.3 156 Mar 04 bio May 191 Rev.3 187 Mar 04 en way 131 Rev.3 158 Mar 06 Revg 158 Mar be Revd 612 Mar 04 Rev.3 160 Mar 04 618 May 701 Rev.3 161 Mar 04 Rev. 3 614 Maer 04 Rov. 162 Mar 04 Rev.3 818 Mar 04 Revs 163 Mar 04 Revi1_ 616 Mar 93 23-70-01 Page 2 Rev 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A1QdA LIST OF EFFECTIVE PAGES Section Page Date Assembly Rev.3 701 Mer 04 Rev.3 702 Mar 04 703 May 1/91 Rev.2 704 Jul 93 708 May 191 708 May 181 Rev.3 707 Mar 04 708 May 1/01 709 May 1/91 m0 May 1/91 m™ May 191 nz May 1191 713 May 1/81 m4 May 1/81 m5 May 1/91 716 May 1794 m7 May 1191 ne May 1/91 m9 Mey 1/91 720 May 1/91 Rev.3 721 Mar 04 722 May 1791 Fits and Glearances Rev.3 804 Mar of 802 May 1/91 Special Tools, Fixtures and Equipment 01 Mar 04 02 Mar 04 903 May 1/01 804 May 91 908 May V9t 908 May 181 Mustrated Parts List Rev.3 1001 Mar 04, Rev.3 1002 Mar 04 Rev.3 1003 Mar 04 Rev.3 1004 Mat 04 Rov.3 1008 Mar 04 Rov. 3 1006 Mar 04 Rev. 3. 1007 Mar 04 Rev.3 1008 Mar 04 Se Page Date Rev.3 1009 Mar 04 Rev.3 1010 Mar 04 Rev.3 1011 Mar 04 Rev. 3 1012 Mar ca Rev.3 1013 Mar 04 Rev.3 1014 Mar 04 Rev.3 1015 Mar 04 Rev.3 1016 Mar 04 Rev.3 1017 Mar 04 Rev.3 1018 Mar 04 Rev.3 1019 Mar 04 Rev.3 1020 Mar 04 Rev.3 1021 Mar 04 Rev.3 1022 Mar 04 Rov.3 1023 Mar 04 Rev. 3 1024 Mar 04 Rev.3 1025 Mar 04 Rov.3 1026 Mar 04 Rev. 1027 Mar Ga Rev.3 1028 Mar 04 Rev. 3 1028 Mar 04 Rev. 3 1030 Mar 04 Rev.3 1031 Mar 04 Rev.3 1032 Mar 04 Rey.3 1033 Mar 04 Rev.3 1034 Mar 04 Rov.3 1035 Mar 04 Rev. 3 1036 Mar 04 Rev.3 1037 Mar 04 Rev.3 1038 Mar 04 Rev. 3 1038.1 Mar 04 Rev. 3 1038.2 Mar 04 Rev. 3 1038.3 Mar 04 Rev. 3 1038.4 Mar 04 1039 May 1191 Rov.3 1040 Mar 04 Rev. 1041 Mar 04 Rev.3 1041.4 Mar 04 Rev.3 1041.2 Mar 04 Rev. 3 1041.3 Mar 04 Rev. 3 1041.4 Mar 04 Rev 31042 Mar 04 23-70-01 Page 3 Rev 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, NOGA LIST OF EFFECTIVE PAGES Section Page Date IMustrated Parts List (cont.) Rev.3 1043 Mar 04 Rev.3 1044 Mar 04 Rev. 1045 Mar 93 Rev.3 1045.1 Mar 04 Rev.3 1045.2 Mar 04 1046 May 1/91 Rev.1 1047 Mar 93 Rew 1048 Mar 93 Rev.1 1049 Mar 93. 1050 May 1191 1051 May 1191 1052 May 1191 Rev. 1 1053 Mar 93 Rov. 1 1084 Mar 93 Rev.1 1085 Mar 93 1056 May 1/91 Rev.1 1087 Mar 93 Rev.3 1058 Mar 04 Rev.3 1059 Mar 04 1060 May 1191 Ret 1061 Mar 93 1062 May 1/91 Rev. 1 1063 Mar 93 Rev.1 1064 Mar 93 1065 May 1/91 1066 May 191 Rev.1 1067 Mar 93 Rev. 1068 Mar 93 1069 May 1791 1070 May 1781 Rev1 1071 Mar 93 Rev. 1072 Mar 93 1073 May 1/91 1074 May 1/91 Rev.1 1075 Mar 93 Rev.t 1076 Mar 93 ‘077 May 1/91 1078 May 1/91 Rev. 1079 Mar 93 1080 May 1/91 Section Page Date Rev.1 1081 Mar 93 Rev. 1 1082 Mar 93 1083 May 1/91 1084 May 1191 1085, Mar 93 1088 Mar 93 1087 May 1191 1088 Mar 04 1089 Mar 04 1990 Mar 04 1091 Mar 04 1992 Mar 04 1993 May 1191 Revs 1094 Mar 04 Rev.3 1095 Mar 04 Rev.3 1096 Mar 04 Rev.3 1097 Mar 04 Rev.3 1098 Mer 04 Rev.3 1099 Mar 04 1100 May 1701 Rev. 1101 Mar 93 1102 May 1/91 Rev. 1103 Mar 93 Rev.1 1108 Mar 93, 1105 May 1/91 1108 May 1/91 1107 May 101 Rev.t 108 Mar 93 Rev.t 1109 Mar 93 amo May 1191 Rev. 4111 Mar 93, ma May 1191 Row 1113 Mar 93 Ret 1114 Mar 93 115 May 1/91 16 May 1/91 Ret 1417 Mar 93 Revit 1118 Mar 93 Rey 1119 Mar 93 1120 May 1/91 Rev t 1124 Mar 93 23-70-01 Page 4 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL LIST OF EFFECTN S CTIVE PAGE ‘Section Page Date Section Page Date Mlustrated Parts List {cont.) Rev. 1136 Mar 93 1122 May 1/9 1137 May 1/91 Revt 125 Mar 93 1138 May 1/91 Rewt 1124 Mar 93 Rov. 1 1139 Mar 93 Rev.t 1125 Mar $3 Rev. 1 1139.1 Mar 93 4126 May 1/91 Rev. 1 1139.2 Mar 93 Revi 1127 Mar 93 Rev.3 1140 Mar 04 Revit 1428 Mar 93, Rev.3 1141 Mar 04 1129 May 1701 Rev. 3 1142 Mar 04 1130 May 1/91 1143 May 1/91 Rev. 1131 Mar 93 1144 May 1/91 Revd 1132 Mar 04 Rov.1 1145 Mar 93 1133 May 1/91 1146 May 1/91 1134 May 1/91 Rev.t 1147 Mar 93 Rev. 11135 Mar 93 1148 May 1/91 23-70-01 Page 5 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL. FAIRCHILD MODEL ‘A100, AI0GA THIS PAGE INTENTIONALLY LEFT BLANK 23-70-01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A SUBJECTIDESCRIPTION PAGE INTRODUCTION 1. General 1 2. Verification 3 3. Recorder Modifications 4 4. Control Unit Modifications 7 DESCRIPTION AND OPERATION 1. Description... 1 ‘A. Cockpit Voice Recorder and Gontrol Unt. 1 B. Cockpit Voice Recorder (See Figure 2) ....... 1 (1) Drive Unit Assembly (see IPL Figure 16). 1 (2) Reel and Tape Assembly (see IPL Figure 16, tem 28 & 254) 1 (3) Reol Cover Assembly (se IPL Figure 15) 3 (4) Insulation Assembly (see (PL Figure 14, item 375) 3 (©) Record Amplifier Board Assemblies (see Figure 3) 3 (8) Bias Generator Board Assembly (see Figure 9) 3 (7) Moritor Amplitier Board Assombly (see Figure 3) 4 (8) Timer Board Assembly (see Figure 3) .. 4 (2) Test Circuit Board Assembly (See Figure 8) «ee. eessvsee . 4 (30). Bulk Erase Timing Board Assembly (see Figure 3) 5 5 5 5 5 3 5 5 8 8 8 (11) Power Supply Board Assembly (see Figure 3}. (12), Acoustic Underwater Locator Beacon Assembly (Optional) (see Figure 4) ©. Control Unit (1) Microphone Preamplier Board Assomtly (a@e Figure §) (2) Remote Area Microphone (see Figure 6) D. Optional Equipment (1) Inverter : (2) Accuste Underwster Locator Beacon Assembly (see Figure 4) (3) Optionai remote area microphones (see Figure 6) . 2. Leading Particulars ‘A. Leading Particulars for the Cockpit Voice Recorder Systom. 8 B._Dilforonces in Models o on : 10 (1) Cockrit Voice Recorder Difererces : 10 (2) Contr: Une Dierencos (see IPL Figure 20 for Part Numbers) 10 3, Operation = 12 ‘A. Block Diagram Description (soe Figure 8 and Figure 9) 12 B. Circuitry Operation : 12 (1) Augio Input - : 12 23—70—01 Table of Contents Page 1 Rev. 3; Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILO MODEL ‘A%00, 100A TABLE OF CONTENTS (continued SUBJECTIDESCRIPTION PAGE a (2) Preampitier Output : 12 (3) Recording Mechanism 0... ee. : coe 13 (4) Test Cirouitry 14 (5) Buk Erase Circuit ..... votes 18 (©) Power Supply 15 (7) Power Supply 205E0827-XX, FSB 161.0... 18 ©. Detailed Circuit Description 6 (1) Control Unit 15 (2) Microphone Preampitier 23008030 coe 15 (8) Control Unit Modification 4 ...... 16 (4) Microphone Preamplifier S9A263-01 0... cece cee : 16 (5) Microphone Preamplifier 938242 . .. 16 (6) Microphone Preamplifier 9A266-(XX) 16 (Record Amplifiers $300A020 16 (8) Bias Generator 93008021 . 16 (8) Bridge Assembly (see IPL Figura, WT AAneo TA) cette 7 (10) Test Circuit 93000025-01 . a (11) Test Circuit 93004025-02 7 (12) Monitor Amplifier 3008023 . 18 (13) Monitor Amplifer 8900A029-02 (soe Figuro 112) 18 (14) Monitor Ampiiar 93008023-04 (see Figure 112) 19 (18) Timer Board 23004098 oe 19 (16) Bulk Erase Circuit 93008024 . 9 (17) Power Supply 9300402201 . - . 20 (18) Power Supply 20SE0527-xX, FSB 161... 20 {19} DCIAC Inverter 8300A140 . 20 {20) DCIAC inverter 9300A140-01 (See Figure 116A) - cee at (21), DCIAC Inverter 93004140-02, FSB 162 (See Figure 1168) . 24 4. Cockpit Voice Recorder Outline & Dimension Drewings 21 TESTING AND TROUBLESHOOTING 4, Testing Procedures... seve . ae voces 401 A. Test Equipment ce 101 B. Mechanical Test Procedure : 102 ©. Electical Test Procedure 103 (1) Recorder... 103 1 (2) Contr! Unit coe 112 (8) Testand Calibration .. . 115 (4) Remote Microphone ce 18 | (8) Inverter 93004140 and 9300A140-01 120 (6) Underwater Locator Beacon CO 4 23—70—01 Table of Contents Page 2 Rv. 3 Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL A100, A100A TABLE OF CONTENTS (continued) ‘SUBJECTIDESCRIPTION PAGE 2, Troubleshooting Procedures. vote cee 124 A. Main Recorder Assembly . 21 8. Record Ampitior Assembly 123 ._Interwing Diagrams 120 D. Circuit Boards of the Cockpit Voice Recerder 129 DISASSEMBLY 4. Disassembly Proo9duF@8 oon 0 A. General . 301 8. Overhaul Parts Replacement wot C. Main Recorder Assembly (See IPL Figures 2, 13, & 14) 303 D. Recorder Assembly (see IPL Figure 14) . .. 304 E, Drive Unit Assembly (see IPL Figure 16). 306 F. Reel Cover Assembly (see IPL Figure 15) . 308 G. Chases Wiring Assembly e68 IPL Figure 195 Figure 198) ve 306 H. Electronic Board Assembles (See IPL Figs. 3t0 12, 21 to 23, & 25) : 307 1 Undersater Locating Device (ULD\See IPL Figure 2, IPL Flgwe 13, and Figure 301)... 308 4. Control Unit Assembly (see !PL Figure 20}... 309 Remote Mirepaone Assemtiy(See IPL Figure 24) . 09 L. Mcropmone Assembly (sae PL Figure 26) 0 M. Microphone Assembly (s6e IPL Figure 27) 310 N._ Access to Belt and Motor (See IPL Figure 2, PL Figure 13, & IPL Figure “4) + m0 0. ecess 1 Tape Compartment (See IPL Figute 2, IPL Figure 14) 310 Stein Breen Assembly (80 PL Figure 1”— Sheets 1 and2, BIPLEIQUO TTA) eee ve dene Ott Q. Inverter Assembly (see IPL Figure. 2A) 3 CLEANING 1. General... . ce a1 A. Matoils Required cesses 401 B. Clearing Procedures oso. scessenssevee 401 ©. Bearings . 01 . Electronic Pants. vives 401 E. Clean and Polish Seoveetesnestire 402 23-70-01 Table of Contents Page 3 fev, 9 Mar 08AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL. A100, A100A TABLE ITS (continue: SUBJECT/DESCRIPTION PAGE CHECK 1. Genera. . a) 2. Mecharical inspection 501 A. Parts, General 501 B. Bearings veceeeeeeeee : 501 ©. Castings... veeteeeee : 501 D. Terminal Boards and Connectors peessitee vee 501 E Wiring a a 501 F. Electonle Boards : : cee 801 G. Maln Recorder Assembly (See IPL Figure 2) - votes ve 5OL H. Recorder Assemaly (see IPL Figura 14) 502 |. Drive Unit Assembly (see IPL Figure 16) vee 303 J. Reel Cover Assembly (see IPL Figure 15) ....... : bones 503 2. Electrical Checks . bovetietieteienieeeseee 504 A. Chassis Wiring Assembly (see (PL Figura 19.and 19A) ..... 508 REPAIR 4. General Repair vie 801 {A Elecroi Components and Assorbis (99 IPL Figures 3 through 12,22 & 23) 602 B, Tape Splicing and Loop Measurement Procedure (see Figures 601 and 602) e02 C, Head Replacement . 605 D. Determination of Head integrity 605 E, Head Reconditioning . 606 F._ Repairof Thermopack Assembly $300K018 ard 8300AG06 (seo Figure 605). 607 G. Circuit Board Mosifications - Monitor Amplifier Circuit Board PIN 9300023 (G90 Figura 608 and IPL Figures 7,8, and 84) aoe Gre, Bord Mxtoatons Test Creat BarePM S900A025) (08 Fgue 607 and IPL Figures YOand 11)... i" arse 310 |. Moaticaion - Volos Recorder Drive Motor Capacior Cicut (See Figura 608)... 610 J. Replacement of Battery in Underwater Locator Beacon (see Figure 609) .. ett K. Transistor Complement... ata L._nverter instalation o bees 615 23—70—01 Table of Contents Page 4 Rev. 2: J $3AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, A100, A1008 TABLE OF CONTENTS (continued) SUBJECTIDESCRIPTION PAGE ASSEMBLY 1._Assembly Procedures Ot A. General 701 8. Drive Unit Assembly (see 1PL Figure 16). m1 C. Reel Cover Assembly (see IPL Figure +5) 703 (D, Recorder Assembly (see IPL Figure 14) 104 E. Chassis Wiring Assembly {see IPL Figure 19 Figure 19A) m F. Main Recorder Assembly (See IPL Figures 28 13) . . at G. Electronic Board Assemblies (See IPL Figs. Sto 12, 21 to 23, & 25) - 2 H. Control Unit Assembly (see IPL Figure 20) re |. Inverter Assembly (see IPL Figure 3A} . 713 44. Microphone assombly (soe IPL Figure 24). 713 K. Microphtone Assembly (soe IPL Figure 26) m4 L. Microphone Assembly (see IPL Figure 27) m4 M. Bridge Assemoly (9300A088) (see IPL Figure 17) ., m4 N. Precision Bridge Assembly (P/N 934328) Alignment Procedure (See IPL Figur 17a) . 718 2. Storage Instructions vee . - . 724 A. Stcrage in Original Containers ma B. Storage Without Original Containers 7a ©. Storage of CVR Bearings : 71 FITS AND CLEARANCES 4. Goneral . foe : ve : 80 SPECIAL TOOLS, FIXTURES AND EQUIPMENT Special Test Equipment ....... : cece 901 Bias Generat Extonder Board (PIN 9300A8S1) Alignment Procedure . + 904 Boll Tension Gauge (PIN 9300A846-01) Calibration . 904 Playback of Information Recorded on individual Channel Using the Record Head Monitor Sard (205E0319-00) ... 23-70-01 Tale otconans PaceAVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL. FAIRCHILD MODEL ‘A100, A100A, TABLE OF CONTENTS (continued) SUBJECTIDESCRIPTION PAGE 4. Introduction... : cette etneeteeeee A. Purpose : 1001 ILLUSTRATED PARTS LIST B._ Using the Datalled Parts List +001 ©. Abbreviations and Symbols... 1002 D. Vendors! Codes... ess. 1003 E. Equipment Designator Index .. 1009 F. Numerical index 1015 G. Mustrated Parts Lists 1039 LIST OF FIGURES FIGURE PAGE Figure 1 Cockpit Voice Recorder. Model A100... 2 Figue2 Cockpit Voice Recorders, Modes A100 and A100A . 3 Figure 3 Subassemblles, Cockpit Voice Recorder, Model A100, - 4 Figure 4 Cockpit Voice Recorder, Underwater Locator Beacon Installed. 6 Figures Exploded View of Control Unit Assembly, A152, A152B.. 7 Figure 6 Area Microphones (Optional)... .sesecseseeeeees se 8B Figure 7 Contol Unt Configurations, Models 151, A161B, 1628, A162, A162-1, and A152-4 12 Figure 8 Cockpit Voice Recorder A109 and Cen! Unk A128, Function Block Diagram 13 Figure 9 Cockpit Voice Recorder System Control Unit A191B, Functional Block Diagram tb Figure 10 Timor Board Incicator vcceeees 19 Figue 11 Medel A100, Outine & Dimension Drawing 2 Figure 12 Modei A100 With Beacon, Outline & Dimension Drawing 23 Figure 13 Model A100, Outline & Dimension Drawing 24 Figure 14 Model A100A With Beacon, Outline & Oimension Drawing 25 Figure 101 CVR Test Setup Block Diagram ....... see 108 Figure 102 A100 and A100A Recorder Test and Adjustment Points oe toa Figure 103 Control Unit Test Setup Block Diagram : : 112 Figure 104 Control Unit Test and Acjustment Point - 12 23-70-01 Table of Contents Pago 6 Fay 1: Mar 93FIGURE Figure 105 Figure 106 Figure 107 Figure 107A Figure 108 Figure 109 Figure 1094 Figure 110 Figure 1104 Figure 111 Figure 112 Figure 113 Figure 114 Figure 115 Figure 116 Figure 1168 Figure 1168 Figure 117 Figure 118 Figure 118 Figure 120 Figue 301 Figure 601 Figure 602 Figure 803 Figure 604 Figure 605 Figure 606 Figure 607 Figure 608 Figure 609 Figure 610 Figure 611 Figure 701 Figure 702 AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL LIST OF Fl SURES | PAGE Remote Microphone Test Setup . 119 Interwiring Diagram, Recorders A100, A100A, Control Units A151, A151B, Remote Microphones ASS, ABES 125 Interwiring Diagram, Recorders A100, A100A, Control Units A182, A128... 126 Interwiring Diagram, Recorders A100, At00A, Control Units A150 vat Record Amplifier Assemoly, 93004020, Schematic Diagram .. 128 Bias Generator Assembly, 83004021, Schematic Diagram 129 Bias Generator Assembly, 9300021, pre-FS8127, Schematic Diagram .. 130 Power Supply Assembly, 8800022, $800022-01, Schematic Diagram 131 Power Supply Assembly, 205E0527-00 , Schematic Diagram 132 Bulk Erase Timing Assembly, 9200A024, Schemalic Diagram 134 Moritor Ampitier Assemblies, 93004023, Schematic Diagram 736 Test Cireuit Assemblies, 9300A025-01, Schematic Diagrams 139 Timer Board 9300-A098 Schematic Diagram ........ sat Microphone Preampliier Assemblies, Schematic Diagrams . 142 Inverter Assembly, 93004140, Schematic Diagram 145 lavorier Assembly, 93008140-01, Scrematic Diagram . 146 Inverter Assembly, 205E0485-00, Scrematic Diagram 147 Remote Microphone Assembly ASS. Wiring Diagram . 150 Contro! Unit Assembly Model A151, Wiring Diagrams 181 Main Recorder Assembly A100 Wiring Diagram . 162 Main Recorder Assembly A1Q0A Wiring Diagram 164 ULD Disassembly ... betters 308 Tape Splicing Diagram 603 Tape Loop Measurement. 02 ‘Sound Head, Schematic 608 Ghecking Head Face Straighness 607 ‘Thermopak 608 Monitor Amplifier Circu Board (P/N 300A023) Modification... 609 ‘Test Circuit Board (Pin @300A026) Modification 610 Voice Recorder Drive Motor Capacier Cireult Modification . on Locating Beacon ane Mounting Hardware on CVR e12 Replacement Battery Parts 613 Inverter Installment 616 Setting Capstan Assembly End Play 703 Sotling Bulk Erase Coil Clearance 23-70-01 Table of Contents Page 7 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A LIST OF FIGURES (continue FIGURE PAGE Figure 703 Setting Drive Balt Tension 706 Figure 704 Pressure Pad and Reel Alignment Diagram ....... 107 Figure 705 Setting Pressure Pad Tension... 710 Figure 706 Setting Pinch Roller Tension cote 710 Figure 707 _Non-Precision Bridge Assembly (93004088) Alignment Diagram m5 Figure 708 Precision Bridge Assembly (P/N 990CAZ30 or PIN 934328) Installed in Recorder Assembly Drive Unit 19 Figure 709 Sound Head Wiring Diagram cect cece 720 Figure 901 Spacial Tast Equipment - 903 Figure 902 Special Tools and Test Fixtures. seseneere 903 Figure 904 Belt Tension Gauge, Calibration Con guration 908, ILLUSTRATED PARTS LIST FIGURES Figure 1 Cockpit Volee Recorder, Model A100 = to40 Figure 2 Cockpit Voive Recorder System Mods! A100 and A100A, Exploded View . 1042, Figure 3 Inverter Assembly, 93008140 - 1046, Figure 3A Inverter Assembly, 93004 140-01, 9300A140-02 1050 Figure 4 Recore Ampifer Board Assembly, 93008020 1056 Figure 5 Bias Generator Board Assembly, 9300021 1058 Figure 6 Power Supply Board, 9300A022-01 1080 Figure 6A Power Supply Board, 205E0527-00 : : 1082 Figure 7 Monitor Amplifer Board Assembly, 93004023, 1086 Figure 8 Monitor Amplifier Board Assembly, 9300A023-01. 1070 Figure 8A Monitor Amplifier Board Assembly, 9300A023-02, -04, 1074 Figure 9 Timer Board Assembly, 93008038 1078 Figure 10 Test Board Assembly, 9300A025-01 . . . 1080 Figure 11 Test Soard Assembly, 9300A025-02 1084 Figure 12. Bulk Erase Timing Board Assembly, 9300024 : 1088 Figure 13. Chassis and Recorder Assembly, 934249, ~253, -270 1090 Figure 14 Recorder Assembly, 93247... 1.45 bs 1084 Figure 15 Reel Cover Assembly, 93004039 . . . 1100 Figure 18 Drive Unit Assembly, 93246, 93008026 oe . 1102 Figure 17 Bridge Assembly, 9300088 ...... 1106 Figure 17A_ Precision Bridge Assembly, 99328 ce i e110 Figure 18 Chassis Wiring Assembly, 934236 ana Figure 19 Chassis Wiring Assembly, 9300A045, 93008212 . 16 23-70~01 Table of Contents Page 8 Rev 1: Mar 93AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100A. LIST OF FIGURES (continued) FIGURE PAGE Figure 19 Front-Panel Assembly, 9200R012, 9300213 : a 1120 Figure 20. Control Unit Assembly, $3151, 93A"S2 . 1122 Figure 21 Microphone Pre-Amp Board Assembly, 93008030, 9300A090-01, 93A263-01. 1126 Figure 22, _Mierophone Pre~Amp Board Assemby, 93426302 . 1130 Figure 23 Microphene Pre-Amp Board Assembly, S2A2K2 .....sccscessseese 1194 Figure 24 Remote Microphone Assembly, 92A055-00, -03,-10, ~20, ~30,~50, -85 1138 Figure 25. Microphone Pre-Amp Assembly, 034266, 93A266-01, cece 140 Figure 26 Remote Microphone Assombly.A3A0S5-40, 85, ~60,-68, 66,87, -95 1144 Figure 27 Remote Microphone Assembly, 9300185, -01 .... 146 LIST OF TABLES TABLE PAGE Teble | Recorders . 1 Table i Control Units 1 Table ll Mlorophone Modules 2 Tablelv ——_Extemal Preamps : 3 TableV Procedure Verification Dates . 3 Table Vi_——_-Faichild Model A100 Modification Descriptions. 4 Tablo Vl jrchild Model A100A Modifation Descriptions 6 Table Vill Modification Table for Model A151 & A152 Control Unis 7 Table IX Modification Table for Made! A1S1A 8 A152B Control Units 7 Table 1 Leading Particulars. 8 ‘Table? —_Diferences Between Recorder Models A100 and ALOOA wo Table 3 Ditferoncos in Control Unit Models : " Table 101 Test Equipment ang Materials. 10% Table 102 Mechanical Test and Caliaration Procedures 102 Table 103 Recorder Electica Test and Galraton Procedures. ...c.-+-0 ce 108 Table 104 Control Unt Electrical Test and Calivation Procedures cee MB Table 105 Control Unit Test and Calbration Prosoduros for Units That inctude Modification 4... "5 Table 198 Control Unit Test and Caliraton Procedures for Units That include Modification 5 116 Table 107 Remote Microphone Assembly Callation Procedure PIN'S S3AOSS-00, 02, 03,04, and SEOOATES ...... 18 Table 108 Remote Microphone Assembly Test Procedure PIN's 93A085-10, 20, 30, 40, 45,60, 55, 60, 65,68, 67, 95, & 92959, 991025, 9300A1601, 9561901, 99A272, 93607 ne 23-70-01 Table of Contents Page 9 Rov 3: Mar 08TABLE Table 1088 Table 109 Table 110 Table 111 Table 112, Table 113 Table 1134, Table 114 Table 1144 Table 115 Table 116 Table 1168 Table 117 Table 1174 Table 118 Table 1184, Table 119 Table 1198 Table 1198, Table 120 Table 301 Table 401 Table 801 Table 601 ‘Table 602 Table 603 Table 701 Table 801 Table 901 AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A108 LIST OF TABLES (continued) PAGE Remote Microphone Assembly Output Specification Table PIN’s $3A055-10, 20, 30, 40, 45, 50, 55, 60, 65, 68, 67, 95, 4 92950, 931025, 04001601, 9861801, 93A272, 43667 ce 19 Inverter 99008140 anc 9300A140-01 Test Procedure 120 Underwater Locator Beacon Test Prozedure 120 Main Recorder Assembly Troubleshooting tat Record Amplifier 99004020 Troubleshooting 128 Bias Generator 9300A021 Troubleshooting . + 129 Bias Generator 92008021 Pre-FSB127 Troubleshooting 130 Power Supply 9800A022 and 8300A(22-01 Troubleshooting . 131 Power Supply 205E0527-01 Troubleshooting . .... 191 Bulk Erase Timing Assembly 98008024 Troubleshooting 134 Monitor Amplifier @200A023 Troubleshooting 195 Monitor Amplifier 9300802304, 9900A023-01X1, '99004023-02, 9209A023-04 Troubleshooting : ce 985 Test Circuit 93000025, 9300A026-01 Troubleshooting 138 ‘Test Cicult 99008025-02 Troubleshooting soe 140 Miecophone Preampliter 82004020, 99A262-01 Troubleshooting “at Microphone Preampiter 99004242, #2A268, S7A2O6-O1 Troubleshooting 141 Inverier Assembly 8200140 Troubleshooting a Inverter Assembly 9300A140-01 Tro,bleshooting 145 Inverter Assembly 9900814002 Troubleshooting 146 Control Unit Troubleshooting . 180 Overhaul Replacement Pats ....... fon : 302 Cleaning Materials cee 40 VR Mocols A100 anc 100A Bal Bearing Tabulation. 02 {ols and Equlpment Needed fr Repair of Cocks Voice Recorder : 601 Iaimum Accoplable Weight fr Ovehauled and Repalred Assemblies . 602 Transistor Complement eta Bulk Materials « ” fies 701 Fits and Clearance : 801 ‘Special Test Equipment & Tools . 01 28-70-041. General AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILC MODEL ‘A100, A100A TION ‘This manual covers the maintenance and repair ofall Fairchild Cockpit Voice Recorder components ‘ptoduced under model designations A100, ATO0A {recarders), A150, A152, A1S2B, A151, A1S1B (con- trol units), and ASS, ASSE (remote microphones} ‘Al units produced under the above madel designaticns have been assigned configuration part num- bers. To assist in identifying early models produced without part numbers, the following tables can be used in determining the assigned configuration part numbers for a paniular model. Attor 35 years of predustion and 8 years since TSO-8¢ has been cancalled, the A10G/A100A CVRs are rearing the ond of their service life due to the absolensence of critical spare parts. As such, revision 3 will be final update to the A100/A1008 CVR CMN, Table | Recorders Inverter Part Number | Model Mount ULB Installed ‘SGA100—10 ‘Av00 ‘BaAT00~17 ‘A100 ¥ ‘3370030 jAt00 * x ‘SaAT00—31 A100 x x x ‘S3A100-32 AI00 x x '@3A100-33, ‘A100 x ‘93A100-80 ATOR x x /S5A100-81 ATOOR ‘S3Ai00-8 ‘ATooA x ‘S3AT00-83 ATOGA x x x ‘93AT 00-84 [ATOOA x x ‘9310-85 [ATOOA x Table I Control Units Meter Part Number | Model | Panel Color | Microphone Mlumination ‘SBATSO—20 ‘A180 Black ‘None None 93A152—00 Asse Gray Dynamic None 93A152-01 At621 Black Dynamic 28 99A152—04 jars24 Gray Dynamic Vv 934152-20 A1828 Gray Condenser None 99A152-25, A528 Gray Condenser None 23-70-01 Irroduetion Page 1 fev 9: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILC MODEL, AiO, A100A Table 13 (Con't) Control Units Meter Part Number | Model | Panel Color | Microphone lumination GA152=30 R828 Black Condenser av 99n162-95 A528 Gray Condenser 2ev ja3nis2—40 51828 Gray Condenser v 93a152—50 A182B Brown (Boeing) Condenser None 98A152—60 |A1S2B Brown (Boeing) Condenser sv 99A152-70 i828 Black Condenser None g9a1s1—00 ast Gray None None 93A151—01 ANSI Black None None 938151—20 AIS1B Gray None None 99a151~30 A818 Black None None 90A151-40 ]Ais18 | Brown (Boeing) None None 9aa1si—50 JaisiB | Brown (arR—a3 None None Table Il Microphone Modules Connector Part Number Model Color Microphone Location 'SBAO55—00 as Black Dynamic /28A055-03 55-3 Slack Dynamic /e3A0s5—10 A58B Black Condenser Rear ]2sA0ss—20 AS5B Black Condenser Side 3A055~30 A5SB Brown (Boeing) Condenser eer 93A055—40 ASSB Gray Condenser Pigiail 99A055—45, |A5SB Brown (ATR—<2) Condenser Pigtail /23A055—60 558 Black Condenser Rear 93A085—55 Asse Black Condenser side 9305560 A556 Gray Coneenser Pigtat 9BA055—65 |ASSB Brown (ATR—42) Condenser Pigtail 93A055—66 /ASSB Gray ‘Condenser Pigtail 93A055-67 A558 Black Condenser Pictat 90A055-95 ASB, Black Condenser Pigtail 23—70—01 Introduction Page 2 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100A Table lV External Preamps Part Number Model Panel Color BEATSO=20 oy BACK 2. Verification All drawings, ilustrations, wiring diagrams and schematics were validated against existing engineering ‘source material. All procedural data has beon previously verified by field usage of the preliminary com- ponent maintenance manual. The following procedures (and. corresponding Manual Sections) have bboen verified as of the date shown in Table V. Table V Procedure Verification Dates Procedure Date Description & Operation March 96 ‘Testing & Troubleshooting March "96 Disassembly March "96 Gieaning March °96 Check March "96 Repair March ‘86 Assombly & Storage March ‘96 Fits & Clearances March ‘96 Special Tools, Frtures, and Equipment March °88 Iustrated Pars List March 96 23-70-01 Introduction Page 3. Rev 3: Mar 08AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, A100, AT00A, 3. Recorder Modifications The Fairchild Models A100 and A100A Cockpit Voice Recorders, through extensive fiekd experience, have ovalved over the years to reflect the most current component technology. AS such, the recorders aro identified on the front panel with a Modtication Label which identities unit configuration at the time Cf production and ater factory repair, The following tables provide a description of Model A100 and Model A100 moxilications as related to Field Service Bulletins. Table VI Fairchild Model A100 Modifi ion Descriptions Mod | Rev. Num | Plate FSB Description 115 [Deactivation of Cockpit Voice Recorder Headphone Jack 2 104 | Added Heat Sink P/N 9800-447 to Motor 3 105 | Replaced Stairtess Steel Case Screw With High Strength Carbon Scrow, P/N LP82U040J12X2 — Steal Pot 4 107 _| Added Crowning to Drive Motor Shatt 5 118 | Replaced Globe Motor PN 9300-218 With IMC Mator PN. 9900-218-01 6 110 | Insulation of Qt on P/N 880064 Test Tone Generator on Model A113 Cockpit Voive Recorder NYA 111 Insulation of TP on Monitor Circuit Board PN 9300423 on both ‘A100 and A113 Models NIA 112 | Insulation of Test Circuit Board PN 8300A25 NA 113 | Modification of L1 Mourting on Monitor Circuit Board PN '9300A23 on A100 and A113 Models 7 121 | addition of Optional Frequency Shift Key Board PN 93008118 8 123 | Modification of 9300826 Test Circuit Board — Replaced 06 — Plus Commencement of PN 8300A25—1 Starting June 1970, NIA 125 | Test Tone Generator — Beta Selection for Cold Problem on Fok lowing PN’S: 9300A25; 9300A25~1; and S300A64 {on A113 CvR). Ret, FSB 123 9 122 | Replaced Bridge Assembly 8800A041 with 9300088 40\ Revi 125 _| Transistor Change on Test Tone Generator if Mod 8 Insufficient 4 126 _| Addition of RF Fier Capacitor PN 9300-534 to Bulk Erese Board, PN 9300Ag24 12 127 _| Addition of Variable Resistor 9300-226 to Bias Generator Board ‘s300A021 13 128) Added Filter Capacttor 8300-83470 Bulk Erase Board /9300-A024 4 141 Introduction of Precis’on Bridge PN 934230 Starting May 1. 1980, Plus Optionat Retrofit 23-70-01 Introduction Page 4 Rev 3: Mar 04AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A1O0A Table VI (Con't) Fairchild Model A100 Modification Descriptions Mod | Rev. Num | Plate FSB Description 5 Ni& Replacement of monitor ampifar SS00A003 with S300A025—OT, Replacement o° Test Board PN 8300A025—01 with PN 9300A025-~02 16 156 | Introduction of Non--Coasive Heads and 934310 Tape 7 162 | Introcuction of New Underwater Locating Device (ULD) PIN 266—E0305-00 18 147 | Adds Now Capstan Shaft Assembly PN 98A279 Plus Bearings PN 9300-12801 19 149] Adds Alternate Drive Motor PN 9300—218-02 20] Revt 148 | Modifies Monitor Amplifer Board PN 9900802302 to a00A025-08 at NA [wa 2 N/A | Optional installation of inverter Assembly PN 99000140 2 134 Jinstatiatan of Timer Board PN 9a00AG8 2a Na |NA 25 Na |NA 2 182 | Adds 2 Capactors PN 304—20-50008 to Channels 2 and 3 Re- cord Board Connectors: a 153 | Changes Moritor Board PN 9300A023~04 Meter Resistor R21 From a0 KOHN 28 KOHM 2a nia | NIA 2 NIA | Unassigned 20 135 __| Addlion of ULB Modification Kit PN 990081 00K30 23—70-—01 natesAVIATION RECORDERS: COMPONENT MAIN-ENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A Table VII Fairchild Model A100A Modification Descriptions Mod | Rev. Num | Plate FSB Description 7 NR | Replace Monitor Ampiffior PN SG00A023 with PN 9300A023—01, Roplace Test Tone Board PN 9300A025—01 with PN. ‘9300402502, 2 Unassigned 3 Unassigned 4 147 | Adds new Capstan Shatt Assembly PN 938279 and Bearings PN 9300-128--01 5 149 | Adds Alternate Drive Motor PN 9300 128-02 6| Revt 148 | Modifies Monitar Ampitier Board PN 9300802302 into 9300A023-04 7) Revi 160 | Installs ULB Mounting Kit @3A271K2 8 152 | Installs 2 Capaciters PN 30420-50009 on Channels 3 and 4 Record Card Connectors 9 163 | Changes Monior Amplifier Board Meter Resistor R21 from 30 K ‘Ohm to 28 K Chm 10 NA | NIA " 156 | Introduction of Non-Corrosive Heads and 984310 Tape 7 159 Introduction of new Underwater Locating Device with six year battery Rev At 165 _| Software sev for 93-SS—MK; fixes CVA Bulk Erasuro anomaly 23-70-01AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100 4. Control Unit Modifications ‘The Fairchild Models A151 and A152 CVR Control Units, through extensive field experience, have evolved over the years to reflect the mast current in component technology. As such, the control urits are identified with a Modification Label which identifias unit configuration at the time of production and alter factory repair. The following tables provide a description of Model A151 and Model A152 mocitica- tions as related to Fleld Service Bulletins, Table Vill Modification Table for Model A151 & A152 Control Units Mod | Rev. Num | Plate FSB Description 1] Revi 107 | Rewite Wierophone per wirelist S300WD7 2] Rev 102 | Relocation of shield wire a Nia |N/A 4 132 | increase Frequency Bandwidth on Microphone Pre—Amp Board ‘Assemily PN 9300430 beginning with SN5400 and all Control Units wth extemal microphones. 8 142 | Relnstituted Attenuation selection capabilty through modifica lionol Pre—Amp Board Assembly PN 9300A30 (Removes Mod 4) boginning with $N6500 and all Control Units with external micto- phones, Table Ix Modification Table for Model A151A & A152B Control Units Mod | Rev. Num] Plate FSB Description 1 143 | Replaces Microphone Pre—amp Board PN 834242 with 930266 SN10188. 2 146 | Makes direct irterchange from A152~2 to A152—20 SN10000 — 10167. tore 151 _| Changes 934236 Pre—amp Board to 934266-01: Models A151--50 and A15S2-35 are Mod 1 All other models are Mod 2 23—70—01 Isc apeAVIATION RECORDERS: ‘COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A10GA THIS PAGE INTENTICNALLY LEFT BLANK. 23—70—01 pert MartAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A SCRIPTION AND OPERATION 1. Description ‘A. Cockpit Voice Recorder and Control Unit. The Cockpit Voice Recorder system (see Figure 1} consists of a Cockpit Voice Recorder (GVR) and a Conizol Unit. This system provides four separate channels of voice recording of ether transmitted or received signals that originats, typically, atthe plats station, the co-pito’s sta- tion, the passenger public address systern or the third crew member's station and in the cock: pit area. The cockpit area microphone is sttategically located to pick up and record cockpit ‘voice signals while electronically suppressing engine or turbine noises. Engine and turbine noises ate electrically suppressed by the recorder system. The Control Unit, containing the area microphone, preamplifier, test meter, and erase and test switches, is remotely located {rom the recorder unit. A bref description cf the electro—mechanical assemblies that comprise the recorder system instalation folows below. (See Table 2, Page 11, for differences between Models A100 and A100) B. Cockpit Voice Recorder (See Figure 2) “Tho Cockpit Voice Recorder, Model A100 oF A1O0A, is an endiess—ioop magnetic tae device that records all voice signals transmitted or received by aircraft crew members for a maximum, petiod af 30 minutes of continuous operation; voice recordings beyond 30 minutes of conti- nous operation ara automatically erased. Tre unit is housed in an international orange, one— half ATR short equipment case and consists of a magnetic tape recorder and an electronic chassis. Tape recordings are protected against aircraft accident. ‘The recorder accepls the headset inputs frem the pilot, co-pilot, area microphone, and the passenger public address system. It is possib'e to substitute a third crew member Input in place of the public address system. The purpose of the recorder is to record all voice signals transmitted and received by the aircraft crew members for a maximum period of 30 minutes cf ‘continuous operation. The recorded voice on the magnetic tape is protected against alrcrat. ‘accident, no matter how extreme, The Reccrder Assembly consists of the Drive Unit Assembly. Reel and Tape Assembly, Reel Cover Assembly, Insulation Assemblies, Record Amplifier Board Assembly, Bias Generator Board Assembly, Monitor Ampifier Board Assembly, Power Supply Board Assembly, Test Tone Assembly, Bulk Erasa Assembly, Timer Board, and acoustic Under- ‘waler—locetor Beacon Assembly, each of which is described in the following paragrephs. (1) Drive Unit Assembly (see IPL Figure 16). ‘The Drive Unit Assembly consists of a bridge assembly containing the recording, moni- tor, and erase heads; the capstan assembly, which contro's rate of maverient of the tape; and the chute subassembly, whch introduces the tape back into the reel and tape assembly, (2) Reel and Tape Assembly (see IPL Figure 14, tern 25 & 258) ‘The Reel And Tape Assembly consists of an endless oop of magnetic tane 0.250—inch ‘wide by 0.0014 inch thick, nominal, The tape is oxide on one side and graphite—lubri- cated on the other. Three hundred and eight ieet are wound on the reel. The reel is a single-sided plate with an inverted core 1.9750 inchos wide at its largest dimension. 23-70-01AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A [EXTERNAL PREAMP. [AREA MICROPHONE, INVERTER (OPTIONAL) I ex ie 2 oro 1008 Font rl Cockpit Voice Recorder, Model A100 Figure 1 23-70-016) “ AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100 Model A100 Model A100A Cockpit Voice Recorders, Models A100 and A100A Figure 2 Reel Cover Assembly (see IPL Figure “S) ‘The Reol Cover Assembly consists of the bulk erase coil; the roller assembly, made up af {ive tape compacting rollars and their ataching hardware; and the reel cover, This as- ‘sembly is installed on the recorder assembly. Insulation Assembly (see IPL Figure 14, Item 375) ‘The Insulation Assembly is a spocial thermal insulating packago sealed with a rosiiont material to provent scutf and damage. The caating provides complete self—sealing in the operational thermal envicanment. The insulator units fully enclose the inner casing (Drive Unit Assembly) of the recorder, and protect i from thermal damage. Record Ampiiier Board Assemblies (s2e Figure 3) ‘The four amplifier cards are Wentical end are fully interchangeable. Each amplifier board contains a one—stage amplifior with record equalization and record bias focd—in. All inputs have an isolation transformer for balanced or unbalanced, grounded or un- grounded input. Input impedance is 7K ohms and the required input signal is 100 milli- volts or higher. Each card has color—soded test points installed to facilitate testing and fault isolation. The cards accept ac voice signals for amplification and recording on the magnetic tape. The four identical cards plug into card cannectors located in the A100 or A100A recorder. Bias Generator Board Assembly (see Figure 3) “The Bias Generator card provides an ac—record bias and pre—record continuous erase, ‘Test points end adjustment controls ate provided and are readily accessible for test and {aul isolation. 23-70-01AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A RECORD AMPLIFER ‘BOARD ASS. BIAS—GENERATOR ‘BOARD ASSY. Powen suppty BOARD ASSY MONITOR AMPLIFIER. ‘BOARD ASSY. Tier BOARD ASSY. ID see rare 2 ose 1008 Fn Pee ‘Subassemblies, Cockpit Voice Recorder, Model A100 Figure 3 7} Monitor Amplilier Board Assembiy (see Figure 3) ‘The Monitor Amplifier amplifies the monitored recorded voice signals on the tape for the simuttaneous playback of all four reccrded tracks, The channels are played back to the headset output for monitoring. When activated, the Monitor Amplifiers output is used simultaneously to drive the test circuit meter, a Go, No~Go indicating device, The indice- tion is displayed on the test meter mounted remotely in the Control Unit or integrally with the mein recorder (A100 only). Test points and gain adjustments are provided to facilitate testing and fault isolation, (8) Timer Board Assembly (see Figure 3) The Timer Board Assembly serves as an hour meter indicsting tatal hours {0 to 5000) that ower has been applied to the CVR, The hours are read direcily from the linear—seale indicator. (9) Test Crcut Board Assembly (see Figure 3) “The Tost Grout generates a test signal from the acivation of a single channel or the ALL test switch, The Test Circuit transmits test tone whicn is recorded on the tape and sub- sequently picked up by the playback head and fed to the moritor ampitior and cispiayed a8.a Go, No—Go indication on the meter. This 600—Hz tone can be heard if monitored ‘trough the headset jack on the Corwrol Unit or the one on the main recorder assem- by. 23-70—01 Pe 3:08AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A108 (10), Butk Erase Timing Board Assembly (see Figure 3) Tho Bulk Erase circult erases the entire recorded information when the erase switch is pushed and released. (The erase circuit is actuated upon release of the erase switch.) ‘The erase circuit contains electrical interlocks that provide positive assurance against accidental erasures. (11) Power Supply Board Assembly (see Figure 3) ‘The Power Supply provides Zener stabilized and fitered de voltages of rated amperage for the operation of the recorder and preamplifier electronics. (12) Acoustic Underwater Locator Beacon Assemibly (Optional) (see Figure 4) Refer to the optional equipment Paragraph (D) in this section for a description of this as- sembly. Control Unit The Control Unt, Models &3A151—XX and 93A152—XX (see Figure 6), Is a standard ATR, pan- ‘el-mountes unit that provides remote control of he cockpit voice recorder. The Control Unit contains the Control Area Microphone (Models A152 and A1528 only), Microphone Preampiii- er Board Assembly, headset jack, ERASE and TEST switches, and the test meter, which make it possible to test, monitor and bulk erase the tape remotely. The Contvol Unit utlizes aitera wiring for connection to the recorder unit. Tre Cockpit Voice Recorder system is designed so thatthe recorder unt is selt—suficient and the Control Unit may bo utilized for housing only the proampiifer card andor is microphone. (O'ferences in Control Units are listed in Table 3, Pago 11.) (1) Microphone Preamplifier Board Assembly (see Figure 5} ‘The purpose of the Microphone Prearrplifier Board is to amplify the output of the micro phone, and through the use of a gain control, to pravide a proper ievel of signal input to the recorder. (2) Remote Area Microphone (see Figure 6) (Used only with A181 and A151B Coniol Units.) When space limitations are extreme, the Control Unit may have to be mounted in a location where a built-in microphone would not be effective. For such conditions, a separate Control Unit and Remote Area Micto- phone is recommended. Optional Equipment ‘The basic Cockpit Voice Recorder and Coniral Unit may be complemented by the fellowing ‘equipments: (1) Inverter The Inverter is an optional accessory, and is completely self-contained. When married with the recorder, the Inverter replaces the aircraft ac electrical system by converting 28 Vide to 400 Hz 118 Vac, NOTE: Units which are factory equipped with this accessory will carry an Identifica- ion label to that effect. 23-70-01 fe 3a@ AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A700, A1G6A, ‘Acoustic Underwater Locator Beacon Assembly (see Figure 4) ‘This unit is a battery powered device which radiates a pulsed acoustic signal into the sur- rounding water upon activation ofits water—sensitive switch, The battery is shock mounted and separated from the elecronic module by a bulkhead built into the case, ‘On older models (L3 P/N 18987, gold case) the ballery is accessible by removal of an ‘O-ring sealed end cover, The opposite end of the beacon contains the teflon insulated water—sensitive switch, On newer models (L3 P/N 266E0305~00, silver case) the whole beacon assembly must be returned ta the beacon vendor for a new battery. Cockpit Voice Recorder, Underwater Locator Beacon Installed Figure 4 23-70-01 Page & May 1191AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100A Test swrcH ERASE SWITCH MICROPHONE MICROPHONE PREAMPLIFIER BOARD ASSY Exploded View of Control Unit Assembly, A152, A152B Figure 5 23-70-01 Page 7 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A100A (8) Optional remote area microphones (see Figure 6) are mounted in locations for optimum ‘cockpit area coverage, usually overhead on the aircraft control panel Yoke & sa00ates so0a0s5—40 ‘so008165~01 ‘Area Microphones (Optional) Figure 6 2. Leading Particulars ‘A, Leading Particulars for the Cockpit Voice Recorder System, Leading particulars for the Cockpit Voice Recorder system are given in Table 1, Table 1 Leading Particulars Model A100 Recorder, Model A100 Recorder Size: 1/2 shor ATA; 4 7/4" Wx 129/45" Lx 7 8/e"H Coior: Intemational Orange, # 12197 Weight (Max): ‘A100, 22.7 Ibs.; A100A, 23.9 tbs Power: 115 Vac, 400 Hz, 50 watts max. bulk erase; 20 watts max. Normal op.; 28 Vale, 21 walts max. normal op. wilh inverter Connector: DPXB — 57-34P—o101 Connections: ARING Characteristios 557 Tape (Endless Loop} 1/3" preconditioned, magnetic, back—lubricated recording tape, mylar 2as0 ‘Transport Drive: Direct — no clutches Tape Speed: Standard NARTB: 1 7/8 ips. Channels: 4 In—tine — coincident recoraing 23-70-01 Page & lev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A004 Table 1 (Cont.) Leading Particulars Model A100 Recorder, Model A100A Recorder Recording Duration: 90 minutes minimum Head Assombly: Pracision aligned — 3 heads Bulk Erase: Fall-safe, double electrical intertock; total erase excess of 35 dB Operational Testing: ‘Automatic 4 channel sequential Recorded Audio Frequency Response! 180 to 8000 Hz ++3 6B Recorded Signal to Noise Ratio. 45.dB minimum Monitor System: Composite 4 channel playback. Performance can be verified on enclosed unit. toner Ou Heutpnefek S00 ae, 0a hamone Ooi tector oh Flutter: 1,5% rms (maximum) pase nut nsder 0 ts ech tae wor ‘apace corecons ane Chua 7 Internal Components: Microphone preamplifier, microphone (Models 52 and A152B only), meter, switches (2), headset jack aac Fast reacting 30—dB range — low distortion, ‘Two ac attenuation Audio Input impedance 20K ohms ‘Audio Input Level: 3 milivolts Outout Impedance: 300 ohms Output Level 500 milivolts ‘Audio Frequency Response: 1000-5000 Hr (A152B 150-5000 He) pin selected 700-5000 Hz Audia Gain: Pin selected 6, 12, 24 dB steps DG Suppiy: +18 volts 23-70-01 Page 9 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A1008 Table 1 (Cont.) Leading Particals System Environment Specifications ‘Operating Environment FAA Code AID BAAAE Temporature: 54°C to +55°C Altitude: = 1000 to +50,000 tt Humidity: 00% Vibration 0-500 He, 86 ‘Shook (Crash safety 56 ‘Audio—Frequency Magnetic Field Unatfected ‘Suscopiibiity Radio Frequency Susceptibilty: Unatiected Emission of Sourious RF Energy. Botow acceptable limits Accident Environment Impact Shock: 100G, 11 Milisoconds Fite 1100°C, 1/2 hour Salt Water Immersion: Unatfected Explosion Proof Models: ‘A100 and A1O0A B. Differences in Models Refer to Table 2 for the differences between the A100 and A100A recorders and to Table 3 for the differences emong Control Units A151, A1818, A182, and A182B and A152—1, A162—2 and A152—4. Refer to Figure ? for the outine diagrams of the different Control Units. (1) Cockpit Voice Recorder Differences The two basic CVR models are functicnally identical and interchangeable, and elther adel can be used with either Contro Unit Model, or equipped with Inverter ar Underwa- ler Locator Beacon. Rofer to Figure 4 for an illustration of the Underwater Lacator Bea- on, (2) Control Unit Differences (see IPL Figure 20 for Part Numbers} ‘The two besic control units are functicnally identical and interchangeable, and either model can be used with elther CVR riodel. Control Units A151 and AtS1B require the Use of Remote Microphones A5® and ASSB, respectively. Control Unit A152B is equipped with a selt—contained micreahone, Control Units A151 and A151B contain the preampltier board, indicating meter, test switch, bulk erase switch and headphone jack 23-70-01 Page 10 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A ‘The A152 and A1S2B contain ail of the above items as well as the microphone which the A181 and A1S1B does nol. In installalions containing the A181 and A151B, due to space limitations, the microphone module, Model ABS or A5SB, is located elsewhere in the ‘cockpit, usually overhead on the aircraft control panel. In all cases, the aircraft wiring is tlized for placing the micraphone module and Control Unit in remote locations. Control Units with $—volt and 28—volt meter ilamination are offered, Table 2 Differences Between Recorder Models A100 and A100A, order Usable with Control Unit # Meter, 5 test Each channel Complete 4 track switches and and ALLtest intemal (in lino} headphone jack available circuit No test Nochannel Same as Same as switches, butionsor A100 A100 ho metor AUL test button. Tests are controled ‘ram Control Unit TEST button. Table 3 Differences in Control Unit Models. With ASS, 3 microphones ABB condenser mike used Condenser miko >At62—1 Biack front panel meter illuminated 2€V white; direct wired mike 5V white illuminated meter NOTE: Models A152, A152—1, and A152—4 are fully interchangeable with the exception of the ‘meter illumination. See IPL Figure 20 for Part Numbers for those Control Unit Models. 23-7001 Page 11 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, ATO0A MODEL A151 AND A161B [MODEL A182, A1528, A152—1, AND ‘atsz— Control Unit Configurations, Models 151, A151B, 152B, A152, A152—1, and A152—4 Figure 7 3. Operation A. Block Diagram Description (see Figure 8 and Figure 9) ‘Tha Cockpit Voice Recorder (CVA) is a volce—qualty, audlo—frequency device that provides: four separate channels of simultaneous voice recordings which may be played back on ‘ground equipment. The recordings are made on an endiess loop magnetic tape which pro- vides a maximum record interval of 30 minures of continuous operation. All recorded data be- yond 30 minutes is automaticaly erased, B. Circuitry Operation For this block description, refer to Figure 8 and Figure 9 @) Audio Input ‘Audio input, from the cockpit area micraphone or from the remote micraphone, is appliod to the control unit microphone preamplifier which raises the signal level so that further processing will nol appreciably degrade the signal-to-noise ratio. This circuit also pro- vides for the electronic suppression of engine and turbine noises by means of a roll-off {or slope) circuit whereby attenuation s gradually increased over the 150—to—5000 Hz range for turbine atcratt @) Preamplifier Output ‘The output of the Control Unit microphone preamplifier is applied to the Channel 4, '9300A020 Record Amplifier: Similarly, inputs from the pilot's station, co—pilot's station land third crew menber or passenger PA system are applied lo the Chane! 8, 2 and 4 Record Ampiiiers, respectively. The Record Amplifiers also accept the 65—kHz output of Bias Gonorator 83008021, The audio and 65~kHz signals are mixed and amplified to provide a combination bias vollage ard record current thet is applied directly to the 4-track recording head. 23-70-01 Page 12 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, Ax00A, () Recording Mechanism ‘The recording head is a 4—track deviee which provides coincident recording of the four record amplifier outputs. The recording head is part of the Bridge Assembly vihicn also contains the continuous erase head and the monitor head. The manitor head reads out the signals impressed on the tape by the recording head, and wher a test signal is de- tected, the monitor head applies the test signal to Monitor Amplifier $300A023—-(XX), The erase head, which is energized by the 65-kH2 erase current output of the bias genera- tor, erases continuously while the recorder is operating. Erasing occurs just before the tape is re—recorded, or 30 minutes after that tape segment was last recorded. Bias Gen Recorder A100 a ‘ae “Tape Trans SYSTEM é “Breced BLOSK DIAGRAM Record Amp "A020 RECORD HEAD | snowNe0° RorateD f———— ‘Record Amp FOR CLARITY 0 ame ‘A0z3~909) 1 ‘eet 00 He "2025 hiao~o1) {95V 4002 Bulk Erase ‘naa Cockpit Voice Recorder A100 and Control Unit A152B. Functional Block Diagram Figure 8 23-70-01 Page 13, Rev 3; Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, AT00A SYSTEM BLOCK OIAGRAM RECORD HEAD ‘SHOWN 90° ROTATED FOR CLARITY I oom fad usveeme mn 4 Mon ' ' Tre ue ' fae L 1 Cockpit Voice Recorder System Control Unit A151B, Functional Block Diagram Figure 9 (3) Test Circuitry Test Circutt 93008025~(00 generates a test signal to verity operation of all four audio ‘channels. The sequence is initiated at the control unit by the TEST switch, or at the CVA I by the ALL TEST switch or by the discrete Channel 1, 2, or 3 TEST switches. When one of the latter switches is pressod, a 600—Hz tone is applied Irom the test circutt to the cor- responding Recorder Ampifier circuit only. When ALL TEST switch is pressed, however, the 600—-Hz test tone is applied to each af the four Record Ampifiors alternately for approximately 0.8 second, The Record Amplifer (or Amplifiers) mixes the test tane with the audio input and transmis the combined audio to the recording haads for impression fon the magnetic tape. The monitor head subsequently detects the tone and applies ito Monitor Amplifier 9300A023—-(XX). The tone is amplified and applied to the HEADSET test jack for aural indication and to the TEST meter for a visual GO, NO-GO indication. 23-70-01 Page 14 Rov 3: Mar 046) 6) a AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILC MODEL ‘A100, ATOOA Bulk Erase Circuit Bulk Erase Circuit 9900A024 is used to erase the entire tape, a condition normally im- posed at the end of a routine fight, Tro bulk orase sequence is intiatod from the Con- trol Unit ERASE switch. To prevent accidental erasure, the switch must be activated for at least two seconds and the landing gear must be down with the weight of the aircraft on the fanding gear and the parking brake on, Power Supply Power supply 8300A022—-(XX) converts 118 Vac at 400 Hz to separate outputs of 30 vols and 78 volts, laverter 3600140, 23008140—01, or 8300414002 's used for aircraft sys- tems that operate on 28 volts de. The inverter converts the 28—volt input to 115 Vac at +400 Hz to operate the power supply. Power Supply 205E0527— XX, FSB 161 Power Supply 205E0527— XX recites, fiters and regulates voltage fram a center—tapped ‘power transformer and optional de power source to produce all de voltages required by the GA CVA. It converts 115 Vac @ 400 Hz to separate outputs of: +90 Vee 410%, current—limited 125 mA 20% 418 Vee 419%, current—limited 69 mA 20%, #21 Vac, 10%, current—limitod 125 mA 20%, short—circuttfold—back to 50 mA =20% ll power supply 205£0527—-XX is used, slight modifications to the chassis assembly must bbe made, Rofer to FSB 161 for chango instructions. C. Detailed Circuit Description a (2) Controi Unit ‘The Control Unit (see Figure 118) corvains the area microphone, TEST switch, bulk ERASE switch, indicating meter, head set jack, ancl Microphone Preamplifier. The TEST switch and indicating meter provide the capability to test the four channels and the head sot jack provides a continuous and simultaneous playback of all four recorded channels, ‘The bulk ERASE switch is used to erace the entire tape after a routine fight, and will only work when the landing gear is down, ihe weight of the plane is on the landing gear, and the parking brake Is on, To prevent accidental erasures, a time~delay circuit makes it necessary to hold the switch down for two seconds ta start the erasure process. Microphone Preamplifier 9800A030 ‘The preamplifier (Figure 115) receives is ow level input volage from the cockpit mounted microphone — either internal or external to the microphone control unt. The tow--level signal is amplified in Q1, gein adjusted by Fa, and further ampified in G2. Pin selectable atlenuation is provided with resistor attenuators R15, R16, R17, AI, and R19, ppermiting gein change in 6 dB steps from 010 24 JB attenuation. Jumpers are required 'n tho alrcratt connecter on the appropriate pins p,«, or tt0 q. Q3 is another amplification slage and G4 is an emittor—follower providing law impedanoe oulput an pin L, which is {e¢ through the airrat to record ampifier @300A020. 1, R27, and C13 filer the {8430V) supply from the CVR. Low frequency roll—olf is provided with coupling capac tor C8, C11. Pin selectable aditional roll-off is achieved through CB and R10, when the aircraft connector has pins T and $ jumpered. 23-7001 Page 19 May 1/91@ @) 9) 6) a 8 AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100A, Control Unit Modification 4 Modification 4 (Figure 115) to the Control Unit changes microphone Preamplifier 9300030 to expand the [requency responee and improve the automatic gain contro. ‘The modified A030 is wired to set attenuation to ~18 dB, making it independent of alr- cratt wiring, Microphone Preamplifier SA263~01 ‘Microphone preamplifier 9200826301 functions the same as 9300A030. This board (Figure 115) eliminates the pin selectable low requency roll-off, The lowr frequency ra- ‘sponse is extended for better recordings. Microphone Preamplifier 934242 Microphone preamplifier 93A242 (Figure 115) is used with condenser type microphones, The circuit functions the same as 930CA030. R20, D3, and C15 provide a fitered 6.2 V de ‘supply voltage required by these microphones. The 834242 does not have the pin se- lectable gain jumpering or low frequency roll—off option, Microphone Preamplifier SSA266~(XX, Microphone preampitier 944265004 (Figure 115) is used with condenser type micro- hones, the same as 93A242. Pin selectable gain control is provided through resistor atienvator R30, R17, R32, R29, and ROY, Low frequency response remains fixed at 150 He (-3 48). Record Amplifiers 93004020 Each of the four record ampiitiors (see Figure 108) consists of a one-stage ampitior with record equalization and record bias feed—in. Input transformer Tt provides impedance matching and isolation for balance or unbalanced, grounded or ungrounded signals, Loyal adjust resistor Fit picks off some portion of the audio input and applies it to ampli er Qt across rf bypass capacitor C3, The amplifer output is couples through Ga, A and Lv fo the circut output, where itis mated with 65-kHz bias input coupled through C8. ‘The mixed audio and €5—KHz signals provide a combination bias voltage and record cur- rent that is applied directly to the recording head. Bias Generator 93000021 The bias generator circuit (see Figure 109) is 4 65—kHz oscillator utilizing transistor Qt and the L1, C2 tuned circuit to develop the 65—KHz bias signal for the recorder. Output at pin E 's attenuated to a current of 590-600 nA by adjustment of A, and an erese cur- rent passed through C4 al a current 0° 32—39 mA is taken olf Lt to erase the tape in ac vance of re-recording, 23-70-01 Page 16 Rov 3: Mar 04® 49) any AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, ATOOA Bridge Assombly (see IPL Figure 17 & Figure 17A) ‘The Bridge Assembly contains the recording head, the cantinuous erase head, and the ‘monitor head, The recording head is a four—postion head with parallel pole pieces ‘which provide simutaneous recording of the four input voice signals on four tracks of the tape, The monitor head is a read—only head that reads out the signals recorded by the record head and transmits thom to the nonitor amplifier. The erase head erases the enc: less tape in advance of recording by ccntinuously recording a 65—kHz signal. Test Circuit 9300A025~-01 The test circuit (see Figure 113) consists of an osciilator, a ring counter, and a set of four solid-state switches. Input to the circuit is a ground at one of the four channel TEST inputs or at the ALL TEST input. The test tone is produced by 600~Hz phase—shitt oscil lator Q8 and is output to the monitor anplifier through one of the Q7 through Q10 ‘switches, (a) _ Ia ground is received at pin K (the TEST 1 switch pressed}, transistor Q2 is biased ‘on, which biases Q7 on and ourpats a 600 Hz tone at the TONE 1 output (pin J). Selection of TEST 2, 3, or 4is essentially the same process, with the lost tone out put by 3/08, 4/09, or 5/010 (b) Ifthe TEST ALL button is pressed, a ground is recoived at pin L which turns on PNP transistor Q1, When Qt turns on its collector voltage rises, with the result that a ‘positive vollago is applied to the 2 through QS emitters through resistor R7. The four transistors wil all move toward conduction, but because of differences in the individual transistor characteristics, one ot them will begin to conduct sooner or stronger than the others, (©) _Iftansistor Q2 conducts first, ts positive—going collector will cause capacitor C2 to ‘charge through RI, cutting Q3 off with a positve voltage at its base. As C2 changes, the current through R1" drops, until the Q3 base voltage is low enough for Q3 to conduct. The additional votage drop across F7 caused by 2's conduc: tion lowers the Q2 collector voltage slightly, with the result that C2 begins to dis- charge, biasing Q3 on more strongly. Q3 saturates, Q2 is cut off, and capacitor C3 begins to charge. The same cyce is continued through Qa and OS, with the dis- charge of C5 turning Q2 on again. (6) As each transistor goos though ils conduction cycle, its associated switch (Q7 through Q10) applies the test tone to its channel. The circuit time constants are such that each channel receives the test tone for approximatoly 0.8 second on each oycle. ‘Test Circuit 9300A025—02 This test circuit is siriar in function to 9300A025~01 except that integrated circuits are used in place of discrete transistors (s2e Figure 113 , Sheet 2 of 2}. (a) When pin L is grounded, R2 and RS voltage divides bias on Q1 to supply a nominal +30 to the on board 12V regulator M1, an¢ power to the meter driver circutt of the 9300A023—(xX) monitor amp beard output on pin M. The cutput of M1 is 12V reg- ulated fora ceuity on this bod. 23-70-01 Page 17 Rov 3: Mar 0402) 13) AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100 {0} M2 Section 2is the basic channel switching oscilator with frequency set by RAS ‘and C9. C10 bypasses interna! circuitry and R17 is the TTL logic gate output “pul up* resistor. Pin 15 i the input on M3 which is a counter that puts out binary ‘coded digital counting on pins 6 and 11. This is then converted to sequent.at ‘counting by Mid in pin sequence 4, 5, 6, 7. Pin 1, Md is normally law but if one channel's to be tested, then the push Outton keeps the “hotd” (Pin C, E, H, or K) at ‘ground with the result that pin 1, Ma goes high and all 4 outputs of M4 go high. Thee of the MB outputs willbe fow (since both inputs are high) but channel se- lected will be MS output high, as the input from the push button line (Pin C, &, H, K) is low. (6) M2 Section + is the 600—Hz testtone generator with square wave cutput filtered into a sine wave by the network R11 through R14, iO is collector output “pull up” resistor which also biases M7 analog switches up to 1/2 of 8+ supply (with R16, ‘through 24) so that they will pass the ac test tone. (8) When an MB output goes high, the channel on M7 will pass the test tone out to the pin J, FP and 8. Monitor Amplifier 9008023 ‘The Monitor Amplifier circutt (see Figu'e 112) recelves the output of the monitor pickup head and develops headphone signal which is a continuous and simultaneous play- bback of all four recorded tracks. The circuit also detects the presence of the 600—-Hz test tone and provices a GO, NO—GO incication on the test moter. “The audia frequency input at pin B is amplified by transistors Q1 through G4 and output 10 the heedohone jack at a level of 10 mW for a 600—chm load. A ppottion ofthe signal is passed to transistor Q5, which has an LC tank tuned to 600 Hz ints collector circuit. Any signal other than the 600—Hz test tone is shunted out by the tank circuit. Ifthe 600—Hz test tone is present, itis developed across the tank circuit and rectiied by diodes D1 and D2 for apelcation to de ampitier QS. 1 the input to O6 is agreator than 250 mV QS will conduct, seveloping the nominal 8 V needed to drive the ‘meter for a GO indication. ifthe input to GBs less than 250 mV the transistor will rot conduct and the meter wil indicate a NO-GO condition. The audio output et pin H per mis the operator to listen to the 600—Hz tone as well as see it on the meter. Monitor Ampitior 9300A023~02 (690 Figure 112) Operational amplifier M1, pin & & 2 ampilies this signal 1,000 times to pint. Gain control 7 is for nta factory adjustments, Mt pins 6 ana 5 further amplify and equalize the signal — boosting the low frequencies. due to R6 and G+ in the feedback line. R11 and CB ge to he output (headphone) fo stening or test measurement, 600 ohm head ‘shones ate normally used. Lower listening lovol wil result with very low impedance sets Operation! amplifiers M2 is used for he internat tost circuit. Ifthe test button is activated the test circuit 9300A025—(XX) will un on B+ tost voltage +30V. M2 pin 2 and 3 with ANS, C9 and C8 function as a Titer ampitying the 600—H? test tone coming from the tape, D1 and D2 rectify this signal anc activate M2 pin 5 and 6. Positive vokage an pin 5 will make the output pin 7 go high whch drives the GO, No~Go meter (1mA) through 21 resistor R19 and R20 provide hysteresis (positive feedback) and C14 and R22 sup- presses an intial GO—reading at powar on. 23-70-01 Pago 18 May 1/91(14) 415) (18) AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘Ai00, A100A Monitor Amplifier 9200802804 (see F gure 112) This board is identical to 9800A023—-02 except the lypes of operational amplifiers used (MIC1858) cannot operate with O—vok bias. M2 pin 6 is the only affected bias input Consequently, R23 is used with R22 and R20 to provide a DC bias of 3V on M2, pin 6, ‘otherwise the meter deve ampiiier may produce an undefined — GO or NO-GO read- ing. ‘Timor Board 9300A088 Tho Timer Board serves as an hour meter, indicating total hours (0 to 8009) that the CVA. has been used. When power is applied to the unit, an indicator dot travels along a cali- braled mercury—illed tube. Whenever power is removed the orocess is stopped and ‘when itis applied again, the process i¢ resumed. The progressive movement of the in ccator is directly proportional to the number of hours power has beon applied throughout ‘he life of the unit, and the hours are read directly from the element. 7 4 Timer Board Indicator Figure 10 Bulk Erase Circuit 9300024 ‘The Bulk Erase Circuit (see Figure 111) provides a quick tape erasure capability with safeguards to prevent accidental erasure. The olay times of time delays RY! and RY2, {and the time constant of the C1, R3 circuit are such that the erase button must be held down for at least two seconds before the erase action will begin, and once begun erase power is supplied for at least five seccnds. The erase power is 115 V 400 Hz which is sed to energize an electromagnetic coil in the reel cover assembly. Erase power |S routed through a series switch in the landing guar circuit and a series switch in the pack~ ing brake circuit which is closed only when the parking brake is on. 23-70-01 Page 19 May 1197an (18) 49) AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A Powor Supply 9300002201 The Power Supply (see Figure 110) ‘sa simple full-wave rectifier circu with a fiterod, Zener—regulated +30V output and a Zener—regulated +18V oulput. The requiated +18V is used in the control unit microphone preamplifier ciruit, and the regulated +30V supplies power to all circuft cards in the recorder. The Zener diode for the +30V output is externally located to the power supply, installed in the main recorder chassis. Power Supply 205E0527—XX, FSB 161 The power supply (see Figure 110A) consists of a pre—regulator circuit and current—lim- ited regulator circuits. The 82 Vac center—tapped transformer input to the power supply is applied to dicdes CRI through CRA to provide a lull-—wave positive—going wavelorm to UIB and Qt. Under normal operating conditions, pins 2 and 3 of U1A remain at approximately 10 V, keeping Q1 OFF However, U1B acts as a zero—crossing detector which pulls U1A~3 momentarily to grcund whenever the Input waveform touches zero voltage. This will turn ON Qt only at these zero crossings as long as the de voltage across C4 remains al or above 32.5 Vdc. When a large load starts to pull this de level below 82.8 V, UIA will hold Q1 ON beyond the time of the zero crassing, supplying more power to the current—limited regulators U2/Q2, U3/Q3, and U4/Q4 and maintaining their input voltage levels. This prevents excessive heat dissipation by these regulators during high load conditions and provides a much more efficient power source than one with a Zener—reguiated output Limiter U2 in combination with power—boost transistor G2 pravides a current limited 125 ‘mA output at a voltage of +39 Vde. Limiter US in combination with transistor Q3 provides +21 Vee current limited to 125 mA and short—circuit foldback limited to SO mA. This lat- ter circuit is capable of cunning off the 27.5 Vdc supplied at card—edge pin B through ciode CH7, as well as the ac input power. Ud and G4 provide the +18 Vde output, cur- rent limited to 60 mA. DC/AC inverter 93008140 ‘The inverter circuit (see Figure 116) receives de power at pins 5, 9 and 4, 8 and outpuls ac power from pins 1, 6 and 2, 7. Transistors Q1 and Q2 are connected in push—pulh, and when power is applied ane or the other will conduct mare quickly, and tre currents ‘through the Te primary wil not be perfectly balanced. 1 Q1 conducts more quickly, the phase of the feedback from the BL—V0 secondary of 12 to the T1 primary will be such. 8 to increase the Qt conduction to saturation and drive Q2 to cutoff. When Q1 is saturated the current through the 12 primary becomes constant and the fl induced in the secondary collapses, sending a reverse current to T1, which reverses the Q1/Q2 bias, cutting off Q1 and satrurating G2. Zener diodes CRI and CAB, in conjunc: tion wath resistor 94, limit the amount of feedback to protect the circuit components. The cycle is repeated back and forth, producing a square wave with a frequency of approximately 400 Hz (determined by the Inductance of transformer T1). R7, C1 and 13 form a wave—shaping circuit which filers ihe square Wave into a sine wave. 23-70-01 Page 20 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100A (20) DC/AC Inverter 8300814001 (See Figure 116A) ‘The DO/AC Inverter 9300A140-01 accapts a 27.5 Vee input and converts it to a 115—Vac, 400-Hz output, As shown in Figure 116A, CRI, a 10-V Zener diode, powers, Astable Multivibrator U1 which is set to 400 Hz by R2. Ut produces two signals, which are 180 degrees oul of phase, to drive FETS Q1 and Q2. These FETS are connected in a push-pull circuit which drives the primary of Transformer Tt. Inductor L1, R18, and C8 shape the resulting waveform, (21) OG/AG Inverter 93008140-02/905E0485~01, FSB 162 (See Figure 116B) DCIAC Inverter 900A140-02 with PWA 905E0485—01 accepts a 27.5 Vde input and converts it 10 115 Vac, 400 Hz, oulput. As shown in Figure 116, CAI, a 10—V Zener diode, powers Astable Multivibrator U1, which is set to 400 Hz by R2. U1 produces two signals, which are 180 degrees out of phase, to drive Comparators U2—3 and U2—5. ‘These in tum drive FETs Q1 and Q2 ina push—pull circuit which drives the primary of transiormer T1, Inductor L1, 115, and C8 shape the resulting full waveform, Comparator U2 also provide the means to shut down the drive to the two FETS. When pin 3 gces high with the shutdown TTL signal, this drives U2—2 and U2—6 high, inhibit- Ing switching at U2—1 and U2—7. These pins are left in their (ow state, turning aff the dive to FETs Q1 and Q2, 4. Cockpit Voice Recorder Outline & Dimension Drawings Refer to Figure 11 through Figure 14 for oulline end dimension drawings for Recorder Models A100 and 100A with and without Underwater Locating Devices. 23-70-01 Page 21 Rey 3; Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A Model A100, Outline & Dimension Drawing Figure 11 23-70-01 Page 22 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘At00, A100 Model A100 With Beacon, Outline & Dimension Drawing Figure 12 23-70-01 Page 23, May 91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A, Model A100A, Outline & Dimension Drawing Figure 13 23-70-01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100 Sd Model A100A with Beacon, Outline & Dimension Drawing Figure 14 23-70-01 Page 25 May 1/91AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘At00, A104 THIS PAGE INTENTIONALLY LEFT BLANK 23-70-01 Page 28 May 81AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A, TESTING AND TROUBLESHOOTING 1. Testing Procedures This section pravides test procedures for the CVA and its accessories. Testing is to be performed prior to repair or troubleshooting, after repair has been completed, and immediately prior to instatla- tion, A. Test Equipment ‘Table 101 lists the standard test equipment or equivalent required to perform testing and trou- bleshooling of the CVA. Special test equipment is listed in Section 800. gauge ‘Table 101 Test Equipment and Materials Part or Model Nomber | Manufacturer Name Purpose ‘93008850 iS vA Test Pane! Test signal input and monitar; de power supply, +7408 Hewlett-Packard | Oscilloscope Signal 2.0% Max, 23-—70—01 Page 110 Rov 3; Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A Table 103 (Con't) Recorder Electrical Test and Calibration Procedures ITEM PROCEDURE REFERENCE 19. Final Test 20. Inverter 21. Underweter Locator Beacon (us) ‘A, ALOVR Test Panel, apply 0. Vac, 1 kHz 0.7 0 7.4 Vac to recorder input and set select switch to channel 1. Monitor recorder outout with ac voltmeter (cB meter). B. Continue to monitor recorder output, but now set channel select switch to 2, then 3. Compare channel 2 and 3 out puls to the channel 1 reference noted in the above step. ‘The outputs of channals 2 and’8 should be within £ 5B of channel 1 . Continue to monitor recorder output, bul now set channel solact swilch to channel 4. Compare channel 4 output 10 channel 1 reference noted in step 19 (A). The output of channel 4 should be within +9 and ~3 dB. At the OVR Test Panel, select DC power (27.5 Vde). Repeat steps 5, 16, 18. NOTE: This step is only necessary if the CVR contains a 93004140 or 830014001 or 9300414002 DC/ ‘AC Inverter. (see Introduction Page 1 for configu. ration table) The ULB 1s not calibrated; however, it must be checked for, prover operation and the battery must be within specified time limits, See Section 100 of this CMM for proper proce- dures, (Wpical 20-25 8) £508 +9, 308, 23-70-01 Page 111 Rev 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL A100, A100A {2) Control Unit Figure 103 is a block diagram of the correct test setup for testing the control unit, and Figure 10¢ shows control unit test ancl adjustment poinis. Tatle 104 describes the elac- trical test procedures for the control unit. 115 + 1¥0>_____ «00K | Freaieer Channet af] ima ‘Aue oes of Lf H Lt f= iD fo g a (reamee || opt Shares |] rele I ‘Output Input K Control Unit ‘Under Test Control Unit Test Setup Block Diagram Figure 103 Control Unit Test and Adjustment Point Figure 104 23-70-01 Page 112 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILO MODEL, ‘A100, A100A Table 104 Control Unit Electrical Test and Calibration Procedures. ITEM PROCEDURE REFERENCE 1 ‘Setup Gain Max Output AVC Signal? Noise Ratio Frequency Response Rol—Off ‘A, Remove dust cover(IPL 20-120). Connect Control Unit to test panel B. Connect jumper between point 8 on preamplifier circu board and chassis. C. Sel Test Panel Switches: Roll Off — 700 Hz; Attonuation 5dB—ON, 12d8—ON, 24aB—CFF; Main power-ON. Lo- gal Ampliier—Controi Unt; Mie~EXT; Channel Select ~ D. GND test — normal (BYPASS) NOTE: If microphone Is wirad Intornally to pine P and N (see Figure 119, page 142) disconnect micro- ‘phone leads and apply input signals through properly shielded cable directly to pins P and N ‘on clrcult board. In all other units the Input signal ‘should be applied to the test panel input with Mic selector switch sot to EXT. ‘A. Apply dmv, 1—KH2 signal to input BB, Adjust AP—4(Figure 104) for a D.SV output VIVM level. Apply 1—KHz (approx. 12mV) sigral to input. Increase input level for output VIVM voltage of 2 Vac. Sine wave output a ‘observed on oscilloscope should show no sign of clioping. Note: For Control Units with MOD DOT 4 installed, proceed to Table 105, For Control Unite with MOD DOT 5 installed, go to Table 106. Momentarily remove 8B jumper (Step 1) and observe that out ut VIM voltage drops to 0.3 10 0.6 volls. Reconnect jump er 5B. ‘Short input and note output VIVM reading. Noise 10 mV Max, level ta be 10m¥ max. A, Set output VIVM on 1 volt full scale range. Apoly a 1—kHe input signal (approximately 6m¥} and adjust output signal level for OdB output VIVM reading. B. Maintaining the above input iexel, adjust audio oscillator {or each of the following frequencies and note output VIVM level in dB. 700 He Oto -8.08, 900 He 610-14 dB kHz 43 to -3.4B ‘A. Apply 1—kHz input signal for 08 output VIVM reading as in Step 6, B. Switch test panel *Roll—Oft” io 1 kHz. The 1—kHz, 0-¢B levet should drop to ~1 to ~7 uB. Block diagram Fig- ure 103 Test point Figure 104 0.5 Vac 2.0 Vac 0.3-0.6 Vac tomy max 1 kHz Oo 08 =I 10-708 23-70-01 Page 113 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, A100, A100A Table 104 (Con’t) Control Unit Electrical Test end Calibration Procedures ITEM PROCEDURE REFERENCE ©. Switch “Roll—Of 10 700 He 8. Attenuation A. Set attenuator switches on test panel to OFF. Apply! 0d kHz, (approximately 0.8mV) input signal for 0. dB output VIVM reading as in Step 6. B, Switch 6aB test panel attenuator ON and note out- 8 to 968 ULVTVM level drop in dB, Switsh 8dB attenuator OFF. C. Repeat for 1208 attenuator. —9 to —15dB D. Repeat for 2408 attenuator. 20 to —28dB 9. Gain Cal- A, Sot Test Panol Switches: Roll—Olf—700 Hz: Attenuator tbration 84B—ON; 12dB—ON; 24dB—OF F Mic—IN ‘Channe! Select — CH1. 8. Reconnect micraphone if disconnected in Step 1 . with microphone subjected to a 1kHz, 100dB sound pras- 0.4 Vac sure level, adjust AP-4 to a VIVM output of 0.8V, NOTE: If jumper between point 5B on preamplifier clreuit board and chassis is still connected, per Item 1, disconnect this jumper. D. For madeis A160, A151 (no microphone), apply 4mV, 1—kH2 signal to input ard adjust AP—4 to & VIVM output ofosy. 10. Test Meter Press test button on control unt. Test meter should read 948 9dB Min, ‘minimum, 11, Bulk Erase NOTE: “Normal” bulk erase test panel meter reads full Switch scale, “Actuate” meter reads zero. Press bulk erase bution on control unit. Normal operation is indicated by “Normal” meter dropaing to halt scale and ‘Actu- ate” meter increasing to half scale, 12, Ground Switch test panel GND test switch lo GND SHORT. GND test Short Test lamp should NOT light. control unit under test has a short between signal ground and chassis, GND test lamp wil light Indicating fault 13. Reversed A, Switch GND test switch to REVERSED GROUND. GND Ground test lamp should NOT light. Touch the control unit's chas- Test sis with the test panel probe, Ifcontrol unit is properly ‘rounded, the GND test lamp will ight. BB, For control units with internal microphone repeat above test touching microphone case. 14, Assembly Reassemble and seal as per Secton 700. Make final audible test and note no distortion when speaking 6” away from microphone. 23-70-01 Page 114AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100A, (3) Test and Calibration (2) Control Units with Modification 4 ‘Special test and calibration procedures for models A151 and A162 control units that include Macitication 4 are presented in Table 105, below Table 105 Control Unit Test and Calibration Procedures (for Units That include Modification 4) ITEM PROCEDURE REFERENCE 7 Test Setup A. When testing models A151 and A152, test signals may be AVC Test Signal— to—Noise Flatio appliod to input terminals on recorder test panel. For moc ols 152—1, A182—2 and A162~4, remove the micropnone ‘wires from pins N and P on the printed circuit board and ‘connect the test signal directly to pins N (hot) and P (ground). B. Turn Main Power ON, Local Amplifier to Control Unit, Mic to EXT. ©. To complete the tost setup, connect a jumper between pin 88 ofthe circuit board end ground. D. Apply & 1—KHz signal to the input Increase the input level foran output VIVE reading of @ ac. The sinewave output ‘observed on the oscilloscope should show no sign af clip- ping. Momentary remove jumper irom rreampifier circuit board fin 5B, observe output VIVM vottage drops to 0.3 to 0.6 vo. Reconnect jumper to pin 58. Short input and note output VIVM reading. Noise level should be 10mV max. Frequency Set output VIVM on 1 volt full scale range. Apply a tkHz input Response signal and adjust ovtput signal level for Od output VTVM Micro- reading. Maintain the same input level. Switch through follow- Ing frequencies and make sure dB outputs are as shown: 190 Hz 1 to 508) 300 He Oto ~348 500 He Oto -34B, 5000 Hz Oto ~4a8, ‘Switch Mic. 10 INT. Reconnect microphone wires if previousty ‘phone Cal- disconnected with microphone subjected to a 1 kHz, 100 a lbvation ‘sound pressure level, adjust gain el control panel for a VIVM output of 0.5V. ‘Test Meter Remove jumper between Pin 68 ard ground, Press TEST bu ton of conirai unit test moter to roed § minimum. 0.3 10.06 volt 23 —70—01 Page 115, Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A Table 105 (Con’t) Control Unit Test and Calibration Procedures (for Units That Include Modification 4) TEN PROCEDURE REFERENCE "Normal" "Normal" bulk erase Wai panel mater reads full scale, "Adlu- Bulk Erase ate” meter reads zoro, Press bulk ERASE button control unit ‘and Aclu- Normal operation is indicated by “Normal” meter cropping to ate Meters halt scale anc Actuated’ meter increasing to half scale. 3. Ground, Switch test panel GND test switch to GND Short position. Short Test GND test lamp should NOT fight. I contro unit under test has a short botween signal ground and chassis GND test lamp ‘wil ight indicating a faut Reversed A. Switch test panel GND test switch to Reversed Ground Ground position, GND test lamp should not tight. Touch the control Test tnt’s chassis withthe test panel probe. if control unit is properly grounded tho GND test lamp wil ight. 8. For control units with internal microphone repeat above test touching microphone case. NOTE: When tosis are completed, replace dust cover. {b) Control Units with Moditication 5 ‘Special test and calibration procedures tor models A151 and A152 control units that include Modification 5 and all models A151B and A1S28 control units are presented In tebe 106. Table 106 Control Unit Test and Calibration Procedures {for Units That Include Modification 5) ITEM PROCEDURE REFERENCE . Test Setup A. For following tests, modal Aisi, ASTR (std) test sianale ‘may be applied to input termirais on recorder test panel. B, For models A152—1, A162—2 and 1524, remove micro- phone wires from pins N and P on printed circutt noard ‘Connect test signals directly tc pins N (hot) and P (ground). ‘Connect jumper between oin SB and ground. D. Turn main power on. Local amplifier to control unit. Mic 10 Ext, Test panel attenuation 6d8-ON, 12dB—ON, 24B— ‘OFF. Channel Seiect ~ CH + E. Apply 1 kHz signal to input. Increase input lovol for output \VIVM voltage of 2 Vac. Sinewave output as observed on oscilloscope should show no sign of clipping. 9 23-—70—01 Page 116AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘At00, A100 Table 106 (Con’t) Contro! Unit Test and Calibration Procedures (for Units That Include Modification 5) ITEM PROCEDURE REFERENCE "AVE Test Momentariy remove SB jumper (Step 3) and observe that out- 0.3 10 0.6 volts, put VTVM voltage drops to 0.3 to C6 vollls. Reconnect jumper 1058. Signal— Short input and note output VIVM reading. Noise level to be 10 mV max to-Noise 10 mV max, Ratio Frequency Set outout VIM on 1 volt full scale range. Apply a 1—kHz Response input signal and adjust output sigral level for OdB output VIVM reading. Maintaining the same Input level switch though following frequencies and read dB outputs, 150 He 1 to -5dB, ‘900 Hz 010-308, 500 Hz Oto -3dB 000 Hz Oto ~4dB 3. Atlenvating Sot 3 tost panel altenuator switches to OFF. Apply 1 kHz input —3 to ~9dB ‘signal for 0B cutput VTVM reading, Switch 668 attenuator ‘ON and note output VIVIM level drop in dB. ‘Switch 64B attenuator OFF, Repeat for 1248 attenuator. 9 10 —180B Repeat for 2408 attenuator. 20 to -28d8 . Micro- A. Switch Mic to Int. Reset test panel Attenuators to —18dB hone Cal- attenuation. Reconnect microphone wires if previously dis~ bration ‘connected, B. With microphone subjected to a1—kHz, 160dB sound = O.8VVTVM output pressure level, adjust gain of control pane! for a VTVM out. put of 0.5V, C. Remove jumper between Pin 5B and ground. Test Moter Press TEST button on control unit. Test meter to read @ mini- mum, “Normal* “Normal” bulk erase test panel meter reads tll scale. “Actu- Bulk Erase ale” meter reads zero. Press bulk ERASE button on control ‘and “Aclu- unit, Normal operation is indicated by “Normal” meter drop- ate" Meters ping to half scale and ‘Actuate’ mater increasing to hatf scale. Ground Switch test panel GND test switch to Position 1 {GND Short) Short Test GND test lamp should NOT light. f contral unit under test has ‘a short between signal ground and chassis GND test lamp wil ight indicating a fault 23-70-01 pov otAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, At00, A100A Table 106 (Con't) Control Unit Test and Calibration Procedures (for Units That Include Modification 5) ITEM PROCEDURE REFERENCE 70. Reversed A. Switch test panel GND test swich to Position 2 (Reversed Ground Ground). GND test lamp should not light. Touch the con- Test trol unit's chassis with the test panel probe. Hf control unit Is propery grounded the GND test lamp wil light. B. For control units with internal microphone repeat above test touching microphone case. NOTE: Whon tests are completed replace dust cover. (4) Remote Microphone ‘Table 107 and Table 108 describe the alectrical test procedures far the optional remote microphones, Table 107 Remote Microphone Assembly Calibration Procedure P/N’s 93A055—00, 02, 03, 04, and 9300A165 ITEM PROCEDURE REFERENCE 1. Continoily With VOM in "RXT" range check far na cantinully between 0 Ohms connector shell and dust cover (IFL 24—65). 2 Output —_With microphone subjected to 1—el4z, 100—dB sound pres: 36m” ‘sure level, measure output across pins 1 and 2 with VIVM. Output wavstorm viewed with osciloscope should be undis- torte. 3. Audible Connect microphone module to ASS input on recorder test panel. Speak into microphone and note distertion—frae per- formance. Table 108 Remote Microphone Assembly Test Procedure PIN’s 93-A055—10, 20, 30, 40, 45, 50, 55, 60, 65, 66, 67, 95, & 92959, 931025, 9300A1601, 9361901, 93A272, 93657 ITEM PROCEDURE REFERENCE 1 Setup ‘Sotup for fest as shown in Figure 105. Use Saund Lavel Figure 105 Source P/N 93004870, Connect microphone to HP 17408 Oscilloscsope anc HP 400EL RMS VTVM, or equivalent. 2 Output Apply 100—cB sound pressure level to microphone. Refer to Refer to Table 108A Table 108A for the output spectfestion according to micro + GdB phone part numeber. The output reading should reflect the stated specification, + 648. The waveform should be undis. toned. 23-70-01 Page 118AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A1008, Table 108 (Con't) Remote Microphone Assembly Test Procedure P/N’s 93—A0S5—10, 20, 30, 40, 45, 50, 55, 60, 65, 66, 67, 95, & 92959, 931025, 9300A1601, 9361901, 93A272, 93657 {TEM PROCEDURE REFERENCE NOTE: Ifa sound level source and oscilloscope are not avallable, use the following alternate method for testing. 3. Setup ‘Connect to AC VIVM and battery or powor supply. 4. Quiput Speak into microphone from a 6—inch distance in anormal 2mV —10mV voice. The VTVM should fluctuate between approximately 2mV and 10mV, “Remote Micophone Caciloscope Vos 1 Volt Baitery or D.. Power Supply + For PIN san05s—20 a 45, ‘ree Ine le blak ant 95 remote micropores, Remote Microphone Test Setup Figure 105 Table 108A Remote Microphone Assembly Output Specification Table P/N’s 93A055—10, 20, 30, 40, 45, 50, 55, 60, 65, 66, 67, 95, & 93959, 931025, 9300A 1601, 9361901, 93272, 93657 PART NUMBERS: PART TYPE ‘OUTPUT RANGE ‘93A055—10, 20, 30 ‘Condenser 7.0 —17.5 mV ‘93A055—40,45 ‘Condenser 10.0 — 42 mV 93A055—50, 55, 60, 65, Condenser 6.0-17.5 mV 66, 67, 95 93959 & 931025 ‘Condenser 6.0- 17.5 mV 9300A165—01 & 9361901 Condenser 7.0 —17.5mV ‘93A272 & 93657 Condenser 10.0 — 30 mV 23-70-01 vasAVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILE MODEL ‘A100, A100A (8) Inverter 93008140 and 930081.40—01 Table 109 describes the electrical test procedure required to perform detailed testing of the inverter. Table 109 Inverter 93004140 and 9300A140—01 Test Procedure ITEM PROCEDURE REFERENCE 1, Test Setup A, Connect a 660 ohm, 20 wait icad to inverter pins 1 and 2, See Figure 116 and and to varical input of scope. Connect an oscillator to hor- Figure 116A izontal input of scope, B. Apply 27.5 Vde slowly (in case of short), with + to pin and ~ tc pin 4. 2. Load vs. In- A. On scope, read output voltage iflat portion of peak, to fat 115 Vac + 10% ut Tests, orton of peak divided by 2} wrich must be 115 Vac + 40%, (Output varies directly wiry input voltage) B. Adjust oscillator for stationary lissalous pattern, 400 He + 59% ©, Switch to peak load of 330 ohms, 50 watts on pins 1 & 2 1. On scope read voltage (flat gottion of peak, to flat perton 115 Vac + 15% of peak/2) which must be 115 Vac + 15%, E, Adjust oscillator (requeney for stationary lissajous pattern, 400 Hz + 103% ~ 8% F. Switch to normnal 660 ohm, 20 Wall load. Repeat Steps A. ang B. for input of 22 Vat. G. Switch to the 330 chm load, Repeat Stops D. though F. for input af 22 Vda. H. Repeat Steps F and G. for input of 30.25 Vo. (8) Underwater Locator Seacon, Using Dukane Model 42A12 Ultrasonic Test Set, lest to see that the ULB is functioning properly according to Table 110, below. Table 110 Underwater Locator Beacon Test Procedure TEM PROCEDURE REFERENCE 1. Test Setup A, Use DuKane Model 42812 Ultrasonic Test Set. 8. Set the test sot INT, — EXT, Swtch to INT. 2. Mic Check With test set turned on, set TUNING cantrol to 35--40 «Hz and GAIN control clackwise while jingling keys or coins near the test set microphone. The unitindicaies correctly if the noise is reproduced by the test set's speaker. 3, Activate A. Using a metal braid or other flexible metal conductor, tern orarly short the ULB switch, hereby activating the unit. The test set will detect a proper output of the ULB in an unobstructed line of sight condition. B. Ifthe ULB is functioning propoty, the test set will so indi. cate through its loudspeaker ty reproducing the sound of the ULB at a lower, audible frequency. 23—70—01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A1D0A 2. Troubleshooting Procedures This eection provides procedures for troubleshooting the overall system and the major components down to the level of the individual circuit boards. Refer to Table 111 for procedures to troubleshoot the main recorder assembly, and see Figure 108 and Figure 107 for the recorder interwiring dia. grams. Refer to Table 112 through 117 and Figures 108 through +18 for the troubleshooting procedures land the schematics of individual circuit boards within the Main Recorder Assembly Rofor to Table 120 for procedures to troubleshoet the control unit assembly, see Figure 119 for the ‘control unit assembly wiring diagrams and Figure 114 for the timer board schematic diagram. Re- {or to Table 118 for troubleshooting procedures, and see Figure 115 for the schematic of the micro phone preamplifier circuit within the control unit assembly. Refer to Table 119 for troubleshooting procedures, and see Figure 116 for a schematic diagram of the Inverter assembly and Figure 117 for a wiring diagram of the remote microphone assembly. ‘See Figure 118 and 120 for the main recorder assembly wiring diagrams. NOTE: The following tables list troubles that can occur during test after overhaul and in an assembly prematurely removed from service. Refer to the appropriate aircraft maintenance manual for troubleshooting of the equipment when it Is installed in the alreraft. A. Main Recorder Assembly Table 111 lists the logical troubleshooting procedure for the main recorder assembly. Table 111 Main Recorder Assembly Troubleshooting Trouble Probable Cause ‘Checks and Corrective Action 1, Motor notrun- |. No pawer to motor or |A.1) Check pawer connections to unit, Check ring pen winging wiring. B Mechanical binding Bia) Check all ve components for fee ra ning. 2, Woior running, [A Bad headset — wrong Art) Check for diferent sound or cick when Nosigral in | connections — bad plugging or unplugging monitor assembly headset — hhoadset jack board. tape moving 2) Replace headset B. Faulty monitor amplifier B.1} Check for humm when touching input. assy. board B.2) Replace monitor ampiifer assy. board. C. No B+ (30) C.1) Check power supply and replace as indi- cated. 23-70—01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A10A Table 111 (Con’t) Main Recorder Assembly Troubleshooting Trouble Probable Cause Checks and Corrective Action 2 Motor running, |B. Open playback head O.i) Carehlly touch soreweriver to top or side of Noswanal in” | Open record head head. Listen for clicking sounds through headset — headset. Lape isdeg_eRETOR OG WOT ALLOW THE SCREW DAVER TO COME WN CONTAGT WITH THE FACE OF THE HEAD OR IRREPARABLE DAMAGE MAY RESULT. 0.2) Replace hoad i found faulty 3. No playback A. Open record head Blor At) Test all four channels, teading signal into or not record: |" playoack head each channel. ing onto tape . forpayoacic |B No recording Bi) Roplace Bias Generator assy, Board. 4. Nol recording |. No bias on recording [E-1) Chock & adjust for 612 Vac on bias Garr low level re. |” (Gives low level highly is- | erator essy. test point. cording andor | _torted recorcing) 62) Pullbias generator card, There should be Geto a cick and change in qualty or loudness. 'G.3) Check for jumpers between pins 7 and 8 ‘67 main connecter P1 on recorder. D. Heads contaminated Dt) Examine heads for contamination and clean per Section 400. E, Faully record amplifier as- sembly E.1) Measure vansisior collector voltage at ‘channel recorder assy. TP. 19 Vdc + 4V. AC voltage with 500mV signal input 0.8 Vac. E.2) Interchange record ampliier assy. cards, E.3) Gain control turned all the way down. Turn CCW for max. signal. Adjust for 0.8 Vac at TP E.4) Replace record amplifier assembly. 5. No lest indica ton on meter A. Faulty meter ‘A:1)_Listen fr test tone in headset, BB. Test tone on tape but not on meter Bat) Fauily meter 8.2) Metering circuit on monitor amplifier assy. card. Not getting B+-30V, of not function: ing. Press TEST outton. Meter should indi cate. Check for 29 VDC on Q6 collector ‘when pressing TEST button. Replace board if necessary. if voice indicates on meter, then test circuil assy. board is faulty, B.3) Replace test circutt assy. board. ©. Ne test tone injection into) record amplifier assembly C3) Measure ac voilage at record amplifier assy. board TP. while prassing TEST but- ton. Should be aporoximately 2 Vac. 23—70—01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A, Table 111 (Con't) Main Recorder Assembly Troubleshooting Trouble Probable Cause ‘Checks and Corrective Action 2) Replace test circuit assy. board 1. Faully record amplifier |D.1) Check record amplifier assy. board. assy. not recording (0.2) Replace record amplifier assy. board. & Bulk erase nat [A. No power Béing fedin due JA1) Measure ac vollage at bulk erase call cone functioning | to broken or faulty connes-| nector while bulk erasing on 1000 Vac tions on wing. range. [A2) Repair wiring 3 Caan reel Gaver open |B.1) Check for continuity on bulk erase coil, 18.2) Replace bulk erase coil. ©. Relays on bulk erase tim- {C.1) Replace bulk erase tming board or check ing board no: sunching teu, Figure 111 properly. D, No B30 Vde to bulk _[B1) Check with de voimoler beiween FG. con- frase timing board rector pin D and chassis, D2) Repair wiring. E_ 0.18 mFD capacitor 1000 E.1) Check for ac valage as in AT), above ‘de tuning condenser, un- acites der belt cover open or 2) Replace Caf ‘rounded 7. Bulk erase not |, Low ine vokage ‘Ray Measure line volaga at motor terminal erasing com board pins while Bulk erasing Bletaly 115 Vac + 10% B 018 mFD capacitor 1060 |B.1) Measure the vollage across the 0.18 mFD Va timing condenser un- | on tre T00QV range ac meter while bulk dor bet cover sherted or srasing vith col plugged in. grounded C. Shorl or groundinTead | C.7) Measure ac vallage ai Duk erase call con rector while bulk erasing. C.2) Replace capacitor. @. Bulk erase [A Evase propery but oftoo [A.1) Switching tmme of bulk—erase ting Grau erasing com- | short a duration is too short pletely but sig- | tH§ PROBLEM 1S NOT }A.2) Tape speed too slow. Tape bundle does nalcomes in | CORRECTED BY LAST COL- Not complete one revolution of outer layer even2-4 se | UMN, LAST COLUMN BE- of lape in § seconds + 0.5 seconds, (See conds LONGS HERE. Ad) B. Record Amplifier Assembly. Follow the troubleshooting chart, Table 112. to treubleshoot the record amplifier, P(N ‘93008020. 23—70—01AVIATION RECORDERS. ‘COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100 THIS PAGE INTENTICNALLY LEFT BLANK. 23-70-01 fev aAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL At00, A100A C. Interwiring Diagrams. ‘The interwiring diagrams show signal paths between recorder sections. staat NRERWABI PERARNE Sn? VOICE RECORDER UNIT (ll Mode's A100 or A1O0A) SUS Voc HOT OUT rovsucrertenn gD HEME RSE Toucan AecSinicn tou some: yaw out Sua SUE? Sais ccowrnot unr ALL MoD- Bis AN staan on aietb SPE INUT orient) 2 fo. csees yee ro-me ‘ 2 pusu10-resr REDE f 1 Paetud Poke on meApeonnine © 1 pres POWER SNE wae Rec root 5 igiios © rere 2 {g NBearoe Garcon |e SS Sao siemete 8 fom stems on tS suagesten suse No.1 Meirekng SUSSESTE SSNS 2 ietnsce SUSEESTED Seen No.3 0 80.10 ‘ om seen ‘ cwunnen toner | 73" : 2 svuevor : conve : " exzinen : 3 Sas 5 to Sestecbeneen: 2 caannens Hamers ee L rey conscmuaren covanness Groearicwenoe " 28 areuanos MICROPHONE HODEL ‘285 OR ASS. meemuatiee, 3 i ce ee EE Fences “etna NOTES: "1 oo. in. who 0 #22. #24 accopabo cop for iong‘un power ads hero #18 sr. ons 297, & 18) 22 Sein somesien ote wih 1h apn 75 Gy one foyer sou oo wed fo alt 1 115 <0 ty saota no canrgcoo bade gh La ale gesotecraanacer 2a race ph cht bea VV Dost mond 8h 13 iter tamnaton sired Cork! Une py wage om ighing bus proper pes. SS snes A orion attek only ts wetage mening bs reper 2, Wing shoes sana fa lion o!19 por ANC 57. BESO Meh sAtEsoty una ic oddosA8 ny CortlUnt ASB er AISA Ia ied who 8 Modo! 4a Sale & Meda go sec’ microphone outeut abing coors aro overs! en th 40 Sars the tiene site night audio sos, andor 80 suis tha iowa sha 40° aon). A100/A100A Interwiring Diag—Control Units A151, A151B, Remote Mic. A55, AS5B Figure 106 23-70-01 Page 125 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAIN-ENANCE MANUAL FAIRCHILD MODEL 100, A100A speoma resume rename sree voice RECORDER UN const SNS ae at LISDELS M00 GH MTOOA “18 vac Hor Our roeevor vom Hector ‘oun AESBENEN Son vewrsme upg ouro A288 Burp Seo Neen ‘CONTROL UNIT ALL Moo. Bus JiNren EIS Ata2 On as Pere an men seo ree » Push-to-Test Sueemnco = § Petia SoNR on | Prealp POWER SNS vac REG Scum —— Racwor noeaar :—, IBearOR Eevee = ES Srouno fue entone — ese) Siemon == se Senne at SUGESTED GenHE NO 1 Sethe i SURSESTER SPAE NS muro : SURED SWE NS § roma STD bt & seme sata BO cones samror in ves Teetttences Le La te a roo ft si0 sivainecr : ats ‘crawver2 St i aa soomewenc tI Lp ti Senne | fio sme comer {ERT > > as Beeenmimenos f Bw ‘SUSGESTED SPAFE NOS i: 1 : Bo a EAE Tr ownnens tt Lffp __sewnt I Ba SW 1 Oe Lie ‘room _— a Bh \___ se, me, 8 Fee min wie sizes #22, #2418 acceptable except or long—tun powe nas where #8iG 96. (one 23.17. 819) Grune cormecton tbo within of B17 *3_Oniy ane power soutes be wree per aera SIAC, 400 He is supped, no connecton to be maciato pin #8. 27.5V0C is cupoles, no cannocton to bs maie 6 pi #3.Snon pins | & 2, be aro vero 8 Used. 14 Shgio Grouse Poire 15 |i maerlurmneton inched in Contek Unit, supoh votags to Ighsng bus to proper Pins '§ Shorts & Tor Deston ance ony, “7 Wining shun for tancara fad ate of 18 a8 per ARNG 567, "8 Jumper wires per ARING 887, 1/2" max long ‘A100/A1004 Interwiring Diag — Control Units A152, A152B, Figure 107 23-70-01 Rov: ir OtAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL. FAIRCHILO MODEL A100, A100A some mance voce neconoen ut ERIC aS ATRESIA oewevenene subst lagen ene SAS on meen assent i Feats "ete a Siore EE Se Pceones JQ ¢ Gass cie 2.1 som arrawaren Oe 1 2 SUGGESTED SPARE NO: cea wut 5 8 a { ieee g if poemsf Fy to woot, vas crane ‘MICROPHONE re 233. a are owen + cuanne 2 Mens ‘CHANNEL ‘CHANNEL ¢ Srenese¢ NOTES: “1 Rocommorsocimin. wiry seis #22. #245 cocapabl except fr long-run power keade whe's #18. 6. (igs 28.47, & 19) 120 Ground cannocton tbe within of pn 7. *3._ Only ene newer saurcs tans wd por alta 11SVAC, 400 Hee auppld. ro camocton ta be made to pn #127 SYD is supped, na eannecton to be made’ pn #3.Short ne 1 82, besute weer used v4 Single Grosra Pow NOTICE: FAA action natios £8900 56, dated January 24, 1980, sistas that he pllot and area ric wl be recorded on the inner two cu of tho GV, To cont to to above hai, somo CVA instlatone vl have te plot connected to CVF shanna No ‘ond ine ties erew member connected to GVA chan. The channel designators under ths ew rule sre Chaciel ‘Biot; Cranmel™ co-pilot; Channel 2 = Sd crew member, Channw &=-are9 mc A100/A100A Interwiring 1g — Control Units A150 Figure 107A 23-70-01 nev MarAVIATION RECORDERS ‘COMPONENT MAINTENANCE MANUAL. FAIRCHILD MODEL ‘A100, MO0A Table 112 Record Amplifier 93004020 Troubleshooting Trouble Probable Cause Remedy ‘No signal at junction 1, R2.No signal |G1, T1, R2 opon, or Ri open or ston, Replace attest point e'open or Qt detective. C3 shorted, Ra or RB or R6 open No signal at"REC HD CURRENT" [Lf open, Fir open, G4 open, C5 shorted Replace ‘Signal distoried at normal level at | T1 defecive, C4 shorted, or QT defective Replace SREC HD CURRENT” Excessive and distorted signal Ti defective, OT detective Replace "Gti, 600 Hz signal applied to G7 oF FS open Replace paints E & A. No signal at junction, Ra, R2 Record Amplifier Assembly, 93004020, Schematic Diagram Figure 108 23-70-01 Pago 128 Rev 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100 D. Circuit Boards of the Cockpit Voice Recorder. The following tablos treat symptoms of specific subsections of the cockpit voice recorder, Table 113 Bias Amplifier 93008021 Troubleshooting Trouble Probable Cause Remedy ‘No B+ at junction 01, 02, or |R4 or Li open or 03 shorted collector [Replace a No signal at Gi collector | O1 defective or low Bota: Lt, C2, C1_| Replace shorted, AZ andlor AS open ‘No B+ orignal at point © _|A@ and/or Lt open Replace No a6 signal at "ERASE HD [C4 open or Lt open CURRENT” [Replace Froquency check at TR not | C2 open, Li shorted, Cf open Topiace ‘correct and/or cannot be cor: rected by adjusting L1 ‘Waveform not symmetrical [LT skug improperly edjusted ‘Adjust slug in toward board sine wave tunbl wavelorm ciears; then go to.a mV to 4 mV lower read: ing L eo (Be) (erase) mp (CWO INCREASE BIAS) Bias Generator Assembly, 9300A021, Schematic Diagram Figure 109 23-70-01 ov hat 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A108 Table 1138 Bias Amplifier 9300A021, Before FSB—127, Troubleshooting Trouble Probable Cause Remedy ‘No B+ at junction C2, 63, or | R4-or L1 open or GS shorted Replace 1 collector No signal at Qt collector | O1 defective or low Bota L1, C2, C1 | Roplace shorted, R2 open No B+ or signal at point | R8 and/or Lt open Replace No ac signal at “ERASE HD /C4 open orLt open Replace CURRENT" Frequency check at TP not [C2 open, Li shorted, C1 open Replace ‘correct and/or cannot be cor- rected by adjusting Lt Waveform not symmetrical [Lt slug improperly adjusied ‘Adjust siug in toward board sine wave until wavetorm clears; then go to a 8mV to 4 mV lower read- ing L e-) aie @é Bias Generator Assembly, 9300021, Before FSB—127, Schematic Diagram Figure 1098 23-70-01 fev: Mar 08AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, A100, A100A, Table 114 Power Supply 9300A022 and 9300A022—01 Troubleshooting ‘Trouble Probable Cause Remedy 784 Vae no at junction | 1 or D2 deecive, power transformer in recorder | Replace Dirt detecive No wolage a juncion Ra, C2 | Ft, Re, open, oF G1, GE shored. Shoned-vaner | Repace Godt intost cord ia véliage a uncon R3, DBF open or D8 shored Feplane Tipple volage Figher tan — [Dt or D2 open, Cl or G2 open or delive, caret | Reglace ten diode in rorder dtocave (4) e 3 og ms (ess07 ot wen a 2 cen cm & phe | () Power Supply Assembly, 93004022, 9300—022—01, Schematic Figure 110 Table 114A Power Supply 205E0527—01 Troubleshooting No voltage at (+) side Us or QI defective, of C4 (32.5Vdo) lasso. discrest components) No voltage at pin K U2 or Q2 defective (+30vee) (ase, ciscrest components} No voltage at pin H US or 8 detective (#21Vae) (asso, ¢iscreat components) No voltage at pin J Ua oF Q4 detective (+18Vd0) {assc. discreat components) 23—70—01 Rev 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL A100, A100A, me apy te de My RE gO 2 G}—-——4 si s20v ao eT Tete Tour | Pier Power Supply Assembly, 205E0527—00 , Schematic Diagram Figure 110A (Sheet 1 Of 2) 23—70—01 Page 192AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, AL0OA Boas aia 5.00 : : i , 5 in os 1 < Wy cio i tee [er We ySaoer ces eee so ue 188orr Power Supply Assembly, 205E0527—00, Schematic Diagram Figure 110A (Sheet 2 Of 2) 23-70-01 pov Mar OtAVIATION RECORDERS COMPONENT MAIN“ENANCE MANUAL FAIRCHILD MODEL, A100, A100A, Table 115 Bulk Erase Timing Assembly 83004024 Troubleshooting Trouble Probable Cause Remedy No voltage at junction of C1, R2 when [D1 or Ri open or Gt shorted Replace Erase button is depressed Voltage at C1, Aa, ancino relay op- | FG, RA, RS open or DG shored Replace eration of BY 07 02, 03, RY2 defective Vokagé at Gi, A and no closure of |R2 open orB1 or D2 shorted Replace RY? with jack B grounded Q1 or RY1 defective L e J ne. womencan { (4) e-emse Bulk Erase Timing Assembly, 9300A024, Schematic Diagram Figure 114 23-70-01AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A100 Table 116 Monitor Amplifier 93004023 Troubleshooting Trouble Probable Cause Remedy 'No signal at junction R2 and Ra (Oi defective, or Gi, Ai, AB, ASRS or ti | Replace jopen, or 2 or G6 shorted No signal al junction Rs and AF G2 detective or C3, AS, RG, AY and Ait open [Replace ‘or 05 or C8 shorted No signal at junction RiO and Ai [8 defective or C4, C7 AB R9, ATO R12 open | Replace 0r 68 oF G10 shorted No signal at test point ‘G4 detective or R14 open or 09, C10 GH1__| Replace shorted Clipping of KHz signal at less than | Gircult G3 stile collector voltage must bea | Replace 2 volts Minimum of 4.0V higher than Q4 emitter No DG with 600—Hz input aljunection |Q8 defective, C12, RIG, AI7 C14, DY D2, L1_ | Ropiace Rig, R19, open, C13, 618, 02 shored No signal at moter with de at junction |O6 defective, R18, F20 or R21 open Replace Rig — A1g Table 116A Monitor Amplifier 9300A023—-01, 9300A023--01X1, 9300A023—-02, 9300A023—-04 Troubleshooting Trouble Probable Cause Remedy TNo signal at junction RS and RT Mi defective, or RT, RB, AS, 2 open, or Gi, [Replace 3 shorted No signal at junction C5 and RS Mt defective or C5, RB open Replace No signal at janction A14, C8, and 8 |M2 defective, R13 shorted, R14 open Replace No signal at test point Mt defective, RY, AV, AS, G2openorGs | Replace shorted Clipping of KHz signal at less than [Mi defective. or C18 shorted, or R2 open | Fieplace 2volts 'No signal al meter with de at junction [M2 defective, or O12 shorted, or R19, R20, |Replace of R16 — RIB Rai open 23—70—01 Page 135 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A (ei30%) army (eno) + (e) 4 (enn oun) (aroun) @+test) cr (aroun) (arin (eno my) @r30y) (eeTesT) (METER) (eno oun w) PIN a2ooac23—01 Monitor Amplifier Assemblies, 93004023, Schematic Diagram Figure 112 (Sheet 1 of 3) 23-70-01 Page 196 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A eu eo inotesn: 7 vere cr jonooun en Pisaooa023—04 Monitor Ampli Assemblies, 93004023, Schematic Diagrams. Figure 112 (Sheet 2 of 3) 23-70-01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100A wsta on enooun. * x IN sa008023—09 Monitor Amplifier Assemblies, 93004023, Schematic Diagrams. Figure 112 (Sheet 3 of 3) Table 117 Test Circuit 9300A025, 9300A025—01 Troubleshooting Trouble Probable Cause Remedy No test function or tone Ai, R2 oper, GY shorted or Gi detective | Heplace ‘Board always on with or without dra- [Qt too low Replace with part matic changes in ring counter cycle having Max. 35 V cor test fone, Turn an with B+ in- leba 5 mieraamp. crease leakage Ring counter holding on one channei | Isclate whether G2, 03, Q4 or G5 stays | Replace defective in ALL test condition fon by measuring collector transistor volt | transistor ages 23-70-01 Pago 138AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A1OA Table 117 (Con’t) Test Circuit 9300A025, 9300A025—-01 Troubleshooting Trouble Probable Cause Remedy Ring counting and gating but no test |A22, R23, RZ6, R25, R26, R27 open, Replace ‘tone C10 shorted; Q8 defective or low Beta; 8, C7, C8 shorted or open Board funclioning normally but test | 06, G7, CB shorted; R22, R23 open; Roplace (G6 mini- tone off frequency 6 low Beta, mum Beta 80) (ery (on-auy (ertesr) eno How) {HOLD 2) (HOLD) tHOLO4) (rTONE’) ATTONE2) AT TONE) (TONE) PRORTOAETRORIT OF F5123, NOTE: Al components remain the same excopt as flows: wns 10087 MEDI OT MED Rag ae VSM AW 2/~ 35 600K ohms 14 +/—5% Test Circult Assemblies, 9300A025—01, Schematic Diagrams Figure 113 (Sheet 1 of 2) 23-70-01 Page 199AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL AN00, A100A Table 117A Test Circuit 9300A025-02 Troubleshooting Trouble Probable Cause Remedy No test function or tone {QI detective, or no BV B+, or MI, M2 do fective Replace ing counter holding on one channel | M2, Md or Ni defective in ALL test condition Replace Board functioning normally but test _ | Gb shorted or changed value RB or RS tone off frequency changed value Replace (30m) fon-auy (ertesr) v (wow) (HOLD) (HOLD?) (HOLD 1} qrroNe) (TONE?) (TONE) (TONES) Test Circuit Assemblies, 9300A025—02, Schematic Diagrams: Figure 113 (Sheet 2 of 2) 23-70-01 Page 140 Rev 3: Mar 08AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘At00, A100A 2 RY oak +20y0¢ 1Vde Frequency out of specifcation G2 detective Replace Aclust R2, fro effect Distorted waveshape at output C2, Oh, Gi or OF Gefecive OF Gi or G2 open | Replace 23-70-01 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A, eoeonent cnaae wate enor on THLE] owsee wnoee [RE] vee] crecutre aay prov] om] a ° ga de 933 2sae0se7 02 sssnicu Le. Ae I let I prcccstaaay s20v +10,0v 1, RESISTOR VALUES ARE IM OMUS, CAPACITOR VALUES. ARE. TH MICROPARAGS. OMLESS OTwERWISE SPCCIFTED: Inverter Assembly, 202E0485—00, Schematic Diagram {used in 9300A140—02) Figure 116B (Sheet 1 Of 3) 23-70-01 Page 147 Rev 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILO MODEL ‘Ai00, M100A ToENa £8 RS, REF Fu 1168 {Stoot 1013) 200K 8 Ru on 25.5 Inverter PWA , 202E0485-00, Schematic Diagram (used in 9300A140-02) Figure 116B (Sheet 2 Of 3) 23—70—01 ow Mar O8AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100A, Inverter PWA , 202E0485-00, Schematic Diagram {used in 9300A140-02) Figure 116B (Sheet 3 Of 3) 23-70-01 areAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘Ai00, A100 CONNECTOR AS VIEWED FROM ALPHA FIT=221-3116 . ‘WHITE HEAT SHRINK FLAT ON THOS. SOLDER TERMINAL EVD, Te MEAT SH y— CONNECTOR SHELL oan brite | “an Ck PLASTIC CovERED 7:32 ‘STRAND WIRE. (MIL -W=16878D) MIC CABLE DETAIL ‘SHIELD Remote Microphone Assembly ASS, Wiring Diagram Figure 117 Table 120 Control Unit Troubleshooting Probable Cause Control Unit fa) Control Unit wiring har— (at) Check out internal wiring connections does noi work "ness with opened or shorted leads (a2) Repair wiring 1. Meter and Refer to Table 110 switches do not work Microphone (a) Defective microphone ‘Switch to external mike and feed in inoperative mv at 1kH2. The output should be or garbled ave 05 Vac (b) Microphone preamplifier ‘Switch to external mike. Measure the defective ‘output of the mike with 1008 sound source, Level at 1 KHz 0 be 3 mV io mv Replace preamplifier and calibrate 23-70-01 Page 150 Rev 3: Mar 08AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A10GA ‘connector somone yA = 1 . | i “ BI H Test ut swincH ct 7 : FL sr wt wl i Model A1S16 (PIN 99815120, 99815130 and 93A161—50) é ree wie opto i were a Eltels fh ao BE | 3 [o warey | HEAD PHONE Jack SBN Mode! A1Si, AiS1=t PIN (PIN SS—A1S1—00, and 83—AI51-—01) Control Unit Assembly Model A151, Wiring Diagrams Figure 118 (Sheet 1 of 9) Orth 277 V4OrRBOR VZOMEN | 23-70—01 Page 181 Ray 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, 100A ‘OPTIONAL COLORS FOR SHIELDED PAIRS Pins G AN Red or Waite Pine H&P Blue or Black Control Unit, Model A151 (P/N 93A151—40) Wiring Diagram Figure 118 (Sheet 1 of 9 continued) 23-70-01 Page 152 Rov 3; Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILE MODEL, ‘A100, A1O0A ‘CONNECTOR, os Test swircH oT Qe LO prone nce ** OPTIONAL COLORS FOR SHIELOED PAIRS Ping G &N Rad or white Pins H& P Blue or Bink Controt Unit, Model A152 (P/N 93A152—00) Wiring Diagram Figure 118 (Sheet 2 of 9) 23—70—01 Rev 3; Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A104, fMerorvont cowecron — ov BK /— METER WiLL (4 bb sk © BOs ¢ : was! 5 5 wHsK| 5 © oH test oats $ SWITCH, T vat p war [9° wnican | o | Bt o « eRase. swiren wwov| BE OF oO 4 LOG -— ee Qe SY Lone incx + METER ILLUMINATION “OPTIONAL COLORS FOR SHIELDED PAIRS, Rig2—1 Pine Z 6 28) Ping G 8 N Ree or White 2352-2 Not Applieabie: Fins HP Blue or lack ‘AIS2—4 Ping ZEY EV, Control Unit Model A152—1 (P/N 93A152—01), Model A152—2 (P/N 93A152—02), Model A152—4 (P/N 93A152—04) Wiring Diagram Figure 118 (Sheet 3 of 9) 23-70-01 Page 154 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, ATOGA ‘connecToR wrornone PRE-AMP Test swircn Ngee reo c ERASE bad swirch * OPTIONAL COLORS FOR SHIELDED PAIRS Pine G & N Red or White Pins H & P Blo or Black Control Unit, Model A152B (P/N 93A152—20) Wiring Diagram Figure 118 (Sheet 4 of 9) 23-70-01AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A100 To meromone = => Mere WiLL, + rest switcH ERASE. switet Lone ex JONAL COLORS FOR SHIELDED PAIRS ‘6.4 N Red or Wit 13H P Blue or Block + METER ILLUMINATION. 93A1E2—30 6 03A152~35 Ping Z 8 b (28) ‘S0a152—40 & O9a1s2—60 Pine AY (SY) ‘ther Pact Numbers ~ Wet Applicable Control Unit, Model A152B (All P/N’s except 93A152—20) Wiring Diagram Figure 118 (Sheet § of 9) 23—70—01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A10GA rennin = | Sinai |_*P fo no] lone loc ERASE. wire fone Jo ne, "OPTIONAL COLORS FOR SHIELDED PAIRS Bina G & N Rod or Wie ine H & P Ble or Black Control Unit, Model A152B (P/N 93A152—-20 only) Wiring Diagram Figure 118 (Sheet 6 of 9) 23—70—01 Page 157 Rov 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100A L wicRoPHONE =| a covwecron a see |. ad oa be Ol ce ° as ~~ a ri “aon |., BK 6 cela. q P won| 5g 3 it pre-amp | s80 Lo woh . é ™~ oF] vest sire | nase ea Fone ex + MBTER ILLUMINATION, ‘OPTIONAL COLORS FOR SHIELDED PAIRS 93415220 & S3A1S2~25 Pine Z& b (28 V) ins @ EN Red or White ‘92A182—40 & S2A152—60 Pine ZAY EV) Pins H & P Blue or Black (Other Par Numbers ~ Not Applicable, Control Unit, Mode! A152B (All P/N's except 93A152—20) Wiring Diagram Figure 118 (Sheet 7 of 9) 23~70—01 Page 158 Rev 3: Mar 04AVIATION RECORDERS. ‘COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100 UL MICROPHONE CONNECTOR | SS ~ + QPTIONAL COLORS FoR SHIELDED PAIRS Pins GN Red or white Pins H&P Blue or Block Control Unit, Model A152B (P/N 93A152—25, 93152—50, 93A152—70, and 93A152—20 with Mod #1 and #2 Wiring Diagram Figure 118 (Sheet 8 of 9) 23-—70—01 Page 159 Rev 8: Mar 04AVIATION RECORDERS COMPONENT MAIN-ENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A TL MICROPHONE SBC sonar zz 00meN oc OL O86 K a ERASE ror switch Lou lo Low lov + OPTIONAL COLORS FOR SHIELDED PAIRS Ping G &N Rog or Vtte Pins H & P blue or Black Control Unit, Model A152B (P/N 93A152—20 only) Wiring Diagram Figure 118 (Sheet 9 of 9) 23--70—01 Rov Mar O¢AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILC MODEL ‘A100, A100A ‘THIS PAGE INTENTIONALLY LEFT BLANK. 23-70-01 fev SMa O§AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A, Se esa ed ae TREE DANE ASS 1 ae arenes ree awa, rene = a =f fyi ‘sa "$200 25Ra we mC ilew | ' sooo | OS eK 3215 2 8557 1 open mek S|) aaa | soon ea owe i POWER TRANSFORMER i Soetoro nd ae as ‘ota: Reviion to orignal = Anger botoon 8&4 or Power Aue toronto no S"=8-1 marta be incepta nm nat Reson oF CM Ea) Main Recorder Assembly A100 Wiring Diagram Figure 119 23-70-01 Page 162 Rov 3: Mar ¢4AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100A idan ay abs) iaxgharcevem san ‘D son cms mewn wen fino acum esn | 50 e]esn Hfevex fous er) ea) | farsi was we 0) ich | erases woe | | 00 fa sll” 238] ihre coms bes 2 Main Recorder Assembly A100 Wiring Diagram Figure 119 (Con‘t) 23-70-01 Page 163 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A, uc 9 3p at tf 9) 4 sae POWER TRANSFORMER Main Recorder Assembly A100A Wiring Figure 120 23-70-01 fev 8 Ba 08AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A1004 Main Recorder Assembly A100A Wiring Diagram Figure 120 (Con't) 23-70-01 Fage 165 Rov 2: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, AICOA THIS PAGE INTENTIONALLY LEFT BLANK. 23-70-01AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL. FAIRCHILD MODEL, ‘Ai00, A100A DISASSEMBLY . Disassembly Procedures NOTE: Seo Testing and Troubleshooting to establish the condition of the component or most probable cause of its malfunction. This is to determine the extent of disassembly re- quirea without completely tearing down and rebuilding the component. Disassembly is performed only to the extent necessary to clean, adjust, repair and replace defective components. Certain assemblies are not to be disassembled or adjusted by the shop maintenance personnel, Those assemblies must be returned to the manufacturer for replacement or repair. Ae Jowances are given for those assemblies thal are replaced. Each such assembly is noted in the disassembly and assembly procedures. A. General The following paragraphs describe special procedures and precautions to be observed in dis- assembling the equipment for overhaul, The index numbers in the exploded view illustrations are assigned to the parts in numerical order by sequence of disassembly except thatthe at- ‘aching parts for an iter ae listed following the item aitached. When a component or assembly requires only service maintenance ot repair, disassemble only to the extent required to elfect the repair. For complete overhaul, disassemble the equipment to the extont indicated. An ovethaul parts replacement schedule is included in this section as Table 301 Provide a clean working area and suitable containers for placing the parts removed. CAUTION: DO NOT MIX PARTS OF LIKE ASSEMBLIES. MANY PARTS HAVE BEEN DRILLED OR OTHERWISE MACHINED DURING ASSEMBLY AND ARE NOT ‘COMPLETELY INTERCHANGEABLE. Loctite or other sealants are used at many places in this recorder. Exercise care when remov- ing screws sealed wilh the sealant. Refer to the list of sealants and lubricants (Table 501 anc Table 701) when required, CAUTION: MOS DEVICES ARE SUBJECT TO DAMAGE BY THE ELECTROSTATIC DIS- CHARGE OF ENERGY THROUGH THE DEVICE. APPROVED PROCEDURES FOR HANDLING THESE DEVICES MUST BE FOLLOWED. B, Overhaul Parts Replacement NOTE: For those CVF’s containing the 93-SS—MK Solid State Memory Kit (FSB 163, Mod Dot 28), there is no mechanical overhaul. The thermal insulation assem- biles for these CVR’s must be removed for inspection and weighing every 24 months. “Tabie 301 identities parts recommended for replacement, Additional procedures to be per- formed are included in the procedures for disassembly of each unit, NOTE: An overhaul period for the Cockpit Voice Recorder Is defined as not more than 4000 operating hours (non—fight Hours). 23-70-01 Page 301 Rev 3: Mar 04AVIATION RECORDERS, COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, ATO0A NOTE: At the time of overhaul the thermal assemblies, P/N 9300A006 and 93004018 ‘must be brought up to proper weight, and any thermal assembly greater than 10 years old must be repiaced. The manufacturing date can be found on the thermal assembly. Allparts listed in Table 901 of this Component Maintenance Manuel must be replaced to com- plete an overhaul of the Model A100/A100A CVA, LAR does not consider the CVR overhauled according to this Component Maintenance Manue al if any substitute parts, not tested and qualified by LAR are used, L3AR is not responsible for CVR operational reliability if such parts are used. Table 301 Overhaul Replacement Parts L-3PiN | MFG. PIN Description | Qty. | IPL Fig. | Reference Item ear008 ~~ | 931006 Record Head, Prec | 1 [17A-55 | Prec. Bridge sion Mount, Cresent Assy. gato07 [831007 Plybk Head, Presi [1 |17A-80 Prec. Bridge sion Mount, Cresent Assy. ‘93092 93092 Head, Erase, Prec | 1 |17A-90 | Prec. Bridge sion Mount, Cresent Assy. S300AD40S [§300-A040S [Pressure Pad Assy. | 2 |17-5 Bridge Assy. 'S3A400 [830400 Reel & Tape Assy, | 1 (14-25 | Recorder Assy A100(A) (930036301 |SSR-377ARSP2 | Bearing, Ball 2 [14-1865 Recorder Assy. BLYBEP s300707 _ [8300-17 Bearing, Ball [74-60 [Recorder Assy. 9300209 |SSRIF-416ZZH | Bearing, Ball 3 [1640 [Drive Unit Assy. ASP 18L02P 330012807 |9300-128-01 _ |Bearing-Capsian 2 [46460 | Drive Unit Assy. S300A015S |$300-A01SS Retainer and Bear | 1 [14405 | Racorder Asey, ing Assy. 9300202 _ | 8300-202 Bolt, Drive 1 [74-125 | Recorder Assy. 9300221 [9300-231 RolleTape Guide| 1 [17-155 __ [Drive Unit Assy. ‘300A004 | 9300-A004 Roller, Pinch, Sub- | 1 [14-345 [Recorder Assy. Assy. 93A279__[SB-ADTS Shatt Assy, 1 [16-145 __[Drive Unit Assy. 9300203 __ [9300-203 [Spacer 2 [16-170 [Drive Unit Assy. 930018101 [9300-19101 |Spacer—Pinci Roll | 3 [16-165 [Drive Unit Assy. er ‘9300210 [9300-210 Spacer, Guide Roler| 9 [1645 | Drive Unit Assy, 930019103 [9300-191-03 [Spacer 3 [14-360 | Recorder Assy. Page 302 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘At00, A100A Table 301 (continued) Overhaul Replacement Parts L-3PIN | MFG. PIN Description | Qty. ] IPL Fig.) Reference Item: 9300213 [9300-213 Guide Roller 7 /16-65 [Drive Unit Assy. 930034207 [9300-342-01 _|Shim-Reel 2 [14-215 [Recorder Assy. 930034202 |9300-342-02__[Shim-Reel 2 [14-220 _ [Recorder Assy. ‘9300340 [9300-340 ‘Shield Stationary 2 [16-175 _ [Drive Unit Assy. 9300341 [9300-347 Shiel- Rotating 4 [16-180 {Drive Unit Assy. 939740207 [9-1402-07 Retaining Ring 1 [t8-80 Drive Unit Assy. 5131-12H 93740307 [9-1403-07 Retaining Ring 7 [16-85 | Drive Unit Assy. BIS 12H 93088501 )8-1385-04 Retaining Ring 3” [T4365 | Recorder Assy. 5101-18 NOTE: In the following, parts are identifiad by Illustrated Parts List (IPL) Figures and their ttem Numbers which are shown as dash numbers enclosed In parentheses; g., (13-125) for IPL Figure 13, Item 125. IPL Section starts on Page 1001. ©. Main Recorder Assembly (See IPL Figures 2, 13, & 14) ay e @ ‘Model A100. Remove underwater locating device by removing screws (18-125) and lockwashers (13-130). Remove cover—plate and slide underwater locating device out of bracket. Remove bracket (13-118) by removing four attaching screws (13—85) and washers (13-10). Model A108, Remove underwater lovating device by removing self—tocking screws (2-20). Slide underwater locating device out of brackel. Remove cradle assembly (2-10) and mounting block (218) by removing four botts (2-25). Romave dust caver (2—135,2—185,2~100) by removing two attaching screws. (2=140,2—140,2—108) Remove inverter (2—60) by removing two attaching screws. Slide inverter downward 1/4 inch ard pull out. If access to the tape compartment only is required, orocead as fol lows, {@) Model A100 — Loosen four screws (14-390) and remove shoulder screw. Model A100A — Remove cover assombly (14-380) by loosening five screws and removing tone screw (14-390) with wing Allen "T" wrench. {b) Remove spacer (14-985) and note its assembly position. (© Lit off insulation assembly (14~376). (a) Remove tape compartment cover (14—280} by loosening five screws (14-295). Page 303 Rey 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, 100A (8) Remove cable cover (13—70} by removing two screws (13~150) and lock-washers (13-185). Replace screws and lockwashers. (6) Remove connector plate assembly (18-148) by loasening two screws to expose wiring pplug connecter. NOTE: To remove recorder assembly trom chassis proceed as follows: Place re- order portion of assembly on wooden block, belt side facing up. Standing the recorder in its normal pesition or laying it on a bench with tape ‘compartment facing up, the recorder may be operated to view function. CAUTION: DO NOT TRY TO REMOVE SCREWS (13-95) AT THIS POINT. (® Loosen but do not remove four serens (13-96) using" spline wrench, (7) Remove recorder assembly (13-20) by disconnecting wiring plug from rear of recorder. (8) _Lift chassis assembly from bench, leaving recorder assembly on wooden block. Use “T spline wrench to remove four retaining screws (13-95). (9) Romove plug-in electronics boards (2-110) through (2130). NOTE: Do not place boards on conductive surface as damage may result. Recorder Assembly (see IPL Figure 14) (1) Remave screws (14~245) and lockwashers (14-250) lo remove belt cover (14~240).. NOTE: Place recorder aseembly or a soft surface, belt side up, to avoid scrat— ching the polished steel cover. CAUTION: DO NOT TURN FLYWHEEL IN OTHER THAN THE INDICATED DIRECTION (2) Romove bolt (14-126), flywheel (14-70), and shim (14-225) by removing left—hand threaded screw (14—120) and triction washer (1410) NOTE: Do not crease or stress belt; keep in dust~free contai NOTE: Tum eccentric to slacken belt before removing motor. CAUTION: DUE TO THE EXTREME DIFFICULTY OF REPLACING MOTOR BEARINGS IN ‘THE FIELD WITHOUT CAUSING DAMAGE TO THE MOTOR, THE ENTIRE MO- TOR MUST BE RETURNED TO THE FACTORY WHEN BEARINGS ARE WORN OR REPAIRS ARE INDICATED (SEE OVERHAUL SCHEDULE). @)_ Remove screws (14—145) and washors (14150 and 14—155) to remove metor (14-140) and eccentric (14-8). Rernove retaining rings (156) to remove bearings (156.5), spacers (186.1), and shim washers (156.2, 3, & 4). (4) Remove scrows (14410) and washers (14-418) fo remave relainer and bearing assom- bly (14—408}.. (8) Remove screws (14-40 and 14—195) and remove terminal board (14~35) and spacer (14-210) and cable clamp (14-130). 23-70-01 Page 304 Rev 2: Jul 93AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL. FAIRCHILD MODEL ‘A100, A100A (6) Remove cable clamps (14-170) and cable assembly (14-420) with screws (14-175 and 14-425). (7) Romove cover assembly (14—380) by oosening five screws (14—390) using a “T" Allen ‘wrench, Lift ut recorder unt and set on bench, tape comoartment facing up. (8) Remove spacer (14—385) and insulation assembly (14-376). (Note position) CAUTION: DO NOT REMOVE CAPTIVE SCREWS FROM COVER ASSEMBLY. (9) Loosen five screws (14-286) and remave inner cover assembly (14~280), (10) Remove spring (14-55) and stud (14-110) with stopnut (14-115). (11) Remove stopnut (14165) and tape guide retainer (14—160). CAUTION: IN THE FOLLOWING STEPS TAKE CARE NOT TO SPILL TAPE. (12) Loosen five screws (14~805) and remove reel cover assembly (14-295). Remove con- nector (14~190) with screw (14198). Do not remove caplive screws from reel cover. 413) Remave bearing screw assembly (14-85) and remove reel and tape assembly (14-25) CAUTION: DO NOT TOUCH SOUND HEADS WITH ANYTHING METAL OR DAMAGE WILL RESULT. (14) Ut spacer (14-105), bearing (14—50) and shim(s) (14-215, 14220) from drive assem- bly shatt. NOTE: Do not remove gasket (14—75) from drive assembly unless damaged. Exer- cise caution as the gasket is cemented in place. (88) Remove pivat pinch roller (14~45) from pinch roller arm (14—350). (16) Remove spring retaining ring (14-388) and shalt (14-325), (17) Remove pinch roller subassembly (14-320) and press aut bearings (14-335) and spacers (14355) (18), Remove screw (14845) and washer (14350) to free stripper wire (14-340). (19) Remove plate (14-90) and attaching hardware (14-95 and 14100). (20), Remove cable clamp (14-180) with screw (14-185) [21) Remove cable assembly (14420) from terminal board (14-35). Remove connector (14=190) from hamess. (22) Remove screw (14-65) from base plate (14—400). (23) Remove two screws (14-20) from Drive Unit Assembly (14-15). Lift off Drive Unit from base plate. 23—70—01 Page 305, Rov 3: Mar 04AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A, (24) Remove insulation assembly (14-398) and two standoffs (14—60).. NOTE: Do not remove gasket (14-30) from plate (14—400) unless damaged. Exer- cise caution since the gasket is cemented in place. (25) Remove cable assembly (14420) from base plate (14—400). NOTE: Do not remave electronic parts untess indicated for replacement. Drive Unit Assembly (see IPL Figure 16) (1) Remove screws (1620 and 16-85/18—80) anc lockwasher (16—25) and terminal (18~75} in order to remove bridge assembly (16~10/16~15). Numerically coce and la- bel each wire as tis removed from the heads to faciilate re—assemily and assure prop- er channel selection. (2) Remove screws (16-105), and washers (16~110) from guide angle bracket (16-115) (Remove scrows (16-140) to remove capstan assembly from plate (16-5). (4) Disassemble capstan assembly by removing retaining ring (16~185), spacer (16~170), spacers (16~165) and spacer {16—150). Pulling shaft assembly (16—145) from housing (16-155), press bearings (16~160) from housing (16185) and remove shields (16—180 and 16-175) and other spacer (18-170), (8) Remove guide roller (16-85) by removing reiaining rings (16-95 and 16-90), screws (16-60) and retainer (16-85) and by pulling out shaft (16—50) and removing spacers (16~45). (6) Disassemble guide roller by removing bearings (16-40) from guide roller (16-65). (7) Remove screw (18—86) from standoff (16-30) and trom plate subassembly (16-5) Reel Cover Assembly (see IPL Figure 15) (1) Remove screw (15-26) trom connectar. Do not remove roller quides. NOTE: Remove shims (15-15 and 15-20) only if required. Do not remove roller guides. {2} Remove erase coll assemaly (15—6) fom reel cover subassembly (15-10) by removing three screws (15-30) and shims (15-15 end 15-20). . Chassis Wiring Assembly (see IPL Figure 19 & Figure 19A) (1) Remove meter (19-60) by removing four screws (19-65). Pull meter from front pane! and disconnect wiring from meter terminals (Model A100 only). (2) Remove headphone jack cover (194-80). (8) Remove front panel (198-5, 194—101 by removing four screws (19-75) and two hold— owns (19-70). Pull panel out. Exercise care when removing front panel as the gasket (794-70) is cemented to the tront panel. 23—70—01 Page 306 Rov 3: Mar 04AVIATION RECORDERS, COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A1OOA (4) Remove test switches (I9A~45 and 194-50). Tag and disconnect wiring from terminals (of switches (Model A100 only) (8) Disconnect wires and remove monitor ack (19-55). () Remove hand (1 removing wo screws (19A~80 or 18A~-25, 194-20) and ° washers (19A—4( aa key ¢ 7 Tegang gos Wires and remove transformer (19-50) by removing four elastic ston- (8) Tag and disconnect wire from terminal and remove Zener diode (19-85) and altaching haraware (1925.19 ~5, 19-36). (9) Remove wiring harness (19-90) by removing screws (19-95, 19-105, 19-110, 19-115, and19 —120) and nuts (19-100). (10), Grommet (19-20} may be removed by pressing from chassis (19-40). Electronic Board Assemblies (See IPL Figs. 3 to 12, 21 to 23, & 25) CAUTION; MOST DEVICES ARE SUBJECT TO DAMAGE BY THE ELECTROSTATIC DIS- CHARGE OF ENERGY THROUGH THE DEVICE, APPROVED PROCEDURES FOR HANDLING THESE DEVICES MUST BE FOLLOWED. NOTE: Do not remove any components from the electronic boards unless replacement of the compenents is indicated. In the event that board replacement is indicated, do not remove components since replacement boards are procured with all electronic components soidered in place. For modifications ta boards, refer to Section 600. NOTE: Removal of the electronic parts from the component boards Is to be performed in the following manner: Using the Endico Model 300 vacuum desoldering Iron ‘or equivalent, heat the solder connection on the terminal In question by applying the heat tip of the iron. When the solder has melted, activate the vacuum bulb to withdraw solder from the connection. Straighten the bent lead from under the board. Using long nos pliors or a similar tool, extract the component lead from the termination point. Repeat the steps for each connection point. Protect the component fram excess heat by using a convenient heat sink clamp between the soldering point and the ‘component itself, 23-70-01 Page 307 May 11911A 5 1N LONG, PLT RUBBER HOSE AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A100 Underwater Locating Device (ULD}(Sze IPL Figure 2, and Figure 301) NOTE: Beginning with manutacturing date of July, 1989, S/N 55195 for the A100 Record- ‘ets and S/N 55087 for Model AtQOA Recorders, and all subsequent serial num- bers will have Underwater Locating Device P/N 266030500 installed. ‘This ULD has a battery life of six years which can not be replaced in the field ‘consequently, these P/N ULD's must be sent back to the manufacturer for battery replacement (reference FSB 159). Units with the new ULD installed will be identl- fied on the Modification Plate with mod, dot numeral 17 painted yellow on both the A100 and A100A recorders. ‘Agousnc, OSBeRareR. - NGERTOR BEACON BATTERY REPLACEMENT SPANNER Bare Laas SiRENGA BobY SHOCK. COsmiow AggusTC “SEACON END stock. ae SHIN orn P END CAP ULD Disassembly Figure 301 (1) Remove cover plate (19-60) by removing screws (13-125) and washers (13130) 2) Pull acoustic beacon (245) out of bracket. CAUTION: DO NOT PERFORM THE FOLLOWING STEP FOR SILVER ULD’S ON A100 RE- CORDERS WITH SIN 55195 AND A100A RECORDERS WITH S/N 55087 OR HIGHER. SEND THESE ULD'S BACK TO THE BEACON VENDOR FOR BAT- TERY SERVICE, (@)_ As shown in Figure 301, if you have @ ULD painted gold, you can use a spanner wrench to unscrew end cap and pull O-ring, end shock cushion, battery, and body shock cushy ion out of acoustic beacon, 23-70-01 Page 308 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘A100, A100A J. Control Unit Assembly (see IPL Figure 20) NOTE: This Control Unit description covers all alternate models of the Control Unit. Dis a) @ @ “ 3) 6) regard those steps and parts that do not pertain to the exact model of Control Unit under disassembly. Remove screws (20-125) and pull dust cover (20-120) from front—panel assembly (20-85) 20-90) 20-85/ 20-100). NOTE: Do not remove insulator unless replacement Is necessary. Remove insulator (20~150) from bottom of dust cover Loosen and swing out Preamplifier Assembly (20—85/20-60) by removing attaching ‘screws (20—-65} from bracket assembly (20-25/20~25). Remove four screws (20-108) from ront—panel assembly (20-86/etc.) and swing out front panel Remove harness wires from Preampitier Assembly (20—55), meter (20-135 20-140/20~145), switches (20-110 and 20-115) and phone jack (20-160). Remove ‘microphone wires from connector or board (20-55) as appropriate, NOTE: Remove mike wires only if mike or hamess replacement Is indicated. Romove meter (20—138/eIc.), phone jack (20-160), switches (20-110 and 20~115) and attaching hardware from front—panei essembly (20—85/ets). Remove grommet (20—45/20~45) from bracket assembly {20~25/20-25), NOTE: Do not remove microphone from bracket assembly unless repiacement is necessary. The microphone is nested in a damper (20—30) and hum shield (20~40) which is cemented in place. Exercise caution when removing the microphone and/or the damper to prevent damage to the damper. Plugs (20-155) (if installed) may be removed at any time to facilitate disas- ‘sembly, inspection, replacement or repair. K. Remote Microphone Assembly(See IPL Figure 24) a @ 6 Remove screws (24-90) and pull off cover (24-65/24—70) NOTE: The damper (24-35) is cemented in place. Exercise caution when remov- Ing cemented parts. Tag and remove wiring of microphone on connector terminals and remove connector (24-80) from connector plate (24—40) and terminal (24-95). Slide damper (24~35) and microphona mount (24~80/ 24~85) from microphone assem- ly. NOTE: Damper (24-35) and microphone mount (24—80) are bonded and cem- ented to hum shield which is in turn cemented to microphone. Exercise caution when removing cemented parts. 23-70-01 Page 309 May 1/91N. oO. AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, M1008, (4) Slide hum shield (2430) ftom microphone (2410/2418). (6) Remove mount (2480) from damper (2435). CAUTION: Microphone washer (24—5) Is cemented to mlerophane (24—10). Exercise ‘caution when removing cemented parts. (6) Remove microphone washer (24~5) from microphone (24~10). CAUTION: The microphone assembly (24—10/24--15) is not repairable in the field. Re- turn to manufacturer for repair and replacement. Microphone Assembly (see IPL Figure 26) NOTE: Parts of this assembly Ing cemented parts. fe bonded together. Exercise caution when remov- (1) Remove screw (26-25), washer (28-20), and cable retainer (26-20). (2) Remove microphone (26-5/26~60), sleeve (26~15}, and washers (26-40) trom holder (26~45/26~50/26-85), Microphone Assembly (see IPL Figure 27) CAUTION: Parts of the microphone assembly are bonded together. Exercise caution when removing cemented parts, Remove mic (27—-5/27—25}, washer (27-10), and hum shield (27—18) trom damper {27—20). Access to Belt and Motor (See IPL F gure 2, IPL Figure 13, & IPL Figure 14) (1) Remove dust cover (2-185) 2—100/ 2~135) by removing attaching sorews (21402-1085, 2-140). (2) Remove cable cover (18-70) by romoving two screws (13-98). (3) Remove screws (14245) and lockwashers (14—250} to remove belt cover (14240). (4) Proceed as required per reguler disassembly procedures, ‘Access to Tape Compartment (See IPL Figure 2, IPL Figure 14) (1) Remove dust cover (2—135/ 2—100/ 2-195) by removing attaching screws (2—140,2-105, 2-140}. (2) Remove cover (14-380) by loosening five screws (14-390) with Allon "T” wrench, (@)_ Remove spacor (14-985) and insulation assombly (14-375). Do not remove caplive serews from cover assombly, 23-70-01BR AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILC MODEL ‘At00, A100 (4) Loosen screws and remove inner cove" assembly (14—280). Do not remove captive screws from cover assembly. Precision Bridge Assembly (see IPL Figure 17 — Sheets 1 and 2, & IPL Figure 17A). (1) Remove two pressure pad assemblies (17-5) by removing four serews (17—10} and washers (17-15). (PAUTION: DO NOT TOUCH FACE OF HEADS WITH ANY METAL TOOLS OR DAMAGE WILL RESULT. (2) Apply a small plastic protectory or a square of masking tape to the face of each of the heads (17-20, 17-25, 17-0) to protect them from damage. (3) Remove three heads (17-20, 17-25, 17-50) by removing attaching nuts ( 17-3 and 17-95}. Store heads in a mechanically protected, moisture—free container. NOTE: Remove spacers (17-60, 17-65, storing. Note qui 70) from erase head (17—-50) before tity of spacers or shims, If present. (4) Romove eight adjusting set screws (17-90). NOTE: Disassemble comer guide roller only if necessary. (6) Remave corner guide roller assembly {17—130) by using comer roller removal tool P/N. {9300-820 or PIN 831000 Corner Roller Removal Tool. Remove and note number of spacers (17-75, 17-80}. 48) Remove and discard retaining ring (17-160). Set aside and note the number and order of spacers (17-140, 17-145) (7) Remave roller assembly (17-155) and press bearings (17136) out of rolor (17185). CAUTION: Do not press out guide bearing unless excessive wear or overhaul Indicates replacement. Press fits lost and part is no tonger usable. (8) Press fixed quide bearing (17-195) out of bridge casting (17-40). Inverter Assembly (see IPL 3A) (1) Remove cover (34-90) by removing screws (2-20) and nuts (24-75). (2) Romove connector (3A—100). 8) necessary, remove circuit board (84-130) by removing screws (3A~25) 23~—70-01 Page 311 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL A100, A100A THIS PAGE INTENTIONALLY LEFT BLANK. 23-70-01 wayAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, At0dA CLEANING 1. General The following paragraphs describe the procedures recommended for cleaning specific parts of the ‘cockpit voice recorder and control unit. Table 401 lists the cleaning materials required for cleaning. WARNING: USE SOLVENT IN A WELL-VENTILATED AREA. AVOID PROLONGED BREATH- ING OF SOLVENT VAPORS OR CCNTACT WITH SKIN. OBSERVE FIRE PRECAU- TIONS. A. Materials Required NOTE: Equivalent substitution may be used for listed items. Table 401 Cleaning Materials MATERIAL SPECIFICATION ‘Diy Cleaning Solvent Federal Specification P-D—680 Cleaner and Flux Remover Alpha No. Head Cleaner Robbins Industries TX—20 Freon Isopropyl Alcoho: Methyl Aicohol 8. Cleaning Procedures Use dry cleaning solvent for cleaning all mechanical components and other metallic parts ex cept bearings, bridge and tape roller, guides and capstan assemblies. Immerse the parts in a solvent bath and use a brush to remove stusoom accumulations of dir, Dry all pars thor- ‘uchly with compressed air or a clean lint=free cloth. Store in containers pending inspection and reassembly. ©. Bearings CAUTION: DO NOT IMMERSE BEARINGS IN SOLVENT. (1) Glean extemal surtaces by wiping witt a clean cloth, slightly moistened wilh solvent. Dry thoroughly with a clean lint-free cloth, D. Electronic Parts CAUTION: DO NOT IMMERSE ELECTRONIC BOARDS AND PARTS IN SOLVENT. (1) Clean external surtaces by wiping with a clean cloth, slightly moistened with solvent, Re- move flux residue with Alpha No. 583 cleaner and flux remover. Perform a final wash in a clean solution of Alpha No. 563 or equivalent, 23-70-01 Page 401 May 91AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A, CAUTION: DO NOT TOUCH THE HEADS WITH ANYTHING METAL OR PLASTIC. DO NOT CLEAN WITH ANY SOLVENT OR SOLUTION OTHER THAN HEAD CLEANERS LISTED IN Table 401. (2) Head cleaning, Cleaning of the bridge assembly heads is to be done in the following manner: Wet a“Q" tip with head cleaners listed in Table 401 and carefully clean sound heads, guides, rollers and capstan. & stubborn spot may be rubbed off anly with tho wooden end of the “Q” tip. Clean and Polish Clean the inner recorder cover thoroughly, making certain that dust and dirt do not adhere to the clean surface, Clean the stainless steel thermal cover thoroughly. Polish the outside of the Stainless steel cover to remove dit, residue and cits lel rom finger marks. 23-70-01 Page 402 May 91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL. ‘A100, A100A CHECK 1, General ‘The inspections outned in the following paragraphs are presented in two groupings, Mechanical Inspection and Electical Checks. The mechanical inspection is performed to determine whethor the equipments within its sence limits. The elecrioal checks help determine deterioration or other obvious detects. This Section is used to determine and ensure that the overhaul equipment will meet new equipment standards of operation. Excessive wear is defined as any obvious deforma- tion oF deterioration of parts that may render the unit inoperative. Fits and Clearances are sted in Section 800. Do nol continue a part in service if tis found to be worn in excess of these allowable service limits. The following paragraphs outline the inspections and checks to be performed on specific parts and assembies. Functional mochenicat checks ata listed in the assembly sections of this manval and repeated under calbration procacures (Section 100}. If any doubt exists concern- ing serviceabilty of a part, replace that part. 2. Mechanical Inspection A. Parts, General. Visually inspect ail parts for cracks, distortion, excessive wear and proper fin- ish. B. Bearings. Check each bearing by rotating @ by hand and detecting any roughness, noise, or excessive radial or axial play. Inspect the razes for evidence of bearing seizure. itis not neces: sary to inspect any part that is scheduled fo” replacement. Reference Overhaul Replacement Parts, Table 301. it bearing(s) require replacement refer to Tabie 501. G.Castings. Visually inspoct all cast parts for cracks, especially at bosses, flanges, and other critical areas. D. Terminal Boards and Connectors. Visually inspect alt terminal boards and connectors for loose terminals, pins, locking rings and screws, and cracks on the boards that may have been brought about by adverse environmental conditions. E, Wiring. Visually chock wiring harness and all wire leads for broken conductors, burried or de- teriorated insulation, and loose connections FEloctronic Boards. Visually check the electronic circuit boards for broken parts and bad solder joints. Check for burnt parts, Check the beards for cracks and abrasions and for the accom: plishment of applicable modifications. G. Main Recorder Assembly (see IPL Figure 2 NOTE: In the following, parts are identitied by Illustrated Parts List (IPL) Figuros and their Item Numbers which are shown as dash numbers enclosed in parentheses; eg., (2-135) for IPL Figure 2, Item 38, IPL Section starts on Page 1001. (1) Dust Cover Check that the dust cover (2-135) is serviceable, exhibting no undue deterioration and wear and is properly painted, 23-70-01 nova: HerodAVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘At00, MOOA (@) General inspection Inspect the electronic boards (2-100 through 2-135) for breaks, cracks and thal the ‘component parts are properly soldered in place and that the leads are not broken, ‘Check that the etched copper circuit lines are not broken or raised from board. Check ‘overall general physical condition, {@) Check general physical integrity of recorder. Table 501 CVR Models A100 and A100A, Ball Bearing Tabulation oral Part ‘Mig. Part Usage/ ‘Number Source Number Lubrication Fill Level Unit (8300-107 New Hampshire SFR 1863PF/295 Humble Oil 25% 6 ABEC 3 Beacon 925 2 Shields Barden SFR 156883 ABEC 7 2 Shields 9300-128-01 M.PB $3632 FOZ27_—_ Humble O11 a8 2 P28LG20 ABEC7 Beacon 325 ‘Special Seal New Hampshire SFRSS6LL3K2E Special See 9300-209 MB. ‘S418FRHH3——MIL-L-6085A, 2 drop 2 New Hampshire SRF 1443PP 2 Shiolds. 9300-216 NewHampshire SRI8i03PP MIL —G—23827A, 25% 1 ABEC 3 2 Shields MPB, ‘SaSi6RHHS 9900-363-1 New Hampshire SR3SPPDK25 —MIL-G-25760A 30% 2 Barden ‘SROSS3 fers packaging. Thereafter, the bearings should be re—tubricated using specified Iu- bricates and fill levels. | Note: Sheff life of all CVR bearings is two years from the date stamped on the manufactur- H. Recorder Assembly (see IPL Figure 14) (1) Check that all pans are clean, especially the stainless outer cover(14—-380). (2) Check that the *W" spring spacer (14—385} will maintain its shape. Page 502 Rev 3: Mar 08@ 4) 6) @ Note: The gaskets listed in Step H.(6) have m ® @ 10) on (12) AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A, Check the condition of the tape (14~26). Refer to overhaul schedule. Check bearings (14-50) except those normally replaced on the overhaul schedule (refer to Table $01). ‘Check insulation assembly (14-378 ard 14-396) for breaks, abrasions and cracks in the outer coating. Check the heat plugs for tightness and check for the correct weight of the Insulators, Actual minimum weight must be within 0.1 Ib. (46.96 gms} of marked ‘weight. Repair of detective insulation is covered in Section 600. Inspect gaskets (1475 and 1480) Icr tears, stretching and deterioration. ‘shelf life of two years. (Due to adhesive coating.) Check spring (14-85) for distortion Inspect terminal board (14—35) for loose terminals and components damaged or with broken leads. Inspect retainer and bearing assembly (14—408) for wear, and check screw (14-120) and friction washer (14—10) for unusual wear Check drive belt (14125) for wear, eler to overhaul parts replacement schedule, Inspect electrical parts (14~200,14~—208) and connector (14420) for damage, loose wiring andl indications of breaks and cracks. ‘Check condition of record heads. Refer to overhaul schedule (Section $00). Drive Unit Assembly (see IPL Figure 16) a @ @ e o Inspect the bridge assembly (16-10, “6—15) for cleanliness and that all screws and seals aro intact. Rofor to overhaul schedule. Check each bearing (16-160 and 16-40) except those normally replaced on the sched- ule, Check shields (16-175 and 16~180) ‘or wear. Inspect the capstan assembly (16—195) for cleanliness, ‘Check spacers (16-160 and 16—145} for unusual wear or for damage. Check channel assembly for wear, Reel Cover Assembly (see IPL Figure 15) a 2 @ 4 @ Inspect he ret quid roles on ee caver subassembly (15-10) for etacks of treks. ‘Check all quide rollers on ree! cover subassembly (15-10) for Iree action. Check that inside of rel cover subassembly (1510) ae of rough or ragged edges Check the connecter for broken condctrs and cracks in canacter Check erase coil assembly for physical and electrical integrity. 23-70-01 Page 503, Rey 3: Mar 06AVIATION RECORDERS ‘COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL. ‘A100, A100A a. Chassis Wiring Assembly (see IPL Figure 19 & Figure 19A) (1) Check the harness assembly for broken connectors, loose connections or broken con- noctor pins, and frayod wires or harnesses. Check general physical integrity of harness. (2) Inspect that all switches (19A—45 anc 19A—S0) are serviceable, and that meter (19-60) ‘and headphone jack (194-55) and cever (19A~60) are serviceable. Check that all con- neclors are properly mating and in seviceable condition, (8) Check that gasket (194-70) is serviceable and that no stretching or deterioration has occurred. (#) Check that chassis (19-40), front panel (18-6, 19A~10), held~downs {19-70} and handle (19A—15) are in serviceable ccndition and exhibit oniy normal wear and are not cracked, bent, chipped or have other obvious damage. 23-70-01 fov3 fer o81 AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL A100, A100A General Repair See Table 601 fra isting of tools and equipment required for repainng the cockpst voice recorder. Repair of paris such as capacitors, resistors, trarsistors, transformers, and integrated circuits is considered impractical. Therefore, all defective paris of these types should be replaced. NOTE: Equivalent substitutes may be used for listed itoms, Table 601 Tools and Equipment Needed far Repair of Cockpit Voice Recorder ‘Standard 1/4" Tape Splicing Kit. Radio Solvent GC #31—8 or Methy! Ethyl Ketone (M.E.K,) ‘Smatl trimming scissors, Splicing material P/N 9300-559 (3M #67) Flat stect plate, Gauge block. No. 410 Crocus cloth Felt and jewelers rouge. Shop microscope, High intensity lamp. Methylene Dichioride or DuPont (Duco) Household Cement (Composition; Ethy! acetate or Methylethyl Ketone). kit P/N Sa00A185. Funnel Scale (2 Kg /'5 lb. capacity) Soldering iron (75~100 Watt), “T" Wrench — PIN 93004737. “T* Wrench — P/N 83004736. 1 Spanner Wrench (P/N 18973). Underwater Locating Device, Battery Replacement Kit ( P/N 93-15971) Pressure Pad Alignment Tool — P/N 177124 Comer Roller Removal Tool — PIN 93-1000 Card Extractor ~ PN 2808900003 Belt Tension Gauge w/S0 Gram Gauge P/N 9000A846—01 30—gram Gauge — P/N 9300-881—01 2000—gram Gauge ~ P/N 9300-882 Tape & Reel Height Adjustment Gauge — P/N9300-918 NOTE: Alter repair or overhaul of the CVR, the unit should be weighed to ensure that the thermal assembly (PN 9300A018, IPL Figure 14—375) has been installed. Aeler to ‘the data included in Table 602. 23-70-04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL ‘Ai00, A100A A. Electronic Components and Assemblies (see IPL 2 through 12, 22 & 23), CAUTION: MOS DEVICES ARE SUSCEPTIBLE TO DAMAGE BY THE ELECTROSTATIC DISCHARGE OF ENERGY THROUGH THE DEVICE. APPROVED PROCE- DURES FOR HANDLING THESE DEVICES MUST BE FOLLOWED. Do not remove any component from the electronic components assemblies unless necessary {or replacement. To remove component, ursolder the appropriate leads, using a 25—walt, encil-lip soldering iron. Tag the unsoldered leads to facilitate assembly, CAUTION: USE A PAIR OF LONG—NOSED PLIERS OR OTHER SUITABLE HEAT SINK PROTECTION WHEN UNSOLDERING COMPONENTS, Table 602 Minimum Acceptable Weight for Overhauled and Repaired Assemblies ‘Assembly Minimum Acceptable Weight Basio OVA 205 Ios. ‘GVR w/ Beacon Mount — wio Beacon 24.4 is. CVR w/ Beacon Mount — w/ Beacon 21,7 Ibs. VR w Inverter onty 215 Ibs, VR w/ Beacon Mount, wi Inverter, wo Beacon 22.1 Ibs. CVE w/ Beacon Mount, w/ Inverter, w/ Beacon 22.7 Ibs. B. Tape Splicing and Loop Measurement Procedure (see Figure 601 and 602). ‘The following tools and supplies are required for this procedure. Standard 1/4" Tape Splicing Kit. Radio Solvent GO #318 or Mothy| Ethyl Kotone (M.E.K) ‘Sina timming scissors. Splicing material PIN 9300-859 (3M #67) NOTE: The recorder is supplied with adequate magnetic tape to permit removal of up to 10 feet and still remain within specitications. ‘Tho steps below should be followed for tape splicing and loop measurement: a @ Follow recorder disassembly (Section 200) and assembly (Section 700) instructions. NOTE: No more than two splices allowed per tape assembly with a separation be- ‘tween splices of no less than 18 inches. Removal of up to 10 feol of mag- netic tape is permissible ard still remain within specifications. ‘Mark the hub appropriately for future ‘deniilication as to number of feet of tape removed ‘during the splicing procedure and number of splices (2 permitted) 23-70-01 wy etAVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A00, A100 AUGN OUT ENDS TAPE GRAPHITE SIDE, GAADURL A SPLICING TAPE: EMNa ST CLEAN THs AREA Tet BENG. gt-4 RADIO SOLENT (OR ETHEL ETHYL KEYTONE (WER ~~ vowwees 7 Tape Splicing Diagram Figure 601 (3) With splicing kit or scissors, remove ott splice or detective portion of magnetic tape in preparation of a new splice (10 feot max) (2) Clamp both ends cf Ree! And Tape Assembly into splicer, graphite side up. (8) With splicer, cut and discard serap. (6) Clean both graphite ends with radio solvent GC #31—8 or MEX. for a least 1/4" or mare ‘on each end, as shown in Figure 601. (7) Bumtends as close as possible without touching, align for joining, clamp both ends. (®) Place spiicing material 9300559 (3M #67) over splice centering both horizontally and vertically with cut in center, press on, Remove any air pockets, (Do not use splicing ma terial over 6-months old from date on container). (9) Remove reel and tape from splicer, trim tape on both sides with scissors in gradual arc. (10), With reel and tape assembly in hand, work excess loop into bundle, unl the joop re- duces and the inner layers loosen. 23-70-01 ‘Page 603, May 1/91on (92) AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A100 Measure the tape loop strength by perorming either the procedure in Step (a) or Step (b) as follows! ‘The hub bore wil ft a tape recorder spindle. (@) Make up a gram scale with a clamp on its end to gp the tape (see Sketch A of Figure 602). Exer a pull on the outer layer unl the gauge reads a sleady 150~200 ‘rans. {b) With a piece of masking tape, make a small loop on the end of the outer layer of the magnetic tape. Insert the pointer of a gram scale in the loop and exert a pull Until the gauge reads a steady 160-200 grams (see Sketch B of Figure 602), Form a loop by buting the end of the cuter layer to the end of the inner layer taking care introcuce a tape twist SKETOHA, Tape Loop Measurement Figure 602 (13) Measure this loop size. This dimension is the distance tram the edge of the reel to the longest poin of tho stretched—out loop and should be between 17 and 18 inches (see Figuro 601). To increase (or decrease) this 'oop size, for gross errors, unwind (or wind) the desired amount of megnetic tane rom the QUTSIDE of the bundle. Finally when within 4 inches of proper loop size, win tapo onds with splice, to establish required loop size. 23-70-04AVIATION RECORDERS. COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘AN00, A1O0A In operation of any ondiess loop system, each layer of magnetic tape moves with respect to adjacent layers. This “slippage” occurs constantly. It follows that the friction between layers should be kept at an absolute minimum; thus, proper tape preconditioning Is Important. The magnetic ‘tape on the reel and tape assembly has been selected and preconditioned by Loral and the incorporation of magnetic tape other than the speciflod properly preconditioned magnetic tape is not permitted. Under no circumstances should there be more than two splices in the tape assembly nor should the separation between splices be less than 18 in- ches. C. Head Replacement ‘Sound heads should only be replaced at the end of their useful life ori all other means to re~ store proper electrical response have beon oxhausted (cleaning, electrical checkout, pressure pad and head realignment). Refer to Assembly Section 700, Paragraph N., for proper head roplacement methods. (1) Reasons for head replacement: @ © © End of usetul ie, Open head: Unable to achieve proper response alter tape replacement and exhaustion of al other means (cleaning, electrical checks, pressure pad andjor head realignment NOTE: Tape manutacturing tolerances occasionally prevent a replacement tape from tracking properly within the channel worn by the previous ‘tape, thus impairing full head contact and response at either Channel 2or3. In such cases, heads must be removed and elther replaced or reconditioned. D. Determination of Head Integrity (1) Discard heads with open electrical connection, After proper cleaning, illuminate hoad ‘with a smail beams of light inline with the gap and check for flattened areas. Ifthe wear pattem extends over more than 3/4 of the pole piece width, reconditioning of ‘the head becomes increasingly dificult and itis recommended to discard the head. NOTE: This statement applies only to heads that have been removed because proper response could not oe obtained by any other means. Heads showing similar wear but giving satisfactory response should definitely not be removed or moved before scheduled overhaul. 23-70-01 Rev 3: Mar 04AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘AY00, A100 E. Head Reconditioning NOTE: The following tools and supplies aro required for this procedure, 4. Flat steo! plate Gauge block No. 410 Crocus cloth Foit and jowelers rouge ‘Shop microscope High intensity lamp (1) Polish with 410 erocus cloth on flat steel plate to remove any steps caused by toe wear and round off fat sections (see Figure 603), Radius should be uniform across entire face ‘of head and area along gap must be straight. No more than 0,002 inch of material should be removed in princjoal gap area. Avoid removal of material from tapered sides of head face. CAUTION: DO NOT DAMAGE HEAD WITH GAUGE BLOCK. (@) Check siraightness of gap area with cauge block and micrascope (see Figure 604). (8) Polish head face with jewelers rouge end felt on flat plate. (4) Check electrical continuity, physical itegrity, demagnetize head (©) Mark head with red dot (paint or indeliple ink} on underside of bracket for first recondi- tioning. Mark with rec: dot on sracket adjacent to mounting stud for second recondition ing. ‘TRACK AREA REMOVE ORIGINAL RADIUS ‘OnIGINAL RADIUS ‘worn suarace ‘WORN SURFACE, (usr section) Wopn sunrace ‘a fA e F 0.002 MAX. CoD DO NOT REMOVE = MATL FROM, ‘SIDES. car RECONDITIONED ‘SHAPE UU U a ‘SECTION A-A DETAIL OF “a” ‘Sound Head, Schematic Figure 603, 23-70-01 Rov ar 04AVIATION RECORDERS ‘COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, ‘A100, A1O0A cavoe ‘Tor VIEW mace | Dp ‘THIS FACE STRAIGHT ‘Gauge SIDE VIEW cance \___] Checking Head Face Straightness Figure 604 ‘UNIFORM LIGHT GAP F._ Repair of Thermopack Assembly 9300A018 and 9300A006 (see Figure 605). ‘The thermal assembly contains a predetermined amount of water and must be within weight specitications to effectively act as a thermal carrer. The following procedure must ne fallowed to repair this assembly, NOTE: The following tools and supplies are required for this procedur 1. Methylene dichloride or DuPont (Duco) household cement (Composition: ethy!-acetate or methylethy! ketone) 2. ABS white plastic (0.040 Atias) 3. Coreta Wax No. 316C (or equivalent) 4. Funnel 5. Scale (2Kq/5 tb. capacity) 6. Soldering iron (75-100 Watt) 7. 1a" ait (1) Weigh the unit, Atno time should the weight of each individual thermopack assembly be (0.4 Ib. (48:96 grams) less than the weight stamped on each pack, NOTE: Due to variations of material density, some percentage of insulation assemblies: will not accept water during refill to bring the assembly to the specified weight. In addition, through field experience, insulation assemblies 10 years or older ‘hould be replaced because of the assemblies’ inability to hold water due to nu- merous refills and temperature cycles. Assemblies with no date stamp are older than 10 years (reference FSB 154). 2) Carefully examine the unit, Minor cracks, abrasions, fractures of an opaned seam may be repaired by brush application of a small quantity of methylene dichloride to the af- fected area. 23-70-01 Page 607 May 1191a @) @ 4 © © AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, AYOOA = PZ) Thermopak Figure 605 Dilla 0,250 hole in the thermopak 8/Binch deep. Remove any residue caused by this Gling operation and wipe pack ciean. Insert tunnel into hole (snug). Pour into funnel that amount of water necessary to bring the pack weight back up to the marked weight + 60 — 0 grams water. NoT! Care should be taken during this step to prevent water from flowing be- tween the waxed inner pack and the plastic shell. ‘After the water has been absorbed by the fibrous materiat remove the funnel and wipe away excess moisture. Re—weigh the pack, If additional water is required repeat stop 4, (Once it has been determined that the pack is within weight specifications, melt some Coreta Wax with the soldering iron and fil the hole. Form this wax flush with the surface of the thermapack. Cut a 2/4 inch round piece of ABS plastic and coat one surface with methylene dichlo- ride. Position this over the wax—flled hole and press firmly to assure intimate contact, Coat edges with additional methylene dichloride and allow to dry. Re—examine the repaired pack for intagtity. Mark its actual weight on the outside and reinstall into recorder. NOTE: Akit containing sufficient Cereta Wax and ABS plastic to repair a number of thermopack assemblies is available from the factory (P/N 93008195). NOTE: The preceding procedure is to be used when performing overhaul or when- ever there is cause to disassemble the recordar assembly. 23-70-01 Page 608 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL A100, A100 G. Circuit Board Modifications — Monito: Amplifier Circuit Board P/N 300A023 (see Figure 606 and IPL7, 8, & 8A) CAUTION: MOS DEVICES ARE SUBJECT TO DAMAGE BY THE ELECTROSTATIC DIS- CHARGE (ESD). FOLLOW AFPROVED PROCEDURES FOR ESD PREVEN- TION. NOTE: The following modification, when accomplished, will prevent a damaging short circuit of the Q4 emitter to the chassis or dust cover and thus to ground via the outer terminal of the TPI. This ia caused by improper lead arlentatlon. (1) Examine the board and compare the position of the outer TPI terminal with the positions shown in Figure 608. Hf position is cor-ect, no rework is required (2) the outer TP! terminal is not positioned correctly, proceed as follows: (@)_Unsolder and lift the terminal, (©) Trim torminal as shown in Figure 608. (©) Bend remainder of terminal towards pad between board marking TP & 3G. {@) Rosolder and patch the terminal and pad with General Electric type RIV 118 adhe- sive sealant, (@)_Gheck of Incuetor Mounting (@) A field evaluation program has shown possible operational failure of the leads to inductor L1 due to improper mounting during assernbly. (©) Examine the board to determing if Lt is mounted flush and securely to the board. If correct, no rework is necessary. Mark the board appropriately to signify that it was ‘examined, (6) inductor L1 is not securely mounted, apply Hyscl (Loral P/N 9300-463} to the Underside of Lt to adhere it to the circuit board, thereby preventing vibration, {@) Note this modification by marking numeral 6 on the modification plate ‘CORRECT POSITION: BAEAK ALL SHARP POINTS AND COVER THIS FAD WITH ‘GE. CLEAR ADHESIVE SEALANT TYPE RIV 16, CURE PER DIRECTIONS. FS. Fe 20 No ADHESNE WTR INCORRECT F0sITION: INCORRECT POSTION Steor BOARD EDGE SHORTS TO GRSe SHORTS 10 CHaSes Monitor Amplifier Circuit Board (P/N 9300A023) Modification Figure 606 23-70-01 Page 609 May 1791AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL, FAIRCHILD MODEL, ‘A100, A100A H. Circuit Board modifications Test Circuit Board (P/N 98004025) (see Figure 607 and IPL Figures 10 and 11) CAUTION; MOS DEVICES ARE SUBJECT TO DAMAGE BY THE ELECTROSTATIC DIS- CHARGE (ESD). FOLLOW AFPROVED PROCEDURES FOR ESD PREVEN- TION. (1) Capacitor ©16 remains charged when the circuit board is removed trom the recorder while power is applied. If the A025 test circuit board is subsequently placed on @ con- ductive surface such as the steel cove; capacitor 016 can discharge through Q1. This shorting to ground of the emitter of Q1 Qunetion of A1 and R3} bypasses the protection of resistor RI, thereby damaging Q1 (2) Shorting of the G1 emitter to collector with C16 charged will result in similar damage. (9) Tho modification herein described, when accomplished, wil prevent discharge of capact tor C16 ft placed on a conductive surface when in a charged candition. CAUTION: PLACE BOARDS ON NON-CONDUCTIVE SURFACES ONLY. (4) Clean the board around transistor Qi (see Figure 607) with Freon cleaner {or equivalent) ‘and remove any sharp protrusions from the area, (©) Insulate the Q1 emitter pad by applying adhesive sealant (@.E, RTV 148) ( Figure 607). (@) (entity accomplishment of this modification by marking numeral 6 on the modification plate. 2 No ADHESIVE ‘WT 9.0618. —, (OF BOARD EOGE t a M4 BREAK ALL SHARP POINTS AND. ‘COVER THIS PAD WiTH Ge. CLEAR ADHESIVE SEALANT TYPE RIV 178, ‘CURE PER DIRECTIONS. Test Circuit Board (P/n 9300A025) Modification Figure 607 |. Modifications — Voice Recorder Drive Motor Capacitor Circuit (see Figure 608). (1) Voice recorder drive motors are of four types: the original P/N 4300~218, and the ater- nates 9900-218-01, 9900-21802, and 9300-218-03. These motors are functionally, and dimensionally interchangeable. When the allemate 9300-21801, ~02, or ~03 motor is used, the two motor phasing capacitors must bo replaced with a single capaci- tor 23-70-01AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL ‘A100, A100A (2) The following procedure must be followed to modify the two—capacitor motor phasing ircuit to a one—capacitor circuit for tha 830-218-014 or 02 motor. (a) Disassemble the recorder assemoly as described in Section 300 to gain access to the drive motor. Unsolder at point A {see Figure 608) the brown and black wira connected to capacitor 9300-258 and unsolder at point B the two black wires con- ected to capacitor 2300-264, (©) Remove the 9200-258 capacitor by removing the retaining nut and washer (0) and caretuly pulling the black Wire fom the tubing. Remove the 8300-264 capacitor bby removing the retaining nut and washer (C), (©) stall roplacement single phasing capacitor PIN €300—258—3 into the space that criginally contained the 8300-264 capacitor and fasten with nut and washer (C). (@) Solder the tree end of the brown wire to point F of capacitor 9300-258-3 and the ites end of the black wire to point G (see Figure 608) (8) This modification is now complete, Reassemble the motor and belt by following the ap- plicable assembly and adjustment procedures outlined in Section 700, Para. D. J. Replacement of Battery in Underwater Locator Beacon (see Figure 609). NOTE: Beginning with manufacturing date of July, 1989, S/N 55195 for the A100 Record- ers and S/N 55087 for Model A1COA Recorders, all subsequent serial numbers will have Underwater Locating Device P/N 266E030500 installed. This ULD has a battery life of six years WHICH CAN NOT BE REPLACED IN THE FIELD; consequently, send ULDs back to the beacan vendor for replacement. Units with the new ULD installed will be identified on the Modification Plate with ‘mod dot numeral 17 painted yellow on both the A100 and A100A reoorders. For older P/N 15957 Beacons, Underwater Locating Device Battery Replacement Kit, P/N 9317971, Is required fo replace the ULD battery. O-ring replacement is recommended when the battery is replaced. | asaoo-2s0 ‘as200-258 —p y— s9808—260 el F = ® ® asaoo-261 —| Ly sss00-255- ° 2 7 8 ct pe ope Voice Recarder Drive Motor Capacitor Circuit Modification Figure 608 23-70-01 Page 611 May 1/91AVIATION RECORDERS COMPONENT MAINTENANCE MANUAL FAIRCHILD MODEL, A100, A100A CAUTION: ENSURE THAT DIRT, MOISTURE AND OTHER FOREIGN MATTER ARE NOT. COLLECTED ON THE THREADS, O-RING OR BATTERY COMPARTMENT DURING REPLACEMENT. (1) Remove the beacon from the CV using the following procedure (see Figure 609 and Figure 610} {2} Remove the tour flat head screws with Shakeproot lockwashers and the cover plate (ee Figure 609). (b) Remove the beacon from the mcunting cradle. {6} Temporarily repiace the cover plate and four flat head screws with Shakeproat look- ‘washers into the mounting cradle so they won't get lost or misplaced. ‘COVER PLATE NO. 8 ST. STEEL SHAKERPROOF 1150600 LOCKWASHER ws—36326-17, No sa22xs8L0 FLD SCREW Measies0—a3 warer_SENsiTIVE ‘SWITCH END Locating Beacon and Mounting Hardware on CVR Figure 609 23-70-01 Rev8 hr O8AVIATION RECORDERS: COMPONENT MAINTENANCE MANUAL FAIRCHILG MODEL, ‘A100, A100A (2) Remove end cap (Figure 610, Item 3) using spanner wrench (P/N 15873), as shown in Figure 301, Page 308. . Use a split longth of hose or other suitable means to hold body of beacon (Figure 610, lem 1) when removing cap. Remove end shock cushion (Figure 610, hem 8) CAUTION: DO NOT CLAMP BEACON IN VISE. (9) Tap body to remove battery (Figure 612, lem 6). Leave shock cushion (Figure 610, lem 2) in body. CAUTION: INCORRECT BATTERY POLARITY WILL PERMANENTLY DAMAGE THE BEACON. (4) _ Install new battery (Figure 610, Item 6). Be sure the end marked "INSET THIS END” is insorted frst, (Newer typo batlerios have a cellar to provent incorrect insertion.) (8) Remove and discard old O-ring (Figure 610, Iter 4}. Ciean threads and groove in body and cover by wiping with freon and clean rag. (8) Apply a thin coating of lubsicant to new O-ring, to threads and O-ring groove. Use only lubricants recommended at the beginsing of this procedure. Install O-ring on end cap. (7) Position end shock cushion en end cap and threaded cap into body. Use hand force ‘only on spanner wrench, t0 tighten cap. (8) Install now replacement battery. Mark date on label on beacon body (labo! is enclosed with the new battery CAUTION: DO NOT PLACE ANY LABELS ON BEACON BODY EXCEPT AS SPECIFIED. (9) Test the beacon operation using Underwater Looation Test Set (P/N 15977) or equivalent, Following the instructions supplied with the test set, activate the beacon by holding a length ot metal braid across the water switch and observe that the beacon is ‘operating propery. BATTERY 5. REPLACEMENT — DATE TABEL Replacement Battery Parts Figure 610 23-70-01 Page 613 May 191