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TM11-2056 Test Set I-239 PDF
TM11-2056 Test Set I-239 PDF
15 March 1944.)
WAR DEPARTMENT TECHNICAL
TM 11-2056
TEST UNIT
1-236
C,'
BY ORDER OF THE SECRETARY OF WAR:
G. C. MARSHALL,
of
. Chief Staff.
(
(
If
L
OFFICIAL:
A. ULIO,
J.
Major General,
The Adjutant General.
\
DISTRIBUTION:
AAF (5); AGF (5); ASF (5); of Opn (5); Base Comd (5);
T
Dept (5); Def Comd (2); AAF Comd (2); Arm 6? Sv Bd (2);
Tech Sv (2); SvC (5); Area ASvC (2); WDGS Lib (5); PC&S
(2); PE (2); Dep, 11(2); Gen Overseas SOS Dep (Sig Sec) (2);
GH (2); M Cone (2); Air Base Hosp (2); Gen Sv Sch (5);
C
Sp-Sv Sch (10); USMA (2); ROTC (5); Lab 11(2); Sig AS (2);
Rep Shop, 11(2); A (5); D (2); AF (2). T/O 6? 1-27(3);
E
II
TM 11-2056
C 1
TECHNICAL MANUAL
PART ONE
INTRODUCTIO
Note (added). Test Unit I-236-A is identical i
and maintenance to Test Unit I-236. Wherever
manual, with the exception of figures 5 and 12, add I-236-A.
Fiqure 5.1 (Added.) Test Unit I-236-A, under side of panel with case removed,
showing mounting of neon lamps.
AGO ii:;7::!];
lacquer. Replace the components that have been removed
and check the equipment to be sure that it is operating
properly. Mark the equipment with the date of treatment,
for example: MFP 15 Feb 49.
c. WINTER MAINTENANCE.
(1) General. Special precautions necessary to prevent poor
performance or total operational failure of equipment in
extremely low temperatures are fully explained in TB SIG
66,Winter Maintenance of Signal Equipment.
(2) Test Unit 1-236 and I-236-A. The test unit will perform
satisfactorily in low temperatures provided precautions are
taken to prevent equipment failure. House and use the test
set in a heated shelter or building whenever possible. On
the march, protect the equipment from the wind by wrapping
it in blankets. Perform PM (preventive maintenance)
routines more frequently to keep the equipment as moisture-
free as possible.
d. DESERT MAINTENANCE.
(1) General. Special precautions necessary to prevent equipment
failure in areas subject to extremely high temperatures, low
humidity, and excessive sand and dust are fully explained
in TB SIG 75, Desert Maintenance of Ground Signal Equip
ment.
(2) Test Unit 1-236 and I-236-A. Special dust-proofing treat
ment is not necessary for the test unit. Take precautions
to prevent dirt, dust, sand, and other foreign matter from
filtering into the equipment. Keep the cover in place when
the test set is not in use and, if possible, keep the set in a tight
cabinet or drawer or cover the equipment with canvas or
other material when it is not to be used immediately. Per
form PM routines frequently to keep the equipment clean.
20. General
a. Test Unit I-236 or I-236-A consists of an ordinary test lamp
*******
equipped with switching and protective features to increase its useful
ness. The test unit * * * and d-c voltages.
Note (added). The relay in Test Units I-236 and I-236-A will act as a circuit
breaker and thus protect the Mazda lamp in case the test prods are applied to a
portion of a circuit having an abnormally high difference of potential.
AGO 2373B
TEST UNIT 1-236-A
CIRCUIT DIAGRAM
APPARATUS LEGEND
REF S.C.TYPE NO. JAN. SPEC. OR JAN OR
DESCRIPTION MFR'S TYPE NO QUAN
SYM OR DWG. NO. MANUFACTURER*
TM 2056-CI-3
Figure 12.1 (Added.) Test Unit 1-236-A, circuit label.
AGO 2373B
21 . Circuit Used to Differentiate Between A-C and D-C Voltases
b. voltage for *
The * *
capacitor under test. Resistor
RI and capacitor Ci have the same functions as described in para
graph 216.
* * *
b. Using the voltohmmeter the relay coil. The re
sistance should measure between 30 and 32 ohms.
AGO 2S73B
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AGO 2373B
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AGO 2373B
BY ORDER OF THE UNDER SECRETARY OF THE ARMY:
DISTRIBUTION*:
Army :
Tech Sv (2); Arm & Sv Btl (1); AFF Bd (ea Sv Test Sec) (1);
AFF (5); OS Maj Comd (5); Base Comd (3); MDW (5); A
(ZI) (20), (Overseas) (5); CHQ (2); FC (2); USMA (2);
Sch (2) except 11 (10); Gen Dep (10); Dep 11 (5) except
Baltimore & Sacramento (20); Tng Div (2); PE (10); OSD
(2); Lab 11 (2); 4th & 5th Ech Maint Shops 11 (2); T/O &
E 11-47 (2); 11-107 (2); 11-127 (2); 11-587 (2); 11-592 (2);
11-597 (2); SPECIAL DISTRIBUTION.
Air Force:
USAF (5); USAF Maj Comd (5); USAF Sub Comd (3);
Services (MATS) (2); Class III Instls (2); SPECIAL
DISTRIBUTION.
For explanation of distribution formula, see SR 310-90-1.
AGO 2373B
U. S. GOVERNMENTPRINTING OFFICE: 1949
TABLE OF CONTENTS
Paragra^ Pdge
PART ONE. Introduction.
SECTION I. Description of Test Unit I-236.
General 1 1
Application 2 1
Technical characteristics of
Test Unit I-236 3 1
Packaging 5 2
*
: M558157 m
TABLE OF CONTENTS
Paragraph Page
SECTION VI. Special instructions.
Use of burnisher 19 16
X. Repairs.
General repair 26 23
Painting and refinishing 27 23
Unsatisfactory equipment report 28 23
APPENDIX.
XI. Maintenance parts list.
Maintenance parts list for
Test Unit I-236 29 25
XII. References.
Army regulations 30 28
Parts list 31 28
Technical manuals on auxiliary
equipment and test equipment 32 28
Painting, preserving and lubrication ..33 28
Shipping instructions 34 28
Decontamination 35 28
Demolition 36 28
Camouflage 37 28
Other technical publications 38 29
Forms 39 29
Abbreviations , 40 29
IV
LIST OF ILLUSTRATIONS
2. Cut
'
As many wires and cables as time permits.
DESTROY EVERYTHING
VI
SAFETY NOTICE
Do not use Test Unit 1-236 to test systems in which the voltage and
frequency are entirely unknown and for which the test set is not
roughly or abuse it. Rough handling will damage the relay. Be careful.
VII
Figure 1. Test Unit 1-236 in use.
VIII
RESTRICTED
PART ONE
INTRODUCTION
SECTION I
DESCRIPTION OF TEST UNIT 1-236
1. GENERAL
2. APPLICATION.
Test Unit I-236 may be used for checking circuits, fuses, and capacitors
found in teletypewriter equipment such as printers, perforators, reperfora
tors, transmitter-distributors, rectifiers, power units, and other related equip-
ment. Tests are made by observing the reaction of either or both of two
lamps when Test Unit I-236 is connected to a circuit, fuse, or capacitor
under test.
a. Power input: 115 to 130 volts, ac or dc. (Alternate power supply from
live circuits of equipment under test.)
5. PACKAGING.
Figure 4. Test Unit 1-236, packing of test leads and power cord
between cover and panel.
SECTION II
INSTALLATION AND ASSEMBLY OF TEST UNIT 1-236
Remove Test Unit I'236 from Case CS-78 and place in a convenient
location where the unit can be inspected for possible damage. Carefully in'
spect the lamps for breakage and other parts for damage which may have
occurred during shipment. Check to make certain that the Lamps are proper-
ly seated in their sockets.
continuous circuit through the test unit as described in part two. For tests
of circuits requiring power from an external source, connect the power cord
of Test Unit I-236 to a 1 15- to 130-volt, a-c or d-c power supply.
PART TWO
OPERATING INSTRUCTIONS
NOTE: For information on destroying the equipment to prevent enemy
use, refer to the destruction notice at the front of the manual.
SECTION
III
OPERATION
USE OF TEST UNIT 1-236 TO DIFFERENTIATE BETWEEN
8.
NOTE: The power cord of Test Unit I-236 may remain connected into
source of a-c or d-c voltage since the power cord disconnected from
is
a
the circuit of Test Unit I-236 when switch SW1 in the INT V
is
position.
Apply the prods of the test leads to the cicuit under test.
b.
both plates of the neon lamp light, the voltage of the circuit under
If
c.
only one plate of
If
is
neither there
d.
present in the circuit under test or the voltagenot high enough to light
is
the neon lamp. The neon lamp will not light on voltages below 55 volts ac
or below 90 volts dc. Try another portion of the same circuit having
a
NOTE: The relay in Test Unit I-236 will act as circuit breaker and
a
protect the neon lamp in case the test prods are applied to portion
a
1-236
Check to make certain that the power cord of Test Unit I-236
b.
pro
is
graph
c. Move switch SW2 to NEON and switch SW1 to EXT V.
Plug the power cord of Test Unit I-236 into a 115- to 130-volt source
b.
of direct current. A source of alternating current cannot be used to test
capacitors.
d. Apply the prods of the test leads to the two sides of the capacitor.
In testing dry electrolytic capacitors it may be necessary to reverse the test
leads to correct the polarity. Incorrect polarity will be indicated by steady
glow of the neon lamp. If after reversing the test leads, the glow of the
neon lamp is still steady, the capacitor is shorted (subpar. f below) .
a. Disconnect the equipment under test from its own source of power.
b. Check to make certain that the power cord of Test Unit I-236 is pro
perly connected into a source of a-c or d-c voltage as described in para
graph 7.
e. A continuous circuit will light the Mazda and the neon lamps.
PART THREE
PREVENTIVE MAINTENANCE
SECTION IV
PREVENTIVE MAINTENANCE TECHNIQUES
12. MEANING OF PREVENTIVE MAINTENANCE.
Preventive maintenance is a systematic series of operations performed at
regular intervals on equipment, when turned off, to eliminate major break'
downs and unwanted interruptions in service, and to keep the equipment
operating at top efficiency. To understand what is meant by preventive
maintenance, it is necessary to distinguish between preventive mainten
ance, trouble shooting, and repair. The prime function of preventive main
tenance is the prevention of break-downs and, therefore, the need for repair.
On the other hand, the prime function of trouble shooting and repair is the
location and correction of existing defects. The importance of preventive
maintenance cannot be overemphasized. The entire system of communica-
tions depends upon the readiness and operating efficiency of each item of
equipment when it is needed. In a similar manner, the test equipment by
which this condition of readiness in communications equipment is realized
must be kept in excellent operating condition at all times.
10
d. Tighten, Clean, and Adjust. These operations are self-explanatory.
Specific procedures to be followed in performing them are given wherever
necessary throughout part three.
SECTION V
ITEMIZED PREVENTIVE MAINTENANCE
14. INTRODUCTION.
The general technique involved and the application of the FITCAL opera-
tionsin performing preventive maintenance on individual parts are dis
cussed in this section. All work is to be performed with the power removed
from the equipment. After preventive maintenance has been performed,
the equipment should be put into operation and checked for satisfactory
performance.
11
Figure 5. Test Unit 1-236, underside of panel with case removed,
shotting mounting of neon lamps.
12
16. EXTERIOR OF TEST UNIT 1-236.
a. Inspect (I).
(1 ) Carefully examine the case and front panel for broken or damaged
places, chipped paint, dirt, dust, rust, corrosion, and loose or missing screws.
(2) Inspect the lamp lenses for dirt, dust, lint, and for cracked places.
(4) Inspect the power cord and the test leads for poor insulation, for
cracks, and for evidences of dry rot.
b. Tighten (T).
(1) Tighten all loose screws with a screwdriver of the proper size.
(2) If lamp lenses are loose, remove the panel and tighten them.
(3) If switches SWl and SW2 are loose, remove the panel from the
case, and while holding the switches in place behind the panel, tighten the
rings which fasten the switches to the panel.
c. Clean (C).
(1) Using a soft, clean, lint-free cloth, wipe off all dirt and dust from
the panel and the case. If necessary, use dry-cleaning solvent (SD) to re
move grease and oil.
(2) Clean the lamp lenses with a soft, clean, lint-free cloth.
(3) Wipe off the power cord and the test leads with a soft cloth. Cut
away frayed strands on the insulation. If the wire is exposed, wrap it with
friction tape.
Take out the four corner screws from the front panel, and remove the
panel from the case. Remove the test leads from the jacks on the front panel.
a. Inspect (I).
(1) Inspect all wiring for dirt, dust, fraying, defective insulation,
cracks, and dry rot. Check to see if all connections are tight.
(2) Carefully examine all parts for loose or missing screws, nuts, and
bolts.
(3) Inspect lamps EI and E2 to see if they are clean and properly
seated in sockets Xx and X2. Check to see if the spare lamps are clean and
tight in their holders.
(6) Inspect relay Kx for dirt, dust, rust, and corrosion. Carefully
examine the contacts for signs of pitting.
Figure 6. Test Unit 1-236, underside of panel with case removed,
showing mounting of Mazda lamps.
14
b. Tighten (T). Tighten all screws, nuts, bolts, and connections found to
be loose. Make certain that connections are clean and free from corrosion
before tightening.
c. Clean (C).
(1) Clean all wiring with a dry cloth or small bristle brush. Cut away
frayed strands on the insulation.
(2) Clean the lamps with a soft cloth. If necessary use drycleaning
solvent (SD).
(3) Clean any corrosion from the lamp bases and sockets with #0000
sandpaper.
(4) Clean capacitor Cj and resistor Rx with a dry cloth or soft brush.
(5) Clean relay Kx with a cloth or soft brush. Give special attention to
cleaning away mildew or fungus, if found on the relay coil. Clean the
relay contacts with a relay burnishing tool as described in paragraph 19.
d. Adjust (A). If necessary, adjust relay contacts so that they will meet
properly.
When performed
Item Oper Ech
Item description Six
Ho. ation Daily Wtfy Month Trly elon
months
F I T C A L
Feel Inspect Tighten Clean Adjust Lubricate
15
SECTION VI
SPECIAL INSTRUCTIONS
19. USE OF BURNISHER.
Relay contacts are accessible when the panel is removed. To clean these
contacts, insert the blade of the burnishing tool between them, press the con-
tacts together tightly, and draw out the burnishing tool. Repeat this opera-
tion until the contacts are clean. Do not use a back-and-forth motion, be-
cause it may cause unevenness in the contact surface and may cause the thin
blade of the burnishing tool to be damaged by bending.
SECTION VII
LUBRICATION
NOTE: Lubrication of Test Unit 1-236 is not required.
16
PART FOUR
AUXILIARY EQUIPMENT
(NOT USED)
17
PART FIVE
REPAIR INSTRUCTIONS
NOTE: Failure or unsatisfactory performance of equipment used by Army
Ground Forces and Army Service Forces will be reported on W.D., A.G.O.
Form No. 468 (Unsatisfactory Report). For particulars see
Equipment
paragraph 28. If see TM 38-250. Failure
Form No. 468 is not available,
or unsatisfactory performance of equipment used by Army Air Forces will
be reported on Army Air Forces Form No. 54 (unsatisfactory report).
SECTION VIII
THEORY OF EQUIPMENT
20. GENERAL
a. Test Unit 1-236 consists of an ordinary test lamp equipped with switch
ing and protective features to increase its usefulness. The test unit provides
means of switching the Mazda test lamp so that it may be used to test live
circuits supplied with current by Test Unit I-236 from a separate power
source. Provision is made so that a neon lamp may be used for testing
capacitors, low-current capacity fuses, and also for differentiating between
a-c and d-c voltages.
b. The basic circuit of Test Unit I-236 is shown in figure 7. From this
basic circuit, three distinct circuits may be obtained by various settings of
switches SWl and SW2 as explained in paragraphs 21, 22 and 23.
EXT. V.
TL 5054&-S
Figure 7. Test Unit 1-236, schematic diagram of basic circuit.
18
TL 50546-S
b. Test Unit I-236 is connected so that the neon lamp E2 is used to test
a live circuit connected at jacks and J2 through the test leads. If the
J
voltage applied across the jacks exceeds the rated striking voltage of the
neon lamp (55 volts ac, 90 volts dc), the neon lamp will light. The current
passes through relay Kl which is normally closed. Since the neon lamp will
pass current in only one direction, d-c voltage applied at the jacks will light
only one plate of neon lamp E2. The constantly reversing polarity of alter
nating current will light both plates of neon lamp E2. A voltage higher than
that for which the test unit is designed will operate relay K^ and open the
circuit to protect the neon lamp from damage. Capacitor GI is provided to
dissipate arcing at the relay contacts. Resistor Rj (30,000 ohms) is in series
with the neon lamp and acts as a current-limiting resistor to protect the
neon lamp.
a. Figure 9 shows the portion of the basic circuit used to test fuses and
capacitors. Switch SW2 is set at NEON and switch SWl at EXT V.
INT. V. l-C
p J '
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rvsw- E
i
'EXT. v.
TL 50547-S
Figure 9. Circuit of Test Unit 1-236 used to test fuses and capacitors.
b. The voltage for these tests is supplied by Test Unit I-236 from an a-C
or d-c source. A continuous path through a fuse connected to Test Unit
19
,I-236 through the test leads will close the circuit of Test Unit I-236 and
Jight the neon lamp. When a capacitor is connected to Test Unit I-236
through the test leads, steady glow of the neon lamp indicates a shorted
capacitor in paragraph 10. A good capacitor will cause the
as described
neon lamp to flash intermittently with a frequency dependent upon the
capacitance of the capacitor under test. Relay Kj, resistor Rj, and capacitor
Cl have the same functions as described in paragraph 21 b.
a. Figure 10 shows the portion of the basic circuit used to check con
tinuity of circuits. Switch SW2 is set at NEON & MAZDA and switch
SW1 at EXT V.
TL 50548-S
Figure 10. Circuit of Test Unit 1-236 used to chec\ continuity of circuits.
b. The voltage for these tests is supplied by Test Unit I-236 from an a-c
or d-c source. A circuit in the equipment under test will light
continuous
both the Mazda and neon lamps. Either of the two lamps may be used to
indicate continuity. However, switch SW2 should be kept in the NEON
6? MAZDA position.
SECTION IX
TROUBLE-SHOOTING PROCEDURES
24. TEST PROCEDURE.
a. Step 1. Plug the power cord of Test Unit I-236 into a 115- to 130-
volt a-c or d-c receptacle. Insert the tips of the test leads into the jacks on
the front panel of Test Unit I-236. Move switch SW1 to EXT V and short-
circuit the test leads.
20
Indication
(1) With switch SW2 in NEON position, one or both plates of the neon
lamp should light, depending upon the source of voltage (ac or dc) to which
the test unit is connected. The Mazda lamp should not light.
(2) With switch SW2 in NEON 6? MAZDA position both lamps should
light.
(3) With switch SW1 in INT V position both lamps should be extinguished.
(1) Neon lamp does not light. (1) Defective neon lamp.
Defective switch SW1.
Dirty relay contacts.
Defective resistor Rv
Both lamps light. Defective switch SW2.
(2) Mazda lamp does not light. (2) Defective Mazda lamp.
Defective switch SW2.
Tsjormal Indication
b. Using the voltohmmeter, measure the resistance of the relay coil. The
resistance should measure between 12 and 16 ohms.
21
WAR DEPARTMENT
UNSATISFACTORY EQUIPMENT REPORT
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'-d ol obro.ttioo o"di'loiITlh*"^^"^^' ihooTdb* .obmlt*dST'i'oc'".oi*ii".th'"'ior"m
2 Tbi.lormwillb* owdloti*port.og moootoctodog defigoot.-pc..honjl Photogroph
Photoqjoph, ...I, K*i 0t
i. k*lch oroth*f
olh*rilloitioti**
ilIuKioliv*m
motwiolorc highlydeurahl*
atwialarc detirobl*
d.lt. mmotttwl ,lho ...-lo ,mpro*,ogoodcriliogSUthd-lli. oodlor
^cV^"*.'^?^''^^.^^^!-' to "T.? mo p^dTho!. *M M ot"oJ*
3 Thi*lormwillootb*oivHlotrtpottiog loilorn,noloi.-dmot*nild*l*ctior x.
oorlorlbi*ploc*m*ot. repoo. orth*ioeolport*oodgoipm*ol. It do*io 7 Th.ilorm willbemod* o otbyoiiog 0tMi*tc*oroomiotioo* oodlorworded
Figure 11. W.D., A.G.O: Form >Jo. 468 with sample entries.
22
SECTION X
REPAIRS
26. GENERAL REPAIR.
a. Use #00 or #000 sandpaper to clean the surface down to the bare
metal. Obtain a bright smooth finish.
c. Using a small brush, apply paint to the bared surfaces. Paint used will
be authorized consistent with existing regulations.
'b. When trouble in equipment used by Army Air Forces occurs more
often than repair personnel feel is normal, Army Air Forces Form No. 54
should be filled out and forwarded through channels.
23
TEST UNIT 1-236
CIRCUIT DIAGRAM
APPARATUS LEGEND
REF. S C TYPE NO. A.S.A. SPEC. OR A.S.A. OB
DESCRIPTION OUAN.
SYM OR DWG. NO. MANUFACTURER- MFR'S TYPE NO.
C, TUBULIlll
CAP4CIIOI.OII O.Smid.400V SOLAR ELECTRICCO. XTIMOW 4-5 1
J|-J| CONNECTOR (JACK) AMERICAN PHENOLIC CORP 78-1P 2
E, LAMP. MAZDA. 15W' 115V. GENERAL ELECTRICCO. 15T7N
E, LAMP.NEON.0.25W. 115V. GENERAL ELECTRICCO. NE - 46
Ki RELAY, 31 OHMS. 6V. ALLIEDCONTROL CO. INC. AR3D32
RI RESISTOR'30.000OHM 1W. INTERNAL RESISTANCE CO. RC30AF303J
SW, SWITCH. TOGGLE. DPDT ARROW HARTiHEGERMAN ST23N
SW, SWITCH' TOGGLE, SPST ARROW HART 4 HEGERMAN ST13A
x, SOCKET' INT. BASE NOMA ELECTRICCO. 1-915
X, SOCKET' PILOT LAMP ASSY. 3IAL LIGHT CO. OF AMERICA 9200-DC.
1 POWER CORD ASSY. 2611"
2 TESTLEAD ASSY. 30" 2
MANUF
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SECTION XII
REFERENCES
30. ARMY REGULATIONS.
AR 380-5 Restricted Documents.
35. DECONTAMINATION.
TM 3-220 Decontamination.
36. DEMOLITION.
FM 5-25 Explosives and Demolitions.
37. CAMOUFLAGE.
FM 5-20 Camouflage, Basic Principles.
28
38. OTHER TECHNICAL PUBLICATIONS.
39. FORMS.
40. ABBREVIATIONS.
29
cont contact
contd continued
d deep (depth)
dc direct current (noun)
d-c direct'current (adj)
diam diameter
Dialco Dial Light Corp
DPDT double-pole, double-throw
dwg drawing
fig- figure
ft foot (feet)
GE General Electric Co
ID inside diameter
Ib pound
lg long (length)
mfg manufacturing
mmf micromicrofarad
No. number
Noma Elec Noma Electric Co
OD outside diameter
SigC Signal Corps
Solar Solar Mfg Corp
Spec specification
SPDT single-pole, double-throw
SPST single-pole, single-throw
subpar. subparagraph
thk thick
v volts
vdcw DC working volts
w watts
wd wide (width)
W.D., A.G.O. War Department, Adjutant General's
Office
30