[R-390] R390_Inspection_List_Part_2

[Roger Ruszkowski]

D. Hard Core RF Module Cleaning
___ 01 Disassemble the gear train
___ 02 When you take the split gears apart, tie themtogether
___ 03 Maintain the orientation that they were originallyassembled with
___ 04 Except for the counter toss all of the parts in acoffee can
___ 05 Add favorite degreaser and let brew
___ 06 Work penetrating oil into the bearings of thecamshafts
___ 07 Keep lubing and wiping them until only clean oilcomes out
___ 08 Now bath the RF deck in soap and water (dish washer)
___ 09 Now bath the Gear parts in soap and water (dishwasher)
___ 10 Dry the RF deck and gears (all day in the sun light)
___ 11 Use 10W30 Mobil 1 synthetic oil for the RF deck
___ 12 Use Pennzoil wheel bearing grease on the detent
___ 13 Use compressed air to work oil into the bearings ofthe camshafts
___ 14 Lubricate each part of gear train prior to assembly
___ 15 Reassemble the Gear Train
___ 16 Use compressed air to work oil into the gears
___ 17 Wipe out excess oil
___ 18 Conduct mechanical alignment of the Gear Train
___ 19 Deoxit all the tube socket pins
___ 20 Deoxit all the connector sockets
___ 21 Deoxit all the plug pins
 
E. Cosmetic RF Module Cleaning
___ 01 Hang Gear Train over edge of bench
___ 02 Rotate the deck any way needed to work out dirt
___ 03 Use liberal amounts of cleaner to wash gears
___ 04 Use compressed air to push cleaner into parts anddirt out
___ 05 Use penetrating oil on first pass
___ 06 Use Alcohol on second pass
___ 07 Use degreaser on third pass
___ 08 Use simple soap on fourth pass
___ 09 Dry the RF deck and gears (all day in the sun light)
___ 10 Use 10W30 Mobil 1 synthetic oil for the RF deck
___ 11 Use Pennzoil wheel bearing grease on the detent
___ 12 Use compressed air to work oil into the bearings ofthe camshafts
___ 13 Use compressed air to work oil into the gears
___ 14 Wipe out excess oil
___ 15 Conduct mechanical alignment of the Gear Train
___ 16 Deoxit all the tube socket pins
___ 17 Deoxit all the connector sockets
___ 18 Deoxit all the plug pins
 
F. Rebuild Inspection / Visual Inspection
___ 01 Spin all of the trimmers caps a couple of turns
___ 02 Tighten the screws holding the tube sockets to thechassis
___ 03 Check the value of all the resistors
___ 04 Check the value of all diodes
___ 05 Check the value of all capacitors
___ 06 Measure the resistance of all the front panelpotentiometers
___ 07 Measure the resistance of the IF gain potentiometer
___ 08 Measure the resistance of the carrier meter zeropotentiometer
___ 09 Remove all of the hoods of the chassis connectors toinspect
___ 10 Measure the resistance of EVERY damn wire in thechassis
___ 11 Inspect the power cord connections under the coverplate.
___ 12 Check the capacitors and resistors inside the IFtransformer cans
___ 13 Test the dial lamps
___ 14 Check the selenium rectifier
___ 15 Check the antenna relay and inspected the contacts inthe relay
___ 16 Check the main power micro switch
___ 17 Check capacitor C-553, which blocks B+ from themechanical filters
___ 18 Check the 2UF AGC capacitor for leaking fluid
___ 19 Check C531 cause of audio and limiter functionproblems
___ 20 Check C547 cause of audio and limiter functionproblems
___ 21 Check C549 cause of audio and limiter functionproblems
___ 22 Check C603 capacitor mounted on the AF deck
___ 23 Check C606 capacitor mounted on the AF deck
___ 24 Check C609 8 ufd electrolytic capacitor mounted inthe AF deck
___ 25 Check C-327, a 100 pf mica capacitor mounted in theRF deck
___ 26 Verify the values of the fuses
___ 27 Inspect the fuse holder operation
___ 28 Inspect the rear panel Antenna and IF outputconnectors
___ 29 Inspect the terminal board screws and jumpers
___ 30 Check all the tubes with a tube tester for minimumvalues
 
G. Reassemble The Receiver
___ 01 Inspect the cams for burrs where the rollers ride on,hone if needed
___ 02 Inspect the gear clamps for cracks replace as needed
___ 03 Inspect the spline bolts in the gear clamps replaceas needed
___ 04 Inspect the roller retainers on the slug racks thesemust roll freely
___ 05 Inspect slug racks for square true operation fix asneeded
___ 06 Inspect slug racks for burrs and gouges on the endsurfaces and fix
___ 07 Replace the RF deck transformer cans
___ 08 Replace the slug racks inspect for properinstallation of racks
___ 09 Install the slug rack springs
___ 10 Install the calibration crystal oven
___ 11 Inspect the slug rack springs for poor tensionreplace as needed
___ 12 "Time" the RF deck band switch
___ 13 "Time" the OSC deck band switch
___ 14 Install OSC deck subassembly
___ 16 Check the alignment and operation of the OSC deckswitch
___ 17 In R390 check the Oldham coupler between OSC and RFdecks
___ 18 In R390 check the OSC deck switch “timing”
___ 19 Install RF subassembly deck
___ 20 In R390 install the calibration sub assembly deck
___ 21 Install VFO subassembly
___ 22 Check the VFO shaft alignment to the KHz shaft adjustas needed
___ 23 Check the VFO Oldham coupler spacing
___ 24 Install the VFO Oldham coupler spring
___ 25 Reinstall the front panel
___ 25 Conduct power supply module: visual inspection
___ 26 Verify power supply 115 volt switch setting
___ 27 Inspect the solder connections in power supply(diodes added)
___ 28 Install the power supply module
___ 29 Install the IF module
___ 20 Install the Audio module
___ 31 Lightly lube the set screws in the knobs and installthe knobs
___ 32 Lightly lube the shafts of each front panel switches
___ 33 Lightly lube the shafts of each front panelpotentiometers
___ 34 Lightly lube the shafts IF gain potentiometer
___ 35 Lightly lube the shafts carrier meter adjustpotentiometer
___ 36 IF deck lightly lube the shaft extensions bushings
___ 37 Reinstall the knobs
___ 38 Check the tightness on all of the screws and clamps
___ 39 Install the tubes
___ 40 Install selected tube shields
___ 41 All the knobs must operate freely
___ 42 Knobs must not be loose on shafts
___ 43 Verify all connectors are properly seated
___ 44 Ensure the wire harness is tucked in on the bottomside
 
H. Mechanical Alignment
___ 01 Set Oven switch to OFF
___ 02 Loosen the dial lock, check the knob and lockoperation
___ 03 Check the zero adjust knob adjustment operation
___ 03 Set the zero adjust to center
___ 04 Check the over run and under run on the KHz knob (10turn stop)
___ 05 Adjust the KHz counter as needed (greater than 25–963 , -972 )
___ 06 Check the over run and under run on the MHz knob (10turn stop)
___ 07 Adjust the MHz counter as needed
___ 08 Set the R390A to 7+000 Set the R390 to 2.000
___ 09 Check the cam alignment starting with the 8-16 MHzCam
___ 10 A If the 8-16 MHz Cam need adjusting then loosen thefollowing
___ 10 B Release the clamp for 2-4 the slug rack should fall
___ 10 C Release the clamp for 4-8 the slug rack should fall
___ 10 D Release the clamp for 16-32 the slug rack shouldfall
___ 10 E The 8-16 slug rack should also fall
___ 11 Hold the 8-16 and 16-32 cam in place
___ 12 Tighten the 16-32 MHz Cam clamp
___ 13 Hold the 4-8 cam in place
___ 14 Tighten the 4-8 MHz Cam clamp
___ 15 Hold the 2-4 cam in place
___ 16 Tighten the 2-4 MHz Cam clamp
___ 17 Adjust the 1-2 MHz Cam if needed
___ 18 Adjust the .5-1 MHz Cam if needed
___ 19 Adjust the 1st Variable IF Cam if needed
___ 20 Adjust the 2nd Variable IF Cam if needed
___ 21 Adjust the VFO if needed
 
I. Knobology Dynamic Testing Monthly Test
___ 01 Set the Function Switch to MGC
___ 02 Eye ball the receiver in the dark for blue tube glow
___ 03 Eye ball the dial lights
___ 04 Get the head phones adjusted over the ears
___ 05 Set the Line Meter to 0
___ 06 Set the Line gain to 10
___ 07 Set the ANT Trim to 0
___ 08 Set the AGC to MED
___ 09 Set the LIMITER to OFF
___ 10 Set the Band Width to 2KHz
___ 11 Set the BFO Pitch to 0
___ 12 Set the BFO OFF
___ 13 Set the Breakin OFF
___ 14 Set the Audio Response to wide
___ 15 Set the Zero Adjust to center and confirm knob is notloose
___ 16 Release the Dial Lock and confirm knob is not loose
___ 17 Set the Local Audio to max and confirm knob is notloose
___ 18 Set the RF to max and confirm knob is not loose
___ 19 Run the Local Audio from end to end and confirm knobis not loose
___ 20 Listen for pot pop in the head phones
___ 21 Confirm Local Audio pot V603, V602A are good
___ 22 Switch the band pass filter from wide to sharp towide
___ 23 Confirm band pass filter knob is not loose
___ 24 Listen for switch pop in the head phones
___ 25 Listen for narrow audio responce in the head phones
___ 26 Confirm Filter, switch, V601A are good
___ 27 Set the LIMITER to ON
___ 28 Listen for switch pop in the head phones
___ 29 Run the LIMITER pot from end to end
___ 30 Listen for a change in Audio spectrum
___ 31 Set the LIMITER to OFF and confirm knob is not loose
___ 32 Confirm Limiter switch, V507 are good
___ 33 Set the Function to CAL
___ 34 Listen for the Antenna Relay to click between MGC andCAL
___ 35 Set the BFO ON and confirm knob is not loose
___ 36 Set the Khz to 500Khz
___ 37 Vary the BFO Pitch and confirm knob is not loose
___ 38 Confirm the BFO pitch goes through zero and the knobstops work
___ 39 Set the Band Width to .1Khz, 1Khz, 2KHz, 4Khz, 8Khz,16Khz
___ 40 Listen for a change in Audio spectrum and confirmknob is not loose
___ 41 Set the Band Width to .1Khz
___ 42 Set the BFO Pitch to zero, confirm knob adjustmentfor zero is good
___ 43 Vary the Khz Knob to get a zero BFO through the .1KHz
___ 44 Confirm V505, V701, V506B, V504, V503, V502, V501 aregood
___ 45 Set the Band Width to 4Khz
___ 46 Set the MHz to 00
___ 47 Verify Mhz stop at 00
___ 48 Set the Khz to 500Khz and listen for a cal tone
___ 49 Move the Mhz knob up one detent
___ 50 Verify detent seats, verify band switch changes asneeded
___ 51 Verify 2nd Crystal Oscillator crystal iswithin 1KHz on each Mhz
___ 52 Move the Mhz knob up one detent
___ 53 Verify Mhz stop at 31
___ 54 Dial Khz to 000
___ 55 Check counter under run
___ 56 Dial Khz to 000 and null cal tone to zero with BFO
___ 57 Dial Khz to each 100 KHz and note VFO spread
___ 58 Dial Khz to 900 and note that total VFO spread isless than 300 Hz
___ 59 Check counter over run
___ 60 Ground break in and set break in ON
___ 61 Confirm audio mutes
___ 62 Set break in OFF
___ 63 Confirm antenna relay operation in STANDBY and CAL
___ 64 Set the Function to AGC
___ 65 Set the AGC to SLOW, MED, FAST
___ 66 Observe that the carrier meter moves upscale anddrops back to zero
___ 67 Set the Function to CAL
___ 68 Set the BFO ON
___ 69 Dial KHz to a cal tone and adjust BFO for a tone
___ 70 Set the line gain to max
___ 71 Set the line meter switch to 0
___ 72 Set the line gain for a meter indication of 0
___ 73 Set the line meter switch to +10
___ 74 Observe the line meter reads –10
___ 75 CARRIER LEVEL meter deflection of at least 40 dB onCal tone
___ 76 Set the Function to AGC
___ 77 Tune KILOCYCLE CHANGE control across any band
___ 78 Tune KILOCYCLE CHANGE control through several signals
___ 79 Output volume should be nearly constant
___ 80 Tune KILOCYCLE CHANGE control to one signal
___ 81 CARRIER LEVEL meter indicates strength of receivedsignals
___ 82 Rotate ANT TRIM control to peak CARRIER LEVEL meter
___ 83 Set FUNCTION switch to MGC
___ 84 Tune the receiver away from any signal
___ 85 CARRIER LEVEL should not indicate (read zero)