INSTALLATION/MAINTENANCE

MANUAL

CNI 5000
INTEGRATED RADIO
MOUNTING PACKAGE

MANUAL NUMBER 006-05330-0003

REVISION 3, MAY, 2004
 WARNING
Prior the export of this document, review for export license requirement is needed.

COPYRIGHT NOTICE

©2000, 2003, 2004 Honeywell International Inc.

Reproduction of this publication or any portion thereof by any means without the express written
permission of Honeywell is prohibited. For further information contact the manager, Technical
Publications, Honeywell, One Technology Center, 23500 West 105th Street Olathe KS 66061
telephone: (913) 782-0400.
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REVISION HISTORY
REVISION: 3 MAY, 2004

Revision Changes
2 Add new version
3 Update vibration specification

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THIS PAGE IS RESERVED

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TABLE OF CONTENTS
\

REVISION HISTORY

REVISION: 3 MAY, 2004 ................................................................................................. RH-1

SECTION I
GENERAL INFORMATION

1.1 INTRODUCTION ........................................................................................................... 1-1

1.2 EQUIPMENT DESCRIPTION ....................................................................................... 1-2
1.2.1 CONFIGURATIONS AVAILABLE ................................................................................. 1-2
1.3 TECHNICAL CHARACTERISTICS .............................................................................. 1-2
1.4 CNI 5000 REQUIRED BASE COMPONENTS ............................................................. 1-4
1.4.1 INTEGRATED RADIO PACKAGE RACK AND INSTALLATION KIT ........................... 1-4
1.4.2 INTEGRATED RADIO PACKAGE RACK FRONT PANEL KIT .................................... 1-5
1.4.3 CNI 5000 REQUIRED RADIOS .................................................................................... 1-5
1.5 CNI 5000 REQUIRED ACCESSORIES ........................................................................ 1-6
1.6 CNI 5000 OPTIONAL ACCESSORIES ........................................................................ 1-6
1.7 RELATED PUBLICATIONS ......................................................................................... 1-7
1.8 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ............................................. 1-7

SECTION II
INSTALLATION

2.1 GENERAL INFORMATION .......................................................................................... 2-1

2.2 UNPACKING AND INSPECTING EQUIPMENT .......................................................... 2-1
2.3 EQUIPMENT INSTALLATION ..................................................................................... 2-1
2.3.1 GENERAL ..................................................................................................................... 2-1
2.3.2 AVIONICS COOLING REQUIREMENTS FOR PANEL MOUNTED EQUIPMENT ...... 2-2
2.3.3 CNI 5000 INTERWIRING AND CABLE HARNESS FABRICATION ............................. 2-2
2.3.4 EQUIPMENT LOCATION ........................................................................................... 2-19
2.3.5 CNI 5000 INSTALLATION .......................................................................................... 2-20
2.4 POST INSTALLATION TEST PROCEDURE ............................................................. 2-25

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TABLE OF CONTENTS

2.4.1 SYSTEM CHECKOUT ................................................................................................ 2-25

2.4.2 POST INSTALLATION CHECK .................................................................................. 2-28

SECTION III
OPERATION

3.1 GENERAL ..................................................................................................................... 3-1

3.2 DETAILED OPERATING MODES ................................................................................ 3-2
3.2.1 TURN ON ...................................................................................................................... 3-2

SECTION IV
THEORY OF OPERATION

4.1 GENERAL ..................................................................................................................... 4-1

4.2 DETAILED CIRCUIT THEORY ..................................................................................... 4-2

SECTION V
MAINTENANCE

5.1 INTRODUCTION ........................................................................................................... 5-1

5.2 TEST ............................................................................................................................. 5-1
5.2.1 TEST EQUIPMENT REQUIRED ................................................................................... 5-1
5.2.2 TESTING AND TROUBLESHOOTING ......................................................................... 5-2
5.2.3 FUNCTIONAL TEST PROCEDURE ............................................................................. 5-2
5.2.4 TROUBLESHOOTING PROCEDURES ........................................................................ 5-5
5.3 OVERHAUL ................................................................................................................ 5-11
5.3.1 DISASSEMBLY ........................................................................................................... 5-11
5.3.2 CLEANING .................................................................................................................. 5-14
5.3.3 CHECK ........................................................................................................................ 5-17

SECTION VI
ILLUSTRATED PARTS LIST

6.1 GENERAL ..................................................................................................................... 6-1

6.2 REVISION SERVICE .................................................................................................... 6-1
6.3 LIST OF ABBREVIATIONS .......................................................................................... 6-2
6.4 SAMPLE PARTS LIST ................................................................................................. 6-3

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TABLE OF CONTENTS

6.5 INSTALLATION KIT ..................................................................................................... 6-5

6.6 ANTENNA CABLE ASSEMBLY ................................................................................ 6-11
6.7 REAR COVER ASSEMBLY ....................................................................................... 6-13
6.8 RACK ASSEMBLY ..................................................................................................... 6-17
6.9 PCB FAN SENSE ....................................................................................................... 6-23
6.10 INTEGRATED RADIO PACKAGE FRONT PANEL ................................................... 6-33
6.11 FRONT PANEL ASSEMBLY ...................................................................................... 6-35
6.12 LIGHT BOARD ASSEMBLY ...................................................................................... 6-41
6.13 AIRCRAFT ADDRESS KIT ........................................................................................ 6-49
6.13A EXTERNAL EEPROM BOARD .................................................................................. 6-49

APPENDIX E
D0-160B ENVIRONMENTAL QUALIFICATION FORMS

CNI 5000 EVIRONMENTAL QUALIFICATION FORM ....................................................APP_E-3

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TABLE OF CONTENTS

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LIST OF FIGURES

REVISION HISTORY

SECTION I
GENERAL INFORMATION

SECTION II
INSTALLATION

FIGURE 2-1 CONTACT, CRIMPING TOOL, AND EXTRACTION TOOL ................................ 2-4
FIGURE 2-2 INSERTING TERMINAL FOR CRIMPING ........................................................... 2-7
FIGURE 2-3 CNI 5000 INTEGRATED RADIO PACKAGE RACK OUTLINE AND MOUNTING 2-
11
FIGURE 2-4 CNI 5000 INSTALLATION KIT DRAWING ........................................................ 2-15
FIGURE 2-5 CNI 5000 INTERCONNECT DIAGRAM ............................................................ 2-17

SECTION III
OPERATION

FIGURE 3-1 FRONT PANEL DISPLAY/CONTROLS ............................................................... 3-1

SECTION IV
THEORY OF OPERATION

FIGURE 4-1 FAN SENSE CIRCUIT, DETAILED BLOCK DIAGRAM ....................................... 4-3

SECTION V
MAINTENANCE

FIGURE 5-1 CNI 5000, TEST SETUP DIAGRAM .................................................................... 5-1

FIGURE 5-2 EXPLANATION AND EXAMPLE OF TEST PROCEDURE FLOW CHART SYM-
BOLS ........................................................................................................................................ 5-7
FIGURE 5-3 TROUBLESHOOTING FLOW CHART(General) ................................................. 5-9
FIGURE 5-4 TROUBLESHOOTING FLOW CHART(Fan Sense Board) ................................ 5-10

SECTION VI
ILLUSTRATED PARTS LIST

FIGURE 6-1 SAMPLE PARTS LIST ......................................................................................... 6-3

FIGURE 6-2 INSTALLATION KIT ASSEMBLY ........................................................................ 6-7
FIGURE 6-3 REAR COVER ASSEMBLY ............................................................................... 6-15
FIGURE 6-4 RACK ASSEMBLY ............................................................................................. 6-19
FIGURE 6-5 FAN SENSE PC BOARD ASSEMBLY .............................................................. 6-27
FIGURE 6-6 FAN SENSE PC BOARD SCHEMATIC ............................................................. 6-29
FIGURE 6-7 FRONT PANEL ASSEMBLY ............................................................................. 6-37

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LIST OF FIGURES

FIGURE 6-8 LIGHT BOARD ASSEMBLY .............................................................................. 6-43

FIGURE 6-9 LIGHT BOARD ASSEMBLY .............................................................................. 6-47
FIGURE 6-10 EXTERNAL EEPROM BOARD ........................................................................ 6-51
FIGURE 6-11 EXTERNAL EEPROM BOARD ........................................................................ 6-53

APPENDIX E
D0-160B ENVIRONMENTAL QUALIFICATION FORMS

FIGURE APP_E-1 CNI 5000 ENVIRONMENTAL QUALIFICATION FORM ...................APP_E-3

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LIST OF TABLES

REVISION HISTORY

SECTION I
GENERAL INFORMATION

SECTION II
INSTALLATION

TABLE 2-1 INSPECTION/CHECK PROCEDURE .................................................................. 2-25

SECTION III
OPERATION

SECTION IV
THEORY OF OPERATION

SECTION V
MAINTENANCE

TABLE 5-1 RECOMMENDED CLEANING AGENTS ............................................................. 5-14

TABLE 5-2 SEALANTS, STAKING COMPOUNDS, AND THERMAL COMPOUNDS ........... 5-25

SECTION VI
ILLUSTRATED PARTS LIST

TABLE 6-1 ABBREVIATIONS .................................................................................................. 6-2

APPENDIX E
D0-160B ENVIRONMENTAL QUALIFICATION FORMS

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LIST OF TABLES

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SECTION I
GENERAL INFORMATION
1.1 INTRODUCTION
This manual contains information relative to the physical, mechanical, and electrical characteris-
tics and installation procedures of the BENDIX/KING CNI 5000 Integrated Radio Mounting Pack-
age. The CNI 5000 is comprised of the following parts:

A. Integrated Radio Package Rack and Installation Kit (P/N 050-03011-00XX)

(1) Rack Assembly (200-05197-0000)

(2) Rear Cover Assembly (200-05155-0000)

(3) Fan Sense PC Board Assembly (200-08519-0000)

B. Integrated Radio Package Front Panel (P/N 050-03104-00XX)

(1) Front Panel Assembly (200-05140-00XX)

(2) Light Board Assembly (200-08486-0000)

Additional information relative to the radios used to form a functional radio package will also be
furnished. The radios are specific version numbers configured for use exclusively in the CNI 5000
radio package.

C. Radio Units:

(1) KY 196A (two) P/N 064-01054-0050 or

KY 196B (two) P/N 064-01084-0201

(2) KN 53 (two) P/N 066-01067-0004

(3) KR 87 P/N 066-01072-0006

(4) KT 70 (two) P/N 066-01141-1101; or KT 71 (two) P/N 066-01141-6101

The remaining three essential accessories needed to form the complete radio package are:

D. Required Accessories

(1) KA 33 (Accessory) P/N 071-4037-01

(2) KA 12 (Accessory) P/N 071-01543-00XX

(3) *Aircraft Address Kits (two) P/N 050-02927-0000 (for use with KT 70/71)

Installation, operating procedures, theory of operation, and an illustrated parts list are also includ-
ed. The CNI 5000 requires no alignment, however testing and troubleshooting procedures are in-
cluded for the field serviceable module.
Information relative to the maintenance, alignment, and procurement of the replacement parts
may be found in the individual radio Maintenance/Overhaul manuals.

*This kit is not used when 050-03104-0002 is used.

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1.2 EQUIPMENT DESCRIPTION

The CNI 5000 is a panel mounted, TSO’d, radio package designed to provide the integration of
separate avionic units into one configuration. The radios housed in the rack provide COMM/NAV/
IDENT capability. Two fans are part of the rack and provide a means of cooling and have a mon-
itoring circuit that provides a signal for status indication on a front panel lamp.
The KA 33 Blower Unit provides auxiliary cooling and the KA 12 Fan Sense Unit provides a mon-
itoring circuit. The status of the fan is indicated on a front panel light.
1.2.1 CONFIGURATIONS AVAILABLE
The CNI 5000 is only available in a +28 VDC primary power/ +5 VDC panel lighting voltage ver-
sion.
1.3 TECHNICAL CHARACTERISTICS

CNI 5000 GENERAL SPECIFICATIONS

TSO Compliance: See Appendix E

PHYSICAL DIMENSIONS:

Width: 7.100 in.18.03 cm. (with bezel)

Height: 10.1 in. 25.65 cm. (with bezel)

Length: 13.263 in. 30.94 cm. (with bezel)

Weight: 23.30 lbs. 10.6 kg (With radios installed)

16.61 lbs. 7.55 kg (With radios less 2
transponders)

Applicable Documents: TSO-C112

TSO-C40a

TSO-C34c

TSO-C36c

TSO-C37c

TSO-C38c

TSO-C41c

TSO-C74c

RTCA DO-160B

Temperature: A1 -15 °C to +55°C

D1 -20 °C to +55°C

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CNI 5000 GENERAL SPECIFICATIONS

Altitude Range: A1 15,000 ft.

D1 50,000 ft.

Cooling: Two integral fans plus remote forced-air

cooling required. (Required accessory,
KA 33)

Vibration: Constant peak displacement of 0.2in

from 5 to 17 Hz with a maximum accel-
eration of 0.26G.
Constant peak displacement of 0.02in
from 37 to 55 Hz with a maximum accel-
eration of 1.4G.
Constant peak acceleration of 3G from
17 to 37 Hz.
Constant peak acceleration of 0.75G
from 55 to 70 Hz.
Constant peak acceleration of 0.5G from
70 to 500 Hz.
Constant peak acceleration of 0.25G
from 500 to 2000 Hz.

Shock: Panel mount, no shock mounting re-

quired.

Power Consumption:

+ 28 VDC Input:

Units: See individual unit installation manuals.

Rack Fans: 220 mA

+ 5 VDC lighting bus input:

Front Panel lamps: 2.0 A maximum

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1.4 CNI 5000 REQUIRED BASE COMPONENTS

1.4.1 INTEGRATED RADIO PACKAGE RACK AND INSTALLATION KIT
The CNI 5000 Integrated Radio Package Rack installation kit P/N 050-03011-00XX contains the
following parts:

050-03011-0000 CNI 5000 INSTALL, NON-PVC 24FT AA

050-03011-0001 CNI 5000 INSTALL, NON-PVC 48FT AA

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000 -0001

J201 030-03137-0006 BERG CONNECTOR EA 1.00 1.00

JKT701 030-01094-0066 CONN W/ POLARIZER EA 2.00 2.00

JKT703 030-00102-0001 CONN PNL MOUNT RF EA 2.00 2.00

P1 030-01094-0085 CONN -09 W/POLAR EA 1.00 1.00

P1961 030-01094-0080 CONNECTOR KEYED EA 2.00 2.00

P1962 030-00101-0002 PANEL MOUNT PLUG EA 2.00 2.00

P531 030-00101-0002 PANEL MOUNT PLUG EA 2.00 2.00

P532 030-01094-0053 CONNECTOR EA 2.00 2.00

P533 030-00101-0002 PANEL MOUNT PLUG EA 2.00 2.00

P871 030-00101-0002 PANEL MOUNT PLUG EA 1.00 1.00

P872 030-01094-0051 CONN W/KEY EA 1.00 1.00

REF1 155-05812-0000 INSTAL KIT ASSY RF .00 .00

S1 031-00222-0008 SW TGL SPDT O-N-O EA 1.00 1.00

030-01107-0080 CONNECTOR TERM 80T EA 3.00 3.00

030-02205-0004 TERM 22-28 EA 8.00 8.00

057-02203-0000 FLAVOR STCKR EA 1.00 .

057-02203-0001 FLAVOR STCKR EA . 1.00

089-02185-0022 NUT LOCK 2-56 EA 2.00 2.00

089-05903-0007 SCR PHP 4-40X7/16 EA 16.00 16.00

089-06004-0012 SCR FHP 2-56X3/4 EA 2.00 2.00

089-08168-0002 WASHER WAVE EA 9.00 9.00

089-08252-0030 WASHER EA 9.00 9.00

090-00019-0007 RING RTNR .438 EA 9.00 9.00

091-00109-0000 CABLE TIE EA 20.00 20.00

200-02586-0001 ANTENNA CABLE ASSY EA 1.00 .

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SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000 -0001

200-02586-0004 ANTENNA CABLE ASSY EA . 1.00

200-05197-0000 RACK ASSY CNI5000 EA 1.00 1.00

1.4.2 INTEGRATED RADIO PACKAGE RACK FRONT PANEL KIT

The CNI 5000 Integrated Radio Package Front panel P/N 050-03104-00XX contains the following parts:

UNIT PN ASSY PN DESCRIPTION UM VENDOR

050-3104-0000 200-05140-0000 Black Frt Panel EA Honeywell
050-3104-0001 200-05140-0001 Grey Frt Panel EA Honeywell
050-3104-0002 200-05140-0002 Grey Frt Panel EA Honeywell
with no Xpdrs

1.4.3 CNI 5000 REQUIRED RADIOS

The CNI 5000 Integrated Radio Package requires the following radios:

Part Number Description UM QTY Vendor

064-01054-0004 KY 196A EA 2 Honeywell
or
064-01084-0201 KY 196B EA 2 Honeywell
066-01067-0004 KN 53 EA 2 Honeywell
066-01072-0006 KR 87 EA 1 Honeywell
*066-01141-1101 KT 70 EA 2 Honeywell
or
*066-01141-6101 KT 71 EA 2 Honeywell

*These units are not used when 050-03104-0002 is used.

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1.5 CNI 5000 REQUIRED ACCESSORIES

The CNI 5000 Integrated Radio Package requires the following accessory remote units:

Part Number Description UOM QTY VENDOR NAME

071-4037-01 KA 33 EA 1 Honeywell

071-01543-01XX KA 12 EA 1 Honeywell

The KA 33 Blower Unit is required for auxiliary cooling. Refer to the individual unit installation
manuals for additional accessory requirements.
The KA 12 is a remote Fan Sense Unit required to provide the circuitry for failure annunciation of
the KA 33 Blower Unit. The FAN 2 annunciation lamp on the front panel will work in conjunction
with the KA 12.
1.6 CNI 5000 OPTIONAL ACCESSORIES
KT 70/71 EEPROM AIRCRAFT ADDRESS KIT
The KT 70/71 Aircraft Address Kit P/N 050-02927-0000, that facilitates external storage of data
contains the following parts:

PN DESCRIPTION REV
050-02927-0000 AC ADD/MAX ARSPD 0

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

089-05903-0007 SCR PHP 4-40X7/16 EA 2.00
200-08334-0000 EXT EEPROM BD EA 1.00

NOTE
THE AIRCRAFT ADDRESS KIT IS NOT USED
WHEN 050-03104-0002 IS USED.

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1.7 RELATED PUBLICATIONS

Below is a listing of related publication for the CNI 5000 Integrated Radio Package.

PUBLICATION Honeywell Manual P/N

KY 196A VHF COMM TRANSCEIVER Installation Manual 006-00695-00XX

OR
KY 196B VHF COMM TRANSCEIVER Installation Manual 006-10570-00XX

KY 196A VHF COMM TRANSCEIVER Maintenance Manual 006-05695-00XX

OR
KY 196B VHF COMM TRANSCEIVER Maintenance Manual 006-15570-00XX

KN 53 VHF Navigation Receiver Installation Manual 006-00174-00XX

KN 53 VHF Navigation Receiver Maintenance Manual 006-05174-00XX

KR 87 Automatic Direction Finder Installation Manual 006-00184-00XX

KR 87 Automatic Direction Finder Maintenance Manual 006-05184-00XX

KT 70 Mode S Transponder Installation Manual 006-00673-00XX

OR
KT 71 ATC Transponder Installation Manual 006-00615-00XX

KT 70 Mode S Transponder Maintenance Manual 006-05306-00XX

OR
KT 71 ATC Transponder Maintenance Manual 006-05615-00XX

KA 33 Cooling Blower/KA 12 Fan Sense Unit Installation Manual 006-01069-00XX

1.8 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

The instructions for continued airworthiness given in the TC or STC approvals for this product sup-
plements or supersedes the instructions for continued airworthiness in this manual.
Most Honeywell products are designed and manufactured to allow "on condition maintenance."
On condition maintenance is described as follows; There are no periodic service requirements
necessary to maintain continued airworthiness. No maintenance is required until the equipment
does not properly perform it's intended function. When service is required, a complete perfor-
mance test should be accomplished following any repair action. Consult the appropriate unit
Maintenance/Overhaul Manual for complete performance test information.

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SECTION II
INSTALLATION
2.1 GENERAL INFORMATION
This section contains suggestions and factors to consider before installing the CNI 5000 Integrat-
ed Radio Package. The CNI 5000 Integrated Radio Package includes the following discrete com-
ponents: Rack Assembly; Front Panel Assembly; Units: KY 1 96A or KY 196B; KN 53; KR 87;
KT 70 or KT 71. Considerations for the required accessories, KA 33 Cooling Blower Unit/KA 12
Fan Sense Unit; KT 70/71 Address Kit will be addressed. Refer to the individual installation man-
uals for a detailed discussion of installation instructions. Close adherence to these suggestions
will assure a more satisfactory performance from the equipment.
2.2 UNPACKING AND INSPECTING EQUIPMENT
Exercise extreme caution when unpacking the equipment. Make a visual inspection of the equip-
ment for evidence of damage incurred during shipment. If a claim for damage is to be made, save
the shipping container to substantiate the claim. When all equipment is removed, replace all pack-
ing materials in the shipping container, for use in unit storage or reshipment.
2.3 EQUIPMENT INSTALLATION
2.3.1 GENERAL
The following paragraphs contain information pertaining to the initial installation of the CNI 5000
Integrated Radio Package, including instructions concerning the location and mounting of the sup-
porting antenna.
The equipment should be installed in the aircraft in a manner consistent with acceptable workman-
ship and engineering practices and in accordance with the instructions set forth in this publication.
To ensure that the system has been properly and safely installed in the aircraft, the installer should
make a thorough visual inspection and conduct an overall operational check of the system on the
ground prior to flight.

CAUTION
AFTER INSTALLATION OF THE CABLING
AND BEFORE INSTALLATION OF THE
EQUIPMENT, A CHECK SHOULD BE MADE
WITH THE AIRCRAFT PRIMARY POWER
SUPPLIED TO THE CONNECTOR TO EN-
SURE THAT POWER IS APPLIED ONLY TO
THE PINS SPECIFIED IN THE INTERCON-
NECT DIAGRAM, FIGURE 2-5.
The CNI 5000 system installation will conform to standards designated by the customer, installing
agency and existing conditions as to the unit location and type of installation. However, the fol-
lowing suggestions should be considered before installing your CNI 5000 system.

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2.3.2 AVIONICS COOLING REQUIREMENTS FOR PANEL MOUNTED EQUIPMENT

The greatest single contributor to increased reliability of all modern day avionics is to limit the max-
imum operating temperature of the individual units whether panel or remote mounted. While mod-
ern day individual circuit designs consume much less electrical energy, the watts per cubic inch
dissipated within avionics units remains much the same because of high density packaging tech-
niques utilized. Consequently, the importance of providing avionics stack cooling is essential to
the life span of the equipment.
Forced air cooling for the CNI 5000 is a requirement. It is required that the auxiliary cooling be
accomplished by the use of a KA 33 blower unit. Refer to the KA 33 installation manual for a de-
tailed discussion of the installation of the KA 33 and KA 12 units.
2.3.3 CNI 5000 INTERWIRING AND CABLE HARNESS FABRICATION
A. General
The CNI 5000 fans and the radios within the rack receives primary power from the
aircraft power source. Power connections, voltage requirements, circuit breaker
requirements are shown on the interconnect diagram Figure 2-5). For additional,
detailed interconnect information, see the individual installation manuals.
2.3.3.A Wire Length
The length of the wires to parallel pins should be approximately the same length, so that the best
distribution of current can be effected. BENDIX/KING recommends that all wires, including spares
as shown on the interconnect diagram be included in the fabrication of the wiring harness. How-
ever, if full wiring is not desired, the installer should ensure that the minimum wiring requirements
for the features and functions to be used be incorporated.
When cables are installed in the aircraft, they must be supported firmly enough to prevent move-
ment and should be carefully protected against chaffing. Additional protection should also be pro-
vided in all location where the cable may be subjected to abuse.
In wire bundles, the cabling should not be tied tightly together as this tends to increase the possi-
bility of noise pickup and similar interference. When routing cables through the aircraft the cables
should cross high level RF lines at right angles.
The following guidelines are recommended:

(1) The installing facility will supply and fabricate all external cables following the in-
structions provided as per the installation drawings. (See Figures 2-3 through 2-5).
The required connectors are supplied as part of the installation kit (P/N 050-0301
1 -OOXX).

(2) The CNI 5000 and the associated wiring harness must be kept a minimum of three
feet from the transceiver/receiver antenna coax and the termination connector of
the antenna to prevent RF interference from the antenna.

(3) Do not route the transceiver/receiver antenna coax near ADF sense or loop anten-
na cables.

(4) Internal wiring should be accomplished as per Figure 2-4 (P/N 155-0581 2-0000).

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2.3.3.B Molex Connector Assembly Procedure

The CNI 5000 wiring harness should be fabricated by crimping the connectors onto the wires. Re-
fer to instructions in Figure 2-1.

(1) Solderless Contact Terminal Assembly using Pliers

(a) Strip each wire 5/32 inches for contact terminal (P/N 030-01107-OOXX).
The last two digits of the contact terminal part number indicates the number
of terminals furnished.

(b) Tin the exposed conductor.

(c) Using needle nosed pliers, fold over each conductor tab, in turn, onto the
exposed conductor. When both tabs have been folded, firmly press the
tabs against the conductor.

(2) Solderless Contact Terminal Assembly using Molex Crimper (Figure 2-1)

(a) Strip each wire 5/32" for contact terminal (KPN 030-01107-OOXX). (The
last two digits of the contact terminal part number indicates the number of
terminals required).

(b) Open the Molex hand crimper HTR-6115 with the engraved side toward the
operator. Place the conductor tab section of a contact terminal on Anvil B
with the contact portion facing away from the operator. Close the crimper
slightly until the contact tabs touch the female jaw.

(c) Insert the stripped conductor until the insulation is even with the side of the
crimper facing the operator. Crimp the conductor tabs by squeezing the
handles together until the jaws are fully closed or a sufficient crimp is ob-
tained.

(d) Move the lead to Anvil A. Place the insulating tab section on Anvil A. Crimp
again until the jaws are fully closed or a sufficient crimp is obtained.

(3) Contact Insertion into Molex Connector Housing

(a) After the contact terminals have been installed on the wiring harness, the
contact terminal can be inserted into the proper location in the connector
housing (PN 030-01094-00XX). The terminal cannot be inserted upside
down. Be sure to push the terminal all the way in, until a click can be felt or
heard.

(b) The self locking feature can be testing by gently pulling on the wire.

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BENDIX/KING CNI 5000

(4) Extraction of Contact from Molex Connector

(a) Slip the flat narrow blade of a Molex contact ejector tool, HT-1884 (BEN-
DIX/KING PN 047-05099-0001), under the contact on the mating side of the
connector. By turning the connector upside down one can see the blade
slide to the stop.

(b) When the ejector is positioned against the stop the locking key of the con-
tact is raised, allowing the contact to be removed by pulling moderately on
the lead.

(c) Neither the contact or position is damaged by removing a contact; however,

the contact should be checked visually before reinstalling in connector, to
be certain that retaining tab “A” extend as shown (see FIGURE 2-1 CON-
TACT, CRIMPING TOOL, AND EXTRACTION TOOL) for retention in con-
nector.
-

FIGURE 2-1 CONTACT, CRIMPING TOOL, AND EXTRACTION TOOL

(Sheet 1 of 3)

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(Sheet 2 of 3)

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(Sheet 3 of 3)

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2.3.3.C Berg Connector Fabrication

To fabricate the Berg Connector wiring harness it is recommended that the installer
use a Berg Electronics Crimping Tool. The tool should be either of the following
model numbers: HT-208A or the HT-95. The Berg handtool HT-208A is preferred.

If the terminal and the tooling are not compatible, damage to the tooling or terminal
could result.

(1) Operating Procedures

CAUTION

TO PREVENT HAND INJURY, KEEP FINGER FROM

BETWEEN THE UPPER AND LOWER TOOLING
AND THE MOVABLE HANDLE WHEN CLOSING
HAND TOOL.
(a) Hold the hand tool in your left hand with the movable handle on the
left. With your left thumb, pivot the spring-loaded connector fixture
down at about a 45° angle (See FIGURE 2-2 INSERTING TERMI-
NAL FOR CRIMPING).

FIGURE 2-2 INSERTING TERMINAL FOR CRIMPING

(Sheet 1 of 3)

(b) With the “U”-shaped barrel up, place the disconnect (box) portion of
the terminal onto the wire stop, which extends from the slot in the
connector fixture. Push the terminal firmly against the shoulder of
the wire stop. This positions and hold terminal for crimping.

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BENDIX/KING CNI 5000

(c) Release your thumb from the connector fixture. The torsion spring
returns the fixture to the crimping position.

NOTE

The connector fixture lock helps to position the con-

nector fixture while crimping.

(d) Insert wire(s) with an insulation strip length of 0.150-0.170 in. into
the terminal with the end of the strands against the wire stop (See
Figure 2-2, Sheet 2). Holding wire in this position, close the hand
tool completely. This will crimp the terminal to the wire(s).

(Sheet 2 of 3)

(e) Release the handle to open the hand tool and remove the crimped
terminal from the connector fixture by lightly pulling straight out on
the wire.

(2) Terminal Inspection

The crimped terminal should be inspected to ensure that the tooling is cor-
rectly aligned and that the wire was correctly inserted. Make the following
visual checks:

• Check that all wire standard were crimped within the wire barrel.

• Check that the end of the wire insulation lies between the insulation
and wire barrel.

• Check that the bellmouth(s) were formed correctly.

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BENDIX/KING CNI 5000

• Check that the spring was no dislodged from the disconnect (box)
portion of the terminal.

• Check that the end of the wire strands form an angle not exceeding
approximately 45°.

• Check that the wire barrel seam is even and tightly closed.

(Sheet 3 of 3)

(3) Terminal insertion into Berg connector housing

(a) After the contact terminals have been installed on the wiring har-
ness, the connect terminals can be inserted into the proper location
in the connector housing (PN 030-03137-00XX). The terminal can-
not be inserted upside down. Be sure to push the terminal all the
way in, until a click can be felt or heard.

(b) The self locking feature can be tested by gently pulling on the wire.

(4) Extraction of Terminal from Berg Connector

(a) Turn the connector on side to expose the retention spring access
window. Slip the flat narrow blade of a scribe tool downward to de-
press the retaining spring.

(b) When the locking spring is depressed, the terminal can be removed
by pulling moderately on the lead.

(c) Neither the contact or position is damaged by removing a contact;

however, the contact should be checked visually before reinstalling
in connector, to be certain that retaining spring is not damaged.

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B CNI 5000

FIGURE 2-3 CNI 5000 INTEGRATED RADIO PACKAGE RACK OUTLINE AND MOUNTING
(Dwg No 155-05807-0000, Rev AB, Sheet 1 of 2)

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B CNI 5000

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FIGURE 2-3 CNI 5000 INTEGRATED RADIO PACKAGE RACK OUTLINE AND MOUNTING
(Sheet 2 of 2)

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B CNI 5000

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B CNI 5000

FIGURE 2-4 CNI 5000 INSTALLATION KIT DRAWING

(Dwg No 155-05812-0000, Rev AB, Sheet 1 of 1)

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B CNI 5000

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B CNI 5000

FIGURE 2-5 CNI 5000 INTERCONNECT DIAGRAM

(Dwg No 002-01031-0000, Rev AA, Sheet 1 of 1)

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2.3.4 EQUIPMENT LOCATION

Care should be exercised to avoid mounting components near equipment operating with high
pulse current or high power outputs such as radar and satellite communications equipment. In
general, the equipment should be installed in a location convenient for operation, inspection, and
maintenance, and in an area free from excessive vibration, heat, and noise generating sources.
All mechanical installation drawings, connector assembly diagrams, interwiring diagrams, and
connector pin assignments tables referenced in this section are located in this section of the man-
ual. Determine the mounting location for system components following the guidelines below.
Prior to installing any equipment, make a continuity check of all wires and cables associated with
the system. Then apply power and check for proper voltages at system connectors, and then re-
move power before completing the installation.
A. CNI 5000 Integrated Radio Package Rack Locations
The panel mounted CNI 5000 can be installed in any convenient location on the
panel that is free from excessive heat and vibration and which provides reasonable
access for inspection and maintenance. To achieve maximum performance, the
CNI 5000 should be installed adjacent to other receivers with similar functions.
To allow for inspection or repair of the wiring of the connector assemblies them-
selves sufficient lead length should be left should be left so that when the mounting
hardware for the side connectors and antenna coaxial cable is removed, the as-
sembly may be pulled forward several inches. In fact, it is recommended that a suf-
ficient length of wire be used to allow for a service loop. The specific installation
requirements will determine the final installation. Also a bend should be made in
the harness (at the rear connectors) to allow water droplets that might for on the
harness due to condensation, to drip off at the bend and not collect in the connec-
tion.
The length of cables from the CNI 5000 connectors to other system is not critical
because unit interfaces are design with high impedance inputs
Outline drawing FIGURE 2-3 CNI 5000 INTEGRATED RADIO PACKAGE RACK
OUTLINE AND MOUNTING shows CNI 5000 Integrated Radio Package Rack di-
mensions.
B. Cooling Blower
It is recommended that the KA 33 Cooling Blower/KA 12 Fan Sense Unit installa-
tion take place before installing the CNI 5000 Radio Package. Refer to the specific
manufacturers installation manual for detailed instructions.

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2.3.5 CNI 5000 INSTALLATION

The rack should be mounted using the dimensions specified in FIGURE 2-3 CNI 5000 INTE-
GRATED RADIO PACKAGE RACK OUTLINE AND MOUNTING. The Interconnect box PN 047-
09742-0010, should be wired according to the system installation kit FIGURE 2-4 CNI 5000 IN-
STALLATION KIT DRAWING and FIGURE 2-5 CNI 5000 INTERCONNECT DIAGRAM.
A. Cable Harness and Connector Assembly
The CNI 5000 users special connectors that mate directly with the printed circuit
board inside the individual units. Assembly the connectors using the procedure de-
scribed in paragraphs 2.3.3.B Molex Connector Assembly Procedure and 2.3.3.C
Berg Connector Fabrication
B. CNI 5000 Rack, Interconnect Box and Rear Cover Assembly
NOTE
ACCOMPLISH THE FOLLOWING BEFORE PERM-
ANTELY FASTENING THE RACK TO THE AIR-
CRAFT PANEL

Side connector wiring must be completed on the Interconnect Box, this includes
mounting the XPDR 1/2 toggle switch PN 031-00222-0008 and connector J201.
Refer to FIGURE 2-4 CNI 5000 INSTALLATION KIT DRAWING Detail P1 and B.
The rear cover assembly PN 200-05155-XXXX; plus the connector into the Fan
Sense PC board assembly PN 200-08519-0000 and using the three captive mount-
ing screws, attach to the rack PB 047-09753-0012.
Attach the house from the KA 33 cooling blower to the port.
The optional (external EEPROM board used by the KT 70/71 must be installed on
the Interconnect Box. Fasten the EEPROM board to the back of the Interconnect
box, such that when the KT 70/71 units is in position within the box, the smaller con-
nector JKT 702 will fit snugly into the optional EEPROM board’s connector.
(1) Remove the area specified on the outline and mounting
drawing (See FIGURE 2-3 CNI 5000 INTEGRATED RADIO
PACKAGE RACK OUTLINE AND MOUNTING) Care must
be taken to avoid damage to the adjacent equipment and ca-
bles.
(2) Make sure the front of the rack is in a vertical position and
slide the rack into the mounting cavity until the front lobes
touch the aircraft panel.
(3) Secure the rack to the aircraft panel using eight(8) #6 fasten-
ers (not provided). Install two(2) #8 fasteners at the bottom
rear of the rack.
(4) Reaching through the rack, grasp the interconnect box, align
and secure the Interconnect Box to the rack using eight(8)
captive screws.
(5) The CNI 5000 rack provides for some potential pin misalign-
ment. To insure the best possible fit of the individual radios,
it is recommended that the center fix(5) (Nav 1 and 2; Comm
2; and Xpdr 1) radios be installed first. Next, loosen the eight
fasteners (See Previous Paragraph) one half turn, that se-
cure the Interconnect Box to the rack. This action will allow
the radios inside the rack to “self align”. After the alignment

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BENDIX/KING CNI 5000

is complete tighten the eirght(8) fasteners and continue in-

serting the radios into the rack.
NOTE
All the radios are shipped with a protective bezel.
This bezel can be left on the radios until the final
steps of the installation. This bezel should be re-
tained for shipping or storage at some future date.

C. KY 196A
(1) Using the 3/32 Allen wrench, turn the locking pawl counter-
clockwise completely until the front lobe is in a vertical posi-
tion.
(2) Make sure the front of the radio is right side up and slide the
radio into the rack until the vertical front pawl contacts the
rack.
(3) Turn the 3/32 inch Allen wrench clockwise until the rear lobe
engages the mounting slot on the rack. Continue turn the
wrench clockwise until tight.

CAUTION
DO NOT OVERTIGHTEN THE LOCKING FAS-
TENR
(4) For removal, turn the 3/32 inch Allen wrench counterclock-
wise until the lobe disengages from the mounting slot, con-
tinue counterclockwise rotation until the unit disengages
from the connectors. The unit can now be pulled completely
out.
D. KN 53
(1) Using the 3/32 Allen wrench, turn the locking pawl counter-
clockwise completely until the front lobe is in a vertical posi-
tion.
(2) Make sure the front of the radio is right side up and slide the
radio into the rack until the vertical front pawl contacts the
rack.
(3) Turn the 3/32 inch Allen wrench clockwise until the rear lobe
engages the mounting slot on the rack. Continue turn the
wrench clockwise until tight.

CAUTION
DO NOT OVERTIGHTEN THE LOCKING FAS-
TENER
(4) For removal, turn the 3/32 inch Allen wrench counterclock-
wise until the lobe disengages from the mounting slot, con-
tinue counterclockwise rotation until the unit disengages
from the connectors. The unit can now be pulled completely
out.

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E. KR 87
(1) Using the 3/32 Allen wrench, turn the locking pawl counter-
clockwise complete until the front lobe is in a vertical posi-
tion.
(2) Make sure the front of the radio is right side up and slide the
radio into the rack until the vertical front pawl contacts the
rack.
(3) Turn the 3/32 Allen wrench clockwise until the rear lobe en-
gages the mounting slot on the rack. Continue turning the
wrench clockwise until tight.

CAUTION
DO NOT OVERTIGHTEN THE LOCKING FAS-
TENER
(4) For removal, turn the 3/32 inch Allen wrench counterclock-
wise until the lobe disengages from the mounting slot, con-
tinue counterclockwise rotation until the unit disengages
from the connectors. The unit can now be pulled completely
out.

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F. KT 70
The KT 70 is a transponder capable of Mode S replys. The KT 70 users the data
from the (external) EEPROM board kit when the (external) data EEPROM board kit
is installed, otherwise, it uses the data from the internal EEPROM.
The Mode S aircraft address and maximum airspeed data must be programmed
into the memory function of the KT 70 in order for the transponder to function. This
data must be programmed into either of the following:

Optional (external) Address EEPROM Board kit

or
Internal EEPROM

Programming the data into the optional (external) address EEPROM board kit is
preferred because this method allows units to be swapped from rack to rack with-
out having to reprogram the aircraft address or the maximum airspeed data.
The KT 70 uses the data from the (external) address EEPROM board kit when the
(external) address EEPROM board kit is installed, otherwise it uses the data from
the internal EEPROM.
NOTE
THE AIRCRAFT MODE S ADDRESS MUST BE OB-
TAINED FROM FAA AND PROGRAMMED INTO
THE KT 70 PRIOR TO INSTALLATION IN AIR-
CRAFT
AIRCRAFT MODE S ADDRESSES MAY BE OB-
TAINED BY CALLING THE FAAA AIRMAN AND
AIRCRAFT REGISTRY DIVISION AT (405)-680-
3116. IF THREE(3) OR MORE ADDRESSES ARE
NEEDED, WRITE TO AIRCRAFT REGISTRATION
BRANCH, ANV-450, P.O. BOX 25082, OKLAHOMA
CITY 73125

To program the aircraft address and/or the maximum air speed please refer to Sec-
tion 3.2.2.F.(2) of the KT 70 Installation Manual PN 006-00673-00XX

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G. KT 71
The KT 71 is an ATCRBS transponder which is not capable of Mode S replys.
These transponders can benefit from the convenience of having information exter-
nally stored. The KT 71 4096 code and certain ATCRBS specific information can
be stored externally.
Follow the previously described procedure to install the KT 70/71.
H. Front Panel Installation
(1) Align the unit push buttons and knobs with the holes in the
front panel. Make sure the pins of the front panel connector
engage and then fasten the lower right DZUS 1/4 turn fas-
tener.
NOTE
Do not force the panel and do not press on
the lenses!

(2) Make sure all buttons and knobs are in their respective holes
before tightening the remaining DZUS fasteners.
(3) After the panel is secure check for proper operation of all
knobs and buttons. Make sure knobs do not drag on the
panel.
(4) Make sure that all the ON/OFF knobs are in the OFF posi-
tion.

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2.4 POST INSTALLATION TEST PROCEDURE

2.4.1 SYSTEM CHECKOUT
The post-installation test is user to apply power and functionally checkout the system. Successful
completion of the post-installation test verifies the proper operation of the CNI 5000 Integrated Ra-
dio Package Rack System.
TABLE 2-1 INSPECTION/CHECK PROCEDURE is a visual inspection/check procedure that
should be performed after system installation as part of a system checkout. A post-installation test
per paragraph 2.4.1.B should be performed. In addition, the procedure should be used as a peri-
odic maintenance inspection check.

EQUIPMENT INSPECTION/CHECK PROCEDURE

CNI 5000 A. Inspect external surface for
damage
B. Check that the unit is securely
installed and that retaining
mechanism is securely tight-
ened.
C. Ensure that all connections in
the rack are properly mounted
and secure.
Antennas A. Inspect external surfaces for
damage
B. Check that the antenna is prop-
erly installed and the mounting
screws are securely tightened.
C. Ensure that antenna coaxial
cable connectors are properly
mated and secure.

TABLE 2-1 INSPECTION/CHECK PROCEDURE

A. Inspection
Perform the following inspection on the overall system:
(1) Check that cables do not interfere with aircraft controls or
other equipment.
(2) Check cabling for proper routing and check security of tie-
down points. Inspect and adjust cable runs to ensure that
cables are not strained, kinked, or severely twisted and are
not exposed to rough or sharp surfaces.

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B. Post-Installation Test/Operation
(1) General
Installation of the integrated system requires three stages of
testing to ensure the proper operation of the CNI 5000. Ini-
tially, prior to the installation, a system interwiring check
should be performed. This check verifies that the aircraft
and all CNI 5000 interconnections are correct, before power
is applied. After the units are installed a visual inspection of
the equipment and connections is made. A post-installation
test contained within this manual should then be performed
along with the post-installation test within individual mainte-
nance manuals.
(2) System Interwiring Check
To check the aircraft and rack system interconnections pro-
ceed as follows.
(a) Check that all cables and interwiring are installed in accor-
dance with the interwiring and Cable Harness Fabrication in-
struction instructions (Paragraph 2.3.3 CNI 5000 INTER-
WIRING AND CABLE HARNESS FABRICATION)
(b) Using the interconnect diagram (See FIGURE 2-5 CNI 5000
INTERCONNECT DIAGRAM) and individual unit installation
drawings from their respective installation manuals, check
wiring for proper destination, opens, and shorts.
(c) Check RF cables for insertion, loss, VSWR.
(3) Visual Inspection
In conjunction with system installation

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BENDIX/KING CNI 5000

(4) Post-Installation Test

The Post-Installation Test verifies the proper operation of
the CNI 5000 Integrated Radio Package Rack System. This
procedure is used after the system units have been installed
and thereafter as an operational check. This procedure is
comprised of a pretest setup, a pre-flight turn on and a visual
inspection. The following tests and check are performed on
the ground.
(a) Pretest Setup
1 Check CNI 5000 system source power as follows:
a Confirm that aircraft +28V dc is operational.
b Confirm that the aircraft panel background
lighting power source is operational by ad-
justing the cockpit dimmer switch for proper
cockpit panel illumination.
2 Operate appropriate aircraft circuit breakers and
switches to apply power to the system as follows:
a Apply +28VDC to the CNI 5000.
b Apply primary power inputs to all interfaces
with the rack per the system configuration.
3 Verify that all CNI 5000 circuit breakers are closed.
4 Allow one minute for warm-up.
(b) Pre-Flight Turn On Test
1 Rotate the ON knobs clockwise from the OFF posi-
tion.
2 Verify that window displays
3 The individual units have adjustable gas discharge
display lighting, therefore, adjust their illumination
level to the reference of the other radios in the panel.
(c) Conformity Inspection
Visually inspect the installed equipment to determine the
use of acceptable workmanship and engineering practices.
Verify that all mechanical and electrical connections have
been make properly

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2.4.2 POST INSTALLATION CHECK

An operation performance flight test is recommended after the installation is completed to insure
satisfactory performance of the equipment in its normal environment. Check all aircraft control
movements to be sure no electrical cables interfere with their operation.

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SECTION III
OPERATION

3.1 GENERAL
The CNI 5000 is an Integrated Avionics System. The integrated design of the CNI 5000 provides
the pilot with full-featured COMM/NAV/IDENT capability in a single unit.
All controls required to operate the CNI 5000 are located on the unit front panel. (See FIGURE 3-
1 FRONT PANEL DISPLAY/CONTROLS)

Freq Transfer Freq

"flip-flop" button Selector
Knob

ON/OFF Volume
control switch.
Pull out for
manual squelch
override.
Fan failure
annunciation
lamps
Frequency
Select Knobs
ON/OFF/VOL
control switch
ADF, BFO, FRQ (pull out for
ET/RT, SET/RST ident tone)

ON/OFF/VOL
control switch

Ident
button

4096 code
selector knobs

Function Select
(push for VFR
code)

FIGURE 3-1 FRONT PANEL DISPLAY/CONTROLS

(Sheet 1 of 1)

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3.2 DETAILED OPERATING MODES

3.2.1 TURN ON
NOTE
All information in this manual is always superseded
by the latest engineering software and hardware
documentation.

To turn on the unit, rotate the ON knob clockwise from the OFF position. When power is activated,
the windows will display the frequencies stored in the non-volatile memory before power down.
On power up, the fail lamps will briefly illuminate, then extinguish. The top (FAN 1) lamp monitors
the status of the two rack cooling fans and the bottom (FAN2) lamp monitors the status of the KA
33 auxiliary blower via the KA 12. If the annunciation lamp continues to illuminate, a failure condi-
tion exists.

CAUTION
THE CNI 5000 UNITS SHOULD BE TURNED
ON ONLY AFTER ENGINE STARTUP.
THIS IS A SIMPLE PRECAUTION WHICH
HELPS PROTECT THE SOLID STATE CIR-
CUITRY AND EXTENDS THE OPERATING
LIFE OF YOUR AVIONICS EQUIPMENT. THE
UNITS SHOULD BE TURNED OFF BEFORE
ENGINE SHUTDOWN.
NOTE
A Pilot’s Guide (P/N 006-08480-0000) supplied by
Honeywell describes the CNI 5000 operation in full
detail.

NOTE
Refer to the individual installation manuals (refer to
Section 1.7) for a detailed explanation of the opera-
tion of each unit within the Integrated Radio Pack-
age.

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B CNI 5000

SECTION IV
THEORY OF OPERATION
4.1 GENERAL
The CNI 5000 is a package of radios integrated into a panel mounted unit. The integrated unit
provides voice communication over the AM band of frequencies (COMM); reception and process-
ing of radio navigation signals (NAV); equipment to determine an aircraft's position relative to a
fixed reference point (ADF); transceivers which automatically transmits specific ident-code pulsed
signals upon reception of properly-coded interrogation pulses from another source (TPDR).
Detailed theory of operation for the specific units within the integrated package are discussed in
the individual maintenance manuals listed in paragraph 1.7 RELATED PUBLICATIONS of this
manual. The theory of operation detailed here only pertains to Fan Sense Board P/N 200-08519-
0000. No detailed theory for the Light Board Assembly P/N 002-08486-0000 will be discussed.
Only a general discussion will be included.
The PCB Fan Sense Board in the CNI 5000 checks for proper operation of the cooling fans. The
fans are located in the back of the rack. The same circuitry also provides status monitoring for the
auxiliary blower (KA 33 or equivalent). Circuitry on the board furnishes voltage to illuminate an
annunciator on the Front Panel of the CNI 5000. The annunciators indicate the status of the fans
and are illuminated to indicate a failed condition. Monitoring circuitry checks for ac signal compo-
nents produced on the power supply line by the fans on the power supply line caused by the DC
fans switching between coils to turn the fan blades. A FAN_LIGHT_TEST test point pin is provid-
ed for checking the operation of the light bulbs. The pin should be connected to the switched, Re-
mote Test ground line.
The Lighting Board contains the FAN ANNUNCIATION lamps and the lighting required for the in-
dividual radios.

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B CNI 5000

4.2 DETAILED CIRCUIT THEORY

Reference schematics are P/N 002-08519-0000, P/N 002-01031-0000 and P/N 002-08486-0000;
Reference Circuit Board Component Layout drawings are P/N 300-08519-0000 and P/N 300-
08486-0000. Diodes CR7 through CR13 are used to Wire-OR the power to the fans. The individ-
ual units, within the rack, are wired using separate circuit breakers. This configuration is required
so that when any one of the units in the rack is turned "ON" the fans are running and the fan sense
circuit will be active.
The low pass filter, R25 and C3, is a low pass filter used to attenuate any transients on the power
supply line.
The emitter follower arrangement of Q1 and Q2 is used to regulate the voltage going to the fans
and protect them from voltages on the power supply lines. The voltage is set by biasing networks
of R1, CR1; and R13, CR4.
The resistor inline with the fans (R2 and R14) are used in conjunction with transistors Q2 and Q8
to sense the ac signal components produced on the power supply line caused by the fans. A spike
on the line caused by the fans will turn on transistors Q2 and Q8 producing a square waveform at
the junction of R4 and R16. Capacitors C1 and C2 are used to decouple the sensing section of
the circuit from the sample and hold section of the circuit.
The diode combinations CR3, CR2, and CR6, CR5 in conjunction with capacitors C4 and C5 re-
spectively, rectify and hold the voltage produced by the square wave produced by the preceding
section. Transistors Q3 and Q9 are emitter followers used to isolate the voltage holding circuits
from the last section (the emitter coupled binary pairs).
The transistors Q4, Q5, Q10, and Q11 make up the emitter coupled binary pairs. When the fans
are running Q4 and Q10 will be turned on which in turn will keep transistors Q5 and Q11 turned off.
When the fans are not running Q4 and Q10 will be off and consequently Q5 and Q11 will be on
which bias Q6 and Q12 on and apply voltage to the lights.
The FAN_LIGHT_TEST has been added to test the operation of the light bulbs. When the
FAN_LIGHT_TEST pin is grounded Q6 and Q12 will be biased on and will turn the light bulbs on.
FIGURE 4-1 FAN SENSE CIRCUIT, DETAILED BLOCK DIAGRAM is block diagram of the circuit-
ry in the Fan_Sense_Board.

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B CNI 5000

FIGURE 4-1 FAN SENSE CIRCUIT, DETAILED BLOCK DIAGRAM

(Sheet 1 of 1)

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B CNI 5000

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SECTION V
MAINTENANCE
5.1 INTRODUCTION
The maintenance section contains testing and maintenance procedures for an operational
CNI 5000. The CNI 5000 contains no adjustable mechanical or electrical components. Therefore,
no alignment is required. The fans should be replaced as complete modules. The serviceable PC
boards are the Fan Sense PC Board Assembly P/N 200-08519-0000 and the Light Board Assem-
bly P/N 200-08486-0000. This section also contains testing and troubleshooting and assembly/
disassembly procedures. Before maintenance is attempted it is advisable to have thorough un-
derstanding of the theory of operation of the unit.
5.2 TEST
5.2.1 TEST EQUIPMENT REQUIRED
This section contains information on special tools, fixtures, and test equipment used to test, trou-
bleshoot, and repair the CNI 5000.
The following is a listing the test equipment required to perform the testing and troubleshooting
procedures described in this manual. Equipment other than that listed can be substituted if the
characteristics fulfill those required.

A. CNI 5000 test harness.

B. Fluke 8000A digital multimeter.

C. Trygon Electronics HR40-7.5B, 14-28 V dc, 4 A, power supply.

Refer to FIGURE 5-1 CNI 5000, TEST SETUP DIAGRAM for information on test equipment re-
quired for testing and troubleshooting the CNI 5000. In the following paragraphs, the common
name for the test equipment is followed by a number in parentheses. This number refers to item
numbers in FIGURE 5-1 CNI 5000, TEST SETUP DIAGRAM.

FIGURE 5-1 CNI 5000, TEST SETUP DIAGRAM

(Sheet 1 of 1)

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BENDIX/KING CNI 5000

5.2.2 TESTING AND TROUBLESHOOTING

This section of the manual contains instructions for functional testing and troubleshooting the
CNI 5000. In general, entry into "Troubleshooting Procedure" paragraph 5.2.4 is from "Functional
Test Procedure" Paragraph 5.2.3. The test equipment should, therfore, have been properly turned
on prior to entry into the "Troubleshooting Procedure". If it is desired to recheck the test equipment
or setup, refer to paragraph (3) of the "Functional Test Procedure" of this manual for the proce-
dures.
The functional test is a cover-on test performed to determine the operational status of
the CNI 5000. The procedures are used after troubleshooting, or a module or component has
been replaced.
5.2.3 FUNCTIONAL TEST PROCEDURE
A. General
The purpose of functional testing, a cover-on test, is to determine the operational
status of the CNI 5000. Functional test procedures are provided for a Return to
Service condition.
If an in-service unit tests within the acceptable limits given in this test procedure,
no further testing is required and the unit should be considered suitable for instal-
lation in an aircraft. If the unit fails any portion of the functional test, proceed to
paragraph 5.2.5 of this section for fault isolation. In general, after fault repair, the
unit should be tested again to make sure that it meets the performance criteria.

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BENDIX/KING CNI 5000

B. Minimum Performance Test Procedures for In-Service Field Units

(1) General
This paragraph contains functional test procedures which specify
the minimum performance limits within which an existing field ser-
vice unit shall meet and still be suitable for installation in an aircraft.
As such, this test procedure may be used to bench test a unit which
has been removed from an aircraft.
(2) CNI 5000 Test System Operating Instructions
This paragraph contains information pertaining to the test equip-
ment required to test the CNI 5000. For additional test equipment
information refer to test equipment manufacturer's publications.
(a) Initial Setup
To initially setup the test system refer to FIGURE 5-1 CNI 5000,
TEST SETUP DIAGRAM and proceed as follows:
1) Ensure all plugs and cables are secure and connected as
shown in Figure 5-1.
2) Allow a short warm up for the unit under test and the test
equipment.
(b) Turn-on/Turn-off
1) Turn-on
To turn the CNI 5000 test system on, proceed as follows:
On CNI 5000 test harness (Power Supply (2)), place ON/
OFF power switch ON.
Verify POWER indicator is illuminated.
(c) Turn-off
To turn the CNI 5000 test system off, proceed as follows:
On the CNI 5000 test harness (Power Supply (2)) place ON/OFF
POWER switch OFF.
(3) ON/OFF and Display Check Function
(a) One by one turn the individual ON/OFF switches to the ON
position.
When power is initially applied to the CNI 5000 the Fan An-
nunciator Lights will illuminate temporarily until the fans
come up to speed and then extinguish.
(b) Check that the Fan Annunciator Lights are extinguished.
(c) Check that all the displays on the individual units are illumi-
nated.

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(4) Fan Sense Circuit Check

(a) Apply power to the individual units as per the interconnect
diagram.
(b) Turn ON any unit/s to activate the fans.
(c) By some means stop the blade of one of the fans. (Pencil
tip eraser)
(d) Check for the annunciator lamp to be illuminated or for more
than 20Vdc on pin 1/2.
(5) KA 12 Fan Sense Unit Check
(a) Attach the Test Harness to the board. (Refer to Figure 5-1).
(b) Apply power by closing switch/s (S1-S8).
(c) By some means stop the blade of one fan.
(d) Check for illumination of the test lamp on pin 1.
(e) Check for more than +20vdc on pin 2. This will serve as an
emulation of a KA 33 failure.
Refer to individual maintenance manuals for detailed tests.

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BENDIX/KING CNI 5000

5.2.4 TROUBLESHOOTING PROCEDURES

A. General
Troubleshooting information for the CNI 5000 is mainly contained in troubleshoot-
ing procedures.
The troubleshooting procedures are for use as deemed necessary, when ever a
unit fails to meet the performance requirements of the functional test procedure in
the Testing paragraphs of this section. Testing procedures are to be used after a
problem has been isolated by the use of the troubleshooting flow charts, and/or
other troubleshooting techniques, and to return levels to customer specification.

CAUTION
THIS EQUIPMENT CONTAINS ELECTRO-
STATIC DISCHARGE SENSITIVE (ESDS) DE-
VICES. EQUIPMENT MODULES AND ESDS
DEVICES MUST BE HANDLED IN ACCOR-
DANCE WITH SPECIAL ESDS HANDLING
PROCEDURES.
B. Test Setup
(1) Refer to paragraph 5.3.4 of this manual for information on test
equipment required for testing this unit. In the following paragraphs,
the common name for the test equipment used is followed by a
number in parentheses. This number refers to the item number in
FIGURE 5-1 CNI 5000, TEST SETUP DIAGRAM.
(2) Preliminary Test Equipment Checkout, Test Setup, and Turn On.
In general, entry into the troubleshooting procedures is from the
Testing paragraph. The test equipment should have been properly
checked out, setup, and turned on prior to entry into troubleshoot-
ing. To recheck the test equipment or setup, refer to paragraph
5.2.2 in this section for the procedures.
C. Troubleshooting Procedures
The correct troubleshooting procedure is determined by the type of failure in the
functional test procedure. A troubleshooting flow chart or similar detailed trouble-
shooting procedures should be used. This method provides general guidelines for
locating fault. The technicians should then use traditional troubleshooting methods
to isolate to the component level. Schematic diagrams and theory of operation are
provided to assist troubleshooting to the component level.
After the faulty area is isolated by the troubleshooting procedure, and repair is
made, the unit should be retested using the functional test procedure in the Testing
paragraphs of this manual.

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BENDIX/KING CNI 5000

D. Troubleshooting Flowcharts
FIGURE 5-2 EXPLANATION AND EXAMPLE OF TEST PROCEDURE FLOW
CHART SYMBOLS explains the use of flow chart symbols an example of a flow
chart procedure. FIGURE 5-3 TROUBLESHOOTING FLOW CHART(General)
and FIGURE 5-4 TROUBLESHOOTING FLOW CHART(Fan Sense Board) pro-
vides a flow chart procedure for fault isolation to a likely circuit module.
The test setup and test equipment required for troubleshooting are given in Figure
5-1. The initial test conditions for troubleshooting are specified at the beginning of
the functional test procedure (paragraph 5.2.2.3 of this section). The flow chart
troubleshooting procedure of FIGURE 5-3 TROUBLESHOOTING FLOW
CHART(General) and/or FIGURE 5-4 TROUBLESHOOTING FLOW CHART(Fan
Sense Board) is begun when either the CNI 5000 unit fails any part of the functional
test or the fault annunciator display on the front panel.
If the CNI 5000 under test contains more than one fault, the fault with the highest
priority should be corrected. When that fault has been corrected, return to sheet
one of the troubleshooting procedure. The next highest priority should then be cor-
rected. The newly displayed fault is isolated by using the appropriate branch of the
flow chart. After all the faulty circuit modules have been repaired and reinserted,
the functional test should be performed to assure the CNI 5000 is operating satis-
factorily.

CAUTION
TURN OFF POWER BEFORE MAKING ANY
DISCONNECTIONS OR CONNECTIONS AND
BEFORE REMOVING OR REINSERTING PC
MODULES.

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BENDIX/KING CNI 5000

FIGURE 5-2 EXPLANATION AND EXAMPLE OF TEST PROCEDURE FLOW CHART SYM-
BOLS
(Sheet 1 of 2)

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BENDIX/KING CNI 5000

FIGURE 5-2 EXPLANATION AND EXAMPLE OF TEST PROCEDURE FLOW CHART SYM-
BOLS
(Sheet 2 of 2)

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BENDIX/KING CNI 5000

FIGURE 5-3 TROUBLESHOOTING FLOW CHART(General)

(Sheet 1 of 1)

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BENDIX/KING CNI 5000

FIGURE 5-4 TROUBLESHOOTING FLOW CHART(Fan Sense Board)

(Sheet 1 of 1)

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BENDIX/KING CNI 5000

5.3 OVERHAUL
This section of the manual contains instruction on the overhaul of the CNI 5000. The overhaul of
the unit consists of a variety of considerations and are discussed within this section.
5.3.1 DISASSEMBLY
A. General
This section contains information for disassembly of the CNI 5000. Disassembly
procedures are to be accomplished only when repairs or modifications are re-
quired, and only to the extent that is required by the repair, or as described in the
modification service bulletin. This section contains the recommended procedures
for removal of all subassemblies. Refer to the Illustrated Parts List (IPL) for aid in
disassembly. Part numbers are used in the IPL drawings to identify specific parts.
Complete disassembly should never be undertaken. Provisions have been made
in the design of the unit to make complete disassembly unnecessary except to re-
place a damaged mechanical part that cannot be reached otherwise.

WARNING
REMOVE ALL POWER FROM THE UNIT BE-
FORE DISASSEMBLY OF ANY MODULE. BE-
SIDES BEING DANGEROUS TO LIFE, VOLT-
AGE TRANSIENTS CAN CAUSE CONSIDER-
ABLE DAMAGE TO THE EQUIPMENT.

CAUTION
EXERCISE EXTREME CARE WHEN DISCON-
NECTING AND RECONNECTING THE MULTI-
PLE PIN CONNECTORS TO ENSURE THAT
THE CONNECTORS ARE NOT DAMAGED BY
MISALIGNMENT OF THE PINS.

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BENDIX/KING CNI 5000

B. Recommended Disassembly Procedures

NOTE
View unit from front for determining left and right
sides. Tag, or by some means, identify all discon-
nected wires or coaxial cables.

(1) Removal and Disassembly of Front Panel Assembly (Refer to draw-

ing numbers 300-05140-00XX, 155-05812-0000, and 300-05197-
0000).
(a) Rotate six captive DZUS fasteners securing the Front Panel As-
sembly (200-05140-00XX) to the Rack Assembly (047-09753-
0012).
(b) Gently rock Front Panel Assembly (200-05140-00XX) from top to
bottom while pulling straight outward. This action will cause sepa-
ration of light board assembly PC board connector pins (P201) from
contacts within connector hood.

(2) Removal and Disassembly of Light Board (Refer to drawing num-

bers 300-05140-00XX and 300-08486-0000)
(a) Lay the Front Panel Assembly face down and remove 14 fasteners
(089-05899-0003); two fasteners (089-05899-0000) with washers
(089-08023-0030) and buttons (088-03022-0003); securing Light
Board (200-08486-0000) to Front Panel (088-02582-0002).
(b) Lift and remove light board.
(3) Individual Units
(a) Locate 3/32" Allen screw on the Hold Down Assembly and turn
counterclockwise until front cam is approximately 90° (vertical),
continue counterclockwise rotation until unit disengages from con-
nector.
(b) Slide unit(s) straight out of rack.
(4) Removal and Disassembly of Rack (Refer to drawing numbers 155-
05812-0000 and 300-05197-0000)
(a) Rotate eight captive fasteners.
(b) Separate the Rack (047-09753-0012) from the Interconnect Box
(047-09742-0010).
(5) Removal and Disassembly of Rear Cover Assembly (Refer to draw-
ing numbers 155-05812-0000, 300-05197-0000 and 300-05155-
0000)
(a) Rotate three captive fasteners securing the Rear Cover Assembly
200-05155-0000 to Interconnect Box (047-09742-0010).
(b) Lift and slide rear cover out from under retaining lip of Interconnect
Box.
(c) Disconnect wiring harness connector from Fan Sense board.

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BENDIX/KING CNI 5000

(6) Removal and Disassembly of Fan Sense Board (Refer to drawing numbers 300-
05197-0000, 300-05155-0000, and 300-08519-0000)
(a) Refer to paragraph (5) steps (a) through (c).
(b) Remove four fasteners (089-05878-0004) securing Fan Sense
Board (200-08519-0000) to standoffs (076-000253-0002).
(c) Unsolder the following: E1 Fan 1 ground (black wire); E2 Fan 1 pow-
er (red wire); E3 Fan 2 ground (black wire); E4 Fan 2 power (red
wire).
(7) Removal and Disassembly of Fans (Refer to drawing number 300-05155-0000)
(a) Refer to paragraph (6) step (a) and (c).
(b) Remove eight (089-05878-0004) fasteners with captive lock wash-
ers securing Fans 1 and 2 to Rear Cover (047-09777-0002).
(8) Removal and Disassembly of Interconnect Box (Refer to drawing numbers 300-
05812-0000 and 300-05197-0000)
(a) Rotate eight captive fasteners securing Interconnect Box (047-
09742-0010) to Rack Assembly 047-09753-0012).
(b) Remove three fasteners (089-06008-0004) securing Cable Clamp
(047-098957-0001) to Interconnect Box.
(c) Remove three (091-00015-0007) one (091-00015-0006) rubber
grommets.
(d) Remove 14 fasteners (089-05903-0007) securing connectors:
1P196A and 2P196A; 1P532 and 2P532; P872; 1JKT701 and
2JKT701; P1; J201 to rack.
(e) Remove nine snap rings (090-00019-0007) securing coaxial con-
nectors (030-00101-0002 or 030-00102-0001) with hardware (089-
08168-0002 and 089-08252-0030) to Interconnect Box.
(f) Remove two fasteners (089-06004-0012) and (089-02185-0022)
securing XPNDR 1/2 Switch (031-00222-008) to rack.
(g) Remove the hose from the external auxiliary blower.
(9) KT 70/71 External EEPROM Board Assembly Removal and Disassembly (Refer to
drawing numbers 300-05812-0000 and 300-08334-0000)
(a) Refer to paragraphs (1) through (8).
(b) Remove two fasteners (089-05903-0007) securing EEPROM board
(200-08334-0000) to Interconnect Box (047-09742-0010).

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BENDIX/KING CNI 5000

5.3.2 CLEANING
A. General
This section contains information to aid in the cleaning of the component parts and
subassemblies of the CNI-5000 Integrated Radio Package.

WARNING
GOGGLES ARE TO BE WORN WHEN USING
PRESSURIZED AIR TO BLOW DUST AND
DIRT FROM EQUIPMENT. ALL PERSONNEL
SHOULD BE WARNED AWAY FROM THE IM-
MEDIATE AREA.
WARNING
OPERATIONS INVOLVING THE USE OF A
CLEANING SOLVENT SHOULD BE PER-
FORMED UNDER A VENTILATED HOOD.
AVOID BREATHING SOLVENT VAPOR AND
FUMES; AVOID CONTINUOUS CONTACT
WITH THE SOLVENT.
B. Recommended Cleaning Agents
Figure 5-5 lists the recommended cleaning agents to be used during overhaul of
the CNI-5000.
NOTE
Equivalent substitutes may be used for listed clean-
ing agents.

TYPE USED TO CLEAN

Denatured Alcohol Exterior Surfaces
Isopropyl Alcohol or as listed in 5.3.2.C.(2) Interior Surfaces

TABLE 5-1 RECOMMENDED CLEANING AGENTS

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BENDIX/KING CNI 5000

C. Recommended Cleaning Procedures

(1) Exterior
(a) Wipe front panel with a lint-free cloth dampened with denatured al-
cohol.
(b) Use a clean camel-hair brush saturated with denatured alcohol to
remove any foreign matter from the rear connector.
(c) If necessary, open any blocked ventilation holes by first saturating
the debris clogging the apertures with denatured alcohol and then
blowing the loosened material out with an air stream.
(2) Interior

CAUTION
ALUMINUM ELECTROLYTIC CAPACITORS
CAN BE DAMAGED BY HALOGENATED HY-
DROCARBON SOLVENTS. BENDIX/KING
RECOMMENDS "ISOPROPYL ALCOHOL" AS
A SAFE CLEANING SOLVENT FOR PRINTED
CIRCUIT BOARDS CONTAINING ALUMINUM
ELECTROLYTIC CAPACITORS. OTHER SOL-
VENTS WHICH MAY BE USED ARE AS FOL-
LOWS:
SAFE SOLVENTS
XYLENE
METHYL ALCOHOL
ETHYL ALCOHOL
PROPYYL ALCOHOL
BUTYL ALCOHOL
CALGONITE (DETERGENT)

PRINTED CIRCUIT BOARDS CONTAINING ALUMINUM ELECTROLYTIC CAPACITORS

SHALL NOT BE CLEANED WITH THE FOLLOWING SOLVENTS:
FREON TF, IMC
TRICHLOROETHANE
CARBON TETRACHLORIDE
ALL ™(DETERGENT)
CHLOROFORM
METHYLENE CHLORIDE
TRICHLOROETHYLENE

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BENDIX/KING CNI 5000

Remove each module subassembly. Then remove any foreign matter from the casting.
(a) Casting covers and shields should be cleaned as follows:
1) Remove surface grease with a lint-free cloth.
2) Blow dust from surfaces, holes, and recesses using an air stream.
3) If necessary use a solvent, and scrub until clean, working over all
surfaces and into all holes and recesses with a suitable non-metallic
brush.
4) Position the part to dry so the solvent is not trapped in holes or re-
cesses. Use an air stream to blow out any trapped solvent.
5) When thoroughly clean, touch up any minor damage to the finish.
(b) Assemblies containing resistors, capacitors, rf coils, inductors, transformers, and
other wired parts should be cleaned as follows:

CAUTION
AVOID AIR-BLASTING SMALL TUNING COILS
AND OTHER DELICATE PARTS.
1 Remove dust and dirt from all surfaces, including all parts and wir-
ing, using soft-bristled brushes in conjunction with air stream.

CAUTION
SOLVENT SHOULD NOT BE USED TO
CLEAN COMPONENTS, COUPLERS, BUSH-
INGS OF NYLON, OR RUBBER GROMMETS.
CLEAN THESE ITEMS USING A WASHING
BATH OF LIQUID DETERGENT AND WATER.

EXCESS CLEANING SOLVENT MUST NOT

BE PERMITTED TO ACCUMULATE IN ANY
OF THE ADJUSTMENT SCREW CREVICES
AND THUS SOFTEN OR DISSOLVE THE AD-
JUSTMENT SCREW OR ITS SEALANT.
2 Any dirt that cannot be removed in this way should be removed with
a brush (not synthetic) saturated with an approved solvent such as
mentioned above. Use of a clean, dry, compressed air stream (25
to 28 psi) is recommended to remove any excess solvent.

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BENDIX/KING CNI 5000

5.3.3 CHECK
A. General
This section provides instructions and information to perform a visual inspection of
the CNI-5000 Integrated Radio Package.
B. Inspection Procedures
(1) Rack/Sheetmetal
Inspect the srack/sheetmetal for dents, deformation, or damage to
the finish that should be repaired.
(2) Front Panel
Check that name, serial, and any plates or stickers are secure and
hardware is tight.
(3) Chassis
Inspect the chassis for loose or missing mounting hardware, defor-
mation, dents, damaged fasteners, or damaged connectors. In ad-
dition, check for corrosion or damage to the finish that should be re-
paired.
(4) Circuit Boards
Inspect for loose, broken, or corroded terminal connections; insuffi-
cient solder or improper bonding; fungus, mold, or other deposits;
and damage such as cracks, burns, or charred track.
(5) Connectors
Inspect the connector bodies for broken parts, check the insulation
for cracks, and check the contacts for damage, misalignment, cor-
rosion, or bad plating. Check for broken, loose, or poorly soldered
connections to the terminals of the connectors. Inspect connector
hoods and cable clamps for crimped wires.
(6) Terminal Connections
Inspect for corrosions or loose connections.
(7) Wiring
Inspect the wiring of the chassis and subassemblies for any signs
of physical damage or charring.
(8) Capacitors
Inspect capacitors for case or body damage and for loose, broken,
or corroded terminal connections.
(9) Resistors and Diodes
Inspect for blistered, charred, or cracked bodies; also check for
loose, broken, or corroded terminal connections.
(10) Filters and Inductors
Inspect for damage to body or casting and for loose, broken, or cor-
roded terminal connections. Check for secure mounting to chassis.
(11) Transformers
Inspect for damage to case and for signs of excessive heating; also,
check for loose, broken, or corroded terminal connections.

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BENDIX/KING CNI 5000

(12) Transistors and Integrated Circuits

Inspect for damage to body or casing and for secure and appropri-
ate attachment to their respective sockets.
(13) Terminal Connections, Soldered
(a) Inspect for cold soldered or resin joints. Bad joints can be recog-
nized by a dull porous appearance.
(b) Check for excessive solder, insufficient solder, or solder splashes
resulting from previous repair.
(c) Check for corrosion at the terminal connections.
(14) Rotary Switches
Check for proper mechanical operation: no binding or looseness
should be evidenced.
(15) Printed Circuit Boards
Inspect for loose, broken or corroded terminal connections and
damage; such as cracks, burns, or charred track. In addition, check
for insufficient solder, proper bonding, fungus, mold or other depos-
its that should be repaired.
(16) Coaxial Interconnections
Check for physical damage, charring, and loose connections.
(17) Hardware and Metal Parts
Inspect for bent, warped, or corroded parts; check plating, painting,
and identification stencils. Check also for exposed or scarred sur-
faces.
(18) Insulators
Inspect for looseness and/or evidence of damage such as burned
areas, cracks, and broken or chipped edges.

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BENDIX/KING CNI 5000

5.3.4 REPAIR
A. General
This section contains information required to perform limited repairs on the CNI-
5000 Integrated Radio Package. The repair or replacement of damaged parts in
airborne electronic equipment usually involves standard service techniques. In
most cases, examination of drawings and equipment reveals several approaches
to perform a repair. However, certain repairs demand following an exact repair se-
quence to ensure proper operation of the equipment.
After correcting a malfunction in any section of the unit, it is recommended that a
repetition of the functional test of the unit be performed.

CAUTION
THIS EQUIPMENT CONTAINS ELECTRO-
STATIC DISCHARGE SENSITIVE (ESDS) DE-
VICES. ALL MODULES CONTAINING ESDS
DEVICES ARE FLAGGED OR IDENTIFIED ON
SCHEMATICS AND ASSEMBLY ILLUSTRA-
TIONS, AND ARE INDIVIDUALLY IDENTIFIED
IN THE PARTS LIST. ALL ESDS DEVICES
MUST BE HANDLED IN ACCORDANCE WITH
PROCEDURES OUTLINED IN THE REPAIR
SECTION OF THIS MANUAL.

ESDS DEVICES INCLUDE, BUT ARE NOT

LIMITED TO, C-MOS, J-MOS, PMOS, NMOS,
SOCMOS, HMOS, MOS/FET, MICROWAVE
MIXER DIODES, SOME BIPOLAR DEVICES,
AND SOME METAL FILM RESISTORS.

MOST DAMAGE TO ESDS DEVICES RE-

SULTS IN DEGRADED PERFORMANCE OR
PREMATURE FAILURE, NOT IN CATA-
STROPHIC FAILURE AT THE TIME EXPERI-
ENCED.

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BENDIX/KING CNI 5000

B. Repair
(1) Repair Precautions
(a) Refer to paragraph 5.3.4.B.(2) for special ESDS and MOS handling
precautions.
(b) Perform repairs and replace components with power disconnected
from equipment.
(c) Use a conductive table top for repairs and connect table to ground
conductors of 60Hz and 400Hz power lines.
(d) Replace connectors, coaxial cables, shield conductors, and twisted
pairs ONLY with identical items.
(e) Reference "component side" of a printed circuit board in this manual
means the side on which components are located; "solder side" re-
fers to the other side. The standard references are as follows: near-
side is the component side; farside is the solder side; on surface
mount boards with components on both sides the nearside is the
side that has the J#### and P#### connector numbers.
(f) When repairing circuits, carefully observe lead dress and compo-
nent orientation. Keep leads as short as possible and observe cor-
rect repair techniques.
(g) There are certain soldering considerations with surface mount com-
ponents. The soldering iron tip should not touch the ceramic com-
ponent body. The iron should be applied only to the termination-sol-
der filet.
(h) Observe cable routing throughout instrument assembly, prior to dis-
assembly, to enable a proper reinstallation of cabling during reas-
sembly procedures.
(2) Electrostatic Sensitive Devices (ESDS) Protection
Devices sensitive to electrostatic discharge are used in this equip-
ment. These devices, including Metal Oxide Semiconductors,
some metal film resistors, and other devices, are susceptible to
damage by electrostatic charges or high-voltage fields. Because of
the very high resistances in ESDS devices, they can be damaged
by electrical sources that cannot deliver enough current to damage
conventional semiconductors. Therefore, special precautions must
be taken during the handling and repair procedures to prevent dam-
aging the device. The most common low-energy source causing
damage to ESDS devices is the human body, which generates and
retains static electricity, in conjunction with non-conductive gar-
ments and floor covering. An individual can easily develop several
thousand volts of electrostatic charge while simply walking across
the floor or moving around in a chair. Electrostatic charges of 20 k
V have been measured on personnel, and 35 k V has been mea-
sured on their garments.
The capacitive elements in all MOS devices can be destroyed by a
voltage field, even when assembled into the circuit. Similar capac-
itive elements in linear integrated circuits, hybrids, and in bipolar in-
tegrated circuits are also susceptible to field voltages.
Not all electrostatic damage will result in immediate catastrophic
failure. Damaged devices may remain operating within the mini-

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BENDIX/KING CNI 5000

mum limits but could experience early field failure or erratic perfor-
mance.
The following precautions are recommended for ESDS circuits, and
are especially important in low humidity or dry conditions when elec-
trostatic problems are more prevalent.

CAUTION
ESDS DEVICES INCLUDE, BUT ARE NOT
LIMITED TO, C-MOS, J-MOS, PMOS, NMOS,
SOCMOS, HMOS, MOS/FET, MICROWAVE
MIXER DIODES, SOME BIPLOAR DEVICES,
AND SOME METAL FILM RESISTORS.

MOST DAMAGE TO ESDS DEVICES RE-

SULTS IN DEGRADED PERFORMANCE OR
PREMATURE FAILURE, NOT IN CATA-
STROPHIC FAILURE AT THE TIME EXPERI-
ENCED.
(3) Storage
Store and transport all ESDS devices in conductive material. Do not
insert ESDS devices into conventional plastic trays used for storing
and transporting standard semiconductor devices. Special bags or
containers must have a maximum resistivity of 104 ohms/cm, or the
leads of the device must be shorted together through a conductive
material (special foam) having a maximum resistivity of 104 ohms/
cm.
Modules, circuit boards, or assemblies containing ESDS devices
must be stored in static shielding bags with a maximum resistivity of
104 ohms/cm in the outer layer of the bag, and 1012 ohms/cm resis-
tivity in the inner layer.
A caution label shall be attached to the outside of all containers con-
taining ESDS devices. The ESDS labels are identified in the advi-
sory information located in the front of this manual. Do not remove
device from container until actually used or tested.
(4) Work Station
All equipment, tools, materials, and personnel at the work station
must be maintained at the same electrical potential. All grounding
connections shall have a common point, and that point shall be con-
nected to electrical ground.
Soldering irons shall be isolated from the power line by transformer,
or shall be direct current isolated. The soldering iron must be
grounded and have a resistance of less than 0.2 ohm from the tip to
ground when the iron is hot.
Test equipment shall have all exposed metallic surfaces electrically
connected to the test equipment power system ground (through 200
ohms or less).

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Do not use rubber mats, carpets, and rugs in the work station area.
Use grounded conductive mats.
Do not allow nonconductive items on the workbench. This includes
such items as plastic ash trays, cellophane wrappers, plastic tools,
styrofoam coffee cups, etc.
Maintain the relative humidity higher than 40 percent (minimum) in
the work area.
Keep all material and work surfaces CLEAN in the work area. Wash
with damp cloth when necessary.
Keep the work station static-safe. Periodically check the area with
a static meter. When a dangerous reading is observed, remove the
nonconductor or take precautions to prevent contact with ESDS de-
vices.
(5) Personnel
When handling electrostatic discharge sensitive devices or assem-
blies, wear a skin-contact wrist strap connected to the work station
common ground.

WARNING
DO NOT CONNECT PERSONNEL DIRECTLY
TO EARTH OR BUILDING GROUND. COM-
MERCIAL GROUNDING STRAPS CONTAIN
AN INTERNAL RESISTANCE OF ABOUT 1
MEGOHM IN THE CORD TO BLEED THE
ELECTROSTATIC CHARGE FROM THE
BODY WHILE PROTECTING PERSONNEL
FROM ELECTRICAL SHOCK.
WARNING
DO NOT WEAR GROUND STRAP WHEN
TROUBLESHOOTING OR TESTING HIGH
VOLTAGE CIRCUITS WITH POWER AP-
PLIED.
Do not wear smocks, gloves, finger cots, or
sleeve protectors made of plastic, nylon, or rub-
ber in the area where ESDS devices are han-
dled.
When the operator is properly grounded, con-
tact with the operator's hand will provide suffi-
cient ground for hand tools or other tools that
may be electrically isolated from ground.
(6) Special Troubleshooting Precautions
In addition to the above considerations, the following specific pre-
cautions should be observed when troubleshooting or repairing
modules containing ESDS devices.

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BENDIX/KING CNI 5000

Do not use high velocity dry air for applying heat during trouble-
shooting. Special infrared heat devices should be used.
Do not use Freon spray during troubleshooting. To cool compo-
nents, use antistatic quick-chill sprays.
Remember, even when the ESDS device is installed on a printed
circuit board it can STILL be damaged by electrostatic discharge.
C. PC Board, Two-Lead Component Removal (Resistors, Capacitors, Diodes, etc.)
(1) Heat one lead from component side of board until solder flows and
lift one lead from board; repeat for other lead and remove compo-
nent (note orientation).
(2) Melt solder in each hole and using desoldering tool remove solder
from each hole.
(3) Dress and form leads of replacement component; insert leads into
correct holes.
(4) Solder in place and clip leads on solder side of board.
D. PC Board, Multi-Lead Component Removal (IC's etc.)
(1) Remove component by clipping each lead along both sides. Clip off
leads as close to component as possible. Discard component.
(2) Heat hole from solder side and remove clipped lead from each hole.
(3) Melt solder in each hole and using a desoldering suction tool re-
move solder from each hole.
(4) Insert replacement component observing correct orientation.
(5) Solder component in place from farside of board. Avoid solder runs.
No solder is required on contacts where no tracks exists.
E. Replacement of Power Transistors
(1) Unsolder leads and remove attaching hardware. Remove transistor
and hard-coat insulator.
(2) Apply Termal Joint Compound Type 120 (Wakefield Engineering,
Inc.) to the mounting surface of the replacement transistor.
(3) Reinstall the transistor insulator and the power transistor using
hardware removed in step (1).
(4) After installing the replacement transistor, but before making any
electrical connections, measure the resistance between the case of
the transistor and the chassis to ensure that the insulation is effec-
tive. The resistance measured should be greater than 10M_.
(5) Reconnect leads to transistor and solder in place.
F. PC Board, Two-Lead Component Removal (Resistors, Capacitors, Diodes, etc.)
(1) Heat one lead from component side of board until solder flows and
lift one lead from board; repeat for other lead and remove compo-
nent (note orientation).
(2) Melt solder in each hole and using desoldering tool remove solder
from each hole.
(3) Dress and form leads of replacement component; insert leads into
correct holes.
(4) Solder in place and clip leads on solder side of board.

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G. PC Board, Multi-Lead Component Removal (IC's etc.)

(1) Remove component by clipping each lead along both sides. Clip off
leads as close to component as possible. Discard component.
(2) Heat hole from solder side and remove clipped lead from each hole.
(3) Melt solder in each hole and using a desoldering suction tool re-
move solder from each hole.
(4) Insert replacement component observing correct orientation.
(5) Solder component in place from farside of board. Avoid solder runs.
No solder is required on contacts where no tracks exists.
H. Replacement of Power Transistors
(1) Unsolder leads and remove attaching hardware. Remove transistor
and hard-coat insulator.
(2) Apply Termal Joint Compound Type 120 (Wakefield Engineering,
Inc.) to the mounting surface of the replacement transistor.
(3) Reinstall the transistor insulator and the power transistor using
hardware removed in step (1).
(4) After installing the replacement transistor, but before making any
electrical connections, measure the resistance between the case of
the transistor and the chassis to ensure that the insulation is effec-
tive. The resistance measured should be greater than 10M_.
(5) Reconnect leads to transistor and solder in place.
I. Replacement of Printed Circuit Board Protective Coating

WARNING
CONFORMAL COATING CONTAINS TOXIC
VAPORS! USE ONLY WITH ADEQUATE VEN-
TILATION!
(1) Clean repaired area of printed circuit board per instructions in
Cleaning section of this manual.

(2) Apply Conformal Coating Humiseal #1B-31 HYSOL PC20-35M-01

(Humiseal Division, Columbia Chase Corp., 24-60 Brooklyn
Queens Expressway West, Woodside, N.Y., 11377) P/N 016-
01040-0000.

(3) Shake container well before using.

(4) Spray or brush surfaces with smooth, even strokes: if spraying,

hold nozzle 10-15 inches from work surface.

(5) Cure time is ten minutes at room temperature.

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5.3.5 ASSEMBLY (INCLUDING STORAGE)

A. General
This section provides information for the assembly of the CNI-5000 Integrated Ra-
dio Package. Assembly procedures are to be followed after the unit has been dis-
assembled for repair or modified by Service Bulletin, cleaning, or inspection.
Refer to the "Illustrated Parts List" (IPL) Section VI, to identify all parts.

WARNING
REMOVE ALL POWER FROM THE UNIT BE-
FORE ASSEMBLY OF ANY MODULE. BE-
SIDES BEING DANGEROUS TO LIFE, VOLT-
AGE TRANSIENTS CAN CAUSE CONSIDER-
ABLE DAMAGE TO THE EQUIPMENT.

CAUTION
EXERCISE EXTREME CARE WHEN RECON-
NECTING MULTI-PIN CONNECTORS. EN-
SURE THAT CONNECTORS ARE NOT DAM-
AGED BY MISALIGNMENT OF THE PINS.
B. Materials Required For Assembly
Figure 5-6 Lists the materials to be applied during assembly on the CNI-5000 Inte-
grated Radio Package.
NOTE

Equivalent substitutes may be used for listed seal-

ants, stacking compounds, and thermal compounds.

REPRESENTATIVE TYPE QUANTITY USED

Loctite 242 Thin coat to threads of screws and retaining
nuts.
Conformal Coating Humiseal #1B-31 Thin coat on all components, not on
HYSOL PC 20-35M-01 connectors.
Adhesive-Sealant RTV 3145 Thin coat for adhesion.
Superbonder 414 Thin coat to threads of screws and retaining
nuts.
Thermal Compound Thin coat on power transistor insulator (both
sides).
Nylon Cable Tie As required to secure wiring.
Solder, 60% Tin 40% Lead As required for connections.

TABLE 5-2 SEALANTS, STAKING COMPOUNDS, AND THERMAL COMPOUNDS

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BENDIX/KING CNI 5000

C. Recommended Reassembly Procedures

The assembly should be accomplished in reverse order of the disassembly.
D. Storage
(1) Short-Time Storage
The CNI-5000 can be temporarily stored on the shelf, but should not
be exposed to extremes of temperature, humidity, or other environ-
mental conditions without additional protection. The use of plug
covers is recommended.
(2) Long-Term Storage
For long-time storage or unlimited storage, it is recommended that
the CNI-5000 be packaged as for shipment and that a suitable des-
iccant be placed within the container. Mark the packing date plainly
on the container. An alternate method is to store the unit in a loca-
tion having a carefully controlled, low-humidity environment. Units
which have been in storage a long time should be visually inspected
and cleaned, and then tested per paragraph 3. in the Testing and
Troubleshooting section, prior to returning to service.
(3) Storage Renewal
Not applicable.

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BENDIX/KING CNI 5000

SECTION VI
ILLUSTRATED PARTS LIST
6.1 GENERAL
The Illustrated Parts List (IPL) is a complete list of assemblies and parts required for the unit. The
IPL also provides for the proper identification of replacement parts. Individual parts lists within this
IPL are arranged in numerical sequence starting with the top assembly and continuing with the
sub-assemblies. All mechanical parts will be separated from the electrical parts used on the sub-
assembly. Each parts list is followed by a component location drawing.
Parts identified in this IPL by Honeywell part number meet design specifications for this equipment
and are the recommended replacement parts. Warranty information concerning Honeywell re-
placement parts is contained in Service Memo #1,
P/N 600-08001-00XX.
Some part numbers may not be currently available. Consult the current Honeywell catalog or con-
tact a Honeywell representative for equipment availability.
6.2 REVISION SERVICE
The manual will be revised as necessary to reflect current information.

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BENDIX/KING CNI 5000

6.3 LIST OF ABBREVIATIONS

Abbreviation Name
B Motor or Synchro
C Capacitor
CJ Circuit Jumper
CR Diode
DS Lamp
E Voltage or Signal Connect Point
F Fuse
FL Filter
FT Feedthru
I Integrated Circuit
J Jack or Fixed Connector
L Inductor
M Meter
P Plug
Q Transistor
R Resistor
RT Thermistor
S Switch
T Transformer
TP Test Point
U Component Network, Integrated Circuit,
Circuit Assembly
V Photocell/Vacuum Tube
W Waveguide
Y Crystal

TABLE 6-1 ABBREVIATIONS

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BENDIX/KING CNI 5000

6.4 SAMPLE PARTS LIST

The above is only a sample. The actual format and style may vary slightly. A 'Find
Number' column, when shown, references selected items on the BOM's accompa-
nying Assembly Drawing. This information does not apply to every BOM. There-
fore, a lack of information in this column, or a lack of this column, should not be
interpreted as an omission.

FIGURE 6-1 SAMPLE PARTS LIST

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6.5 INSTALLATION KIT

050-03011-0000 CNI 5000 INSTALL, NON-PVC 24FT AA
050-03011-0001 CNI 5000 INSTALL, NON-PVC 48FT AA

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000 -0001

J201 030-03137-0006 BERG CONNECTOR EA 1.00 1.00

JKT701 030-01094-0066 CONN W/ POLARIZER EA 2.00 2.00

JKT703 030-00102-0001 CONN PNL MOUNT RF EA 2.00 2.00

P1 030-01094-0085 CONN -09 W/POLAR EA 1.00 1.00

P1961 030-01094-0080 CONNECTOR KEYED EA 2.00 2.00

P1962 030-00101-0002 PANEL MOUNT PLUG EA 2.00 2.00

P531 030-00101-0002 PANEL MOUNT PLUG EA 2.00 2.00

P532 030-01094-0053 CONNECTOR EA 2.00 2.00

P533 030-00101-0002 PANEL MOUNT PLUG EA 2.00 2.00

P871 030-00101-0002 PANEL MOUNT PLUG EA 1.00 1.00

P872 030-01094-0051 CONN W/KEY EA 1.00 1.00

REF1 155-05812-0000 INSTAL KIT ASSY RF .00 .00

S1 031-00222-0008 SW TGL SPDT O-N-O EA 1.00 1.00

030-01107-0080 CONNECTOR TERM 80T EA 3.00 3.00

030-02205-0004 TERM 22-28 EA 8.00 8.00

057-02203-0000 FLAVOR STCKR EA 1.00 .

057-02203-0001 FLAVOR STCKR EA . 1.00

089-02185-0022 NUT LOCK 2-56 EA 2.00 2.00

089-05903-0007 SCR PHP 4-40X7/16 EA 16.00 16.00

089-06004-0012 SCR FHP 2-56X3/4 EA 2.00 2.00

089-08168-0002 WASHER WAVE EA 9.00 9.00

089-08252-0030 WASHER EA 9.00 9.00

090-00019-0007 RING RTNR .438 EA 9.00 9.00

091-00109-0000 CABLE TIE EA 20.00 20.00

200-02586-0001 ANTENNA CABLE ASSY EA 1.00 .

200-02586-0004 ANTENNA CABLE ASSY EA . 1.00

200-05197-0000 RACK ASSY CNI5000 EA 1.00 1.00

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THIS PAGE IS RESERVED

Rev 3, May/2004 05330I03.CKS Page 6-6

B CNI 5000

FIGURE 6-2 INSTALLATION KIT ASSEMBLY

(Dwg No 155-05812-0000, Rev AB, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-7

B CNI 5000

DELETE

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B CNI 5000

FIGURE 6-2 INSTALLATION KIT ASSEMBLY

(Dwg No 155-05812-0000, Rev AA, Sheet 1 of 1, For Reference Only)

Rev 3, May/2004 05330I03.CKS Page 6-9

B CNI 5000

DELETE

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6.6 ANTENNA CABLE ASSEMBLY

200-02586-0001 ANTENNA CABLE ASSY 24 FT 12
200-02586-0004 ANTENNA CABLE ASSY 48 FT 1
200-02586-0099 COMMON BOM AA

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0001 -0004 -0099

REF 300-02586-0000 KA 44 ANTENNA CABL RF . . .00

024-00024-0000 CA TRIAXIAL 50 OHM IN 290.00 578.00 .

025-00018-0000 WIRE 26 BLK IN . . 5.40

025-05120-0000 WIRE, TIN PLTD CU IN 290.00 578.00 .

030-02346-0001 CONN SUB-D CA 9S EA . . 1.00

030-02351-0000 HOOD/LVR ASSY ST E EA . . 1.00

150-00052-0010 SHRNK TUBING WHT IN . . 2.40

150-00072-0000 SLDR SLEEVE .62 EA . . 2.00

150-00104-0002 TBG HT SHRNK 1/16 AR . . .00

150-00104-0002 TBG HT SHRNK 1/16 IN . . 4.00

150-00104-0004 TBG HT SHRNK 3/32 AR . . .00

150-00104-0004 TBG HT SHRNK 3/32 IN . . .25

200-02586-0099 COMMON BOM EA 1.00 1.00 .

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BENDIX/KING CNI 5000

6.7 REAR COVER ASSEMBLY

200-05155-0000 REAR COVER ASSY 2

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

REF1 300-05155-0000 REAR COVER ASSY RF .00

047-09777-0002 REAR CVR W/HDWR EA 1.00

057-05561-0000 S/N TAG, CNI 5000 EA 1.00

076-00253-0002 SPACER .531 EA 4.00

089-05878-0004 SCR PHP 4-40 X 1/4 EA 16.00

091-00109-0000 CABLE TIE EA 3.00

091-00603-0000 TIE HOLDER ADH MT EA 1.00

148-05175-0003 BLOWER MOD EA 2.00

187-01795-0000 PROTECTIVE COVER EA 1.00

200-08519-0000 PCB FAN SENSE EA 1.00

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THIS PAGE IS RESERVED

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B CNI 5000

FIGURE 6-3 REAR COVER ASSEMBLY

(Dwg No 300-05155-0000, Rev 1, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-15

B CNI 5000

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6.8 RACK ASSEMBLY

200-05197-0000 RACK ASSY CNI5000 AA

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

REF1 300-05197-0000 RACK ASSY CNI5000 RF .00

047-09742-0010 INTERCONNECT BOX EA 1.00

047-09753-0012 RACK INSTALLATION EA 1.00

047-09857-0001 CABLE CLAMP EA 1.00

057-02203-0000 FLAVOR STCKR EA 1.00

057-05540-0000 S/N TAG, CNI 5000 EA 1.00

057-05625-0000 CAUTION 190 VOLTS EA 2.00

076-02139-0001 HOSE ADAPTER STRT EA 1.00

089-05874-0004 SCR PHP 2-56X1/4 EA 4.00

089-05878-0004 SCR PHP 4-40 X 1/4 EA 12.00

089-06008-0004 SCR FHP 4-40X1/4 EA 3.00

089-08025-0030 WSHR FLT STD #4 EA 12.00

091-00015-0006 RUBBER GRMT 1/2 EA 1.00

091-00015-0007 RUBBER GRMT 5/8 EA 3.00

091-00610-0000 MOUNT CABLE TIE EA 12.00

200-05155-0000 REAR COVER ASSY EA 1.00

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B CNI 5000

FIGURE 6-4 RACK ASSEMBLY

(Dwg No 300-05197-0000, Rev AA, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-19

B CNI 5000

DELETE

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B CNI 5000

FIGURE 6-4 RACK ASSEMBLY

(Dwg No 300-05197-0000, Rev 0, Sheet 1 of 1, For Reference Only)

Rev 3, May/2004 05330I03.CKS Page 6-21

B CNI 5000

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6.9 PCB FAN SENSE

200-08519-0000 PCB FAN SENSE AA

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

C1 111-00001-0032 CAP CR 1UF 50V EA 1.00

C2 111-00001-0032 CAP CR 1UF 50V EA 1.00

C3 097-00096-0015 CAP EL 150UF 63V EA 1.00

C4 096-01082-0040 CAP TN 3.3UF 35V EA 1.00

C5 096-01082-0040 CAP TN 3.3UF 35V EA 1.00

C6 111-00001-0032 CAP CR 1UF 50V EA 1.00

C7 111-00001-0028 CAP CR .47UF 50V EA 1.00

C8 111-00001-0032 CAP CR 1UF 50V EA 1.00

C9 111-00001-0028 CAP CR .47UF 50V EA 1.00

CR1 007-05011-0021 DIO Z 24V 1W 5% EA 1.00

CR10 007-06048-0000 DIO RECTIFIER EA 1.00

CR11 007-06048-0000 DIO RECTIFIER EA 1.00

CR12 007-06048-0000 DIO RECTIFIER EA 1.00

CR13 007-06048-0000 DIO RECTIFIER EA 1.00

CR14 007-06048-0000 DIO RECTIFIER EA 1.00

CR15 007-06048-0000 DIO RECTIFIER EA 1.00

CR2 007-06016-0000 DIO S 1N4154 EA 1.00

CR3 007-06016-0000 DIO S 1N4154 EA 1.00

CR4 007-05011-0021 DIO Z 24V 1W 5% EA 1.00

CR5 007-06016-0000 DIO S 1N4154 EA 1.00

CR6 007-06016-0000 DIO S 1N4154 EA 1.00

CR7 007-06048-0000 DIO RECTIFIER EA 1.00

CR8 007-06048-0000 DIO RECTIFIER EA 1.00

CR9 007-06048-0000 DIO RECTIFIER EA 1.00

Q1 007-00965-0000 XSTR NPN TIP50 EA 1.00

Q10 007-00257-0000 XSTR S NPN MPSA42 EA 1.00

Q11 007-00257-0000 XSTR S NPN MPSA42 EA 1.00

Q12 007-00254-0000 XSTR S PNP MPSA92 EA 1.00

Q2 007-00254-0000 XSTR S PNP MPSA92 EA 1.00

Q3 007-00257-0000 XSTR S NPN MPSA42 EA 1.00

Q4 007-00257-0000 XSTR S NPN MPSA42 EA 1.00

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BENDIX/KING CNI 5000

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

Q5 007-00257-0000 XSTR S NPN MPSA42 EA 1.00

Q6 007-00254-0000 XSTR S PNP MPSA92 EA 1.00

Q7 007-00965-0000 XSTR NPN TIP50 EA 1.00

Q8 007-00254-0000 XSTR S PNP MPSA92 EA 1.00

Q9 007-00257-0000 XSTR S NPN MPSA42 EA 1.00

R1 131-00202-0023 RES CF 2K QW 5% EA 1.00

R10 131-00202-0023 RES CF 2K QW 5% EA 1.00

R11 131-00392-0023 RES CF 3.9K QW 5% EA 1.00

R12 131-00752-0023 RES CF 7.5K QW 5% EA 1.00

R13 131-00202-0023 RES CF 2K QW 5% EA 1.00

R14 132-00057-0000 RES WW 22 3W 5% EA 1.00

R15 131-00512-0023 RES CF 5.1K QW 5% EA 1.00

R16 131-00103-0023 RES CF 10K QW 5% EA 1.00

R17 131-00154-0023 RES CF 150K QW 5% EA 1.00

R18 131-00243-0023 RES CF 24K QW 5% EA 1.00

R19 131-00511-0023 RES CF 510 QW 5% EA 1.00

R2 132-00057-0000 RES WW 22 3W 5% EA 1.00

R20 131-00102-0023 RES CF 1K QW 5% EA 1.00

R21 131-00752-0023 RES CF 7.5K QW 5% EA 1.00

R22 131-00392-0023 RES CF 3.9K QW 5% EA 1.00

R23 131-00202-0023 RES CF 2K QW 5% EA 1.00

R24 131-00103-0023 RES CF 10K QW 5% EA 1.00

R25 132-00057-0000 RES WW 22 3W 5% EA 1.00

R26 131-00113-0023 RES CF 11K QW 5% EA 1.00

R27 131-00113-0023 RES CF 11K QW 5% EA 1.00

R3 131-00512-0023 RES CF 5.1K QW 5% EA 1.00

R4 131-00103-0023 RES CF 10K QW 5% EA 1.00

R5 131-00154-0023 RES CF 150K QW 5% EA 1.00

R6 131-00243-0023 RES CF 24K QW 5% EA 1.00

R7 131-00511-0023 RES CF 510 QW 5% EA 1.00

R8 131-00103-0023 RES CF 10K QW 5% EA 1.00

R9 131-00102-0023 RES CF 1K QW 5% EA 1.00

REF1 300-08519-0000 PCB FAN SENSE ASSY RF .00

REF2 002-08519-0000 SCH PCBD FAN SENSE RF .00

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BENDIX/KING CNI 5000

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

REF3 192-08519-0000 CNI 5000 FAN SENSE RF .00

009-08519-0000 PCBD FAN SENSE EA 1.00

016-01040-0000 COATING TYPE AR AR 1.00

091-00055-0004 SCR RHS 4-40X.250 EA 2.00

091-00058-0001 NUT FLAT 4-40 EA 2.00

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THIS PAGE IS RESERVED

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B CNI 5000

FIGURE 6-5 FAN SENSE PC BOARD ASSEMBLY

(Dwg No 300-08519-0000, Rev 1, Sheet 1 of 1)

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B CNI 5000

DELETE

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B CNI 5000

FIGURE 6-6 FAN SENSE PC BOARD SCHEMATIC

(Dwg No 002-08519-0000, Rev 3, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-29

B CNI 5000

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B CNI 5000

FIGURE 6-6 FAN SENSE PC BOARD SCHEMATIC

(Dwg No 002-08519-0000, Rev 1, Sheet 1 of 1, For Reference Only)

Rev 3, May/2004 05330I03.CKS Page 6-31

B CNI 5000

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6.10 INTEGRATED RADIO PACKAGE FRONT PANEL

050-03104-0000 FRT PNL 5VGCNI5000 0
050-03104-0001 FRT PNL 5VBCNI5000 1
050-03104-0002 FRT PNL 5VGCNI5000 MODFD, CNI5000 -

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000 -0001 -0002

REF1 300-05140-0000 CNI5000 PANEL ASSY RF .00 .00 .00

200-05140-0000 PANEL ASSY 5V GRY EA 1.00 . .

200-05140-0001 PANEL ASSY 5VBLK EA . 1.00 .

200-05140-0002 FRT PNL 5VGCNI5000 EA . . 1.00

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6.11 FRONT PANEL ASSEMBLY

200-05140-0000 PANEL ASSY 5V GRY 6
200-05140-0001 PANEL ASSY 5VBLK 4
200-05140-0002 FRT PNL 5VGCNI5000 MODFD, CNI5000 -

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000 -0001 -0002

REF1 300-05140-0000 CNI5000 PANEL ASSY RF .00 .00 .00

016-01131-0000 CONTACT CEMENT #77 AR 1.00 1.00 1.00

035-01361-0022 PROTEC CVR CNI5000 EA 1.00 1.00 1.00

047-09755-0003 FRAME FRMD W/PAINT EA 1.00 . 1.00

047-09755-0004 FRAME FRMD W/BLK EA . 1.00 .

047-10449-0001 BUTTON SUPPORT EA 2.00 2.00 .

057-01764-0000 WRN TAG 5V LGT EA 1.00 1.00 1.00

057-02203-0000 FLAVOR STCKR EA 1.00 . 1.00

057-02203-0001 FLAVOR STCKR EA . 1.00 .

057-05551-0000 SIN FRONT PANEL EA 1.00 1.00 1.00

057-05552-0000 S/N TAG, CNI 5000 EA 1.00 1.00 1.00

057-05552-0001 SERIAL TAG CNI5000 EA 1.00 1.00 1.00

057-05635-0000 LABEL EA 1.00 1.00 1.00

088-02538-0003 LENS W/FILTER EA 2.00 2.00 2.00

088-02582-0002 FRT PNL DEC 5V GRY EA 1.00 . .

088-02582-0003 FRT PNL DEC 5V BLK EA . 1.00 .

088-02582-0006 PANEL, 5VG, MODFD, EA . . 1.00

088-02589-0001 LENS KT 70 EA 2.00 2.00 .

088-02590-0001 LENS W/DECO KY196A EA 2.00 2.00 2.00

088-03004-0001 LENS KR 87 EA 1.00 1.00 1.00

088-03005-0001 LENS PLAR MACH EA 2.00 2.00 2.00

088-03022-0003 BUTTON W/FINISH EA 2.00 2.00 .

089-05899-0003 SCR PHP 2-56X3/16 EA 14.00 14.00 14.00

089-05899-0004 SCR PHP 2-56X1/4 EA 2.00 2.00 .

089-06004-0003 SCR FHP 2-56X3/16 EA 1.00 1.00 1.00

089-06008-0004 SCR FHP 4-40X1/4 EA 17.00 17.00 17.00

200-08486-0000 LIGHT PCB,CNI5000 EA 1.00 1.00 1.00

Rev 3, May/2004 05330I03.CKS Page 6-35

BENDIX/KING CNI 5000

THIS PAGE IS RESERVED

Rev 3, May/2004 05330I03.CKS Page 6-36

B CNI 5000

FIGURE 6-7 FRONT PANEL ASSEMBLY

(Dwg No 300-05140-0000, Rev AB, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-37

B CNI 5000

DELETE

Rev 3, May/2004 05330I03.CKS Page 6-38

B CNI 5000

FIGURE 6-7 FRONT PANEL ASSEMBLY

(Dwg No 300-05140-0000, Rev 0, Sheet 1 of 1, For Reference Only)

Rev 3, May/2004 05330I03.CKS Page 6-39

B CNI 5000

DELETE

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BENDIX/KING CNI 5000

6.12 LIGHT BOARD ASSEMBLY

200-08486-0000 LIGHT PCB,CNI5000 0

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

DS101 037-00027-0002 LAMP 6832AS15 EA 1.00

DS102 037-00027-0002 LAMP 6832AS15 EA 1.00

DS103 037-00027-0002 LAMP 6832AS15 EA 1.00

DS104 037-00027-0002 LAMP 6832AS15 EA 1.00

DS105 037-00027-0002 LAMP 6832AS15 EA 1.00

DS106 037-00027-0002 LAMP 6832AS15 EA 1.00

DS107 037-00027-0002 LAMP 6832AS15 EA 1.00

DS108 037-00027-0002 LAMP 6832AS15 EA 1.00

DS109 037-00027-0002 LAMP 6832AS15 EA 1.00

DS110 037-00027-0002 LAMP 6832AS15 EA 1.00

DS111 037-00027-0002 LAMP 6832AS15 EA 1.00

DS112 037-00027-0002 LAMP 6832AS15 EA 1.00

DS113 037-00027-0002 LAMP 6832AS15 EA 1.00

DS114 037-00027-0002 LAMP 6832AS15 EA 1.00

DS115 037-00027-0002 LAMP 6832AS15 EA 1.00

DS116 037-00027-0002 LAMP 6832AS15 EA 1.00

DS117 037-00027-0002 LAMP 6832AS15 EA 1.00

DS118 037-00027-0002 LAMP 6832AS15 EA 1.00

DS119 037-00027-0002 LAMP 6832AS15 EA 1.00

DS120 037-00027-0002 LAMP 6832AS15 EA 1.00

DS121 037-00027-0002 LAMP 6832AS15 EA 1.00

DS122 037-00027-0002 LAMP 6832AS15 EA 1.00

DS123 037-00027-0002 LAMP 6832AS15 EA 1.00

DS124 037-00027-0002 LAMP 6832AS15 EA 1.00

DS125 037-00027-0002 LAMP 6832AS15 EA 1.00

DS126 037-00027-0002 LAMP 6832AS15 EA 1.00

DS127 037-00027-0002 LAMP 6832AS15 EA 1.00

DS128 037-00027-0002 LAMP 6832AS15 EA 1.00

DS129 037-00027-0008 T1 SHORT BULB 28V EA 1.00

DS130 037-00027-0008 T1 SHORT BULB 28V EA 1.00

DS131 037-00027-0002 LAMP 6832AS15 EA 1.00

Rev 3, May/2004 05330I03.CKS Page 6-41

BENDIX/KING CNI 5000

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

DS132 037-00027-0002 LAMP 6832AS15 EA 1.00

DS133 037-00027-0002 LAMP 6832AS15 EA 1.00

P201 030-02453-0003 CONN, HDR, PLG, .1 EA 1.00

009-08486-0000 LIGHT PCB,CNI5000 EA 1.00

Rev 3, May/2004 05330I03.CKS Page 6-42

B CNI 5000

FIGURE 6-8 LIGHT BOARD ASSEMBLY

(Dwg No 300-08486-0000, Rev 1, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-43

B CNI 5000

DELETE

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B CNI 5000

FIGURE 6-8 LIGHT BOARD ASSEMBLY

(Dwg No 300-08486-0000, Rev 0, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-45

B CNI 5000

DELETE

Rev 3, May/2004 05330I03.CKS Page 6-46

B CNI 5000

FIGURE 6-9 LIGHT BOARD ASSEMBLY

(Dwg No 002-08486-0000, Rev 0, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-47

B CNI 5000

DELETE

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BENDIX/KING CNI 5000

6.13 AIRCRAFT ADDRESS KIT

050-02927-0000 AC ADD/MAX ARSPD 0

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

089-05903-0007 SCR PHP 4-40X7/16 EA 2.00

200-08334-0000 EXT EEPROM BD EA 1.00

6.13A EXTERNAL EEPROM BOARD

200-08334-0000 EXT EEPROM BD 7

SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0000

C7001 106-04104-0047 CH 100KX7R/50V EA 1.00

I7001 120-02434-0003 256BIT EEPROM CMOS EA 1.00

I7002 999-09999-0098 PLACE HOLDER RF .00

PKT702 030-01120-0000 CONN PC BD EA 1.00

R7001 139-01002-0000 RES CHIP 10K EW 1% EA 1.00

REF1 300-08334-0000 EXT EEPROM BD ASY RF .00

REF2 002-08334-0000 SCH EXT EEPROM BD RF .00

009-08334-0000 PCBD EXT EEPROM BD EA 1.00

016-01040-0000 COATING TYPE AR AR 1.00

016-01096-0000 SUPERBONDER 150 AR 1.00

030-00107-0099 POLARIZING KEY EA 1.00

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BENDIX/KING CNI 5000

THIS PAGE IS RESERVED

Rev 3, May/2004 05330I03.CKS Page 6-50

B CNI 5000

FIGURE 6-10 EXTERNAL EEPROM BOARD

(Dwg No 300-08334-0000, Rev 0, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-51

B CNI 5000

DELETE

Rev 3, May/2004 05330I03.CKS Page 6-52

B CNI 5000

FIGURE 6-11 EXTERNAL EEPROM BOARD

(Dwg No 002-08334-0000, Rev 0, Sheet 1 of 1)

Rev 3, May/2004 05330I03.CKS Page 6-53

B CNI 5000

DELETE

Rev 3, May/2004 05330I03.CKS Page 6-54

BENDIX/KING CNI 5000

APPENDIX E
D0-160B ENVIRONMENTAL QUALIFICATION FORMS

Rev 3, May/2004 05330I03.CKS Page APP_E-1

BENDIX/KING CNI 5000

THIS PAGE IS RESERVED

Rev 3, May/2004 05330I03.CKS Page APP_E-2

BENDIX/KING CNI 5000

CNI 5000 EVIRONMENTAL QUALIFICATION FORM

FIGURE APP_E-1 CNI 5000 ENVIRONMENTAL QUALIFICATION FORM

(Dwg No 004-09087-0000, Rev AB, Sheet 1 of 3)

Rev 3, May/2004 05330I03.CKS Page APP_E-3

BENDIX/KING CNI 5000

FIGURE APP_E-1 CNI 5000 ENVIRONMENTAL QUALIFICATION FORM

(Sheet 2 of 3)

Rev 3, May/2004 05330I03.CKS Page APP_E-4

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FIGURE APP_E-1 CNI 5000 ENVIRONMENTAL QUALIFICATION FORM

(Sheet 3 of 3)

Rev 3, May/2004 05330I03.CKS Page APP_E-5

BENDIX/KING CNI 5000

THIS PAGE IS RESERVED

Rev 3, May/2004 05330I03.CKS Page APP_E-6

THE END
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