PART V

REPAIR

501. GENERAL.

(a) For the purpose of periodic maintenance, service and repair, Major ECM Repair Facilities, Intermediate ECM Repair Facilities, and Minor ECM Repair Facilities have been established at the following locations:

(c) Each repair facility with the exception of the Emergency Minor ECM Repair Facility is prepared for periodic overhaul of the ECM, and insofar as possible, has been provided spare machines in order that a ship can exchange its machine for a thoroughly re-conditioned machine.

(d) The above ECM Repair Facilities are provided with the "Repair and Maintenance Instructions", Blueprints, Parts Catalogs, etc. and service personnel attached thereto have attended a course of instruction at an ECM training school.

502. TRAINING SCHOOLS.

(a) Schools for the instruction and training of personnel in the repair and maintenance of cryptographic machines are maintained at each of the Major ECM Repair Facilities. Instruction of three weeks duration is given for the purpose of training personnel attached to an individual activity in the technique of cleaning, oiling and performing emergency repairs, utilizing the Spare Parts Box (ENG 109) supplied with each ECM. Two or three day "appreciation" courses are available for communicators to familiarize them with the general mechanical operation, oiling and cleaning of the ECM.

(b) Commanding officers are urged to nominate trustworthy personnel for these schools. Arrangements should be made by directly contacting the Major Repair Facility.

(c) In addition to the Major ECM Repair Facilities, schools are located at the following points:

(a) Personnel who satisfactorily complete the full course at an ECM training school are issued the card illustrated below. Personnel from a repair facility should be required to present this card and the standard Navy Identification Card before being allowed to service the machine. Holders of qualification cards who are not assigned to duty at authorized ECM Repair Facilities are normally authorized to perform only routine cleaning, oiling and emergency repairs to the extent of the tools and parts available in the ENG 109. The services of the personnel at established ECM Repair Facilities should be utilized to the greatest practicable extent for monthly inspections and major overhaul. Unsatisfactory performance of duties by any card holder should be reported to the Bureau of Ships, Code 945.

504. EMERGENCY REPAIRS.

(a) When the ECM requires attention, either for routine inspection, emergency repairs, overhaul, adjustment, etc., service should be requested from the nearest ECM repair facility. Experience has shown that cryptographic machines have suffered more from attempted repairs by inexperienced personnel than from wear and tear, therefore, routine tests and overhauls should be undertaken only by experienced personnel.

(b) It is realized that in many cases the above procedure is not a satisfactory solution to an immediate problem and emergency repairs will have to be effected, if at all possible. The emergency repair instructions given herein are written for the individual who has not had a course of instruction, therefore, they contain no information on adjustment tolerances, repairs requiring special tools, etc. Any emergency repairs effected should be rechecked as soon as practicable in an ECM repair facility.

(c) The effecting of emergency repairs is chiefly a matter of common sense. The decision is the responsibility of the Commanding Officer. For example, with tender facilities available, it would be undesirable to subject the machine to possible mistreatment at the hands of inexperienced personnel. On the other hand, if the machine breaks down while at sea, the ship's force should attempt any repair considered to be within its capabilities, even at the risk of further damage. Reasonable effort must be made to keep the machine in operation.

505. SPARE PARTS BOX (ENG 109).

(a) A Spare Parts Box (ENG 109) has been issued to each activity holding the ECM. The parts included are those required for repairs and maintenance normally considered to be within the capabilities of the ship's force.

EMERGENCY REPAIRS

506. ZEROIZING.

(a) Condition: Code Wheels will not zeroize.

(b) Probable cause:

(a) Condition: None of the Code Wheels of the Stepping Maze step.

(b) Probable cause:

508. CODE WHEELS OF ALPHABET MAZE.

(a) Condition: None of the Code Wheels of the Alphabet Maze will step.

(b) Probable cause:

509. KEYLEVER FAILURE.

(a) Condition: All of the Keylevers are inoperative.

(b) Probable causes:

(d) Probable causes:

510. MOTOR FAILURE.

(a) Condition: The motor fails to start.

(b) Probable causes:

511. 26-30 LETTER CHECK.

(a) Condition; The 26-30 Letter Check is not produced.

(b) Probable cause:

(a) Condition; Printing on the tape is smudged, or indistinct.

(b) Probable causes:

(a) Condition: Excessive sparking at the timing (Stepping and Printing) contacts at the main shaft.

(b) Probable cause: Excessive spark at the timing contact (Printing) may be caused by failure of the spark suppressor circuit which is composed of a resistor, 400 ohms, and a capacitor, 1 mfd., located to the rear of the keylevers. The capacitor of the timing contact (Printing) is the one located next to the base. To test for failure see para. (e).

(c) Excessive sparking at the timing contact (Stepping) may be caused by failure of the spark suppressor circuit which is composed of a capacitor, 2 mfd., located on top of the one mfd. capacitor referred to in part (b) above. To test for failure see part (e).

(d) To test the resistor, measure the resistance with an ohmmeter.

(e) To test the capacitor:

(f) It is realized the above test is not a conclusive test, and is given only because an ohmmeter is generally available, whereas a capacitor tester generally is not. If a capacitor tester is available, it should be used to test the capacitor in lieu of the above tests.

514. CODE WHEELS.

(a) Condition: Code Wheel contacts badly pitted or worn, path between contacts indicates sparking between contacts has occurred.

(b) Probable cause:

(c) If a Code Wheel is defective, the best procedure is to exchange the defective set for another set at the nearest Issuing Office which in turn will send the defective set to the nearest ECM Repair Facility for repair. The defective set of Code Wheels should be suitably tagged, indicating the defective Code Wheel, and in such a manner that the defective set will not accidentally be issued before being repaired. If the set cannot be exchanged, the Code Wheel should be repaired locally.

(d) To repair a Code Wheel:

(e) Obtain another spare Code Wheel for the Spare Parts Box by ordering it from the most convenient ECM Repair Facility.

515. MOTOR ADJUSTMENT.

(a) The Condition: Machine runs sluggishly, the motor labors, the hand drive operates with difficulty.

(b) Probable cause:

516. CLUTCH MAGNET.

(a) A spare clutch magnet is included in the Spare Parts Box, but replacement should not be attempted unless the operator has had training in the replacement. The adjustments required in making a replacement require certain tolerances, some of which are rather critical and unless the operator has been trained and the proper tools are available, it is very difficult to make a repair.

517. RECHECKS REQUIRED.

(a) It is emphasized that the repair operations given in this part are for reference only in the event emergency repairs are required and the services of an ECM Repair Facility are not available. In each instance of an emergency repair, it should be re-checked at the first available opportunity by an ECM Repair Facility.

518. ADJUSTMENT SPECIFICATIONS.

(a) The following tabulation of adjustment specifications is provided for the convenience of repair personnel. It is to be used only by qualified ECM repairmen (holders of CSPM 390 qualification cards - see para. 503).

519. STEPPING CHECKS.

(a) The following chart provides a means of checking the operation of the machine through the first ten-thousand (10,000) steps from the zeroize position.

(b) To make the Stepping Check

STEPPING CHECK TABLE

CODE WHEEL SETTINGS

CODE WHEEL ALIGNMENTS

PLATE 9 B - PRINTER UNIT (Opened)