Heathkit IM-36 User Manual

Assembly and Operation of the Heathkit Transistor Tester

Model IM-36

595-861-03
Heath Company Benton Harbor, Michigan 49022
----------------------------------­This electronic edition of the Heathkit IM-36 Transistor Tester manual was prepared, by Gary Edwards, garyedwa@hwy.com.au November 2004.
It has been partially retyped, and partially scanned to obtain the graphics.
The document was prepared in Word 2000, and converted to *.pdf with Acrobat 5.0
The layout is slightly different than the original, which was altered primarily to economise on space (or number of pages), however apart from the alterations to the layout and some minor formatting changes it contains all of the information from the original document.
, 3rd

Table of Contents

Introduction 2 Parts List 3 Step-by-step Assembly
Switch Pre-wiring 5 Control Panel Parts Mounting and Initial Wiring 13 Battery Housing Assembly and Wiring 23 Knob Installation 28
Battery Installation 29 Initial Tests and Adjustments. 30 Operational Check 33 Final Assembly 34 Operation 35 Reference Material 41 In Case of Difficulty 41 Troubleshooting Chart 42 Specifications 43 Factory Repair Service 43 Circuit Description 44 Replacement Parts Price List 47 Schematic (fold-out from page) 47

Introduction

The Heathkit Model IM-36 Transistor Tester is a professional quality instrument for shop, laboratory, or remote on-the-job testing of transistors and diodes.
Direct readings of DC Beta (gain) from 0 to 400 and accurate measurements of currents and leakage in transistors permit testing under simulated operating conditions. These conditions are set up by switch-selecting the voltages and currents that are applied to the transistor elements to duplicate published characteristics.
Four lever switches permit eight different tests and measurements, which result in a comparative quality figure (beta, gain) rather than the simple good-bad test made by many other transistor testers.
The self-contained power supply, that consists of seven readily obtainable standard D­cell batteries, makes the instrument fully portable. Since no battery current is drawn unless a transistor is being tested, long battery life is assured.
External voltage sources for higher values of bias, collector, or leak voltages, can be connected to convenient binding posts for higher voltage transistor testing.
Diodes can be tested for forward and reverse characteristics under appropriate current conditions.
By following the step-by-step assembly, test, and operating instructions in the manual, you can build, test, and use this instrument in a few hours.
The attractively styled cabinet, functionally designed control panel, and efficient circuitry, combine to give you a transistor tester that you will use with confidence for many years.
Refer to the "Kit Builders Guide" for complete information on unpacking, parts identification, tools, wiring, soldering, and step-by-step assembly procedures.

Parts List

Note: the numbers in parenthesis in the Parts List are keyed to the numbers on the Parts Pictorial (Fold-out from Page 5).
To order replacement parts, refer to the "Replacement parts Price List" on Page 47 and use the Parts Order Form furnished with this kit.
Note: Precision resistors may be marked in , K, or M. (K equals 1000, M equals 1,000,000Ω).
Part No. Resistors Precision 1%, 0.5 watt.
(1) 2-148 1 0.09
2-148 1 0.9 2-229 1 2
(2) 2-19 1 9
2-230 2 18 2-24 1 90
Parts Per
Kit
Description
Parts Per
Part No. Kit Description
2-231 2 180 2-29 1 900 2-232 1 1800Ω (1.8kΩ) 2-233 1 2020 (2.02kΩ) 2-35 1 9000 (9kΩ) 2-189 1 18K 2-156 1 145K 2-157 1 350K 2-14 1 1M 2-158 1 3.5M 2-17 1 10M
2 watt.
(3) 2-15-2 1 2 1% (4) 3-5-2 1 2.2 10% (red-red-gold-silver)
Other Resistances.
(5) 340-12-1 1 0.01 resistance wire.
Capacitors
(6) 21-48 2 0.05 uf Disc.
Controls
(7) 11-75 1 20K 2 Watt (8) 11-79 1 100 4 Watt
Switches
(9) 62-14 1 3-position 6 wafer 4 lever (10) 63-440 1 3-position 2-wafer rotary (11) 63-441 1 10-position 4-wafer rotary (12) 63-442 1 6-position 3-wafer rotary (13) 63-443 1 10-position 3-wafer rotary (14) 63-444 1 6-position 1-wafer rotary (15) 60-4 1 SPDT Slide (16) 60-5 1 DPST slide
Wire Harnesses and Wire
(17) 134-138 1 Main wire harness (18) 134-152 1 Battery pack wire harness (19) 134-153 1 Small wire harness
344-6 1 Red wire 344-59 1 White wire
Hardware #6
(20) 250-56 10 6-32 x ¼" screw (21) 250-89 24 6-32 x 3/8" screw
Parts Per
Part No. Kit Description
(22) 250-8 7 #6 x 3/8" sheet metal screw (23) 255-23 2 6-32 threaded spacer (24) 252-3 40 6-32 nut (25) 252-22 8 6-2 speednut (26) 254-1 15 #6 lockwasher (27) 253-1 7 #6 fibre flat washer (28) 253-2 14 #6 fibre shoulder washer (29) 259-1 23 #6 solder lug
Other Hardware
(30) 250-175 2 2-56 x 3/8" screw (31) 252-51 2 2-56 nut (32) 254-7 2 #3 lockwasher
4-40 Hardware
(33) 250-52 4 4-40 x ¼" screw (34) 252-2 4 4-40 nut (35) 254-9 4 #4 lockwasher (36) 250-107 2 10-24 x ¼" screw (37) 254-3 2 #10 lockwasher (38) 253-6 7 #10 flat fibre washer
Control Hardware
(39) 252-7 7 Control nut (40) 253-10 7 Control flat washer (41) 254-4 7 Control lockwasher
Binding Post and Knob Parts
(42) 427-3 9 Binding Post Base (43) 75-17 18 Binding Post base insulator (44) 100-16-2 6 Black Binding Post Cap
100-16-18 3 Red Binding Post Cap (45) 462-97 4 Lever Switch Knob (46) 462-245 6 Small Round Knob (47) 462-253 1 Large Pointer Knob (48) 455-50 7 Knob bushing
Metal Parts
(49) 203-740-1 1 Panel (50) 90-502-2 1 Cabinet Shell (51) 205-307-2 1 Rear Cover (52) 214-14 1 Battery Housing (53) 204-413 2 Battery Spacing bracket (54) 258-43 7 Battery Contact Spring (55) 211-14 1 Handle
Miscellaneous
(56) 56-10 2 Silicon Diode
Parts Per
Part No. Kit Description
(57) 407-122 1 Meter (10-0-10 uA) (58) 434-116 1 Transistor Socket (59) 260-16 1 Alligator clip (60) 438-14 2 Alligator clip with adaptor (61) 261-4 4 Rubber Foot (62) 261-28 4 Plastic Foot (63) 207-18 2 3/8" cable clamp (64) 390-114 1 Battery label
391-34 1 Blue & white identification label (65) 490-5 1 Nut starter
597-308 1 Kit Builders Guide
597-260 1 Parts Order Form
1 Manual (See front cover for part
number.
Solder.
Note: Seven D-cell flashlight batteries (not furnished) will be required for operation of the completed Transistor Tester. You may want to purchase these batteries now to have them ready when you finish assembling the kit.

Step-By-Step Assembly

Before you start to assemble the Transistor Tester, read the Kit Builders Guide for complete information on wiring, soldering, and step-by-step assembly procedures.
As you perform a step in the Step-by-step assembly, first read the step completely through. Then perform the operation as directed. Position each part as wire as shown on the pictorial that accompanies the series of steps. The details provide specific information for individual steps.

Switch Pre-wiring

The assembly of this kit will begin with the pre-wiring of the switches. Before you begin to pre-wire a switch, compare its physical construction with its pictorial so you can identify the contacts and lug positions. Note that each contact position has a number, even if it does not have a lug.
To hold the switch firmly while you connect the wires, you may find it convenient to temporarily mount the switch in one of the 3/8" holes in the control panel. Place a towel or soft cloth on your work surface to avoid scratches, and mount the control on the inside of the panel.

Polarity Switch (#63-440)

Note: When wiring some of the parts in this kit, you will be instructed to prepare lengths of wire ahead of time, as in the following steps. To prepare a wire, cut it to the indicated length and remove ¼" of insulation from each end. The wires are listed in the order in which they will be used.
( ) Prepare the following lengths of wire:
Wire Colour Length
Red 3-¼" White 4–¼" White 4–¼" White 6–¼" White 8–¼" * Red 3-½" * Red 2-¼" * Red 2-¾"
* Remove ¼" of insulation from one end and ¾" of insulation from the other end of
these three red wires.
Refer to Pictorial 1 for the following steps.
( ) Locate the 3-position 2-wafer Polarity switch (#63-440) and compare its wafer
and lug positions with those numbered in the Pictorial. Note that the long contact on wafer 2 is identified as lug 3.
Note: Only the switch wafer and lug number will be called out in the following steps. As you connect a wire to a lug, pass the end of the wire through the lug. Then crimp the end of the wire around the lug to hold it in place until you are instructed to solder the connection, be sure to solder the connection, be sure to solder both lugs and the wire.
Connect one end of each of the prepared wires to the 3-position 2-wafer Polarity switch as follows.
( ) 3-¼" red to wafer 1 lug 1 (S-1). ( ) 4-¼" white to wafer 1 lug 4 (S-1). ( ) 4-¼" white to wafer 1 lug 6 (S-1). ( ) 6-¼" white to wafer 2 lug 1 (S-1). ( ) 8-½" white to wafer 2 lug 11 (S-1). ( ) 3-½" red, short end to wafer 1 lug 3 (S-1). ( ) 2-¼" red, short end to wafer 2 lug 2 (S-1). ( ) 2-¾" red, short end to wafer 2 lug 4 (S-1).
This completes the pre-wiring of the Polarity switch. Set the switch aside until it is called for later.

Collector Voltage Switch (#63-441)

( ) Prepare the following lengths of white wire:
1-¼", 1-¾", 2", 2-½", 2-¾"
Refer to Pictorial 2 for the following steps:
( ) Locate the 10 position 4 wafer Collector voltage switch (#63-441). Compare the
lug positions with those shown in Pictorial 2. Note that the long contact on wafer 4 is lug 7.
Connect the prepared wires from wafer 3 to wafer 1 in the following steps:
Wire From Wafer 3 To Wafer 1 ( ) 1-¼" Lug 4 (NS) Lug 4 (NS)
( ) 1-¾" Lug 3 (NS) Lug 5 (NS) ( ) 2-¾" Lug 2 (NS) Lug 6 (NS) ( ) 2" Lug 5 (NS) Lug 3 (NS) ( ) 2-½" Lug 6 (NS) Lug 2 (NS)
( ) Strip the insulation from a 1-½" length of white wire. Then cut this bare wire into
two ¾" lengths.
Connect the two ¾" bare wires as follows:
( ) From wafer 1 lug 1 (NS) to wafer 2 lug 1 (S-1).
( ) From wafer 4 lug 3 (NS) to wafer 4 lug 2 (S-1).
( ) Locate the small wire harness (#134-153) and note the end that has the shortest
red, white and blue wires.
Wires from the end of the wire harness just identified will be connected to the Collector Voltage switch in the following steps. Wires at the other end of the harness will be connected later.
( ) Bend the four longest wires back away from the five short wires. This will help
avoid accidentally burning any wires while soldering.
Connect the following harness wires to wafer 1 of the switch.
( ) Black to lug 2 (S-2).
( ) White to lug 3 (S-2).
( ) Blue to lug 4 (S-2).
( ) Red to lug 5 (S-2).
( ) Brown to lug 6 (S-2).
Connect the following harness wires to wafer 4 of the switch.
( ) Violet to lug 12 (S-1).
( ) Grey to lug 1 (S-1).
( ) Yellow to lug 3 (S-2).
( ) Green to lug 7 (S-1).
( ) Carefully examine the lugs of the switch. All lugs on wafers 1, 2 and 4 that have
wires attached should have been soldered, except lug 1 on wafer 1. Lugs 2, 3, 4, 5 and 6 of wafer 3 have wires that are not soldered.
This completes the pre-wiring of the Collector Voltage switch. Set the switch aside until it is called for later.

Leak Voltage Switch (#63-443)

Refer to Pictorial 3 for the following steps.
( ) Locate the 10-position 3-wafer Leak Voltage switch (#63-443). Compare the
switch with Pictorial 3 so that you can identify the lug numbers. Notice that lug 8 is the long contact on wafer 3.
Note: When you connect a precision resistor, as in the following steps, do not handle the resistor body with pliers or other tools. Preshape the resistor leads so its body can be positioned as show in the Pictorial; then cut of the excess lead lengths after the resistor is installed.
The following 1% precision resistors will be connected to the lugs on wafer 3 of the Leak Voltage switch. Position each resistor as shown in Pictorial 3.
( ) 145K from lug 4 (NS) to lug 2 (NS)
( ) 10 M from lug 5 (S-1) to lug 6 (NS)
( ) 3.5 M from lug 6 (NS) to lug 7 (NS).
( ) 1 M from lug 7 (NS) to lug 12 (NS)
Note: Where a wire passes through one lug then goes to another point, as in the following step, it will count as two wires in the soldering instruction (S-2) one entering and one leaving.
( ) Pass one lead of the 350K precision resistor through lug 1 (NS) to lug 12 (NS).
Shape the lead away from the switch spacer. Then connect the other lead of this resistor to lug 2 (NS). Now solder lug 1 (NS).
( ) Prepare the following lengths of wire.
7/8 ", 1-¾", 2 x 1-½", 2-½"
Connect these prepared wires from lugs on wafer 1 to lugs on wafer 2 as follows.
( ) 1-¾" 1 (NS) 5 (S-1) ( ) 1-½" 2 (NS) 4 (S-1) ( ) 1-½" 4 (NS) 2 (S-1) ( ) 2-½" 5 (NS) 1 (S-1) ( ) 7/8" 3 (NS) 3 (S-1)
( ) Prepare the following lengths of wire:
2 x 4", and 2 x 4-½"
Connect only one end of each of these prepared wires to lugs on the switch as follows.
( ) 4-½" to wafer 1 lug 6 (S-1).
( ) 4" to wafer 2 lug 6 (S-1).
( ) 4" to wafer 1 lug 8 (S-1).
( ) 4-¼" to wafer 2 lug 8 (S-1). (There appears to be a small error here, no 4-¼" length was prepared)
This completes the wiring of the Leak Voltage switch. Set the switch aside until it is called for later.
Wire From Wafer 1 Lug To Wafer 2 lug

Collector Current Switch (#63-442)

Refer to Pictorial 4 (fold-out from page 6) for the following steps.
( ) Locate the 6-position 3-wafer Collector Current switch (#63-442) and compare its
contacts and lugs with those shown in Pictorial 4. Notice that some lugs on wafers 2 and 3 are closer together than the lugs on wafer 1. The long contact on wafer 3 is lug 20.
Caution: Use extra care in making connections to the closely spaced lugs on the switch. Bend wires over the end of the lug. Trim excess lead lengths close to the lug. Be careful not to bend or break a lug. Where there is a front and rear lug at a position on a wafer, pass the wire through both lugs. Then be sure to solder both lugs and the wire when you are instructed to solder.
Note: The 1% precision resistors may be marked in Ω, K, or M (K = 1000, M = 1,000,000). For example: 1800 = 1.8K, 2020 = 2.02K, Examine each resistor carefully to be sure you install the correct value each time. As you install a resistor on the switch, pre-shape the leads so the resistor body can be positioned as shown in Pictorial 4.
Read each step completely through first; then perform the operation described in the step. Connect both leads of each resistor before you solder either lead.
In the following steps, you will connect 1% precision resistors to lugs on the wafers of the Collector Current switch.
( ) Connect the 18K resistor from lug 1 (NS) to lug 11 (NS) on wafer 2. Position
the resistor away from the movable parts of the switch.
( ) Pass one end of the 1800 (1.8K) through lug 2 on wafer 3 (S-2) to lug 3 on
wafer 2 (NS). Connect the other end of this resistor to lug 1 on wafer 2 (S-2).
( ) Pass one lead of a 180 resistor through lug 4 on wafer 3 (S-2) to lug 5 on wafer
2 (NS). Connect the other lead to lug 3 on wafer 2 (S-2).
( ) Pass one lead of an 18 resistor through lug 6 on wafer 3 (S-2) to lug 7 on wafer
2 (NS). Connect the other lead to lug 5 on wafer 2 (S-2).
( ) Connect the 20.5 watt precision resistor from lug 7 on wafer 2 (NS) to lug 9 on
wafer 2 (NS).
( ) Connect the 22 watt precision resistor from lug 11 on wafer 2 (NS) to lug 7 on
wafer 3 (NS).
( ) Connect the remaining 18 precision resistor from lug 7 (S-2) to lug 5 (NS) on
wafer 3.
( ) Connect the remaining 180 precision resistor from lug 5 (S-2) to lug 3 (NS) on
wafer 3.
( ) Connect the 2020 (2.02 K) resistor from lug 3 (S-2) to lug 1 (S-1) on wafer 3.
( ) Connect the 0.09 resistor from lug 6 (NS) to lug 7 (NS) on wafer 1.
( ) Pass one lead of the 0.9 resistor through lug 10 on wafer 2 (S-2) to lug 6 on
wafer 1 (NS). Connect the other lead to lug 5 on wafer 1 (NS).
( ) Pass one lead of the 9 resistor through lug 8 on wafer 2 (S-2) to lug 5 on wafer
1 (NS). Connect the other lead to lug 4 on wafer 1 (NS).
( ) Pass one lead of the 90 resistor through lug 6 on wafer 2 (S-2) to lug 4 on
wafer 1 (NS). Connect the other lead to lug 3 on wafer 1 (NS).
( ) Connect the 900 resistor from lug 4 on wafer 2 (NS) to lug 2 on wafer 1 (NS).
( ) Remove the insulation from a 1-½" white wire. Then connect this wire from lug 4
on wafer 2 (S-2) to lug 3 on wafer 1 (NS).
( ) Pass one lead of the 9000Ω (9KΩ) resistor through lug 2 on wafer 2 (S-2) to lug
2 on wafer 1 (NS). Connect the other lead to lug 1 on wafer 1 (NS).
( ) Remove the insulation from a 2-¾" length of red wire. Then cut this bare wire
into two 1-3/8" lengths.
In the next two steps, you will connect the heavy bare wires you have just prepared.
( ) 1-3/8" bare wire from lug 7 on wafer 1 (S-2) to lug 12 on wafer 2 (S-1).
( ) 1-3/8" bare wire from lug 8 on wafer 1 (S-1) to lug 14 on wafer 2 (NS).
( ) Remove ¼" of insulation from each end of a 2" red wire. Then, connect one end
of this wire to lug 16 on wager 2 (S-1). The other end will be connected later.
( ) Prepare the following lengths of red wire.
3", 2 x 3-½", 5-½"
Connect one end of each of these prepared wires in the following steps.
( ) 3-½" to lug 6 on wafer 1 (S-3).
( ) 5-½" to lug 9 on wafer 2 (S-2).
( ) 3" to lug 11 on wafer 2 (S-3).
( ) 3-½" to lug 20 on wafer 3 (NS).
( ) Prepare a 5-½" white wire, then connect one end of this wire to lug 20 on wafer 3
(S-2).
( ) Prepare five 3" lengths of white wire.
In the following steps you will connect one end of each of these prepared 3" wires to lugs on wafer 1.
( ) Lug 1 (NS).
( ) Lug 2 (S-3).
( ) Lug 3 (S-3).
( ) Lug 4 (S-3).
( ) Lug 5 (S-3).
This completes the pre-wiring of the Collector Current Switch. Set the switch aside until it is called for later.

Lever Switch (#62-14)

Refer to Pictorial 5 for the following steps.
( ) Locate the 3-position 6-wafer 4-lever switch (#62-14) and compare its sections,
wafers, and lugs with those shown in Pictorial 5.
Note: the lever switch contains four separate switch sections, marked A, B, C, and D in Pictorial 5. Sections A and B each have two wafers, while sections C and D each have one wafer. To identify the wafers and lugs on the lever switch, a letter-number combination will be used as follows: The letter will identify the section and the first number will identify the wafer in that section. The number that follows the dash will indicate the lug. For example A2-11 would refer to section A, wafer 2, lug 11.
( ) Cut the following lengths of red wire (10), then remove the insulation from each
of them. (These will be the bare wires used in the steps that follow.)
2 x ¾", 1", 1-¼", 1-1/8", 2 x 1-½", 2-3/8", 2 x 2-¾",
Note: You will connect the bare wires to lugs on the lever switch in the following steps. Pass the wire through the lugs in the order given; then solder only the lugs indicated. Where two lugs appear at a position on a wafer, and you are instructed to solder, be sure to solder both of the lugs and the wire. Be sure none of the bare wires touch any metal parts.
Position the lever switch as shown in the upper part of Pictorial 5. Then connect the prepared bare wires as follows:
( ) 1" from B2-6 (S-1) to A2-6 (S-1).
( ) 2-¾" through lug 5 on all wafers. Solder all but D1-5 (NS).
( ) ¾" from D1-4 (S-1) to C1-4 (NS).
( ) 1-½" through B2-2 (S-1), B1-2 (S2), A2-2 (S-2), A1-2 (S-1).
( ) 1-½" through B2-1 (NS), B1-1 (S-2), A2-1 (S-2), A1-1 (S-1).
( ) Connect the 2.22 watt (red-red-gold-silver) resistor from C1-1 (S-1) to B2-1 (S-
2). Position the resistor as shown.
( ) Remove ¼" of insulation from each end of a 2" length of red wire. Then connect
this wire from C1-4 (S-2) to B2-4 (NS). Shape and position the wire as shown.
( ) Remove ¼" of insulation from each end of a 2-½" length of red wire. Then
connect this wire from B2-4 (S-2) to A1-4 (S-1).
( ) Remove ¼" of insulation from each end of a 2-½" length of white wire. Then
connect one end of this wire to D1-2 (NS). The other end will be connected later.
Position the switch as shown in the lower part of Pictorial 5. Then connect the rest of the prepared bare wires as follows.
( ) 1-1/8" from B2-7 (S-1) to A2-7 (NS).
( ) ¾" from D1-7 (S-1) to C1-7 (NS).
( ) 1-¼" from B1-9 (S-1) to A1-9 (NS).
( ) 2-¾" through lug 10 on al wafers. Solder all of the lugs.
( ) 2-3/8" through lug 11 on all wafers. Solder all but A2-11 (NS).
( ) Connect a 2-7/8" red wire from A1-8 (S-1) to D1-8 (NS).
Refer to Pictorial 6 (fold-out from Page 6) for the following steps.
( ) Locate the main wire harness (#134-138). Form the harness as shown in Detail
6A. Note that the breakout #1 has a large yellow and small yellow wire, and breakout #3 has a long large brown wire.
( ) Position the wire harness and the lever switch as shown in Pictorial 6.
Note: In the following steps, you will connect the harness wires to the lever switch. Some of the switch lugs were left unsoldered to accept the small wires from the harness. When you connect the large wires, form a hook in the end of the wire; then wrap the hook around the bare wire near the specified lug and solder the connection. Small wires are called out by their colors, while large wires are labelled "large". For example, "yellow" and "large yellow."
Connect the wires from breakout #2 as follows:
( ) Green to D1-2 (S-2).
( ) Violet to C1-2 (S-1).
( ) Large green to B2-2 (S-1).
( ) Large black to B1-1 (S-1).
Connect the wires from breakout #1 as follows:
( ) Gray to D1-5 (S-2).
( ) Red to D1-4 (S-2). Note that this lug was soldered previously. Heat the
connection; then insert the red wire and resolder.
( ) Large yellow to B2-6 (S-1).
( ) Yellow to A1-6 (S-1).
The remainder of the harness wires will be connected after the lever switch is installed. Carefully examine the connections on the lever side of the switch. Every lug should be connected and soldered. Be sure that no bare wires touch any metal parts. Set the lever switch aside temporarily.

Control Panel Parts and Initial Wiring.

Most of the parts in the Transistor Tester will be mounted and wired on the control panel. The operations in this part of the manual are divided into three sections as follows:
1. Initial parts mounting.
2. Switch mounting and wiring
3. Other parts mounting and wiring.
Initial Parts Mounting.
Refer to Pictorial & (fold-out from page 15) for the following steps.
( ) Locate the control panel and position it as shown. Place a towel or soft cloth on
your work surface to avoid scratching the panel.
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