Military Surplus rigs AN-PRC-104B Service guide

MARINE CORPS TM 07748B-12/1

ARMY TM 11-5820-1046-12

OPERATOR’S AND ORGANIZATIONAL

MAINTENANCE MANUAL

RADIO SET

AN/PRC-104B(V)1,(V)4
(NSN 5820-01-269-5603)
(NSN 5820-01-262-9550)

This document required for official use or for administrative purposes only.
Distribution authorized to U.S. Government Agencies only. Other requests
for this document must be referred to: Commandant of the Marine Corps
(HSPQ-2), Washington, D.C. 20380-0001 or Commander, U.S. Army
Communications Electronics Command, ATTN: AMSEL-LC-ME-P, Fort
Monmouth, N.J. 07703-5000.

Destroy by any method that will prevent disclosure of contents or
reconstruction of document.

HEADQUARTERS, U.S. MARINE CORPS

HEADQUARTERS, DEPARTMENT OF THE ARMY

PCN 1840 77480 00

1 SEPTEMBER 1989

TM 07748B-12/1
TM 11-5820-1046-12

DEPARTMENT OF THE NAVY

Headquarter , U. S. Marine Corps

Washington,

D. C. 20380-0001

1 September 1989

1.

This Manual is effective upon receipt and contains Operation
Instructions and Organizational Maintenance Instructions
including Components List for the Radio Set, AN/PRC-104B

(V)1, (V)4.

2.

Notice of discrepancies or suggested changes should be

forwarded on NAVMC 10772 to: Commanding General, Marine Corps

Logistics Base (Code 850),

Albany, Georgia 31704-8000,

BY DIRECTION OF THE COMMMDAMT OF THE MARINE CORPS

OFFICIAL:

J. G. O’ Neill
Director,
Marine Corps Research,

Program Support

Development, l nd Acquisition Command

By Order of the Secretary of the Army:

OFFICIAL:

WILLIAM J. MEEHAN II

Brigadier General,

United States Army

The Adjutant General

DISTRIBUTION: 07748B
copy to:

7230054 (2)

General,

CARL E. VOUNO

United States Army

Chief of Staff

TM 07748B-12/1, TM 11-5820-1046-12

The following are general safety precautions that are not related to any specific procedures and therefore
do not appear elsewhere in this publication. These are recommended precautions that personnel must

understand and apply during many phases of operation and maintenance.

For ESD precautionary procedures, refer to: AF TO 00-25-234, Army TM 43-0158, or USMC TM 9999-15/2.

SAFETY STEPS TO FOLLOW IF SOMEONE
IS THE VICTIM OF ELECTRICAL SHOCK

DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL

IF POSSIBLE, TURN OFF THE ELECTRICAL POWER

IF YOU CANNOT TURN OFF THE ELECTRICAL
POWER, PULL, PUSH, OR LIFT THE PERSON TO

SAFETY USING A WOODEN POLE OR A ROPE OR

SOME OTHER INSULATING MATERIAL

SEND FOR HELP AS SOON AS POSSIBLE

AFTER THE INJURED PERSON IS FREE OF

CONTACT WITH THE SOURCE OF ELECTRICAL

SHOCK, MOVE THE PERSON A SHORT DISTANCE
AWAY AND IMMEDIATELY START ARTIFICIAL
RESUSCITATION

a

TM 07748B-12/1, TM 11-5820-1046-12

The following warnings appear in the text of this volume and are repeated here for emphasis.

Dangerous voltages exist at the radio antennas on the shelter when the radio sets are operating. Do not
touch these antennas. Observe the precautions given in TB SIG 291 concerning vehicular whip antennas.

A lithium-sulfur dioxide (lithium) battery used with the radio set contains pressurized sulfur dioxide (S02)
gas. To prevent rupture, do not heat, short circuit, crush, puncture, mutilate, or disassemble lithium
batteries; do not recharge or test lithium batteries for capacity; do not use a HaIon type fire extinguisher on
a lithium battery.

Do not use any lithium battery which shows the following signs of rupture: bulging, swelling,
disfigurement, brown liquid in the plastic wrap, or a swollen plastic wrap. if the battery compartment
becomes hot to the touch, or a hissing sound or the smell of S0

2 gas (rotten egg smell) is present,

Immediately turn off the equipment. Move the equipment to a well-ventilated area or leave the area.
in the event of a fire near a lithium battery, use a carbon dioxide (C02) type extinguisher. Rapid cooling of

lithium batteries is necessary to prevent venting and the potential exposure of lithium. In the event that
lithium metal becomes involved in fire, the use of a graphite-based Class D fire extinguisher is
recommended, such as Lith-X or MET-L-X.

Do not store lithium batteries with other hazardous materials and keep away from open frame or heat.
(Pages 2-1 and 6-1.)

Do not touch or stand near antenna when equipment is energized. Dangerously high rf voltages exist on
and around antennas and antenna terminals during transmission. Protect yourself by knowing safety
procedure in TB SIG 291. (Pages 3-12 and 4-7.)

When using a compressed airjet, use eyeshields to prevent severe eye injury. (Page 4-2.)

Antenna installation area must be free of power lines. Antenna contact with power lines during installation

may cause serious injury or DEATH to operator. (Page 2-6.)

b

TM 07748B-12/1, TM 11-5820-1046-12

TECHNICAL MANUAL

No. TM 07748B-12/1,

TM 11-5820-1046-12

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of
a way to improve the procedures, please let us know. Mail your letter, DA
Form 2028 (Recommended Changes to Publications and Blank Forms) or DA
Form 2028-2 located in the back of this manual, direct to: Commander, US
Army Communications-Electronics Command and Fort Monmouth,
ATTN: AMSEL-LC-ME-PS, Fort Monmouth, New Jersey 07703-5000. For Air
Force, submit AFTO Form 22 (Technical Order System Publication
Improvement Report and Reply) in accordance with paragraph 6-5,
Section Vl, T.O. 00-5-1. Forward direct to prime ALC/MST.

HEADQUARTERS, US MARINE CORPS

HEADQUARTERS, DEPARTMENT OF THE ARMY

Washington, DC, 1 September 1989

Operator’s and Organizational

Maintenance Manual

AN/PRC-104B(V)1,(V)4
(NSN 5820-01-269-5603)
(NSN 5820-01-262-9550)

Chapter 1

Section I

Section II

Section Ill

Chapter 2

Section I

Section II

Chapter 3

In either case, a reply will be furnished direct to you.
Marine Corps units, submit NAVMC 10772 (Recommended Changes to

Technical Publications) to: Commanding General, Marine Corps Logistics
Base (Code 850) Albany, Georgia 31704-5000.

INTRODUCTION
General Information
Equipment Description and Data

Principles of Operation

SERVICE UPON RECEIPT AND INSTALLATION
Service Upon Receipt
Installation Procedures

OPERATION

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Page

1-1
1-1
1-5

1-9

2-1
2-1

2-3

3-1

Section I

Section II

Controls, Indicators, and Connectors

Operator Preventive Maintenance Checks and Services (PMCS)

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3-1

3-9

i

TM 7748B-12/l , TM 11-5620-1046-12

Page

Section III

Section IV

Chapter 4

Section I

Section Il

Section III

Section IV

Chapter 5

Section I

Section II

Section III

Operation Under Usual Conditions

Operation Under Unusual Conditions

OPERATOR MAINTENANCE
Maintenance Procedures

Lubrication

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Operator Troubleshooting
Preoperational Check

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ORGANIZATIONAL MAINTENANCE

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Repair Parts; Special Tools; Test, Measurement, and Diagnostic

Equipment (TMDE); Support Equipment; and Materials . . . . . . . . . . . . . . . . .

PMCS
Organizational Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3-11

3-15

4-1
4-1
4-5
4-5
4-5

5-1

5-1
5-3
5-3

Section IV

Chapter 6

APPENDIX A

APPENDIX B

APPENDiXC

APPENDIX D

APPENDIX E

APPENDIX F

GLOSSARY

INDEX

Maintenance Procedures

PREPARATION FOR STORAGE OR SHIPMENT

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References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Allocation Chart

Components of End Item and Basic Issue items Lists

Additional Authorization List

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Expendable/Durable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . .

Propagation of Radio Waves and Operating Considerations

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5-15

6-1

A-1

B-1

C-1

D-1

E-1

F-1

Glossary-1

Index-1

ii

TM 077480-12/1, TM 11-5820-1048-12

LIST OF ILLUSTRATIONS

Figure

1-0
1-1

1-2
2-1
2-2
2-3
2-4
3-1
3-2
3-3
3-4
3-5
3-6
4-1
4-2
5-1
5-2
5-3

Title

Radio Set AN/PRC-104B
Location and Description of Major Components
Principles of Operation
Radio Set Installation
Manpack Whip Antenna Installation
NVIS Antenna Installation
Dipole Antenna Installation (5 Sheets)
RT Controls and Indicators
RT Connectors
Amplifier/Coupler Controls and Indicators
Amplifier/Coupler Connectors
Initial Checks
Single Sideband Operation
Maintenance Procedures
Preoperational Check
Test Setup
RT and Amplifier/Coupler Removal and Replacement
Battery Pack Removal and Replacement

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Page

1-0
1-5
1-9
2-4
2-5
2-7
2-8
3-3
3-4
3-5

3-6
3-11
3-13

4-4

4-7

5-4

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5-16
5-19

Copyright 1989 Hughes Aircraft Company

All Rights Reserved
The contents of this document may not be reproduced in
whole or in part without the written consent of the
copyright owner.

[Note: This material may be reproduced by or for the
U.S. Government pursuant to the Copyright License
under the Clause at 52.227-7013 (1987 May).]

iii

TM 077480-12/1, TM 11-5820-1046-12

1-0

Figure 1-0.

Radio Set AN/PRC-104B

CHAPTER 1

INTRODUCTION

TM 07748B-12/1, TM 11-5820-1046-12

Section I.

Scope
Maintenance Forms, Records, and Reports

Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . .

Destruction of Electronics Materiel
Preparation for Storage or Shipment

Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . .

Administrative Storage

This manual provides operator and organizational level operating and maintenance information for the
short term antijam (STAJ) compatible Radio Sets AN/PRC-104B(V)1 and AN/PRC-104B(V)4. These two
radio sets are identical except for the antennas and antenna mounting hardware furnished. The STAJ
compatible AN/PRC-104B radios differ from previous versions of the AN/PRC-104 because they contain a
modified RT-1209A. The information in this manual applies to both radio sets, except where noted for the
Marine Corps or Army use only.

The radio set is configured for the manpack using Receiver-Transmitter RT-1209A/URC (RT), Radio
Frequency Amplifier AM-6874/PRC-104 (amplifier/coupler), and Battery Case CY-7875/PRC-104 (battery
pack).

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Nomenclature Cross-Reference

GENERAL INFORMATION

Page

1-1

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1-1
1-1
1-2
1-2
1-2
1-2

1-3

REPORTS OF MAINTENANCE AND UNSATISFACTORY EQUIPMENT

USMC personnel will use Equipment Record Procedures TM 4700-15/1. Department of the Army forms and
procedures used for equipment maintenance are those prescribed by DA Pam 738-750 as contained in
Maintenance Management Update. Air Force personnel will use AFR 66-1 for maintenance reporting and

TO-00-35D54 for unsatisfactory equipment reporting. Navy personnel will report maintenance performed

utilizing the Maintenance Data Collection Subsystem (MDCS) IAW OPNAVINST 4790.2, Vol 3 and
unsatisfactory material/conditions (UR submissions) IAW OPNAVINST 4790.2, Vol 2, chapter 17.

REPORTING OF ITEM AND PACKAGING DISCREPANCIES

Fill out and forward SF 364 (Report of Discrepancy (ROD)) as prescribed in AR 735-11-2/DLAR

4140.55/SECNAVlNST 4355.18/AFR 400-54/MCO 4430.3J.

TRANSPORTATION DISCREPANCY REPORT (TDR) (SF 361)

Fill out and forward TDR (SF 361) as prescribed in AR 55-38/NAVSUPINST 4610.33C/AFR 75-18/MCO
P4610.19D/DLAR 4500.15.

Refer to the latest issue of DA Pam 25-30 to determine if there are new editions, changes, or additional
publications for the equipment.

USMC, refer to Marine Corps stocklist 1-2 for complete list of required publications.

1-1

TM 077480-12/1, TM 11-5820-1046-12

Destruction of electronics materiel to prevent enemy use will be in accordance with TM 750-244-2.

Disassembly and repacking of equipment for shipment or limited storage is covered in chapter 6,
Preparation for Storage or Shipment.

a. USMC personnel shall submit SF 368 in accordance with MCO 4855.10.
b.

Army. if your equipment needs improvement, let us know. Send us an EIR. You, the user, are the

only one who can tell us what you don’t like about the design or performance. Put it on an SF 368
(Product Quality Deficiency Report). Mail it to Commander, US Army Communications-Electronics
Command and Fort Monmouth, ATTN:

AMSEL-PA-MA-D, Fort Monmouth, New Jersey

07703-5000. We’ll send you a reply.

c. Air Force. Air Force personnel are encouraged to submit EIRs in accordance with AFR 900-4.
d. Navy. Navy personnel are encouraged to submit EIRs through their local Beneficial Suggestion

Program.

Administrative storage of equipment issued to and used by Army activities will have preventive
maintenance performed in accordance with the PMCS charts before storing. When removing the
equipment from administrative storage the PMCS should be performed to assure operational readiness.
Disassembly and repacking of equipment for shipment or limited storage are covered in chapter 6,

Preparation for Storage or Shipment. Marine Corps personnel will refer to MCO P4450.7 for preparation of

storage (Marine Corps Warehousing Manual).

1-2

TM 07748B-12/1 , TM 11-5820-1046-12

Common names are used for the equipment listed in the following table throughout the rest of this manual.
Refer to this table whenever official nomenclature is desired for a common name.

Common Name

Amplifier/Coupler
Antenna Base
Antenna Ground Base
Antenna Pack
Antenna Wire
Battery Charger Cable
Battery Extender Cable
Battery Pack (for Lithium

or NICAD batteries)
Bench Test Cable
Cargo Shelf
CW Key

Official Nomenclature

Radio Frequency Amplifier AM-6874/PRC-l 04
(NVIS) Antenna Base AB-1241/PRC-104
(NVIS) Antenna Ground Base P/N A3023292*
Carrying Case
Antenna Wire Assembly CX-7303/G
Electrical Power Cable Assembly
Electrical Power Cable Assembly

CX-13032/PRC-104
CX-13031/PRC-104

Battery Case CY-7875/PRC-104

Electrical Power Cable Assembly

CX-13030/PRC-104

Cargo Support Shelf 2-3-291

Telegraph Key KY-872/PRC-104
Dipole Antenna
Dipole Antenna Adapter
Dipole Carrying Bag
Dipole Rf Cable
Field Pack
Halyard
Handset
Instruction Card

Insulator
Manpack Whip Antenna

Antenna Group AN/GRA-50
(AN/GRA-50) Adapter UG-349A/U
Bag BG-175
Radio Frequency Cable Assembly CG-678/U
Field Pack 2-2-344
Halyard MX-2706/G
Handset H-250A/U
Instruction Card
Insulator lL-4/GRA-4

Antenna AT-271A/PRC

* Note: For Army installations, use antenna ground base (P/N A3023292). Do not use base

assembly P/N 7270-5061-001 or adapter MX-9313/GR that is part of NAVIS antenna.

1-3

TM 07748B-12/1, TM 11-5820-1046-12

Common Name

Mast Sections
NVIS Antenna
NVIS Rf Cable
NVIS Rf Cables
Pack Frame
Radio Set
Reel
RT

Shock Mount
Tape Measure
Top Mast
Transit Case

Official Nomenclature

Mast Sections
(NVIS) Antenna AS-2259( )/GR
Radio Frequency Cable Assembly CG-3815/U
Radio Frequency Cable Assemblies

Pack Frame 2-3-290

Radio Set AN/PRC-104B(V)1,(V)4

Hand Cable Reeling Machine RC-432-G
Receiver-Transmitter RT-1209A/URC
Antenna Spring Section AB-129/PR
Measuring Tape

Top Mast Assembly

Radio Case CY-8291/PRC-104

Webbing Strap

Webbing Strap 2-2-313

1-4

TM 07748B-12/1, TM 11-5820-1046-12

Section Il.

Equipment Characteristics, Capabilities, and Features

Location and Description of Major Components
Differences Between Models
Radio Set Data
Equipment Configuration
Safety, Care, and Handling

Radio set components are RT, amplifier/coupler, and battery pack.

Quick disconnect latches secure RT to amplifier/coupler.
RT is electrically interconnected with amplifier/coupIer via a built-in connector.
Radio set provides single sideband transmit and receive operation.
Total weight of RT and amplifier/coupler is 10.1 pounds, making a lightweight package.

1. RT —

2.

AMPLIFIER/COUPLER —

amplification.

3. BATTERY PACK — Provides all dc power required for operation in the manpack configuration.

Provides single sideband radio communications in the HF band (2,000 — 29,999.9 KHz).

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EQUIPMENT DESCRIPTION AND DATA

Page

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Provides antenna tuning or matching and 20 watts of rf power

1-5
1-5

1-6
1-6
1-8
1-8

Figure 1-1.

Location and Description of Major Components.

1-5

TM 07748B-12/1, TM 11-5820-1048-12

Refer to equipment configuration data on page 1-8.

This data applies only to the standard radio mode of the radio set.

Specification

Antennas

Antenna Tuning

Audio input impedance
Battery Case CY-7875/PRC-104

Dimensions

Battery Types

Dimensions

Duty Cycle

Description

Whip
Dipole
NVIS

Automatic to 1.5:1 vswr (3 seconds nominal, 12
seconds maximum)

0.6 mv rms
3-1/4 x 12/1/2 x 6-1/2 in.

(8.26 x 31.75 x 16.51 cm)
H x W x D

Two Battery Cases CY-7875/PRC-104, each containing

two 12-Volt lithium primary batteries BA-5590/U or two
NICAD storage batteries BB-590/U

12-1/2 x 10 1/2 x 2 5/8 in.
(31.75 x 26.67 x 6.66 cm)
W x D x H

1 minute keydown, 9 minute receive 1:9 ratio

Frequency Accuracy

Frequency Range

Operating Modes

1-6

±1 ppm for -51°F (-46°C) to +160°F (+71°C) (±2 to

30 Hz of setting) from 2 to 30 MHz, respectively

2,000 to 29,999.9 kHz in 100-Hz increments (280,000

frequency settings)

— Singie sideband (selectable USB or LSB)

— Voice/cw (Morse or burst cw at 300 wpm)
— Data (FSK or DPSK up to 2400 bps) compatible

with 75 baud military teletype

— Receive only (inhibits transmit operation)

TM 077480-12/1, TM 11-5820-1046-12

Specification

Operating Temperature Range
Power Requirements

Receiver Audio Output

Receiver Sensitivity

RF Output Impedance

RF Output Power

Weight

Description

-51°F (-46°C) to +160°F (+71°C)

20.0 to 32.0 V dc with input at 3.5 A (24.0 V dc) for
transmit (typical); 200 mA for receive (typical)

25 mW into 500 (nominal)

0.7 V for 10 db SINAD (-110 dbm voice, -70 dbm
data)

50

0.3 to 1.0 W (PEP) for RT-1209A, 20 W (PEP or
average) with AM-6874

17.94 lb (8.15 kg), including lithium batteries (without
accessories), or 20.59 lb (9.32 kg), including
nickel-cadmium batteries (without accessories)

1-7

TM 077480-12/1, TM 11-8820-1046-12

AN/PRC-1048 Configurations

Equipment (Common Name)

Amplifier/Coupler
Antenna Ground Base
Battery Charger Cable
Battery Extender Cable
Battery Pack (for lithium or NICAD batteries)
Bench Test Cable
Cargo Shelf
CW Key
Dipole Antenna
Dipole Antenna Adapter
Field Pack
Handset
Instruction Card
Manpack Whip Antenna
NVIS Antenna
NVIS Rf Cable

V1(Marine Corps)

X

X X
X X
X X
X
X
X
X

X
X
X
X

X

V4(Army)

X

X

X
X
X
X
X
X

X
X

X

X

Pack Frame
Radio Set
RT
Shock Mount
Transit Case
Webbing Strap

SAFETY, CARE, AND HANDLING

There are no safety, care, and handling instructions for the radio set other than the warnings, cautions,

and notes in the maintenance instructions.

X
X
X
X
X
X

X
X
X
X
X

X

1-8

TM 07748B-12/1, TM 11-5820-1046-72

Section Ill.

PRINCIPLES OF OPERATION

Figure 1-2.

—

RT

standard Receiver-Transmitter RT-1209 A/URC. The RT control panel contains AUDIO and CONT
connectors and the following controls which are described in detail in chapter 3, Controls, Indicators, and
Connectors:

FREQUENCY KHz pushbutton switches (six)
MODE select pushbutton switches (two)
LIGHT pushbutton switch
VOLUME OFF/MAX control switch

Amplifier/Coupler

During transmit operation, the power amplifier boosts the transmitted rf from the RT to 20 watts. Rf is then
routed through the harmonic filter to the antenna tuner. The antenna tuner automatically matches antenna
impedance to the radio set at the selected frequency, during transmit and receive operation. In receive
operation, the amplification circuits are bypassed. The amplifier/coupler control panel contains the whip
antenna socket,
interface connector J1, and the ANT SEL switch, which are described in detail in chapter 3, Controls,
Indicators, and Connectors.

The RT performs the conversion of audio signals to rf and rf to audio. The RT operates as a

The amplifier/coupler contains a power amplifier and an antenna tuner.

—

BNC

connector,

GND

terminal, receiver/exciter interface connector P1, amplifier/coupler

Principles of Operation

1-9/(1-10 blank)

TM 07748B-12/1, TM 11-5820-1046-12

CHAPTER 2

SERVICE UPON RECEIPT AND INSTALLATION

Section I.

Unpacking Radio Set
Checking Unpacked Radio Set
Equipment Supplied

A lithium-sulfur dioxide (lithium) battery used with the radio set contains
pressurized sulfur dioxide (S0
circuit, crush, puncture, mutilate, or disassemble lithium batteries; do not
recharge or test lithium batteries for capacity; do not use a Halon type fire

extinguisher on a lithium battery.

Do not use any lithium battery which shows the following signs of rupture:
bulging, swelling, disfigurement, brown liquid in the plastic wrap, or a
swollen plastic wrap. If the battery compartment becomes hot to the touch,
or a hissing sound or the smell of S0
immediately turn off the equipment. Move the equipment to a well-ventilated
area or leave the area.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE UPON RECEIPT

Page

2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

) gas. To prevent rupture, do not heat, short

2

gas (rotten egg smell) is present,

2

2-2
2-2

In the event of a fire near a lithium battery, use a carbon dioxide (C0

) type

2

extinguisher. Rapid cooling of lithium batteries is necessary to prevent
venting and the potential exposure of lithium. In the event that lithium metal
becomes involved in fire, the use of a graphite-based Class D fire

extinguisher is recommended, such as Lith-X or MD-L-X.
Do not store lithium batteries with other hazardous materials and keep away

from open flame or heat.

To prevent equipment damage, press relief valve button to equalize pressure
before unlatching transit case cover.

The radio set is normally placed in a transit case and closed for transportation, storage, or shipment.
Check transit case for damage. To unpack the equipment, unfasten the four latches and remove the
transit case cover. Each of the individual pieces of equipment fits in a molded space in the case.

2-1

TM 07748B-12/1, TM 11-5820-1048-12

1. Inspect equipment for any damage that may have occurred during shipment. If equipment has been

damaged, report damage on DD Form 6, Packaging Improvement Report.

2. Check equipment against packing slip to see if shipment is complete. Report all discrepancies in
accordance with instructions of DA Pam 738-750. Marine Corps personnel will refer to MCO P4610.19
(Transportation and Travel Record of Transportation Discrepancies).

3. Check MWO/Ml to see If equipment has been modified.

Refer to appendix C, Components of End Item and Basic Issue Items Lists.

2-2

TM 07748B-12/1, TM 11-5820-1046-12

Section Il.

Tools and Materials Required for Installation
Installation Instructions
Radio Set Installation
Manpack Whip Antenna Installation
NVIS Antenna Installation
Dipole Antenna Installation

This paragraph lists the tools and materials required for installing the radio set.

Name

Electronic Equipment Tool Kit TK-101/G

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION PROCEDURES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

National Stock

Qty

1

5180-00-064-5178

Page

2-3
2-4
2-4
2-5
2-6
2-8

Number

2-3

TM 0774SB-12/1, TM 11-5820-1046-12

The installations of the manpack whip antenna, Near Vertical Incidence Skywave (NVIS), and dipole
antennas are outlined in the following paragraphs. For Marine Corps, before installing the antenna, select
the type of antenna to be installed per Operating Considerations paragraph on page F-9.

Attach battery pack (1) to power connector (2) on bottom of latched RT (3) - amplifier/coupler (4)
combination and secure by fastening and tightening 2 latches (5).

2-4

Figure 2-1.

Radio Set Installation

TM 07748B-12/1, TM 11-5820-1046-12

1. Attach whip antenna (1) to antenna shock mount (2).

2. Attach antenna shock mount (2) (with whip antenna (1) attached) to antenna socket (3) on
amplifier/coupler (4).

Figure 2-2.

Manpack Whip Antenna Installation

2-5

TM 07748B-12/1, TM 11-5820-1046-12

To erect the NVIS antenna, perform the following steps:

Antenna installation area must be free of power lines. Antenna contact with

power lines during installation may cause serious injury or DEATH to
operator.

NOTE

The NVIS antenna is efficient at frequencies between 2 and 12 MHz.

Determine installation area. An 85- by 85-ft area is required for NVIS installation.

1.

NOTE

For Army installations, use antenna ground base (P/N A3023292). Do not use
base assembly P/N 7270-5061-001 or adapter MX-9313/GR that is part of

NVIS antenna.

Place antenna base (1) on ground next to radio set (2). Antenna base (1) must be located close

2.

enough to allow NVIS rf cable (3) to connect between antenna base (1) and amplifier/coupler (4).
Open antenna pack and remove top mast section (5).

3.

Install top mast section (5) in antenna base (1) on ground and uncoil antenna elements (6) one at a

4.

time. Verify antenna elements

(6)

are stretched along direction in which they leave top housing

are not shorted to each other or to mast. If necessary, adjust direction of antenna elements (6).

5.

Measure anchor (8) positions, using metal sleeve cable markers (9) as guides, and install anchors.
Leave slack in antenna elements (6) lying on ground.

NOTE

Dirty mast sections (10) reduce NVIS antenna performance.

6.

Before connecting mast sections

(10),

wipe unpainted mating surfaces clean of mud or dirt to provide

good electrical contact.

7.

Assemble mast by raising top mast section

(5)

and inserting each of seven 22-inch mast sections

one at a time. Insert bottom mast section (10) in antenna base (1).

8.

Adjust tightness of all elements

(6)

until mast sections

(10)

are vertical and straight. Antenna elements

(6) need not be excessively tight.

(7)

and

(10)

2-6

TM 07748B-12/1, TM 114820-1046-12

Figure 2-3. NAVIS Antenna Installation

2-7

TM 077486-12/1, TM 11-5620-1046-12

To put up a dipole antenna, refer to Illustrations on pages 2-8 thru 2-12, and perform the following steps:

NOTE

The two-support, one-support sloping, and one-support Inverted V dipole

antennas are shown on pages 2-11 and 2-12.

1. Connect antenna wire (1) and terminal hooks (2) to thumb nuts (3) on opposite ends of insulator (4).

2. Connect rf cable (5) to insulator (4).

3. Temporarily fasten insulator (4) to one of supports (6).

2-8

Figure 2-4. Dipole Antenna installation (Sheet 1)

TM 07748B-12/1, TM 11-5820-1048-12

4.

Temporarily fasten free end of frequency tape measure (7) to center of Insulator (4).

Unwind frequency tape measure (7) to length for desired frequency, using marks on back of tape.

5.

Grasp one reel (8) firmly in one hand, loosen center thumb nut (9), and clamp thumb nut (10).

6.

7.

Slowly move away from insulator

(4)

center, keeping wire

(1)

tight at all times. Hold thumb on wire
to prevent backlash.
After unwinding required amount of wire (1), tighten clamp thumb nut (10) and then center thumb

8.

nut

(9).

Repeat steps 6,7, and 8 for other reel.

9.

10.

Unfasten frequency tape measure (7) (if used) from insulator (4).

11.

Unfasten insulator (4) from support and lay wires (1) out in a straight line.

12.

Check overall length of two wires (1) plus insulator (4) and reels (8). Overall length should be twice
length indicated in step 5 by frequency tape measure (7). Adjust wires (1) for exact overall length.
Keep insulator (4) centered.

(1)

Figure 2-4.

Dipole Antenna Installation (Sheet 2)

2-9

TM 07748B-12/1, TM 11-5820-1046-12

Figure 2-4.

Dipole Antenna Installation (Sheet 3)

13. Attach each reel (8) to halyard snaphook fastener (11).

To avoid equipment damage, allow antenna to sag at least 6 inches when
installing.

Rf cable (5) should be at right angles to antenna for first several feet from
insulator

(4).

Lay rf cable

(5)

out as straight as possible. Do not allow loops to

form in rf cable (5).

14.

Tie halyard

(12)

to tree, fence post, vehicle, etc at a height of at least 3 feet or 1/3 the antenna length.

2-10

TM 07748B-12/1, TM 11-5820-1046-12

Figure 2-4. Dipole Antenna Inatallation (Sheet 4)

2-11

TM 07748B-12/1, TM 11-5820-1046-12

2-12

Figure 2-4.

Dipole Antenna Installation (Sheet 5)

TM 07748B-12/1, TM 11-5820-1046-12

CHAPTER 3
OPERATION

Section I. CONTROLS, INDICATORS, AND CONNECTORS

Page

RT Controls and Indicators
RT Connectors
Amplifier/Coupler Controls and Indicators
Amplifier/Coupler Connectors
Audible Indicators

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2
3-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5
3-6
3-7

3-1

TM 07748B-12/1, TM 11-5820-1046-12

Key

Control or Indicator

Function

1 VTRCV indicator V RCV - indicates voice and cw receive only during single

sideband operation when turned on by repeated pressing
and releasing of left-hand MODE pushbutton, as necessary.

VTR - indicates voice and cw transmit and receive during
single sideband operation, when turned on by repeated

pressing and releasing of left-hand MODE pushbutton, as
necessary.

2

DTRCV indicator

D RCV - indicates data receive only during single sideband

operation, when turned on by repeated pressing and

releasing of left-hand MODE pushbutton, as necessary.

DTR - indicates data transmit and receive during single
sideband operation, when turned on by repeated pressing
and releasing of left-hand MODE pushbutton, as necessary.

ECCM indicator

3
4

RMT indicator Not used.

5

USB LSB indicator

Not used.

USB - indicates upper sideband has been selected during
single sideband operation, when turned on by repeated

pressing and releasing of right-hand MODE pushbutton, as
necessary.

LIGHT pushbutton

6

LSB - indicates lower sideband has been selected during
single sideband operation, when turned on by repeated
pressing and releasing of right-hand MODE pushbutton, as
necessary.

Turns on display light while pressed. Turns off display light
when released.

3-2

TM 07748B-12/1, TM 11-5820-1046-12

Key

7

8

9

10
11
12

13

Figure 3-1. RT Controls and Indicators

Control or Indicator

VOLUME OFF/MAX switch

Turns power on or off and adjusts audio (volume) level of

Function

RT. At OFF, power is removed. At MAX, audio level is
maximum.

MODE pushbutton(s)

USB LSB - repeated pressing and releasing, as necessary,

(right-hand) turns on USB and LSB indicators, indicating upper

sideband or lower sideband has been selected during single
sideband operation.

MODE pushbutton(s)
(left-hand)

V RCV, VTR, D RCV, and DTR - repeated pressing and

releasing, as necessary, during single sideband operation,
turns on V RCV, VTR, D RCV, or DTR indicator. This
indicates voice and cw receive mode, voice and cw

transmit and receive mode, data receive mode, or data

transmit and receive mode has been selected.

F2 indicator Not used.
F1 indicator
FREQUENCY KHz

pushbuttons (6)

Not used.

Turns on and sequences 6-digit display of single sideband

operating frequency when pressed. 280,000 frequencies
between 2,000 and 29,999.9 KHz are available in 100-Hz
steps.

Frequency display FREQUENCY KHz - lights when FREQUENCY KHz
indicators (6-digit)

pushbuttons are pressed during single sideband operation

to select 1 of 280,000 frequencies between 2,000 and

29,999.9 KHz, in 100-Hz steps.

3-3

TM 077480-12/1, TM 11-5820-1046-12

Key

1

2

3

Connector

CONT

Receiver/Transmitter
interface connector P1

AUDIO

Function

RT 19-pin connector provides Interface connection between
RT and controller. (The controller is not provided in this
configuration).

Connects RT to amplifier/coupler (not shown). This
connector is on the side of the RT.

6-pin connector provides interface connection between RT
and handset or amplifier-power supply.

3-4

Figure 3-2.

RT Connectors

TM 07748B-12/1, TM 11-5820-1046-12

Key

1

Control or Indicator

ANT SEL switch

Function

Selects whip antenna socket, BNC connector through
antenna tuner, or BNC connector with antenna tuner
bypassed (50 position).

Figure 3-3.

Amplifier/Coupler Controls and Indicators

3-5

TM 07748B-12/1, TM 11-5820-1046-12

Key

1

2

3

4
5

Connector

Amplifier/Coupler

Connects amplifier/coupler to RT (not shown).

Function

Interface
connector J1

Whip antenna Screw-in connection for shock mount of whip antenna.

socket
BNC connector Provides BNC connection to compatible antenna other than

the whip.
GND terminal Ground point for counterpoise or earth ground.
AN/PRC-104

Connects AN/PRC-104 to connector on battery pack.
power input
connector

3-6

Figure 3-4. Amplifier/Coupler Connectors

TM 07748B-12/1, TM 11-5820-1046-12

Audio signals are provided in the handset to tell the trained operator the operational condition of the radio
set.

LOW VOLTAGE INDICATOR

On a properly operating radio, a repetitive clicking sound indicates the battery voltage has fallen to less
than 20 volts. The clicking sound is first heard when the PTT is pressed during a tune-up or voice
transmission. The sound stops when the PTT switch is released, and the radio receives when the power
drain is at a minimum. At this point, the battery retains only enough charge for limited transmission and
reception. When the voltage level falls low enough that the clicking sound is heard continuously in the
receive mode, the battery must be replaced.

POWER OUTPUT INDICATOR

Sidetone occurs when the operator’s own voice is heard in the handset during transmission. The presence
of sidetone guarantees that the radio set is generating an rf signal and the power output to the antenna is
within 3 dB (500A) of the normal limits. The absence of sidetone during transmission means the handset or

radio set is defective.

TUNING INDICATOR

The tuning indicator is a continuous high-pitched tone that is heard in the handset. The ANT SEL switch
must be set to the BNC (middle) or whip (top) position. This tone is typically heard for 3 seconds when the
radio set is turned on and the PTT switch is first pressed to start the tuning operation. The PTT switch may
be released before the tuning operation is complete. After the tuning operation is complete, the tone is
heard again if the frequency is changed and the PTT switch is pressed. When the tone stops during single
sideband operation, an increase in receiver noise level (static) indicates the antenna has been matched
and the radio set is now receiving atmospheric noise. If the tone stops but the static does not increase, the
selected antenna is shorted or otherwise faulty.

TUNE FAULT INDICATOR

If the tuning tone continues for a long time (8 thru 12 seconds) and a tune fault consisting of high-pitched

beeping tones is heard after the tuning stops with no static, the tuner has failed to tune. The tune fault
indicator may be caused by the following:

Selecting a frequency below 2 MHz
An open or short in the antenna
An antenna not suitable for the frequency in use

Antenna obstructions
Malfunction of the amplifier/coupler.

This fault can be cleared by any of the following:

Turning the radio off and back on
Switching to D RCV or V RCV mode and back to DTR or VTR mode
Changing frequencies by at least 1 kHz

3-7

TM 07748B-12/1, TM 11-5820-1046-12

VSWR INDICATOR

The vswr indicator is a singular, short, high-pitched tone heard in the handset earpiece at the beginning of
a transmission (when vswr is greater than 1.5 to 1 but less than 1.6 to 1). The meaning of the vswr indicator
depends on the setting of the ANT SEL switch on the amplifier/coupler.

NORMAL OPERATION

If the ANT SEL switch is in the BNC (middle) position, the vswr indicator

—
indicates a previous momentarily high vswr condition. The high vswr condition can occur if the antenna or
its immediate environment is disturbed. Such a disturbance causes the antenna’s impedance to change,
which produces the high vswr (unmatched) condition. The antenna tuner measures the vswr at the
beginning of the next transmission and retunes if the impedance change is permanent.

ANTENNA TUNER BYPASSED

If the ANT SEL switch is set to 50 (bottom), which bypasses the

—
antenna tuner, the vswr indicator indicates the antenna vswr is higher than 4 to 1, but can still provide
useful communications.

3-8

TM 07748B-12/1, TM 11-5820-1046-12

Section Il.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(PMCS)

The PMCS table lists the Inspections and care of the radio set required to keep it in good operating
condition.

The interval column of the PMCS table indicates how often to perform a certain check or service. The item
to be inspected column lists what to inspector service. The procedure column of the PMCS table explains

how to perform the check or service.

M-Monthly

Check and Have Repaired

or Adjusted as Necessary

Check cables for cracked or
worn insulation and bare wires.

Item

No.

1

B

Interval

A W M

D

B-Before

D-During

Item to Be Inspected

Dipole RF, NVIS RF, handset,
and CW key electrical cables

A-After
W-Weekly

To avoid damage from
electrostatic
(ESD), use ESD precau­tionary procedures when

removing or replacing the
RT CONT connector cap.

2

3

4

5

6

RT and amplifier/coupler
connectors, and electrical cable
connectors

RT and amplifier/coupler external
surfaces

RT and amplifier/coupler knobs
RT and amplifier/coupler external

surfaces

RT and amplifier/coupler controls

and switches

Check connectors for damage or
corrosion. Tighten connectors, if

loose. Clean, if necessary. Check
that RT CONT connector cap is
secured to connector; attach if

necessary.
Check for cracks, dents, or

holes.
Check for broken knobs.

Check for loose nuts and bolts.

Check that mechanical action is
smooth and free of binding.

discharge

3-9

TM 07748B-12/1, TM 11-5820-1046-12

Item

No.

7

8

9

B D

Interval

A W

B-Before

M

D-During

Item to Be Inspected

A-After
W-Weekly

Dipole reel

Dipole tape measure

Canvas bags (dipole, NVIS, and
field pack)

M-Monthly

Check and Have Repaired
or Adjusted as Necessary

Check that mechanical action is
smooth and free of binding.

Check that mechanical action is
smooth and free of binding.

Check for cuts or tears.

3-10

TM 07748B-12/1, TM 11-5820-1046-12

Section Ill.

Initial Checks
Single Sideband Operation
Shutdown

1. Verify PMCS procedure on page 3-9 has been completed.

2. Verify Installation procedures on page 2-4 have been performed.

3. Verify radio set troubleshooting procedure on page 4-6 has been completed.

4. Connect handset and, if applicable, voice encryption device to RT AUDIO (1) connector.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION UNDER USUAL CONDITIONS

Page

3-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .

3-12
3-13

Figure 3-5

Initial Checks

3-11

TM 07748B-12/1, TM 11-5820-1046-12

Do not touch or stand near antenna when equipment Is energized.
Dangerously high rf voltages exist on and around antennas and antenna
terminals during transmission. Protect yourself by knowing safety procedure

in TB SIG 291.

To prevent equipment damage, avoid operating transmitter with antenna

touching any natural or man-made object (metal, power lines, etc).

The following procedure is used to operate the STAJ radio in the single sideband mode.

Step

1.

2.

3.

4.

Procedure

VERIFY INITIAL CHECKS
PROCEDURE HAS BEEN
PERFORMED.

SET

VOLUME OFF/MAX

SWITCH

(3)

TO MIDRANGE.

SET AMPLIFIER/COUPLER

ANT SEL

SWITCH

(4)

TO

CORRECT POSITION.
ENTER FREQUENCY AND

MODE OF OPERATION.
a.

Sequentially press

FREQUENCY KHz

pushbuttons (7) to select
a frequency.

Press right-hand MODE

b.

pushbutton (5) to select

a sideband.

Normal Indication

1. On RT display, all LCD
segments are on.

2. On RT, sideband,

frequency, and mode

are displayed.

Frequency is displayed.

LSB or USB indicator (2)
lights.

Remarks

Refer to page 3-11.

Self-test Indication lasts approx
4 seconds.
Last sideband, frequency, and
mode chosen are displayed
after self-test.

Any frequency from 2,000 to
29,999 KHz can be selected.

3-12

Press left-hand MODE

c.

pushbutton (6) to select
an operating mode.

VTR, V RCV, DTR, or D

RCV indicator (1) lights.

TM 07748B-12/1, TM 11-5820-1046-12

Step

5.

6.

Procedure

PRESS AND RELEASE PTT
SWITCH ON HANDSET.

COMMUNICATE WITH
OTHER RADIOS.

Normal Indication

Tune tone in handset.

Remarks

A continuous high-pitched tune
tone is heard in handset for 3
seconds typical. Tone indicates
radio is being tuned to
antenna.

Figure 3-6.

Single Sideband Operation

1. Set VOLUME OFF/MAX (3) switch on RT to OFF.

3-13/(3-14 blank)

TM 07748B-12/1, TM 11-5820-1046-12

3-15/(3-16 blank)

SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS

When the temperature is lower than -20°C, it takes up to 5 seconds to change the frequency and mode
display indicators after a pushbutton switch has been pressed. No other special operating procedures are

required for operation of the radio in cold weather. All other operation is normal.

When no transmissions may be made, the operating mode selected should be V RCV or D RCV. These

modes prevent accidental transmission if the handset PTT switch is pressed and released.

TM 07748B-12/1, TM 11-5820-1046-12

CHAPTER 4

OPERATOR MAINTENANCE

Section I.

Initial Setup
Cleaning
Inspection
Painting

Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools:

None

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brush, Bristle (item 1, App E)
Brush, Paint (item 2, App E)
Cheesecloth (item 3, App E)
Cleaning Compound (solvent)

(item 4, App E)
Detergent (item 5, App E)
Paint, (item 6, App E)
Paint, Primer (item 7, App E)
Sandpaper (item 8, App E)
Tape, Masking (item 9, App E)
Wiping Rags (item 10, App E)

MAINTENANCE PROCEDURES

Material/Parts:

Page

4-1
4-1
4-2
4-2
4-3

Personnel Required:

1

1. Verify RT VOLUME OFF/MAX switch is set to OFF.

2. Disconnect handset (4) from RT (1) and manpack whip antenna (5) from amplifier/coupler (2).

Avoid water contact with the handset and any other items that may be
damaged.

3.

Remove all dirt, dust, grease, or other debris from RT

with a cloth or brush moistened with cleaning compound or soap and water.

4. Dry RT (1), amplifier/coupler (2), and battery pack (3) with a clean cloth.

(1),

amplifier/coupler

(2),

and battery pack

(3)

4-1

TM 07748B-12/1, TM 11-5820-1046-12

1.

Visually Inspect each connector for bent, recessed, or missing pins. If any pins are bent, recessed,

or missing, notify organizational maintenance.

2.

Visually inspect rubber seal on each connector at front end of radio to verify it is not out of place or

damaged. If any rubber seals are out of place, adjust them to correct position. If any rubber seals
are damaged, notify organizational maintenance.

3. Position radio set so RT (1) and amplifier/coupler (2) panels are facing you.

4.

Loosen and unfasten 2 latches

5. Pull attached battery pack (3) toward rear of RT (1) and amplifier/coupler (2). When battery pack
connector
pack (3).

6. Visually inspect RT (1), amplifier/coupIer (2), and battery pack (3) for dents, cracks, holes, or
missing items. If any equipment is dented, cracked, missing, or punctured, notify organizational
maintenance.

7.

Visually inspect RT

equipment is corroded or has exposed metal, complete the painting procedure below.

8.

Position RT

9. Position battery pack (3) on back of RT (1) and attached amplifier/coupler (2).

10.

Pull battery pack

amplifier/coupler (2) will engage battery pack connector (7).

11. Secure battery pack (3) to RT (1) and attached amplifier/coupler (2) and fasten and tighten 2
latches

12. Connect handset (4) to RT AUDIO) connector (9) and manpack whip antenna (5) to whip antenna
socket

(6).

(10).

(7)

disengages from power connector

(1),

amplifier/coupler

(1)

with attached amplifier/coupler

(3)

toward front of RT

(6)

that secure battery pack

(8)

(2),

and battery pack (3) for bare metal or corrosion. If any

(2)

facing you when ready to install battery pack

(1)

and amplifier/coupler

(3)

to RT

(1)

and amplifier/coupler

on rear of amplifier/coupler

(2).

Power connector

(2),

remove battery

(8)

on rear of

(2).

(3).

1. Locate all areas of exposed bare metal on exterior of RT (1), amplifier/coupler (2), and battery
pack (3).

2. Use masking tape to cover all areas or items (connectors, knobs, and switches) that do not

warrant painting.

3. Prepare surfaces to be painted by sanding each with sandpaper.

4. Wipe each surface after sanding with a cloth to remove dust caused by sanding.

5. Use paint brush to apply primer to cover exposed bare metal. Let primer dry for six hours.

6. Use paint brush to apply epoxy paint to cover primer and let dry for four hours.

7. Remove all masking tape.

4-2

TM 07748B-12/1, TM 11-5820-1046-12

When using a compresed airjet, use eyeshields to prevent severe eye
injury.

To prevent equipment damage, compressed air must be clean, dry, and at
a maximum pressure of 28 psi. Do not overlook the force of the airjet when
cleaning delicate parts.

8. Dry components and remove water from inside of each connector with an airjet (if available) or dry
cloth.

Perform operator troubleshooting procedure on page 4-6.

4-3

TM 07748B-12/1, TM 11-5820-1046-12

4-4

Figure 4-1.

Maintenance Procedures

TM 07748B-12/1, TM 11-5820-1046-12

Section Il.

No lubrication is required during operator maintenance.

OPERATOR TROUBLESHOOTING

a.

b. RT faulty
Battery low
a.

b. RT faulty
a. Amplifier/coupler faulty

b. Antenna connection bad

Item

1.

2.

3.

4.

Section Ill.

Symptom

No receiver noise at turn-on

Clicking sound
No tune-up tone

Tune-up tone then tune fault
tone

LUBRICATION

Dead battery

Amplifier/coupler faulty

Probable Cause

Tune fault tone at turn-on

5.
No transmit sidetone

6.

7.

No receiver audio

Section IV.

The operator preoperational check is performed when:

any unit or accessory is replaced to verify the system is operating properly
the radio set does not operate in accordance with operating procedures

Another similar radio set is needed to perform this procedure. If any of the requirements are not met or if
fault tones are evident, refer to organizational troubleshooting on page 5-3.

RT faulty or frequency selected is lower than 2 MHz

RT faulty

a.
b. Amplifier/coupler faulty

Volume too low

a.
b. Antenna connection bad

RT faulty

c.
d. Amplifier/coupler faulty

PREOPERATIONAL CHECK

4-5

TM 07748B-12/1, TM 11-5820-1046-12

Tools:

TK-101/G

Materials/Parts:

None

Personnel Required:

1. Verify installation instructions procedure on page 2-4 has been performed.

2. Verify there is no evident damage that affect operation.

NOTE

An automatic power-up test of RT is run, lasting approximately 4 seconds.
If operational, the RT display indicates the digit O and asterisk for all
characters during test. The RT ECCM, DTRCV, VTRCV, USB, LSB and
unused display indicators should turn on. If test is successful, RT display
changes to indicate frequency, sideband, and mode of operation last
used. If test is unsuccessful, RT display alternately indicates failed internal
component and NO-GO. RT must be repaired or replaced.

3.

Turn RT

VOLUME OFF/MAX

switch

(1)

on and adjust for desired listening level of received noise in

handset.

NOTE

1

Failure of RT display lights in steps 4 and 5 is not a high maintenance
priority. Radio set under test will still perform its mission.

4. Press and hold RT LIGHT button (2). Display light turns on.

5. Release RT LIGHT button (2). Display light turns off immediately.

6.

Press and release RT

FREQUENCY KHz

pushbuttons

(6)

to select authorized operating frequency

of a similar radio set.

7. Verify authorized operating frequency is selected on similar radio.

8. Verify amplifier coupler ANT SEL switch (3) is set to whip (top).

9. Press and release left-hand RT MODE pushbutton (5) until V RCV indicator turns on.

10. Press and release right-hand RT MODE pushbutton (4) until USB indicator turns on.

11. Verify USB has been selected on RT indicator of similar radio set.

12. Verify transmission from similar unit is clearly heard in handset.

13. Press and release right-hand RT MODE pushbutton (4) until LSB indicator turns on.

14. Verify LSB has been selected on RT indicator of similar radio set.

15. Verify transmission from similar radio set is clearly heard in handset.

16. Press and release right-hand RT MODE pushbutton (4) until USB indicator turns on.

17. Verify USB has been selected on RT indicator of similar radio set.

16. Press and release left-hand RT MODE pushbutton until VTR (5) indicator turns on.

19. Press and release RT FREQUENCY KHz pushbuttons (6) to select another authorized operating

frequency of a similar radio set.

20. Verify authorized operating frequency is selected on similar radio.

4-6

TM 07748B-12/1, TM 11-5820-1046-12

Do not touch or stand near antenna when equipment is energized.
Dangerously high rf voltages exist on and around antennas and antenna
terminals during transmission. Protect yourself by knowing safety proce­dures in TB SIG 291.

To prevent equipment damage, avoid operating transmitter with antenna
touching any natural or man-made object (metal, power lines, etc).

21.

Press and release PTT switch to begin tuning radio set under test to antenna.

NOTE

A series of beeps may be heard in handset following tuning indicator.

These beeps indicate a tune fault has occurred. This maybe corrected by

one of the following:
Turn the radio off and back on

Switch to D RCV or V RCV mode and back to DTR or VTR mode

Change frequency by at least 1 kHz

22.

Verify a continuous, high-pitched tone (tuning indicator) is heard in handset for approximately 3
seconds, depending on frequency of operation selected. If no tone is heard, press and release PTT
switch again.

Figure 4-2. Preoperational Check

4-7

TM 07748B-12/1, TM 11-5820-1046-12

One short beep (vswr indicator) maybe heard at beginning of transmis­sion. This is normal.

23.

Press and hold PTT switch and speak into handset. Establish two-way communication with similar
radio set. The voice audio should be heard in handset when transmitting. Check quality of

transmitted signals.

24.

Release PTT switch to hear reply from similar radio set when transmission is complete. If similar
radio set is heard, check quality of received signals.
Readjust RT VOLUME OFF/MAX switch (1) to a comfortable listening position.

25.

When communications are completed, set RT VOLUME OFF/MAX switch (1) to OFF.

26.

NOTE

4-8

TM 07748B-12/1, TM 11-5820-1046-12

CHAPTER 5

ORGANIZATIONAL MAINTENANCE

Section I.

REPAIR PARTS; SPECIAL TOOLS;

TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);

SUPPORT EQUIPMENT; AND MATERIALS

U.S. Army, for authorized common tools and equipment refer to the Modified Table of Organization and
Equipment (MTOE) applicable to your unit.

For a list of the repair parts and special tools used in organizational maintenance of the radio set, refer to
the repair parts and special tools list, TM 11-5820-1046-20P. Tools and test equipment used in
organizational maintenance of the radio set are listed in appendix B, Maintenance Allocation Chart.

No materials are required for organizational maintenance of the radio sets.

TM 07748B-12/1, TM 11-5820-1046-12

Section Il.

There are no organizational level preventive maintenance checks and services. Refer to page 3-9 for
operator level preventive maintenance checks and services.

PMCS

Section Ill. ORGANIZATIONAL TROUBLESHOOTING

Page

Introduction
Test Setup
Troubleshooting Flowchart

Receiver Sensitivity Test

Radio set organizational troubleshooting is performed using the test setup shown on page 5-4. Upon
completion of radio set troubleshooting, the faulty unit is removed, if applicable, in accordance with
maintenance instructions starting on page 5-15. The replacement unit is then installed. Upon installing a
replacement unit, the radio set preoperational check procedure on page 4-6 is run to verify proper
operation.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3
5-4
5-5

5-11

5-3

TM 07748B-12/1, TM 11-5820-1046-12

Detailed setup instructions and initial control settings are discussed in the troubleshooting charts starting
on page 5-5. Distinct audio tones produced by the radio set, along with measurements taken with an rf
wattmeter and a multimeter, will aid you in isolating a faulty unit.

5-4

NOTES:

1. TEST STATION SHOULD BE WITHIN 50 METERS OF
UNIT UNDER TEST AND SET TO SAME FREQUENCY.

2. OTHER ANTENNA CONFIGURATIONS CAN BE USED.

3. MARINE CORPS ONLY

Figure 5-1.

Test Setup

TM 07748B-12/1, TM 11-5820-1046-12

PAGE 5-6

REPLACE BATTERY
PACK (PG 5-16)

PAGE 5-7

REPLACE RT

(PG 5-12)

5-5

TM 07748B-12/1, TM 11-5820-1046-12

PAGE 5-5

REPLACE BATTERY

PACK (PG 5-16)

REPLACE RT

(PG 5-12). LISTEN
FOR RECEIVER
NOISE IN HANDSET

REPLACE
AMPLIFIER/
COUPLER

(PG 5-14)

5-6

PAGE 5-5

TM 07748B-12/1, TM 11-5820-1046-12

REPLACE RT

(PG 5-12)

REPLACE RT

(PG 5-12)

PAGE 5-8

5-7

TM 07748B-12/1, TM 11-5820-1046-12

PAGE 5-7

REPLACE RT

(PG 5-12)

PAGE 5-9

REPLACE RT

(PG 5-12)

PAGE 5-9

5-8

PAGE 5-9

PAGE 5-8

PAGE 5-8

TM 07748B-12/1, TM 11-5820-1046-12

PAGE

5-10

PAGE 5-8

REPLACE RT

(PG 5-12)

PAGE
5-10

PAGE
5-10

5-9

TM 07748B-12/1, TM 11-5820-1046-12

PAGE 5-9

REPLACE

AMPLIFIER/COUPLER

(PG 5-14)

PAGE 5-9

PAGE 5-9

REPLACE RT

(PG 5-12)

5-10

TM 07748B-12/1, TM 11-5820-1046-12

PAGE
5-12

NOTE 1.

NOTE 2. TUNE-UP TONE WILL ONLY BE HEARD FIRST TIME PTT IS CLOSED AFTER THE FREQUENCY

NOTE 3. TEST FREQUENCIES FOR IMPEDANCE MATCHING:

TEST FREQUENCY

1.

2.

3.

4.

5.

6.

IS CHANGED, AND ALSO AFTER MODE IS CHANGED FROM V-TR TO V-RCV AND BACK TO V-TR

1. 2,400.0

2. 3,200,0

3. 4,300.0

4. 6,000.0

5. 8,500.0

6. 12,000.o

7. 16,000.0

8. 20,000.0

RADIO SET FREQUENCY

2,221.2 KHZ
3,334.3 KHZ
6,665.6 KHZ
8,889.8 KHZ

15,554.5 KHZ

29,993.9 KHZ

9. 25,000.0

10. 27,000.0

11. 29,000.0

SIDEBAND

USB

LSB
USB
LSB
US8
LSB

RF GENERATOR FREQUENCY

2.2222 MHZ

3.3333 MHZ

6.6666 MHZ

8.8888 MHZ

15.5555 MHZ

29.9929 MHZ

—

5-11

TM 07748B-12/1, TM 11-5820-1046-12

PAGE
5-11

5-12

PAGE
5-13

PAGE
5-12

TM 07748B-12/1, TM 11-5820-1046-12

5-13/(5-14 blank)

TM 07748B-12/1, TM 11-5820-1046-12

Section IV. MAINTENANCE PROCEDURES

Page

Introduction
RT Removal and Replacement
Amplifier/Coupler Removal and Replacement

Battery Pack Removal and Replacement

To verify proper operation, the preoperational check procedure on page 4-6 should be run when a

replacement unit is installed.

Tools:

None

1. Lay RT (2) and amplifier/coupler (3) on fiat surface and align guide with hole between the two
units.

2. Verify VOLUME OFF/MAX switch on RT is set to OFF.

3. Remove battery pack (1) in accordance with removal instructions on page 5-18.

3. Lay latched RT (2) and amplifier/coupler (3) on a fiat surface and unfasten front and rear latches
(4), respectively, securing the RT and amplifier/coupler together.

4. Carefully separate RT (2) from amplifier/coupler (3).

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Material/Parts:

None

Personnel Required:

1

5-15
5-15
5-17
5-18

1. Lay RT (2) and amplifier/coupler (3) on fiat surface and align guide with hole between the two
units.

2. Secure RT (2) to amplifier/coupler (3) and fasten latches (4).

3. Replace battery pack (1) in accordance with replacement instructions on page 5-18.

Perform preoperational check procedure on page 4-6.

5-15

TM 07748B-12/1, TM 11-5820-1046-12

5-16

Figure 5-2.

RT and Amplifier/Coupler Removal and Replacement

TM 07748B-12/1, TM 11-5820-1046-12

Tools

Material/Parts

Personnel Required:

None None

1. Lay RT (2) and amplifier/coupler (3) on a flat surface and align guide with hole between the two
units.

2. Verify VOLUME OFF/MAX switch on RT is set to OFF.

3. Remove battery pack (1) in accordance with removal instructions on page 5-18.

3. Lay latched RT (2) and amplifler/coupler (3) on a flat surface and unfasten front and rear latches
(4), respectively, securing the RT and amplifier/coupler together.

4. Carefully separate amplifier/coupler (3) from RT (2).

1. Lay RT (2) and amplifier/coupler (3) on a flat surface and align guide with hole between the two

units.

2. Secure amplifier/coupler (3) to RT (2) and fasten latches (4).

3. Replace battery pack (1) in accordance with replacement instructions on page 5-18.

Perform preoperational check procedure on page 4-6.

5-17

TM 07748B-12/1, TM 11-5820-1046-12

Tools:

None

Matetial/Parts

None

Personnel Required:

1

1. Verify RT VOLUME OFF/MAX switch is set to OFF.

2. Position radio set so RT (1) and amplifier/coupler (2) panels are facing you.

3. Loosen and unfasten 2 latches (3) that secure battery pack (4) to RT (1) and amplifler/coupler (2).

4. Pull attached battery pack (4) toward rear of RT (1) and amplifier/coupler (2). When battery pack

connector
pack

(4).

(5)

disengages from power connector

(6)

on rear of amplifler/coupler

(2),

remove battery

1. Position RT (1) with attached amplifier/coupler (2) facing you when ready to replace battery pack

(4).

2. Position battery pack (4) on back of RT (1) and attached amplifier/coupler (2).

3.

Pull battery pack

(4)

toward front of RT

(1)

and amplifier/coupler

(2).

Power connector

(6)

on rear of

amplifier/coupler (2) will engage battery pack connector (5).

4. Secure battery pack (4) to RT (1) and attached amplifier/coupler (2) and fasten and tighten 2
latches

(3).

Perform preoperational check procedure on page 4-6.

5-18

TM 07748B-12/1, TM 11-5820-1046-12

Figure 5-3. Battery Pack Removal and Replacement

5-19/(5-20 blank)

TM 07748B-12/1, TM 11-5820-1046-12

CHAPTER 6

PREPARATION FOR STORAGE OR SHIPMENT

The radio set should be stored in the best available site that provides protection from the elements and

unauthorized personnel. Covered sites are the best. If there is not enough covered space for all items, keep
items covered that are most Iikely to be damaged by the weather. Items that cannot be covered should be
stored on hard surfaces that drain well. Trucks, vans, and containers may be used if they give the best
available protection. Be sure to comply with the fire plan for fire-fighting equipment and personnel.

A lithium-sulfur dioxide (lithium) battery used with the radio set contains
pressurized sulfur dioxide (S0
circuit, crush, puncture, mutilate, or disassemble lithium batteries; do not

recharge or test lithium batteries for capacity; do not use a Halon type fire

extinguisher on a lithium battery.

) gas. To prevent rupture, do not heat, short

2

Do not use any lithium battery which shows the following signs of rupture:

bulging, swelling, disfigurement, brown liquid in the plastic wrap, or a
swollen plastic wrap. If the battery compartment becomes hot to the touch,
or a hissing sound or the smell of S0

gas (rotten egg smell) is present,

2

immediately turn off the equipment. Move the equipment to a well-ventilated
area or leave the area.

In the event of a fire near a lithium battery, use a carbon dioxide (C0

) type

2

extinguisher. Rapid cooling of lithium batteries is necessary to prevent
venting and the potential exposure of lithium. In the event that lithium metal

becomes involved in fire, the use of a graphite-based Class D fire
extinguisher is recommended, such as Lith-X or MET-L-X.

Do not store lithium batteries with other hazardous materials and keep away
from open frame or heat.

PREPARATION

Preparation consists of disassembling the radio set in accordance with organizational maintenance
removal procedures on pages 5-15 thru 5-19.

PACKAGING

To package the radio set for reshipment, proceed as follows:

1. Place latched RT and amplifier/coupler in space provided in transit case.

2. Place handset, telegraph key (if used), antenna, and battery pack in transit case.

3. Replace transit case cover and fasten four latches.

6-1/(6-2 blank)

TM 07748B-12/1, TM 11-5820-1046-12

APPENDIX A

REFERENCES

This appendix lists all forms, field manuals, technical manuals, and miscellaneous publications

referenced in this manual.

DA Form 2028

DA Form 2028-2
NAVMC 10772

SF 361
SF 368

FM 21-11
FM 21-26

RS-07748A-50/4

TM 07748B-45/2/TM 11-5820-1046-40

TM 11-5820-1046-20P

TM 11-5820-1046-40P

Recommended Changes to Publications and Blank Forms
Recommended Changes to Equipment Technical
Publications
Recommended Changes to Technical Publications

Transportation Discrepancy Report (TDR)

Product Quality Deficiency Report

Artificial Respiration
Map Reading

Rebuild Standards for Radio Set AN/PRC-104
Field and Depot Maintenance Instructions for Radio Set

AN/PRC-104
Organizational Maintenance Repair Parts and Special Tools

List for Radio Set AN/PRC-104
General Support Maintenance Repair Parts and Special

Tools List for Radio Set AN/PRC-104

TM 4700-15/1
TM 750-244-2

AMDF
AR 55-38

AR 735-11-2

Equipment Record Procedures
Procedures for Destruction of Army Electronic Materiel to

Prevent Enemy Use (Electronic Command)

(AR708-1) IAW Packaging Segment of AMDF by NSN
Reporting of Transportation Discrepancies in Shipments
Reporting of Item and Packaging Discrepancies

A-1

TM 07748B-12/1, TM 11-5820-1046-12

AR 750-244-2
AR 755-2

CTA 8-100
CTA 50-970

DA Pam 25-30

DA Pam 738-750

MCO 4430.3J
MCO P4450.7
MCO P4610.19

SB 11-131
SB 11-573

Destruction of Army Materiel
Disposal of Excess, Surplus, Foreign Excess, Captured, and

Unwanted Material
Army Medical Department Expendable/Durable Items

Expendable/Durable Items (Except Medical, Class V, Repair

Parts, and Heraldic Items)
Consolidated Index of Army Publications and Blank Forms
The Army Maintenance-Management System (TAMMS)

Report of Discrepancy (ROD)

Marine Corps Warehousing Manual

Transportation and Travel Record of Transportation

Discrepancies

Vehicular Radio Sets and Authorized Installations

Painting and Preserving of Supplies Available for Field Use

for Electronics Command Equipment

SB 11-614

SB 38-100

TB 43-0118

TB SIG 291

Caution Notice for Antenna Bases, Towers, and Other Mast

Structures
Preservation, Packaging, Packing and Marking Materials,

Supplies and Equipment Used by the Army
Field Instructions for Painting and Preserving Electronics

Command Equipment Including Camouflage Pattern Painting
of Electrical Equipment Shelters

Safety Measures to Be Observed When Installing and Using

Whip Antennas, Field Type Masts, Towers, Antennas, and

Metal Poles That Are Used with Communication, Radar,
and Direction Finder Equipment

A-2

TM 07748B-12/1, TM 11-5820-1046-12

(ARMY ONLY)

APPENDIX B

MAINTENANCE ALLOCATION CHART

Section I.

This appendix provides a summary of the maintenance operations for STAJ. It authorizes categories of

maintenance for specific maintenance functions on repairable items and components and the tools and

equipment required to perform each function. This appendix may be used as an aid in planning

maintenance operations.

Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or

electrical characteristics with established standards through examination.

b. Test.

characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition, ie, to clean
(decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or
compressed air supplies.

To verify serviceability and to detect incipient failure by measuring the mechanical, or electrical

INTRODUCTION

d. Adjust. To maintain, within prescribed limits, by bringing into proper or exact position, or by setting

the operating characteristics to the specified parameters.

e. Aline. To adjust specified variable elements of an item to bring about optimum or desired
performance.

f. Calibrate. To determine and cause corrections to be made or adjusted on instruments or test,
measuring, and diagnostic equipments used in precision measurement. Consists of comparisons of two
instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy
in the accuracy of the instrument being compared.

g. Install. The act of emplacing, seating, or fixing into position an item, part, or module (component or

assembly) in a manner to allow the proper functioning of an equipment or system.

h. Replace.

assembly) for an unserviceable counterpart.

The act of substituting a serviceable like type part, subassembly, or module (component or

B-1

TM 07748B-12/1, TM 11-5820-1046-12

i. Repair. The application of maintenance services (inspect, test, service, adjust, aline, calibrate,

replace) or other maintenance actions (welding, grinding, riveting, straightening, facing, remachining, or
resurfacing) to restore serviceability to an item by correcting specific damage, fault, malfunction, or failure
in a part, subassembly, module (component or assembly), end item, or system.

j. Overhaul. That maintenance effort (service/action) necessary to restore an item to a completely
serviceable/operational condition as prescribed by maintenance standards (ie, DMWR) in appropriate
technical publications. Overhaul is normally the highest degree of maintenance performed by the Army.
Overhaul does not normally return an item to a like new condition.

k. Rebuild.

to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree
of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to
zero those age measurements (hours/miles, etc) considered in classifying Army equipment/components.

a. Column (1)

components, assemblies, subassemblies, and modules with the next higher assembly.

b. Column (2) — Component/Assembly. Column 2 contains the noun names of components,

assemblies, subassemblies, and modules for which maintenance is authorized.

c. Column (3)

in column 2. When items are listed without maintenance functions, it is solely for the purpose of having the
group numbers in the MAC and RPSTL coincide.

d. Column (4)

the appropriate subcolumn(s), the lowest level of maintenance authorized to perform the function listed in
column 3. This figure represents the active time required to perform that maintenance function at the

indicated category of maintenance. If the number or complexity of the tasks within the listed maintenance
function varies at different maintenance categories, appropriate “work time” figures will be shown for
each category. The number of task-hours specified by the “work time” figure represents the average time
required to restore an item (assembly, subassembly, component, module, end item, or system) to a

serviceable condition under typical field operating conditions. This time includes preparation time,

troubleshooting time, and quality assurance/quality control time in addition to the time required to

perform the specific tasks identified for the maintenance functions authorized in the maintenance

allocation chart. Subcolumns of column 4 are as follows:

Consists of those services/actions necessary for the restoration of unserviceable equipment

— Group Number. Column 1 lists group numbers, the purpose of which is to identify

— Maintenance Function.

— Maintenance Category. Column 4 specifies, by the listing of a “work item” figure in

Column 3 lists the functions to be performed on the item listed

B-2

c

— Operator/Crew

o

– Organizational

F

— Direct Support

H

— General Support

D

— Depot

TM 07748B-12/1, TM 11-5820-1046-12

e. Column (5)

— Tools and Equipment. Column 5 specifies, by code, those common tool sets (not

individual tools) and special tools, test, and support equipment required to perform the designated
function.

f. Column (6)

— Remarks.

Column 6 contains an alphabetic code that leads to the remark in section IV,

Remarks, which is pertinent to the item opposite the particular code.

a. Tool or Test Equipment Reference Code. The numbers in this column coincide with the numbers

used in the tools and equipment column of the MAC. The numbers indicate the applicable tool or test

equipment for the maintenance functions.

b. Maintenance Category. The codes in this column indicate the maintenance category allocated the

tool or test equipment.

c. Nomenclature. This column lists the noun name and nomenclature of the tools and test equipment

required to perform the maintenance functions.

d. National/NATO Stock Number. This column lists the National/NATO stock number of the specific

tool or test equipment.

e. Tool Number. This column lists the manufacturer’s part number of the tool followed by the

Commercial and Government Entity (5-digit) in parentheses.

a. Reference Code. This code refers to the appropriate item in section II, column 6.
b. Remarks. This column provides the required explanatory information necessary to clarify items

appearing in section Il.

B-3

TM 07748B-12/1, TM 11-5820-1046-12

Section Il. MAINTENANCE ALLOCATION CHART

RADIO SET AN/PRC-104B

(1)

Group

Number

00

Component/Assembly

RADIO SET AN/PRC-104B

(2) Maintenance

FOR

(3)

Function

SERVICE

INSPECT
TEST
TEST
REPAIR

(4)

Maintenance Category

C O

0.2

0.2 0.2

0.2

0.4

0.3

F

H

D

(6)

Tools

and Eqpt

1,9,10,11
1,9,10,11

(6)

Remarks

A
B
D,F

01

0101

010101

0102

0103

RECEIVER-TRANSMITTER RT-1209A/URC

HOUSING, RT ASSEMBLY

PTD CA ASSEMBLY FLEX

HARMONIC FILTER ASSEMBLY

MODULATOR/DEMODULATOR ASSEMBLY

REPLACE
SERVICE

INSPECT
TEST

REPAIR 0.4
OVERHAUL 2.5

REPLACE
TEST
REPAIR 0.8

REPLACE
TEST
REPAIR

REPLACE
TEST

REPAIR 0.4

ALIGN

REPLACE

0.1

0.1

0.1

0.4 1,2,7

0.3

0.5

0.6

0.4

0.4

0.1 12

0.3 1,3,thru C,l

0.1

0.1

thru 12,14

1,2,7

thru 12,14

1 thru
11,14,20

12

1

1,2,7

thru 12,14

12

1

1,12,19

12,14,20
1,2,7

thru 12,

14,19
1,7 thru
11,14,20

12

G

K
E,H,N

I

K,l
E,H,I

C,l

E,H,I

H,l

I

P
0104
0105

0106

B-4

SYNTHESIZER ASSEMBLY

ELECTRONIC FRONT PANEL
POWER SUPPLY ASSEMBLY

REPLACE
REPLACE
REPLACE

TEST

REPAIR 0.4

ALIGN

0.1

0.1

0.1

0.7

0.1

12
12
12

1,8,9 C,l

thru 11,

14,20
1,2,7 H,l

thru 11,

12,14,19

1,8,12,
14,20

P

P

I

TM 07748B-12/1, TM 11-5820-1046-12

(1)

Group

Number

02

0201

0202

Section Il.

MAINTENANCE ALLOCATION CHART

RADIO SET AN/PRC-104B

Component/Assembly

AMPLIFIER, RADIO FREQUENCY
AM-6874( )/PRC-104

RF AMPLIFIER ASSEMBLY

POWER AMPLIFIER MODULE ASSEMBLY

(2)

FOR

(3)

Maintenance

Function

REPLACE
SERVICE
INSPECT

TEST
REPAIR
OVERHAUL

REPLACE

TEST

REPAIR

REPLACE
TEST

REPAIR

ALIGN

Maintenance Category

C

0.2

0.2

(4)

O

F H

0.1

0.4

D

0.1

0.2

2.5

0.5

0.2

0.9

0.2

0.1

(8)

Tools

and Eqpt

1,8 thru
12, 14
1,8 thru
12,14
1,8 thru

2,14,20

12

1

1,8 thru

12,14,20
12

1,3 thru
11,14,15,

20

1,8 thru
12,14,19
1,3 thru
12,14,15,

20

(6)

Remark

G

K
E,H

I

C,l
H,l

C,l

E,H,I

I

020201

020202

0203

AMPLIFIER, POWER TOP CCA

AMPLIFIER, POWER BOTTOM CCA

ANTENNA TUNER MODULE ASSEMBLY

REPLACE
TEST

REPAIR

REPLACE
TEST

REPAIR

REPLACE
TEST

REPAIR
ALIGN

0.1

0.4

0.9

0.2

0.4

0.9

0.2

0.7

0.2

0.1

13
1,3 thru
11,14,15,
20
1,8 thru
12,14,19

12
1,3 thru
11,14,15
20
1,3 thru
12,14,19

12
1,7 thru
11,14,15,
20
1,8 thru
12,14,19
1,7,8,
12,14,20

C,l

H,l

C,l

H,l

C,l

E,H,I

B-5

TM 07748B-12/1, TM 11-5820-1046-12

(1)

Group

Number

020301

020302

03

Section Il.

MAINTENANCE ALLOCATION CHART

RADIO SET AN/PRC-104B

Component/Assembly

TUNER, ANTENNA TOP CCA

TUNER, ANTENNA BOTTOM CCA

CASE RADIO SET CY-8291/PRC-104(V)

(2)

FOR

(3)

Maintenance

Function

REPLACE
TEST

REPAIR

REPLACE
TEST

REPAIR

REPLACE
REPAIR

0.1

(4)

F

H

D

0.4

0.7

0.2

0.4

0.7

0.2

0.3

Maintenance Category

C O

(5)

Tools

and Eqpt

12
1,7 thru C,l
11,14,15
20
1,3 thru
12,14,19

12
1,7 thru C,l

11,14,15,
20
1,8 thru
12,14,19

12,21

Remarks

H,l

H,I

(6)

04
05
06

07

ANTENNA AS-2259( )/GR
ANTENNA GROUP AN/GRA-50

BATTERY, STORAGE BB-590/U

BATTERY ASSEMBLY CASE
CY-7875/PRC-104A

REPAIR
REPAIR
REPLACE

SERVICE
REPAIR

0.1

0.1

0.1

0.3

0.1

13 M

18
13

L

J
O

B-6

TM 07748B-12/1, TM 11-5820-1046-12

Tool or Test

Euipment

Ref Code

1
2
3
4
5

6

7
8
9

Section Ill.

Maintenance

Category

O,H,D
H,D
D
D
D
D

H,D
H,D
O,H,D

TOOL AND TEST EQUIPMENT REQUIREMENTS

FOR

RADIO SET AN/PRC-104B

National/NATO

Nomenclature

MULTIMETER AN/PSM-45 6625-01-139-2519
GENERATOR, SIGNAL SG-1171( )/U
SPECTRUM ANALYZER, MAINFRAME IP-1216(T)/GR 6625-00-424-4370

— SPECTRUM ANALYZER, IF SECTION PL-1388/11 6625-00-431-9339
— SPECTRUM ANALYZER, RF SECTION PL-1399/U 6625-00-432-5055
— SPECTRUM ANALYZER, TRACKING GENERATOR 6625-00-155-5990

SG-1122/U
RF SIGNAL GENERATOR SG-1170/U
DC POWER SUPPLY PP-2309C/U 6130-01-139-2514

TEST SET, RADIO FREQUENCY AN/USM-298 6625-00-880-5119

Stock Number

6615-01-133-6160

6625-01-120-3501

Tool

Number

10
11
12
13
14

O,H,D
O,H,D
H,D
0
H,D

DETECTING ELEMENT, 50H 6625-00-945-6092
DUMMY LOAD, 8085 5985-00-477-8165

TOOL KIT, ELECTRONlC EQUlPMENT TK-105/G 5180-00-610-8177
TOOL KIT, ELECTRONIC EQUIPMENT TK-101/G 5180-00-064-5178
GENERAL SUPPORT MAINTENANCE KIT

0A-9161/GRC-213A

— RECEIVER/TRANSMllTER RT-1209A
— AMPLIFIER, RF, AM-6874/PRC-104
— HANDSET H-250
— CABLE ASSEMBLY, ELECTRICAL POWER CX-13030
— AUDIO INPUT/KEYING, ADAPTER
— AMPLIFIER, POWER SUPPLY AM-7152/GRC-213
— ADAPTER, WHIP
—MOUNT, ELECTRICAL EQUIPMENT

MT-6234/GRC-213

— CABLE ASSEMBLY, RF.
— CABLE ASSEMBLY, AUDIO
— CABLE ASSEMBLY, CONDITIONED POWER
— ATTENUATOR, STEP, CN-1128/U
— ATTENUATOR, COAXIAL, NARDA 765-20
— PROBE HIGH IMPEDANCE, HP MODEL NO. 1121A
— TECHNICAL MANUAL
— SPEAKER LS-454
— DC POWER CABLE CX-4720

B-7

TM 07748B-12/1, TM 11-5820-1046-12

Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS

RADIO SET AN/PRC-104B

Tool or Test

Equipment

Ref Code

15

Maintenance

Category

D

— EXTENDER CABLE, AM-7152 POWER CONDITIONER

CCA
— EXTENDER CABLE AM-7152 VIC-1 CCA
— EXTENDER CABLE AM-7152 AMPLIFIER/SQULECH

CCA

OSCILLOSCOPE OS-261 C(V)1/U

FOR

Nomenclature

National/NATO
Stock Number

6825-01-119-7314

Tool

Number

16
17
18
19
20

21 H

NOTE: ALL EQUIPMENT DEFINED IN THIS SECTION (Ill) MAY BE SUBSTITUTED WITH EQUIVALENT ITEMS. EACH

MAINTENANCE SHOP SHOULD EVALUATE THEIR CURRENT EQUIPMENT AVAILABLE AGAINST THEIR
REQUIREMENTS.

D

D
O
D
D

DISTORTION ANALYZER AN/URM-184A
FREQUENCY COUNTER AN/USM-459
BATTERY CHARGER PP-6241/U 6130-00-106-6445
BENCH REPAIR CENTER PRC-350C 4940-00-403-8176
DEPOT ACCESSORIES:

— MODULATOR/DEMODUIATOR TEST EXTENDER

CABLE, 755002B9420
— RF COAXIAL CABLE, 755002B9425
— RF EXTENDER CABLE, 75500269430
— FREQUENCY CONVERTER TEST BED A1A1A1,

755002B9440
— FREQUENCY CONVERTER TEST BED A1A1A2,

755002B9450
— FREQUENCY CONVERTER TEST BED A1A1A3,

755002B9480
— HARMONIC FILTER/POWER AMPLIFIER TEST

EXTENDER CABLES, 755002B9435
— SYNTHESIZER TEST EXTENDER CABLE,

755002B9470
— ANTENNA TUNER EXTENDER CABLE, 755002B9480
— 100 OHM LOAD, 755002B9475
— 130 OHM LOAD, 755002B9490

DENT FILLER

8625-00-802-8718
8625-01-061-8828

8010-00-926-2135

B-8

TM 07748B-12/1, TM 11-5820-1046-12

Section IV. REMARKS

RADIO SET AN/PRC-104B

Reference

Code

A
B

C
D

E

F

G

H
I

J

Remarks

OPERATIONAL TEST.
TEST REQUIRED TO FAULT ISOLATE DEFECTIVE RT-1209A, AM-6874, AM-7152, SA-2365

ASSEMBLIES/COMPONENTS OR WIRING PROBLEMS.
TEST REQUIRED TO FAULT ISOLATE DEFECTIVE MODULES, CIRCUIT CARDS, OR WIRING PROBLEMS.

REPAIR IS ACCOMPLISHED BY REPLACEMENT OF ASSEMBLIES/COMPONENTS OR CABLE
ASSEMBLIES.

REPAIR IS ACCOMPLISHED BY REPLACEMENT OF MODULES, CIRCUIT CARDS, OR CABLE
ASSEMBLIES.

THIS TASK CAN INCLUDE THE REPLACEMENT OF NONREPAIRABLE ASSEMBLIES (CABLE ASSEMBLY
CG-3815 ( )/U, ADAPTER UG-3490( )U, BATTERY EXTENDER CABLE ASSEMBLY CX-13031, ANTENNA
SPRING AB-129/PR, FRAME PACK FIELD, PACK SHELF, CARGO SHELF, HANDSET H-250/U, BATTERY
CASE CY-7875, ANTENNA BASE AB-1241, TELEGRAPH KEY KY-872/PRC-104, WHIP ANTENNA
AT-271 , PRIMARY BATTERY BA-590/U, CARGO STRAP TIE-DOWN, CHARGER CABLE ASSEMBLY).

THIS TASK INVOLVES REMOVING THE RT-1209A OR AM-6874 FROM THE AN/PRC-104B.
THIS TASK CAN INCLUDE THE REPLACEMENT OF NONREPAIRABLE ASSEMBLY/PIECE PARTS.
THIS TASK WILL BE PERFORMED BY USMC DEPOT, ALBANY, GEORGIA.
THIS TASK INCLUDES THE REPLACEMENT OR BRINGING CURRENT CHEMICAL LEVELS WITHIN

SPECIFIED STANDARDS. SEE TM 11-5820-( )-12

K

L
M
N

O
P

TEST REQUIRED TO FAULT ISOLATE TO DEFECTIVE MODULES, CIRCUIT CARDS, OR WIRING
PROBLEMS.

SEE TM 11-5895-(
SEE TM 11-5820-467-15 FOR MAINTENANCE ALLOCATION.

ALTHOUGH THE REPLACEMENT OF FUSE (F-1) IS PERFORMED AT GSM, THE CONFIGURATION

DRAWINGS IDENTIFY THIS ITEM AS PART OF FGC 01010101.
SEE TM 11-5820-(

THE MODULES, CIRCUIT CARD SUBASSEMBLIES, OR PIECE PARTS WILL BE REPAIRED BY THE

USMC DEPOT, ALBANY, GEORGIA.

)-14&P FOR MAINTENANCE ALLOCATION.

)-12 FOR MAINTENANCE ALLOCATION.

B-9/(B-10 blank)

TM 07748B-12/1, TM 11-5820-1046-12

(ARMY ONLY)

APPENDIX C

COMPONENTS OF END ITEM AND

BASIC ISSUE ITEMS LISTS

Section I. INTRODUCTION

This appendix lists STAJ-unique components and basic issue items for Radio Set AN/PRC-1046 to help

inventory items required for safe and efficient operation.

This Components of End Item List is divided into the following sections:

a. Section Il. Components of End Item. These items, when assembled, make up Radio Set

AN/PRC-104B and must accompany it whenever it is transferred or turned in. The illustrations will help

identify these items.

b. Section Ill. Basic Issue Items (Bll).

Set AN/PRC-104B in operation, to operate it, and to perform emergency repairs. Although shipped
separately packed, they must accompany Radio Set AN/PRC-1046 during operation and whenever it is
transferred between accountable officers. The illustrations will assist you with hard-to-identify items. This

manual is your authority to requisition replacement Bll, based on TOE/MTOE authorization of the end item.

a. Column (1)

the item is shown.

b. Column (2)

it to request or requisition the item.

c. Column (3)

to identify the item. The physical location of each item follows the description in this column. The lists are
designed to inventory all items in one area of the major item before moving on to an adjacent area.

— Illustration Number (Illus Number).

— National Stock Number.

— Description.

Indicates the Federal item name and, if required, a minimum description

These are the minimum essential items required to place Radio

Indicates the number of the illustration on which

Indicates the National stock number assigned to the item; use

C-1

TM 07748B-12/1, TM 11-5820-1046-12

d. Column (3)

— CAGE and Part Number.

Indicates the primary number used by the manufacturer that
controls the design and characteristics of the item by means of its engineering drawings, specifications,
standards, and inspection requirements to identify an item or range of items. Preceding the part number,
the Commercial and Government Entity (CAGE) is shown in parentheses. If the required item differs
between serial numbers of the same model, effective serial numbers are shown in the last line of the
description. If the required item differs for different models of this equipment, the model number is shown
under the Usable On Code heading in the description column. These codes are identified in paragraph e.

e. Usable On Code.

Usable on codes, when included, help identify which component items are used on

the different models. identification of the codes used in these lists are:

f. Column (4) —

Unit of Measure (U/M). Indicates the measure used in performing the actual

operational/maintenance function. This measure is expressed by a two-character alphabetical
abbreviation (for example, ea. in., pr).

g. Column (5)

— Quantity Required (Qty Reqd).

This column lists the quantity of each item required for

a complete major item.

C-2

TM 07748B-12/1, TM 11-5820-1046-12

Section Il.

COMPONENTS OF END ITEM

(1)

Illus

Number

1

2

3

4

(2)

National Stock

Number

5820-01-262-9550

5935-00-204-5118

5820-01-065-5044

5985-00-646-2365

(3)

Description

CAGE and Part Number

RADIO SET AN/PRC-104B
(87990) 755002C0050

(AN/GRA-50) ADAPTER UG-349A/U
(in transit case) Army only
(80058)

RADIO FREQUENCY AMPLIFIER
AM-6874/PRC-104
(connected to RT)
(80058)

ANTENNA AT-271A/PRC
(in transit case)
(80058)

Usable

On

Code U/M

EA

EA

(4)

EA

EA

(5)

Qty

Reqd

1

1

1

1

C-3

TM 07748B-12/1, TM 11-5820-1046-12

COMPONENTS OF END ITEM (Cont)

(1)

Illus

Number

5

6

7

(2)

National Stock

Number

5985-00-892-0758

5985-00-106-6130

5820-00-234-4127

(3)

Description

CAGE and Part Number

ANTENNA GROUP AN/GRA-50
(in bag) Army only

(80058)

(NVIS) ANTENNA AS-2259( )/GR
(in roll pack) Army only
(80058)

ANTENNA SPRING SECTION AB-129/PR
(in transit case)
(80058)

Usable

On

Code

(4)

U/M

EA

EA

EA

(5)

Qty

Reqd

1

1

1

C-4

COMPONENTS OF END ITEM (Cont)

TM 07748B-12/1, TM 11-5820-1046-12

(1)

Illus

Number

8

9

10

11

(2)

National Stock

Number

5895-01-245-6160

5935-00-231-3180

5820-01-065-4442

5995-00-405-9097

(3)

Description

CAGE and Part Number

(NVIS) ANTENNA GROUND BASE
(in transit case)
(80063) A3023292

ELECTRICAL POWER CABLE ASSEMBLY
CX-13032/PRC-104
(in transit case)
[phone]A1250

ELECTRICAL POWER CABLE ASSEMBLY
CX-13023/PRC-104
(in transit case)
(87990) 755002A1260

RF CABLE ASSEMBLY 2249-C-22
(in transit case)
(05276)

Usable

On

Code

(4)

U/M

EA

EA

EA

EA

(5)

Qty

Reqd

1

1

1

1

C-5

TM 07748B-12/1, TM 11-5820-1046-12

COMPONENTS OF END ITEM (Cont)

(1)

Illus

Number

12

13

14

15

(2)

National Stock

Number

6135-01-080-2886

5820-01-214-8802

8465-01-019-9102

(3)

Description

CAGE and Part Number

INSTRUCTION CARD
(in transit case)
(87990) 755002C0057

BATTERY CASE CY-7875/PRC-104
(in transit case)
(01365) 79A5029A0000

TRANSIT CASE CY-8291/PRC-104
(in vehicle)
(80058) 755002A3108

FIELD PACK 2-2-344
(in transit case)
(81337)

Usable

On

Code

(4)

U/M

EA

EA

EA

EA

(5)

Qty

Reqd

1

2

1

1

C-6

COMPONENTS OF END ITEM (Cont)

TM 07748B-12/1, TM 11-5820-1046-12

(1)

IIlus

Number

16

17

18

19

(2)

National Stock

Number

8465-00-001-6475

5965-00-043-3463

5305-01-067-5388

(3)

Description

CAGE and Part Number

PACK FRAME 2-3-290
(in transit case)
(81337)

HANDSET H-250A/U
(connected to RT)
(80058)

TELEGRAPH KEY
(in transit case)
(87990) 755002A1000

RECEIVER-TRANSMITTER RT-1209A/URC
(connected to amplifler/coupler)
(87990) 755002C0150

Usable

On

Code

(4)

U/M

EA

EA

EA

EA

(5)

Qty

Reqd

1

1

1

1

C-7

TM 07748B-12/1, TM 11-5820-1046-12

COMPONENTS OF END ITEM (Cont)

(1)

Illus

Number

20

21

(2)

National Stock

Number

8465-00-001-6476

8465-00-001-6477

(3)

Description

CAGE and Part Number

CARGO SUPPORT SHELF 2-3-291
(within frame)
(81337)

WEBBING STRAP 2-2-313

(in transit case)
(81337)

Usable

On

Code

(4)

U/M

EA

EA

(5)

Qty

Reqd

1

1

C-8

TM 07748B-12/1, TM 11-5820-1046-12

Section Ill. BASIC ISSUE ITEMS

(1)

Illus

Number Number

National Stock

(2)

(3)

Description

CAGE and Part Number

Operator’s and Organizational
Maintenance Manual for Radio Set
AN/PRC-104B TM 07748B-12/1,
TM 11-5820-1046-12

Usable

On

Code

(4)

U/M

EA

(5)

Qty

Reqd

1

C-9/(C-10 blank