TO

31R2-2PR-101
TECHNICAL
MANUAL
OPERATION,
ORGANIZATIONAL,
AND
FIELD
MAINTENANCE
INSTRUCTIONS
RADIO
SET
AN/PRC-90
AND
RADIO
TEST
SET
AN/PRM-32
RADIO
TEST
SET
TS-20/PRM-32A
SYLVANIA
ELECTRONIC
SYSTEMS
NEEDHAM,
MASS
FA8501-04-F-0029
FA8501-05-D-0002
BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION
DISCLOSURE
NOTICE
-This
information
is
furnished
upon
the
condition
that
it
will
not
be
released
to
another
nation
without
the

specific
authority
of
the
Department
of
the
Air
Force
of
the
United
States,
that
it
will
be
used
for
military
purposes
only,
that
individual
or
corporate
rights
originating
in
the
information,
whether
patented
or
not,
will
be
respected,
that
the
recipient
will
report
promptly
to
the
United
States,
any
known
or
suspected
compromise,
and
that
the
information
will
be
provided

substantially
the
same
degree
of
security
afforded
it
by
the
Department
of
Defense
of
the
United
States.
Also,
regardless
of
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it
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approval
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DISTRIBUTION
STATEMENT
C
-Distribution
authorized
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Agencies
and
their
contractors
(Administrative
or
Operational
Use)

(15
February
2006).
Other
requests
for
this
document
shall
be
referred
to
406
SCMS/GUEE,
Robins,
AFB,
GA
31098.
Questions
concerning
technical
content
shall
be
referred
to
AFLCMC/WNUS.
WARNING
-This
document
contains
technical
data
whose
export
is
restricted
by
the
Arms
Export
Control
Act
(Title
22,
U.S.C.,
Sec
2751,
et
seq.)
or
the
Export
Administration
Act
of
1979,
as

amended,
Title
50,
U.S.C.,
App.
2401,
et
seq.
Violations
of
these
export
laws
are
subject
to
severe
criminal
penalties.
Disseminate
in
accordance
with
provisions
of
DoD
Directive
5230.25.
HANDLING
AND
DESTRUCTION
NOTICE
-Comply
with
distribution
statement
and
destroy
by
any
method
that
will
prevent
disclosure
of
contents
or
reconstruction
of
the
document.
Published
Under
Authority
of

the
Secretary
of
the
Air
Force
15
FEBRUARY
2006
CHANGE
4
-18
JANUARY
2014

TO
31R2-2PR-101
INSERT
LATEST
CHANGED
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DESTROY
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LIST
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NOTE
The
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text
affected
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indicated
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vertical
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in
the
outer
margin
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Changes
to
illustrations
are
indicated
by
shaded
or
screened
areas,
or
by
miniature
pointing
hands.

Dates
of
issue
for
original
and
changed
pages
are:
Original.......0.....15February2006
Change.......3.......5August2010
Change.......1....15December2006
Change.......4......18January2014
Change.......2....15December2007
TOTAL
NUMBER
OF
PAGES
IN
THIS
PUBLICATION
IS
66
CONSISTING
OF
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USAF

TO
31R2-2PR-101
TABLE
OF
CONTENTS
Chapter
Page
Chapter
Page
LIST
OF
ILLUSTRATIONS
...........
iii
4.6
THEORY
OF
SYSTEM
OPERATION
...................
4-1
4.7
CONSTRUCTION
............
4-1
LIST
OF
TABLES
..................
iii
4.8
TRANSMITTER
MICROCIRCUITS
A1TR1
AND
A1TR2
........
4-1
INTRODUCTION
..................
v

4.9
MODULATOR
AMPLIFIER
A1AR1
..................
4-2
SAFETY
SUMMARY
...............
ix
4.10
BEACON
AND
MCW
.........
4-2
4.11
AMPLIFIER
................
4-2
1
INTRODUCTION
..................
1-1
4.12
RECEIVER
MICROCIRCUITS
A1RE1
AND
A1RE2
........
4-2
4.13
RECEIVER
AMPLIFIER
A1AR2
.
.
4-2
1.1
PURPOSE
AND
LIMITATIONS
.
.
1-1
4.14
ANTENNA
SWITCHING
CARD
1.2

AN/PRC-90
SERIES
RADIO
SET
.
1-1
A1A1
...................
4-2
1.3
AN/PRC-90
SERIES
RADIO
SET
4.15
CONTROL
CIRCUITS
.........
4-2
POWER
SUPPLY
..........
1-2
4.16
VOICE/MCW
243.0
...........
4-3
1.4
DESCRIPTION
..............
1-2
4.17
MCW
BUTTON
IMPRESSED
....
4-3
1.5
TECHNICAL
CHARACTERIS
TICS

...................
1-3
4.18
BCN-243.0
.................
4-3
2
OPERATION
.....................
2-1
5
PREPARATION
FOR
MAINTENANCE
.
.
.
5-1
2.1
GENERAL
.................
2-1
5.1
GENERAL
.................
5-1
2.2
CONTROLS,
INDICATORS,
AND
5.2
UNPACKING
...............
5-1
FUNCTIONS
.............
2-1
5.3
VISUAL-MECHANICAL
INSPEC
2.3
OPERATING
INSTRUCTIONS
.
.
.
2-1
TION
...................
5-1

2.4
OPERATING
PROCEDURE
.....
2-5
5.4
CLEANING
................
5-1
2.5
BATTERY
REPLACEMENT
.....
2-6
5.5
BATTERY
INSPECTION
.......
5-2
2.6
BATTERY
LIFE
.............
2-6
5.5.1
Battery
Life
.................
5-2
2.7
QUICK
OPERATIONAL
CHECK
.
2-6
5.6
BATTERY
SERVICE
LIFE
TEST
.
5-2
2.8
SERVICE
AFTER
IMMERSION
.
.
2-9
5.6.1
Battery
Test

Using
Multimeter
and
a
130
Ohm
1
Watt
Resister
.....
5-2
5.7
SERVICE
LIFE
TEST
.........
5-2
3
TEST
EQUIPMENT
AND
SPECIAL
5.7.1
Radio
Battery
...............
5-2
TOOLS
.......................
3-1
5.8
BATTERY
TEST
(BA-5368/U)
.
.
.
5-3
5.9
BATTERY
TEST
(BA-5123/U)
.
.
.
5-3
3.1

TEST
EQUIPMENT
REQUIRED
.
.
3-1
5.10
INSPECTION
RECORD
........
5-4
3.2
RADIO
TEST
SET
AN/PRM-32
.
.
3-1
5.11
INSPECTION
RECORD
........
5-4
3.3
RADIO
TEST
SET
TS-24B
......
3-3
3.4
TEST
SET
CALIBRATION
......
3-4
6
ORGANIZATIONAL
MAINTENANCE
.
.
.
6-1
3.5
CALIBRATION
PROCEDURE

.
.
.
3-6
3.6
LOCALLY
MANUFACTURED
PARTS
..................
3-7
6.1
GENERAL
.................
6-1
3.6.1
Fabrication
of
Power
Supply
Leads
.
3-7
6.2
PERIODIC
INSPECTION
.......
6-1
3.7
CALIBRATION
FOR
TS-20A/PRM-6.3
OPERATIONAL
CHECKS
......
6-3
32A
....................
3-7
6.4
BATTERY
CHECK
...........
6-3
6.5
TRANSMITTER
AND
RECEIVER
TEST
SET-UP
.............
6-3

4
THEORY
OF
OPERATION
............
4-1
6.6
GUARD
CHANNEL
BEACON
TRANSMITTER
CHECK
.....
6-3
4.1
GENERAL
.................
4-1
6.7
GUARD
CHANNEL
BEACON
4.2
IDENTIFICATION
OF
TEST
SIDETONE
CHECK
........
6-3
POINTS
.................
4-1
6.8
GUARD
CHANNEL
MCW
4.3
MAJOR
TEST
POINTS
........
4-1

TRANSMITTER
CHECK
.....
6-3
4.4
SECONDARY
TEST
POINTS
....
4-1
4.5
MINOR
TEST
POINTS
........
4-1

TO
31R2-2PR-101
TABLE
OF
CONTENTS
-CONTINUED
Chapter
6.9
GUARD
CHANNEL
VOICE
TRANSMITTER
CHECK
.....
6.10
ALTERNATE
CHANNEL
VOICE
TRANSMITTER
CHECK
.....
6.11
GUARD
CHANNEL
RECEIVER
CHECK
.................
6.12
ALTERNATE
CHANNEL
RECEIVER
CHECK
...........
6.13
EARPHONE
CHECK
..........
6.14
REMOVAL
AND
REPLACEMENT
..................

6.14.1
Battery
Removal
and
Replacement
.
6.14.2
Earphone
Removal
and
Replacement
...................
6.14.3
Antenna
Removal
and
Replacement
...................
7
FIELD
MAINTENANCE
.............
7.1
GENERAL
.................
7.2
PRELIMINARY
CHECKOUT
....
7.3
INITIAL
TEST
SETUP
FOR
USE
EXTERNAL
DC
VOLTAGE
INPUT
....................
7.3.1
Initial
Test
Set
Up

............
7.3.2
OPERATION
INSTRUCTIONS
.
.
.
7.4
TROUBLESHOOTING
.........
7.5
ACCESS
TO
TEST
POINTS
.....
7.6
GUARD
CHANNEL
BEACON
TRANSMITTER
...........
7.7
GUARD
CHANNEL
BEACON
SIDETONE
...............
7.8
GUARD
CHANNEL
MCW
TRANSMITTER
...........
Page
6-3
6-4
6-7
6-7
6-7
6-8
6-8
6-8
6-8

7-1
7-1
7-2
7-2
7-3
7-4
7-7
7-7
7-7
7-7
7-7
Chapter
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18
7.19

7.20
7.21
7.22
7.23
7.24
7.25
7.26
Page
GUARD
CHANNEL
VOICE
TRANSMITTER
...........
7-7
ALTERNATE
CHANNEL
VOICE
TRANSMITTER
...........
7-7
GUARD
CHANNEL
RECEIVER
.
.
7-8
ALTERNATE
CHANNEL
RE
CEIVER
.................
7-8
EARPHONE
CIRCUIT
.........
7-8
ANTENNA

TIP
INSPECTION
....
7-8
DELETED
.................
7-9
DELETED
.................
7-9
REMOVAL
AND
REPLACE
MENT
..................
7-9
ELECTRONICS
ASSEMBLY
RE
MOVAL
.................
7-9
ELECTRONICS
ASSEMBLY
REIN
STALLATION
.............
7-9
MCW
AND
PUSH
TO
TALK
SWITCH
REPLACEMENT
....
7-9
VOL
CONTROL
REPLACE
MENT
..................
7-9
BATTERY
CAP
REPLACEMENT
.
7-9
PUSH
TO

TALK
OR
MCW
BUT
TON
REPLACEMENT
.......
7-10
NAVY
MODEL
PUSH
TO
TALK
OR
MCW
BUTTON
REPLACE
MENT
..................
7-10
FUNCTION
SWITCH
KNOB
RE
PLACEMENT
.............
7-10
RETRIEVAL
LANYARD
RE
PLACEMENT
.............
7-11

TO
31R2-2PR-101
LIST
OF
ILLUSTRATIONS
Figure
Title
Page
Figure
Title
Page
2-1
Radio
Set
AN/PRC-90
Controls
and
5-1
Radio
and
Battery
Inspection
Label
.
.
.
5-4
Indicators
...................
2-2
6-1
Test
Set-Up
...................
6-5
2-2
Antenna
Orientation
.............
2-5
6-2
Antenna
Removal
...............
6-6
2-3
Antenna
Bracket
Weight
Check
......
2-8
6-3

AN/PRC-90/90-2
Antenna
Weight
....
6-8
2-4
Strap
Antenna
Weight
Check
........
2-8
6-4
Electronics
and
Switch
Assembly
3-1
Radio
Test
Set
AN/PRM-32
........
3-2
Hold-down
Screws
and
Test
Points
.
6-10
3-2
Antenna
Test
Adapter
7-1
Load
Carriage
Assembly
..........
7-1
MX-8802/PRC-90
.............
3-4
7-2
RF
Power
Output
vs
DC
Voltage
3-3
Battery
Supply
Test
Adapter
Reading
at
RF
Power

T.P.
........
7-2
MX-8829/PRC-90
.............
3-4
7-3
RF
Module
External
DC
Power
3-4
Calibration
Test
Set
..............
3-6
Terminal
Locations
............
7-3
3-5
Load
Resister
Battery
Test
.........
3-7
7-4
External
DC
Power
and
Test
Point
3-6
Fabrication
of
Power
Supply
Leads
.
.
.
3-7
Terminal
Locations
............
7-3
3-7
Calibration
Test
Set-Up
...........
3-8
7-5
RF
Power
Output

vs.
DC
Voltage
4-1
Schematic
and
Wiring
Diagram
of
Reading
at
RF
Power
Test
Point
.
.
.
7-4
AN/PCRC-90
................
4-5
LIST
OF
TABLES
Table
Title
Page
Table
Title
Page
1-1
Characteristics
and
Leading
Particulars
of
3-3
Calibration
Test
Equipment
Required
.
.
.
3-5
the
AN/PRC-90
................
1-3
3-4
Alternate
Calibration
Test

Equipment
.
.
.
3-5
2-1
Controls
and
Indicators
.............
2-3
6-1
Periodic
Inspection
and/or
Test
........
6-1
3-1
Test
Equipment
Required
for
Maintenance
..................
3-3
3-2
Special
Tools
for
AN/PRC-90
Maintenance
..................
3-3
iii/(iv
blank)

TO
31R2-2PR-101
INTRODUCTION
1
GENERAL.
This
publication
covers
operation,
organizational,
and
field
maintenance
instructions
for
Radio
Set
AN/PRC-90,
Part
No.
01-524860-1,
and
Radio
Test
Set
AN/PRM-32,
Part
No.
01-524930-1,
manufactured
by
Sylvania
Electronic
Systems
Eastern
Division,
Needham,
Massachusetts
(refer
to
Figure
1
and
Figure
3-1).
Radio
Test
Set
TS-20/PRM-32A
is
also

included
(refer
to
Figure
2).
All
essential
information
needed
to
enable
operating
personnel
to
use
the
radio
set
to
maximum
advantage
during
search,
location,
and
rescue
operations
is
contained
in
this
publication.
Air
crewmen
issued
this
equipment
are
urged
to
become
familiar
with
the
functions
of
all
controls
before
operating
the
radio
set.

TO
31R2-2PR-101

Figure
1.
Radio
Set
AN/PRC-90

TO
31R2-2PR-101

Figure
2.
Test
Set
TS-20/PRM-32A
vii/(viii
blank)

TO
31R2-2PR-101
SAFETY
SUMMARY
1
GENERAL
SAFETY
INSTRUCTIONS.
This
manual
describes
physical
and
chemical
processes
which
may
cause
injury
or
death
to
personnel,
or
damage
to
equipment
if
not
properly
followed.
This
safety
summary
includes
general
safety
precautions
and
instructions
that
must
be
understood
and
applied
during
operation
and
maintenance
to
ensure
personnel

safety
and
protection
of
equipment.
Prior
to
performing
any
task,
the
WARNINGs,
CAUTIONs
and
NOTEs
included
in
that
task
shall
be
reviewed
and
understood.
2
WARNINGS,
CAUTIONS,
AND
NOTES.
WARNINGs
and
CAUTIONs
are
used
in
this
manual
to
highlight
operating
or
maintenance
procedures,
practices,
conditions
or
statements
which
are
considered
essential
to
protection
of
personnel
(WARNING)

or
equipment
(CAUTION).
NOTEs
are
used
in
this
manual
to
highlight
operating
or
maintenance
procedures,
practices,
conditions
or
statements
which
are
not
essential
to
protection
of
personnel
or
equipment.
The
headings
used
and
their
definitions
are
as
follows:

Highlights
an
essential
operating
or
maintenance
procedure,
practice,
condition,
statement,
etc.,
which
if
not
strictly
observed,
could
result
in

injury
to,
or
death
of,
personnel
or
long
term
health
hazards.

Highlights
an
essential
operating
or
maintenance
procedure,
practice,
condition,
statement,
etc.,
which
if
not
strictly
observed,
could
result
in
damage
to,
or
destruction
of,
equipment
or
loss
of
mission
effectiveness.
NOTE
Highlights
an
essential
operating
or
maintenance
procedure,
condition
or
statement.

3
SAFETY
PRECAUTIONS.
The
following
safety
precautions
shall
be
observed
while
performing
procedures
in
this
manual.

Cleaning
compound
may
affect
skin,
eyes
and
respiratory
tract.
Use
in
a
well
ventilated
area.
Avoid
prolonged
breathing
of
vapors.
Avoid
eye
and
skin
contact.
Chemical
goggles
and
neoprene
gloves
will
be
worn.
Keep
away
from
sparks
and

flames.
If
necessary
to
remove
grease
and
oil,
wipe
the
exterior
with
a
cloth
dampened
(not
wet)
with
isopropyl
alcohol
(70%)
and
wipe
dry.
The
AN/PRC-90
series
Radio
uses
a
Lithium
Manganese
Dioxide
battery
as
its
power
source.
Do
not
short
circuit,
crush,
puncture
mutilate,
or
disassemble
batteries.
The
BA-5368/U
battery
contains
Lithium
Manganese
dioxide
mixture.
Under
conditions

of
abuse
misuse,
partial
discharge,
or
depletion,
will
produce
gases,
fire
and
explosions,
heat,
short
circuit,
crush
puncture,
mutilate,
or
dissemble.
If
one
battery
is
weak,
excessive
heating
may
result
and
the
weak
battery
may
explode.
Battery
is
a
potential
explosive
hazard.
Wear
face
shield
or
goggles
when
handling
battery.
Wear
rubber
gloves
when
handling
the
battery
to
prevent

skin
contamination.
BA-5123/U
Battery
contains
lithium.
If
liquid
contacts
skin
or
eyes,
wash
affected
area
with
water
and
get
immediate
medical
attention.
The
Test
Set
shall
be
grounded
to
earth
ground
by
means
of
braided
ground
strap
or
shielded
ground
cable,
will
further
attenuate
radiation
below
the
35
dB
minimum
attenuation
specified
for
the
ungrounded
Test
Set.
Test

chamber
shall
be
grounded
to
earth
ground
by
means
of
a
breaded
ground
strap
or
shielded
cable.
This
step
will
further
attenuate
radiation
below
the
35dB
minimum.
Do
not
use
the
BA-5368/U
batteries
to
power
test
set.
Lithium
batteries
will
cause
failures
and
erroneous
indications,
which
could
cause
and
otherwise
serviceable
radio
to
be
rejected.
Use
only
external
power

shall
be
for
all
radio
tests.
ix/(x
blank)

TO
31R2-2PR-101
CHAPTER
1
INTRODUCTION
1.1
PURPOSE
AND
LIMITATIONS.
Radio
Set
AN/PRC-90
is
a
dual-channel,
self-powered
personal
emergency
rescue
transceiver,
used
principally
for
two-way
voice
or
MCW
(modulated
continuous
wave)
communications
between
a
downed
air
crewman
and
a
rescue
aircraft.
Provisions
are
included
for
transmitting
tone
(MCW)
and
swept-frequency
homing
beacon
signals
to
guide
rescue

efforts.
Radio
Set
AN/PRC-90
is
compatible
with
UHF
AM
radios
and
Direction
Finders.
Radio
Set
AN/PRC-90
is
designed
to
provide
the
following
capabilities:
a.
Two-way
voice
communications
over
a
range
of
60
nautical
miles
to
aircraft
operating
at
10,000
feet
altitude
can
be
expected.
b.
An
ADF
(automatic
direction
finder)
range
of
50
nautical
miles
and
a
tone

range
of
80
nautical
miles
to
aircraft
operating
at
10,000
feet
altitude
can
be
expected.
NOTE
In
general,
signal
range
increases
proportionally
with
the
altitude
of
the
rescue
aircraft,
provided
that
line-of-sight
is
not
obstructed
Degradation
can
be
expected
when
the
radio
set
is
operated
in
bad
weather
or
jungle
areas.
Radio
test
set
AN/PRM-32/TS-20/PRM-32A
is

a
portable
self-contained
test
set
to
perform
operational
checkout
simultaneously
on
two
AN/PRC-90
radio
sets.
Testing
is
done
in
a
closed
circuit
manner;
this
prevents
tests
from
interfering
with
operational
radio
channels.
1.2
AN/PRC-90
SERIES
RADIO
SET.
The
AN/PRC-90
series
radio
set
is
powered
by
a
single
BA-5368/U
Lithium
Manganese
Dioxide
(Li/MnO2).
The
Li/MnO2
battery(s)
provide
reliable
power

for
radio
operation
in
all
temperature
environments.
However,
exposure
to
extreme
heat
or
cold
can
cause
battery
failure
or
reduced
operational
efficiency.
Therefore,
scheduled
checks
and
inspections
are
required
to
assure
serviceability.
The
BA5368/
U
battery
has
a
shelf
life
of
60
months
(5
years)
from
the
date
of
manufacture
and
an
installed
service-life
of
36
months
(3
years).
Condemn

and
replace
batteries
that
exceed
service
or
shelf
life.
Condemned
batteries
may
be
used
for
training
or
disposed
of
in
accordance
with
TO
00-25-213WA1.
1.2.1
The
AN/PRC-90
series
radio
set
can
be
powered
by
a
single
BA-5368/U,
NSN
6135-01-455-7947,
(Li/MnO2)
battery;
hereafter
referred
to
as
BA-5368/U.
NOTE

When
the
battery
adapter,
NSN:
5940-01-4846261,
P/N

1794AS0988,
is
installed
on
the
radio
the
radio
length
is
extended
by
approximately
2
inches.
Due
to
the
limited
survival
kit
space
in
the
T-6
aircraft,
the
battery
adapter
application
is
not
authorized
for
radios
placed
in
this
aircraft.
Reference
TO
14S-1-131,
Operational
and
Maintenance
Instruction
for
Survival
Vest
Assembly,
for
the
appropriate
survival
vest
pocket
to
accommodate
radio

with
battery
adapter
installed.
1.2.1.1
BA-5123/U,
NSN:
6135-01-351-1131,
(I.E.
approved
commercially
available
CR-123A-Type
3
VDC
photocell
non-rechargeable
Li/MnO2
battery),
Duracell
(P/N
Dl123A),
Eveready
(P/N
El123AP),
Panasonic
(P/N
CR123A),
Kodak
(P/N
K123/A),
Varta
(P/N
Vl123),
Maxwell
(P/N
CR123),
and
Sanyo
(P/N
CR123A)
batteries
conforming
to
American
National
Standards
Institute
(ANSI)
c18.3m
1999,
standard
parts1&2,are
authorized
for
use
as
a
power
source

when
the
battery
adapter
is
used
in
place
of
the
BA-5368/U.
Batteries
non-compliant
with
ANSI
c18.3m
1999,
standard
parts1&2,arenot
authorized
for
use.
NOTE
A
ZTS
Multi-Battery
Tester,
NSN
6625-01-4949163,
PIN
MBT-Mil,
or
equivalent
will
be
used
to
test
the
BA-5123/U
Batteries.
The
MBT-Mil
Tester
displays
capacity
measurements
in
increments
of
10%,
20%,
40%,
60%,
80%
and
100%
Range.

1.2.2
The
AN/PRC-90
series
radio
set
with
a
battery
adapter,
P/N
1794AS0988,
NSN
5940-01-484-6261,
installed
can
be
powered
by
4
BA-5123/U,
NSN
6135-01-351-1131,
approved
commercially
available
123A-type
3
VDC
photocell
non-rechargeable
Li/MnO2
batteries;
hereafter
referred
to
as
BA-5123/U.
The
4
BA-5123/U
batteries
must
be
matched
sets
from
the
same
manufacturer
and
with
the
same
date
codes.
The
matching

ensures
that
all
BA-5123/U
batteries
are
at
the
same
approximate
state
of
charge;
thus,
minimizing
the
possibility
of
voltage
reversal
during
usage.
The
useable
operating
life
of
the
BA-5123/U
power
supply
option
is
approximately
2/3
longer
than
that
of
a
BA-5368/U
when
new
batteries
are
installed.
The
BA-5123/U
is
considered
to
have
a
maximum
shelf
life
of
120
months
(10

years)
Change
4
1-1

TO
31R2-2PR-101
from
date
of
manufacture.
The
BA-5123/U
service-life
is
72
months
(6
years),
as
long
as
80%
of
its
initial
capacity
is
retained.
Batteries
falling
below
80%
capacity
may
be
used
for
training.
NOTE

Prior
to
operating
the
AN/PRC-90
series
radio,
the
user/operator
shall
be
thoroughly
familiar
with
the
information
contained

in
TO
31R22PRC901,
TO
33D7-71-42-1
for
the
TS-24B
Radio
Test
Set,
and
manufacturers
commercial
manual,
1002-003S-102,
for
the
Radio
Communications
Test
Set
RCTS
-003.
ALS
personnel
use
the
TS-24B
Radio
Test
Sets
to
conduct
testing
on
the
AN/PRC-90
Series
Radio
Set.
1.2.3
Operational
radio
testing
will
be
accomplished
using
the
TS-24B
test
set.
This
test
set
shall
be

operated
using
an
external
DC
power
supply
to
provide
power
for
both
the
RF
and
DC
modules.
TO
33D7-71-42-1
contains
information
on
the
TS-24B
radio
test
set.
See
Chapters
2,
4,
and
5
for
additional
information
on
testing.
1.2.4
For
BA-5368/U
and
BA-5123/U
battery
service-life
testing,
refer
to
Chapter
5.
Typical
discharge
characteristics
describing
voltage
(With
Temperature
Variations)
profiles
for

approved
commercially
available
123A-Type
3
VDC
photocell
non-rechargeable
Li/MnO2
batteries
can
be
found
in
specification/engineering
data
sheets
for
the
respective
manufacturer
via
the
internet.
1.3
AN/PRC-90
SERIES
RADIO
SET
POWER
SUPPLY.
The
AN/PRC-90
Series
Radio
Set
requires
a
12
VDC
source
of
power
to
operate.
1.3.1
The
BA-5368/U
battery
has
a
flange
located
1-inch
from
the
negative
end

of
the
case.
The
BA-5368/U
battery
shall
be
inserted
into
radio
battery
well
(+)
positive
end
first.
The
positive
end
of
the
BA-5368/U
battery
is
labeled
with
both
an
arrow
insert
this
end
and
+
polarity
sign.
The
flange
prevents
polarity
reversal,
which
will
damage
the
electronic
circuits
due
to
improper
installation.
If
installed
correctly,
approximately
1/2-inch
of
the
battery

is
visible
and
the
battery
will
spring
back
when
finger
pressure
is
applied.
NOTE
Reference
TO
14S-1-131,
Operational
and
Maintenance
Instruction
for
Survival
Vest
Assembly,
for
the
appropriate
survival
vest
pocket
to
accommodate
radio
with
battery
adapter
installed.
The
battery
adapter,
NSN
5940-01-484-6261,
P/N
1794AS0988,
allows
the
AN/PRC-90
series
radio
set
to
use
4
BA-5123/U
batteries

as
a
power
source.
When
installed,
the
adapter
extends
the
length
of
the
radio
by
approximately
2
inches.
The
combined
use
of
this
adapter
and
4
BA-5123/U
batteries
will
provide
a
downed
crew
member
with
a
radio
which
contains
batteries
with
an
operational
usage
life
(i.e.,
16
to
18
hours)
approximately
2/3
over
that
of
the
current
BA-5368/U

battery.
1.4
DESCRIPTION.
In
general,
signal
range
increases
proportionally
with
the
altitude
of
the
search
aircraft,
provided
that
line-of-sight
is
not
obstructed.
Degradation
can
be
expected
when
the
radio
set
is
operated
in
bad
weather
or
jungle
areas.
The
operator
can
select
three
modes
of
operation
on
the
guard
channel
to
aid
in
search,
location,
and

rescue
operations;
a.
The
beacon
mode
of
operation
transmits
a
variable
frequency
which
sweeps
from
1000
to
300
Hz
and
then
returns
instantaneously
to
the
1000-Hz
frequency
and
repents
the
cycle.
This
occurs
at
a
rate
of
2
to
3
times
per
second.
The
swept-tone
signal
is
readily
distinguishable
from
other
signals
or
noise,
and
is
used
for

homing
purposes
by
the
pilot
or
radio
operator
of
an
ADFequipped
aircraft
when
conducting
search
operations.
The
MCW
and
beacon
modes
extend
the
one-way
communication
range
of
the
AN/PRC-90
beyond
the
range
attainable
in
the
voice
mode.
b.
The
voice
mode
permits
two-way
voice
communications
with
another
AN/PRC-90
or
with
compatible
airborne
communications
equipment.
c.
The
MCW
mode
transmits

a
1000-Hz
tone
when
the
operator
depresses
the
MCW
button.
This
mode
is
intended
primarily
for
Morse
Code
communications
in
covert
situations
when
used
in
conjunction
with
the
earphone.
MCW
may
also
be
used
for
general
purpose
signaling.
Only
the
two-way
voice
communication
mode
is
available
when
operating
on
the
282.8-MHz
alternate
channel.
The
voice
operating
range
is
the
same

as
for
the
guard
channel.
The
guard
channel
is
a
distress
calling
frequency
used
to
locate
downed
air-crewmen.
Once
the
men
are
located,
the
alternate
channel
may
be
used
for
further
communication
so
that
the
guard
channel
is
left
open
for
other
distress
operations.
Radio
Set
AN/PRC-90
has
four
operating
controls:

PUSH
TO
TALK
button

VOL
control
4-position
function
switch
MCW
button
The
controls
arc
conveniently
located
to
permit
operation
with
either
hand.

TO
31R2-2PR-101
There
are
presently
two
types
of
antennas
used
on
the
AN/PRC-90
radio
set.
One
is
a
fully
flexible
quarter-wave
length
rubber
covered
whip;
the
other
is
a
combination
flexible
and
telescopic
half-wave
length
partially
rubber
covered
whip.
Once
Time
Compliance
TO
12R2-2PRC90501
is
complied
with,
the
half-wave
antenna
is
mandatory
for
Air
Force
use.

NOTE
No
operational
test
shall
be
made
with
the
antenna
in
the
stowed
position.
A
miniature
earphone
is
provided
with
the
radio
set.
The
earphone,
which
is
stored
in
a
case
on
the
carrying
strap,
is
intended
to
permit
quiet
operation
of
the
radio
set.
The
AN/PRC-90
is
enclosed
in
a
rugged
water-tight

aluminum
case
which
protects
internal
circuits.
The
radio
set
will
operate
satisfactorily
after
immersion
in
water
to
depths
of
50
feet.
A
threaded
cap
at
the
bottom
of
the
radio
secures
the
battery
and
externally
seals
the
battery
compartment.
Since
this
compartment
is
sealed
from
the
rest
of
the
radio
set,
the
battery
can
be
changed
under
adverse

weather
conditions
without
exposing
any
electronic
circuits.
1.5
TECHNICAL
CHARACTERISTICS.
Table
1-1
gives
characteristics
and
leading
particulars
to
aid
in
understanding
the
capabilities
and
limitations
of
the
AN/PRC-90.
Table
1-1.
Characteristics
and
Leading
Particulars
of
the
AN/PRC-90
a.
General
Weight
18
oz
without
battery,
24
oz
with
battery
External
dimensions
6.0
x
3.1
x

1.4
in
(H
x
W
x
D)
Antenna
height
1/4
wave,
12
in.
1/2
wave,
24
1/2
in.
Volume
26.0
cu
in.
Channels
available
to
operator
2,
fixed
frequency
(see
Channel
frequencies
under
b.,
below)
Operating
temp,
range
without
battery
-30
to
+50
C
Operating
temp,
range
with
battery
0
to
+50
C
Storage
temperature
without
battery
-60
to
+60

C
Humidity
98%
Operating
altitude
10,000
ft
NOTE
Beacon
transmitter
operates
to
40,000
feet
above
sea
level.
Storage
altitude
40,000
ft
Submersible
depth
in
water
50
ft
max
for
5
min
2
ft
max
for
24
hr
b.
Transmitter
Typical
communication
ranges
(ground-to-air,
ideal
line-of-sight
with
aircraft
at
10,000-ft
altitude)
Voice
mode
60
N
Mi
Beacon
mode
80
N
Mi

MCW
mode
80
N
Mi
Automatic
Direction
Finder
range
50
N
Mi
RF
Power
output:
Voice
mode
100
mw
average
(400
mw
peak-envelope
power
min)
MCW
and
beacon
modes
125
mw
average
(500
mw
peak-envelope
power
min)
Voice
percent
modulation
80%
min
for
115
db
sound
pressure
at
microphone
(ref
to
0.0002
dyn/sq
cm)
Voice
distortion
15%
max
for
80%

modulation
Voice
audio
bandwidth
500-3000
Hz
+1,
-3
db
ref
to
1000
Hz
Type
of
voice
modulation
AM
Guard
channel
frequency
243.0
MHz
(Voice,
MCW,
and
Beacon)

TO
31R2-2PR-101
Table
1-1.
Characteristics
and
Leading
Particulars
of
the
AN/PRC-90
-Continued
Alternate
channel
frequency
282.8
MHz
(Voice
only)
Frequency
stability
0.005%
Antenna
Omni
Directional
vertically
polarized,
half-wave
(nominal)
or
quarter
wave
(nominal).
Function
switch
4-position
magnetic
switch
with
no
mechanical
linkage
extending
through
the
case
Earphone
switch
Magnet
on
earphone
switches
speaker
off
and

earphone
on;
no
mechanical
linkages
through
the
case.
Earphone
may
be
connected
either
way
(no
polarity).
Volume
control
Varies
audio
level
of
received
signals
in
the
earphone
or
speaker;
does
not
vary
transmitted
signal
level
or
transmitter
side
tone
level.
Reliability
800
hr
Mean-time-between-failures
Power
supply
+12
VDC
Lithium
Manganese
Dioxide
BA-5368/U
Input
Current
Drain
40
ma
max
receive,
(No

input
signal)
transmit
voice,
(No
modulation)
70
ma
max
transmitting
beacon
or
MCW
Beacon
modulation
wave
shape
Rectangular
Beacon
modulation
duty
cycle
25
5%
Beacon
upper-pulse
frequency
1000
200
Hz
Beacon
lower-pulse
frequency
300
60
Hz
Beacon
sweep
rate
2-3Hzper
second
Frequency
sweep
direction
Down
MCW
modulation
wave
shape
Rectangular
MCW
modulation
duty
cycle
25
5%
MCW
pulse
frequency
1000

 200
Hz
c.
Receiver
Type
of
Circuit
Superheterodyne
Sensitivity
At
least
10
hard
v
with
30%
modulation
for
6
db
signal-plusnoiseto-noise
[(S
+
N)/N]
ratio
NOTE
One
hard
microvolt
is
defined
as
that
RF
signal
at
the
input
of
a
receiver
when
the
receiver
is
connected
through
a
50-ohm
6-db
attenuator
to
a
signal
generator
with
its
output
set

at
1
microvolt.
Thus
10
hard
microvolts
is
the
RF
signal
at
the
input
of
the
receiver
when
connected
through
a
50-ohm
6-db
attenuator
to
a
signal
generator
set
for
10
microvolts
output.
Selectivity
Less
than
-6
db
at
50
kHz,
Greater
than
-60
db
at
10
MHz
Audio
output
At
least
6
volts
pp
across
4000
ohms
for
30%

modulation
at
1
kHz
for
50
to
10,
000
hard
v
applied
to
input.
Audio
frequency:
Response
500
-3000
Hz
+
2,
-5
db
ref
to
1000
Hz
Distortion
15%
max
for
100
hard
v
with
-1
kHz
30%
modulation
with
6
volts
pp
output
into
4000
ohms

TO
31R2-2PR-101
CHAPTER
2
OPERATION
2.1
GENERAL.
This
Chapter
contains
complete
operating
instructions
for
the
radio
set.
Prior
to
activating
the
radio
set,
the
operator
should
be
thoroughly
familiar
with
the
information
contained
here.
2.2
CONTROLS,
INDICATORS,
AND
FUNCTIONS.
All
controls
and
indicators
are
shown
in
Figure
2-1,
and
their
functions
described
in

Table
2-1.
2.3
OPERATING
INSTRUCTIONS.
Operation
of
Radio
Set
AN/PRC-90
is
prohibited
except
during
rescue
operations,
emergency
ground-to-ground
communications,
or
under
controlled
test/training
conditions.
False
distress
signals
can
confuse
and
delay
rescue
operations.
Operation
of
the
AN/PRC-90
is
quite
simple,
and
is
accomplished
by
following
the
procedure
given
on
the
operating
instruction
plate
(Figure
2-1,
15)

on
the
radio-set
rear
cover.
However,
additional
information
beyond
the
scope
of
the
instruction
plate
is
presented
here,
and
users
are
urged
to
read
these
instructions
as
well
as
the
preceding
Chapter
of
this
manual
to
increase
their
overall
knowledge
of
the
equipment.
The
AN/PRC-90
is
normally
operated
as
a
hand-held
twoway
radio
when
operated

in
the
voice
mode.
In
this
mode,
hold
the
radio
set
in
either
hand
and
operate
the
function
switch
and
PUSH
TO
TALK
switch
controls.
When
transmitting
voice,
hold
it
against
your
cheekbone
so
that
the
TALK
microphone
is
near
your
mouth
and
the
LISTEN
speaker
is
near
your
ear.
The
AN/PRC-90
may
be
held
close
to
your
ear
with

the
VOL
control
adjusted
for
low
volume,
or
it
may
be
held
further
away
with
the
VOL
control
turned
up
toward
MAX.
By
using
the
earphone,
the
radio
may
be
held
up
to
24
inches
from
your
ear
while
listening.
Observe
the
following
precautions
when
operating
the
AN/
PRC-90:
a.
Since
it
is
a
line-of-sight
communications

device,
whenever
possible
operate
it
in
a
cleared
area,
one
free
of
trees
or
hills
or
any
other
major
obstruction
that
might
impede
its
transmission
and
diminish
its
communication
range.
To
insure
maximum
range,
transmit
from
atop
a
hill
or
other
high
point
if
possible.

TO
31R2-2PR-101

Figure
2-1.
Radio
Set
AN/PRC-90
Controls
and
Indicators

TO
31R2-2PR-101
Legend
for
Figure
2-1
1.
Earphone
Case
2.
Battery
Cap
3.
TALK
Microphone
4.
VOL
Control
5.
LISTEN
Speaker
6.
EARPHONE
JACK
7.
MCW
Button
8.
PUSH
TO
TALK
Button
9.
Function
Switch
Position
Indicator
and
Arrow
Button
10.
Function
Switch
Knob
11.
Antenna
Retaining
Loop
11A.
Half-wave
antenna
retaining
band
12.
Earphone

Connector
13.
Earphone
14.
Antenna
15.
Instruction
Plate
16.
Rear
Cover
17.
Rear
Cover
Holding
Screws
18.
Battery
b.
Hold
the
radio
set
so
that
the
antenna
is
essentially
vertical
when
transmitting
(Figure
2-2).
This
helps
to
assure
maximum
transmitting
range.
NOTE
All
5
telescoping
sections
of
half-wave
antenna
must
be
fully
extended
for
proper
operation.
A
bend

in
the
antenna
of
up
to
20
is
acceptable
and
will
not
hamper
radio
transmission.
c.
Conserve
battery
power
by
setting
function
switch
to
OFF
when
radio
set
is
not
in
use.
d.
Although
the
AN/PRC-90
circuits
are
operable
over
a
temperature
range
of
-30
to
-54
C,
the
battery
power
supply
is
only
operable
over
a
0

to
+20C
temperature
range.
Operating
at
low
temperatures
reduces
battery
life.
Make
certain
that
the
selector
switch
is
not
inadvertently
left
in
BCN
243.0
(swept-tone)
position.
The
transmitter
is
keyed
automatically
when
the
switch
is
in
this
position.
e.
When
the
radio
set
is
not
issued
it
will
not
be
stored
with
the
battery
installed.
Table
2-1.
Controls

and
Indicators
Control
or
Indicator
Location
(Figure
2-1)
Control
Position
Function
Function
switch
9,
10
OFF
VOICE/MCW
243.0
BCN
243.0
VOICE
282.8
NOTE
The
button,
(Figure
2-1,
9)
must
be
depressed
to
place
function
switch
in
the
VOICE
282.8
position.
Completely
removes
power
from
radio
set.
Turns
on
the
guard
channel
receiver
to
the
emergency
frequency
of
243.0

MHz.
Also
enables
voice
and
MCW
guard
channel
transmission
which
are
keyed
by
the
PUSH
TO
TALK
or
MCW
buttons.
Turns
on
243.0
MHz
guard
channel
transmitter,
and
transmits
a
beacon
tone.
Swept
audio
tone
is
continuously
transmitted
for
rescue
aircraft
to
home
on.
Turns
on
alternate
channel
to
receive
on
282.8
MHz.
Also
enables
voice
transmission
on
auxilliary
channel

when
PUSH
TO
TALK
button
is
depressed.

TO
31R2-2PR-101
Table
2-1.
Controls
and
Indicators
-Continued
Control
or
Indicator
Location
(Figure
2-1)
Control
Position
Function
PUSH
TO
TALK
button
8
Depressed
Released
Turns
receiver
off
and
turns
transmitter
on
when
function
switch
is
in
either
VOICE
MCW
243.0
or
VOICE
282.8
position.
Best
voice
transmissions
are
obtained
when
spoken
directly
into
the
talk

microphone.
Turns
off
transmitter
and
turns
on
receiver;
received
signal
is
heard
with
ear
close
to
LISTEN
speaker
or
earphone.
MCW
button
7
Depressed
Released
This
button
is
a
telegraph
key;
it
enables
the
operator
to
transmit
code
when
the
normal
transmitting
level
of
his
voice
may
reveal
his
position.
MCW
is
only
obtainable
when
the
function
switch
is
in

the
VOICE/MCW
243.0
position.
Causes
radio
set
to
transmit
a
continuous
tone,
receiver
off.
Turns
transmitter
off,
receiver
on.
VOL
control
4
Fully
up
MAX
Fully
down
This
controls
the
volume
of
the
sound
from
the
LISTEN
speaker
or
earphone.
It
controls
received
signals,
not
sidetone.
Loudest
sound
Quietest
sound,
but
radio
set
is
not
turned
off.
NOTE
Volume
control

does
not
affect
transmitted
power
output.
LISTEN
speaker
5
Sound
of
received
signal
is
heard
by
placing
ear
close
to
LISTEN
speaker.
Sound
of
MCW
or
beacon
transmitter
may
also
be
heard.
The
LISTEN
speaker
is
shut
off
when
the
earphone
is
connected.
TALK
microphone
3
Picks
up
the
voice
being
transmitted
when
PUSH
TO
TALK
button
is
depressed
and

function
switch
is
set
to
either
VOICE/MCW
243.0
or
VOICE
282.8.
Earphone
jack
6
Earphone
connected
NOTE
Connector
may
be
joined
to
jack
in
either
of
two
polarities.
Earphone
disconnected
Causes
sound
to
be
heard
in
earphone.
A
magnet
in
the
earphone
connector
(Figure
2-1,
12)
shuts
off
the
LISTEN
speaker.
Sound
is
heard
through
LISTEN
speaker.
Battery
cap
2

Holds
battery
in
place.
(Figure
2-1,
18).

TO
31R2-2PR-101

Figure
2-2.
Antenna
Orientation
f.
Loss
of
springiness
of
antenna
or
cracks
and
breaks
in
g.
Battery
life
can
be
extended
by
following
the
theater
its
rubber
cover
will
not
detract
from
antennas
perforrescue
procedure.
mance.
So
long
as
the
fully
extended
antenna
can
be
erected
to
an
approximately
straight
vertical
position

(by
2.4
OPERATING
PROCEDURE.
bending
the
flexible
portion
if
necessary),
it
will
radiate.
These,
however,
are
signs
of
deterioration,
and
the
antenna
should
be
replaced
when
possible.
As
an
option,
To
operate
the
AN/PRC-90,
proceed
as
follows:
the
antenna
cover
can
be
replaced
by
using
insulation
a.
Free
the
antenna
from
its
stowed
position
by
pulling
its
sleeving,
part
number

5-8NT
for
the
bottom
portion
and
end
from
the
retaining
ring
or
band
as
appropriate.
The
part
number
874576
for
the
upper
half.
antenna
snaps
into
an
upright
position.
Fully
extend
all

TO
31R2-2PR-101
five
telescopic
sections
of
the
half-wave
antenna
by
grasping
it
by
its
tip
and
pulling
outward.
NOTE
Both
quarter
wave
and
half-wave
antennas
are
currently
in
use
on
the
PRC-90
radio.
The
quarter-wave
antenna
is
fully
flexible
and
is
approximately
12-inches
long.
The
half-wave
antenna
(Air
Force
required)
has
a
flexible

lower
section
and
a
telescoping
upper
section.
Its
length
is
approximately
12-inches
collapsed
and
24-1/2
inches
extended.

Be
sure
to
connect
the
earphone
before
turning
on
the
radio
set,
if
quiet
operation
is
desired
to
prevent
speaker
sound
from
disclosing
your
position
to
nearby
enemy
forces.
b.
For
earphone
(quiet)
operation,
remove
the
earphone
from

its
case
and
uncoil
the
wire.
Snap
the
earphone
connector
to
the
two
mating
connectors
marked
EARPHONE
JACK
(Figure
2-1,
6)
on
the
radio
set,
and
insert
the
earpiece
in
your
ear.
NOTE
The
earphone
connector
fits
in
either
of
two
positions
(or
polarities)
on
the
EARPHONE
JACK
terminals.
c.
Set
the
function
switch
to
the

desired
mode
of
operation.
The
function
switch
is
set
by
rotating
the
thumb
knob
on
the
right-hand
side
so
that
the
arrow
points
to
the
mode
selected.
The
function
switch
is
detented
and
positively
catches
in
position.
Rotate
the
knob
down
one
click
(from
OFF)
for
VOICE/MCW
243.0
operation,
or
two
clicks
for
BCN
243.0
operation.
For
VOICE
282.8
operation,

depress
the
button
with
the
arrow
(Figure
2-1,
9)
and
rotate
the
function
switch
knob
(Figure
2-1,
10)
up
one
click.
d.
For
voice
operation,
hold
the
radio
set
in
the
manner
previously
described
(Refer
to
Paragraph
2.2)
and
adjust
the
VOL
control
for
the
desired*audio
output
level
from
the
LISTEN
speaker
or
earphone.
e.
To
transmit
voice,
depress
and

hold
the
PRESS
TO
TALK
button
and
speak
directly
into
the
TALK
microphone.
f.
If
guard
channel
steady-tone
transmission
or
Morse
code
operation
is
desired,
set
the
function
switch
to
VOICE/MCW
243.0.
Depress
the
MCW
button
to
transmit
the
tone.
Listen
for
the
sidetone
in
the
LISTEN
speaker
or
earphone
while
the
MCW
button
is
depressed.
This
sidetone
indicates
proper

transmitter
operation.
g.
For
guard
channel
beacon
operation,
set
the
function
switch
to
BCN
243.0.
The
transmitter
continuously
sends
the
swept-tone
beacon
signal
at
this
setting.
Listen
for
the
sidetone
as
an
indication
of
proper
operation.
In
the
beacon
mode,
the
sidetone
is
a
chirping
sound.
NOTE
Since
the
transmitter
is
keyed
automatically
in
the
beacon

mode,
and
since
continuous
transmission
may
be
needed
for
a
prolonged
period
of
time,
the
AN/PRC-90
may
be
placed
upright
on
a
flat
surface.
It
will
then
transmit
automatically.
h.
When
stowing
the
half-wave
antenna,
first
collapse
the
telescopic
sections
by
holding
the
lowest
rigid
section
(mid-antenna
at
top
of
rubber
sleeving)
with
one
hand
and
pushing
inward

on
the
tip
of
the
antenna
with
the
other
hand.
Stow
the
collapsed
antenna
by
bending
it
down
around
the
control
side
of
the
radio
so
that
the
tip
of
the
antenna
is
approximately
1-inch
below
the
mode
control
knob.
Slip
the
ball
tip
of
the
antenna
completely
under
the
antenna
retaining
band
so
that
the
tip
extends
below
the

band.
Check
to
make
sure
the
telescoping
sections
are
still
fully
collapsed.
2.5
BATTERY
REPLACEMENT.
To
replace
the
battery,
unscrew
the
battery
cap
(rotate
counterclockwise)
and
slide
the
old
battery
out.
The
fresh
battery
can
be
inserted
into
the
radio
set
in
one
direction
only,
positive
end
first.
2.6
BATTERY
LIFE.
Batteries
exceeding
accumulated
service
and
latest
shelf

life
will
be
condemned
regardless
of
condition.
Refer
to
Paragraph
5.5
for
additional
information
on
total
battery
life
cycle
and
field
service
life.
These
batteries
may
be
used
for
training
purposes.
2.7
QUICK
OPERATIONAL
CHECK.
The
following
instructions
provide
a
quick
check
of
the
radio
set.
The
procedures
are
intended
for
organizational
personnel
who
must
check
out
a

radio
set
when
no
test
equipment
is
available.
A
second
Radio
Set
AN/PRC-90
(known
to
be
operating
properly)
must,
however,
be
available
to
perform
these
tests.
The
operational
checkout
procedures
in
Chapter
6
are
a
more
thorough
test
of
the
operating
capability
of
the

TO
31R2-2PR-101
AN/PRC-90,
and
should
be
used
whenever
possible.
Carry
out
the
steps
in
the
order
presented.

While
performing
these
tests,
the
transmitter
is
keyed
and
the
radio
set
transmits.
Always
keep
the
transmission
test
as
short
as
possible,
to
avoid
interfering
with
rescue
channels.
If
possible,
do
the
testing
in
an
authorized
screen

room.
a.
Set
the
function
switches
on
both
radio
sets
to
VOICE/
MCW
243.0.
b.
Adjust
the
VOL
control
on
the
radio
set
under
test
to
MAX:
(1)
If
a
definite
rushing
noise
is
heard
in
the
LISTEN
speaker,
proceed
to
step
c.
(2)
If
nothing
is
heard,
replace
the
battery.
If
battery
replacement
does
not
correct
the

situation,
send
the
radio
set
to
field
maintenance
facility.
c.
Connect
the
earphone
to
the
EARPHONE
JACK
and
hold
earpiece
near
your
ear.
NOTE
You
should
be
able
to
hear
sounds
from
the
earpiece
without
actually
inserting
it
in
your
ear.
Since
ear
wax
will
accumulate
on
the
earpiece
when
it
is
in
the
ear,
do
not
insert

during
checkout.
(1)
If
LISTEN
speaker
is
quiet
and
rushing
noise
is
heard
in
earpiece,
disconnect
earphone
and
proceed
to
step
d.
(2)
If
rushing
noise
is
not
heard
in
earpiece,
replace
the
earphone
and
repeat
the
test.
If
rushing
noise
is
still
not
heard,
send
the
radio
set
to
field
maintenance
facility.
(3)
If
rushing
noise
is

heard
in
LISTEN
speaker
when
earphone
is
connected,
replace
the
earphone
and
repeat
the
test.
If
rushing
noise
is
still
heard
in
the
speaker,
send
the
radio
set
to
field
maintenance
facility.
d.
On
the
second
radio
set,
depress
the
PUSH
TO
TALK
button
and
blow
into
the
TALK
microphone.
(1)
If
blowing
sound
is
heard
in
the
LISTEN
speaker

of
the
AN/PRC-90
under
test,
proceed
to
step
e.
(2)
If
blowing
sound
is
not
heard,
send
the
radio
set
to
field
maintenance
facility.
e.
On
radio
set
under
test,
depress
PUSH
TO
TALK
button
and
blow
into
TALK
microphone.
(1)
If
blowing
sound
is
heard
in
LISTEN
speaker
of
second
radio
set
(adjust
second
radio
set s
VOL
control
if

necessary),
proceed
to
step
f.
(2)
If
blowing
sound
is
not
heard,
send
radio
set
under
test
to
field
maintenance
facility.
f.
On
radio
set
under
test,
depress
MCW
button:
(1)
If
tone
is
heard
in
LISTEN
speaker
of
both
radio
sets,
proceed
to
step
g.
(2)
If
tone
is
not
heard
in
both
speakers,
send
radio
set
to
field

maintenance
facility.
g.
On
AN/PRC-90
radio
set
under
test,
set
function
switch
to
BCN
243.0
for
a
second
and
then
set
to
OFF.
(1)
If
chirping
sound
is
heard
in
LISTEN
speaker
of
second
radio
while
radio
set
under
test
is
set
for
beacon
operation,
proceed
to
step
h.
(2)
If
chirping
sound
is
not
heard,
send
radio
set
to

field
maintenance
facility.
h.
Set
the
function
switches
on
both
radio
sets
to
VOICE
282.8.
(1)
If
a
definite
rushing
noise
is
heard
in
LISTEN
speaker
of
radio
set
under
test,
proceed
to
step
i.
(2)
If
rushing
noise
is
not
heard,
send
radio
set
to
field
maintenance
facility.
i.
On
second
radio
set,
depress
PUSH
TO
TALK

switch
and
blow
into
TALK
microphone.
(1)
If
blowing
sound
is
heard
in
LISTEN
speaker
of
radio
set
under
test,
proceed
to
step
j.
(2)
If
blowing
sound
is
not
heard,
send
radio
set
to
field
maintenance
facility.

TO
31R2-2PR-101

Figure
2-3.
Antenna
Bracket
Weight
Check

Figure
2-4.
Strap
Antenna
Weight
Check

TO
31R2-2PR-101
j.
On
radio
set
under
test,
depress
PUSH
TO
TALK
switch
and
blow
into
TALK
microphone.
(1)
If
blowing
sound
is
heard
in
LISTEN
speaker
of
second
radio
set,
proceed
to
step
k.
(2)
If
blowing
sound
is
not
heard,
send
radio
set
to
field
maintenance
facility.
k.
On
radio
set
under
test,
adjust
VOL

control
back
and
forth
from
MAX
to
minimum
positions.
(1)
If
the
loudness
of
rushing
noise
in
LISTEN
speaker
of
radio
set
under
test
varies
smoothly
from
an
easy-to-hear
level
at
MAX
to
a
quiet
level
at
minimum,
the
radio
set
is
probably
operating
properly.
Set
the
function
switch
to
OFF
and
return
the
earphone
to
its
case.
(2)
If

noise
level
variation
is
sudden
or
intermittent,
send
the
radio
set
to
field
maintenance
facility.
NOTE
Although
an
AN/PRC-90
passes
the
quick
operational
check,
it
may
have
a
weak
battery,
low
receiver
sensitivity,
or
low
power
output.
The
operational
checkout
in
Chapter
5
is
required
to
assure
proper
operation.
2.8
SERVICE
AFTER
IMMERSION.
If
the
radio

set
has
been
immersed
in
salt
water,
wash
it
in
fresh
water
as
soon
as
possible.
Sometimes
an
accumulation
of
dried
salt
causes
the
function
switch
to
bind.
If
the
radio
set
has
been
immersed
in
either
salt
or
fresh
water
to
a
depth
greater
than
50
feet,
send
it
to
organizational
maintenance
for
inspection.
2-9/(2-10
blank)

TO
31R2-2PR-101
CHAPTER
3
TEST
EQUIPMENT
AND
SPECIAL
TOOLS
3.1
TEST
EQUIPMENT
REQUIRED.
Table
3-1
lists
and
describes
the
use
of
test
equipment
required
for
organizational
and
field
level
maintenance
of
Radio
Set
AN/PRC-90.
Special
tools
are
listed
in
Table
3-2.
3.2
RADIO
TEST
SET
AN/PRM-32.
Radio
Test
Set
AN/PRM-32
(Figure
3-1)
is

the
primary
piece
of
test
equipment
used
to
check
out
Radio
Set
AN/PRC-90
at
organizational
level
maintenance.
The
test
set
is
build
into
a
carrying
case
and
contains
two
accessories,
a
spanner
wrench
(2)
used
to
remove
AN/PRC-90.
Antennas
and
an
instruction
book
(1).
Radio
Test
Set
TS-20/PRM-32A
may
also
be
used
to
check
out
AN/PRC-90.

Radio
Test
Set
AN/PRM-32/TS-20/PRM-32A
provides
a
fully
shielded
test
path.
Thus,
by
using
the
test
set
for
transmitter
tests,
there
is
no
interference
with
operating
channels.

TO
31R2-2PR-101

Figure
3-1.
Radio
Test
Set
AN/PRM-32

TO
31R2-2PR-101
3.3
RADIO
TEST
SET
TS-24B.
Radio
Test
Set
TS-24B
is
used
by
life
support
shops
in
the
checkout
of
the
AN/PRC-90
radio.
Test
radio
in
accordance
with
Paragraph
7.3.
Table
3-1.
Test
Equipment
Required
for
Maintenance
Name
AN
Type
or
Designation
Alternate
Use
Variable
Power
Supply
0-30
VDC
Oscilloscope
30-db
step

attentuator
Frequency
counter
Multimeter
Radio
test
set
Radio
test
set
Pull
Scale
BK
Precision
Mod#:
1651A
Tektronix
545A
with
plug-in
adapter
AN/USM-26
FLUKE
8000,
or
27A
or
87
Multimeter
or
Equivalent
PRM-32
TS-24B
NSN
6625-01-1288588LS
Model
80D
Equivalent
Tektronix
317
HP-524B,
HP-525C
plug-in,
HP5245L
with
HP-5253B
plug-in
T5-20/PRM-32A
Any
10
lb.
wt.
Supply
external
DC
power
Visual
comparisons
of
frequencies

and
waveforms
Used
with
frequency
counter
Frequency
checks
Field
level
DC
Measurements/
Tests.
Organizational
checkout
Field
level
checkout
and
troubleshooting.
Apply
10
lb.
Pull
to
antenna
tip.
Table
3-2.
Special
Tools
for
AN/PRC-90
Maintenance
Figure
and
Index
Number
Part
Number
Nomenclature
Use
and
Application
Figure
6-1
MX-8801/PRC-90
Battery
test
adapter
Battery
testing,
with
Battery
Tester
TS-2530/UR

Figure
3-2
MX-8802/PRC-90
Antenna
Test
Adapter
Connection
of
radio
set
antenna
jack
to
BNC
series
connectors
Figure
3-3
MX-8829/PRC-90
Battery
Supply
Test
adapter
Feeler
gages
for
0.004
through
0.010
inch
Supply
power
to
radio
during
maintenance.
Check
of
clearance
of
buttons
and
switches
Figure
7-4,
6
71-485750-1
Spanner
Wrench
Navy
models
only;
replacement
of
buttons
(supplied
with
spare
button
assemblies)

TO
31R2-2PR-101

Figure
3-2.
Antenna
Test
Adapter
MX-8802/PRC-90

Figure
3-3.
Battery
Supply
Test
Adapter
MX-8829/PRC-90
3.4
TEST
SET
CALIBRATION.
Calibration
of
the
Category
II
PMEL
supported
test
set
can
be
performed
using
the
following
procedures.
Table
3-3
lists
the
test
equipment
required
to
perform
the
calibration.
Equivalent
test
equipment
may
be

substituted
as
required.
Calibration/
certification
interval
is
in
accordance
with
TO
33K-1-100.
The
PRM-32
will
be
calibrated
and
certified
to
within
5%
of
input
level
specified.
The
TS-20/PRM-32A
will
be
calibrated
in
accordance
with
Paragraph
3.5.
a.
Connect
test
equipment
and
test
set
as
shown
in
Figure
3-4.
b.
Turn
signal
generator,
frequency
counter
and
power
amplifier
switch

to
ON .
Allow
equipment
to
warm
up
for
approximately
15
minutes.
c.
Place
signal
generator
MOD
SELECTOR
switch
to
CW,
FREQUENCY
RANGE
selector
to
E,
and-OUTPUT
ATTENUATOR
control
to
50
MV.
d.
Place
frequency
counter
FUNCTION
switch
to
FREQUENCY,
TIME
BASE
switch
to
10
MS,
and
SENSITIVITY
switch
to
PLUG-IN.
e.
Adjust
FREQUENCY
knob
on
signal
generator
for
a
243.0

MHz
indication
on
frequency
counter.
f.
Set
power
meter
so
that
it
will
indicate
up
to
one
watt
in
the
region
of
200
to
300
MHz.
Place
the
resistive
element
with
its
arrow
pointing
toward
the
load
end.
g.
Place
the
power
amplifier
band
switch
to
the
125
-250
position
and
tune
amplifier
until
the
FREQUENCY
MC

TO
31R2-2PR-101
h.
dial
indicates
243.0
MHz
and
a
power
indication
is
observed
on
the
power
meter.
Place
signal
generator
MOD
SELECTOR
switch
to
1000
Hz
position
(1000
Hz,
internal
modulation),
and
adjust
the
MOD
level
control
until
a
reading
of
80
is
obtained
on
the
MODULATION
PERCENTAGE
meter.
k.
l.
Replace
cover
over
the
SIG
ADJ

potentiometer.
Adjust
output
of
the
signal
generator
until
the
power
meter
indicates
31
milliwatts
average
power.
Mark
meter
indication
on
meter
face.
Use
cloth
tape,
marker
pen
or
suitable
means
to
indicate
needle
position
on
scale
face.
i.
Adjust
output,
attenuator
of
the
signal
generator
until
the
power
meter
indicates
100
milliwatts
average
power.
NOTE
j.
Remove
cover
from
the

SIG
ADJ
potentiometer
of
the
test
set.
Use
screwdriver
to
adjust
potentiometer
until
the
meter
indicates
mid-scale
(red-green
intersection).
This
mark
is
the
go-on-go
test
point
for
training
radios.
Table
3-3.
Calibration
Test
Equipment
Required
Test
Equipment
Type
or
Model
No.
Manufacturer
Signal
Generator
VHF
Power
Amplifier
Power
Meter
In-Line
Power
Meter
Element
1
watt
200

-300
MHz
Interconnecting
Cables
Attenuation
Measurement
System
20DB
Directional
Coupler
Power
Meter/Thermistor
Mount
8640B
or
AN/USM
323
230B
4312
200-1
RG223
U
1295
3039-20
432B/478A
Hewlett
Packard
Hewlett
Packard
Bird
Bird
Local
Micro-Tel
NARDA
Hewlett
Packard
NOTE
Substitutes
of
equipment
indicated
in
Table
3-3
may
be
made
as
long
as
accuracy
and
operating
characteristics
are
not
compromised.
If

the
special
BNC
connector,
Part
No
MX-8802,
is
not
readily
available,
local
shop
manufacture
is
authorized.
Table
3-4.
Alternate
Calibration
Test
Equipment
Test
Equipment
Type
or
Model
No.
Manufacturer
Unit
Oscillator
Power
Supply
Audio
Oscillator
Power
Oscillator
Power
Oscillator
Frequency
Counter
1209CL
1201-C
208
125
408
B
AN/USM-26
General
Radio
General
Radio
Hewlett-Packard
Airborne
Inst
Labs

Micro
Dot

TO
31R2-2PR-101

Figure
3-4.
Calibration
Test
Set
m.
Disconnect
test
set
up.
Test
set
is
now
ready
for
use.
3.5
CALIBRATION
PROCEDURE.
Prepare
test
setup
in
accordance
with
instructions
contained
in
Figure
3-4
and
perform
the
procedure
as
follows:
a.
Connect
test
equipment
and
test
set
as
shown
in
Figure
3-4.
NOTE

The
following
procedure
is
for
use
only
with
Navy
PRC-90
radios
made
under
contract
N00019-67-C-0098.
Use
procedure
starting
with
Paragraph
3.4
when
testing
all
other
PRC-90
radios.

Interconnecting
cables
must
be
short
as
possible.
Long
cables
will
introduce
excessive
losses
and
calibration
will
not
be
accurate.
b.
Turn
signal
generator
and
power
amplifier

power
switch
to
ON .
c.
Turn
the
FREQUENCY
knob
until
MEGACYCLE
dial
indicates
243
on
band
E.
Place
the
FREQUENCY
RANGE
selector
at
E.
Place
the
MOD
SELECTOR
switchatCW.
d.
Set
power
meter
so
that
it
will
indicate
up
to
one
watt
in
the
region
of
200
to
300
MHz.
Place
the
resistive
element
with
its
arrow
pointing
toward
the

load
end.
e.
Place
power
amplifier
band
switch
to
the
125
-250
position
and
tune
amplifier
until
the
FREQUENCY
MC
dial
indicates
approximately
243
MHz.
f.
Set
signal
generator
output
attenuator
control
to
minimum
level;
then,
advance
control
to
increase
output
until
an
indication
of
signal
is
observed
on
power
meter.
g.
Tune
power
amplifier
(by
adjusting
it
to
either

side
of
the
243
MHz
position)
until
a
maximum
reading
is
observed
on
the
power
meter
h.
Place
signal
generator
MOD
SELECTOR
to
the
1000
position
(1000
Hz
internal
modulation)
and
adjust
the
MOD
level
control
until
a
reading
of
80
is
obtained
on
the
MODULATION
PERCENTAGE
meter.
i.
Adjust
output
attenuator
of
the
signal
generator
until
the
power
meter

indicates
exactly
81
milliwatts,
average
power.

TO
31R2-2PR-101
j.
Remove
cover
over
the
SIG
ADJ
potentiometer
of
the
test
set.
Use
screw
driver
to
adjust
potentiometer
until
the
meter
indicates
mid-scale
(RED
-GREEN
INTERSECTION).
k.
Replace
cover
over
the
SIG
ADJ
potentiometer.
Disconnect
test
setup.
The
test
set
is
now
ready
for
use.
3.6
LOCALLY
MANUFACTURED
PARTS.
To
test
radios
when
Lithium
batteries

are
used
a
130
Ohm
resister
and
an
extension
wire
attached
is
required.
See
Figure
3-7.
3.6.1
Fabrication
of
Power
Supply
Leads.
Power
supply
leads
may
be
commercially
procured
or
can
be
locally
manufactured,
obtain
the
following:
Two
sets
of
power
leads
either
commercial
or
locally
manufactured.
See
Figure
3-6.
One
set
to
connect
power
supply

to
RF
module
assembly
external
power.
One
set
with
a
15
ohm
1%,
1
watt
resister
in
line
on
positive
lead
to
connect
the
regulated
power
supply
DC
module
assembly
AN/PRC-90/-106
external
power
on
the
TS-24B.
NOTE
A
15
ohm
1%,
1-watt
minimum
resister
must
be
soldered
in
line
on
positive
(red)
terminal
wire.
The
purpose
of

this
resistor
is
to
limit
in
rush
current
through
the
radios
reed
switches
to
prevent
damage.

Figure
3-5.
Load
Resister
Battery
Test

Figure
3-6.
Fabrication
of
Power
Supply
Leads
a.
Cut
positive
lead
wire
approximately
3
inches
back
from
the
end
determined
to
be
connected
to
the
power
supply.
(1)
Strip
insulation

to
expose
1/4
to
3/8
inch
of
bare
wire
on
both
newly
cut
free
ends.
Obtain
a
length
of
heat
shrinkable
insulation
long
enough
to
enclose
entire
length
of
resister
and
extending
a
minimum
of
1/2
inch
on
either
side
over
lead
wire.
(2)
Strip
insulation
to
expose
1/4
to
3/8
inch
of
bare
wire
as
required
on
end
of

each
lead
wire
tin
bare
wire
to
prevent
fraying.
Solder
the
15
Ohm
1%,
1-Watt
resistor
between
the
two
free
ends
on
red
or
positive
power
lead
wire.
This
action
places
the
limit
resister
between
the
power
supply
and
the
DC
power
module.
b.
The
lines
supplying
power
to
the
test
set
require
at
least
six
banana
type
test
plugs

be
installed
if
not
previously
on
the
power
supply
leads.
c.
Cut
and
remove
any
unusable
items
such
as
test
probes
from
the
ends
of
lead
wires,
remove
insulation
from
previously
exposed
ends.
Only
remove
enough
insulation
to
insert
into
the
type
banana
plug
being
used.
Install
or
solder
on
end
of
lead
wire.
3.7
CALIBRATION
FOR
TS-20A/PRM-32A.
a.
Determine

the
ratio
of
the
power
from
the
output
port
to
the
coupled
port
of
the
20
dB
directional
coupler,
using

TO
31R2-2PR-101
the
microtel
1295
at
243.0
MHz
and
121.5
MHz.
Record
the
respective
value
of
attenuation
at
each
frequency.
b.
Calculate
the
correction
factor
for
each
frequency
as
shown
in
the
following
example,
i.e.:
(1)
121.5
MHz
output
to
coupled
port
is
20.472
dB.
(2)
Divide
20.472
by
10
=
2.0472.
(3)
Obtain
the

antilog
of
9.
0472
=
111.481
=
correction
factor.
(4)
For
100
mw
into
the
TS-20/PRM
32A,
divide
100
mw
by
the
correction
factor
to
determine
the
indicated
reading
for
the
HP432B/478A.
100/111.481
=
0.897
mw.
c.
Connect
test
equipment
as
shown
in
Figure
3-7.
NOTE
To
calibrate
the
tester
for
frequency
243.0
MHz
see
steps
d,
c

and
f.
For
calibration
of
tester
for
frequency
121.5
MHz
use
steps
i,
j
and
k.
d.
Tune
signal
generator
and
the
230B
power
amplifier
to
243.0
MHz
3
kHz,
adjust
the
output
until
the
HP432B/
478A
indicates
the
calculated
value
for
243.0
MHz.
e.
Adjust
the
signal
generator
output
for
80%,
1
kHz
AM
modulation.
f.
Adjust

output
until
the
HP432B/478A
indicates
the
calculated
value
for
243.0
MHz.
g.
Adjust
243/282.8
cal
for
midscale
(red-green
intersectional)
meter
reading.
h.
Set
RF
output
on
signal
generator
to
-80
DBM.
i.
Tune
signal
generator
and
the
230B
power
amplifier
to
121.5
MHz
3
kHz,
adjust
the
output
until
the
HP432B/
478A
indicates
the
calculated
value
for
121.5
MHz.
j.

Adjust
the
signal
generator
output
for
80%,
1
kHz
AM
modulation.
k.
Adjust
output
until
the
HP432B/478A
indicates
the
calculated
value
for
121.5
MHz.
l.
Select
121.5
MHz
on
the
TS-20/PRM-32A
and
adjust
121.5
cal
for
midscale
(red-green
intersection)
meter
reading.
Figure
3-7.
Calibration
Test
Set-Up

TO
31R2-2PR-101
CHAPTER
4
THEORY
OF
OPERATION
4.1
GENERAL.
This
Chapter
contains
a
brief
functional
description
of
the
operation
of
Radio
Set
AN/PRC-90.
Where
applicable,
a
system
of
test-point
identification
is
incorporated
as
an
aid
in
troubleshooting
and
maintaining
the
radio
set.
4.2
IDENTIFICATION
OF
TEST
POINTS.
On
applicable
illustrations,
tables,
and
text,

a
system
of
test-point
identification
is
used
to
aid
in
troubleshooting
and
maintenance.
An
explanation
of
test-point
identification
is
included
here.
Some
of
the
test
points
are
used
only
by
depot
maintenance,
and
therefore
are
not
referenced
in
the
procedures
of
this
Technical
Order.
4.3
MAJOR
TEST
POINTS.
A
major
test
point
is
used
for
checking
the
overall

functions
of,
and
localizing
trouble
to,
assemblies
which
together
comprise
a
primary
functional
loop;
groups
of
components;
and
individual
components.
The
identification
symbol
designating
major
test
points
consists
of
an
arabic
numeral
enclosed
in
.
Text
and
tabular
references
to
major
test
points
are
written
as
follows:
test
point
1,
test
point
2,
etc.
4.4
SECONDARY
TEST
POINTS.

A
secondary
test
point
is
used
to
isolate
causes
of
subnormal
performance
within
a
specific
assembly
or
subassembly.
The
symbol
designating
secondary
test
points
consists
of
a
capital
letter
enclosed
in
a
circle
.
Text
and
tabular
references
to
secondary
test
points
are
written
as
follows:
test
point
A,
test
point
B,
etc.
4.5
MINOR
TEST

POINTS.
Minor
test
points
are
used
to
isolate
causes
of
abnormal
indications
within
a
specific
circuit.
The
symbol
identifying
minor
test
points
consists
of
capital
letters
combined
with
arabic
numerals
enclosed,
in
a
circle
.
Text
and
tabular
references
to
minor
test
points
are
written
as
follows:
test
point
A1,
test
point
B2,
etc.
4.6
THEORY

OF
SYSTEM
OPERATION.
A
functional
schematic
and
wiring
diagram
of
Radio
Set
AN/PRC-90,
Figure
4-1,
illustrates
the
modular
and
switching
concept
of
the
radio
set
and
the
related
interconnections.
4.7
CONSTRUCTION.
The
primary
electronic
functions
of
the
radio
set
are
performed
by
six
microcircuits
which
are
totally
enclosed,
non-repairable
modules.
The
general
internal
functioning
of
the
microcircuits
listed

below
is
shown
in
Figure
4-1,
to
aid
in
understanding
the
theory
of
operation
and
to
assist
troubleshooting.
a.
A1TR1
Guard
Channel
Transmitter
b.
A1TR2
Alternate
Channel
Transmitter
c.
A1RE1
Guard
Channel
Receiver
d.
A1RE2
Alternate
Channel
Receiver
e.
A1AR1
Modulator
Amplifier
f.
A1AR2
Receiver
Amplifier
The
six
microcircuits
are
mounted
on
an
interconnecting
printed-circuit
board
A1A2,
together

with
antenna
switch
A1A1.
There
are
also
several
individual
components
(crystals,
diodes,
and
resistors)
mounted
on
A1A2.
The
remaining
components
are
mounted
on
the
radio
set
housing
and
are
not
part
of
electronics
assembly
A1.
4.8
TRANSMITTER
MICROCIRCUITS
A1TR1
AND
A1TR2.
Both
transmitter
microcircuits
function
in
a
similar
manner;
they
consist
of
a
crystal
oscillator,
a
frequency
doubler

and
an
amplifier.
The
243.0
MHz
guard
channel
transmitter
generates
its
frequency
with
a
121.5
MHz
crystal
oscillator,
doubles
this
frequency
to
243.0
MHz
in
a
doubler,
and
applies
this
signal
to
a
driver
and
final
amplifier
where
these
signals
are
amplified
to
the
correct
power
and
impedance
level
for
matching
of
the
antenna.
The
RF
signal
is
amplitude
modulated

by
audio
fluctuations
on
the
DC
power
input
to
the
final
amplifier.
The
presence
of
modulated
RF
at
the
final
amplifier
causes
an
audio
signal
to
be
detected
by
the
sidetone
detector;
this
signal
is
directly
applied
to
the
LISTEN
speaker
through
attenuating
resistor
A1A2R2
and
produces
the
sidetone.
The
282.8
MHz
alternate
channel
transmitter
generates
its
frequency

with
a
70.7
MHz
crystal
oscillator,
doubles
its
frequency
twice
in
two
doubler
stages
to
produce
282.8
MHz.
The
signal
is
amplified
in
a
final
amplifier.
Where
modulation
is
applied
on
the
positive
power
line
there
is
no
sidetone
connection
in
the
alternate
channel
transmitter.

TO
31R2-2PR-101
4.9
MODULATOR
AMPLIFIER
A1AR1.
This
microcircuit
develops
audio
signals
which
modulate
the
RF
in
the
final
amplifiers
of
the
guard
and
alternate
channel
transmitters.
4.10
BEACON
AND
MCW.
A
single
audio-tone
generator
is
common
to
both
the
beacon
generator
and
MCW
tone.
When
the
beacon
mode
is
selected
the
sweep
generator
produces
a

2.5
Hz
saw-tooth
which
sweeps
the
tone
generator
frequency
from
approximately
1000
Hz
to
300
Hz
at
a
rate
of
two
or
three
cycles
per
second.
When
MCW
is
selected,
the
sweep
generator
is
made
inoperative
and
the
tone
generator
produces
a
single
tone
of
1000
Hz
in
accordance
with
the
depression
of
the
MCW
button.
The
beacon
or
MCW

signal
is
then
amplified
by
the
modulator.
The
beacon
and
MCW
signals
are
applied
to
the
transmitters
on
the
same
line
as
the
voice
modulation
signals.
Only
the
guard
channel
transmitter
is
modulated
by
the
beacon
and
MCW
signals,
because
the
control
circuits
do
not
activate
the
tone
and
sweep
generators
in
the
alternate
mode.
4.11
AMPLIFIER.
This

circuit
on
A1AR1
is
a
speech
amplifier
which
raises
the
low-level
signals
from
the
TALK
microphone
or
beacon
and
MCW
signals
sufficiently
to
drive
the
modulator.
The
output
of
A1AR1
is
then
routed
to
the
final
amplifiers
of
both
transmitters,
where
the
selected
intelligence
amplitude
modulates
the
carrier
wave.
4.12
RECEIVER
MICROCIRCUITS
A1RE1
AND
A1RE2.
Both
receiver
microcircuits,

practically
identical,
are
crystalcontrolled
super
heterodyne
circuits.
They
incorporate
a
single
RF
amplifier,
a
mixer
stage,
an
IF
detector,
and
an
audio
amplifier.
The
circuits
contain
a
crystal
local
oscillator
(LO).
In
guard
channel
receiver
A1RE1,
the
local
oscillator
operates
from
the
second
overtone
of
106.0
MHz
crystal
Yl
to
produce
the
212
MHz
local
oscillator
signal.
In
alternate

channel
receiver
A1RE2,
the
local
oscillator
operates
from
the
third
overtone
of
89.933
MHz
crystal
Y2
to
produce
the
251.799
MHz
LO
signal.
In
both
receivers,
the
LO
is
coupled
to
the
mixer
circuit
to
produce
an
intermediate
frequency
of
31
MHz.
The
31
MHz
IF
is
amplified,
detected,
and
reamplified
to
audio
levels
sufficient
to
drive

receiver
amplifier
A1AR2.
4.13
RECEIVER
AMPLIFIER
A1AR2.
The
audio
from
both
receivers
is
applied
through
VOL
control
R1
to
the
input
of
receiver
amplifier
A1AR2.
Receiver
Amplifier
A1AR2
amplifies
the
received
audio
signals
to
a
power
level
sufficient
to
drive
LISTEN
speaker
LS1
or
earphone
LS3.
4.14
ANTENNA
SWITCHING
CARD
A1A1.
This
card
provides
the
necessary

circuitry
for
routing
signals
to,
or
from,
the
antenna
terminals
to
the
output
terminals
of
the
transmitters
and
input
terminals
of
the
receivers.
Terminals
3,
5,
6,
and
10
are
control
terminals
that,
when
made
positive
with
respect
to
terminals
1
and
11
by
battery
voltage,
will
cause
diodes
CR1,
CR2,
CR3,
and
CR7
to
conduct
and
thus
provide
a

low
impedance
signal
path
from
the
antenna
to
terminals
2,
4,
7
and
9.
The
card
also
routes
the
positive
power
supply
voltage
from
terminal
8
to
activate
the
amplifier
on
A1AR1,
when
either
guard
or
alternate
channel
transmit
functions
are
selected.
This
DC
voltage
is
also
applied
through
CR5
to
reverse
bias
and
cut
off
diodes
CR1
and
CR2

during
either
guard
or
alternate
channel
transmission;
this
blocks
the
receivers.
4.15
CONTROL
CIRCUITS.
VOICE
282.8.
With
the
function
switch
in
this
position,
switch
S2
connects
the
positive
terminal
of
the
battery
(B+)
through
a
normally-closed
contact
of
PUSH
TO
TALK
switch
S5
to
pin
3
of
alternate
receiver
A1RE2,
to
pin
2
of
receiver
amplifier
A1AR2,
through

A1A2
CR4,
and
to
pin
5
of
antenna
switch
A1A1.
At
A1A1-5
it
causes
diode
A1A1
CR2
to
conduct
and
thus
connects
the
antenna
terminals,
through
diode
A1A1
CR2
and
A1A1
pin
4
and
finally
to
the
input
of
alternate
receiver
A1RE2
at
pin
2.
The
detected
low-level
audio
from
this
receiver
at
pin
11
passes
through
VOL
control
R1

and
then
to
pin
4
of
receiver
amplifier
A1AR2.
The
amplified
output
at
A1AR2-3
passes
through
the
normallyclosed
contact
of
EARPHONE
JACK
switch
S6
to
LISTEN
speaker
LS1.
When
the
earphone
is
plugged
in,
the
magnet
mounted
inside
the
plug
actuates
reed
switch
S6
inside
the
housing.
The
reed
switch
routes
the
audio
output
signal
to
the
earphone
and

opens
the
LISTEN
speaker
circuit.
To
transmit
on
282.8
MHz,
the
PUSH
TO
TALK
button
must
be
depressed.
This
alters
the
control
voltages
(B+)
as
follows:
a.
Removes
B+
from
pin
3
of
alternate
receiver
A1RE2
and
pin
2
of
receiver
amplifier
A1AR2.
b.
Removes
B+
from
pin
5
of
antenna
switching
A1A1,
thus
opening
the
signal
path

of
the
antenna
to
pin
2
of
the
receiver.
c.
Applies
B+
to
pin
2
of
alternate
transmitter
A1TR2,
turning
it
on.
d.
Applies
B+
to
pin
10
of
antenna
switch
A1A1,
thus
closing
the
antenna
circuit
path
from
pin
9
to
the
antenna.
When
B+
is
applied
to
pin
10
of
the
antenna
switch,
diode
A1A1
CR5
conducts
and

provides
B+
at

pin
8,
thus
turning
on
modulator
amplifier
A1AR1,
via
pins
3
and
4.
A
modulating
signal
is
routed
to
pin
8
of
alternate
transmitter
A1TR2.
4.16
VOICE/MCW
243.0.
With
the
function
switch
in
this
position,
switch
Sl
applies
B+
through
the
normally-closed
contact
of
MCW
switch
S4
and
normally-closed
contacts
of
PUSH
TO
TALK
switch
S5
to

pin
3
of
guard
receiver
A1RE1
and
to
pin
3
of
antenna
switch
A1A1.
Here
the
B+
causes
diode
A1A1
CR1
to
conduct,
and
thus
completes
the
antenna
circuit
to
pin
2
of
guard
receiver
A1RE1.
B+
is
also
applied
to
pin
2
of
receiver
amplifier
A1AR2
through
diode
A1A2
CR3.
Low-level
audio
from
pin
11
of
A1RE1
passes
to

pin
4
of
receiver
amplifier
A1AR2.
The
resulting
high-level
audio
drives
LISTEN
speaker
LS1.
Transmitting
on
243.0
MHz
is
accomplished
by
depressing
the
PUSH
TO
TALK
button.
This
alters
the
control
voltage
(B+)
as
described
below:
a.
Removes
B+
from
pin
3
of
guard
receiver
A1RE1
and
pin
2
of
receiver
amplifier
A1AR2,
shutting
those
circuits
off.
b.

Removes
B+
from
pin
3
of
antenna
switch
A1A1,
thereby
opening
the
signal
path
from
to
pin
2
of
the
receiver.
c.
Applies
B+
to
pin
2
of
guard
transmitter
A1TR1.
d.
Applies
B+
to
pin
3
of
antenna
switch
A1A1,
thereby
closing
the
antenna
circuit
path
from
pin
11
of
the
guard
transmitter
to
the
antenna.
TO
31R2-2PR-101

e.
Applies
B+
(from
pin
6
of
antenna
switch
A1A1
through
diode
A1A1
CR3
to
pin
8
of
this
card)
from
pin
8
of
the
antenna
switching
card
to
pins
3
and
4
of
modulator
amplifier
A1AR1.
4.17
MCW
BUTTON
IMPRESSED.
With
the
function
switch
in
VOICE/MCW
243.0
position,
switch
S1
applies
B+
to
MCW
switch
S4.
Depressing
MCW

switch
S4
applies
B+
to
the
following
circuits:
a.
Pin
2
of
guard
transmitter
A1TR1
through
isolation
diode
A1A2
CR1.
b.
Pin
6
of
antenna
switch
A1A1,
closing
the
antenna
circuit
path
from
A1TR1
pin
11
to
the
antenna.
c.
Pin
9
of
modulator
amplifier
A1AR1,
turning
on
the
tone
generator.
4.18
BCN-243.0.
With
the
function
switch
in

this
position,
switch
S3
applies
B+
to
the
following
circuits:
a.
Pin
6
of
antenna
switch
A1A1
through
isolation
diode
A1A2
CR2;
this
closes
the
antenna
circuit
path
from
pin
11
of
guard
transmitter
A1TR1
to
the
antenna.
B+
is
also
applied
to
pin
2
of
guard
transmitter
A1TR1,
turning
on
the
oscillator.
b.
Pin
11
of
modulator

amplifier
A1AR1,
turning
on
the
beacon
tone
generator
and
sweep
generator.
4-3/(4-4
blank)

TO
31R2-2PR-101

Figure
4-1.
Schematic
and
Wiring
Diagram
of
AN/PCRC-90
4-5/(4-6
blank)

TO
31R2-2PR-101
CHAPTER
5
PREPARATION
FOR
MAINTENANCE
5.1 GENERAL.
This
Chapter
describes
the
work
necessary
to
prepare
Radio
Set
AN/PRC-90
for
organizational
and
field
maintenance.
This
service
is
also
required
before
issuing
the
AN/PRC-90
to
air
crewmen.
5.2 UNPACKING.
The
complete
radio
set
and
battery
are
shipped
in
a
standard
package,
and
therefore
require
no

unpacking
instructions.
5.3 VISUAL-MECHANICAL INSPECTION.
Inspect
the
equipment
exterior
for
cleanliness
and
proper
operation
of
all
controls.
Check
that
function
switch
turns
with
proper
detent
action
without
binding,
that
MCW
and
PUSH
TO
TALK
buttons
return
when
depressed,
and
that
VOL
control
turns
freely
and
stops
at
MAX
and
minimum
limits.
Check
that
perforations
at
TALK
and
LISTEN
are
clear,

antenna
is
clean
and
snaps
to
the
erect
position
when
released
from
the
stowed
position,
and
that
telescopic
sections
of
the
antenna
can
be
fully
extended
and
collapsed;
that
the
antenna
retaining
band
is
not
cracked,
deteriorated,
or
outstretched,
and
that
control
markings
and
identification
and
instruction
plates
are
clean
and
legible.
NOTE
Some
antennas
have

a
loose-fitting
rubber
cover
which
may
have
a
twisted
or
wrinkled
appearance.
The
antenna
is
not
defective
unless
the
rubber
is
cracked
or
broken
or
the
uncovered
telescopic
sections
do
not
extend
and
collapse
fully.

When
using
Cleaning
Compound
FSN
6850-5979765
avoid
prolonged
inhalation
of
the
fumes.
Provide
ample
ventilation
and
keep
away
from
flame.

5.4 CLEANING.
Cleaning
compound
may
affect
skin,
eyes
and
respiratory
tract.
Use
in
a
well
ventilated
area.
Avoid
prolonged
breathing
of
vapors.
Avoid
eye
and
skin
contact.
Chemical
goggles
and
neoprene
gloves
will
be
worn.
Keep
away
from
sparks
and
flames.
If
necessary
to
remove
grease
and
oil,
wipe
the
exterior
with
a
cloth
dampened
(not
wet)
with
isopropyl
alcohol
(70%)

and
wipe
dry.
Clean
the
equipment
by
wiping
with
a
clean
lint
free
cloth
or
soft
brush.
If
the
radio
set
has
been
exposed
to
salt
water
or
if
such
exposure
is
suspected
because
of
difficulty
in
operating
the
function
switch,
wash
the
radio
set
in
fresh
water.
To
do
this,
immerse
the
entire
radio
in

a
basin
of
fresh
water
and
agitate
while
operating
the
function
switch.
If
repeated
fresh
water
washing
do
not
free
the
function
switch,
send
the
radio
set
to
field
maintenance
for
disassembled
cleaning
or
replacement
of
the
function
switch.
Battery
leakage
creates
a
buildup
of
a
caustic
and
corrosive
chemical
on
the
battery
cap,
springs,
and
battery
well,

which
will
eventually
cause
the
radio
set
to
malfunction.
a.
Clean
battery
cap
as
follows:
(1)
Remove
spring
and
sealing
washer
from
the
battery
cap.
(2)
Soak
spring,
washer,
and
cap
in
equal
parts
of
vinegar
and
hot
water
for
30
minutes.
(3)
Carefully
scrub
off
any
remaining
chemical
so
that
all
surfaces
are
clean.

TO
31R2-2PR-101
b.
If
the
battery
well
or
top
spring
is
corroded
send
the
radio
to
field
maintenance.
Field
maintenance
activities
will
clean
and
treat
corroded
areas
as
outlined
in
TO
12R2-2PRC90-3.
c.
Dry
and
reassemble
the
battery
cap.
If
serious
pitting
has
occurred,
replace
the
faulty
parts.
5.5
BATTERY
INSPECTION.
NOTE
The
BA-5368/U
battery

has
a
shelf
life
of
60
months
(5
years)
from
the
date
of
manufacture
and
an
installed
service-life
of
36
months
(3
years).
Condemn
and
replace
batteries
that
exceed
service
or
shelf
life.
Condemned
batteries
may
be
used
for
training
or
disposed
of
in
accordance
with
TO
00-25-213-WA-1.
5.5.1
Battery
Life.
Remove
the
battery
from
the
radio
set

and
inspect
for
evidence
of
swelling;
chipped/cracked
surfaces
for
moisture.
If
any
of
these
conditions
are
present,
the
battery
will
be
condemned.
The
BA-5368/U
battery
has
a
shelf
life
of
60
months
(5
years)
from
the
date
of
manufacture
and
an
installed
service-life
of
36
months
(3
years).
Condemn
and
replace
batteries
that
exceed
service
or
shelf
life.
Condemned
batteries

may
be
used
for
training
or
disposed
of
in
accordance
with
TO
00-25-213-WA-1.
5.6
BATTERY
SERVICE
LIFE
TEST.
5.6.1
Battery
Test
Using
Multimeter
and
a
130
Ohm
1
Watt
Resister.
NOTE
If
test
indicates
a
good
battery,
reinstall
in
survival
radio.
If
it
indicates
a
bad
battery,
replace
it
with
a
new
battery
which
has
been
tested
good.

a.
Remove
battery
from
radio
set
and
inspect
for
evidence
of
swelling,
chipped/cracked
surface,
and
moisture.
If
any
of
these
conditions
are
present
the
battery
will
be
condemned.The
BA-5368/U
battery
has
a
shelf
life
of
60
months
(5
years)
from
the
date
of
manufacture
and
an
installed
service-life
of
36
months
(3
years).
Condemn
and
replace
batteries
that

exceed
service
or
shelf
life.
Condemned
batteries
may
be
used
for
training
or
disposed
of
in
accordance
with
TO
00-25-213-WA-1.
NOTE
Any
one
Watt
125
to
135
Ohm
resister
may
be
substituted
in
place
of
those
NSN s
listed
below
as
long
as
it
meets
the
same
criteria.
(1)
BA-5368/U
Battery
test
for
use
Li/MnO2
battery.
The

purpose
test
is
to
place
load
on
the
battery
that
simulates
battery
transmitting
in
the
beacon
mode
(approximately
100
milliamp
load).
(2)
Any
one
watt
125
to
135
ohm
resister
may
be
used
in
place
of
those
NSNs
listed
below:
1
Watt
carRCR32G131JM
5905-00-455-2301
bon:
5905-00-121590500-520-5388
9927
1
Watt
Wire
RWR81N1300FR
5905-01-073-2919
wound:
1
Watt

Wire
RWR81S1300FR
5905-00-152-7565
wound:
b.
Obtain
a
one
watt
130
ohm
resister
with
extender
lead
and
multimeter.
5.7
SERVICE
LIFE
TEST.
The
AN/PRC-90
series
Radio
uses
a
Lithium
Manganese
Dioxide
battery
as
its
power
source.
Do
not
short
circuit,
crush,
puncture,
mutilate,
or
disassemble
batteries.
The
BA-5368/U
battery
contains
Lithium
Manganese
dioxide
mixture.
Under
conditions
of

abuse,
misuse,
partial
discharge,
or
depletion,
will
produce
gases,
fire
and
explosions.
Do
not
heat,
short
circuit
crush,
puncture,
mutilate,
or
dissemble.
5.7.1
Radio
Battery.
Remove
battery
from
radio
if
not
previously
removed.
Test
battery
in
accordance
with
procedures
listed
in
the
following
steps.
5-2
Change
4

NOTE

New
batteries
failing
to
meet
the
minimum
first
time
test
voltage
requirements
will
be
processed
under
product
quality
deficiency
report
(PQDR)
and
will
be
retained
until
receipt
of
disposition
instructions.
Lithium
batteries
shall
be
tested
only
after
allowing
to
stand
at
ambient
(shop)
temperature
for
4
hours
after
removal
from
radio.
New
batteries
shall

not
be
tested
if
they
are
known
to
have
not
been
stored
at
ambient
(shop)
temperature
for
at
least
4
hours.
Voltage
checks
shall
not
exceed
one
10
second
test
check
per
1
hour
time
period.
If
retest
is
necessary
to
obtain
the
voltage
reading,
a
minimum
of
1
hour
is
required
to
allow
voltage
return.
5.8
BATTERY
TEST

(BA-5368/U).
Battery
is
a
potential
explosive
hazard.
Wear
face
shield
or
goggles
when
handling
battery.
Wear
rubber
gloves
when
handling
the
battery
to
prevent
skin
contamination.
BA-5368/U
Battery
contains
lithium.
Contact
with
liquid
or
vapor
can
cause
skin
irritation,
headache,
and
fatigue.
If
liquid
contacts
skin
or
eyes,
wash
affected
area
with
water
and
get
immediate
medical
attention.
Resistor
can

become
hot
and
cause
burns
during
test.
a.
Only
one
test
procedure
is
authorized
for
use
in
voltage
test
for
BA-5368/U
and
BA-5123/U
battery(s).
Support
equipment
required
(See
Chapter
3)
Multimeter
and
130
Ohm
Resistor.
NOTE
Since
battery
performance
varies
with
temperature,
the
battery
test
should
be
performed
at
room
temperature
(25C,
77F).
If
the
test

is
performed
at
a
lower
temperature,
a
good
battery
may
not
pass
the
test.
b.
Using
Multimeter,
measure
resistance
of
130
Ohm
Resistor.
Resistance
must
be
between
127
and
133
Ohms.
c.
Connect
Resistor
across
Multimeter
test
leads.
d.
While
observing
battery
polarity,
connect
test
leads
to
battery
for
10
seconds.
(1)
(BA-1568/U)
Battery
voltage
should
not
drop

below
12.0
VDC.
If
voltage
drops
below
specified
value,
condemn
battery
per
local
procedures.
TO
31R2-2PR-101
(2)
(BA-5368/U)
Battery
voltage
should
not
drop
below
10
VDC.
If
voltage
drops
below
specified
value,
condemn
battery
per
local
procedures.
e.
Place
inspection
decal
on
Radio
Set
as
shown
in
Figure
5-1,
and
enter
date
of
test,
type
of
battery,
and

date
of
manufacture
on
decal.
5.9
BATTERY
TEST
(BA-5123/U).
If
one
battery
is
weak,
excessive
heating
may
result
and
the
weak
battery
may
explode.
Battery
is
a
potential
explosive
hazard.
Wear
face
shield
or
goggles
when
handling
battery.
Wear
rubber
gloves
when
handling
the
battery
to
prevent
skin
contamination.
BA-5123/U
Battery
contains
lithium.
If
liquid
contacts
skin
or
eyes,
wash

affected
area
with
water
and
get
immediate
medical
attention.
5.9.1
When
using
accessory
battery
adapter
and
four
BA-5123/U
(commercial
type
CR
-123)
batteries
instead
of
the
BA-5368/U
battery,
all
four
batteries
must
be
tested
and
check
good.
Resistor
can
become
hot
and
cause
burns
during
test.
Support
Equipment
Required
(See
Chapter
2)
ZTS
Multi
battery
tester
or
a

Multimeter
and
10
Ohm
Resistor.
NOTE
Since
battery
performance
varies
with
temperature,
the
battery
test
should
be
performed
at
room
temperature
(25C,
77F).
If
the
test
is
performed
at
a
lower
temperature,
a
good
battery
may
not
pass
the
test.
a.
Using
Multimeter,
measure
resistance
of
10
Ohm
Resistor.
Resistance
must
be
between
9.8
and
10.2

Ohms.
b.
Connect
Resistor
across
Multimeter
test
leads.
c.
While
observing
battery
polarity,
connect
test
leads
to
battery
for
10
seconds.
Battery
voltage
should
not
drop
below
2.95
VDC.
If
voltage
drops
below
specified
value,
condemn
battery
per
local
procedures.
d.
Place
inspection
decal
on
Radio
Set
as
shown
in
Figure
5-1
and
enter
date
of
test
and
type
of

battery
on
decal.
NOTE
After
maintenance,
batteries
will
not
be
installed
in
radios
unless
the
radio
is
required
to
fill
an
immediate
operational
requirement.
Repaired
radios
leaving
the
depot
will
not
be
shipped
with
a
battery
installed
in
the
radio
or
placed
in
the
shipping
container.

TO
31R2-2PR-101

Figure
5-1.
Radio
and
Battery
Inspection
Label
NOTE
Batteries
shall
be
inspected
at
intervals
that
coincide
with
that
of
the
next
higher
assembly.
(i.e.....survival
kit
container
ACES
II
Ejection
Seat,
back
style
parachutes,
etc).
But
not
to
exceed
360
10
days
for
the
BA-5368/U
battery.
5.10
INSPECTION
RECORD.

A
small
inspection
label,
will
be
used
to
indicate
replacement
date,
last
inspection
date,
and
battery
type.
Decal
can
be
locally
reproduce
on
scotch
cal
type
pressure
sensitive
material.
The
measurements
of
this
Label
are:
1
inchHX1
1/2
inches
L.
See
Figure
5-1.
5.11
INSPECTION
RECORD.
A
small
inspection
label
will
be
used
to
indicate
battery

mandatory
replacement
date
as
stamped
on
battery
and
the
date
of
each
radio
inspection.
Obtain
local
fabrication
using
Scotch
Cal
Material
or
suitable
substitute.

TO
31R2-2PR-101
CHAPTER
6
ORGANIZATIONAL
MAINTENANCE
6.1 GENERAL.
The
purpose
of
this
Chapter
is
to
inform
organizational
maintenance
personnel
how
to
perform
visual/mechanical
inspections
of
the
AN/PRC-90
and
to
test
the
operation
of
the
radio.
If
other
deficiencies
demanding
repair,
replacement,
or
disassembly
of
components
other
than
the
battery,
earphone,
or
antenna
are
discovered
as
a

result
of
this
inspection,
the
deficiencies
should
be
noted
as
found
and
the
radio
set
forwarded
to
field
maintenance
for
the
necessary
repairs.
6.2 PERIODIC INSPECTION.
A
periodic
inspection
shall
be
performed
at
the
organizational
and
field
maintenance
levels,
in
accordance
with
the
proce
dures
listed
in
Table
6-1.
Certain
tests,
as
indicated,
shall
be
performed
by
aircrewmen

as
a
preflight
checkout,
but
results
of
preflight
tests
shall
not
be
recorded.
Life
support
shops
which
have
a
TS-24B
test
set
will
test
survival
radios
for
serviceability
in
accordance
with
Paragraph
7.3.
When
a
questionable
radio
is
identified
by
this
testing,
suspected
radio
will
be
routed
to
the
avionics
shop
for
verification
and
maintenance
action
as
required.

Table
6-1.
Periodic
Inspection
and/or
Test
Inspection
or
Test
Preflight
Organizational
120
Days
Field
NOTE
External
scratches,
dents
or
slight
twisting
of
antenna
rubber
covering
not
affecting
the
operational
capability
of
the
radio
set
should
be
disregarded.
A
bend
in
the
antenna
of
up
to
20
is
acceptable
and
will
not
hamper
radio
transmission.
NOTE
Performed
by
aircrew

man
or
life
support
shop
prior
to
immediate
issue.
NOTE
Do
not
accomplish
concurrently
with
120
day
field
level
inspection.
NOTE
This
inspection
will
also
be
performed
at
the
organizational
level
when
the
TS-24B
test
set
bused.
1.
Inspect
the
exterior
of
the
radio
set
for
damage,
cleanliness,
and
proper
operation
of
all
controls.
Check
that
the
following
conditions
are

as
stated:
a.
VOL
control
knob
is
keyed
tightly
to
the
staff.
1.
--NOTE
Organizational
inspection
applies
only
to
radio
sets
installed
in
survival
vests.
1.
1a.
1.
1a.
Change
3
6-1

TO
31R2-2PR-101
Table
6-1.
Periodic
Inspection
and/or
Test
-Continued
Inspection
or
Test
Preflight
Organizational
120
Days
Field
2.
3.
4.
5.
6.
7.
8.
9.
b.
Function
switch
turns
with
proper
detent
action,
without
binding.
c.
Antenna
is
clean
and
may
be
extended
and
stowed-without
binding.
Rubber
cover
is
not
cracked
or
broken.
Antenna
tip

is
secure.
d.
Inspect
rubber
covers
on
PUSH
TO
TALK
and
MCW
buttons
for
cracks
and
breaks,
and
note
covers
are
firmly
attached
to
seal
the
buttons.
Depress
both
buttons;
buttons
must
move
freely
and
spring-return
to
original
positions.
e.
Inspect
wrist-strap
webbing
for
fraying
or
deterioration.
f.
Inspect
half-wave
antenna
retaining
band
for
cracks,
deterioration,
or
an
outstretched
condition.

Perform
Paragraph
5.4.
Remove
the
battery
wellcap
inspect
cap
for
sealing
washer
or
spring
damage.
Inspect
battery
well
for
signs
of
corrosion
and
cleanliness
of
surfaces
and
contacts.
Install
battery
and
reinstall
battery
well
cap.
Turn
radio
on
insure
audible
noise
can
be
heard
on
both
channels
from
the
listen
speaker.
Turn
radio
off,
check
inspection
decal
to
insure
date

is
current.
Perform
quick
operational
check
in
accordance
with
Paragraph
2.7.
May
be
accomplished
concurrently
with
step
6.
Perform
the
operational
check
in
accordance
with
Paragraph
6.3
through
Paragraph
6.13.
Perform
the
preliminary
operational
check
in
accordance
with
Paragraph
7.2
or
with
TS24B
radio
test
set
in
accordance
with
Paragraph
7.3.
Antenna
tip.
Perform
Paragraph
7.14
procedure.
Ensure
all
back

plate
screws
are
installed
and
tight.
Loose
screws
will
be
tightened
as
follows:
Rotate
with
screwdriver
until
screw
is
snug
against
back
plate
then
rotate
1/4
to
1/2
turn.
--1c.
-----3.
4.
------1b.
1c.
1d.
1e.
1f.
2.
---5.
6.
----1b.
1c.
1d.
1e.
1f.
2.
-----7.

8.
9.

NOTE
Radios
and
batteries
shall
be
inspected
at
intervals
that
coincide
with
that
of
the
next
higher
assembly
(Back
style
parachutes,
survival
kits
etc....).
Operational
Radio
Testing
interval
shall
not
exceed
365
10
days.
6.3
OPERATIONAL
CHECKS.
The
instructions
in
Paragraph
6.4
through
Paragraph
6.13
serve
as
a
guide
for
organizational
personnel
in
detecting
latent

or
impending
trouble
in
the
AN/PRC-90.
Perform
these
operational
checks
in
the
following
manner:
6.4
BATTERY
CHECK.
Test
battery
per
Paragraph
5.5.
6.5
TRANSMITTER
AND
RECEIVER
TEST
SET-UP.
The
following
tests
use
Radio
Test
Set
AN/PRM-32/TS-20/
PRM-32A
and
a
second
radio
set
AN/PRC-90
to
check
the
operational
status
of
radio
set
AN/PRC-90.
The
procedures
as
presented

assume
that
the
second
radio
set
is
known
to
be
operating
properly.
It
is
possible,
however,
to
checkout
both
radio
sets
simultaneously
using
these
procedures.
To
do
this,
first
perform
the
transmitter
checks
(Paragraph
6.4
through
Paragraph
6.10)
on
both
radio
sets.
The
receiver
and
earphone
checks
(Paragraph
6.11
through
Paragraph
6.13)
may
then
be
performed.
For
the

transmitter
tests,
connect
the
test
equipment
as
follows
(see
Figure
6-1).
When
using
TS-20/PRM-32A
turn
the
test
set
switch
to
243/
282.8
MHz.
a.
Verify
that
both
radio
sets
have
good
batteries
installed.
b.
Remove
antennas
from
both
radio
sets
using
antenna
wrench,
as
in
Paragraph
6.14.
See
Figure
6-1.
NOTE
Inspect
rubber
portion
of
sealing

washer
for
cuts
and
deterioration.
Replace
damaged
washer
accordingly.
Use
extreme
care
that
you
do
not
lose
sealing
washer
from
antenna.
c.
Connect
test
cables
of
test
set
to
radio
set
antenna
jacks,
test
point
1,
as
shown
in
Figure
6-1.
The
radio
set
under
test
is
connected
to
the
transmitter
cable.
Carefully
avoid
cross
threading
when
screwing

test-set
cable
connectors
to
radio
set
housing.
Seat
connectors
fingertight
only.
TO
31R2-2PR-101
6.6
GUARD
CHANNEL
BEACON
TRANSMITTER
CHECK.
Perform
the
following
steps
to
check
the
operation
of
the
guard
channel
beacon
transmitter
under
operating
load.
a.
Set
the
function
switch
of
radio
under
test
(transmitting)
to
BCN
243.0
and
observe
the
meter
of
the

test
set.
b.
Meter
needle
should
move
into
the
green
(Go)
area
to
indicate
that
beacon
power
output
is
satisfactory
and
battery
is
good;
proceed
to
Paragraph
6.7.
c.
If
meter
indicates
red
(No-Go)
the
radio
set
is
unsuitable
for
use.
Send
radio
to
field
maintenance
6.7
GUARD
CHANNEL
BEACON
SIDETONE
CHECK.
Perform
check
of
guard
channel
beacon
sidetone
as

follows:
a.
Set
transmitting
radio
VOL
control
to
MAX.
Beacon
swept
tone
should
be
clearly
audible
at
the
LISTEN
speaker.
If
not,
send
the
radio
set
under
test
to
field
maintenance.
6.8
GUARD
CHANNEL
MCW
TRANSMITTER
CHECK.
This
test
is
optional,
depending
upon
operation
requirements
of
the
radio
set.
Perform
check
of
guard
channel
MCW
transmitter
as
follows:

a.
Set
the
function
switch
of
radio
under
test
to
VOICE/
MCW
243.0.
Depress
and
hold
the
MCW
button
of
the
radio
set
and
observe
the
meter
of
the
test
set.
Release
the
MCW
button.
b.
If
meter
indicates
green
(Go),
MCW
power
output
is
satisfactory.
Proceed
to
Paragraph
6.9.
c.
If
meter
indicates
red
(No-Go),
send
radio

set
under
test
to
field
maintenance.
6.9
GUARD
CHANNEL
VOICE
TRANSMITTER
CHECK.
Perform
check
of
guard
voice
transmitter
as
follows:
a.
Depress
the
PUSH
TO
TALK
button.
Whistle
clearly
into
the
TALK
microphone
at
a
close
distance
(2
to
3
inches)
and
observe
the
meter
of
the
test
set.
Release
the
PUSH
TO
TALK
button.
b.
If
meter

indicates
green
(Go)
momentarily
during
whistle,
voice
power
output
is
satisfactory.
Proceed
to
Paragraph
6.10.

TO
31R2-2PR-101
NOTE
a.
Set
the
function
switch
of
radio
under
test
to
VOICE
282.8.
It
is
normal
for
the
meter
indication
to
fall
back
into
the
red
region
if
the
microphone
is
not
held
close
for
full
sound
volume.
NOTE
c.
If
meter
indicates
red
(No-Go)
voice
power
output
is
not
Radio
under
test
must
pass

guard
channel
beacon
satisfactory.
Send
radio
set
to
field
maintenance.
and
transmitter
check,
Paragraph
6.6,
before
proceeding.
6.10
ALTERNATE
CHANNEL
VOICE
TRANSMITTER
CHECK.
b.
Depress
the
PUSH
TO
TALK
button.
Whistle
steadily
and
clearly
into
the
TALK
microphone
and
observe
the
Perform
the
following
steps
to
check
the
282.8
MHz
alternate
channel
voice
transmitter.
meter
of
the
test
set.
Release

the
PUSH
TO
TALK
button.

TO
31R2-2PR-101

Figure
6-1.
Test
Set-Up

TO
31R2-2PR-101

Figure
6-2.
Antenna
Removal

TO
31R2-2PR-101
c.
If
meter
reading
indicates
green
(Go)
or
moves
no
more
than
quarter-way
into
the
red
(No-Go)
area
momentarily
during
whistle,
voice
power
is
satisfactory.
NOTE
On
282.8
MHz
voice
transmission
the
radiated
power
is
slightly
less
than
at
243.0
MHz,
and
since
the
test
set
is
calibrated
at
the
minimum
beacon
signal,

readings
up
to
quarter-way
into
the
red
(No-Go)
area
are
allowable.
d.
If
meter
indicates
in
the
lower
3/4
of
the
red
(No-Go)
area,
voice
power
is
not
satisfactory.
Send
radio
set
to
field
maintenance.
e.
If
the
battery
and
transmitter
checks
have
thus
far
indicated
wholly
normal
conditions,
the
transmitter
radio
is
qualified
to
provide
proper
test

signals
to
the
test
set
for
receiver
checking.
6.11
GUARD
CHANNEL
RECEIVER
CHECK.
Perform
the
following
steps
to
check
the
243.0
MHz
guard
channel
receiver:
a.
Connect
the
radio
under
test
to
the
test
set
receiver
cable
and
an
AN/PRC-90
with
good
transmission
to
the
transmitter
cable.
b.
Set
the
function
switch
of
the
radio
under
test
(receiving)

to
VOICE/MCW
243.0
and
VOL
control
to
MAX.
Set
the
function
switch
of
the
transmitting
radio
to
BCN
243.0.
c.
If
the
set
under
test
receives
a
beacon
signal
(swept-tone
audible
in
the
LISTEN
speaker),
guard
channel
receiver
is
good.
d.
Absence
of
beacon
signal
from
the
speaker
of
receiving
radio
set
indicates
inoperative
condition.
Send
radio
to

field
maintenance.
NOTE
The
presence
of
an
audible
interfering
signal
from
a
nearby
243.0
MHz
transmitter
is
generally
an
acceptable
condition,
unless
the
interfering
transmitter
is
of
unusually
high
power
or
its
antenna
is
located
within
100
feet,
creating
excessive
disturbance.
6.12
ALTERNATE
CHANNEL
RECEIVER
CHECK.
Perform
the
following
steps
to
check
the
282.8
MHz
alternate

channel
receiver:
a.
Set
the
function
switch
of
both
radio
sets
to
VOICE
282.8.
NOTE
To
rotate
the
function
switch
knob
into
this
position,
the
round
button
with
an
arrow
in
the
center
of
the
function
switch
knob
must
be
depressed
while
the
knob
is
turned
in
a
counterclockwise
direction.
b.
Set

the
VOL
control
of
transmitting
radio
set
to
minimum
and
of
receiving
radio
set
to
a
level
that
does
not
cause
feedback.
Depress
the
PUSH
TO
TALK
button
on
transmitting
radio.
c.
Any
reduction
in
noise
level
from
the
LISTEN
speaker
of
receiving
radio
set
indicates
a
satisfactory
282.8
MHz
receiver.
d.
Complete
lack
of
noise
or
no
change
in

noise
level
indicates
an
inoperative
condition.
Send
radio
set
to
field
maintenance.
NOTE
The
presence
of
an
audible
interfering
signal
from
a
nearby
282.8
MHz
transmitter
is
generally
an
acceptable
condition,
unless
the
interfering
transmitter
is
of
unusually
high
power
or
its
antenna
is
located
within
100
feet,
creating
excessive
disturbance.
6.13
EARPHONE
CHECK.
To
check

the
operation
of
a
radio
set
accessory
earphone,
perform
the
steps
as
follows:
a.
Plug
the
earphone
connector
into
EARPHONE
JACK
of
receiving
radio
set.
The
speaker
should
be
silent,
and
the
receiver
noise
should
be
clearly
audible
in
the
earphone.
If
satisfactory,
set
function
switch
to
OFF,
disconnect
radios
from
test
set,
and
replace
antennas.
If
earphone

is
silent,
perform
steps
b
through
d.
b.
Remove
and
check
earphone
connections
for
clean
contacts.
c.
Reconnect
earphone
to
EARPHONE
JACK.

TO
31R2-2PR-101

Figure
6-3.
AN/PRC-90/90-2
Antenna
Weight
d.
Repeat
step
a.
If
no
sound
is
heard,
try
another
earphone.
If
substitute
earphone
is
still
inoperative,
send
radio
set
to
field
maintenance.
e.
To
prevent
loss
of
earpiece,
unsnap
earpiece
from
earphone
and
place
a
small
amount
of
Superglue
(NSN
8040-00-142-9193)
on
earphone
and
reattach

earpiece
to
earphone.
6.14
REMOVAL
AND
REPLACEMENT.
Removal
and
replacement,
organizational
maintenance
level
is
limited
to
the
battery,
earphone,
and
antenna
assembly.
6.14.1
Battery
Removal
and
Replacement.
To
replace
the
battery,
proceed
in
the
following
manner:
a.
Unscrew
the
battery
cap.
b.
Lift
or
slide
the
battery
out
of
the
battery
well.
c.
Slide
the
new
battery
into

the
battery
well,
positive
side
first.
(It
only
fits
one
way.)
d.
Screw
on
the
battery
cap,
finger-tight.
6.14.2
Earphone
Removal
and
Replacement.
The
earphone
is
replaced
merely
by
inserting
the
new
one
in
the
earphone
storage
case.
6.14.3
Antenna
Removal
and
Replacement.
To
replace
the
antenna,
proceed
as
follows
(see
Figure
6-2):

TO
31R2-2PR-101
NOTE
Spanner
wrench
provided
with
AN/PRM-32
test
set
or
a
suitable
substitute
is
required
for
removal
of
quarter-wave
antenna.

Do
not
attempt
to
loosen
antenna
by
twisting
antenna
mast;
damaged
antenna
may
result.
a.
To
remove
a
quarter-wave
antenna,
engage
spanner
wrench
lugs
in
two
opposing
slots
in

the
antenna
base
and
unscrew
with
wrench
until
loose
enough
to
turn
by
hand.
b.
To
remove
a
half-wave
antenna,
grasp
the
thick
rigid
base
of
the
antenna
by
hand
and
unscrew.
c.
Unscrew
and
remove
antenna
and
sealing
washer
by
hand.
d.
Inspect
rubber
portion
of
sealing
washer
for
cuts
and
deterioration.
Replace
damaged
washer
accordingly.
Use
extreme
care

that
you
do
not
lose
sealing
washer
from
antenna.
NOTE

A
weight
check
on
the
antenna
ball
is
rerequired
any
time
a
new
ball
is
installed
or
when
an
UNSERVICEABLE
antenna
is
replaced
with
a
new
or
serviceable
like
item.
A
bracket
and
strap
assembly
may
be
locally
manufactured
to
aid
in
the
antenna
ball

weight
check
requirement.
e.
To
install
antenna,
slip
sealing
washer
over
threads
on
antenna
base.
f.
Screw
antenna
into
antenna
jack
by
hand.
g.
When
installing
a
quarter-wave
antenna
tighten
with
spanner
wrench
just
enough
to
slightly
compress
sealing
washer.
h.
When
installing
a
half-wave
antenna,
grasp
the
antenna
by
its
thick
rigid
base
and
hand-tighten
firmly.

TO
31R2-2PR-101

Figure
6-4.
Electronics
and
Switch
Assembly
Hold-down
Screws
and
Test
Points

TO
31R2-2PR-101
CHAPTER
7
FIELD
MAINTENANCE
7.1
GENERAL.
NOTE
AN/PRC-90T
trainer
radios
do
not
require
120
The
purpose
of
this
Chapter
is
to
provide
instructions
day
inspection
and
will
be
returned
to
depot
if
enabling
field
maintenance
personnel
to
test,
troubleshoot,
defective.
and
repair
the
radio

set
and
thereby
ensure
its
serviceability.
Except
for
certain
accessible
and
necessarily
replaceable
components
such
as
straps,
some
switches,
volume
control,
housing,
and
covers
which
are
field-replaceable,
the
majority
of
internal
electrical
repair
is
performed
by
depot.
No
alignment
is
required
for
the
AN/PRC-90.

Figure
7-1.
Load
Carriage
Assembly

TO
31R2-2PR-101

Figure
7-2.
RF
Power
Output
vs
DC
Voltage
Reading
at
RF
Power
T.P.
7.2
PRELIMINARY
CHECKOUT.
7.3
INITIAL
TEST
SETUP
FOR
USE
EXTERNAL
DC
VOLTAGE
INPUT.
To
insure
proper
operation
of
the
AN/PRC90-2
radio
the
following
equipment
and
peace
parts
are
required
and
can
be
The
Test
Set
shall
be
grounded
to

earth
ground
by
purchased
from
commercial
sources
or
locally
manufactured.
means
of
braided
ground
strap
or
shielded
ground
Parts
required
0-30VDC
Variable
Power
Supply
see
Table
3-1
cable,
will
further
attenuate
radiation
below
the
for
test
equipment
and
Power
Leads
to
connect
Power
supply
35dB
minimum
attenuation
specified
for
the
un-to
TS-24B.
grounded
Test
Set.

Test
chamber
shall
be
grounded
to
earth
ground
by
means
of
a
breaded
ground
strap
or
shielded
cable.
This
step
will
further
attenuate
radiation
below
the
35
dB
minimum.
Do
not
use
the
BA-5368/U
batteries
to
power
test
set.
Lithium
batteries
will
cause
failures
and
erroneous
indications,
which
could
cause
an
otherwise
serviceable
radio
to
be
rejected.

Only
external
power
shall
be
used
for
all
radio
tests.
NOTE
A
test
plug
double
banana
(same
as
used
to
connect
the
acoustical
coupler
to
the
test
set)
is
required
on
the
end
of
the
lead
wires
supplying
power
to
the
RF
module
TS-24B
when
using
the
regulated
power
supply.
TO
31R2-2PR-101
7.3.1
Initial

Test
Set
Up.
The
following
test
procedures
requires
the
use
of
an
external
13.5
VDC
regulated
power
supply
and
connecting
lead
wires.
See
Chapter
2
for
applicable
parts
requirements
to
comply
with
following
test.
a.
Connect
power
lead
with
the
duel
test
plug,
double
banana
to
power
supply
then
attach
the
remaining
ends
to
RF
module
Ext.
Pwr
(Red
+,

Black
-)
jacks
on
the
TS-24B
Test
Set.
(See
Figure
7-3).
b.
Connect
the
second
set
of
power
leads
having
the
15
ohm
1%
1
watt
resister
inline
on
positive
lead
to
the
DC
Pwr
module
PRC-90/106
jacks,
TS-24B
test
set.
Connect
power
supply
to
available
120
VAC
outlet.
(See
Figure
7-4).
Figure
7-3.
RF
Module
External
DC
Power
Terminal

Locations

Figure
7-4.
External
DC
Power
and
Test
Point
Terminal
Locations
c.
With
the
multi-meter
function
selector
set
to
MA,
black
d.
Connect
test
probes
to
the
current
test
points
on
the
DC
lead
to
Com,
the
red
lead
to
Amp
positions
on
multi-module.
Red
+
to
upper
jack.
Black
to
outside
edge
turn
meter

front
face.
meter
on
if
required.

TO
31R2-2PR-101
e.
Set
RF
module
radio
select
switch
to
AN/PRC-90
position
and
frequency
to
be
tested.
Unlatch
and
open
test
chamber
cover.
h.
Remove
battery
from
radio
if
not
previously
complied
with.
Install
Battery
adapter
24-BAM/PRC-90
in
the
radio
in
place
of
the
battery.
f.
g.
Refer
to
Table
1-1
on
inside
test
chamber
cover.
Loosen

load
carriage
to
set
pointer
to
AN/PRC-90
Radio
setting.
Retighten
Load
carriage
knob.
Attach
radio
cradle
24RC/PRC-90
to
the
end
of
test
chamber
by
placing
the
radio
cradle
key
slots
over
buttons
on
end
of
test
chamber.
NOTE
Failure
to
fully
extend
the
antenna
and
place
between
the
carriage
contacts
may
result
in
erroneous
parameter
measurements.
NOTE
Always
remove
batteries

from
radios
to
be
tested.
The
test
set
interlock
that
prevents
unwanted
radiation
is
active
only
when
DC
current
is
present
at
the
test
points
on
DC
Module
and
test
chamber
cover
is
closed
and
latched.

Figure
7-5.
RF
Power
Output
vs.
DC
Voltage
Reading
at
RF
Power
Test
Point
7.3.2
OPERATION
INSTRUCTIONS.
Operation
in-Test

Chamber
of
the
set
(i.e.,
all
transmitter
and
receiver
tests
structions
are
organized
so
that
complete
testing
of
one
are
completed
on
one
channel
before
undertaking
transmitter
channel
of
a
two-channel
survival
radio
may
be
accomplished
and
receiver
tests
of
the
second
channel).
Figure
7-1
shows
without
requiring
resetting
of
the
Load
Carriage
inside
the
the
Load
Carriage
Assembly.

TO
31R2-2PR-101
a.
The
graph
in
Figure
7-2
provides
a
means
of
determining
approximate
RF
power
output
if
more
than
an
RF
POWER
pass/fail
indication
is
desired.
Each
of
the
following
test
procedures
note
when
to
use
the
graph.
Always
remove
batteries
from
radios
to
be
tested.
The
Test
Set
interlock,
that
prevents
unwanted
radiation,
is
active

if
12
VDC
is
turned
on
an
applied
to
the
DC
Test
Module
and
the
Test
Chamber
cover
is
closed.
b.
Connect
battery
adapter
24-BAM/PRC-90
to
connector
2J1.
Assure
test
chamber
cover
is
closed
and
locked.
Check.
7.3.2.1
Initial
Test
Setup.
The
initial
test
setup
is
the
same
for
all
PRC-90
transceivers.
Refer
to
Figure
7-1
and
perform

initial
setup
procedures
below.
NOTE
If
more
than
one
frequency
is
applicable,
begin
with
lowest
frequency.
a.
Set
RF
Analysis
Module
RADIO
SELECT
switch
to
the
position
for
unit
and
frequency
to
be
tested.
b.
Unlatch
and
open
Test
Chamber
cover.
NOTE
The
table
referenced
in
the
following
step
is
for
specific
values
and

not
a
variable.
These
values
are
based
on
known
electrical/physical
antenna
characteristics
and
are
not
subject
to
change
for
the
specified
antennas.
c.
Refer
to
Table
1-1,
located
on
the
inside
of
the
Test
Chamber
cover,
for
load
scale
setting
information
on
the
unit
under
test.
d.
Loosen
load
carriage
position
securing
knob.
Slide
load
carriage
to
set

pointer
at
the
guide
scale
setting
obtained
in
step
c.
e.
Lightly
tighten
position
securing
knob
to
secure
load
carriage
at
this
setting.
f.
Select
the
correct
radio
cradle
and
battery
adapter
for
the
unit
to
be
tested.
g.
Attach
radio
cradle
to
the
end
of
the
Test
Chamber
by
placing
radio
cradle
key
slots
over
buttons
on
the
end

of
the
Test
Chamber.
h.
Remove
battery
from
unit
to
be
tested.
Install
battery
adapter
in
the
unit
in
place
of
battery.
i.
Close
and
latch
Test
Chamber
cover.
j.
Connect
remaining
battery
adapter
plug
P1
to
DC
TEST
MODULE
at
2J1.
Apply
External
DC
to
DC
TEST
MODULE.
k.
Initial
setup
test
complete.
7.3.2.2
AN/PRC-90
Transceiver
Test.
NOTE

Refer
to
Figure
6-4
for
Test
Set
switch,
indicator,
and
test
point
locations.
a.
Perform
Initial
Test
Setup
Paragraph
7.3.
b.
Set
transceiver
to
VOICE/MCW
243.0
mode.
Be
sure
RADIO
SELECT
switch
is
set
for
PRC-90
(243.0).
c.
Set
XMIT
TEST
REC
TEST
switch
to
XMIT
TEST.
d.
Plug
mounting
cradle
Audio
Coupler
Unit
into
Test
Set

AUDIO
OUTPUT.
Remove
Audio
Coupler
Unit
from
holding
clip
and
place
open
end
squarely
over
transceiver
TALK
microphone.
e.
Actuate
transceiver
PUSH
TO
TALK
button
by
rotating
cam
lever
on
mounting
cradle.
f.
Observe
all
DC
Test
Module
LED
indicators.
(1)
If
the
BATTERY
VOLTAGE
green
PASS
indicator
is
lit,
the
BATTERY
CURRENT
green
PASS
indicator
is
lit
or
both

the
BATTERY
CURRENT
green
PASS
and
red
FAIL
indicators
simultaneously
flicker,
and
the
SHORT
CIRCUIT
indicator
is
not
lit,
proceed
to
step
(g).
(2)
If
red
SHORT
CIRCUIT
indicator
is
lit,
reject
transceiver
for
short/over
current.
If
red
FAIL
indicator
for
either
BATTERY
VOLTAGE
or
BATTERY
CURRENT
is
lit,
reject
radio
for
indicated
malfunction.
NOTE
A
fail
condition

during
RF
testing
may
be
caused
by
a
marginal
battery
that
passes
the
DC
voltage
and
current
tests.
If
an
RF
test
failure
is
noted,
first
replace
the
battery
with
a
known
good
battery
and
repeat
the
test.
A
failed
condition
during
RF
or
%
of
modulation
testing
may
be
caused
by
a
defective
antenna.
If
this
condition
occurs,
replace

antenna
and
repeat
the
test.

TO
31R2-2PR-101
g.
Momentarily
depress
RF
POWER
PRESS
pushbutton.
Observe
RF
POWER
indicators.
If
green
PASS
indicator
is
illuminated,
proceed
to
step
(h).
Reject
transceiver
if
RF
POWER
red
FAIL
indicator
is
illuminated.
NOTE
Although
a
BATTERY
CURRENT
red
FAIL
indication
may
occur
in
the
following
step,
it
does
not
indicate
a
current
failure
nor

any
other
type
of
failure.
h.
Depress
and
hold
%
MODULATION
PRESS
pushbutton
for
three
seconds.
If
after
three
seconds
the
%
MODULATION
green
PASS
indicator
is
lit,
proceed
to
step
(i).
Reject
transceiver
if
after
the
three
seconds,
the
%
MODULATION
red
FAIL
indicator
is
lit.
i.
Rotate
mounting
cradle
cam
lever
to
release
transceiver
PUSH
TO

TALK
button.
j.
Disconnect
plug
and
remove
audio
coupler
unit
from
test
set.
k.
Momentarily
actuate
transceiver
MCW
button
by
depressing
MCW
lever
on
radio
cradle.
At
the
same
time,
momentarily
depress
RF
Analysis
Module
AUDIO
PRESS
pushbutton.
If
steady
tone
is
heard,
proceed
to
step
(l).
Reject
transceiver
if
no
tone
is
heard.
l.
Set
transceiver
to
BCN
243

MHz
mode.
m.
Momentarily
depress
AUDIO
PRESS
pushbutton.
If
characteristic
radio
beacon
sweep
tone
is
heard,
proceed
to
step
(h).
Reject
transceiver
if
no
tone
or
a
steady
tone
is
heard.
n.
Set
transceiver
to
VOICE/MCW
243.0.
o.
Set
XMIT
TEST
REC
TEST
switch
to
REC
TEST.
p.
Momentarily
depress
REC
TEST
PRESS
pushbutton.
If
steady
tone
is
heard
from

transceiver,
proceed
to
step
(q).
Reject
transceiver
if
no
tone
is
heard.
q.
Set
transceiver
to
VOICE
282.8
MHz.
r.
Set
RADIO
SELECT
switch
to
PRC-90
(282.8).
s.
Set
XMIT
TEST
REC
TEST
switch
to
XMIT
TEST.
t.
Actuate
transceiver
PUSH
TO
TALK
button
by
rotating
cam
lever
on
mounting
cradle.
u.
Observe
all
DC
Test
Module
indicators.
If
no

red
indicators
are
lit,
proceed
to
step
(v).
Reject
transceiver
if
any
DC
Test
Module
red
indicator
is
lit.
v.
Plug
mounting
cradle
Audio
Coupler
Unit
into
Test
Set
AUDIO
OUTPUT
and
place
open
end
squarely
over
transceiver
TALK
microphone.
w.
Depress
and
hold
%
MODULATION
PRESS
pushbutton
for
three
seconds.
If
after
three
seconds
the
%
MODULATION
green
PASS

indicator
is
lit,
proceed
to
step
(x).
Reject
transceiver
if
after
the
three
seconds,
the
%
MODULATION
red
FAIL
indicator
is
lit.
x.
Momentarily
depress
RF
POWER
PRESS
pushbutton.
Observe
RF
POWER
indicators.
If
green
PASS
indicator
is
lit,
proceed
to
step
(y).
y.
Reject
transceiver
if
RF
POWER
red
FAIL
indicator
is
lit.
z.
Return
Audio
Coupler

Unit
to
holding
clip.
Disconnect
plug
from
AUDIO
OUTPUT.
aa.
Rotate
mounting
cradle
cam
lever
to
release
transceiver
PUSH
TO
TALK
button.
ab.
Set
XMIT
TEST
REC
TEST
switch
to
REC
TEST.
ac.
Momentarily
depress
REC
TEST
PRESS
pushbutton.
If
steady
tone
is
heard
from
transceiver
LISTEN
speaker,
proceed
to
step
(ad).
Reject
transceiver
if
no

tone
is
heard.
ad.
Remove
battery
from
DC
Test
Module.
Unlatch
and
open
Test
Chamber
cover.
ae.
Remove
transceiver
from
Test
Chamber.
Set
transceiver
to
OFF.
Collapse
antenna.
Reinstall
battery
in
transceiver.
NOTE
If
desired,
a
frequency
check
for
this
transceiver
may
be
performed
as
outlined
in
Paragraph
7.3d.
PRC-90
Transceiver
Test

complete.
af.
Reinstall
battery
in
radio.
ag.
Check
Earphone
by
snapping
it
in
place
over
earphone
contacts.
Turn
radio
on
by
rotating
function
switch
to
either
voice
position.
Listen
for
tone
being
emitted
from
speaker.
If
tone
is
being
emitted
at
speaker,
reject
radio.
ah.
Turn
OFF
and
remove
external
12
VDC
Power
if

frequency
check
is
not
required.
7.3.2.3
Optional
Frequency
Check
for
the
AN/
PRC-90
Transceiver.
NOTE
In
the
following
frequency
check,
the
frequency
for
the
radio
should
be
tested
in
the
voice
mode,
without
modulation.
a.
Disconnect
the
RF
coaxial
cable
BNC
connector
at
the
Test
Chamber
RF
port.
Connect
frequency
counter
to
the
Test

Chamber
RF
port.
b.
Transceiver
frequencies
should
correspond
with
the
chart
below
243.0
MHz
+
12.1
kHz
282.8
MHz
14.1
kHz.

TO
31R2-2PR-101
7.4
TROUBLESHOOTING.
NOTE
NO
field
level
replacement
of
Radio
components
other
than
antenna,
battery,
or
the
wrist
strap
is
authorized
by
USAF
personnel.
Radios
failing
to
pass
the
test
requirement
in
this
manual
shall
be
condemned
per
local
directives.
The
following
troubleshooting
data
relates
defect
symptoms
encountered
during
operational
checks
to

field-replaceable
components
which
may
be
at
fault.
In
most
cases,
further
tests
are
provided
to
verify
the
fault
isolation.
If
the
source
of
a
fault
is
not
traceable
to
a
field-replaceable
part,
send
the
radio
set
to
depot
for
repair.
Unless
otherwise
indicated,
the
TS-24B
will
be
used
for
the
checkout
steps.
After
a
field
level
repair
is
made,
repeat

the
checkout
procedures.
7.5
ACCESS
TO
TEST
POINTS.
Access
to
the
secondary
test
points
shown
in
Figure
6-4
is
required
for
trouble
shooting
at
field-level
maintenance.
These
test
points
may
be
reached
by
removing
the
rear
cover
(Figure
2-1,
15)
as
described
in
Paragraph
7.18a.
The
colors
associated
with
the
test
points
will
not
hold
true
for
radios

manufactured
by
Florida
Communication
and
Electronics
Inc.
7.6
GUARD
CHANNEL
BEACON
TRANSMITTER.
Perform
the
following
steps
if
the
radio
set
failed
the
checkout
procedures
in
Paragraph
7.3e
(6).
a.
Set
radio s
function
switch
to
BCN
243.0.
b.
Measure
DC
voltage
at
test
point
A,
using
the
radio
set
housing
as
ground.
This
voltage
shall
be
+10

.5
volts.
c.
If
test
point
A
voltage
is
not
present,
the
function
switch
magnet
may
be
faulty.
Replace
the
function
switch
knob
assembly
as
in
Paragraph
7.25
and
repeat
test.
If
radio
set
still
fails
test,
send
it
to
depot.
d.
If
the
test
point
A
voltage
is
present
and
radio
set
is
inoperative,
send
the
radio
set
to

depot.
7.7
GUARD
CHANNEL
BEACON
SIDETONE.
If
the
radio
set
fails
to
provide
an
audible
swept-tone
at
the
test
set
speaker
(Paragraph
7.3
e
(6))
send
it
to
depot.
7.8
GUARD
CHANNEL
MCW
TRANSMITTER.
a.
Set
the
radio
function
switch
to
VOICE
MCW
243.0.
Measure
the
DC
voltage
at
test
point
B
while
depressing
the
MCW
button.
The

test
point
B
voltage
shall
be
+10
.5
volts.
b.
If
the
signal
at
test
point
B
is
normal
and
radio
set
is
inoperative,
send
the
radio
set
to
depot.
c.
If
the
normal
DC
voltage
is
not
present
at
test
point
B,
measure
the
DC
voltage
at
test
point
C.
The
MCW
button
need
not
be
depressed
for
this

test.
The
test
point
C
voltage
shall
be
+10
.5
volts.
d.
If
the
DC
voltage
is
present
at
test
point
C
and
radio
set
is
inoperative,
replace
MCW
switch
S4
as
in
Paragraph
7.20.
e.
If
the
DC
voltage
is
not
present
at
test
point
C,
the
function
switch
magnet
may
be
faulty.
Replace
the
function
switch

knob
assembly
as
in
Paragraph
7.25
and
repeat
test.
If
radio
set
still
fails
test,
send
to
depot.
7.9
GUARD
CHANNEL
VOICE
TRANSMITTER.
Perform
the
following
steps,
if
the
radio
set
fails
the
checkout
procedures
in
Paragraph
7.3e
(3).
a.
Set
the
radio s
function
switch
to
VOICE/MCW
243.0.
Measure
the
DC
voltage
at
test
point
D
while
depressing

PUSH
TO
TALK
button.
The
DC
voltage
at
test
point
D
shall
be
+10
.5
volts.
b.
If
DC
voltage
is
present
at
test
point
D
and
radio
set
is
inoperative,
send
radio
set
to
depot.
c.
If
DC
voltage
is
not
present
at
test
point
D,
measure
DC
voltage
at
test
point
E.
The
PUSH
TO
TALK
button
need

not
be
depressed
during
this
test.
The
DC
voltage
at
test
point
E
shall
be
+10
.5
volts.
d.
If
DC
voltage
is
present
at
test
point
E
and
radio
set
is
inoperative,
replace
PUSH
TO
TALK
switch
S5
as
in
Paragraph
7.20.
e.
If
DC
voltage
is
not
present
at
test
point
E,
measure
DC
voltage
at
test
point

C.
The
DC
voltage
at
test
point
C
shall
be
+10
.5
volts.
f.
If
DC
voltage
is
present
at
test
point
C
and
radio
set
is
inoperative,
replace
MCW
switch
S4
as
in
Paragraph
7.20.
g.
If
DC
voltage
is
not
present
at
test
point
C,
send
radio
set
to
depot.
7.10
ALTERNATE
CHANNEL
VOICE
TRANSMITTER.
Perform

these
steps
if
radio
set
fails
checkout
procedures
in
Perform
the
following
steps
if
the
radio
set
fails
the
checkout.
Paragraph
7.3e
(2).

TO
31R2-2PR-101
a.
Set
function
switch
to
VOICE
282.8.
Measure
DC
voltage
at
test
point
F
while
depressing
PUSH
TO
TALK
button.
The
DC
voltage
at
test
point
F
shall
be
+10
.5
volts.
b.
If
DC
voltage
is
present
at
test
point
F
and
radio
set
is
inoperative,
send
radio
set
to
depot.
c.
If
DC

voltage
is
not
present
at
test
point
F,
measure
DC
voltage
at
test
point
G.
The
PUSH
TO
TALK
button
need
not
be
depressed
while
measuring
test
point
G.
The
DC
voltage
at
test
point
shall
be
+10
.5
volts.
d.
If
DC
voltage
is
present
at
test
point
G
and
radio
set
is
inoperative,
replace
PUSH
TO
TALK
switch

S5
as
in
Paragraph
7.20.
e.
If
DC
voltage
is
not
present
at
test
point
G,
the
magnet
in
the
function
switch
may
be
faulty.
Replace
function
switch
knob
assembly
as
in
Paragraph
7.25
and
repeat
test.
If
radio
set
still
fails
test,
send
to
depot.
7.11
GUARD
CHANNEL
RECEIVER.
Perform
the
following
steps
if
radio
set
fails
the
checkout

procedures
in
Paragraph
7.3d
(10).
a.
Set
function
switch
to
VOICE/MCW
243.0.
Measure
the
DC
voltage
at
test
point
H.
This
voltage
shall
be
+10
.5
volts.
b.
If
the
DC
voltage
is
not
present
at
test
point
H,
replace
PUSH
TO
TALK
switch
S5
as
in
Paragraph
7.20.
c.
If
the
DC
voltage
is
present
at
test

point
H
and
radio
set
is
inoperative,
check
VOL
control
R1
as
follows:
(1)
Observe
the
Audio
Signal
(AC)
peak-to-peak
voltage
at
test
point
J
with
the
oscilloscope.
(2)
If
the
audio
signal
is
not
present
at
test
point
J,
send
radio
set
to
depot.
(3)
If
the
audio
signal
is
present
at
test
point
J,
observe
the
peak-to-peak
voltage

at
test
point
K
with
the
oscilloscope.
Start
with
the
VOL
control
adjusted
to
maximum
and
slowly
adjust
the
control
to
minimum.
The
amplitude
of
test
point
K
shall
smoothly
decrease
to
zero
(less
than
0.01
volts
pp)
as
the
control
is
adjusted
to
minimum.
(4)
If
the
audio
signals
at
test
point
K
are
not
normal,
replace
the
VOL

control
as
in
Paragraph
7.21.
(5)
If
the
audio
signals
at
test
point
K
are
normal
and
radio
set
is
inoperative,
send
the
radio
set
to
depot.
7.12
ALTERNATE
CHANNEL
RECEIVER.
Perform
the
following
steps
if
the
radio
set
fails
the
checkout
procedures
in
Paragraph
7.3d
(11).
a.
Set
the
radio s
function
switch
to
VOICE
282.8.
Measure
the

DC
voltage
at
test
point
L.
This
voltage
shall
be
+10
.5
volts.
b.
If
the
DC
voltage
is
present
at
test
point
L
and
radio
set
is
inoperative,
send
radio
set
to
depot.
c.
If
DC
voltage
is
not
present
at
test
point
L,
replace
PUSH
TO
TALK
switch
as
in
Paragraph
7.20.
7.13
EARPHONE
CIRCUIT.
If
checkout
procedure

in
Paragraph
7.3d
(6)
fails
to
cut
off
the
LISTEN
speaker
on
radio
set,
use
the
accessory
earphone.
If
accessory
earphone
fails
to
cut
off
the
LISTEN
speaker,
send
the
radio
set
to
depot.
7.14
ANTENNA
TIP
INSPECTION.
To
test
and
replace
(if
needed)
the
antenna
tip,
follow
these
steps:

Antenna
tip
may
become
detached.

Eye
protection
must
be
observed.
Keep
feet
from
under
test
area.
Goggles
must
be
worn
when
removing
or
replacing
the
antenna
ball
tip.
NOTE

Any
10
lb.
weight
can
be
used,
with
antenna
hung
vertically.
This
is
a
one
time
inspection
or
when
the
tip
requires
replacement.
Record
inspection
on
the
applicable
inspection
card.

a.
Extend
antenna
assembly.
b.
Attach
any
ten
(10)
pound
weight
to
the
antenna
tip
then
suspend
weight
vertically
for
30
seconds
using
a
model
80D
pull
scale.
c.
Inspect
antenna
for
any
sign
of
damage.
d.
Antennas
that
fail
will
be
replaced
through
normal
supply
procedures.

TO
31R2-2PR-101
e.
Antenna
tips
that
become
detached
may
be
replaced
by
using
adhesive
that
conforms
to
specification
MIL-A46050
or
equivalent.
Allow
adhesive
to
dry
and
retest.
7.15
DELETED.
7.16
DELETED.
7.17
REMOVAL
AND
REPLACEMENT.
Remove
and
replace
the
electrical
components
listed
in
Paragraph
7.18
through
Paragraph
7.25
when
directed
by
the
troubleshooting
procedures
in
Paragraph
7.7

through
Paragraph
7.12.
The
mechanical
portions
of
the
PUSH
TO
TALK
and
MCW
buttons
should
be
replaced
if
the
inspections
performed
in
Table
6-1
reveal
faulty
rubber
covers
which
may
cause
leaking,
or
if
binding
impairs
the
switch
operation.
7.18
ELECTRONICS
ASSEMBLY
REMOVAL.
At
field-level
maintenance,
Electronics
Assembly
A1
may
only
be
removed
and
not
disconnected
from
the

radio
set.

Be
careful
not
to
scratch
or
otherwise
damage
the
watertight
seal
molded
into
the
rear
cover
when
lifting
the
cover
from
the
housing.
a.
Take
off
the
rear
cover
assembly
of
the
radio
set
by
first
cutting
out
the
screw-head
seals
with
a
sharp
knife.
Then
extract
the
screws

with
a
No.
0
Phillips
screwdriver.
b.
Unscrew
the
electronic
assembly
hold-down
screw
shown
in
Figure
6-4.
c.
Carefully
lift,
parallel
to
the
radio
set
housing,
the
electronics
assembly.
Do
not
disconnect
or
unsolder
any
attaching
wires.
7.19
ELECTRONICS
ASSEMBLY
REINSTALLATION.
Reinstalling
of
the
electronics
assembly
is
essentially
the
reverse
of
the
removal
procedure.
However,
because
of
the
very
close

spacing
involved,
be
careful
to
dress
wires
to
permit
the
electronics
assembly
to
fit
into
the
housing
without
forcing.
Use
a
small
wooden
stick
to
help
adjust
wire
positions
as
the
electronics
assembly
is
slid
into
the
housing.
7.20
MCW
AND
PUSH
TO
TALK
SWITCH
REPLACEMENT.
Switches
S4
and
S5
are
permanently
mounted
together
in
an
assembly.
This

assembly
must
be
replaced
if
either
switch
is
defective.
a.
Remove
the
rear
cover,
as
in
Paragraph
7.18a.
b.
Remove
the
switch
assembly
by
removing
the
two
hold-down
screws,
and
lift
out
the
assembly.
(See
Figure
6-4.)
c.
Unsolder
the
interconnecting
wires.
(Do
not
remove
jumpers
between
switch
contacts.)
d.
Attach
and
solder
interconnecting
wires
to
new
switch

assembly.
e.
Place
the
switch
assembly
in
its
normal
position
and
replace
the
mounting
screws,
but
do
not
tighten
screws
until
the
assembly
is
positioned
so
that
from
0.005
to
0.010
inch
of
clearance
exists
between
the
switch
buttons
and
the
switch
actuators.
Check
with
the
feeler
gage.
Then
tighten
hold-down
screws.
f.
Replace
rear
cover.
7.21
VOL
CONTROL
REPLACEMENT.

To
replace
VOL
control
R1,
perform
the
following:
a.
Take
off
the
rear
cover
as
in
Paragraph
7.18a,
and
remove
the
VOL
control
cover.
b.
Remove
the
single
hold-down
screw
and
lift
out
the
electronics
assembly
as
in
Paragraph
7.18b.
Do
not
unsolder
interconnecting
wiring.
c.
Unsolder
leads
to
VOL
control
R1.
d.
Remove
lock
ring
securing
the

VOL
control
knob.
e.
Remove
VOL
control
knob,
spring
washer,
and
hardware
securing
the
VOL
control
to
the
housing,
and
finally
take
off
the
VOL
control.
f.
Replace
the
VOL
control
assembly
by
reversing
the
above
procedure,
from
items
5
through
1.
Make
sure
that
the
locking
stud
fits
into
its
mating
slot
in
the
housing
wall.
7.22
BATTERY
CAP

REPLACEMENT.
The
battery
cap
assembly
should
be
repaired
or
replaced,
if
it
leaks
or
if
the
threads
are
damaged.
A
leaking
cap
can
usually
be
repaired
by
simply
replacing
the
sealing
washer
mounted
in
the
base
of
the
cap.
No
special
tools
are
required.
If
threads
are
damaged,
the
entire
cap
assembly
should
be
replaced
as
follows:
a.

Cut
the
wrist
strap
webbing
and
remove
it
from
the
housing.
Discard
the
wrist
strap
and
retain
the
earphone
case.
b.
Remove
and
discard
battery
cap
and
retainer.
Change
2
7-9

TO
31R2-2PR-101
c.
Install the new battery cap and retainer by screwing the
battery cap onto the radio set, and inserting the retainer
strap at the bottom of the housing.
d.
Insert new wrist-strap webbing through loops in earphone
case, through slot in first web of housing, through
battery cap retainer strap and through other slot in web
of housing.
e.
Fold the ends of the wrist strap webbing. Insert and
swage the grommets.
NOTE
The wrist strap is supplied with grommets.
7.23
PUSH
TO
TALK
OR
MCW
BUTTON
REPLACEMENT.
The PUSH TO TALK or MCW
the rubber button cover
may allow water to leak
of these buttons may be

button should be replaced if

is damaged. A damaged button cover
into the radio set. Removal of either
accomplished as follows:

a.
Remove the rear cover, as in Paragraph 7.18a.
b.
Remove the hold-down screws from the S4/S5 switch
assembly. Carefully lift out this assembly; do not
disconnect wires.
c.
Remove PUSH TO TALK or MCW button by removing
internal (hexagonal) retaining nut (Figure 7-4, 3) and
sliding out button assembly (1).
NOTE
Spare button assemblies are supplied with a
packing ring (4), an adapter (5), and a spanner
wrench (6). These three items are required only
for Radio Set AN/PRC-90, P/N 01-524795-1.
d.
To install the button assembly, insert button assembly
(1) through housing from the outside. Install hexagonal
nut (3); turning clockwise until assembly is seated
against shoulder of housing (2).
e.
Reinstall S4/S5 switch assembly. Make sure that switch

actuators are 0.005 to 0.010 inch from the button by

checking with feeler gage.
f.
Replace rear cover.
7.24
NAVY
MODEL
PUSH
TO
TALK
OR
MCW
BUTTON
REPLACEMENT.
This procedure is applicable only to Radio Set AN/PRC-90,
P/N 01-524795-1, used by the Navy.
a.
Remove rear housing cover and S4/S5 switch assembly.
b.
Remove the button assembly by inserting the spanner
wrench (Figure 7-4, 3) supplied with the spare button
assembly into the retainer (see following note) and
turning it counterclockwise.
NOTE
The retainer performs the same function as the
adapter (5), and is located in the same position.
However, the shape of the retainer is slightly
different. The adapter (5) replaces the retainer
when a button is replaced.
c.
Install packing ring (4).
d.
Install adapter (5) using spanner wrench. Turn adapter
until firmly seated, assuring proper compression of
packing ring (4).
e.
Install button assembly (1).
f.
Reinstall S4/S5 switch assembly with 0.005 to 0.010
inch clearance to buttons.
g.
Replace rear cover.
7.25
FUNCTION
SWITCH
KNOB
REPLACEMENT.
A binding or inoperative function switch knob can be caused
by accumulation of dirt within the knob cavity, broken detent,
or broken springs. Frequently, binding can be corrected by
disassembling, cleaning (in fresh water if salt accumulation is
the problem), and reassembling.
a.
Remove function switch knob cover mounting screws

and lift off cover.

b.
Remove function switch knob assembly.
c.
Clean all parts. Inspect for worn or broken parts. If
assembly is defective, proceed to step e.
d.
Reassemble in reverse order of disassembly and check
function switch knob for normal operation in all modes.
e.
Discard defective assembly and replace with function
switch knob assembly, as follows:
(1) Position function switch knob cover (Figure 7-5, 7)
face down on bench or other flat surface with the
straight edge on the left and the alignment pin at the
2 o clock position.
(2) Insert short hub of indicator knob (6) into center hole
of function switch knob cover, pointing white arrow
(on hub) toward straight edge of cover.
(3) Position compression spring (5)
on long hub of
indicator knob.
(4) Position control knob (4) over indicator knob.
(5) Fit the exposed magnet visible inside knob (4) into
the radial clearance slot on indicator knob (6).
(6) Insert two compression springs (3) into holes in
control knob (4).
7-10
Change
2

TO
31R2-2PR-101
(7)
Position
two
steel
balls
(2)
on
springs.
(8)
Position
detent
plate
(1)
over
steel
balls,
aligning
flats
on
plate
with
straight
edge
of
function
switch
knob
cover.
(9)
Hold
housing
of
radio
set
with
battery
cap
facing
toward
you
and
function
switch
knob
cavity
facing
down.
Lower
radio
set
down
over
function
switch
knob

assembly,
compressing
springs,
until
function
cover
is
flush
with
case.
(10)
Slide
radio
set
(with
function
switch
knob
assembly
in
place)
toward
edge
of
bench
until
function
switch
cover
can
be
held
in
position
with
fingers.
(11)
Maintain
grip
on
radio
set
and
function
switch
knob
cover
with
one
hand,
and
insert
and
tighten
mounting
screws.
(12)
Check
function
switch

knob
assembly
for
normal
operation
of
radio
set
in
all
modes.
7.26
RETRIEVAL
LANYARD
REPLACEMENT.
Lanyard
use
is
optional.
Its
main
purpose
is
for
retention
of
the
radio
during
water
survival
conditions.
To
replace
or
add
the
lanyard
slip
a
one-inch
piece
of
suitable
heat
shrink
tubing
on
the
cord.
Tie
new
lanyard
to
the
D
ring
located

at
the
wrist
strip.
Then
slide
heat
shrink
tubing
over
knot
and
shrink
by
application
of
heat.
The
cord
is
then
wrapped
around
the
lanyard
D
ring
and
the
assembly
secured
with
suitable
tape
to
the
base
of
the
radio.
Other
convenient
taping
locations
may
be
used
provided
operation
of
the
radio
is
not
impaired.
7-11/(7-12

blank)