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Racal Instruments AN/TRC-199 Additional Installation, Operation And Maintenance Instructions

Radio set (tactical repeater)
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TO 31R2-2TRC199-1
OPERATION AND MAINTENANCE INSTRUCTIONS
WITH ILLUSTRATED PARTS BREAKDOWN
ORGANIZATIONAL LEVEL
RADIO SET
AN/TRC-199
(TACTICAL REPEATER)
RACAL COMMUNICATIONS, INC.
5 RESEARCH PLACE
ROCKVILLE, MD 20850
CONTRACT NO: F19628-91-D-0012
DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government agencies only for administrative or
operational use 15 June, 1993. Other requests for this document shall be referred to Sacramento ALC/TILBE, 3200
Peacekeeper Way, Suite 1, McClellan AFB, CA 95652-1026.
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.
HANDLING AND DESTRUCTION NOTICE - Handle in compliance 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 JUNE 1993
CHANGE 1 - 10 AUGUST 1994

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  • Page 1 TO 31R2-2TRC199-1 OPERATION AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN ORGANIZATIONAL LEVEL RADIO SET AN/TRC-199 (TACTICAL REPEATER) RACAL COMMUNICATIONS, INC. 5 RESEARCH PLACE ROCKVILLE, MD 20850 CONTRACT NO: F19628-91-D-0012 DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government agencies only for administrative or operational use 15 June, 1993.
  • Page 2 TO 31R2-2TRC199-1 INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margin of the page. Changes to illustrations are indicated by a vertical line adjacent to the illustration identification number.
  • Page 3 TO 31R2-2TRC199-1 RECORD OF CHANGES CHANGE DATE TITLE OR BRIEF DESCRIPTION ENTERED BY 10 August 1994 Change 1...

  • Page 5: Table Of Contents

    TO 31R2-2TRC199-1 TABLE OF CONTENTS Chapter Page LIST OF ILLUSTRATIONS ......................... iv LIST OF TABLES ............................iv SAFETY SUMMARY ............................ v FOREWORD ..............................ix CHAPTER 1.0 GENERAL INFORMATION ....................... 1-3 DESCRIPTION AND PURPOSE..................... 1-3 1-1.1 Equipment Function and Purpose..................1-3 1-1.2 Equipment Description.
  • Page 6 TO 31R2-2TRC199-1 CHAPTER 4.0 OPERATION ..........................4-1 INTRODUCTION..........................4-1 CONTROLS AND INDICATORS....................4-1 4-2.1 Indicators, Controls and Switches................... 4-1 4-2.2 Power Supply Switches and Connectors................. 4-1 4-2.3 Connectors........................4-1 4-2.4 Diplexer Controls......................4-1 Section II. OPERATING INSTRUCTIONS ....................4-7 INITIAL POWER-UP AND DIPLEXER TUNING PROCEDURES.
  • Page 7 TO 31R2-2TRC199-1 CHAPTER 7.0 ILLUSTRATED PARTS BREAKDOWN ................... 7-1 Section I. INTRODUCTION ........................7-1 GENERAL............................7-1 MAINTENANCE PARTS LIST....................... 7-1 NUMERICAL INDEX........................7-2 REFERENCE DESIGNATION INDEX................... 7-3 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES..........7-3 CAGE CODE SUMMARY....................... 7-4 Section II.
  • Page 8 Figure 5-2. Repeater Control CCA (A3), Functional Block Diagram ..............5-5 Figure 5-3. 15 Watt Power Amplifier Assembly (A6), Functional Block Diagram ..........5-6 Figure 7-1. Radio Set AN/TRC-199 (Sheet 1 of 2) ....................7-8 Figure 7-2. Tactical Repeater Assembly (SS-4100806-501) ................. 7-13 Figure 7-3.

  • Page 9: Safety Summary

    TO 31R2-2TRC199-1 SAFETY SUMMARY The following are general safety precautions that are not related to any specific procedure, and do not appear elsewhere in this manual. These Safety Summaries are recommended precautions that all personnel must understand and apply during any given phase of operation and maintenance. Each chapter has other specific warnings and cautions. WARNING KEEP AWAY FROM LIVE CIRCUITS Personnel must at all times observe all safety regulations.
  • Page 10 TO 31R2-2TRC199-1 WARNING VOLTAGES WITHIN THIS EQUIPMENT ARE HIGH ENOUGH TO ENDANGER LIFE. Covers are not to be removed except by persons qualified and authorized to do so and these persons should always take extreme care once the covers have been removed. Page WARNING - Installation of the tactical repeater requires a minimum of two people.
  • Page 11 TO 31R2-2TRC199-1 Page CAUTION - Because of the miniaturization of parts for electronic assembly construction, the leads, connectors, and pins have been stiffened to make them more rugged. As a result, such parts are brittle and will break easily if bent too often or pulled on too hard. When handling an assembly that has been removed from its chassis, be careful not to press against the leads and pins.

  • Page 13: Foreword

    TO 31R2-2TRC199-1 FOREWORD This manual meets the technical content requirements of specification MIL-M-38798B, paragraph 3.3 (1 December 1975) and MIL-M-38807A (1 June 1982) and format requirements of specification MIL-M-38784B (16 April 1983) for the tactical repeater. Chapter 1 - General Information. This chapter provides general information for the tactical repeater including equipment description and purpose, leading particulars, capabilities and limitations, equipment supplied, equipment required but not supplied, optional equipment, special tools and test equipment, and related technical manuals.
  • Page 14 Cable Assembly, TR, 240 VAC, Power (W9) Cable Assembly, TR, 10-32 VDC, Power (W9) Case, Transit, Diplexer Case, Transit, Diplexer Cover, Frame Cable Assembly, Coaxial, RF (W2) Cable Assembly, Coaxial, RF (W3) Cable Assembly, Coaxial, RF (W4) Figure 1-1. Radio Set AN/TRC-199 (Sheet 1 of 3)
  • Page 15 TO 31R2-2TRC199-1 Figure 1-1. Radio Set AN/TRC-199 (Sheet 2 of 3)
  • Page 16 TO 31R2-2TRC199-1 Figure 1-1. Radio Set AN/TRC-199 (Sheet 3 of 3)

  • Page 17: Chapter 1.0 General Information

    Equipment Function and Purpose. Radio Set AN/TRC-199 (hereinafter referred to as the tactical repeater) is a communications unit capable of operating in the 30-88, 136-174, or 403-470 Megahertz (MHz) frequency bands. It is used to extend the communications range of fixed, mobile, or portable receiver-transmitters.

  • Page 18: Figure 1-3. Diplexer Front Panel (30-88 Mhz)

    TO 31R2-2TRC199-1 Figure 1-1Figure 1-2. Receiver-Transmitter RT-1695/TRC-199 1-1.2.4 Diplexer. (See Figure 1-3.) The tactical repeater diplexer provides a method of using a receiver and a transmitter on a common antenna. The diplexer, when properly tuned, provides a transmitter-to-receiver isolation of 70 decibels (dB) at any frequency spacing of 4 MHz or 3% of the operating frequency, whichever is greater.

  • Page 19: Leading Particulars

    TO 31R2-2TRC199-1 1-1.2.5 Power Supply Assembly. The power supply assembly provides power for the operation of the tactical repeater. The power supply will operate from any direct current (DC) voltage between 10 and 32 volts and from 120/240 or 220 volts alternating current (VAC). The operation of the power supply is controlled by AC/OFF/DC and internal/external (INT/EXT) DC switches on the power supply.

  • Page 20: Capabilities And Limitations

    TO 31R2-2TRC199-1 CAPABILITIES AND LIMITATIONS. Capabilities and limitations of the tactical repeater are given in Table 1-3. Table 1-3. Capabilities and Limitations Characteristic Parameter Frequency Range (RCV and XMT) 30-88 MHz 136-174 MHz 403-470 MHz Transmitter Output 2 and 10 watts selectable Security Tactical repeater is COMSEC transparent Interoperability...

  • Page 21: Equipment Supplied

    TO 31R2-2TRC199-1 EQUIPMENT SUPPLIED. Equipment supplied with Radio Set AN/TRC-199 is listed in Table 1-4. Table 1-4. Equipment Supplied Official Nomenclature Part Number Quantity Tactical Repeater Assembly SS-4100806-501 Power Supply Assembly SS-4100733-501 Power Supply Enclosure Battery Enclosure Diplexer Assembly, 30-88 MHz...

  • Page 22: 1-4.1 Equipment Required But Not Supplied

    TO 31R2-2TRC199-1 1-4.1 EQUIPMENT REQUIRED BUT NOT SUPPLIED. Table 1-5 lists equipment required but not supplied. Table 1-5. Equipment Required But Not Supplied Equipment Part Number Programmer Unit, Frequency Radio SS-4100797-501 MX-11531/U Batteries Lithium Type BA-5590/U NiCad Type BB-590/U NiCad Battery Charger/Conditioner MRC-590 SPECIAL TOOLS AND TEST EQUIPMENT.

  • Page 23: Chapter 2.0 Installation

    TO 31R2-2TRC199-1 CHAPTER 2.0 INSTALLATION INTRODUCTION. This section is divided into two sections. Section I. Installation Logistics provides information for site preparation, unloading, unpacking, and inspections, housing, receiving data, material handling, cabling, and buildings and other structures. Section II. Installation Procedures lists tools and equipment required for field installation and describes the installation sequence.

  • Page 24: Figure 2-1. Packaging Diagram For The Tactical Repeater

    TO 31R2-2TRC199-1 Legend for Figure 2-1: Operating instructions Barrier bag Polystyrene top Polystyrene bottom Tactical repeater assembly Fiberboard box Desiccant bag Packing slip Figure 2-1. Packaging Diagram for the Tactical Repeater...

  • Page 25: Housing

    TO 31R2-2TRC199-1 Store all packing materials (except the desiccant bag) in shipping container and store shipping container for re-use. New desiccant material must be used when repacking. Inspect top and bottom, both sides, and front and rear panels of equipment for dents, scratches or any visually identifiable damage.

  • Page 26: Cables

    TO 31R2-2TRC199-1 CABLES. Table 2-2 lists all tactical repeater interconnecting cables. Table 2-2. Tactical Repeater Interconnecting Cables Cable Cable Part No. Description Designation SS-4500110-501 Cable Assembly, TR Power Connects power supply DC output to tactical repeater SS-3500292-501 Cable Assembly, Coaxial, RF Connects diplexer receiver (RX) output to tactical repeater assembly SS-3500292-502...

  • Page 27: Section Ii. Installation Procedures

    TO 31R2-2TRC199-1 Section II. INSTALLATION PROCEDURES SPECIAL TOOLS AND EQUIPMENT REQUIRED FOR FIELD INSTALLATION. No special tools or equipment are needed for installation and initial setup of the tactical repeater. 2-10 INSTALLATION SEQUENCE. (See FO-1.) Perform the following procedure to install the tactical repeater. Cables required for installation are listed in Table 2-2.
  • Page 28 TO 31R2-2TRC199-1 Remove both mast sections from the transit bag (3). Note that the socketed end is the lower end of each section. Place the tubes in line along the ground. Assemble the two tube sections together. Remove the base plate (4), two ground spikes (5), and hammer from the transit bag. Place the base plate at the mast base, arrowhead style, so that the socketed lower end of the mast will engage in the heel.
  • Page 29 TO 31R2-2TRC199-1 Figure 2-5. Antenna Mast/Antenna Installation (Sheet 4 of 6) Using the same guy rope as a radius guide, walk across to the approximate location of the second ground anchor. Establish the required 120 from the first ground anchor by using the triangular shape of the base plate as a reference.
  • Page 30 TO 31R2-2TRC199-1 Ensure foot of mast is securely located in the base plate heel. While person a pushes up mast head Iwo Jima style, person b pulls on guy ropes to raise mast to vertical. Person a should progressively walk towards bottom of mast as it is raised and should hold mast steady as it reaches the vertical.

  • Page 31: 2-10.2 Lithium Battery Installation

    TO 31R2-2TRC199-1 2-10.2 Lithium Battery Installation. (Optional) (This procedure is also applicable to the Type BB-590/U NiCad batteries.) The battery enclosure has connectors for four type BA-5590/U Lithium batteries. The connectors are mounted in the bottom of the enclosure. To install the batteries, first open the battery enclosure.

  • Page 32: Chapter 3.0 Preparation For Use And Reshipment

    TO 31R2-2TRC199-1 CHAPTER 3.0 PREPARATION FOR USE AND RESHIPMENT INTRODUCTION. This chapter is divided into two sections. Section I. Preparation For Use provides post-installation operational checks that must be performed prior to operating the tactical repeater. Section II. Preparation For Reshipment contains procedures for reshipment of the unit.

  • Page 33: 3-3.2 Alignment And Adjustment

    TO 31R2-2TRC199-1 3-3.2 Alignment and Adjustment. The tactical repeater is aligned and adjusted for normal operation at the factory/depot. No other alignments or adjustments are authorized or required. The diplexer will require retuning as described in paragraph 4-3 whenever the transmit or receive frequencies are changed.

  • Page 34: 3-6.1 Protective Measures For Electrical Connectors

    TO 31R2-2TRC199-1 CAUTION Never apply pressure sensitive tape directly to connectors. This could damage connector pins. 3-6.1 Protective Measures for Electrical Connectors. Protect all unmated connectors that are exposed to physical or environmental damage by covering with supplied protective caps. 3-6.2 Preparation for Shipment and Storage.
  • Page 35 TO 31R2-2TRC199-1 Be very careful when removing or inserting an assembly into the equipment. If it is a plug-in CCA, be sure the guide pins are properly aligned before pressing the assembly in place. If the CCA tilts while being inserted, do not continue to press into position;...

  • Page 37: Chapter 4.0 Operation

    TO 31R2-2TRC199-1 CHAPTER 4.0 OPERATION Section I. CONTROLS AND INDICATORS INTRODUCTION. This section describes and illustrates indicators, controls, switches, and connectors of the tactical repeater. CONTROLS AND INDICATORS. The following paragraphs describe and illustrate all operational controls and indicators of the tactical repeater. 4-2.1 Indicators, Controls and Switches.

  • Page 38: Table 4-1. Description Of Indicators, Controls And Switches

    TO 31R2-2TRC199-1 Table 4-1. Description of Indicators, Controls and Switches Fig & Index Number Control/Switch Function STATUS: 4-1-1 DISPLAY Switch (two- Controls whether the front panel indicators are position rotary switch) operational (ON position) or not operational (OFF position) (The DISPLAY switch should be kept in OFF position to conserve battery life following initial power-up and function check.) 4-1-2...
  • Page 39 TO 31R2-2TRC199-1 Figure 4-2. Location of Power Supply Switches (Power Supply Top View) Table 4-2. Description of Power Supply Switches Fig & Index Number Switch Function 4-2-1 DC SEL (INT/EXT) Select Allows selecting either the internal battery power switch (two-position toggle source or an external DC source when the AC/DC switch)
  • Page 40 TO 31R2-2TRC199-1 Figure 4-3. Location of Power Supply Connectors (Power Supply Side View) Table 4-3. Description of Power Supply Connectors Fig & Index Number Connectors Function 4-3-1 AC Power Fuse 1 Amp In-line fuse for AC input power 4-3-2 External Power Input Connector External power supply input.
  • Page 41 TO 31R2-2TRC199-1 Figure 4-4. Location of Tactical Repeater Unit Connectors Table 4-4. Description of Repeater Unit Connectors Fig & Index Number Connectors Function 4-4-1 TX (Transmit) Connector J3 Input from diplexer transmit connector to repeater. 4-4-2 POWER Connector J1 Connects repeater to repeater power supply unit. 4-4-3 GND (Ground) Stud Provides chassis ground point;...

  • Page 42: Figure 4-5. Location Of Tactical Repeater Diplexer Controls

    TO 31R2-2TRC199-1 Figure 4-5. Location of Tactical Repeater Diplexer Controls Table 4-5. Description of Diplexer Controls Fig & Index Number Indicator/Control/Switch Function 4-5-1 Tuning Meter Measures relative strength of transmit or receive signals 4-5-2 SENS Control The SENS control is only active when the TUNE switch is held depressed.

  • Page 43: Section Ii. Operating Instructions

    TO 31R2-2TRC199-1 Section II. OPERATING INSTRUCTIONS NOTE Be aware that while performing the initial power-up and diplexer tuning procedures, the tactical repeater will radiate RF energy which can cause frequency interference. Do not perform this procedure before the frequency use authorization is obtained and in effect. INITIAL POWER-UP AND DIPLEXER TUNING PROCEDURES.

  • Page 44: Receiving And Retransmitting Message

    TO 31R2-2TRC199-1 RECEIVING AND RETRANSMITTING MESSAGE. Whenever the tactical repeater is turned on, it is capable of receiving messages and transmitting them (relaying them) back out. Receive and retransmit messages as follows: Perform the initial power-up and diplexer tuning procedure of paragraph 4-3 to turn on the tactical repeater and prepare it for operation.

  • Page 45: Electromagnetic Pulse Protection

    TO 31R2-2TRC199-1 ELECTROMAGNETIC PULSE PROTECTION. Electromagnetic Pulse (EMP) is a pulse of broad bandwidth, high amplitude radio frequency electromagnetic energy produced by the radiation from a nuclear burst. 4-9.1 EMP Susceptibility. EMP can deliver a power density to a radio receiver a billion times greater than the power necessary for reception. The voltage and current surges resulting from EMP can overload most modern solid state electronic devices.

  • Page 47: Chapter 5.0 Theory Of Operation

    TO 31R2-2TRC199-1 CHAPTER 5.0 THEORY OF OPERATION Section I. FUNCTIONAL SYSTEM(S) OPERATION GENERAL. This section describes the theory of operation of the tactical repeater. From both technical and operational standpoints, the tactical repeater is designed to be a component of a communications system. It must function in conjunction with other receiver-transmitters to perform receiver-transmitter communication.

  • Page 48: Figure 5-1. Tactical Repeater System, Functional Block Diagram

    TO 31R2-2TRC199-1 Figure 5-1. Tactical Repeater System, Functional Block Diagram...

  • Page 49: 5-2.6 +28V Dc-Dc Converter Circuit Card Assembly (Cca) (A7)

    TO 31R2-2TRC199-1 5-2.6 +28V DC-DC Converter Circuit Card Assembly (CCA) (A7). The +28V DC-DC converter (A7) provides regulated +28 VDC to the RF power amplifier (A6). The power converter operates from a 10-32 VDC input. 5-2.7 Receiver-Transmitter. Two receiver-transmitters are used in the tactical repeater. One is designated for receive operation and the other is designated for transmit only.

  • Page 50: Section Ii. Functional Operation Of Electronic Circuits

    TO 31R2-2TRC199-1 All external power sources are accessed through a common connector. A unique cable is provided to accommodate each source. Two toggle switches operate as described in Table 4-2. The power supply also incorporates an RF peak detector which produces a DC voltage that is proportional to the transmitted RF power.

  • Page 51: Figure 5-2. Repeater Control Cca (A3), Functional Block Diagram

    TO 31R2-2TRC199-1 Figure 5-2. Repeater Control CCA (A3), Functional Block Diagram...

  • Page 52: Figure 5-3. 15 Watt Power Amplifier Assembly (A6), Functional Block Diagram

    TO 31R2-2TRC199-1 Figure 5-3. 15 Watt Power Amplifier Assembly (A6), Functional Block Diagram...

  • Page 53: Chapter 6.0Maintenance

    TO 31R2-2TRC199-1 CHAPTER 6.0MAINTENANCE GENERAL. This chapter provides organizational maintenance instructions for the tactical repeater. This includes operational checkout, inspection and preventive maintenance, troubleshooting, and removal/replacement procedures. OPERATIONAL CHECKOUT. Perform the procedures in paragraphs 6-2.1 through 6-2.5 to check the tactical repeater for normal operation. These checks should be performed when equipment is used for the first time, when the equipment has been damaged, or if the equipment has not been used for an extended period of time.

  • Page 54: 6-2.3 Receive Tune Mode Verification

    TO 31R2-2TRC199-1 6-2.3 Receive Tune Mode Verification. Verify functionality of receive mode as follows: Set the tactical repeater switches and controls as indicated in Table 6-2. Table 6-2. Initial Switch and Control Settings for Receive Tune Mode Verification Switch/Control Position AC/DC POWER switch (1, Figure 4-2) AC or DC, as applicable INT/EXT switch (2, Figure 4-2)

  • Page 55: Fault Led

    TO 31R2-2TRC199-1 Verify that the only LEDs illuminated on the tactical repeater front panel are POWER and XMT. Verify the green LED on the XMT receiver-transmitter is illuminated and the green LED on the RCV receiver-transmitter is not illuminated. 6-2.5 Fault LED.

  • Page 56: Troubleshooting

    TO 31R2-2TRC199-1 6-3.3.1 Inspection. Inspect the tactical repeater as follows: Inspect the equipment covers and front panel for condition of finish and panel markings. Inspect the unit for dents, punctures, or worn areas. Inspect external surfaces for loose or missing screws or washers. Inspect the receptacles and connectors for condition of pins, contacts, and mounting.

  • Page 57: Table 6-5. Organizational Maintenance Guide - Operator

    TO 31R2-2TRC199-1 Table 6-5. Organizational Maintenance Guide - Operator Symptom Possible Cause Remedy Repeater does not have Failed power source Restore prime power any lamps illuminated, and Failed batteries Replace batteries/check power source Failed RCV receiver-transmitter Replace RCV receiver-transmitter Repeater does not receive Failed XMT receiver-transmitter Replace XMT receiver-transmitter or transmit with power and...
  • Page 58 TO 31R2-2TRC199-1 Table 6-5. Organizational Maintenance Guide - Operator - CONT Symptom Possible Cause Remedy Repeater transmits with correct Failed RCV receiver-transmitter Replace RCV receiver-transmitter power but with no modulation Failed XMT receiver-transmitter Replace XMT receiver-transmitter Failed tactical repeater assembly Return the tactical repeater assembly to the repair specialist for repair a.
  • Page 59 TO 31R2-2TRC199-1 Table 6-5. Organizational Maintenance Guide - Operator - CONT Symptom Possible Cause Remedy Repeater receive characteristics are Mismatched receiver-transmitter Ensure same configuration of receiver- frequency sensitive; some but not transmitter, diplexer, and antenna are all frequencies meet specified installed levels Failed RCV receiver-transmitter...
  • Page 60 TO 31R2-2TRC199-1 Table 6-5. Organizational Maintenance Guide - Operator - CONT Symptom Possible Cause Remedy Repeater some indicators Failed RCV receiver-transmitter Replace RCV receiver-transmitter working but not all Failed XMT receiver-transmitter Replace XMT receiver-transmitter Failed tactical repeater assembly Return the tactical repeater assembly to the repair specialist for repair Repeater will not pass either clear or Failed RCV receiver-transmitter...

  • Page 61: Table 6-6. Organizational Maintenance Guide - Repair Specialist

    TO 31R2-2TRC199-1 Table 6-6. Organizational Maintenance Guide - Repair Specialist Symptom Possible Cause Remedy a. Repeater does not have any Failed repeater control CCA Remove and replace repeater control lamps illuminated, and Fault cannot be isolated/repaired at Return the tactical repeater assembly the repair specialist level to depot for repair b.

  • Page 62: Removal/Replacement Procedures

    TO 31R2-2TRC199-1 Table 6-6. Organizational Maintenance Guide - Repair Specialist - CONT Symptom Possible Cause Remedy Repeater transmit characteristics Fault cannot be isolated/repaired at Return the tactical repeater assembly are frequency sensitive; some but the repair specialist level to depot for repair not all frequencies meet specified levels Repeater has some indicators...
  • Page 63 TO 31R2-2TRC199-1 6-5.1.1 Antenna Cable Removal/Replacement. Remove/replace antenna cable as follows: Disconnect the antenna cable from the connector at the rear of the diplexer by turning counterclockwise. Disconnect the antenna cable from the connector at the base of the antenna mast by grasping the connector on the antenna cable and turning counterclockwise.

  • Page 64: 6-5.2 Removal/Replacement Procedures - Repair Specialist

    TO 31R2-2TRC199-1 Replace the power supply with a known good power supply. 6-5.1.6 Diplexer Removal/Replacement. Remove/replace the diplexer as follows: To remove the diplexer (33, Figure 7-1), disconnect the coaxial cables (23, 30, and 31) leading to the tactical repeater assembly (1) and the power supply (21). Remove the screws (35), washers (36), and shock mounts (24, 27, and 28) under the diplexer holding the diplexer to the weldment frame (5).
  • Page 65 TO 31R2-2TRC199-1 Reattach the bottom cover by tightening the 16 screws that secure the bottom cover to the chassis. When refitting the bottom cover to the chassis, check the EMI gasket (19) to ensure that it is undamaged and properly seated. 6-5.2.2 Control Panel Assembly (A5) (SS-4100071-501) Removal/Replacement.

  • Page 67: Chapter 7.0 Illustrated Parts Breakdown

    GENERAL. The Illustrated Parts Breakdown (IPB) lists, illustrates, and describes the parts used in the Scope Shield Radio Set AN/TRC-199. The items are manufactured by Racal Communications, Inc., Rockville, Maryland. MAINTENANCE PARTS LIST. The Maintenance Parts List (MPL), (Section II), consists of the complete systems divided into main groups. The main groups are broken down into assemblies, subassemblies, and details.

  • Page 68: Numerical Index

    TO 31R2-2TRC-199-1 preceding and subsequent figures concerning assemblies and subassemblies. This data is considered an integral part of the item description assuring the correctness of repair maintenance procedures. Attaching Parts. Items used to attach parts or assemblies to each other are listed immediately after the part.

  • Page 69: Reference Designation Index

    TO 31R2-2TRC-199-1 REFERENCE DESIGNATION INDEX. The Reference Designation Index (Chapter 7, Section IV) is listed by figure as it appears in the MPL, then in alphabetical- numerical order, the reference designations used in schematic diagrams and instruction books. Opposite the reference designation is listed the figure index number as shown in the MPL.

  • Page 70: Cage Code Summary

    TO 31R2-2TRC-199-1 CAGE CODE SUMMARY. CAGE Code Manufacturer 1BZ19 C and S Antennas, Inc. 05972 Locktite Corp. 07700 Technical Wire Products, Inc. 13074 Multi-Flex Seals, Inc. 23386 Racal Communications, Inc. 23657 Shakespeare Co. 27264 Molex Inc. 52437 Bretford MFG, Inc. 73734 Federal Screw Products, Inc.
  • Page 71 TO 31R2-2TRC-199-1 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN...
  • Page 72 TO 31R2-2TRC-199-1 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN...
  • Page 73 TO 31R2-2TRC-199-1 This Page Left Blank Intentionally...

  • Page 74: Figure 7-1. Radio Set An/Trc-199 (Sheet 1 Of 2)

    TO 31R2-2TRC-199-1 Figure 7-1. Radio Set AN/TRC-199 (Sheet 1 of 2)
  • Page 75 TO 31R2-2TRC-199-1 Figure 7-1. Radio Set AN/TRC-199 (Sheet 2 of 2)

  • Page 76: Section Ii. Maintenance Parts Lists

    TO 31R2-2TRC-199-1 Section II. MAINTENANCE PARTS LISTS Table 7-1. Radio Set AN/TRC-199 Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code SS-4100793-502 23386 Radio Set AN/TRC-199 .........
  • Page 77 TO 31R2-2TRC-199-1 Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code 7-1-20 MS51958-73 96906 @ Screw, Machine ............ 0024 PAOZZN (23386/SS-77776) (SPEC CTRL DRW) 7-1-21 SS-4100733-501 23386 @ Power Supply ............
  • Page 78 TO 31R2-2TRC-199-1 Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code 7-1-41 SP10SS 1BZ19 @ Mast Kit, Tactical Repeater ........0001 PAOZZN (23386/SS-1600281-1) (SPEC CTRL DRW) 7-1-41a SL/33644 1BZ19 $ $ Antenna Adapter ..........

  • Page 79: Figure 7-2. Tactical Repeater Assembly (Ss-4100806-501)

    TO 31R2-2TRC-199-1 Figure 7-2. Tactical Repeater Assembly (SS-4100806-501) (Sheet 1 of 2) 7-13...
  • Page 80 TO 31R2-2TRC-199-1 Figure 7-2. Tactical Repeater Assembly (SS-4100806-501) (Sheet 2 of 2) 7-14...

  • Page 81: Table 7-2. Tactical Repeater Assembly (Ss-4100806-501)

    TO 31R2-2TRC-199-1 Table 7-2. Tactical Repeater Assembly (SS-4100806-501) Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code SS-4100806-501 23386 Tactical Repeater Assembly ........0001 PAOLDT (refer to Figure 7-2 for breakdown) (ESD) 7-2-1 SS-4100853-501 23386 @ Power Amplifier Assembly ........
  • Page 82 TO 31R2-2TRC-199-1 Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code 7-2-21 SS-4100805-501 23386 @ CCA, Control, Repeater ........0001 PAOLDT (A3) (refer to T.O 31R2-2TRC199-3 for breakdown) (ESD) 7-2-22 SS-4100730-501...
  • Page 83 TO 31R2-2TRC-199-1 Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code 7-2-43 5710-54-25 86928 @ Washer, Flat ............0001 PADZZN (23386/75106) (SPEC CTRL DRW) 7-2-44 F4NY-250BK 85480 @ Cable, Clamp ............
  • Page 84 TO 31R2-2TRC-199-1 This Page Left Blank Intentionally 7-18...

  • Page 85: Figure 7-3. Power Amp Assembly, 15W (Ss-4100853-501)

    TO 31R2-2TRC-199-1 Figure 7-3. Power Amp Assembly, 15W (SS-4100853-501) 7-19...

  • Page 86: Table 7-3. Power Amp Assembly, 15W (Ss-4100853-501)

    TO 31R2-2TRC-199-1 Table 7-3. Power AMP Assembly, 15W (SS-4100853-501) Figure & Description Units per Usable Index No. Part Number CAGE 1 2 3 4 5 6 7 Assy on Code SMR Code SS-4100853-501 23386 Power Amplifier Assy, 15W (ESD) ....... 0001 PAOLDT 7-3-1...

  • Page 87: Section Iii. Numerical Index

    TO 31R2-2TRC-199-1 Section III. NUMERICAL INDEX Part Number Figure & Item Part Number Figure & Item Part Number Figure & Item Number Number Number 2111-440-SS-20 7-2-4 9268-A257-16 7-1-28 MS21919WDG4 7-1-29 275-160-100-000 7-1-49 9286-A194-16AB 7-1-18 MS21919WDG7 7-1-26 275-160-070-000 7-1-44 CPRG223/U-30-XX 7-1-42 MS3212-4 7-2-34 416-1613-001...
  • Page 88 TO 31R2-2TRC-199-1 Part Number Figure & Item Part Number Figure & Item Part Number Figure & Item Number Number Number SS-1600322-503 7-1-33 SS-4100823-502 7-2-27 Z-2212 7-2-45 SS-2400523-1 7-1-3 SS-4100836-501 7-3-3 SS-2400577-1 7-1-27 SS-4100853-501 7-2-1 SS-2400578-1 7-1-24 SS-4100853-501 SS-2500091-501 7-2-12 SS-4100855-501 7-3-1 SS-3100531-502 7-2-23...

  • Page 89: Section Iv. Reference Designation Index

    TO 31R2-2TRC-199-1 Section IV. REFERENCE DESIGNATION INDEX Reference Designator Figure & Item Reference Designator Figure & Item Reference Designator Figure & Item Number Number Number Radio Set AN/TRC-199 7-1-REF 7-2-12 7-1-1 7-2-39 7-1-33 7-2-40 7-1-33 7-2-17 7-1-33 7-2-16 A4,A5 7-1-2...

  • Page 90: Section V. Common Bulk Items List

    TO 31R2-2TRC199-1 Section V. COMMON BULK ITEMS LIST Part Number CAGE Code Description Unit of Measure No 222 50CC 05972 Threadlocking Compound No. 222 (23386/91172) 7-24...

  • Page 91: Chapter 8.0

    TO 31R2-2TRC199-1 CHAPTER 8.0 IRCUIT DIAGRAMS SCOPE. This chapter contains the following diagram: Figure No. Title FO-1 Radio Set AN/TRC-199, Interconnection Diagram 8-1/(8-2 blank)
  • Page 93 TO 31R2-2TRC199-1 FO-1. Radio Set AN/TRC-199, Interconnection Diagram FP-1/(FP-2 blank)
  • Page 95 TO 31R2-2TRC199-1 GLOSSARY Alternating current Automatic level control Antenna ASSY Assembly Celsius (centigrade) Circuit card assembly Controlled cryptographic item Clear Centimeter CTCSS Continuous tone-controlled squelch system CTRL Control Continuous wave Decibels Decibel (isotropic) Decibels relative to a 1/2 wavelength dipole Power in decibels (referenced to 1 milliwatt) Direct current Drawing...
  • Page 97 TO 31R2-2TRC199-1 ALPHABETICAL INDEX Paragraph, Figure Subject or Table Number Antenna Assembly: Description P1-1.2.3 Removal and Replacement Procedures P6-5.1.2 Cables, Interconnecting T2-2 Capabilities and Limitations P1-3, T1-3 Control Panel Assembly (A5): Functional System Operation P5-2.4 Removal/Replacement Procedures P6-5.2.2 Controls and Indicators: P4-2 Diplexer Controls T4-4, F4-4...
  • Page 98 TO 31R2-2TRC199-1 Paragraph, Figure Subject or Table Number Functional Operation of Electronic Circuits Repeater Control CCA (A3) P5-3, F5-2 15 Watt Power Amplifier Assembly (A6) P5-4, F5-3 Functional System(s) Operation P5-2 AC/DC Power Supply (A2) P5-2.10 Antenna System P5-2.8 Control Panel (A5) P5-2.4 Diplexer P5-2.9...
  • Page 99 TO 31R2-2TRC199-1 Paragraph, Figure Subject or Table Number Operating Procedures: Covert Operations P4-6 Equipment Shutdown P4-8 Initial Power-Up and Diplexer Tuning P4-3 Receiver-Transmitters P4-7 Receiving Message P4-4 Transmitting Message P4-5 Operational Checkout: Display Off Control P6.2.2 Fault LED P6-2.5 Power-Up Verification P6-2.1 Receive Tune Mode Verification P6-2.3...
  • Page 100 TO 31R2-2TRC199-1 Paragraph, Figure Subject or Table Number Repeater Control CCA (A3): Functional Operation of Electronic Circuits P5-3 Functional System Operation P5-2.2 Removal/Replacement Procedures P6-5.1.3 Servicing: P6-3 Inspection P6-3.2 Preventive Maintenance P6-3.3 Servicing Intervals P6-3.1, T6-4 Site Preparation P2-2 Support Equipment P1-6, T1-4 Tactical Repeater Assembly: Description...

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