AN-PRC-132_serv_1993.pdf

CECOMDMWR11-5820-11:02 t;(fioi., DEPOTMAINTENANCEJWORKREQUIREMENT INCLUDINGFIEPAIR PARTS AND S,PECIALTOOLS:LIST FOR RADIO SET,ANlPRC.-132 (NSN5820-01-320-8831)(EIC:N/A) This publication is notavailablethrOLlgh theAGpublication centers. This publication is available through US Army Communications-Electronics Command, Fort Monmouth; NJ07703-5007. NOTICE:Reproduction for non-military useofthe informationdi)r illustrations containedin;this.ublicationis not per-mitted without specific approvaloftheUSArmy Communications-ElectronicsCbmmand, Fort Monmouth, NJ07103-5007. OiSTRIBUTIONRESTRICTION: This publication contains,technical information that isforofficial Government use tit-dy.Distribution is limited to US Government Agencies, Requests from outside the US Government for release ofthispublication under the Freedom of Information Act or the Foreign Military Sales program must be made to AM$EL-LC7LM-LT,Fort Monmouth, NJ07703-5007. 1lE:I!._.-il!.,.l:*. ,.,iioi.61pa11ii_. US ARMY COMMUNICATIONS-ELECTRONICS COMMAND aFORTMONtgUERH07703.5007 DATE 1 Sep 93 + 1;:1SAFETY STEPSTOFOLLOW IF SOMEONE 1:.1ISTHEVICTIMOFELECTRICALSHOCK DDO NOT TRY TO PULL OR GRAB THE INDIVIDUAL IFPOSSIBLE, TURN OFF THE ELECTRICAL POWER IiiIIFYOU CANNOT TURNOFFTHE ELECTRICAL l!IPOWER, PULL, PUSH, OR LIFT THE PERSONTO SAFETY USING A DRY WOODEN POLE OR ADRY ROPE OR SOME OTHER INSULATING MATERIAL IISEND FOR HELPASSOON AS POSSIBLE RAFTER THE INJURED PERSON IS FREEOF I!ICONTACT WITH THE SOURCE OF ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMMEDIATELY START ARTIFICIAL RRESUSCITATION DMWR 11-5820-1102 WARNINGSANDCAUTIONS WARNING RADIOFREQUENCY RADIATION HAZARD DONOT STAND IN THE DIRECT PATH OF THE ANTENNA WHEN THE POWERISON! DO NOT WORKONTHE WAVEGUIDES WHILE THE POWERISONII Radiofrequency electromagnetic radiationcancause fatal internal burns. It can literally cook internal organs and flesh.Ifyoufeel the slightest warming effect while near this equipment, MOVE AWAY QUICKLY! a TM11-5820-1102 WARNING HIGHVOLTAGE is usedinthe operation of this equipment. DEATH ONCONTACT may resultifpersonnel failtoobserve safety precautions Never work on electronic equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment and who is competent in administering first aid.When the technicians are aided by operators, they must be warned about dangerous areas. Whenever possible, the power supply to the equipment mustbeshut off before beginning work on the equipment. Take particular care to ground every capacitor likely to hold a dangerous potential. When working inside the equipment. after the power has been turned off. always ground every part before touchingit. Becareful not to contact high-voltage connections or115voltacinput connections when installing,or operating this equipment. Whenever the nature of the operation permits. keep one hand away from the eqUipment to reduce the hazard of current flowing through the body. Warning: Donotbemisledbythe termlowvoltage.Potentials aslowas 50voltsmaycause deathunderadverseconditions. For Artificial Respiration, refer toFM21-11. b DMWR11-5820-1102 WARNING RF VOLTAGE WARNING Exposed metal transceiver parts can assume an RF potentialtoground when antenna is tuned without grounding transceiver.Toavoid RF bums, tie transceiver GND stud to ground. WARNING DO NOT SERVICE OR ADJUST ALONE Do not attempt initial serviceoradjustment unless another person capable of rendering first aid and resuscitation is present. WARNING REMOVE ALL WATCHES, RINGS, NECKLACES, OR OTHER METAL ADORNMENTS FROM BODY Dangerous voltages are-present in the equipment and CAN RESULT IN SEVERE BURNS, INJURY,orEVEN DEATH if they come in contact with jewelry. WARNING GROUND THE SYSTEM To minimize shock hazard, the equipment chassis must be connected to an electrical ground. WARNING KEEP AWAY FROM LIVE CIRCUITS The antenna is a source of electrical and radio frequency energy. NEVER TOUCH THE ANTENNA WHEN RADIO IS IN USE. An RF burn may occur as a result of contact with an active antenna system. WARNING ACCIDENTAL CONTACT WITHDCLINE VOLTAGE Use caution when performing equipment maintenance. Accidental contact withdeline voltage can cause injury. c TM11-5820-1102 WARNING DO NOT REMOVE OR REINSERT MODULES OR PCBs WITHOUT REMOVING PRIMARY POWER FROM EQUIPMENT To prevent the possibility of damaging the equipment dUring maintenance. always remove primary power from the transceiver when removingor reinserting modules. PCBs.orother plugInassemblies. CAUTION The ANPRC-132 contains parts and assemblies susceptible to damageby electrostatic discharge (ESD). Use good shop practice to prevent such damage in accordance withDODSTD-1686 and MIL-HDBK-263. WARNING DO NOT SUBSTITUTE PARTS OR MODIFY SYSTEM Donot substitute partsormodify system In any manor. WARNING BERYLLIUM OXIDE WARNING Beryllium oxide is used asanelectrical insulatorlthermal conductor in some electronic components contained within the equipment. Beryllium oxide easily goes to powder when crushed. and in this form is a toxic health hazard. Avoid crushing components which may contain beryllium oxide.Inthe event that suspected beryllium oxide powderIsInhaledor swallowed, obtain medical assistance immediately. Dispose of items containing beryllium oxide materials in accordance with standardArmyprocedures. WARNING A13 POWER AMPLIFIER WARNING Circuit card A13contains BERYLLIUM OXIDE (BeO) CERAMICS. The dust or fumes from BERYLLIUM OXIDE CERAMICS are HIGHLY TOXIC and breathing them can result in serious personal injuryorDEATH. For logical guidance/assistance on disposal of unserviceable A13 circuit card. contact yourservicing Defense Reutilization and Marketing Office (DRMO). d DMWR 11-5820-1102 WARNING A1 PROCESSOR BOARD WARNING Processor board A1 contains a lithium battery. The lithium battery contains flammable organic materials. Incorrect handling may cause an explosion. Donot short battery leads together in any fashion.Donot expose battery to extreme heat for more than five seconds.Donot Immerse battery in waterorcleaning solution. Ensure battery polarity Is correct. Do not strike ordrop battery. A lithium-sulfur dioxide (LiS02) battery used with the AN/PRC-132 contains pressurized sulphur dioxide (S02) gas. The gasIstoxic, and the battery MUST NOT be handled in any way that may cause It to rupture. DONOT heat, short circuit, crush, punctureordisassemble batteries. DONOT use any battery which shows sign of damage, bulgingorleaking. DONOT testBA-5590/l!battery for capacity. DONOT rechargeBA-5590/Ubatteries. DONOT dispose of BA-5590/U batteries with ordinary trash. Turn them over to Defense Reutilization and Marketing Officeordispose in accordance with standard Army procedures. DONOT attempt to transmit while charging the BB-590 battery. DONOT store batteries in unused eqUipment for more than 30 days. WARNING BATTERY HEAT WARNING If battery compartment becomes hot to the touch, if a hissing sound is heard (i.e., battery venting), or smell irritating sulfur dioxide gas, IMMEDIATELY turn eqUipment off and leave the area. 1.Allow eqUipment to cool at least one hour. 2.Remove and replace battery only after the equipment has cooled to the touch. 3.Ifthere is a safety incident, or if a hazard exists, notify Safety Officer and file a Quality Deficiency Report,SF368, and notify the CECOM Safety Office, Ft. Monmouth,NJatDSN995-3112. e f TM11-5820-1102 WARNING HALON FIRE EXTINGUISHER WARNING DO NOT use a halon type fire extinguisher on a BA-5590/U battery. In the event of a fire involving lithium batteries, rapid coolingofthe batteries is important. Flood eqUipment with wateroruse a carbon dioxide (C02)extinguisher. Control of eqUipment fire, and cooling, may prevent the exposure of lithium metal. In the event that the lithium metal becomes involved the fire, use a graphite based Class0fire extinguisher such as Lith-XorMet-L-X, as the unit contains lithium, whichisnot extinguishable by CO2 WARNING Use approved personal protective equipment (goggleslfaceshield) when using canned/compressed air. Maximum allowableairpressureforcleaning operations is restricted to less than 30 PSI. Provide protection from flying particles when using compressed air. Do not direct airstream toward self orother personnel. Depot Maintenance Work Requirement No.11-5820-1102 DMWR 11-5820-1102 USARMY COMMUNICATIONS-ELECTRONICS COMMAND Fort Monmouth, NJ, 1Sep93 DEPOT MAINTENANCE WORK REQUIREMENT INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR RADIO SET, AN/PRe-132 (NSN 5820-01-320-8831) (EIC: N/A) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual.Ifyou find any mistakes,orifyou know of awayto improve the procedures, please let us know.Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms) or DA From 2028-2 located in backofthis manual direct to: Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL- LC-LM-LT, Fort Monmouth, New JerseyOn03-5007. Ineither case a reply will be furnished direct to you. TABLE OF CONTENTS Chapter Page INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . .1-1 SectionI.GENERAL1-1 1-1SCOPE.1-1 1-2 CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS1-1 1-3 FORMS, RECORDS AND REPORTS1-1 1-4 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATION (EIRs)1-1 1-5 ENGINEERING CHANGE PROPOSALS (ECPs)1-1 1-6 DEVIATIONS AND EXCEPTIONS1-2 SectionII.DESCRIPTION DATA PLATES AND DATA1-2 1-7DESCRiPTION. . . . . . . . . . . . . . . . . . . . .1-2 1-8 DATA PLATES1-2 1-9 DATA1-4 Section III. MOBILIZATION REQUIREMENTS1-5 1-10 GENERAL1-5 2TECHNICAL SUPPORT REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 SectionI.SUPPORT ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1FACiLITIES2-1 2-2 TOOLS AND EQUIPMENT2-1 DMWR 11-5820-1102 TABLEOFCONTENTS (CONT.) ChapterPage Section II. FINITE LIFE ITEMS, TIME BETWEEN OVERHAUL (TBO) ITEMS, PARTS AND MODIFICATIONS,.,2-7 2-3 FINITE LIFE ITEMS AND TIME BETWEEN OVERHAUL (TBO) ITEMS, 2-7 2-4 MANDATORY REPLACEMENT PARTS2-7 2-5 REPAIRPARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 2-6 MODIFICATIONS2-7 Section III. STANDARDS2-7 2-7 QUALITY OF MATERIAL2-7 2-8 ELECTROMAGNETIC COMPATIBILITY STANDARDS,2-7 2-9 ELECTROSTATIC DISCHARGE (ESD)2-7 2-10 NUCLEAR HARDNESS2-8 3PRESHOP ANALYSIS OPERATIONS3-1 SectionI.TEST AND ANALYSIS STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1PURPOSE3-1 3-2 GENERAL3-1 Section II. PRESHOP ANALYSIS CHECKLIST3-3 3-3 GENERAL3-3 4OVERHAUL OPERATIONS4-1 SectionI.GENERAL REQUIREMENTS4-1 4-1GENERAL ARRANGEMENT4-1 4-2 REFERENCES4-1 4-3 SAFETY4-1 4-4 IN-PROCESS INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 4-5PROCESSES.4-2 Section II. AN/PRC-132 RADIO SET4-2 4-6 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 4-7 REMOVAL4-2 4-8 DISASSEMBLY4-2 4-9 CLEANING4-4 4-10 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-11MANDATORY REPLACEMENTPARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-12 REPAIR/REPLACE4-4 4-13 RECLAMATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-14 ASSEMBLY4-4 4-15 LUBRiCATION4-5 4-16 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4-17 PAINTING AND MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4-18 FINAL ASSEMBLY/INSTALLATION4-5 ii DMWR 11-5820-1102 TABLEOFCONTENTS(CONT.) Chapter Page SectionIII.RT-1648/PRC-132 RADIO RECEIVER-TRANSMITIER. . . . . . . . . . . . . . .45 4-19 GENERAL45 4-20 REMOVAL.45 4-21DISASSEMBLY4-6 4-22 CLEANING46 4-23 INSPECTION. .47 4-24 MANDATORY REPLACEMENT PARTS4-7 4-25REPAIR/REPLACE.4-7 4-26 RECLAMATION,4-7 4-27 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 4-28 LUBRICATION,4-7 4-29 TESTING,4-7 4-30 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 4-31PAINTING AND MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 4-32 FINAL ASSEMBLYIINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Section IV. SOHFRAD RADIO TRANSCEIVER4-8 4-33 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 4-34 REMOVAL,4-8 4-35 DISASSEMBLY4-9 4-36 CLEANING4-9 4-37 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 4-38 MANDATORY REPLACEMENT PARTS4-10 4-39REPAIR/REPLACE.4-10 4-40 RECLAMATION4-10 4-41ASSEMBLY4-10 4-42 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4-43 TESTING4-11 4-44 PAINTING, REFINISHING AND MARKING4-11 4-45 FINAL ASSEMBLY/INSTALLATION4-11 SectionV.CONTROL PANEL COVER ASSEMBLY4-11 446 GENERAL4-11 4-47 REMOVAL4-11 4-48 DISASSEMBLY4-11 4-49 CLEANING4-11 4-50 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4-51MANDATORY REPLACEMENT PARTS4-12 4-52 REPAIR/REPLACE4-12 4-53 RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4-54 ASSEMBLY4-13 4-55 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13 4-56 PAINTING AND MARKING4-13 4-57 FINAL ASSEMBLYIINSTALLATION4-13 iii DMWR11-5820-1102 TABLE OF CONTENTS (CaNT.) ChapterPage SectionVI.REARPANEL COVER ASSEMBLY4-13 4-58 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4-59REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4-60DiSASSEMBLy4-13 4-61CLEANING4-13 4-62 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 4-63 MANDATORY REPLACEMENT PARTS4-14 4-64 REPAIR/REPLACE4-14 4-65 RECLA