ARMY TM 11-5820-882-23

MARINE CORPS TM 06827A-23/2

TECHNICAL MANUAL

ORGANIZATIONAL AND DIRECT SUPPORT

MAINTENANCE MANUAL

RADIO SET AN/PRC-68

(NSN 5820-01-079-9260)

This copy is a reprint which includes current

pages from Changes 1

DEPARTMENTS OF THE ARMY AND THE NAVY,

19 JANUARY 1981
WARNING
 TM 11-5820-882-23/TM 06827A-23/2
Cl

CHANGE) HEADQUARTERS DEPARTMENT OF THE ARMY

) HEADQUARTERS US MARINE CORPS
No. 1 ) Washington, DC,30 June 1981

ORGANIZATIONAL AND DIRECT SUPPORT

MAINTENANCE MANUAL
RADIO SET AN/PRC-68
(NSN 5820-01-079-9260)

TM 11-5820-882-23/TM 06827A-23/2, 19 January 1981, is changed as follows:

1. New or changed material is indicated by a vertical bar in the margin.

2. Remove and insert pages as indicated in the page list below:

Remove Insert

i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i and ii
1-1and 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1and 1-2
2-3 through 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 through 2-10
3-15 and 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 and 3-16
A-1 and A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 and A-2
B-3 through B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 through B-5

3. File this change sheet in front of the manual for reference purposes.

By Order of the Secretary of the Army:

EDWARD C. MEYER
General, United States Army
Official: Chief of Staff
ROBERT M. JOYCE
Brigadier General, United States Army
The Adjutant General

DISTRIBUTION:
To redistributed in accordance with Special List.
 TM 11-5820-882-23
TM 06827A-23/2

TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY

No. 11-5820-882-23 HEADQUARTERS, US MARINE CORPS
No. 06827A-23/2 W ASHINGTON , DC 19 January 1981

ORGANIZATIONAL AND DIRECT SUPPORT

MAINTENANCE MANUAL

RADIO SET AN/PRC-68

(NSN 5820-01-079-9260)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You con help improve this manual. If you find any mistakes or if you know
of a way to improve the procedures, please let us know. Mail your letter, or
DA Form 2028 (Recommended Changes to Publications and Blank Forms), or
DA Form 2028-2 located in back of this manual direct to: Commander, US
Army Communications-Electronics Command, ATTN: DRSEL-ME-MQ, Fort
Monmouth, New Jersey 07703. Marine Corps units should submit a NAVMC
10772. A reply will be furnished to you.

Paragraph Page
HOW TO USE THIS MANUAL ---------------------------------------------- 0-1
CHAPTER 1. INTRODUCTION
SECTION I. General information --------------------------------------------- 1-1 1-1
II. Equipment description and data ------------------------------ 1-6 1-1
III. Principles of operation ------------------------------------------ 1-9 1-2
CHAPTER 2. ORGANIZATIONAL MAINTENANCE
SECTION I. Repair parts, special tools, TMDE, and support
equipment ------------------------------------------------------- 2-1 2-1
II. service upon receipt --------------------------------------------- 2-4 2-2
III. Preventive maintenance checks and services
(PMCS)---------------------------------------------------------- 2-9 2-8
IV. Troubleshooting -------------------------------------------------- 2-10 2-10
V. Maintenance procedures ---------------------------------------- 2-13 2-13
VI. Preparation for storage or shipment ------------------------- 2-19 2-14
CHAPTER 3. DIRECT SUPPORT MAINTENANCE
INSTRUCTIONS
SECTION I. Repair parts, special tools, TMDE, and support
equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1
II. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-3
III. Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3-15
IV. Principles of operation----. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-17
APPEND IX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPEND IX B MAINTENANCE ALLOCATION
SECTION I. Introduction------------------------------------------------------------------------- B-1
II. Maintenance allocation chart for Radio set
AN/PRC-68--------------------------------------------------------------------- B-3
III. Tool and test equipment requirements for Radio
set AN/PRC-68---------------------------------------------------------------- B-4
IV. Remarks ----------------------------------------------------------------------------- B-5

Change 1 i
TM 11-5820-882-23/TM 06827A-23/2

Paragraph Page
APPENDIX C EXPENDABLE SUPPLIES AND MATERIALS
LIST
SECTION I Intrduction ------------------------------------------------------------------------- C-1
II Expendable supplies and materials list ----------------------------------------- C-2
INDEX ----------------------------- ------------------------------------ ------------------- ------ I-1

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Radio Set AN/PRC-68------------------------------------------------------------------------- 1-0

1-2 Radio Set, Major Components ---------------------------------------------------------------- 1-3
1-3 Receiver Operation, Simplified Block Diagram ------------------------------------------- 1-4
1-4 Transmitter Operation, Simplified Block Diagram ---------------------------------------- 1-4
2-1 Radio Set Component Locations, Front View --------------------------------------------- 2-1
2-2 Radio Set Component Locations, Rear View ---------------------------------------------- 2-2
2-3 Battery Test --------------------------------------------------------------------------------------- 2-10
2-4 Transmitter Power Output Test --------------------------------------------------------------- 2-11
2-5 Sensitivity Test ------------------------------------------------------------------------------------ 2-11
2-6 Radio Set Packaging Diagram---------------------------------------------------------------- 2-15
3-1 Maintenance Kit MK-()/PRC-68----------------------------------------------------------- 3-1
3-2 Receiver Troubleshooting Test Setup -------------------------------------------------------- 3-2
3-3 Transmitter Troubleshooting Test Setup --------------------------------------------------- 3-3
3-4 Receiver Fault Isolation Test Setup ---------------------------------------------------------- 3-7
3-5 Receiver Fault Isolation Test Setup (Alternate Procedure)----------------------------- 3-7
3-6 Transmitter Fault Isolation Test Setup ------------------------------------------------------ 3-8
3-7 Module Socket Test Point Location, Front ------------------------------------------------ 3-8
3-8 Module Socket Test Point (E Numbers) Location, Front ------------------------------- 3-9
3-9 Module Socket Test Point Location, Rear-------------------------------------------------- 3-9
3-10 Module Removal --------------------------------------------------------------------------------- 3-16
3-11 Pin Straightening Procedure ------------------------------------------------------------------- 3-17
FO-1 Radio Set Block Diagram (2 Sheets)---------------------------------------------------------

LIST OF TABLES

Number Title Page

2-1 Frequency Chart (Printed on battery)------------------------------------------------------- 2-3
2-2 Frequency Chart (Switch Code)--------------------------------------------------------------- 2-4
2-3 Organizational Preventive Maintenance Checks and Services -------------------------- 2-10
2-4 Troubleshooting Procedures ------------------------------------------------------------------ 2-12
3-1 Maintenance Kit MK-( )/PRC-68 Description ------------------------------------------- 3-2
3-2 Radio Set Minimum Performance Test ----------------------------------------------------- 3-4
3-3 Fault Isolation Test ------------------------------------------------------------------------------ 3-11
3-4 Synthesizer Test Voltages and Frequencies ------------------------------------------------- 3-15

ii
 TM 11-5820-882-23/TM 06827A-23/2

HOW TO USE THIS MANUAL

● Army maintenance levels and related Marine Corps maintenance levels are as
follows:
Operator/Crew Echelon 1 Maintenance
Organizational Echelon 2 Maintenance
Direct Support Echelon 3 Maintenance
General Support Echelon 4 Maintenance
Depot Echelon 5 Maintenance
● This manual contains all the necessary information to service Radio Set AN/
PRC-68 at the organizational (echelon 2) and direct (echelon 3) support
maintenance levels.
● Use the MAC (located in Appx. B) to determine the proper maintenance levels.
● To service Radio Set AN/PRC-68 at organizational (echelon 2) maintenance
level, consult chapters 1 and 2.
● To service Radio Set AN/PRC-68 at direct support (echelon 3) maintenance
level, consult chapters 1 and 3.

0-1
TM 11-5820-882-23/TM 06827A-23/2

Figure 1-1. Radio Set AN/PRC-68.

1-0
 TM11-5820-882-23/TM 06827A-23/2

CHAPTER 1
INTRODUCTION

Section I. GENERAL INFORMATION

1-1. Scope 1-4. Preparation for Storage or Shipment
This manual describes Radio Set AN/PRC-68 (fig. 1-1) Refer to Chapter 2, section VI for administrative
and provides instructions for organizational and direct storage instructions.
support maintenance. Maintenance allocation chart
(MAC) is included in appendix B. 1-5. Reporting Equipment Improvement
Recommendations (EIR)
1-2. Maintenance Forms, Records, and
EIR can and must be submitted by anyone who is aware
Reports
of an unsatisfactory condition with the equipment
Department of the Army forms and procedures used for design or use. It is not necessary to show a new design or
equipment maintenance will be those prescribed by TM
list a better way to perform a procedure, just simply tell
38-750. The Army Maintenance Management System.
Marine Corps units should refer to the current edition why the design is unfavorable or why a procedure is dif-
of TM 4700-15/1. ficult. EIR maybe submitted on standard Form (SF) 368
(Quality Deficiency Report). Mail directly to Comman-
1-3. Destruction of Army Materiel to Pre- er, US Army Communications - Electronics
vent Enemy Use Comnand, ATTN: DRSEL-ME- MQ, Fort
Demolition and destruction of electronic equipment will Monmouth, NJ 07703. Marine Corps units mail to Com-
be under the direction of the commander and in accor- manding Gereral, Marine Corps Logistics Base (P840),
dance with TM 750-244-2. Albany, GA 31704. A reply will be furnished to you.

Section II. EQUIPMENT DESCRIPTION AND DATA

1-6. Equipment Characteristics, Capa- 1-7. Location and Description of Major
bilities, and Features Components
Radio Set AN/PRC-68 (radio set) is a hand-held Figure 1-2 shows the major components of the radio
receiver-transmitter that provides ground-to-ground set. The unit consists of: the rt unit, which contains the
voice communications in the 30 megahertz (MHz) to 79.
eight modules and all necessary operating controls and
95 MHz band. The unit is capable of secure speech
operation when it is used with the secure voice module connectors; the module cover, held by two captive
(svm). The radio set can be used with a short or long screws to the chassis frame, which also holds the fre-
antenna, with a standard military handset such as H- quency changing and alignment tool; the battery, which
138/U, H-189/U or H-250/U, or with its built-in speak- snaps onto mating connectors on chassis frame; the bat-
er-microphone. tery case, held on by two latches; and the short antenna.
1-8. Equipment Data
GENERAL

Frequency -------------------------------------------------30.00 MHz—79.95 Long antenna ------------------------------------------ 1 mile ( 1.6 Kilo-

MHz meters)
Available channels--------------------------------------1000 Operating temperature range ------------------------- - 40°F to + 159°F
Channel spacing -----------------------------------------50 kHz (-40°C to +
Preset channels-------------------------------------------10 65°C)
Preset channel spacing----------------------------------200 kHz Weight (including battery and antenna,
Modulation ------------------------------------------ frequency modula- no headset)---------------------------------------------- 40oz. (1.30 kg)
tion (fro) Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 8.35 in (212.0 mm)
Range x 3.80 in (96.0
Short antenna -----------------------------------------330 yards (300 mm)
meters) x 1.52 in (38.6
mm)

Change 1 1-1
TM 11-5820-882-23/TM 06827A-23/2

Frequency stability -------------------------------------- ± 0.005 percent Sensitivity- . . . . . . . . . . . .. . . .0.5 uV for 10 dB

Spurious and harmonics radiation--------. ----------50 dB below rf car- SINAD*
rier level Squelch sensitivity ---------------------------------------0.5 uV
Modulation limiting ------------------------------------- ± 15 kHz deviation Selectivity: 6 dB down------------------------------bandwidth greater
(maximum) than ± 15 kHz
Squelch tone (2.5—3.5 kHz deviation) -------------- 148 to 152 Hz 60 dB down------------------------------bandwidth less than
± 50 kHz
RECEIVER Response to spurious signals -------------------------- – 60 dB
Frequency stability -------------------------------------- ± 0.005 percent
Audio output -------------- -------------------------------less than 10 percent
Adjacent channel rejection ---------------------------- – 60 dB
distortion at 20
Image rejection ------------------------------------------- – 40 dB
m W
● SINAD = Signal + Noise + Distortion

Noise + Distortion

Section III. PRINCIPLES OF OPERATION

1-9. General Information When the radio set is in the transmit mode (unit turned
The radio set contains eight plug-in modules which pro- on and PUSH TO TALK switch depressed), the speaker/
vide all the circuitry necessary for receive and transmit microphone is used as a microphone to apply a voice
operation. These operations can be broken down into signal to the modulator/mixer. Here the signal is fre-
two basic functions, described below. quency modulated on a carrier singal determined by the
synthesizer and voltage controlled oscillator (controlled
1-10. Receiver Opration (fig. 1-3) by the frequency select switches). The output of the
When the radio set is turned on (PWR OFF/ON/ modulator/mixer goes to the transmitter module where
SQUELCH DIS switch in the ON position), the unit is it is amplified to 1 watt minimum. The antenna coupler
in the receive mode (squelch is on, no receiver noise pre- matches the transmitter circuit impedance to the anten-
sent). Signals entering the antenna are routed through
na (long or short) for maximum power transfer.
the antenna coupler to the converter stage. The frequen-
cy synthesizer and voltage controlled oscillator (vco) 1-12. Secure Voice Operation
provide a mixer frequency for the coverter stage. This
Secure voice operation may be utilized on the radio set
mixer signal is determined by the setting of the frequen-
by connecting the secure voice module (svm) to the bot-
cy select switches (three located on the synthesizer
module and one located on the top panel of the radio tom of the rt unit. The battery case and battery must be
set). After the incoming signal is converted to a 12.0 removed first. The svm connector (located next to the
MHz signal, it is routed to the filter/i-f module for battery connector) has a small black shorting plug in-
amplification and a second conversion to 6.5 MHz and stalled. This plug must be removed to install the svm in
then to the i-f/a-f module. The intermediate frequency its place. If the radio set is not being used with secure
and audio frequency (i-f/a-f) module detects and voice equipment, the shorting plug must be installed in
amplifies the signal and connects it to the built-in the svm connector for normal set operation. The re-
speaker/microphone or external handset. tainer (attached to SVM plug) must be wrapped around
the connector before installation of plug to prevent
1-11. Transmitter Operation (fig.1-4) damage to retainer line.

1-2
 TM 11-5820-882-23/TM 06827A-23/2

Figure 1-2. Radio set, major components.

1-3
TM 11-5820-882-23/TM 06827A-23/2

Figure 1-3. Receiver operation, simplified block diagram.

Figure 1-4. Transmitter operation simplified, block diagram.

1-4
 TM 11-5820-882-23/TM 06827A-23/2

CHAPTER 2
ORGANIZATIONAL MAINTENANCE

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

2-1. Common Tools and Equipment for tools and equipment to be used at the organizational
For authorized common tools and equipment refer to maintenance level. Refer to applicable T/F (table of
the Modified Table of Organization and Equipment equipment) for Marine Corps units.
(MTOE) applicable to your unit. 2-3. Repair Parts
2-2. Special Tools, TMDE, and Support Repair parts are listed in the Repair Parts and Special
Tools List (TM 11-5820-882-23P) covering organiza-
Equipment
tional and direct support maintenance for this equip-
Refer to the maintenance allocation chart (Appx. B), ment.

Figure 2-1. Radio set component locations, front view.

2-1
TM 11-5820-882-23/TM 06827A-23/2

Section II. SERVICE UPON RECEIPT

2-4. Checking Unpacked Equipment minals.
a. Inspect the equipment for damage incurred dur- c. Remove module cover by turning the two captive
ing shipment. If the equipment has been damaged, screws counterclockwise (located on bottom of module
report the damage on DD Form 6, Packaging Improve- cover).
ment Report. NOTE
b. Check the equipment against the packing slip to Make sure that the svm shorting plug (located
see if the shipment is complete. Report all discrepancies next to the battery terminal connector in the rt
in accordance with the instructions of TM 38-750. unit, fig. 2–2), is installed and in good condi-
Marine Corps units should refer to current edition of tion. The radio set will not work unless the
TM 4700-15/1. shorting plug or svm is installed.
c. Check DA PAM 310-7 to see whether there are
any modification work orders pertaining to this equip- 2-6. Reassembly Instructions
ment. To reassemble the radio set, perform the following:
a. Apply a thin coat of silicone grease (NSN 6850-
2-5. Disassembly Instructions
00-177-5094) to top edge of the module cover. Slide
To disassemble the radio set for battery replacement or module cover over rt unit and secure with the two cap-
channel changing and alignment (fig, 1-2), perform the tive screws located on the bottom of the cover (turn
following: clockwise),
a. Unfasten latches on battery case and remove bat- b. Attach battery to battery connector on rt unit,
tery case. (Handle case carefully as damaged case will c. Apply a thin coat of silicone grease to the top edge
not seal properly). of the battery case and attach battery case and secure
b. Remove battery by disconnecting snap ter- with the two latches,

Figure 2-2. Radio set component locations, rear view.

2-2
2-7. Frequency Changing and Align- coupler) for maximum (peak) indication on the test Set
meter.
ment Procedures. (11) Release PUSH TO TALK switch.
The ten position (0 through 9) CHAN switch on the (12) With alignment tool, adjust squelch (SQ
front panel provides ten preset sequential channels spac- ADJ) control on i-f/a-f module counterclockwise until
ed 200 kHz apart over a 2 MHz bandwidth. Any portion noise is heard.
of the 30.00 MHz to 79.95 MHz range can be selected by (13) Slowly turn SQ ADJ control clockwise until
changing the three switches (A, B, and D) on the syn- receiver quiets, then advance control one full turn
thesizer module and the CHAN switch on the top panel clockwise.
of the radio set. (Refer to table 2-1 or table 2-2 for fre- (14) Return CHAN switch to channel originally
quencies and their respective switch settings). Whenever selected.
the frequency of a radio set is changed (excluding the (15) Set PWR OFF/ON/SQUELCH DIS switch
ten preset channels), the transmitter module and anten- to PWR OFF.
na coupler module must be realigned to ensure proper (16) Remove battery.
matching and maximum power transfer of the radio set (17) Reinstall alignment tool on module cover.
to the antenna. (18) Reassemble unit (para 2-6).
a. Changing Frequency. To change the frequency c. Frequency Chart (Battery). To use the chart in
of the radio set, perform the following: table 2-1, select the frequency value for each synthesizer
(1) Disassemble unit (para 2-5). switch in turn, that comes closest to (but not over) the
(2) refer to figure 2-2. Set synthesizer switches, desired frequency. Then add the values of the switches
with the enclosed alignment tool (or JFD 5284 align- (A, B, CHAN (C), and D) to determine the operating
ment tool), and the top panel CHAN switch, to the new frequency. By using the proper combination, any fre-
frequency using table 2-1 or table 2-2, as applicable. quency between 30.00 to 79.95 MHz (in 50 MHz steps)
NOTE may be selected.
The frequency chart shown in table 2-1 is
printed on the battery. Table 2-2 is a complete
listing of all frequencies including degraded
(low sensitivity) channels.
(3) Set the transmitter switch and antenna coupler
switch (fig. 2–1) with the enclosed alignment tool to the
same position as switch A on the synthesizer module.
(4) Connect battery.
b. Alignment. After the frequency of the radio set
has been changed, perform the following procedures for
Table 2-1. Frequency Chart (Printed on Battery)
radio set alignment (fig. 2-1 ):
(1) Install antenna (either short or long).
(2) Set CHAN switch to 5.
(3) Preset Cl on the transmitter module fully
clockwise (use enclosed alignment tool of JFD 5284).
(4) Set PWR OFF/ON/SQUELCH DIS switch to
ON.
(5) Press push-to-tune switch (on side of radio
set) and adjust VOL control for comfortable level.
(6) Using the alignment tool, adjust C1 on the
transmitter module counterclockwise for the lowest
tone.
(7) Release push-to-tune switch.
(8) The antenna coupler adjustment (L1) must be
made using Test Set TS–3354/PRC-68 (test set),
(a) Remove cover from test set.
(b) Install test set antenna. d. Frequency Chart (Switch Code). T h e f o l l o w i n g
(c) Set FUNCTION switch to FSM position. charts in table 2-2 may be used to determine an
(9) Hold radio set so the antenna is approximately operating frequency from the synthesizer switch codes
6 to 24 inches from FSM antenna on test set. or the synthesizer switch codes from a known frequen-
(10) Press PUST TO TALK switch on radio set cy. (Each chart covers a 2 MHz band). To find the
and use alignment tool to adjust L1 (located on antenna

Change 1 2-3
 TM 11-5820-882-23/TM 06827A-23/2

operating frequency (in MHz) from the switch codes, To find the synthesizer switch codes when the
find the numbers that correspond to the A, B, CHAN frequency (in MHz) is known, find the frequency in the
and D positions. chart and read off the A, B, CHAN, and D switch
codes.
Example: Switch code is 3412, where: Example: Frequency is 53.15 MHz
A = 3
(1) Find the chart which contains the fre-
B = 4
quency.
CHAN = 1
(2) Read the upper left hand comer codes (A,
D = 2
B,) first (2, 6).
(1) Find the chart which has A = 3 and B = 4 at
(3) Go to the CHAN column and locate the
the top left hand corner.
number that corresponds to frequency (5).
(2) Next locate 1 in the CHAN column.
(3) Read across until you come to the frequency (4) Read the number in the D column that cor-
number under the 2 in the D column. responds to the frequency (3).
(4) Answer should be 62.30 MHz. (5) The synthesizer switch code is 2653.

Table 2-2. Frequency Chart

(Switch Code)

● See Notes at foot of table.

2-4 Change 1
 TM 11-5820-882-23/TM 06827A-23/2

Table 2-2. Frequency Chart—Continued

(Switch Code)

Change 1 2-5
 TM 5820-882-23/TM 06827A-23/2

Table 2-2. Frequency Chart—Continued

(Switch Code)

2-6 Change 1
 TM 11-5820-882-23/TM 06827A-23/2

Table 2-2. Frequency Chart-Continued

(Switch Code)

Change 1 2-7
TM 11-5820-882-23/TM 06827A-23/2

Table 2-2. Frequency Chart—Continued

(Switch Code)

2-8 Change 1
 TM 11-5820-882-23/TM 06827A-23/2

Table 2-2. Frequency Chart—Continued

(Switch Code)

Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

WARNINGS AND CAUTIONS.
2-8. General
To insure that the radio set is always ready for opera- WARNING
tion, it must be inspected systematically so that defects Adequate ventilation should be provided while
may be discovered and corrected before they result in using TRICHLOROTRIFLUOROETHANE.
serious damage or failure. Organizational preventive Prolonged breathing of vapor should be avoid-
maintenance procedures are designed to help maintain
ed. The solvent should not be used near heat or
equipment in serviceable condition. They include what
open flames; the products of decomposition
items should be checked and how to check them. These
are toxic and irritating. Since TRICHLORO-
checks and services are to be made at specific (W) week-
TRIFLUOROETHANE dissolves natural oils,
ly, (M) monthly, (Q) quarterly, (S) semiannually, and
(A) annual intervals. prolonged contact with skin should be avoid-
ed. When necessary, use gloves which the sol-
2-9. PMCS Table vent cannot penetrate. If the solvent is taken
Table 2-3 describes the organizational preventive internally, consult a physician immediately.
maintenance checks and services for the radio set. Compressed air is dangerous and can cause
Routine checks like CLEANING, DUSTING, WASH- serious bodily harm if protective means or
ING, CHECKING FOR FRAYED CABLES, STOW- methods are not observed to prevent a chip or
ING ITEMS NOT IN USE, COVERING UNUSED particle (of whatever size) from being blown into
RECEPTACLES AND CHECKING FOR LOOSE the eyes or unbroken skin of the operator or
NUTS AND BOLTS are not listed as PMCS checks. other personnel. Compressed air shall not be
They are things that you should do anytime you see they used for cleaning purposes except where reduc-
must be done. If you find a routine check like one of ed to less than 30 p.s.i.g. and then only with
those listed, in your PMCS, it was listed because other effective chip guarding and personel protective
operators reported problems with this item. equipment. Do no use compressed air to dry
WHEN YOU ARE DOING ANY PMCS OR parts when trichlorotrifluoroethan has been
ROUTINE CHECKS, KEEP IN MIND THE used.

Change 1 2-9
TM 11-5820-882-23/TM 06827A-23/2

Table 2-3. Organizational Preventive Maintenance Checks and Services

Section IV. TROUBLESHOOTING

malfunction is still not located, higher level trouble-
2-10. Visual Inspection

2-11. Troubleshooting Procedures 2-12. Test Equipment Required

If visual inspection does not locate the trouble, consult Test Set TS-3354/PRC-68 (test set) is used to trouble-
troubleshooting table 2-4. Use the applicable section of shoot the radio set. Refer to figures 2-3, 2-4, and 2-5
this table as determined by the malfunction, If the for test equipment hookups.

Figure 2-3. Battery test.

2-10
 TM 11-5820-882-23/TM 06827A-23/2

Figure 2-4. Transmitter power output test.

Figure 2-5. Sensitivity test.

2-11
TM 11-5820-882-23/TM 06827A-23/2

Table 2-4. Troubleshooting Procedures

fig. 2-3 para 2-18

para 2-17

fig. 2-2
paragraph 2-7

para 2-5
figure 2-4

para 2-7
fig 2-1

para 2-7
para 2-6

para 2-7

para 2-5
figure 2-5

para 2-7
fig. 2-1

2-12
 TM 11-5820-882-23/TM 06827A-23/2

Table 2-4. Troubleshooting Procedures—Continued

para 2-7 para 2-6

Section V. MAINTENANCE PROCEDURES

2-13. General
Maintenance procedures at the organizational level for Remove rust and corrosion from metal surfaces by
the radio set are limited to cleaning, painting, and lightly sanding them with fine sandpaper, item 4, App.
replacement of broken external parts (knobs and anten- C. Brush two thin coats of paint on the bare metal to
na) and battery replacement. protect from further corrosion, items 3 and 7, App. C.
Refer to SB 11-573 and 43-0118.
2-14. Cleaning
Inspect the exteriors of the radio set. The exterior sur- 2-16. Knob Replacement
faces should be clean, free from dust, dirt, grease and The three knobs on the radio set are held onto their
fungus. shafts by setscrews. If knob replacement becomes
a. Remove dust and loose dirt with a clean soft necessary:
cloth, item 2, App. C. a. Loosen setscrew with an appropriate wrench.
WARNING b. Remove defective knob.
Adequate ventilation should be provided while c. Install new knob.
using TRICHLOROTRIFLUOROETHANE. d. Tighten setscrews (if knob has two setscrews,
Prolonged breathing of vapor should be avoid- tighten the setscrew that engages the flatted shaft first).
ed. The solvent should not be used near heat or
open flame; the products of decomposition are 2-17. Antenna Replacement
toxic and irritating. Since TRICHLOROTRI- Remove damaged antenna from connector by turning
FLUOROETHANE dissolves natural oils, antenna counterclockwise. Check connector on radio
prolonged contact with skin should be avoid- set for corrosion or thread damage. Remove and signs
ed. When necessary, use gloves which the sol- of corrosion. If connector is damaged, refer radio set to
vent cannot penetrate. If the solvent is taken higher level of maintenance. Insert new antenna into
internally, consult a physician immediately. connector and hand tighten clockwise.
b. Remove grease, fungus, and ground-in dirt from
2-18. Battery Replacement
the radio set; use a cloth dampened (not wet) with tri-
clorotrifluoroethane, item 6, App. C. Remove battery case by unfastening latches on side of
c. Remove dust or dirt from antenna and audio con- radio set case and sliding case off. (Handle case careful-
nectors with a brush, item 1, App. C. ly as damaged case will not seal properly). Detach old
battery from battery connector and attach new battery
2-15. Touchup Painting Instructions to connector. Apply a thin coat of silicone grease, item

2-13
TM 11-5820-882-23/TM 06827A-23/2

5, App. C, to the top edge of the battery case (to In order to prevent water seepage make sure
facilitate “O” ring sealing). Reinstall battery case and battery case and rubber gasket are not damag-
fasten latches. ed. Make sure battery case and module cover
CAUTION are properly aligned before fastening latches.

Section VI. PREPARATION FOR STORAGE OR SHIPMENT

2-19. Packaging, Marking and Shipping can be readied for mission performance within 24
Requirements hours. Before placing an item in administrative storage,
the next scheduled preventive maintenance checks and
Refer to figure 2-6 for packaging diagram. services should be performed, all known deficiencies
2-20. Type of Storage corrected, and all current modification work orders ap-
plied. The administrative storage site should provide re-
Short term (administrative storage) = 1 to 45 days. Ad- quired protection from the elements and allow access
ministrative storage covers storage of equipment which for visual inspection and exercising when applicable.

2-14
 TM 11-5820-882-23/TM 06827A-23/2

Figure 2-6. Radio set packaging diagram.

2-15
 TM 11-5820-882-23/TM 06827A-23/2

CHAPTER 3
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS

Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

3-1. Common Tools and Equipment tools and equipment to be used at direct support
For authorized common tools and equipment refer to maintenance level.
the Modified table of Organization and Equipment
(MTOE) applicable to your unit.
3-3. Maintenance Kit
Figure 3-1 shows Maintenance Kit MK-( ) /PRC-68 us-
3-2. Special Tools, TMDE, and Support ed with the test equipment to troubleshoot the radio set.
Equipment Table 3-1 provides a brief description of the contents of
Refer to the maintenance allocation chart (App. B), for the kit.

Figure 3-1. Maintenance Kit MK-( )/PRC-68.

3-1
TM 11-5820-882-23/TM 06827A-23/2

Table 3-1. Maintenance Kit Description MK-( ) /PRC-68

Figure 3-2. Receiver troubleshooting test setup.

3-2
 TM 11-5820-882-23/TM 06827A-23/2

3-4. Repair Parts

Repair parts are listed in the repair parts organizational and direct support maintenance for this
and special tools list (TM 11-5820–882-23P) covering equipment.

Section II. TROUBLESHOOTING

3-5. Troubleshooting Procedures isolation test, as outlined in table 3-3. This table will
Troubleshooting instructions for the radio set contained isolate a problem down to a particular module which
in this section are separated into two procedures. The will then be replaced. If module replacement does not
first procedure consists of a minimum performance test, repair unit, higher level maintenance is required.
as outlined in table 3-2. This table will be used to deter-
mine the general nature of the malfunction and, after a 3-6. Test Equipment Setups
repair has been made, to ensure the radio set is working The test setup requirements for performing the
properly for all functions. Minimum performance of troubleshooting procedures are shown in f’igures 3-2
the radio set may also be performed using the test set and 3-3. The maintenance kit required for the test
(table 2-4). The second procedure consists of a fault setups is described in table 3-1.

Figure 3-3. Transmitter troubleshooting test setup.

3-3
TM 11-5820-882-23/TM 06827A-23/2

Table 3-2. Radio Set Minimum Performance Test

figure 3-2

Table 3-3, steps 1 through 11

Table 3-3, steps 1 through 11.

Table 3-3, steps 1 through 11.

Table 3-3, steps 1 through 11.

Table 3-3, steps 1 through 11.

3-4
 TM 11-5820-882-23/TM 06827A-23/2

Table 3-2. Radio Set Minimum Performance Test—Continued

figure 3-3

Table 3-3, steps 12 through 21.

Table 3-3, steps 12 through 21.

Table 3-3,steps 12 through 21.

Table 3-3, steps 12 through 21.

Table 3-3, steps 12 through 21.

figure 3-3 Table 3-3, steps 12 through 21.

Table 3-3, steps 2 through 21.

3-5
 TM 11-5820-882-23/TM 06827A-23/2

Table 3-2. Radio Set Minimum Performance Test—Continued

Table 3-3, steps 12 through 21.

3-7. Fault Isotation Test Figure 3-4 and 3-6 show the equipment setups necessary
Table 3-3 is a fault isotation test for the radio set. By us- to perform the fault isolation tests.
ing these tests and the associated test equipment, the 3-9. Test Point Locations
radio set may be fault isolated to a defective module. If
the problem cannot be located to a defective module or Figures 3-7 and 3-8 show the test point locations used in
other DS level maintenance, then higher level mainte- fault isolation testing. Test point connections are made
nance is required. In all cases, after a defective module by a special rf cable assembly 565461-801 (part of Main-
has been replaced or a repair made to the radio set, the tenance Kit MK-( ) /PRC-68). In all cases where this
minimum performance test (table 3–2), or minimum per- cable is used, the center conductor is connected to the
formance check using the test set (table 2-4), must be test point called for, and the shield is connected to the
performed to ensure the radio set is fully operational. nearest ground point on the printed circuit board. The
3-8. Fault Isolation Test Equipment Set- BNC connector end mates with the applicable test
equipment unit, when called for.
ups

3-6
 TM 5820-882-23/TM 06827A-23/2

Figure 3-4. Receiver fault isolation test setup.

Figure 3-5. Receiver fault isolation test set up (alternate procedure.

3-7
TM 11-5820-882-23/TM 06827A-23/2

Figure 3-6. Transmitter fault isolation test setup.

Figure 3-7. Module socket test point location, front.

3-8
 TM 11-5820-882-23/TM 06827A-23/2

Figure 3-8. Module socket test point (E numbers) location, front.

Figure 3-9. Module socket test point location, rear.

3-9
TM 11-5820-882-23/TM 06827A-23/2

Table 3-3. Fault Isolation Test

table 3-3
figures 3-5 and 3-8
para 2-5
fig. 2-1

figure 3-4 para 3-10

fig. 3-7

3-10
 TM 11-5820-882-23/TM 06827A-23/2

Table 3-3. Fault Isolation Test—Continued

para 2-5
fig. 2-1

para 3-10

fig. 3-7

3-11
TM 11-5820-882-23/TM 06827A-23/2

Table 3-3. Fault Isolation Test—Continued

fig. 3-8

fig. 3-8

figure 3-8

fig. 3-8

para 2-5
fig. 2-1

3-12
 TM 11-5820-882-23/TM 06827A-23/2

Table 3-3. Fault Isolation Test—Continued

figure 3-6
para 3-10

table 3-4

fig. 3-7

3-13
TM 11-5820-882-23/TM 06827A-23/2

Table 3-3. Fault Isolation Test—Continued

para 2-5

para 3-10

table 3-4 table 3-4

table 3-4

3-14
 TM 11-5820-882-23/TM 06827A-23/2

Table 3-3. Fault Isolation Test—Continued

Table 3-4. Synthesizer Test Voltages and Frequencies

Section III. MAINTENANCE PROCEDURES

3-10. Removal and Replacement
. of (2) Inset corner of screwdriver tip into forward
Modules (panel end) pry slot on converter module. Extend left
The following procedures are used for removal and in- thumb over converter module to stop module travel and
sertion of the modules in the Radio Set. The Special in- pry up this end of the module (see fig. 3-10). Move
structions in paragraph 3-11 should also be observed to screwdriver to other slot on the converter module and
prevent secondary damage and failures, Refer to pry up. Remove module from radio with fingers.
paragraph 2-5 for disassembly instructions. (3) To insert converter module, align module pins
with frame sockets and gently press module into place,
a. Converter Module.
b. I-f/A-f Module.
(1) Hold radio in left hand with control panel (1) Hold radio in left hand with bottom side (bat-
toward palm, thumb over converter module and fingers tery connector side) in palm and left thumb over i- f/a-f
over radio on opposite side. module and fingers on back side of radio.

Change 1 3-15
TM 11-5820-882-23/TM 06827A-23/2

(2) Insert screwdriver into side slot nearest bot- module into place.
tom side (battery side) of radio and pry up module using f. Vco, Modulator MixerJ and Synthesizer
the left thumb to restrict travel. Move screwdriver to the Modules.
middle slot on i–f/a–f module and pry up. Remove
(1) Hold radio in left hand with modules facing
module with fingers by using slight side to side rocking
up. Insert screwdriver into slots in frame and gently pry
motion of module.
up the removable circuit board with the three modules
(3) To inset i-f/a-f module, align module pins
attached.
with frame sockets and gently push module into place.
c. Filter/ I-F Module. modules from frame sockets and pull it away from the
(1) First remove the i-f/a-f module. radio panel to expose the CHAN switch cable connec-
(2) Hold radio in left hand with bottom side (bat- tor. Pull removable circuit board far enough away from
tery connector side) in palm and left thumb over anten- panel (approximately 3/4 inch) to grip the cable connec-
na coupler module (rear part of thumb should be over tor with the thumb and forefinger of the left hand; then
the filter/i-f module). Carefully pry up the i-f/a-f end unplug the connector by gently pulling away with the
of the filter/i-f module with the screwdriver. Then pry removable circuit board assembly.
up the opposite end of filter/i–f module and remove (3) The three modules may be removed now by
module with your fingers. pulling them up from the removable circuit board with
(3) To insert filter/i-f module, align module pins the fingers.
with frame sockets and gently push module into place. (4) To insert the vco, modulator/mixer, or syn-
d. Transmitter Module. thesizer module, align the module pins with the sockets
on the removable circuit board. Gently push the module
(1) First remove the i-f/a-f and converter
into place. When all three modules are installed on the
modules.
removable circuit board, connect the synthesizer cable
(2) Hold radio in left hand with transmitter
assembly. Align the removable circuit board pins with
module facing up. Remove module with right thumb
the frame sockets and gently push the removable circuit
and forefinger on ends. Use a top (panel) -to-bottom
board into place. Make sure the modules and removable
rocking motion to loosen the module in the frame
circuit board are properly seated.
sockets.
(3) To insert the module, align module pins with 3-11. Special Instructions
frame sockets and gently push module into place.
a. Always inspect a module for bent or broken pins
e. Antenna Coupler Module. before inserting it into the frame sockets. To straighten
(1) First remove i-f/a-f and converter modules. bent pins, use needle-nose or long-nose pliers with
(2) Hold the radio in left hand with antenna smooth jaws. Position the jaws so that the whole pin is
coupler module facing up. Remove module with right straightened simultaneously (see fig. 3-11 ).
thumb and forefinger on the ends. Use a top (panel) -to- b. When inspecting for bent pins, the pins should
bottom rocking motion to loosen the module in the appear to be reasonably vertical in relation to the
sockets. module bottom surface. Bent pins usually result when
(3) To insert antenna coupler module, align excessive prying force is applied to only one end or side
module pins with frame sockets and gently push of a module. The thumb of the opposite hand should

Figure 3-10. Module removal.

3-16
 TM 11-5820-882-23/TM 06827A-23/2

always be used to stop the module travel and oppose the All sealing surfaces (module cover and battery case)
prying force. should have a thin film of silicone grease (NSN 6850-
c. Always inspect frame sockets for damage before 00-177-5094) applied to hepl preserve watertightness
inserting a module. .4 normal socket should have four and keep the rubber seals pliable. If a handset is used
spring leafs visible. If a spring leaf is pushed over to the with the radio set, a small amount of silicone grease
wrong side of a socket, it can be pushed back into place
should also be applied to the “O” ring in the connector
with a sharp pointed tool (pin, needle, scribe, etc.). If
to facilitate insertion.
the leaf breaks off or is smashed into the bottom of the
socket, the socket should be replaced if possible. 3-13. Placing in Service
However, the socket will still make good contack with
After the radio set has been repaired, the unit must be
the module pin after the damaged leaf is removed from
checked out completely with the minimum performance
the socket. The radio set is still operational until repairs
can be made at a higher level. test (table 3-2). Upon the completion of the test, the
radio set should be set to some predetermined frequency
3-12. Lubrication and properly aligned before being returned to service.

Section IV. PRINCIPLES OF OPERATION

3-14. General 3-16. Receive Operation
Radio Set AN/PRC-68 consists of eight plug-in The receiver is packaged in three modules. These
modules, a frame assembly, and battery assembly. Prin- modules are:
ciples of operation of the radio set is limited to descrip- a. Converter Module (1A6). The converter
tion of the modules and their interfacing with each module consists of two bandswitched, varactor-tuned rf
other. Refer to figures 2-1 and 2-2 for module loca- amplifiers and the receiver 1st mixer which converts the
tions. operating frequency to the first i-f of 12 MHz. The low-
band rf amplifier tunes the frequency range from 30 to
3-15. Circuit Functioning 54 MHz while the high-band tunes 54 to 80 MHz. The
Circuit functioning of the radio set (fig. FO-1) can be settings of the frequency select switches (A, B, and D,
broken down into modules that comprise separate func- on synthesizer module, and preset CHAN switch) deter-
tions (receive and transmit) and modules that are used mine the operating frequency of the rf amplifier and the
for both functions (synthesizer and voltage controlled local oscillator injection frequency to the first mixer.
oscillator). The battery saver circuitry, tone tuning, and This injection signal is provided by the voltage controll-
150 Hz squelch tone signal are also discussed. ed oscillator (VCO) module. For the low-band (30 to 54

Figure 3-11. Pin Straightening procedure.

3-17
TM 11-5820-882-23/TM 06827A-23/2

MHz), it is 12.000 MHz above the rf input frequencies; fication to approximately 1 vrms. The output of the
for the high-band (54 to 80 MHz), it is 12.000 MHz driver stage is approximately 100 mw. This stage has a
below the rf input frequencies. tuned circuit which tunes the output of the transmiter.
b. Filter/I-f Module (1A3). The filter/i-f module Tuning is accomplished by using the built-in tone tuner
contains a 12 MHz crystal filter, 12 MHz i–f amplifier, and adjusting C1 on the module. The tone tuner cir-
18.5 MHz crystal oscillator, and a 6.5 mixer/amplifier cuitry is located in the i-f/a-f module and converts the
(2nd mixer), The output of the second mixer (6.5 MHz) variation in the collector currents of the transmitter
is the difference of the 12.0 MHz input and 18.5 MHz stages to a tone frequency when the tone tuner button
input from the crystal oscillator. (located on the side of the frame assembly) is depressed.
c. I-f/A-f Module (1A2). The i-f/a-f module The final output (approximately 1.5 watts) is routed
contains a 6.5 MHz i-f amplifier/discriminator, squelch through one of four band-selected low-pass harmonic
circuits, audio amplifier, and a low-pass filter. Other filters to the antenna coupler (1A5).
functions contained within the module are a tone tuner c.Antenna Coupler Module (1A5). The antenna
circuit and battery saver switch. The input signal to the coupler module contains the rf transmit/receive diode
i–f/a-f module is the 6.5 MHz frequency modulated sig- switching circuits and the antenna matching circuit. Pin
nal from the filter/i-f module. The signal is detected diodes in the module provide transmit/receive switching
and routed through the low-pass filter to the audio functions to the antenna matching network. These di-
amplifier. When a handset of other audio accessory is odes also isolate the transmit/receive circuitry to pre-
connected to the AUDIO connector of the radio set, the vent the transmitted signal from entering the receiver in-
speaker mute circuit electronically switches off the put. The antenna matching network provides an imped-
audio signal to the speaker and routes it to the handset. ance match between the antenna and transmitter circuits
The squelch threshold is adjusted by a potentiometer (between 50 ohms and 100 ohms). The matching range is
located in the module. The squelch circuit is normally determined by the position (1 through 4) of the rotary
on when the radio set is turned on. However, squelch switch located on the module (set the same as the A
can be disabled by turning the function switch to the switch on the synthesizer). Optimum tuning is ac-
SQUELCH DIS position. complished by using the field strength meter on the test
set and adjusting L1 on the coupler module (tune for
3-17. Transmit Operation maximum indication).
The transmitter is packaged in three modules. These
modules are: 3-8. Frequency Synthesizer (1A7 and
a. Modulator/Mixer Module (1A8). The modulator/ 1A8)
mixer module contains a speech amplifier and filter, 150
The radio set frequency synthesizer consists of the vco
Hz (squelch tone) buffer, 12 MHz deviation oscillator rf
module (1A7) and the synthesizer module ( 1A9). The
mixer, and two bandswitched, varactor-tuned rf pream-
functon of the frequency synthesizer is to generate the
plifiers. The speech amplifier increases the level of the
required mixer injection frequency and tuning voltage
microphone signal sufficiently for clipping action. The
for the converter and modulator modules when a given
output of the amplifier passes through a low-pass filter
operating frequency is selected. The frequency syn-
before it is superimposed upon a 12 MHz deviation os-
thesizer also determines which band (low or high) is ac-
cillator. The 150 Hz squelch tone from the synthesizer
tive depending upon selection of the operating frequen-
is also routed to the deviation oscillator after passing
cy.
through a buffer and the speech filter network. The fre-
quency modulated output of the oscillator is combined a. The frequency range of the synthesizer is from
in a varactor-tuned mixer stage with the frequency syn- 42.000 MHz to 67.950 MHz which corresponds with a
thesizer output signals to create the desired rf output generated tuning voltage range from 2.0 vdc to 11.0 vdc
frequency. The rf output is amplified by two bandswit- respectively. The frequency synthesizer is programmable
ched, varactor-tuned rf preamplifiers. For frequencies in 50 kHz steps with the frequency select (A, B. and D)
in the low-band (30 to 54 MHz), the output frequency is switches on the synthesizer module and the CHAN (C)
12.000 MHz below the synthesizer frequency; and for switch on the panel of the radio set.
the high-band (54 to 80 MHz), the output frequency is b. The frequency range of the synthesizer is
12.000 MHz above the synthesizer frequency. generated twice to provide low-band radio set operation
b. Transmitter Module (1A4).. The transmitter from 30,000 MHz to 53.950 MHz (positions 1 and 2 of
module contains an rf preamplifier, driver, final power the A switch), and high-band radio set operation from
amplifier and low-pass band filters. The output from 54.000 MHz to 79.950 MHz (positions 3 and 4 of the A
the modulator is applied to the preamplifier for ampli-

3-18
 TM 11-5820-882-23/TM 06827A-23/2

switch). The two bands are required to cover the 30 to the output frequency of the vco with the ± 4 prescaler in
80 MHz range of the radio set with varactor tuning. the vco module. The prescaler output is routed to the
c. The basic purpose of the frequency synthesizer is mixer in the synthesizer module. The output of the mix-
to generate the discrete channel frequencies with an ac- er is the difference frequency of the prescaler input and
curacy of ±25 ppm. This is accomplished by phase lock- the 10 MHz or 12.5 MHz reference oscillator.
ing a voltage controlled oscillator (VCO) to a standard f. Because the capture range of the phase detector is
crystal controlled reference frequency. The reference narrow (approximately ± 500 kHz at the vco frequency),
frequency of the synthesizer is 12.5 kHz crystal oscilla- the vco must be swept over its frequency range to a fre-
tor by a factor of 800, or dividing the output of the 12.5 quency within this capture range. When this occurs, the
MHz crystal oscillator by a factor of 1000. The division phase detector output control voltage (superimposed on
factor is determined by the position of the A switch. The the sweep voltage) pulls the vco into phase-lock with the
reference divider ( ÷ K) consists of an injection locked reference frequency of the synthesizer.
oscillator which divides by 4 (10 MHz) or 5 (12.5 MHz), g. The sweep voltage is a sawtooth staircase
and a fixed divide ratio (200) digital counter. The 12.5 waveform consisting of additive coarse tune voltage
kHz output of the reference divider is routed to the steps over a voltage range from 1.5 vdc to 13.0 vdc. The
phase comparator (detector). ramp sweeps the vco over its frequency range by stepp-
d. To achieve phase locking, the output of the vco ing up from 1.5 vdc to the coarse tune voltage required
(42 to 68 MHz) must be frequency translated and divid- to put the vco frequency within the capture range of the
ed douwn to 12.5 kHz for phase comparison with the 12. phase detector. Once phase lock is achieved, the ramp
5 kHz reference frequency. Because the vco must pro- stops and holds at that coarse tune voltage. The tune
vide 520 discrete frequencies spaced 50 kHz apart, a voltage output from the synthesizer is the phase detector
variable frequency divider is required to divide each one control voltage superimposed on the ramp coarse tune
of these discrete frequencies down to 12.5 kHz. The voltage. The level of the phase-locked tuning voltage is
variable divider ( ÷ N) ratio is determined (programmed) proportional to the selected operating frequency, and
by setting the synthesizer switches to the code cor- varies from 2.0 vdc to 11.0 vdc.
responding with the desired operating frequency. Once h. The loop filter attenuates the 12.5 kHz reference
the ÷ N ratio is programmed, the vco can phase lock on- frequency to minimize frequency modulation of the
ly at that frequency which translates down to 12.5 kHz. Vco.
e. Because the maximum counting speed of the i. The synthesizer also generates the battery saver
cmos programmable divider is 5 MHz, the 42 to 68 MHz timing waveform and the 150 Hz squelch tone wave-
range of the vco must be frequency translated down to form, Both of these signals are derived from the crystal
less than 5 MHz. This is accomplished by first dividing reference frequency with digital frequency dividers.

3-19
 TM 11 -5820-882-23/TM 06827A-23/2

APPENDIX A
REFERENCES

A-1. S c o p e
This appendix lists the forms and publications that are referenced in this manual or that contain information ap-
plicable to the operation and maintenance of Radio Set AN/PRC-68.

A-2. Forms
DA Form 2028 Recommended Changes to Publications and Blank Forms
DA Form 2028-2 Recommended Changes to Equipment Technical Publications
NAVMC 10772 (USMC) Suggested Recommendations and Improvements for Marine Corps
Technical Manuals
SF 364 Report of Discrepancy (ROD)
SF 368 Quality Deficiency Report
TM 4700-15/1 (USMC) Forms and Records Procedures

A-3. Publications
DA Pam 310-4 Index of Technical Publications
SB 11-573 Painting and Preservation Supplies Available for Field Use for Elec-
tronics Command Equipment
SB 38-100 Preservation, Packaging, Packing and Marking Materials, Supplies
and Equipment Used by the Army
SC 5180-91 -CL-R07 Tool Kit, Electronic Equipment TK-105/G (NSN 5180-00-610-8177)
SC 5180-91 -CL-R13 Tool Kit, Electronic Equipment TK-101/G (NSN 5180-00-064-5178)
TB 43-0118 Field Instructions for Painting and Preserving Electronics Command
Equipment Including Camouflage Pattern Painting of Electrical
Equipment Shelters
TM 11-5820-882-10 Operator’s Manual: Radio Set AN/PRC-68 (NSN 5820-01-079-9260)
TM 11-5820-882-23P Organizational and Direct Support Maintenance Repair Parts and
(To Be Published) Special Tools Lists for Radio Set AN/PRC-68
TM 11-5965-257-l5 Operator’s, Organizational, Direct Support, General Support and
Depot Maintenance Manual (Including Repair Parts and Special
Tools Lists): Handset H-138/U (FSN 5965-892-0972)
TM 11-5965-280-15 Operator’s, Organizational, Direct Support, General Support, and
Depot Maintenance Manual (Including Repair Parts and Special
Tools Lists): Handset H-189/GR (NSN 5965-00-069-8886)
TM 11-6130-247-15 Operator’s, Organizational, Direct Support, General Support, and
Depot Maintenance Manual for Power Supply PP-3940/G
TM 11-6625-255-14 Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual: Spectrum Analyzer TS-723A/U,
TS-723B/U, TS-723C/U, and TS-723D/U (NSN 6625-00-668-9418)
TM 11-6625-400-12 Operator’s and Organizational Maintenance Manual for Meter, Modu-
lation ME-57/U
TM 11-6625-444-15 Operator’s, Organizational, Direct Support, General Support, and
Depot Maintenance Manual: Digital Voltmeter AN/GSM-64
TM 11-6625-524-14 Operator’s, Organizational and Field Maintenance Manual: Volt-
meter Electronic AM/URM-145
TM 11-6625-586-12 Operator and Organizational Maintenance Manual: Generator,
Signal AN/URM-103
TM 11-6625-683-15 Operator’s, Organizational, Direct Support, General Support, and
Depot Maintenance Manual: Signal Generator AN/URM-127
(NSN 662540783-5965)

Change 1 A-1
TM 11-5820-882-23/TM 06827A-23/2

TM 11-6625-700-10 Operator’s, Manual: Digital Readout, Electronic Counter,

AN/USM-207 (NSN 6625-00-911-6368)
TM 11-6625-1576-15 Organizational, Direct Support, General Support, and Depot Mainte-
nance Manual for Distortion Analyzer, Hewlett-Packard Model
333A and 334A, (AN/URM-184A)
TM 11-6625-2658-14 Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual for Oscilloscope AN/USM-281C (NSN 6625-
00-106-9622)
TM 11-6625 -2718-14-1 Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual: Test Set, Radio Frequency, Power
AN/URM-182A
TM 11-6625-2941-14&P Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual for Counter, Electronic Digital Readout
AN/USM-459 (NSN 6625-01-061-8928)
TM 11-6625-2946-14 Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual for Test Set TS-3354/PRC-68 (NSN
6625-01-091-3157)
TM 11-6625-2953-14 Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual: Multimeter, AN/USM-451 (NSN 6625-01-
060-6804)
TM 11-6625-2954-14&P Operator’s, Organizational, Direct Support, and General Support
Maintenance Manual (Including Repair Parts and Special Tools
Lists) for Signal Generator SG- 1144/U (NSN 6625-01-075-8478)
TM 38-750 The Army Maintenance Management System (TAMMS)
TM 750-244-2 Procedures for Destruction of Electronics Materiel to Prevent Enemy
Use (Electronics Command)

A-2 Change 1
 TM 11-5820-882-23/TM 06827A-23/2

APPENDIX B
MAINTENANCE ALLOCATION

Section I INTRODUCTION
B-l. General to restore serviceability to an item by correcting
specific damage, fault, malfunction, or failure in a
This appendix provides a summary of the maintenance
operations for AN/PRC–68. It authorizes categories of part, subassembly, module (component or assembly),
maintenance for specific maintenance functions on end item, or system.
repairable items and components and the tools and j Overhaul. That maintenance effort (service/act-
equipment required to perform each function. This ap- ion) necessary to restore an item to a completely ser-
pendix may be used as an aid in planning maintenance viceable/operational condition as prescribed by mainte-
operations. nance standards (i.e., DMWR) in appropriate technical
publications. Overhaul is normally the highest degree of
B-2. Maintenance Function maintenance performed by the Army. Overhaul does not
Maintenance functions will be limited to and normally return an item to like new condition.
defined as follows: k. Rebuild. Consists of those services/actions
a. Inspect. To determine the serviceability of an necessary for the restoration of unserviceable equip-
item by comparing its physical, mechanical, and/or ment to a like new condition in accordance with
electrical characteristics with established standards original manufacturing standards. Rebuild is the highest
through examination. degree of materiel maintenance applied to Army equip-
b. Test. To verify serviceability and to detect inci- ment. The rebuild operation includes the act of return-
pient failure by measuring the mechanical or electrical ing to zero those age measurements (hours, miles, etc.)
characteristics of an item and comparing those charac- considered in classifying Army equipments/com-
teristics with prescribed standards. ponents.
c. Service. Operations required periodically to B-3. Column Entries
keep an item in proper operating condition, i.e., to
clean (decontaminate), to preserve, to drain, to paint, or
a. Column 1, Group Number. Column 1 lists
group numbers, the purpose of which is to identify com-
to replenish fuel, lubricants, hydraulic fluids, or com-
ponents, assemblies, subassemblies and modules with
pressed air supplies,
the next higher assembly,
d. Adjust. To maintain, within prescribed limits,
by bringing into proper or exact position, or by setting b. Column 2, Component/Assembly. Column 2
the operating characteristics to the specified parameters. contains the noun names of components, asemblies,
e. Align. To adjust specified variable elements of subassemblies, and modules for which maintenance is
an item to bring about optimum or desired perfor- authorized.
mance. c. Column 3, Maintenance Functions. Column 3
f. Calibrate. To determine and cause corrections lists the functions to be performed on the item listed in
to be made or to be adjusted on instruments or test column 2. When items are listed without maintenance
measuring and diagnostic equipments used in precision functions, it is solely for purpose of having the group
measurement. Consists of comparisons of two instru- numbers in the MAC and RPSTL coincide.
ments, one of which is a certified standard of known ac- d. Column 4, Maintenance Category. column 4
curacy, to detect and adjust any discrepancy in the ac- specifies, by the listing of a “work time” figure in the
curacy of the instrument being compared. appropriate subcolumn (s), the lowest level of mainte-
g. Install. The act of emplacing, seating, or fixing nance authorized to perform the function listed in
into position an item, part, module (component or column 3. This figure represents the active time required
assembly) in a manner to allow the proper functioning to perform that maintenance function at the indicated
of the equipment or system. category of maintenance. If the number or complexity
h. Replace. The act of substituting a serviceable of the tasks within the listed maintenance function vary
like type part, subassembly, or module (component or at different maintenance categories, appropriate “work
assembly) for an unserviceable counterpart. time” figures will be shown for each category. The
Repair. The application of maintenance services number of task-hours specified by the “work time”
figure represents the average time required to restore an
(inspect, test, service, adjust, align, calibrate, replace)
or other maintenance actions (welding, grinding, rivet- item (assembly, subassembly, component, module, end
ing, straightening, facing, remachining, or resurfacing) item or system) to a serviceable condition under typical

B-1
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field operating conditions. This time includes prepara- numbers in this column coincide with the numbers used
tion time, troubleshooting time, and quality assurance/ in the tools and equipment column of the MAC. The
quality control time in addition to the time required to numbers indicate the aplicable tool or test equipment
perform the specific tasks identified for the maintenance for the maintenance functions.
functions authorized in the maintenance allocation b. Maintenance Category. The codes in this COl-
chart. Subcolumns of column 4 are as follows: umn indicate the maintenance category allocated the
C—Operator/Crew tool or test equipment.
O—Orangizational c. Nomenclature, This column lists the noun name
F—Direct Support and nomenclature of the tools and test equipment re-
H—General Support quired to perform the maintenance functions.
D—Depot d. National/NATO Stock Number. This column
e. Column 5, Tools and Equipment. Column 5 lists the National/NATO stock number of the specific
specifies by code, those common tool sets (not in- tool or test equipment.
dividual tools) and special tools, test, and support e. Tool Number. This column lists the manufac-
equipment required to perform the designated function. turer’s part number of the tool followed by the Federal
f. Column 6, Remarks. Column 6 contains an Supply Code for manufacturers (5-digit) in parentheses.
alphabetic code which leads to the remark in section IV,
Remarks, which is pertinent to the item opposite the B-5. Remarks (See IV)
particular code. a. Reference Code, This code refers to the ap-
propriate item in section II, column 6.
B-4. Tool and Test Equipment Require- b. Remarks. This column provides the required
ments (Sect III) explanatory information necessary to clarify items ap-
a. Tools or Equipment Reference Code. The pearing in section II.

(Next printed page is B-3)

B-2
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SECTION II MAINTENANCE ALLOCATIN CHART

(1)
GROUP
NUMBER

00

01

0101

Change 1 B-3
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SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS

B-4 Change 1
 TM 11-5820-882-23/TM 06827A-23/2

SECTION IV. REMARKS

SB 11-30

1981-703-029/1260 Change 1 B-5/(B-6 blank)

 TM 11-5820-882-23/TM 06827A-23/2

APPENDIX C
EXPANDABLE SUPPLIES AND MATERIALS LIST

Section I INTRODUCTION
1. S c o p e O—Organizational Maintenance
This appendix lists expendable supplies and materials F—Direct Support Maintenance
you will need to operate and maintain Radio Set AN/ H—General Support Maintenance
PRC-68. These items are authorized to you by CTA 50- c. Column 3—National Stock Number. This is the
970, Expandable Items (Except Medical, Class V, Re- National stock number assigned to the item; use it to re-
pair Parts, and Heraldic Items). quest or requisition the item.
d. Column 4—Description. Indicates the Federal
2. Explanation of Columns item name and, if required, a description to identify the
a. Column 1—Item Number. This number is item. The last line for each item indicates the part
assigned to the entry in the listing and is referenced in number followed by the Federal Supply Code for Manu-
the narrative instructions to identify the material (e.g., facturer (FSCM) in parentheses, if applicable.
“Use cleaning compound, item 5, App. C“). e. Column 5— Unit of Measure (UM), Indicates
b. Column 2—Level. This column identifies the the measure used in performing the actual maintenance
lowest level of maintenance that requires the listed item. function. This measure is expressed by a two-character
alphabetical abbreviation (e. g., ea, in, pr). If the unit of
(enter as applicable)
measure differs from the unit of issue, requisition the
C—Opoerator/Crew lowest unit of issue that will staisfy your requirements.

(Next printed page is C-2)

C-1
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SECTION II EXPENDABLE SUPPLIES AND MATERIALS LIST

C-2
 TM 5820-882-23/TM 06827A-23/2

INDEX

SUBJECT Para Organzational------------------------------------------------------2-13

Preventive . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-8
Modules
Alignment procedures . . . . . . . .. . . .. . . . . . . ... . . . 2-7
Pin straightening . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .3-11
Ancillary equipment . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Antenna replacement . . . . . . . . . .. . . . . . . . . . . . . . 2-7
Painting-----------------------------------------------------------------2-15
Battery
Freguency chart . . . . . .. . . . . . . . . . . .. ... . . 2-7c Reassembly instructions .. . . . . .. . . . . . . . . . . .. . . . . . . . . . 2-6
Replacement . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 2-18 Receiver operation
Orgntiational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .2-14
Direct support . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .3-16
Common tools and equipment . . . . . . . . . . . . . . . . . . . . . . .. . . . .. .. . 2-1
Repair parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Component location . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . .. . 1-7
Storge --------------------------------------------------------------2-19
Data, tabulated . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-8
SVM operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Destruction to prevent enemy use . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .1-3
Switch code . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7d
Disassembly instructions . . . . . . . . . . . . . . . . . . . . . .. . . .2-5
Synthesizer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Equipment capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1-6
Test point locations . . . . . . . . . . . . . . . . . . . . . .. . . . . . .3-9
Equipment improvement recommendations .. .. . . . . . . . .. . . . . 3-7
Test set . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-12
Fault isolation . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . .. . . .. 3-7 Tools
Common . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. .. 3-1
Knob replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. 3-2
Transmitter operation
Lubrication Orgnizational . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . 1-11
Gasket seal -----------------------------------------------------------6-6 Direct Support . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . .. 3-17
Troubleshooting procedures
Maintenance Organizational -----------------------------------------------------2-11
Direct support . . . . . . . . . . . . . . . ... . . . . ... . . . . . . . . . . . . . . . 3-1 Direct support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-5
Kit----------------------------------------------------------3-3

● U.S. GOVERNMENT PRINTING OFFICE : 1995 0 - 388-421 (01391) Index-1

 TM 11-5820-882-23/TM 08827A-23/2

Figure FO-1. Radio Set Block Diagram (Sheet 1 of 2).

 TM 11-5820-882-23/TM 08827A-23/2

Figure FO-1. Radio Set Block Diagram (Sheet 2 of 2).

By Order of the Secretary of the Army and the Navy:

E. C. MEYER
General, United States Army
Official: Chief of Staff

J. C. PENNINGTON
Major General, United States Army
The Adjutant General

H. A. HATCH
Major General, US Marine Corps
Deputy Chief of Staff for Installations
and Logistics

Distribution:
PIN ;047728-000