GRC-193B 100 or 400 Watt H.F. Vehicle Mount Radio System

Brooke Clarke 2011


Versions
Manuals
Training
Vehicles , Radio
Shipped In Two Packages
Power Up 1
    What Went Wrong
Components
    RT-1209 Receiver Exciter
    AM-6545A/GRC-193A Amplifier 100 or 400 Watts Harris
    CU-2064 Antenna Coupler Harris
    AM-6879 Audio Amplifier-RTTY Converter
    MT-6232 Mount , Two Level Radio
    MT-6233 Mount, Single Level Radio
    MT-6378 Mount, Antenna Coupler, Remote Siting
    MT-4495 Antenna Coupler Mount (no antenna)
    Power Supplies
    Cables
    Antennas
    NSN & p/n Table
Related
Links

Background

When looking at the H.F. radio systems I have in relation to the the TCI 651T antenna it seems that there are better choices.
The URC-113 H.F. radio based on the PRC-104 uses the AM-7148 power amplifier that only can drive a wire (no coax output).
The RF3200ET is a 125 Watt radio that will drive the TCI 651T antenna. (by not using the antenna coupler).
The GRC-193 is a 400 Watt radio (switchable to 100 Watts) that uses the RT-1209() R-T as used on the PRC-104 & GRC-206.

The PRC-138 would be great, but it's expensive.  I've heard the following power amps work with the PRC-138:
Model
Power
Nomenclature
RF-5030 20
Amp/Coupler
RF 5031 125
Amp
RF-5033 150
Amp
RF-5034 400
Amp
(RF-5031 drives 10221-6100) RF-3230 1,000
Amp

Versions

System
NSN
NSN
R-T
RF Amp
Ant Coupler
Mount
GRC-193
5820-01-067-8359 RT-1209
AM-6545
5996-01-050-5881
CU-2064
5985-01-050-4869

GRC-193A 5820-01-133-4195 RT-1209
5820-01-069-2368
5820-01-332-6152?
AM-6545A
5965-00-069-8886
CU-2064
5985-01-050-4869
MT-6232 (common)
5975-01-133-3974
MT-6233 (low profile)
MT-6378 Ant Siting
5975-01-200-9797
GRC-193B(V)1
GRC-193B(V)3
5820-01-262-9546
5820-01-270-5103
RT-1209A
5820-01-270-5099
AM-6545B
5996-01-270-5095
CU-2064A
5985-01-270-5098

Manuals 

Technical Manuals (TM)


GRC-193




GRC-193A TM 11-5820-924-13



GRC-193B(V)1  Army
GRC-193B(V)3  Marine Corps
TM 11-5820-1045-12  Sep 1989
             "
TM 11-5820-1045-20P TM 11-5820-1045-40P TM 11-5820-1045-34
RT-1209 R-T


TM 11-5820-1046-40

RT-1209A R-T




AM-6545A RF Amp
TM11-5820-921-
TM11-5820-921-40-1
TM11-5820-921-40-2
TM 11-5820-921-50/3
CU-2064 Ant Cplr
TM11-5895-373-
TM11-5895-373-40-1 TM 11-5895-373-50/3
CU-2064A Ant Cplr



AM-6879 Audio Amp/RTTY
5820-01-070-1950
TM 11-5820-922-12
WANTED Contact

TM 11-5820-922-40-1
Jan 1986


TM 2000-OD/2C Marine Corps Electronic Equip.

Rebuild Standards (RS)

WANTED Contact
RS 07748A-50/4  PRC-104B
RS 87107B-50/3  AM-6545B
RS 87117B-50/3  CFU-2064A
RS 07749A/07743A-50/3  AM-68790

Training

SS0710 - Part 1

SS0711 - Part 2

Vehicles

Overall Systems

When the Marine Corps GRC-193 is mounted in a vehicle the overall system gets a new nomencalture.

UYQ-3 Direct Air Support Central

 Marine Corps Air/Mobile Direct Air Support Central (DASC) mounted in a shelter (S250? What else is in there?)
Includes the VRC-83 hi-power version of the PRC-113.

MRC-138

 When in the M151 Jeep or HMMWV.  Includes the VRC-83 hi-power version of the PRC-113.
Coupler to the Back for use with Whip antenna on Jeep.


Front
GRC-193B
                  Coupler Facing to the Back for use in Jeep MRC-138
Back
GRC-193B Coupler
                  Facing to the Back for use in Jeep MRC-138


Model
Description
Install Kit
Kit NSN
TM
M151, M151A1 or M151A2 (CJ5 Jeep) Army         Utility Truck 1/4 Ton Mk-2461/GRC-193A 5820-01-189-9795 TM 11-2300-475-13&P-3
M151, M151A1 or M151A2 (CJ5 Jeep) Marine Corp Utility Truck 1/4 Ton p/n: 755017C9000 (14304)


M998, M1038 HMMWV 1 -Ton, 4X4
Mk-2451/GRC-193A 5820-01-227-5842 TM 11-2300-475-13&P-6
M882 or M1008A1 CUCV (Wiki)
Cargo Truck 1-1/4 Ton, 4x4 MK-2462/GRC-193A 5820-01-189-9794 TM 11-2300-475-13&P-1
M1009 CUCV (Wiki)
Cargo Truck 3/4 Ton, 4x4 MK-2544/GRC-193A
5820-01-227-5839

M561 Gama Goat
Cargo Truck 1 1/4 Ton, 6x6 Mk-2458/GRC-193A 5820-01-189-9796 TM 11-2300-475-13&P-4
M113A1 APC & Carrier Command Post - M577A1 Full Tracked Mk-2460/GRC-193A 5820-01-189-9798 TM 11-2300-475-13&P-6
General Purpose
--
MK-2459/GRC-193A
5820-01-189-9797 TM 11-2300-475-13&P-2

Shipped In Two Packages

One box contained the MT-6232 with the Audio Amp and the RT-1209 installed along with the interconnecting cables.
The other box contained the RF Amp and Antenna Coupler.

MT-6232, AM-6879, RT-1209



GRC-193B Mount
                  w/ Audio Amp & RT-1209

51 lbs.
Package 61 lbs.
Packing 10 lbs

AM-6545B, CU-2064A



GRC-193B RF
                  Amp AM-6545B GRC-193B Ant
                  Coup CU-2064A
54 lbs.
40 lbs.
Package 101.2 lbs.
packing 7.2 lbs.

Power Up 1

DC input from PP-6224. Antenna coax connection (not HV connection) to TCI651 (which has very low return loss using the RF3200ET).
Power Amp set to 100 Watts which is well within the capability of the PP-6224 DC power supply.
RT1209A set to 3996 USB VTR.

At power on there is beeping in the loudspeaker and the Tune light is on
as everything warms up.

Pressing the FAN/Lamp Test button turns on the fans and all 6 Test Lamps light.
GRC-193 Power Up Sequence #0 just
                after power on

After about a minute the beeping stops and the RDY and TUN lights are on.
Unit warmed up and ready.
GRC-193 Power Up Sequence #1 after
                warm up
Pressing the mike PTT starts the tune operation and XMT & TUN are on
this lasts only about 5 to 10 seconds.


TUN and PA Fault lights are on and there a lot of beeping.

PP-6224 is running at about 4 amps.
GRC-193 Power Up Sequence #4 after
                antenna tune
The most likley cause of the problem is a poor electrical connection.  See Hints and Tips: What Goes Wrong
Fig PU4 AM-6545 Top Inside
AM-6545 Inside
                  Top
AM-6545 Inside Lid
AM-6545 Inside
                  Top Cover Closing Instructions & Meter Functions
Pulling and reinstalling the 6 PCBs (1A1 to 1A6) and the tank assembly (1A8) did not solve the problem.
The tank assembly does NOT move when tune is under way so maybe the servo (1A5) circuit has a problem.
Main Test Points
AM-6545
                  Main Test Points
1A8 Tank Assembly
AM-6545
                  1A8 Tank Assy Front

AM-6545
                  1A8 Tank Assy Back
Prior to making the meter readings I noticed that a nut holding a white wire from the transformer had been melted,probably by a short to ground.  What is the function of that wire?

Meter Readings
Switch
Rx
Meas
REF
0
60
FWD
0
60
ALC
0-500
430 (-60=370)
IP
0
60
RFK
0
60
HV
0
60
-14V
200-350
500 (-60=440)
+19V
210-255
400 (-60=340)
V2F
50-300
100 (-60=40)
V1F
50-300
300 (-60=240)
+26
220-320
340 (-60=280)

Aapped Nut photo taken after removing 1A13 HV module.
Am-6545
                  Zapped nut and 1A13 Module removed
The 1A5 Servo pwb test voltages are:
Test Point
Rx
Meas
1 Bias
+12
6.3
2 Enable
+6.1
0.9
3 B enable
-1.14
-1.4
4 A enable
-1.1
+2.9
5 +19
+19.5
+30
6 A
0
28
7 B
0
0
At this point there was a flash of light from the 1A13 HV module, smoke and smell.

Now to open the 1A13 HV module and see what burned up.  It was R12 1 Ohm 1/2 Watt in series with the emitter of Q1 (2N3055).  The collector is tied to the +26.5 buss and R12 is in series with the HV Start pin M on the interface connector.
AM06545 Pwr Amp
                  1A13 HV Module blown R12
Input Voltage Regulator Bracket
There are a number of places where the main input power supply has been used like an arc welder.  Two of the 2N3055 cans have holes and the bracket and a number of strike markes.  You can also see this in the first
top inside view above (Fig PU4)
AM-6545 RF
                  Power Amplifier Input Regulator Bracket

These three 2N3055 transistors are:
Q3 - 19V regulator pass transistor (2 holes)
          (explains meas)

Q4 - Filament regulator for V1 (1 hole)
         (explains meas)

Q5 - Filament regulator for V2 (no holes)

What Went Wrong

As the final power tubes age they have lower gain and that lets the plate voltage rise.  When the plate voltage gets high enough an arc from the plate to other parts of the tube (including the cathode/filaments) burns out the tubes and the circuitry associated with the power tubes.

If the power amp had received regular maintenance where the plate voltage was kept adjusted there would not have been a arc over.
But this seems to be a common problem with high power RF amps.
Eimac app note 17 recommends adding a resistor in series with all the high voltage terminals to limit the energy in any arc to 4 Joules.
I haven't found a copy of the app note that contains the figures.

Replacement tube ideas (may require different filament voltage or mechanical heat sinking:
Y621B (stock tubes no longer available)
8873 (replacement, but different filament voltage)
8874
3CX-800A7 - 3CPX-800A7
8660AS
4CX-250B
4CX-300A

RT-1209 Receiver Exciter

RE-1209

NSN: 5820-01-069-2368

RT-1209A

NSN: 5820-01-270-5099

AM-6545A/GRC-193A Amplifier 100 or 400 Watts Harris

Motors

Like the CU-2064 Antenna Coupler, this R.F. Amplifier also has motors and needs to be Lubed.


AM-6545A/GRC-193B Front Panel
Note the DC input connector, J3, has a central threaded hole, not the common DC input connector male threaded post.
See the CX-4721 cable photos.

This is the same DC Input connector as used on the GRC-106.  A cable with a mating connector is the CX-10071/U, but is has bare wires at the other end for connection to a battery.

A & B = + 26.5 VDC
C & D = Ground

The meter can read 11 different things depending on an internal switch setting.

Starting with a cable that has the connecotr for J3 (UW1220FA 17) has four female sockets and male threaded center anchor.
The wire colors are:
Func
AM-6545
J3 Pin
Wire
P.S.
(J3 or J4)
+26
A
Red
B
+26
B
Org
B
Gnd
C
Brn
A
Gnd
D
Blk
A
The connector to mate with the PP-6224 Power Supply is the MW10M(M)A17 which is the standard military vehicle 24 V power connector with male pins and a female center threaded anchor.
MW10M(M)A17 military vehicle 24 Volt Power Plug
                    Opened
To get access to the solder lugs:

Remove top and bottom clamp rings using special spanner tool.
Pull center locking assembly out.

The stock wiring of the CX-4721 is:
A: Black
B: White
C: Red
D: Green
Liquid Wrench helped in getting the old cable out of the connector shell and free up the brass ferrel that the nut compresses.
Removed the old yellow label since the new shrink tube would not pass over it.
Marked:

On the PP-6224 two rear output connectors (J3 or J4) A = Gound, B= +28 VDC.  Pins C and D are not used.
PP-6224 to
                    GRC-193 DC Power Cable


This is the new GRC-193 DC power cable made to be driven by the PP-6224 or any other Mil Vehicle 4-socket source.




CU-2064 Antenna Coupler Harris

Motors

There may be an issue with this tuner sticking or not tuning properly.  Looking at the manuals it's clear that they have a LUBE section.
Dave Ross said it first anThed uses it for the title of his web page: Real Radios Have Motors.
So Lubing the tuner may be the first order of business since it's sat for some decades without being used.
The RF Amp and Antenna Coupler both have 1987 contract dates and it's now 2012 so about 25 years.


CU-2064 J2 Control
                  Connector Pin Out




AM-6879 Audio Amplifier-RTTY Converter

Alows for Teletype, Computer or FAX communications.

MT-6232 Army GRC-193 System Mount

This is the common Army mount for the system.  It's a two level rack where the CU-2064 Antenna Coupler is at the upper left with the HV antenna connection facing the back.
The AM-6545 RF amp is in the upper right facing forward as are all the other items.
Top showing Dogs.  The outside dogs are clamps but the
inside dogs are fixed. Tere is provision for 4 dogs at the left, why?
MT-6232/GRC-193 Mount Top View Showing Dogs
Side View of RF Amp and Coupler
The CU-2064 has 5" spacing on the other side instead of 6-1/4".
Side View
                    of AM-6545 & CU-2064 Showing Dog Notches
Top & Back with center Dogs positioned correctly.
MT-6232 Rear
                    With Center Dogs in Correct Postions

Front
MT-6232/GRC-193 Mount Front Showing AM-6879
                    Audio Amp & RT-1209A

MT-6233 Single Level GRC-193 System Mount

This mount is for installing the GRC-193 into tracked vehicles like the  M1113 APC.
MT-6233/GRC-193
            Single Lever for Tracked Vehicels

MT-6378 Mount

The stock version is for use with AB-21 or MS-116 type mast elements.

MT-6378/GRC-193A
                    Mount, Remote Siting
MT-6378/GRC-193A Mount, Remote Siting Lowered Position

This base is the AB-652.
MT-6378 Mount
                    taken apart so see what's needed to convert to the
                    AT-1011 Mast elements
What's needed to convert to the AT-1011 mast elements?
Ans:  The Witch's Hat AT-1011 base.
This is part of the remote antenna siting kit (MK-2560) aka Remoting Kit.

Power Supplies

Military Vehicle 24 Volts

This would be the most common way to power the GRC-193 system.

PP-7333

TM 08077A-15 PP-7733D

PP-8474

NSN: 6130-01-475-4999
Input: 115VAC, 47 - 63 Hz
Output V: 24-28 VDC
Output I:  0 60 Amps

World Power Supply

Like the PP-8474 except
Input: 115/230 VAC 47 - 63 Hz
Output V: 18 - 30 VDC
Output I: 0 - 60 Amps
DC out cojnnector: 3-pin Cannon Type MS3106F222S

Cables

DC mil V 4S to 6P  80063-A3191576-001

GRC-193 Cable
            diagram
#
Function
Equip 1 - Jack No.
Equip 2 - Jack No.
1
Audio to Amp-Speaker


2
RT Interface


3
low level RF to/from Pwr Amp


4
Control to/from Pwr Amp
75501780714 Mfg 14304, Ends: P1 & P2
Note the P2 end has a mangled connector nut.

GRC-193 Low Level RF Cable w/Problem
Before reinstalling nut
GRC-193 low lever RF Cable before
                          reinstalling nut
After reinstalling nut
GRC-193 low lever RF Cable after
                          reinstalling nut
The cable was OK.  0.0269 dB loss at 30 MHz. 
Wiggling had no effect.


5
Control to/from Ant Coupler


6
RF to/from Ant Coupler


7
HV Conn on Ant Coupler to Whip
AM-6545 High
                    Voltage RF Cable FP156853
Conn:  SM-C-S029 I 2
Cable: CX-10171/U

8
Coax to 50 Ohm Ant


9
DC power input



Antennas

RF-4032 Tactical Antenna Siting Kit
1. MT-6378 NSN: 5975-01-200-9797 - holds AT-1011/U or smaller diameter antanna made from AB- or MS- mast sections.
2. Reel with Coax and Control cables (100 foot?) WANTED Contact
AS-2259 - NVIS
AT-1011/U - 16' or 32' whip
GRA-50 Dipole
TCI-651T - 2 - 30 MHz crossed delta loop

Remote Control

GRA-39

NSN & p/n Table



Related

PRC-104
GRC-206
RF3200ET
GRA-39 Remote
KY-65 Crypto

75 BAUD RTTY at 20 or 60 ma loop current. 
Mark: 1575 Hz
Space: 2425 Hz
What machines were used with the GRC-193B?  Let me know.

Links

System from Mike Murphy

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[an error occurred while processing this directive] page created 5 Dec 2011.