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SERVICE

MANUAL

SURVIVAL CRAFT 2-WAY RADIO

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Summary of Contents for IC-GM1600

Page 1: ...SERVICE MANUAL SURVIVAL CRAFT 2 WAY RADIO ...

Page 2: ... convenience 1 Make sure a problem is internal before disassembling the transceiver 2 DO NOT open the transceiver until the transceiver is disconnected from its power source 3 DO NOT force any of the variable components Turn them slowly and smoothly 4 DO NOT short any circuits or electronic parts An insulated turning tool MUST be used for all adjustments 5 DO NOT keep power ON for a long time when...

Page 3: ...ER SUPPLY CIRCUITS 4 4 4 5 PORT ALLOCATIONS 4 4 SECTION 5 ADJUSTMENT PROCEDURES 5 1 PREPARATION 5 1 5 2 SOFTWARE ADJUSTMENTS 5 4 SECTION 6 PARTS LIST SECTION 7 MECHANICAL PARTS AND DISASSEMBLY SECTION 8 SEMICONDUCTOR INFORMATION SECTION 9 BOARD LAYOUTS 9 1 MAIN UNIT 9 1 9 2 VR BOARD 9 3 9 3 MIC BOARD 9 3 9 4 BC 158 9 3 SECTION 10 BLOCK DIAGRAM SECTION 11 VOLTAGE DIAGRAM 11 1 MAIN UNIT 11 1 11 2 VR...

Page 4: ...GHz 1 00 µ W 1 GHz 2 GHz Adjacent channel power 70 dB Audio harmonic distortion 10 at 60 deviation FM hum and noise 40 dB Residual modulation 40 dB Audio frequency response 1 dB to 3 dB of 6 dB oct from 300 Hz to 3000 Hz Limiting charact of modulation 60 100 of max deviation Microphone impedance 2 kΩ RECEIVER Receive system Double conversion superheterodyne system Intermediate frequencies 1st 31 0...

Page 5: ... geographical separation USA channels Survival operation channels for U K version only CH Frequency MHz CH Frequency MHz CH Frequency MHz CH Frequency MHz CH Frequency MHz CH Frequency MHz Transmit Receive Transmit Receive Transmit Receive Transmit Receive Transmit Receive Transmit Receive 01A 156 050 156 050 12 156 600 156 600 22A 157 100 157 100 64A 156 225 156 225 77 156 875 156 875 86 157 325 ...

Page 6: ...7 R5 Regulator Q322 2SA1588 S5V Regulator Q561 2SA1588 Power amplifier Q111 RD07MVS1 Pre drive Q101 RD01MUS1 CPU IC661 PD78F0338 GC 9EB VCO circuits EEPROM IC591 BR24L32FV W Reset IC IC581 S 80942CNMC Antenna Switches D131 D151 1SV307 D152 MA2S077 RF amplifier Q165 3SK294 D A converter IC IC251 M62363FP 657C Located in under the plate ...

Page 7: ...ANEL 1 Remove the speaker panel A 2 Unscrew 2 screws B and remove 2 washers C 3 Unscrew 2 screws D 4 Unscrew 2 screws E and remove 2 washers F 5 Remove the rear panel and the main seal from the front panel REMOVING THE MAIN UNIT 1 Unscrew 9 screws L 2 Unsolder 2 points M and take off the main unit in the direction of the arrow Note When replacing the screws 10 12 kg of torque MUST be applied to en...

Page 8: ...IF signal by mixing with local oscillator LO signal The converted 1st IF signal is filtered at the 1st IF filter then amplified at the 1st IF amplifier The signals from the two stage BPF are converted into the 31 05 MHz 1st IF signal at the 1st mixer Q191 by being mixed with the 1st LO signals generated at RX VCO Q41 D31 D34 The 1st IF signal from the 1st mixer is passed through the crystal filter...

Page 9: ... the splatter filter IC491 B pins 6 7 to suppress unwanted 3 kHz and higher audio signals then applied to the modulation circuit via the D A converter IC251 pins 3 4 4 2 2 MODULATOR CIRCUIT The modulation circuit modulates the VCO oscillating signal with the audio signals from the microphone AF signals from the D A converter IC251 pin 3 are applied to the modulation circuit D39 to modulate the osc...

Page 10: ...from the phase of the reference frequency causing a lock voltage change to compensate for the drift in the oscillated frequency 4 3 2 TRANSMIT LOOP A portion of the generated signal at the TX VCO Q51 D35 D39 is applied to the PLL IC IC1 pin 8 via buffer amplifier Q71 The applied signal is divided at the prescaler section and programmable divider section and is then applied to the phase detector se...

Page 11: ...ET Input port for the MIC SP detect signal 29 VOXT Input port for VOX signal 30 BATTV Input port for battery voltage detection signal 31 TDETV Input port for TX power level 32 NOISV Input port for noise level 33 RSSIV Input port for RSSI level 34 LOINV Input port for PLL lock voltage level 35 TEMPV Input port for temperture level 75 76 CONT1 CONT2 Output ports for LCD contrast control signal PIN N...

Page 12: ...UIRED TEST EQUIPMENTS When adjusting IC GM1600 E the optional CS M90 GM1600 ADJ ADJUSTMENT SOFTWARE Rev 1 0 or later OPC 478 RS 232 type or OPC 478U USB type CLONING CABLE OPC 1028 and JIG cable see page 5 2 are required Microsoft and Windows are registered trademarks of Microsoft Corporation in the U S A and other countries STARTING SOFTWARE ADJUSTMENT 1 Connect IC GM1600 E and a PC with OPC 478 ...

Page 13: ...m to 17 dBm DO NOT transmit while an SSG is connected to the antenna connector To CLONE line BLACK To MIC line WHITE To red line RED IC GM1600 E JIG cable PC To SP To SP connector connector to USB port to RS 232C port OPC 478 RS 232C type OPC 478U USB type OPC 1028 CONNECTION JIG CABLE 5 2 OPC 478 U WHITE MIC line SP line BLACK SHIELD CLONE line OPC 1028 RED To audio generator AC millivoltmeter To...

Page 14: ...pecific values for each setting q Adjustment condition w Reference frequency e RF output power r FM deviation Wide t Receive sensitivity Automaticaly y Receive sensitivity Manualy u Squelch level i S meter o VOX q w e i o r t u y I O check button PC SCREEN EXAMPLE 5 3 ...

Page 15: ...erify 2 Operating CH 16 RF power Low Transmitting 1 4 2 9 V Verify REFERENCE FREQUENCY Ref Freq 1 Operating CH 16 Connect the RF power meter or a 50 Ω dummy load to the antenna connector RF power Low Transmitting Top Panel Loosely couple the frequency counter to the antenna conector 156 8000 MHz 500 Hz PLL LOCK VOLTAGE NOTE The above screen is an example Each transceiver has its own specific value...

Page 16: ... De emphasis OFF Detector P P 2 Connect the audio generator to the MIC SP jack through OPC 1028 and set as Frequency 1 kHz Level 25 mV rms Transmitting Top panel Connect the FM deviation meter to the antenna connector through the attenuator 4 15 4 25 kHz VOX VOX 1 Operating CH 16 Set to VOX mode Push SQL Hi Lo No audio applied to the MIC SP jack PC screen Push the ENTER key on the keyboad of the c...

Page 17: ...ey 2 The connected PC tunes BPF T1 T4 to peak level automaticaly or 1 Put the cursor on the one of BPF T1 T4 as desired 2 Push the ENTER key to start tuning 3 Repeat 1 and 2 to perform additional BPF tuning SQUELCH LEVEL Noise 1 Operating CH 16 Connect the standard signal generator to the antenna connector and set as Frequency 156 800 MHz Level 5 dBµ USA 6 dBµ Others Modulation 1 kHz Deviation 3 0...

Page 18: ...5 D38 1750000711 S VCP HVC350B E B 63 8 18 8 D39 1720000400 S VCP 1SV245 TPH3 T 66 4 20 1 D40 1790001620 S DIO 1SV308 TPL3 Except USA B 65 4 10 D41 1790000680 S DIO SB20 03P TD B 118 7 29 3 D91 1790000620 S DIO MA77 TX T 82 5 18 4 D92 1790000620 S DIO MA77 TX T 81 3 22 D121 1790001670 S DIO RB706F 40T106 T 108 3 15 9 D131 1750000580 S DIO 1SV307 TPH3 T 111 9 9 8 D132 1790001210 S DIO 1SS375 TL T 1...

Page 19: ... 2 16 8 R201 7030005120 S RES ERJ2GEJ 102 X 1 kΩ T 84 8 23 7 R202 7030005050 S RES ERJ2GEJ 103 X 10 kΩ T 83 5 22 8 R203 7030005000 S RES ERJ2GEJ 471 X 470 Ω T 87 2 22 R204 7030010430 S RES ERJ2GEJ 120 X 12 Ω T 85 9 20 8 R205 7030005000 S RES ERJ2GEJ 471 X 470 Ω T 86 4 19 5 R206 7030005040 S RES ERJ2GEJ 472 X 4 7 kΩ B 85 9 16 5 R211 7030005120 S RES ERJ2GEJ 102 X 1 kΩ B 85 9 25 2 R213 7030005030 S ...

Page 20: ... 8 R657 7030005010 S RES ERJ2GEJ 681 X 680 Ω T 15 3 11 8 R658 7030005120 S RES ERJ2GEJ 102 X 1 kΩ T 16 2 22 7 R659 7030005010 S RES ERJ2GEJ 681 X 680 Ω T 15 2 22 7 R662 7030007280 S RES ERJ2GEJ 331 X 330 Ω USA GEN T 68 9 4 3 7030005010 S RES ERJ2GEJ 331 X 680 Ω Others T 68 9 4 3 R663 7030004990 S RES ERJ2GEJ 221 X 220 Ω T 70 3 3 3 R681 7030009150 S RES ERJ2GEJ 824 X 820 kΩ B 12 7 27 2 R682 7030005...

Page 21: ...0007010 S CER C1608 CH 1H 100D T B 60 1 28 1 C222 4030016790 S CER ECJ0EB1C103K B 61 3 29 8 C223 4030007040 S CER C1608 CH 1H 180J T B 67 30 4 C224 4030009520 S CER C1608 CH 1H 020B T B 67 28 1 C225 4030007050 S CER C1608 CH 1H 220J T B 68 3 30 4 C226 4030006980 S CER C1608 CH 1H 070D T B 70 9 28 9 C231 4030017460 S CER ECJ0EB1E102K B 82 8 38 2 C232 4030007130 S CER C1608 CH 1H 101J T T 75 7 34 7 ...

Page 22: ...CER ECJ0EB1E102K B 32 1 42 3 C695 4030018860 S CER ECJ0EB0J105K B 48 8 39 5 C696 4030016930 S CER ECJ0EB1A104K B 48 5 41 8 C697 4030016930 S CER ECJ0EB1A104K B 36 45 5 C698 4030017460 S CER ECJ0EB1E102K B 113 8 31 3 C699 4030017460 S CER ECJ0EB1E102K B 90 9 48 C700 4030018860 S CER ECJ0EB0J105K B 92 9 48 J352 6910016370 CNR IMSA 9230B 1 06Z032 PT1 J412 6510021900 S CNR BM02B ASRS TF T 107 3 40 1 J...

Page 23: ...12110 Knob N 321 A 1 MP35 8830001480 VR nut O 1 MP41 8010019740 2795 chassis 1 MP46 8930064200 2795 main seal 1 MP47 8810009510 Screw B0 2X4 NI ZU BT 9 MP51 8830001600 Screw nut L 1 MP52 8930065190 O ring BB 1 MP66 8930059800 2600 pet sheet 1 MP69 8820001330 Screw M3X3 BS NI 2 MP70 8810010150 Screw B0 2X10 SUS ZK 2 MP71 8820001320 2795 screw 4 MP73 8930063690 O ring BA 4 MP74 8810009560 Screw B0 2...

Page 24: ...P73 MP71 C MP73 MP66 C MP70 C MP24 C MP75 C MP74 C MP74 C MP74 C MP41 C MIC BOARD W3 C MP26 C MP25 C MP20 C MP77 C NOTE 1 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 Unit mm inch 294 9 11 5 8 176 6 15 16 159 6 6 9 32 145 3 5 23 32 65 2 5 6 57 3 2 1 4 44 1 23 32 Grease Once the VR BOARD is removed from the front panel grease must be applied to the area described as above when assembling Manufacture Shin Ets...

Page 25: ...B1 C2 C1 B2 E2 E C B E E C B E C B E1 C2 B1 C1 E2 B2 DIODES HVC350B Symbol B0 MA2S111 Symbol A RB706F 40 Symbol 3J MA2S728 Symbol B 1SV307 Symbol TX MA2S077 Symbol S 1SS375 Symbol FH 1SV245 Symbol T3 1SV308 Symbol TX DA221 Symbol K DAN222 Symbol N A1 A2 C MA77 Symbol 4B C A SB20 03P Symbol SC A1 A2 C A1 A2 C BC 158 CHARGER PARTS LIST CHASSIS UNIT REF ORDER NO DESCRIPTION QTY MP1 8510016540 2810 ca...

Page 26: ... R91 R202 C201 R205 R201 R246 C246 R245 R244 R231 C245 C215 R215 C216 R213 R232 R214 R216 R321 C324 R561 R141 R431 R148 C115 R144 C137 C128 R146 R323 R415 R414 C92 C100 R391 R31 R37 R36 R39 R305 C36 R38 R298 R296 R277 DS658 IC282 IC281 C272 Q291 D39 L33 L31 Q82 Q81 C82 L82 L81 C81 Q91 C111 L92 C37 D91 C91 D92 C202 Q321 Q322 Q561 C210 C411 Q232 C412 IC551 Q444 Q441 Q443 Q442 Q411 Q323 IC141 C326 J4...

Page 27: ...R222 C222 R247 R64 C64 C63 R63 R71 C72 R72 R390 R40 C38 R62 R61 R53 R43 R32 R47 R33 R468 C461 R718 R552 C426 R422 C165 C181 R185 R191 R192 C194 R211 C192 C211 C191 R193 C61 R65 D35 D38 D37 D36 C56 C55 C44 C45 C195 C173 R181 C172 R172 D171 R173 D153 D152 R698 D41 C553 L156 L154 C160 C164 R572 Q552 Q165 C185 C189 Q191 C193 L181 C188 C184 C171 C159 C163 L153 C153 C152 L131 C135 C151 L151 L152 C156 C1...

Page 28: ... B5787B 35 30 25 20 15 10 5 0 Horizonal 65 60 55 50 45 40 20 15 10 5 0 Vertical J1 to the AC adapter AC 147A E HV GND GND 9 3 MIC BOARD TOP VIEW 9 4 BC 158 TOP VIEW R801 0 5 10 Vertical 15 10 5 0 Horizontal J416 0 5 10 Vertical 15 10 5 0 Horizontal 15 ...

Page 29: ...AFOUT AFOUT GND GND 1 7 14 8 GND GND GND EXDET EXTMIC TLED RLED J415 to the MAIN unit J414 15 10 5 0 Vertical 15 10 5 0 Horizontal BOTTOM VIEW B6191C F1 0 5 10 Vertical 15 10 5 0 Horizontal BOTTOM VIEW 35 3 0 25 20 15 10 5 0 Horizonal 65 60 55 50 45 40 20 15 10 5 0 Vertical BOTTOM VIEW ...

Page 30: ...U IC491A NJM2904V IC491B NJM2904V W N SW ANALOG SW IC282 TC4W53FU LPF LPF IC261D NJM12902V NJM12902V IC261C IC251 M12363FD 650C DETMS IC281A TC4W66FU Q411 2SC4213 AFMS BEEPO Q501 UNR9213J Q321 2SA1588 Q323 2SA1588 Q322 2SA1588 IC551 NJM2870 REG R5V ATT D154 HVC350B HVC350B D155 HVC350B D181 HVC350B D182 Q165 3SK294 3SK299 Q191 FI211 FL 377 W N SW W NS W N SW Q232 2SC5107 Q231 UNR9213J W NS FI231 C...

Page 31: ...81 100 k R583 100 k R584 100 k C689 0 001 R294 10 k IC591 BR24L32FV W 1 A0 2 A1 3 A2 4 VSS 5 SDA 6 SCL 7 WP 8 VCC C662 0 001 R490 56 k EP682 CV1083 C698 0 001 C699 0 001 IC661 PD78F0338GC 9EB FX 2795A 1 P30 TO0 2 P31 TI00 3 P32 TI01 4 P33 TO50 TI50 5 P34 TO51 TI51 6 P20 RXD0 SI3 7 P21 TXD0 SO3 8 P22 SCK3 9 P23 SI1 10 P24 SO1 11 P25 SCK1 12 P00 INTP0 13 P01 INTP1 14 P02 INTP2 15 P03 INTP3 ADTRG 16 ...

Page 32: ... 6 C571 0 01 R572 150 k C4 47 P C83 47 P C97 47 P C114 47 P C128 47 P C166 47 P C192 47 P Q553 UNR9213J Q82 UNR9213J Q231 UNR9113J Q141 UNR9113J D41 SB20 03P C173 47 P EP2 ACZ1005Y 102 EP3 ACZ1005Y 102 EP4 ACZ1005Y 102 C11 0 001 C181 0 001 C211 0 001 C12 10 P R15 10 k R21 10 k R93 10 k R146 10 k R154 10 k R156 10 k R171 10 k R183 10 k R185 10 k R202 10 k R321 10 k R323 10 k R325 10 k R551 10 k R56...

Page 33: ...d Centre 150 6165 Highway 17 Delta B C V4K 5B8 Canada Phone 1 604 952 4266 Fax 1 604 952 0090 URL http www icomcanada com E mail info icomcanada com A B N 88 006 092 575 Unit 1 103 Garden Road Clayton VIC 3168 Australia Phone 61 03 9549 7500 Fax 61 03 9549 7505 URL http www icom net au E mail sales icom net au 146A Harris Road East Tamaki Auckland New Zealand Phone 64 09 274 4062 Fax 64 09 274 470...

Page 34: ...S 141221Z C1 q 2005 Icom Inc ...

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