SERVICE MANUAL SURVIVAL CRAFT 2-WAY RADIO
INTRODUCTION This service manual describes the latest service information for the IC-GM1600/E VHF MARINE TRANSCEIVER at the time of publication. MODEL VERSION USA GEN EUR UK IC–GM1600 IC–GM1600E TX Hi-POWER 2W 2W 2W 2W To upgrade quality, all electrical or mechanical parts and internal circuits are subject to change without notice or obligation. DANGER NEVER connect the transceiver to an AC outlet or to a DC power supply that uses more than 7.5 V.
TABLE OF CONTENTS SECTION 1 SPECIFICATIONS SECTION 2 INSIDE VIEWS SECTION 3 DISASSEMBLY INSTRUCTIONS SECTION 4 CIRCUIT DESCRIPITON SECTION 4-1 RECEIVER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-2 TRANSMITER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-3 PLL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 SPECIFICATIONS • Frequency coverage IC-GM1600 IC-GM1600/E [USA] [GEN], [EUR], [UK] TX 156.025–157.425 MHz [ON-BOARD] 156.000–161.450 MHz [ON-BOARD] RX 156.050–163.275 MHz [ON-BOARD] 156.000–163.425 MHz [ON-BOARD] TX/RX 156.300–156.875 MHz [SURVIVAL] GENERAL • Number of programable channels • Type of emission 100 channels 16K0G3E 16K0G3E (for ATIS) 50 Ω (nominal) • Antenna impedance • Operating temperature range −4˚F to +140˚F • Power supply requirement –20˚C to +55˚C 7.
• CHANNEL LISTS • International channels Frequency (MHz) CH Transmit Receive 01 156.050 160.650 02 156.100 03 156.150 04 CH Frequency (MHz) Transmit Receive 11 156.550 156.550 160.700 12 156.600 160.750 13 156.650 156.200 160.800 14 05 156.250 160.850 06 156.300 156.300 07 156.350 160.950 08 156.400 156.400 18 09 156.450 156.450 19 10 156.500 156.500 CH Frequency (MHz) Transmit Receive 21 157.050 161.650 156.600 22 157.100 156.650 23 157.150 156.
SECTION 2 INSIDE VIEWS • MAIN UNIT TOP VIEW BOTTOM VIEW Antenna Switches *D131, D151: 1SV307 D152: MA2S077 S5V Regulator (Q561: 2SA1588) T5V Regulator (Q323: 2SA1588) IF amplifier (Q211: 2SC4215) Power amplifier (*Q111: RD07MVS1) Pre-drive (*Q101: RD01MUS1) RF amplifier R5 Regulator (Q165: 3SK294) (Q322: 2SA1588) TX/RX swith (D91, D92: MA77) VCO circuits D/A converter IC (IC251: M62363FP-657C) CPU IC661: PD78F0338 GC-9EB EEPROM (IC591: BR24L32FV-W) *Located in under the plate.
SECTION 3 DISASSEMBLY INSTRUCTIONS • REMOVING THE REAR PANEL 1 2 3 4 5 Remove the speaker panel A. Unscrew 2 screws B, and remove 2 washers C. Unscrew 2 screws D. Unscrew 2 screws E, and remove 2 washers F. Remove the rear panel and the main seal from the front panel. Note: When replacing the screws, 10–12 kg of torque MUST be applied to ensure water resistance. B C Rear panel D -)# 30 Main seal Front panel F E A R 7!2.).' .
SECTION 4 CIRCUIT DESCRIPTION The 1st IF signal from the 1st mixer is passed through the crystal filter (FI211) to suppress unwanted signals, and amplified at the 1st IF amplifier (Q211). 4-1 RECEIVER CIRCUITS 4-1-1 ANTENNA SWITCHING CIRCUIT The antenna switching circuit toggles receive line and transmit line. This circuit does not allow transmit signals to enter the receiver circuits. The amplified 1st IF signal is applied to the FM IF IC (IC231).
4-1-6 SQUELCH CIRCUIT 4-2-2 MODULATOR CIRCUIT Squelch circuit mutes AF output signal when no signals are received. The modulation circuit modulates the VCO oscillating signal with the audio signals from the microphone. A portion of the AF signals from the FM IF IC (IC231, pin 9) are applied to the IC251 to control the level, and the active filter (R239–R241, C237, C238). The filtered signals are applied to the noise amplifier section in the FM IF IC (IC231, pin 8) to amplify the noise components only.
The phase detector compares the input signal with a reference frequency, and then outputs the control signal (pulse-type) from pin 5. The pulse-type signal is converted into DC voltage at the loop filter (R17–R19, C16, C17), and then applied to the RX VCO (Q41, D31–D34) as the lock voltage. 4-3 PLL CIRCUITS 4-3-1 GENERAL PLL circuits control TX and RX VCO circuits. IC1 is a PLL IC and contains prescaler, programmable counter, programmable divider, phase detector, charge pump in its package.
4-4 POWER SUPPLY CIRCUITS 4-4-1 VOLTAGE LINES LINE VCC DESCRIPTION The voltage from the connected DC power supply passed through the [VOL] switch (R1: VR BOARD). PIN NUMBER PORT NAME 77, 78 LEDS1, LEDS2 80 MICMS DESCRIPTION Output port for dimmer control signal. Output port for microphone mute signal. "HIGH": Microphone mute Output port for internal speaker mute signal. "HIGH": Speaker mute CPU5V 5V for the CPU (IC661) converted from the VCC line at the CPU5V regulator circuit (IC551).
SECTION 5 ADJUSTMENT PROCEDURES 5-1 PREPARATION REQUIRED 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. EQUIPMENT GRADE AND RANGE : 0.1–3 W : 100–300 MHz : 50 Ω : Less than 1.
• CONNECTION AC millivoltmeter Audio generator OPC-478 (RS-232C type) to RS-232C port to the antenna connector Standard signal generator 0.1 µV to 32 mV (–127 dBm to –17 dBm) OPC-478U (USB type) DO NOT transmit while an SSG is connected to the antenna connector. to USB port PC Attenuator 20 dB / 30 dB To CLONE line (BLACK) To MIC. line (WHITE) RF power meter 0.
• PC SCREEN EXAMPLE I/O check button q w e r t y i u o NOTE: The above screen is an example. Each transceiver has its own specific values for each setting.
5-2 SOFTWARE ADJUSTMENT (FREQUENCY) Select the adjustment item with [↑] / [↓] keys, then set the value with [←] / [→] keys on the connected PC. MEASUREMENT ADJUSTMENT ADJUSTMENT CONDITION VALUE UNIT PLL LOCK VOLTAGE 1 • Operating CH. : 16 • Receiving PC screen 1.5–3.0 V [USA] Check the LVIN Data cell's v a l u e i n t h e I / O c h e c k 1.85–3.35 V [Others] window. (Verify) Click the "I/O check button" 1.4–2.
5-2 SOFTWARE ADJUSTMENT (TRANSMITTING) Select the adjustment item with [↑] / [↓] keys, then set the value with [←] / [→] keys on the connected PC. MEASUREMENT ADJUSTMENT ADJUSTMENT CONDITION VALUE UNIT OUTPUT POWER [RF Power (High)] 1 • Operating CH. : 16 • RF power : High • Transmitting [RF Power (Low)] 2 • Operating CH. • RF power • Transmitting OPERATION Top Connect the RF power meter to panel the antenna connector. : 16 : Low 2.0 W 0.
5-2 SOFTWARE ADJUSTMENT (RECEIVING) Select the adjustment item with [↑] / [↓] keys, then set the value with [←] / [→] keys on the connected PC. ADJUSTMENT MEASUREMENT ADJUSTMENT CONDITION UNIT RECEIVE SENSITIVITY [BPF T1] [BPF T2] [BPF T3] [BPF T4] VALUE OPERATION Top Connect the distortion meter with an 8 Ω 1 • Operating CH. : 16 • C o n n e c t th e s ta n d a rd s i g nal pannel load to the [MIC/SP] jack through the JIG cable. generator to the antenna connector and set as; Frequency : 156.
SECTION 6 PARTS LIST • IC-GM1600/E [MAIN UNIT] REF NO. IC1 IC141 IC231 IC251 IC261 IC281 IC282 IC341 IC382 IC383 IC421 IC481 IC491 IC551 IC581 IC591 IC661 IC681 IC682 IC683 [MAIN UNIT] ORDER NO. 1140005990 1110002750 1110003201 1190000350 1110005340 1130007301 1130006220 1130007570 1110003800 1130007990 1110001811 1130007301 1110003800 1110005350 1110005770 1130011570 1140012420 1130007301 1130007301 1110002750 S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.IC S.
[MAIN UNIT] [MAIN UNIT] REF NO. ORDER NO. DESCRIPTION R21 R22 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 7030005050 7030005210 7030005530 7030005120 7030005120 7030005530 7030008300 7030005240 7030005090 7030005240 7030005090 7030005040 S.RES S.RES S.RES S.RES S.RES S.RES S.RES S.RES S.RES S.RES S.RES S.
[MAIN UNIT] [MAIN UNIT] REF NO. ORDER NO.
[MAIN UNIT] [MAIN UNIT] REF NO. ORDER NO.
[VR UNIT] [MAIN UNIT] REF NO. ORDER NO.
SECTION 7 MECHANICAL PARTS AND DISASSEMBLY 7-1 CABINET PARTS [MAIN UNIT] [MIC BOARD] REF. ORDER. NO. DS681 5030002790 LCD A0286 DESCRIPTION QTY. 1 EP681 8930064210 LCD contact SRCN-2795-SP-N-W 1 MP681 8930063850 2795 LCD holder 1 REF. J416 ORDER. NO. 6510024650 DESCRIPTION REF. EP1 EP5 EP8 ORDER. NO.
EP1 (A) Grease MP73 NOTE 2 MP71 (C) MP66 (C) MP80 (C) MP46 (C) NOTE 2 J41 (C) MP71 (C) MP75 (C) Unit: mm (inch) MP69 (C) MP74 (C) NOTE 1 : Once the VR BOARD is removed from the front panel, grease must be applied to the area described as above when assembling. Manufacture : Shin-Etsu Chemical Type : G-501 176 (6 15/16) MP73 MP74 (C) MP26 (C) MP23 (C) MP25 (C) MP20 (C) MP74 (C) 57.3 (2 1/4) 44 (1 23/32) VR BOARD MP24 (C) W470 (MI) 145.3 (5 23/32) 159.6 (6 9/32) 294.
SECTION 8 • TRANSISTORS AND FET’s • BC-158 CHARGER PARTS LIST 2SA1588 GR (Symbol: ZG) MECHANICAL PARTS 2810 case 2523 cover Screw B0 3 x 8 NI-ZU (BT) Leg cushion (C) QTY. 1 1 2 2 2SC4215 O (Symbol: QO) 8930057120 8930057120 DESCRIPTION 2523 Terminal 2523 Terminal MP1 1 1 2SK880 Y (Symbol: XY) CHARGE unit B C C C E E E S 3SK299 U73 (Symbol: U73) 3SK294 (Symbol: UV) 2SK1829 (Symbol: K1) E B C E G1 S G2 D DTA144 TU (Symbol: 06) B G ORDER. NO.
SECTION 9 BOARD LAYOUTS 9-1 MAIN UNIT • TOP VIEW Horizontal 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 50 0 R233 Q441 IC421 R433 J414 C326 C144 R693 D132 L132 C138 L124 L123 C131 C132 C123 L121 R112 C124 R132 R133 C129 R121 C114 Q111 R111 R122 C142 R145 R147 C143 C431 R432 IC141 C141 R142 R149 C145 R143 D141 Q323 R562 C122 L122 C113 D131 C127 C125 C126 R114 C112 R102 R113 C137 C128 C121 C105 C104 C11
• BOTTOM VIEW 50 C392 R388 C398 X381 R389 C393 C394 C386 C686 IC681 C670 C535 R535 IC661 C664 R534 R533 C581 R532 IC581 R581 R591 15 R638 R637 R635 R715 CP1 R633 R631 IC341 EP2 10 R592 C591 C643 R634 R4 R639 R694 R717 C19 R22 Q3 20 C666 C665 R531 R20 C20 l C668 R632 R21 25 IC591 R636 5 C48 0 115 110 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 Horizontal 9-2 20 15 10 5 0 120 V ti C682 C671 C683 C667 C341 R18 R687 R6
9-2 VR BOARD • TOP VIEW Horizontal 0 5 10 15 R801 Vertical 0 5 10 9-3 MIC BOARD • TOP VIEW Horizontal 0 5 10 15 0 Vertical 5 10 J416 15 9-4 BC-158 TOP VIEW Horizonal 65 60 55 50 45 40 35 30 25 20 15 10 5 0 0 5 R3 DS1 R2 10 MP1 MP2 R1 B5787B J1 15 20 HV GND GND J1 to the AC adapter AC-147A/E 9-3 Vertical •
• BOTTOM VIEW Horizontal 15 10 5 0 Vertical F1 B6191C 0 5 10 • BOTTOM VIEW Horizontal 10 5 0 0 J415 to the MAIN unit J414 8 EP452 J415 SPG SPG AFOUT AFOUT GND GND GND EXDET EXTMIC TLED RLED 10 C702 C700 EP458 EP451 Vertical C703 EP454 5 R714 R713 Q655 B6192B DS655 15 7 1 BOTTOM VIEW Horizonal 0 5 10 15 20 25 03 0 5 Vertical • 14 GND GND 15 10 15 20 9-4 35 40 45 50 55 60 65
SECTION 10 BLOCK DIAGRAM ANTENNA V5V RIPPLE FIL VCO Q47: XP6501 Q41: 2SC4226 D31-34: HVC350B LOINV Q3: 2SK880 15.3 MHz FM MOD LOOP FIL D35-38: HVC350B X231: CDBC450CX24 30.6 MHz DET D231: DAN222 W/N SW RLED BPF D182: HVC350B Q191: 3SK299 BPF 31.
C691 0.018 11 - 1 R716 R711 100 k IC261 NJM12902V 3 AG3V AG3V IC481 TC4W66FU 1 2 3 4 MOD 8 7 6 5 R491 15 k 1 2 3 4 UNLKI EXOEO VSSTBO EXSTBO R493 560 k R495 4.7 k DASTBO PLSTBO SDATAO SCLKO R717 ERJ2GE-JPW S103 EVQP2T02M R631 10 k R634 10 k R635 10 k R636 10 k R633 10 k R637 10 k R638 10 k R639 10 k 8 7 6 5 AFOUT S5V AG3V ISPMS CPU5V ATIS C643 0.
A B C SRXMS DET R5V NOTES : Contorol line Common line TX line CTFIS DETMS MODIN C129 0.001 R121 15 k R131 82 k C132 22 P D132 1SS375 C138 0.5 P C136 9 P C134 24 P C151 9 P C152 10 P D151 1SV307 C153 3P D152 MA2S077 C155 0.001 R132 15 k C137 0.001 TDETV R133 10 k D153 1SV308 C158 0.001 R154 10 k C162 0.001 L156 56 nH [GM1600] 47 nH [GM1600E] R151 100 L153 1 H T1CON J352 IMSA-9230B-1-06Z032-PT1 1 2 3 4 5 6 D41 SB20-03P R571 330 k C282 0.001 CP283 R693 1k R572 150 k R434 2.
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