Icom IC-M802 User Manual

MF/HF MARINE TRANSCEIVERiM802SERVICEMANUAL

3 - 43-2-5 RF CIRCUIT (MAIN, PA UNITS AND DRIVERBOARD)The RF circuit amplifies operating (transmitting) frequencyto obtain 150 W of RF output.The sign

3 - 5• 14–19.9999 MHz signalThe signal is applied to the relay (FILTER unit; RL7211)which is controlled by the band control IC (MAIN unit;IC3602) as t

3 - 63-3 PLL CIRCUITS3-3-1 GENERALThe PLL circuits generate a reference frequency (32.000MHz); 1st LO frequencies (64.485–94.455 MHz); 2nd LOfrequency

3 - 73-4 DSC CIRCUITS ([USA], [CAN] ONLY)3-4-1 DSC BANDPASS FILTER AND RF AMPLIFIERCIRCUITS (MAIN UNIT)The RF circuit filters out-of-band signals and

3 - 83-5-3 GROUP AND CHANNEL DIALS CIRCUIT(DISPLAY AND SENSOR BOARDS)• GROUP DIALThe signals from the group dial (SENSOR board; S8801) isapplied to th

3 - 9Pinnumber9092939497PortnameECKASENTEMPNSENRFMLDescriptionOutputs serial clock signal for theEEPROM (IC3301, pin 6).Input port for the SEND signal

3 - 103-7-5 OUTPUT EXPANDER IC (IC3603)Pinnumber456111314PortnameNMSEMSMMSNMRSAFMSCSENDescriptionOutputs NBDP MOD control signal forthe gate mod IC (I

3 - 113-7-8 FRONT CPU PORT ALLOCATIONS (RC-25,DISPLAY BOARD; IC8201)Pinnumber172122232425262831323334353641–4648–5557585960616263646566676869707172Por

4 - 14-1 PREPARATIONWhen adjusting the contents on page 4-9, a JIG CABLE (see illustration as shown below) is required.Some adjustments must be perfor

ENTERING THE ADJUSTMENT MODE1 Turn the power OFF.2 Push and hold the HM-135’s [DOWN] key, [TX] and [RX] buttons, then turn the power ON.NOTE: Insert

INTRODUCTIONThis service manual describes the latest service information for the IC-M802 MF/HF MARINE TRANSCEIVER at the timeof publication.DANGERNEV

4 - 34-2 PLL UNIT ADJUSTMENTLPL LOCKVOLTAGEHPL LOCKVOLTAGEREFERENCEFREQUENCY121212• Operating frequency : 0.5000 MHz• Mode : J3E• Receiving• Operating

4 - 4HPL lock voltage check pointCP5401C5394Reference frequency adjustment (USA, CAN)X5251LPL lock voltage check pointCP5301Reference frequency check

4 - 54-3 PA AND FILTER UNITS ADJUSTMENTIDLINGCURRENT(For driveFETs)(For finaltransistors)SWRDETECTOR12• Operating frequency : 12.2350 MHz• Mode : J3E•

SWR detector check pointCP7331 (REF line)Connect to groundCP7332 (FOR line)SWR detector adjustmentC72754 - 6R6304Idling current adjustment(For drive F

4-4 RECEIVER ADJUSTMENTS”TOTAL GAIN”, “S-METER” and “DSC PEAK” adjustments must be performed at “ADJUSTMENT MODE”.NOISE NULLPOINTRECEIVERGAINTOTAL GAI

4 - 8L307Receiver gain adjustmentNoise null point adjustmentL302L208L209L301L210L207DSC peak adjustmentL2307L2306[ENT]• IC-M802 TOP VIEW• RC-25 FRONT

4 - 94-5 TRANSMITTER ADJUSTMENTSThe following adjustments must be performed at “ADJUSTMENT MODE” after “SWR DETECTOR” and “RECEIVER” ADJUST-MENTS in t

[CH][ENT]Transmit peak and total gainadjustmentL706R6516Ic-APC adjustmentJ3101 pin 15Connect to ground when adjusting IC-APC4 - 10• IC-M802 TOP VIEW•

[MAIN UNIT]5-1 IC-M802[MAIN UNIT]IC1 1110004080 S.IC µPC2709T-E3IC501 1110005460 S.IC TA4107F (TE12L) IC901 1110005460 S.IC TA4107F (TE12L) IC10011130

[MAIN UNIT][MAIN UNIT]S.=Surface mountL55 6200002040 S.COIL NL 252018T-101JL56 6200002040 S.COIL NL 252018T-101JL101 6200003940 S.COIL NL 252018T-5R6J

TABLE OF CONTENTSSECTION 1 SPECIFICATIONS SECTION 2 INSIDE VIEWSSECTION 3 CIRCUIT DESCRIPTIONSECTION 4 ADJUSTMENT PROCEDURESSECTION 5 PARTS LISTSECT

S.=Surface mount[MAIN UNIT][MAIN UNIT]L2702 6200003520 S.COIL ELJFB 102K-F [USA], [CAN]L2703 6200002040 S.COIL NL 252018T-101J [USA], [CAN]L3301 62000

[MAIN UNIT][MAIN UNIT]S.=Surface mountR1222 7030003240 S.RESISTOR ERJ3GEYJ 220 V (22 Ω) R1223 7030003480 S.RESISTOR ERJ3GEYJ 222 V (2.2 kΩ) R1224 7030

S.=Surface mount[MAIN UNIT][MAIN UNIT]R2708 7030003440 S.RESISTOR ERJ3GEYJ 102 V (1 kΩ) [USA], [CAN]R2709 7030003320 S.RESISTOR ERJ3GEYJ 101 V (100 Ω)

[MAIN UNIT][MAIN UNIT]S.=Surface mountC62 4030006870 S.CERAMIC C1608 JB 1H 222K-TC63 4030008860 S.CERAMIC C1608 JB 1H 153K-TC64 4030011600 S.CERAMIC C

S.=Surface mount[MAIN UNIT][MAIN UNIT]C707 4030006970 S.CERAMIC C1608 CH 1H 060D-TC709 4030007080 S.CERAMIC C1608 CH 1H 390J-TC710 4030007040 S.CERAMI

[MAIN UNIT][MAIN UNIT]S.=Surface mountC2104 4030011600 S.CERAMIC C1608 JB 1E 104K-T [USA], [CAN]C2105 4030008920 S.CERAMIC C1608 JB 1H 473K-T [USA], [

S.=Surface mount[PLL UNIT][MAIN UNIT]EP1 0910054676 PCB B 5722F EP2 0880000900 UNIT BOARD EX-2432 #02 [USA], [CAN]0880001190 UNIT BOARD EX-2432 #03 [

[PLL UNIT][PLL UNIT]S.=Surface mountR5113 7030007210 S.RESISTOR ERA3YEB 102V R5114 7030007210 S.RESISTOR ERA3YEB 102V R5115 7030007210 S.RESISTOR ERA3

S.=Surface mount[PLL UNIT][PLL UNIT]R5901 7030007220 S.RESISTOR ERA3YED 202V [USA], [CAN]R5902 7030007230 S.RESISTOR ERA3YED 102V [USA], [CAN]R5903

[PLL UNIT][PLL UNIT]S.=Surface mountC5705 4030006880 S.CERAMIC C1608 JB 1H 472K-TC5706 4030006880 S.CERAMIC C1608 JB 1H 472K-TC5707 4030006880 S.CERAM

• IC-M802‘‘GENERAL• Frequency coverage : • Mode : TX/RX J3E (USB/LSB), J2B (AFSK), F1B (FSK), A1A (CW)H3E [OTH]RX H3E [USA], [CAN]DSC J2B [USA], [CAN]

S.=Surface mount[PA UNIT][PA UNIT]R6403 7030010260 S.RESISTOR ERJ1TYJ 3R3 UR6404 7030010260 S.RESISTOR ERJ1TYJ 3R3 UR6405 7030010260 S.RESISTOR ERJ1TY

[FILTER UNIT][FILTER UNIT]S.=Surface mountQ7301 1590000680 S.TRANSISTOR DTC114EUA T106D7271 1750000190 S.DIODE 1SS322 (TE85R) D7272 1750000190 S.DIODE

S.=Surface mount[DRIVER UNIT][FILTER UNIT]C7218 4030006880 S.CERAMIC C1608 JB 1H 472K-TC7221 4030014460 S.CERAMIC GRM31M2C2H820JV01LC7222 4010005860 C

[DSP UNIT]EX-2432[DSP UNIT] S.=Surface mountIC1 1130010010 S.IC TC7WHU04FUIC3 1130010540 S.IC SN74AHC74PWRIC4 1130010540 S.IC SN74AHC74PWRIC51 1130010

S.=Surface mount[DSP UNIT][DSP UNIT]C54 4030006900 S.CERAMIC C1608 JB 1H 103K-TC101 4030011600 S.CERAMIC C1608 JB 1E 104K-TC102 4510004630S.ELECTROLYT

[DISPLAY UNIT]RC-25[FRONT UNIT]S.=Surface mountW8001 8900009531 CABLE OPC-942A (P=1 N=10 L=170) W8005 8900008860 CABLE OPC-875 (N:20 L:70) IC8201 1140

S.=Surface mount[DISPLAY UNIT][DISPLAY UNIT]C8206 4030007020 S.CERAMIC C1608 CH 1H 120J-TC8207 4030007020 S.CERAMIC C1608 CH 1H 120J-TC8208 4030011600

HM-135[MAIN UNIT][VR UNIT]S.=Surface mountR8901 7210002360 VARIABLE TP96N97-15F-10KB-1301EP89010910054742 PCB B 5730B L8220 6200001830 S.COIL NL 3225

6-1 RC-256-2 SP-246-3 HM-135[CHASSIS PARTS]J4501 6510000370 Connector MR-DS 1J4503 6510000370 Connector MR-DS [USA],[CAN] only 1W4501 8900011050 Cable

[MAIN UNIT]J1451 6450000140 Connector HSJ0807-01-010 1J1801 6510023670 Connector TCS4480-01-4151 1J2051 6510023180 Connector TCS7282-01-211 1EP2 08800

1 - 2• RC-25 Remote controller‘‘GENERAL• Microphone impedance : 600 Ω• Audio output power : More than 5 mW at 16 Ω headphone with 10 % distortion• Aud

Unit abbreviations (F): FRONT PARTS(D): DISPLAY BOARD(J): JACK BOARD(S): SENSOR BOARD(V): VR BOARD(C): CONNECT BOARDRC-25MP8020 (F)J8602 (J)J8061 (J)M

6 - 4MP6 (C)MP5 (C)MC1 (M)MP14 (C)MP8 (C)MP9 (C)MP11 (C)MP4 (C)W1 (C)MP7 (C)MP9 (C)MP1 (C)MP12 (C)MP7 (C)SP1 (C)MP1 (C)MP8 (C)MP2 (C)MF4501 (C)MP4512

7 - 1SECTION 7 SEMI-CONDUCTOR INFORMATION• TRANSISTOR AND FET’SBECBCEBECBCEBECBECBECBECBCEBECBECBCEBCEDGSSDGSGDGGSDSG1G2SDBECBEC2SA1037AK S 2SA1213 Y

to IC-M802 MAINunit J2051J8602H13VTXDRXDFAFGFAFGNDFMODFMODG8 - 1SECTION 8 BOARD LAYOUTS8-1 HM-1358-1-1 SW BOARD• TOP VIEW8-1-2 MAIN BOARD• TOP VIEWPTT

H13V TXD RXDFAFGFAFGNDFMOD FMODGFMOD91to DISPLAYboard J890310 2J8601GNDFAFGTXDGNDFMODGFAFH13VRXDGNDVOLto DISPLAY board8 - 28-2-4 VR BOARD• BOTTOM VIEW

8-2-5 DISPLAY BOARD• TOP VIEWMICEMICJ8701PTTEMISWAFEPTTAF1AF2DISTRESSCLAR/RXTHRU/TUNECANSEL/CALLHEADPHONESET/MODETXF/TX FREQ/CH0/DIMCE ENT8/Mid7/Lo 9/

• BOTTOM VIEW (DISPLAY BOARD)W8702 [CAN][USA],[OTH]GND19210J8902GNDFZMDFZRSFZRXGNDNCNCFZTXFZ5V19210to JACKboard J8601J8903GNDRXDH13VFAFFMODGGNDTXDFAFG

8 - 58-3 IC-M8028-3-1 DSP BOARD• TOP VIEW1816911020111714814851361087372 37109 1441485114281513641364

8 - 6• BOTTOM VIEW (DSP BOARD)121to MAIN unit J1102222J901DSPI1GNDGNDGND8VGNDAGC2GNDDSPO1GNDGNDGNDGNDDSPI2GND8VGNDAGC1GNDGNDGNDDSPO2291MAIN unit J1101

[USA],[CAN] only[USA],[CAN] only[USA],[CAN] only[USA],[CAN] only[OTH] only[USA],[CAN] only[OTH] only136411816 9918 10130805131 50100 8117148118169918

SECTION 2 INSIDE VIEWS2 - 1• RC-25• IC-M802VR BOARDReset IC(IC8202: S-80942ANMP)CPU(IC8201: HD64F2134AFA20)LCD unit(DS8220: HLC770-018800)Power amplif

• BOTTOM VIEW (MAIN UNIT)8 - 8

from CHASSIS J4501ANTto MAIN unit J51MRXP7321to PA unit J6401FLINP7001TRXS115216to MAIN unit J1301J7331L22ML12ML6ML2MGNDREFFORS13VL16ML8ML4ML1MGNDGNDG

• BOTTOM VIEW (FILTER BOARD)8 - 10

[OTH][USA],[CAN]R5207[OTH]L5201[OTH] only[OTH] only[USA],[CAN] only[USA],[CAN] only[USA],[CAN] only[USA],[CAN] only[USA],[CAN] only[USA],[CAN] only3

148514J6703to CHASSISW4502KEYSTART13.6ANTC/GND41J6301to DRIVERboardGNDGNDDRVIDRVI14J6302to DRIVERboardDRVODRVOGNDGND13J6411toVARISTOR-1boardGNDVAROVAR

8-3-6 DRIVER BOARD• TOP VIEW8 - 13GNDVAROVARIto PA unit J64118-3-7 VARISTOR-1 BOARD

DRVIDRVIGNDGNDto PA unit J6301GNDGNDDRVODRVOto PA unit J6302• BOTTOM VIEW (DRIVER BOARD)8 - 14GNDGNDVAROto PA unit J64128-3-8 VARISTOR-2 BOARD

9 - 1SECTION 9 BLOCK DIAGRAMTXRXCOMMONBus line[USA],[CAN]only[USA],[CAN]only1.8VREG3.3VREG+5REGIC152TK11218CMIC-161BA033FPIC171TK11250CM8V5V3.3V1.8VDI

10 - 1SECTION 10 WIRING DIAGRAMP5601J5601M1LOP5201J5201M2LOP5801J5801D1LOAF/MODAF-GNDAF+NSENDGNDNCMOD-MOD+GNDGNDNCDTRPXRXDPCTXDJ5051[USA],[CAN] only[U

11 - 1SECTION 11 VOLTAGE DIAGRAMS11-1 RC-25 and HM-135C82181012345678J8701MICC82220.0047R8701 33 [USA],[OTH]R8702 33[USA],[OTH]PMUTPHEPHOL870110µR8703

3 - 1SECTION 3 CIRCUIT DESCRIPTION3-1 RECEIVER CIRCUITS3-1-1 RF FILTER CIRCUIT (FILTER AND MAINUNITS)Received signals from the antenna connector are

11 - 211-2 IC-M80211-2-1 MAIN UNIT (1)e8VgfdcbaT8HV13RXST8T8R8R13V8V5V5V-5VS13VR8R80.1C1315T8 T8HV13 HV130.1C20031kR20034.7C2004S13VPOCVR13VR8DSC ANT

11 - 311-2-2 MAIN UNIT (2)h48RXSeDAGCICA1kR105748RXSDSPO2T8MAGCT8R84827kR5030.1C4032SA1586Q1203MAGCgfdcba8.2MR12320.0047C805FOR(3)UNITMAIN0.1C225418pC

11 - 411-2-3 MAIN UNIT (3)hH5V10kR3315NMRUNLKDRESLSTBMSTBLDATLCKFNCOPODNTRVSTXVSUSASSTMDGENE8VS13VH5V5VR3340220DRESPTMP1ECKESIOH5VW1102W1101H5V8V5VS13

11 - 511-2-4 PA UNITfrom MAINunit J1J6702YGRto MAINunit J1901PONHVHVFANCS13VS13VS13VS13VS13VKEYSSTATANTCICVGNDGNDGNDJ6701KEYSTART13.6ANTC/GNDJ6703FAN+

11 - 611-2-5 PLL UNIT (1)AF/MODto MAINunitJ3602AF-GNDAF+NSENDGNDMOD-GNDMOD+R59012kR59021kR59031kR59041kR59051kR59061kR59071kR59081kR59091kR59101kR5911

11 - 711-2-6 PLL UNIT (2)C58020.0047R58202kR58192kR58182kR58172kR58162kR58152kR58142kR58132kR58122kR58101kR58091kR58081kR58071kR58061kR58051kR58041kR5

11 - 811-2-7 DSP BOARDTMS320VC33PGEA120IC3011A202VSS3A194A185A176DVDD7A168A159VSS10A1411A1312CVDD13A1214A1115DVDD16A1017A918VSS19A820A721A622A523DVDD2

11 - 911-2-8 FILTER BOARDC7035 470p C7038 270p C7049 180pC7042 390pRL7032AJS1315C7067 270p C7075 330p C7081 120pRL7062AJS1315C7094 330p C7106 150p C71

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1-1-32, Kamiminami, Hirano-ku, Osaka 547-0003, JapanS-13901HZ-C1-2C 2002, 2003 Icom Inc.

3 - 2The level-shifted signal is applied to the DSP IC (IC301) forthe digital IF filter, demodulator, automatic notch and noisereduction, etc.The outp

3 - 33-2 TRANSMITTER CIRCUITS3-2-1 MICROPHONE AMPLIFIER CIRCUIT (RC-25, MAIN AND DSP UNITS)The microphone amplifier circuit amplifies microphone audio