1. MEASUREMENT CONDITIONS

A. Reference temperature-------------70 to 75 degrees
B. Reference humidity----------------45 to 80%


2. REQUIRED TEST EQUIPMENT (Calibrated)

A. 50 ohm Resistive Antenna Load rated at 100 watts.
B. RF Wattmeter rated at 0-50 watts. (Peak reading)
C. Frequency Counter with 50Mhz range. (10mv input sens.)
D. RF Signal Generator with 50Khz to 60Mhz range.
E. 100Mhz Oscope with x1 and x10 probes.
F. FM Deviation Meter.
G. Digital Multimeter.
H. External Speaker rated at 8 ohms 5 watts.
I. Two AF Generators with 10Hz to 20Khz range.
J. Two AF attenuators. (variable)
K. Regulated 13.8 volt at 10 amp Power Supply.
L. Microphone Test Connector wired for transmit.


3. RADIO SETUP PROCEDURES

A. Remove top and bottom covers.
B. Unsolder RF shield covering PLL pins.
C. Set Volume to 12 o'clock.
D. Set Squelch fully counterclockwise.
E. Set Mic Gain fully clockwise.
F. Set RF Gain fully clockwise.
G. Set radios with HI/LOW Band SW to HI
H. Set Band SW to D on radios with 6 bands
I. Set Band SW to E on radios with 8 bands
J. Set channel selector to 1
K. Set mode SW to AM
L. Set Clarifier to 12 o'clock (Fine and Course if applicable)
M. Set Echo/VC/Robo to OFF (if applicable)
N. Set Talkback to OFF (if applicable)
O. Set Roger Beep to OFF (if applicable)
P. Set NB/ANL to OFF
Q. Set Freq Counter to ON (if applicable)
R. Set +10khz SW to OFF
S. Set power to HI
T. Set Band SW to HI (if applicable)
U. Connect radio to a 13.8 volt, 10-amp source.
V. Allow 15 to 20 min warm up for radio to stabilize.

4. PLL CIRCUIT ALIGNMENT

A. 10.240MHZ REFERENCE OSCILLATOR CHECK.
1. Connect Frequency Counter to emitter of TR24. (R110)
2. Frequency Counter should display 10.2400Mhz.
3. Replace crystal if tolerance is beyond +/- 200Hz.


B. PLL MIXER ALIGNMENT
1. Connect Oscope to output of J107. (Int. F/C jack)
2. Adjust L22 for max RF output. (>.5 volts all bands)


C. VCO ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Connect Oscope to TP3 (bare lead of R74)
3. Adjust L18 for max. RF output
4. Connect DC Voltmeter to TP2 (bare lead of R116)
5. Set Channel Selector to 40
6. Adjust L17 for 5 vdc on radios with 6 bands
7. Adjust L17 for 6 vdc on radios with 8 bands
8. Set Band SW to Band A
9. Set radios with HI/LOW SW to LOW
10. Set Channel Selector to 1
11. Check that voltage at TP2 is >1.5 vdc



D. OFFSET OSCILLATOR ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Connect Frequency Counter to TP3
3. Adjust L19 for 16.270Mhz +/- 50Hz (>1 vdc)
4. Set Mode SW to USB
5. Adjust L20 for 16.2725Mhz +/- 50Hz (>1 vdc)
6. Set Mode SW to LSB
7. Adjust L21 for 16.2675Mhz +/- 50Hz (>1 vdc)
8. Insert Mic test connector (key radio)
9. Adjust VR21 for 16.2675Mhz +/- 50Hz


E. CARRIER OSCILLATOR ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Connect Frequency Counter to TP6 (bare lead R102)
3. Set Mode SW to LSB.
4. Adjust L28 for 10.6975Mhz +/- 50Hz
5. Set Mode SW to USB.
6. Adjust L27 for 10.6925Mhz +/- 50Hz
7. Connect Frequency Counter to read RF output Frequency
8. Set Mode SW to AM
9. Insert Mic test connector (key radio)
10. Adjust L26 for 26.965 +/- 50Hz
11. Adjust VC1 on int. F/C to read 26.965 (if applicable)

5. TRANSMITTER ALIGNMENT

A. DRIVER FINAL BIAS ALIGNMENT (SSB models only)
1. Refer to paragraph 3 for radio setup
2. Set mode SW to USB
3. Set Mic gain fully counter clockwise
4. Remove shorting bar from TP7, TP8, TP9
5. Connect ammeter + lead to TP9 and - lead to TP8
6. Insert Mic test connector (key radio)
7. Adjust VR11 for 25ma +/- 1ma
8. Connect ammeter + lead to TP9 and - lead to TP7
9. Set VR10 and VR20 fully counter clockwise (0ma)
10. Adjust VR10 for 50ma +/- 1ma
11. Adjust VR20 for a total of 100ma +/- 5ma
12. Remove Mic test connector (unkey radio)
13. Replace shorting bar


B. RF OUTPUT ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Set mode SW to USB (AM on AM/FM models)
3. Insert Mic test connector (key radio)
4. Inject 1Khz 30mv signal to pin 2 of Mic test connector
5. Adjust VR12 and L42 for peak RF to wattmeter
6. Adjust L40, L43, L44, L33 for peak RF to wattmeter
7. Repeat steps 4 and 5 until all coils are peaked
8. Readjust L42, L43, L33 to balance highest/lowest freq


C. SIDEBAND ALC ALIGNMENT (SSB models only)
1. Refer to paragraph 3 for radio setup
2. Set mode SW to USB
3. Insert Mic test connector (key radio)
4. Connect 2 AF generators to pin 2 of Mic test connector
5. Inject 500Hz at 30mv and 2400Hz at 30mv
6. Adjust VR12 for max RF with min distortion


D. AM/FM RF POWER LEVEL ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Insert Mic test connector (key radio)
3. Adjust VR13 for 10 watts in radios with dual finals
4. Adjust VR13 for 7 watts in radios with single finals
5. Set radios with POWER switch to MID
6. Adjust VR in R188 for 3 watts
7. Set RF PWR fully counter clockwise
8. Set radios with POWER switch to LOW
9. Adjust VR16 for 1 watt

E. AM MODULATION ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Set MIC GAIN fully clockwise.
3. Insert Mic test connector (key radio)
4. Connect AF generator to pin 2 of Mic test connector
5. Inject a 1Khz signal at 30mv
6. Adjust VR14 for 95% modulation
7. Set radios with POWER switch to MID
8. Adjust VR in C139 for 95% modulation
9. Set radios with POWER switch to LOW
10. Adjust VR12 for 95% modulation




F. FM DEVIATION ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Set mode SW to FM
3. Set MIC GAIN fully clockwise
4. Insert Mic test connector (key radio)
5. Connect AF generator to pin 2 of test Mic connector
6. Inject 1Khz at 30mv
7. Adjust VR5 for 5Khz on Deviation Meter


G. RF METER ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Set MIC GAIN fully counter clockwise
3. Insert Mic test connector (key radio)
4. Adjust VR8 for 10 on large RF meters with dual finals
5. Adjust VR8 for 7 on large RF meters with single finals
6. Adjust VR8 to the "T" on all small RF meters


6. RECEIVER ALIGNMENTS

A. AM SENSITIVITY ALIGNMENT
1. Refer to paragraph 3 for radio setup
2. Set RF signal generator for 30% modulation at 50uv
3. Connect Scope and VTVM through 8 ohms to speaker out
4. Adjust L3, L4, L6, L7, L8, L10, L11, and L12 for max
5. Re-adjust L8 for balance of highest and lowest freq
6. Re-adjust L4 clockwise for 3 volts p-p on scope

B. SIDEBAND SENSITIVITY ALIGNMENT
1. Set signal generator to 26.966Mhz
2. Set signal generator for .5uv, modulation off
3. Set mode SW to USB
4. Set clarifier to center
5. Adjust L13 and L14 for max audio out on scope

C. FM SENSITIVITY ALIGNMENT
1. Refer to step 3 for radio setup
2. Set mode SW to FM
3. Set signal generator to FM
4. Inject 100uv at 5Khz dev. and 1Khz audio
5. Adjust L5 for best tone from speaker

D. SQUELCH ALIGNMENT
1. Refer to step 3 for radio setup
2. Set squelch knob fully clockwise
3. Inject 1000uv 30% modulation at 1Khz tone
4. Adjust VR4 to where audio just disappears
5. Set mode SW to USB
6. Set signal generator to 26.9660mhz
7. Inject 1000uv no modulation
8. Adjust VR3 to where audio just disappears

F. RECEIVE S-METER ALIGNMENT
1. Refer to Paragraph 3 for radio setup
2. Inject 100uv 30% modulated at 1Khz
3. Adjust VR1 to indicate 9 on s-mtr scale
4. Set mode SW to USB
5. Adjust clarifier for max s-mtr reading
6. Adjust VR2 to indicate 9 on s-mtr scale

G. NOISE BLANKER ALIGNMENT
1. Refer to Paragraph 3 for radio setup
2. Set NB SW to on
3. Set signal generator 10khz above radio freq
4. Set signal generator for 1000uv no modulation
5. Connect DC voltmeter to TP1 (cathode D2)
6. Adjust L1 and L2 for max (2-3 volts)