1966 Motorola Sapphire III Service Manual
Contents
1. SIN TVA ISIHL 20092 038331 270191 OL 23096 JONVY ONINAL 90 21 JOVLIOA INANI 915 ON OT WALA Y ONNOY9 OL LNIOd 03415 3 SIOVLIOA AWW 583 10 TIY AW SINIYA 1 1230 131312345 ISIMYIHLO 5531 0112 4 2 S3LON 2Y 289 64 SI 62 SY 000000 1431238 INV 1141010 31949 00 30 UVM T 803 2 9 9 ANZI 114100 5312 9 00 40 1 804 201 ANO T 114110 5312 2 00 30 T 404 2 001 AND stsseyo MOUNT CONDENSER 8840353801 UNDER SCREW amp LOCKWASHER ARMATURE LEAL CONNECT CONDENSER HEAVY RED LEAD LEAD TO ARMATURE HEADLIGHT SWITCH 29 2 TONE CONTROL Disc 3440039801 ON OFF VOLUME CONTROL KNOB 36840252801 MANUAL TUNING CONTROL KNOB 36840252801 GRILLE TRIM LET 64C40265B01 DISC DUMMY 2 36 40039801 lt DUAL me HEX NUT 2 1 2 28 25124821 L TRIM RIGHT k 64C40264B01 sza 3640039801 9 ORIGINAL DECORATIVE STRIP RETAINERS SCREW ana 20 000 2 2 35134144 DRILL Va MOUNTING HOLE _ PLATE MOUNTING SPEEDOMETER CABLE 16440037801 LEFT FROM WHEEL f ANTENNA gt gt 1 crease te TRIMMER 7 i 1 BOTTOM 2 H A 20 STAMPED MO2. 4 1020 Tuner carriage 8 9 amp 10 f Adjust for maximum Use 9 16 from high alignment tool such as GC end stop type 9050 L 5 n 1610 High end stop 5 6 amp 7 Adjust for maximum 6 Repeat Steps 4 and 5 until no further increase Step 5 should be last step Then cement cores in place 7 Final adjustment 1610 High end stop 7 Adjust for maximum NOTE align antenna The 53mmf capacitor approx trimmer thru a imates the car antenna capac 53mmf series ity capacitor ANTENNA TRIMMER ADJUSTMENT IN CAR IF NECESSARY 8 High end stop 7 Adjust for maximum noise with radio installed in car antenna fully extended and volume control at maximum if needed TO CALIBRATE POINTER Tune radio to 1000 signalandbend pointer until center of pointer coincides with the center of the 100 mark on dial scale we 258 eg Ses ze BE 2 5 OSC TRIM ot SSE 1610 KC zea 6 RF TRIM ao 1610 KC 2 oS lt ANT TRIM 1610 KC 5 l l F 1ST IF 1ST IF Ne 2ND IF ane 262 5KC 2625KC 225 225 RECEPT DUMMY ANTENNA r PLATED CHASSIS MOUNTING BRACKET 381887 9 RF CORE OSC CORE CORE 1020 KC 1020 KC 1020 KC TO SIGNAL GENERATOR ALIGNMENT POINTS LOCATION DETAIL PLATED CHASSIS REMOVAL 315 5 32 394343 SISSWHD 31 14 MIIA S
3. tuning shaft WASHER tuning shaft WASHER DENOTES NEW ITEM APPEARING ON ANY LIST FOR FIRST TIME
4. it in firmly SERVICE NOTES 1 RADIO POLARITY WHEN SER VICING THIS RECEIVER THE LEAD MUST BE CONNECTED TO To remove the plated chassis for servicing unsolder the plated chassis mounting bracket see photo on Page 2 bend the ears straight then spread the housing so that the bracket ears will be free of the hous ing Lift chassis and bracket to a more servicable position NOTE Since the bracket serves as a chassis ground an external wire must be connected from the bracket to the radio housing After servicing is performed re repairs only those radios within the THE POSITIVE SIDE OF POWER install plated chassis board and Z year or 12 000 miles whichever SOURCE IFCONNECTEDOTHER bracket then bend the bracket 5 amp occurs first guarantee period The WISE RECEIVER WILL NOT OP mounting ears over and solder to lt removal or re installation of this ERATE AND DAMAGE TO COM housing 2 gt receiver is customarily performed PONENTS MAY RESULT S x gt by the Volkswagen dealer and is not 5 When replacing a power output a 5 covered by this guarantee Also 2 POWER SUPPLY REQUIRE transistor remember to use the 2 gt the removal of motor noise tire MENTS It is preferable to use a transistor specified inthe parts list static electrical interference storage battery without a battery coat both sides of the transistor in faulty installations and aerial re charge
5. 34587 480134587 658125595 50 40261 01 50 42526 01 50C42592A01 E 5 65R122345 COILS CHOKES 1 2 3 1 4 24 40788 11 1 5 25042032407 RESISTORS amp CONTROLS 68129875 65128227 65124506 65128952 65121847 65127632 65122445 65127005 65119930 65124507 65125535 65127632 65127534 65127005 65127513 65125531 65128952 18C42340A01 TE it 1 65121301 65127534 65124797 65127542 65125531 R 24 68129221 25 65127001 TRANSFORMERS T 1 24D42517A01 T 2 24D42517A02 T 3 25D42101A06 TRANSISTORS 485134797 485134796 485134798 488134667 488134667 485134749 DIODE 15139 DIODE 18139 BULB pilot 15 6 SPEAKER 5 1 4 62 6TMVG SPEAKER 5 PM 6Q VC 6TMVW SPEAKER 6 PM 622 VC GIMVT 12 6 FUSE 5 amp SEE TUNER PARTS IMAGE TRAP FILTER CHOKE 2200 10 1 2W 330K 10 1 2W 3300 10 1 2 180 10 1 2W 4700 10 1 2W 33K 10 1 2W lt lt 1800 10 1 2W 5600 10 1 2W 6800 10 1 2W 68K 10 1 2W 39K 10 1 2W 33K 10 1 2 820 10 1 24 5600 10 1 2W 1500 10 1 24 180K 10 1 2W 180 10 1 2W CONTROL vol tone sw USE 18C42540A01 1000 10 1 2W 820 10 1 2W 150 10 1 2W 47 10 1 2W 180K 10 1 21 100 LOR IAME 2 2 meg 10 1 2 IST IF ecole see 2ND IF USE 24D42517A04 2SA72 USE 48813479
6. 7 2SA72 USE 485134797 M54 USE 485134809 M54 USE 485134809 2N176 USE 485134747 MECHANICAL PARTS 13B40033B02 BEZEL radio incls gasket 6 13C42377A01 13B40033B01 84D42590A03 7B41644A02 15D42348A01 61C40036B01 32B42688A01 5K611519 144543810 36 40039 01 36840252 01 294541679 29C41506A01 29K534326 33C40040B01 9A531066 9C41095A14 34 40035 01 35134015 3K560695 9K564923 9 40264 03 4C40104A10 3A40730A01 7A42537A01 7B42530A01 7B42401A02 8B40353B01 8B42529A01 29A42410A01 2B521926 24563491 25124821 25119959 64C40037B01 35134144 35134145 41B42528A01 64C40265B01 64040264 01 29A64295A01 77D42372A03 43 K471633 1V564641 1V42300A95 76C40706A12 76K563223 1B40220A03 5B562438 52B42600A03 38D40009B01 49A562480 1V562830 3A563128 1B42375A01 41A562449 41A562447 41B41805A01 4K692188 4K501364 4A501015 44562431 Ref Part List No Number Description Price BEZEL radio 6TMVT BEZEL radio 6 BOARD plated chassis CHANNEL chassis supp COVER bottom CRYSTAL dial GASKET bezel 6TMVG amp VW GROMMET insul radio hsg INSULATOR trans mtg KNOB tone amp pendent KNOB vol tuning sw LUG term blade type spkr lead LUG term fuse recept LUG term pilot amp spkr leads NAMEPLATE Sapphire 111 RECEPTACLE ant RECEPTACLE fuse 9C41095A17 SCALE dial SCREW tpg 8
7. EMENT PARTS LIST Ref Part List Ref Part List No Number Description Price No Number Description Price C 6 ELECTRICAL PARTS CAPACITORS NOTE The capacitors in this list are recommended replacement types for the original equipment all are ceramic disc type unless otherwise specified 8C40906A31 0033 mf 100V mylar 21R10052A10 8C40906A16 8C40906A02 0068 mf 100V 05 mf 100 8 40906 23 1 10 mE 3V 21K565267 mylar 21K565252 C 7 8 9 10 11 20 40481 07 DUAL TRIMMER C 6A 250 to 390 pf 6 240 to 350 pf me 005 mf 100V N750 USE 8C40906A27 150 pf 100V N750 21R124608 005 mf 100V mylar USE 8C40906A27 oe 1 mf 100V mylar 8C40906A05 l mf 100V mylar 8C40906A05 8C40906A25 mylar 21D40536A31 8C40906A01 8C40906A06 8C40906A06 Ref Part List No Number Description Price 23C41928A13 21D40339A44 21D40339A08 21K564765 23C41928A09 21K564764 21D40339A64 8C40906A06 23C41928A10 23 41928 10 64A41668A01 64A41668A01 23C41928A16 21D40536A44 21D40339A72 16 mf 16V lytic USE 23C41928A06 150 pf 100V 01 mf 100V 1 0 mf 3V 21K565267 1 6 mf 25V lytic 23C41928A05 47 mf USE 21R10003A01 025 mf 100V 1 mf 100V 8C40906A05 1000 mf 10V 1000 mf 10V SPARK PLATE SPARK PLATE 400 mf 10 lytic 23C41928A15 68 pf 100V 21D40536A32 001 mf 100V 21K121678 MISCELLANEOUS ELECTRICAL PARTS 4801
8. INIOd 32 343434 SISSVHD 1 1 MIIA 401 SINIOd JINIAIIIA 01 Slavd SISSVHD 31 14 MAIA LOG NNOO 21 ISIMYFHLO 03123 02 31 LINSIY TIM SININOd WOI 01 JOVWVG ANY 31 340 LON TIIM O1GVY 5 YIMOd 30 1015 IALLISOd 01 GILOINNOD 38 LSNW AYTI NOIHNYO 9 ovia TWNOILdO MAIA 109 NNOD PAREA ZA ii 6 9 9 i a 4 30001 229 029 20 21 OVI 2 AL S 1H91 Wid ae in WAZ 4 or p25 Lo 700 6 0 7 1 INOS TOA NO MS 440 NO A g 1 M ly 3 971912 ASIA Log NNOO IL wWVadvVId gt 5 MIIA 108 MAIA 109 MIIA 109 NNOD 9A g NNOO SA 8 NNOD ZA TA AGB 26 5 2 asyo 8 3 MAIA Loa NNOO 92 a 41815 JHL LSJYVIN 7371 1102 30 WOLLOG LV 0 31 OL 543434 108 119130 1123 02 619 TI NO OST 914 XST 614 130 29 6 INT 819 INOL Y 8814 olany 151 8 MI68dS 9ZTNZ EN 2 SA vA 9A SLas NI 8 2081 04 uy 114100 31242 007 40 play 531242 0 9 T X04 1081 02 30 401 9 200 05292 AN 009 NOILOINNOD 13 1 TI 3v all a 3931 9 SISSYHI 5 011 21412345 133W OL NOILONGOYd NI AWA ONY TWNIWON
9. UNTING BRACKET WHEEL HUB WHEEL STATIC COLLECTOR 41842528401 1 ON OFF VOLUME CONTROL TONE CONTROL 36840252801 Disc MANUAL TUNING 3640039801 CONTROL KNOB 29840252801 F DISC DUMMY 36040039801 PLATE MOUNTING TOP amp BOTTOM NOT SUPPLIED IN PART OF VEHICLE ANTENNA TRIMMER 2207 Se 6 RADIO 5 5 9 lt ANTENNA ASSEMBLY 85042570401 LEAD HOLDER FUSE FUSE AND LEAD ASSEMBLY SPEAKER GRILLE HEX 29 STAMPED 20563491 ON OFF VOLUME CONTROL KNOB MANUAL TUNING aa eS es REMOVE THESE SCREWS LOOSEN SHELF 00 30 j GRILLE CLOTH PLASTIC FOAM CUSHION TRSAS2 SPEAKER AND BAFFLE ASSEMBLY REMOVE THIS SCREW EY TO LOOSEN SHELF SPEEDOMETER CABLE FRONT WHEEL WHEEL HUB 2207 MODEL 6TMVT RADIO INSTALLATION NOT SUPPLIED IN KIT PART OF VEHICLE BLY ANTENNA MOUNTING NUTS PART OF ANTENNA ASSEMBLY SPEAKER GASKET S2BAZALGADL SPEAKER ASSEMBLY MOUNTING SCREWS 4 12 38135147 SPEAKER ASSEMBLY 504252601 FUSE HOLDER FUSE AND LEAD ASSEMBLY CONNECT LEADS TO RESPECTIVE TERMINALS SPEAKER LEADS lt CONNECT CONDENSER LEAD TO TERMINAL WITH EXISTING BLUE LEAD MODEL 6TMVW RADIO INSTALLATION REPLAC
10. auto radio MANUAL 68P43100A69 VOLKSWAGEN 6TMV SERIES MOTOROLA service manual GENERAL INFORMATION TYPE Automotive type all transistor superheterodyne AM radios oper ate from 6 volt negative ground system Designed for custom in stallation in the following vehicles Model6TMVG Model 6 Transporter Model 6TMVW Volkswagen Sedan Karmann Ghia Volkswagen These receivers contain 6 transis tors 2 diodes anda plated chassis board they differ from each other in mounting hardware only SERVICE STATION PROCEDURE 1 A defective in guarantee radio mist be accompanied by the Custom er s Guarantee Policy Tag This tag must be properly filled in by the Volkswagen dealer at the time of radio purchase Accept as guarantee 4 Defective parts for guarantee re pairs made on this model are to be sent to your Motorola Distributor for free replacement supported with the defective parts return tag which you are now using 5 Only those service shops author ized by their Motorola Distributor can perform guarantee repairs ona no charge basis to the customer If you not already authorized as Motorola Service Station and youare interested in handling this service please contact your Motorola Dis tributor for complete details TO SET PUSHBUTTONS Unlock pushbutton by pulling it out about 1 2 forward of its normal position Tune in station and lock the pushbutton to the station by pushing
11. hen the chassis board is re Transistorized Car Radios station for his files installed later Motorola Part No 68 64980 51 MOTOROLA INC 9401 WEST GRAND AVENUE FRANKLIN PARK ILLINOIS PART NO 68P43100A69 4 66 PRICE 20 CENTS COPYRIGHT 1966 BY MOTOROLA INC PRINTED IN U S A m ALIGNMENT Connect an output meter across the speaker voice coil Set volume to maximum and tone to treble Atten uate signal generator output to maintain 2 45 volts 1 watt across 6 ohm load on output meter at all times to prevent receiver overloading Cover must be removed to gain access to some of the adjustments GENERATOR FREQUENCY 400 cycle mod GENERATOR CONNECTION STEP TUNER SET TO ADJUST REMARKS IF ALIGNMENT Antenna recept t acle thru l mf and chassis High end stop 1 2 3 amp 4 JAdjust for maximum RF ALIGNMENT Antenna recept acle thru dummy see Figure High end stop Adjust for maximum NOTE Do not perform Steps 3 4 5 and 6 unless tuner has been tampered with or components have been replaced Before proceeding with Step 3 a cores as far as possible out of coil forms to eliminate their effect on trimmer adjustment Rem dial scale dial background then loosen pilot light bracket mounting screw and turn bracket down to gain access to core screws 3 Antenna recept 1610 High end stop 5 6 amp 7 Adjust for maximum acle thru dummy see Figure
12. r in place of a battery elim sulator with DC 4 grease Motorola pairs are not considered as guar inator If a battery eliminator is Part No 11M490487 and securely antee repairs and therefore used it must be well filtered and tighten the transistor mounting penses related to such services regulated and adjusted for 7 2volts screws When replacing all other a should be handled by the car dealer transistors use long nose pliersas e os 3 IMPORTANT SERVICE NOTE a heat sink i e grasp transistor 5 2 MotorolaGuarantee Labor It is important that the tape removed leads close to transistor base with Claim Part Number 68P60016A30 and mail Green and Pink copies to Motorola Guarantee Service Motorola Automotive Products Inc 9401 West Grand Avenue Franklin Park Illinois 3 The yellow copy of the Motorola Guarantee Labor Claim is to be re from the outside of the radio during servicing be replaced in the same location as originally found this is necessary to prevent air leaks 4 PLATED CHASSIS REMOVAL NOTE Before removal of plated chassis note location of wires and cables they should be dressed the the pliers to dissipate heat while soldering 6 Servicing techniques applicable to these models can be found in the following Motorola publications Profitable Transistor Radio Servicing Motorola Part Number 68P60011A53 and Discussion of tained by the authorized service same w
13. x 5 8 spkr to spkr plate 6TMVT SCREW trans mtg SOCKET pilot light SOCKET trans 9C40264A01 WASHER spring crystal retainer INSTALLATION PARTS BOLT radio mtg 1 4 20 x 23 32 mtg 6TMVG BRACKET rec mtg 6TMVT BRACKET rec mtg 6TMVW CAPACITOR generator amp VT CAPACITOR generator 6TMVW LUG adaptor dial light NUT hex 1 4 20 bolt mtg NUT hex 1 42 20 brkt to radio NUT hex 1 228 radio MES acs CARER NUT hex 782 32 spkr mtg ETN TE REVS e a oi a PLATE radio adaptor GTMVG SCREW mach 1 4 20 1 2 radio mtg 6TMVG SCREW tpg 10 20 x 3 8 spkr mtg 6TMVT SPRING static coil STRIP trim 6TMVG STRIP trim RH 6TMVG TERMINAL female 6TMVG amp TUNER PARTS TUNER AT 587 BEARING DALL CLUTCH amp DISC ASSEM set screw COILS amp MTG PLATE ASSEM incls L 1 L 2 amp L 3 CORE tuning ant amp CORE tuning osc GEAR BUSHING amp DISC ASSEM GROMMET core mtg POINTER dial PUSHBUTTON ROLLER clutch rel SCREW amp NUT ASSEM adjust SCREW set 4 40 x 5 16 clutch assem SHAFT tuning incls C washers SPRING anti rattle SPRING clutch release SPRING pointer tension WASHER C pointer WASHER
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