KENWOOD TK8180 - Service Manual Immediate Download

B51-8692-00 (N) 1007

UHF FM TRANSCEIVER

TK-8180

SERVICE MANUAL

Panel assy

(A62-1094-23)

Key top

(K29-9312-21)

Cabinet

(A01-2194-11)

Microphone

(T91-0639-05)

GENERAL .................................................................. 2

SYSTEM SET-UP ...................................................... 3

REALIGNMENT ......................................................... 4

INSTALLATION ......................................................... 7

DISASSEMBLY FOR REPAIR ................................. 13

CIRCUIT DESCRIPTION .......................................... 16

SEMICONDUCTOR DATA ...................................... 20

COMPONENTS DESCRIPTION .............................. 22

PARTS LIST ............................................................. 24

EXPLODED VIEW .................................................... 33

PACKING ................................................................. 34

ADJUSTMENT ........................................................ 35

TERMINAL FUNCTION ........................................... 46

PC BOARD

DISPLAY UNIT (X54-3480-10) ............................ 50

TX-RX UNIT (X57-6990-10) (A/3, C/3) ............... 52

TX-RX UNIT (X57-6990-10) (B/3) ....................... 54

SCHEMATIC DIAGRAM

DISPLAY UNIT (X54-3480-10) ............................ 58

TX-RX UNIT (X57-6990-10) ................................ 60

INTERCONNECTION DIAGRAM ............................ 69

BLOCK DIAGRAM ................................................... 70

LEVEL DIAGRAM .................................................... 72

OPTIONAL ACCESSORIES

KRK-10 (Control Head Remote Kit: 23ft/7m) ...... 74

KAP-2 (Horn Alert/P.A. Relay unit) ................... 79

KCT-40 (Radio Interface Cable) .......................... 79

KCT-46 (Ignition Sense Cable) ........................... 79

KMC-35 (Microphone) ........................................ 79

KMC-36 (Keypad Microphone) .......................... 79

SPECIFICATIONS ................................. BACK COVER

CONTENTS

TK-8180

INTRODUCTION

SCOPE OF THIS MANUAL

This manual is intended for use by experienced techni-

cians familiar with similar types of commercial grade commu-

nications equipment. It contains all required service informa-

tion for the equipment and is current as of this publication

date. Changes which may occur after publication are covered

by either Service Bulletins or Manual Revisions, which are

issued as required.

ORDERING REPLACEMENT PARTS

When ordering replacement parts or equipment informa-

tion, the full part identification number should be included.

This applies to all parts : components, kits, and chassis. If the

part number is not known, include the chassis or kit number

of which it is a part and a sufficient description of the required

component for proper identification.

PERSONAL SAFETY

The following precautions are recommended for personal

safety :

·DO NOT transmit if someone is within two feet (0.6

meter) of the antenna.

·DO NOT transmit until all RF connectors are secure and

any open connectors are properly terminated.

· SHUT OFF this equipment when near electrical blasting

caps or while in an explosive atmosphere.

· All equipment should be properly grounded before power-

up for safe operation.

· This equipment should be serviced by only qualified tech-

nicians.

PRE-INSTALLATION CONSIDERATIONS

1. UNPACKING

Unpack the radio from its shipping container and check for

accessory items. If any item is missing, please contact

KENWOOD immediately.

2. LICENSING REQUIREMENTS

Federal regulations require a station license for each radio

installation (mobile or base) be obtained by the equipment

owner. The licensee is responsible for ensuring transmitter

power, frequency, and deviation are within the limits permit-

ted by the station license.

Transmitter adjustments may be performed only by a li-

censed technician holding an FCC first, second or general

class commercial radiotelephone operator's license. There is

no license required to install or operate the radio.

3. PRE-INSTALLATION CHECKOUT

3-1. Introduction

Each radio is adjusted and tested before shipment. How-

ever, it is recommended that receiver and transmitter opera-

tion be checked for proper operation before installation.

3-2. Testing

The radio should be tested complete with all cabling and

accessories as they will be connected in the final installation.

Transmitter frequency, deviation, and power output should

be checked, as should receiver sensitivity, squelch operation,

and audio output. Signaling equipment operation should be

verified.

4. PLANNING THE INSTALLATION

4-1. General

Inspect the vehicle and determine how and where the ra-

dio antenna and accessories will be mounted.

Plan cable runs for protection against pinching or crushing

wiring, and radio installation to prevent overheating.

4-2. Antenna

The favored location for an antenna is in the center of a

large, flat conductive area, usually at the roof center. The

trunk lid is preferred, bond the trunk lid and vehicle chassis

using ground straps to ensure the lid is at chassis ground.

4-3. Radio

The universal mount bracket allows the radio to be

mounted in a variety of ways. Be sure the mounting surface

is adequate to support the radio's weight. Allow sufficient

space around the radio for air cooling. Position the radio close

enough to the vehicle operator to permit easy access to the

controls when driving.

4-4. DC Power and wiring

1. This radio may be installed in negative ground electrical

systems only. Reverse polarity will cause the cable fuse to

blow. Check the vehicle ground polarity before installation

to prevent wasted time and effort.

2. Connect the positive power lead directly to the vehicle

battery positive terminal. Connecting the Positive lead to

any other positive voltage source in the vehicle is not rec-

ommended.

3. Connect the ground lead directly to the battery negative

terminal.

4. The cable provided with the radio is sufficient to handle

the maximum radio current demand. If the cable must be

extended, be sure the additional wire is sufficient for the

current to be carried and length of the added lead.

5. INSTALLATION PLANNING CONTROL STATIONS

5-1. Antenna system

Control station. The antenna system selection depends on

many factors and is beyond the scope of this manual. Your

KENWOOD dealer can help you select an antenna system

that will best serve your particular needs.

5-2. Radio location

Select a convenient location for your control station radio

which is as close as practical to the antenna cable entry point.

Secondly, use your system's power supply (which supplies

the voltage and current required for your system). Make sure

sufficient air can flow around the radio and power supply to

allow adequate cooling.

GENERAL

TK-8180

SERVICE

This radio is designed for easy servicing. Refer to the

schematic diagrams, printed circuit board views, and align-

ment procedures contained in this manual.

NOTE

· If you do not intend to use the speaker 3.5-mm jack and

the D-sub 25-pin connector, fit the supplied speaker-jack

cap and D-sub cap to stop dust and sand from getting in.

· If the transceiver is turned ON or OFF when the power-on/

off status message is enabled, the transceiver sends the

status.

GENERAL / SYSTEM SET-UP

Speaker

jack cap

D-sub

cap

Power input

connector

Ignition

sense cable

Antenna

connector

Merchandise received

License and frequency allocated by FCC

Choose the type of transceiver

Transceiver programming

See page 4.

A personal computer (IBM PC or compatible), programming

interface (KPG-46), and programming software (KPG-89D)

are required for programming.

Are you using

the remote kit?

Are you using

the ignition sense cable?

Are you using

the radio interface cable?

Are you using

the public address?

Are you using

the voice guide & storage

unit?

KRK-10

KCT-46

KCT-40

KCT-36 Extension cable

KGP-2A

Modem GPS receiver

KGP-2B

Modem GPS controller

KDS-100

Mobile data terminal

KAP-2

VGS-1

YES

Supplied microphone

Delivery

Are you using

the external speaker?

Are you using

the keypad microphone?

KES-3 or KES-5 External speaker

KMC-32 or KMC-36

YES

Desk top microphone KMC-9C

See page 9.

See page 7.

See page 8.

See page 10.

(Option)

Frequency range

RF power

Type

450~520MHz

30W

(490~520MHz : 25W)

SYSTEM SET-UP

TK-8180

1. Modes

Mode

Function

User mode

For normal use.

Panel test mode

Used by the dealer to check the funda-

mental characteristics.

Panel tuning mode

Used by the dealer to tune the radio.

PC mode

Used for communication between the

radio and PC (IBM compatible).

Data programming

Used to read and write frequency data

mode

and other features to and from the radio.

PC test mode

Used to check the radio using the PC.

This feature is included in the FPU.

See panel test.

PC tuning mode

Used to tune the radio using the PC.

This feature is included in the FPU.

See panel tuning.

Firmware

Used when changing the main program

programming mode

of the flash memory.

Clone mode

Used to transfer programming data from

one radio to another.

Firmware version

Used to confirm the internal firmware

information

version.

Clock adjustment mode

Used to adjust date and time.

2. How to Enter Each Mode

Mode

Operation

User mode

Power ON

Panel test mode

[A] + Power ON

PC mode

Received commands from PC

Panel tuning mode

[Panel test mode] + [S]

Firmware programming mode

[S] + Power ON

Clone mode

[B] + Power ON

Firmware version information

[

] + Power ON

Clock adjustment mode

[C] + Power ON

3. Panel Test Mode

Setting method refer to ADJUSTMENT.

4. Panel Tuning Mode

Setting method refer to ADJUSTMENT.

5. PC Mode

5-1. Preface

The transceiver is programmed by using a personal com-

puter, programming interface (KPG-46) and programming

software (KPG-89D).

The programming software can be used with an IBM PC

or compatible. Figure 1 shows the setup of an IBM PC for

programming.

User mode

Panel test mode

Firmware version information

Panel tuning mode

Data programming mode

PC test mode

PC tuning mode

PC mode

Clone mode

Firmware

programming mode

Clock adjustment mode

KPG-89D

IBM PC

KPG-46 or

KPG-46 +

Tuning cable

(E30-3383-05)

Fig. 1

REALIGNMENT

TK-8180

5-2. Connection procedure

1. Connect the transceiver to the personal computer with

the interface cable.

2. When the POWER switch on, user mode can be entered

immediately. When PC sends command the radio enter

PC mode, and "PROGRAM" is displayed on the LCD.

When data transmitting from transceiver, the red LED is

lights.

When data receiving to transceiver, the green LED is

lights.

Note:

· The data stored in the personal computer must match

model type, when it is written into the flash memory.

5-3. KPG-46 description

(PC programming interface cable: Option)

The KPG-46 is required to interface the transceiver to the

computer. It has a circuit in its D-sub connector (25-pin) case

that converts the RS-232C logic level to the TTL level.

The KPG-46 connects the modular microphone jack of the

transceiver to the computers RS-232C serial port.

5-4. Programming software KPG-89D description

The KPG-89D is the programming software for the trans-

ceiver supplied on a CD-ROM. This software runs under MS-

Windows 98, ME, Windows 2000 or XP on an IBM-PC or

compatible machine.

The data can be input to or read from the transceiver and

edited on the screen. The programmed or edited data can be

printed out. It is also possible to tune the transceiver.

6. Firmware Programming Mode

6-1. Preface

Flash memory is mounted on the transceiver. This allows

the transceiver to be upgraded when new features are re-

leased in the future. (For details on how to obtain the firm-

ware, contact Customer Service.)

6-2. Connection procedure

Connect the transceiver to the personal computer (IBM

PC or compatible) with the interface cable (KPG-46). (Con-

nection is the same as in the PC Mode.)

Note :

You can only program firmware from the 8-pin micro-

phone connector on the front panel. Using the 25-pin logic

interface on the rear panel will not work.

6-3. Programming

1. Start up the firmware programming software (Fpro.exe).

2. Set the communications speed (normally, 115200 bps)

and communications port in the configuration item.

3. Set the firmware to be updated by File name item.

4. Turn the transceiver power ON with the [S] key held

down. Then, the orange LED on the transceiver lights and

"PROG 115200" is displayed.

5. Check the connection between the transceiver and the

personal computer, and make sure that the transceiver is

in the Program mode.

6. Press write button in the window. When the transceiver

starts to receive data, the [PG] display is blinking.

7. If writing ends successfully, the checksum is calculated

and a result is displayed.

8. If you want to continue programming other transceivers,

repeat steps 4 to 7.

Notes:

· This mode cannot be entered if the Firmware Program-

ming mode is set to Disable in the Programming software.

· When programming the firmware, it is recommend to

copy the data from the floppy disk to your hard disk before

update the radio firmware.

Directly copying from the floppy disk to the radio may not

work because the access speed is too slow.

6-4. Function

1. If you press the [

] key while "PROG 115200" is dis-

played, the display changes to "PROG 19200" (The LED

blinks green) to indicate that the write speed is low speed

(19200 bps). If you press the [

] key again while "PROG

19200" is displayed, the display changes to "PROG

38400" (The LED lights red and orange alternatively). If

you press the [

] key again while "PROG 38400" is dis-

played, the display changes to "PROG 57600" (The LED

blinks orange). If you press the [

] key again while

"PROG 57600" is displayed, the display returns to "PROG

115200" (The LED lights orange).

2. If you press the [

] key while "PROG 115200" is dis-

played, the checksum is calculated, and a result is dis-

played.

If you press the [

] key again while the

checksum is displayed, "PROG 115200" is redisplayed.

Note:

Normally, write in the high-speed mode.

7. Clone Mode

Programming data can be transferred from one radio to

another by connecting them via their 8-pin microphone con-

nectors. The operation is as follows (the transmit radio is the

master and the receive radio is a slave).

1. Turn the master transceiver power ON with the [B] key

held down. If the read authorization password is set to the

transceiver, the transceiver displays "CLONE LOCK". If

the password is not set, the transceiver displays "CLONE

MODE".

2. When you enter the correct password, and "CLONE

MODE" is displayed, the transceiver can be used as the

cloning master. The following describes how to enter the

password.

REALIGNMENT