KENWOOD TK860G - Service Manual Immediate Download

B51-8498-10 (N) 1268

UHF FM TRANSCEIVER

TK-860G/862G

SERVICE MANUAL

REVISED

Microphone

(T91-0597-15)

Cabinet (Upper)

(A01-2165-13)

Panel assy

(A62-0642-03)

Key top

(K29-5343-02)

Microphone

(T91-0597-15)

Cabinet (Upper)

(A01-2165-13)

Panel assy

(A62-0731-03)

Key top

(K29-5344-02)

TK-860G (K)

TK-862G (K)

Please use this manual in place of the service manual (preliminary version), B51-8498-00.

We have added the information on the circuit description, specifications, and K3 version specifications to the service

manual (preliminary version), B51-8498-00.

TK-860G/862G

CONTENTS / GENERAL

GENERAL

INTRODUCTION

SCOPE OF THIS MANUAL

This manual is intended for use by experienced techni-

cians familiar with similar types of commercial grade com-

munications equipment. It contains all required service in-

formation for the equipment and is current as of the publica-

tion data. Changes which may occur after publication are

covered by either Service Bulletins or Manual Revisions.

These 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, or 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 re-

quired component for proper identification.

PERSONNEL SAFETY

The following precautions are recommended for person-

nel safety :

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

meter) of the antenna.

· DO NOT transmit until all RF connectors are verified se-

cure and any open connectors are properly terminated.

· SHUT OFF and DO NOT operate this equipment near

electrical blasting caps or in an explosive atmosphere.

· All equipment should be properly grounded before

power-up for safe operation.

· This equipment should be serviced by a qualified techni-

cian only.

PRE-INSTALLATION CONSIDERNATIONS

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 ra-

dio installation (mobile or base) be obtained by the equip-

ment owner. The licensee is responsible for ensuring trans-

mitter power, frequency, and deviation are within the limits

permitted 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.

CONTENTS

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

SYSTEM SET-UP ..................................................... 4

OPERATING FEATURES ......................................... 5

REALIGNMENT ...................................................... 10

INSTALLATION ...................................................... 20

CIRCUIT DESCRIPTION ......................................... 24

SEMICONDUCTOR DATA ..................................... 29

DESCRIPTION OF COMPONENTS ....................... 31

PARTS LIST ............................................................ 33

EXPLODED VIEW .................................................. 42

PACKING ................................................................ 44

ADJUSTMENT ....................................................... 45

PC BOARD VIEWS

DISPLAY UNIT (X54-3270-10) : TK-860G ........ 54

DISPLAY UNIT (X54-3280-10) : TK-862G ........ 55

PLL/VCO (X58-4670-XX) .................................. 56

TX-RX UNIT (X57-5960-XX) (A/2) ................... 57

TX-RX UNIT (X57-5960-XX) (B/2) .................... 63

SCHEMATIC DIAGRAM ........................................ 67

BLOCK DIAGRAM .................................................. 75

LEVEL DIAGRAM ................................................... 78

TERMINAL FUNCTION ......................................... 80

SPECIFICATIONS ................................................... 81

TK-860G/862G

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 sys-

tem 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.

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

When you modify your radio as described in system set-

up, take the following precaution.

The rating of pin 7 (SB) of the accessory connector cable

(KCT-19) on the rear of the radio is 13.6V (1A). Insert a 1A

fuse if you use the SB pin for external equipment.

Accessory connector

cable (KCT-19)

If you do not intend to use the 3.5-mm jack for the exter-

nal speaker, fit the supplied speaker-jack cap (B09-0235-05)

to stop dust and sand getting in.

Speaker-jack cap

(B09-0235-05)

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 installa-

tion. Transmitter frequency, deviation, and power output

should be checked, as should receiver sensitivity, squelch

operation, and audio output. QT equipment operation

should be verified.

4. PLANNING THE INSTALLATION

4-1. General

Inspect the vehicle and determine how and where the

radio antenna and accessories will be mounted.

Plan cable runs for protection against pinching or crush-

ing 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 installa-

tion 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.

CAUTION

If DC power is to be controlled by the vehicle ignition

switch, a switching relay should be used to switch the posi-

tive power lead. The vehicle ignition switch then controls

DC to the relay coil.

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.

GENERAL

TK-860G/862G

SYSTEM SET-UP

Merchandise received

License and frequency allocated by FCC

Choose the type of transceiver

Are you using the public address?

Are you using the external speaker?

Are you using ignition sense cable?

Delivery

Are you using the KGP-1A Modem GPS receiver

or the KGP-1B Modem GPS controller?

Transceiver programming (Option)

8ch models

TK-862G

128ch models

TK-860G

Frequency range (MHz)

450~490

400~430

RF power

25W

Type

K,M

KAP-1

PA/HA unit

KCT-20

Connection cable

KES-3

External speaker

KCT-19

Accessory connector cable

KCT-18

Ignition sense cable

Frequency range (MHz)

450~490

RF power

25W

Type

See page 11.

A personal computer (IBM PC or compatible), programming interface (KPG-22),

and programming software (KPG-56D) are required for programming.

(The frequency and signalling (option) data are programmed for the transceiver.)

(Option)

See page 22.

Installation the TX-RX unit when used KAP-1.

YES

See page 21.

See page 20.

See page 23.

See the KCT-20 instruction manual

(B62-0733-11).

* : You can install either KCT-19 or KCT-20 to the

TK-860G/862G transceiver

TK-860G/862G

1. Controls and Functions

1-1. TK-860G Front Panel

IO (Power) switch

Press to switch the transceiver ON (or OFF).

LED indicator

Lights red while transmitting. Lights green while receiv-

ing. Flashes orange while receiving a Code Squelch or

Selective Call code, or a 2-Tone code that matches the

one set up in your transceiver.

keys

These are PF (Programmable Function) keys. Press each

key to activate its auxiliary function. The default settings

are Volume Up and Volume Down.

Display

See right.

keys

These are PF (Programmable Function) keys. Press each

key to activate its auxiliary function. The default settings

are Channel Up and Channel Down.

Microphone jack

Insert the microphone plug into this connector.

MON, A, D/A,

, and SCN keys (TK-860G)

MON, ,

, and A keys (TK-862G)

These are PF (Programmable Function) keys. Press each

key to activate its auxiliary function.

PTT (Push-to-Talk) switch

Press this switch, then speak into the microphone to call

a station.

1-2. TK-862G Front Panel

1-3. Microphone

1-4. Display

s TK-860G

Indicator

Description

Appears while using SmarTrunk.

Appears when the selected channel

in busy.

Appears when QT, DQT, DTMF, or

2-Tone decoding is deactivated (by

pressing the Monitor key).

Appears when you receive a Code

Squelch, Selective Call, 2-Tone code.

Also appears when you transmit

using Code Squelch or Selective Call.

Appears while scanning.

Appears when the AUX port is

activated.

Appears when the selected channel

is included in the scanning sequence.

Displays the selected channel

number (or name), DTMF digits

(when entering digits, confirming

digits, or making a call), and mes-

sages received via Selective Call.

s TK-862G

Indicator

Description

Appears when QT, DQT, DTMF, or

2-Tone decoding is deactivated (by

pressing the Monitor key).

Appears when the AUX port is

activated.

Displays the selected channel

number.

OPERATING FEATURES