Kenwood TK 480 Service Manual

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2 TK-480/481 GENERAL / SYSTEM SET-UP 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 this publica- tion 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. PERSONNEL SAFETY The following precautions are recommended for person- nel safety : - 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. - This equipment should be serviced by only qualified tech- nicians. SERVICE This radio is designed for easy servicing. Refer to the schematic diagrams, printed circuit board views, and align- ment procedures contained within. NOTE WE CANNOT guarantee oscillator stability when using channel elements manufactured by companies other than KENWOOD or its authorized agents. You must use the KPG-49D to program TK-480/481 trans- ceivers with a serial number of 30100001 or greater. You cannot use the KPG-35D for those radios. TK-480/481 transceivers with a serial number of 30100001 or greater have a red triangle in the KENWOOD logo label (B43-1139-04) on the front panel. You will also find the model name plate marked as Ver 2.0 on the rear of the transceiver. Unit TX-RX unit Display unit Model &X57-5630-XX X54-3210-XX Frequency range Remarks QT/DQT DTMF Charger Battery 16 key destination 0-10 0-11 0-10 0-11 TK-480K

806~870MHzIF1 : 44.85MHz

Option
-“ K2

LOC : 44.395MHz
TK-481K

896~941MHzIF1 : 44.85MHz

Option
-“ K2

LOC : 44.395MHz
Note X57-5630-XX/X54-3210-XX : Produced in Singapore Merchandise received License and frequency allocated by FCC Choose the type of transceiver Transceiver programming Are you using the speaker microphone? Delivery TX 806~825 2.5W TK-480 K,K2 851~870 RX 851~870 TX 896~902 TK-481 K,K2 935~941 RX 935~941 Frequency range (MHz) RF power Type A personal computer (IBM PC or compatible), programming interface (KPG-36), and programming software (KPG-49D) are required for programming. (The frequency, trunked system features, conventional system features, TX power HI/LOW, and signaling data are programmed for the transceiver.) YES NO KMC-25 Speaker microphone (Option) SYSTEM SET-UP

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3 TK-480/481 OPERATING FEATURES 1. Operation Features The TK-480/481 is an 800/900MHz band EFJ LTR-„¢-com- patible trunked radio designed to operate in both trunked and conventional modes. The programmable features are summarized. Model Trunking mode Conventional mode This model can handle up to 32 systems with up to 250 groups in each system. The transceiver can be used in both trunked mode and conventional mode. Systems, groups, and their functions are programmed. 2. Transceiver Controls and Indicators 2-1. Physical Layout 5 4 1 2 3Microphone Speaker 6 10 11 12 9 7 8 Note :The transceiver is also available without the DTMF keypad ( ). 2-2. Panel controls The key on the top and front panel is momentary-type push buttons. The functions of these keys and knob are ex- plained below. Antenna connector Connect the supplied antenna here. System or Group selector knob (Programmable) Turning the system (or group) selector knob clockwise increases the system (or group) number by one. Turning the knob in the counterclockwise direction decreases the system (or group) number by one. After the system number (or group number) reaches the highest system number (or group number), it goes back to lowest system number (or group number). System numbers (or group numbers) not set are skipped. Caution : The FPU (KPG-49D) allows selecting between system selector and group selector. Volume/Power switch Transceiver Power and Volume switch. Turn clockwise to switch On the transceiver. Turn counterclockwise fully to switch OFF the transceiver. Also adjusts the volume level. When the power is switched off, all the param- eters, such as the system and group, are stored in memory. When the power is switched on again, the sys- tem returns to the previous conditions. Auxiliary (orange) key (Programmable) Battery pack release catch Push down to release the battery pack. See Installing the Ni-Cd Battery Pack. MONITOR key* (Programmable) PTT (Push-To-Talk) key Press this key, then speak into the microphone to call a station. LAMP key* (Programmable) TX/BATT indicator This red LED lights during transmission (it does not light during busy or when transmit is prohibited). If the battery voltage falls below the programmed voltage during trans- mission, the brightness of this indicator decreases at in- tervals of about one second, so it can be used as the bat- tery voltage alert function. S, A, B, and C key (Programmable) DTMF keypad (keypad model only) Press the keys on the telephone keypad to send DTMF tones. Universal connector Connect the external KMC-25 speaker/ microphone (op- tional) here. Otherwise, keep the supplied cover in place. * : MONITOR and LAMP are arbitrary names chosen for these buttons. They can be used for any of the auxiliary functions. 2-3. Programmable keys The FPU (KPG-49D) enables programmable keys to se- lect the following functions. Auto Tel, AUX(only when Voice Scrambler is not se- lected), DTMF ID (BOT), DTMF ID (EOT), Display Character, Emergency (only AUX key), Function, Group Down, Group Up, Home Group, Key Lock, Lamp, Memory (RCL/STO), Memory (RCL), Memory (STO), Monitor A, Monitor B, Moni- tor C, Monitor D, Redial, RF Power Lo, Scan, Scan Del/Add, Scan Temporary Delete, Scrambler (Only when Voice Scrambler is selected), SP Attenuation (Only MIC switch), System Down, System Up, TEL Disconnect and none. These functions the FPU programs to the function keys are described in the following sections.

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20 TK-480/481 SEMICONDUCTOR DATA Pin function Pin No. Port name I/O Function 1 LSDOUT O Low speed data output. 2 HSDOUT O High speed data output. 3 HSDIN I Not used. 4 DTMSTD I DTMF decode IC data detect input. 5 SELF I Not used. 6 BYTE I +5V. 7 CNVSS I GND. 8 SFTOE O Shift register output enable. 9 LCDCS O LCD driver chip select output. 10 RESET I Microcomputer reset input. 11 XOUT - 9.8304MHz (System clock). 12 VSS - GND. 13 XIN - 9.8304MHz (System clock). 14 VCC - +5V 15 AUX I AUX switch input. 16 AFTRD I MSK modulation data output timing pulse input. 17 AFRTM I MSK demodulation data input timing pulse input. 18 EN2 I Encoder pulse input 2. 19 PLLCLK O PLL IC clock output. 20 BEEP O Beep data output. 21 AFRDT I MSK demodulation data input. 22 AFREG1 O AF IC register switching data output 1. 23 AFREG2 O AF IC register switching data output 2. 24 EEPDAT O EEPROM data output. 25 DACSTB O D/A converter IC data strobe output. 26 AFCLR O MSK flame reset output. 27 SAVE O Not used. 28 LAMP I LAMP switch input. 29 AUXTXD O External Serial interface output. 30 AUXRXD I External Serial interface input. 31 PLLUL I PLL unlock detect input. 32 AFMSKE O MSK modulation enable (Enable active H). 33 TXD O Serial interface output (ex. PC). 34 RXD I Serial interface input (ex. PC). 35 AFDAT O MSK data output. 36 PTT I PTT switch input. 37 RDY - Not used. 38 ALE - Not used. Pin No. Port name I/O Function 39 HOLD - Not used. 40 HLDA - Not used. 41 BLCK - Not used. 42 RD - Flash memory RD bus. 43 BHE - Not used. 44 WR - Flash memory WR bus. 45 DTMCLK O DTMF decode IC clock output. 46 CNTCLK O Common clock output. 47 PLLSTB O PLL IC data strobe output. 48 CS0 O Flash memory chip enable. 49 A19 - Not used. 50~59 A18~A9 - Flash memory address bus. 60 VCC - +5V 61 A8 - Flash memory address bus. 62 VSS - GND. 63~70 A7~A0 - Flash memory address bus. 71 MONI I Monitor switch input. 72 EN4 I Not used. 73 EN3 I Not used. 74 EN1 I Encoder pulse input 1. 75 MINDAT O Common data output. 76 KEY2 I Key scan input 2. 77 KEY1 I Key scan input 1. 78 RESET O Key scan IC reset output.. 79~86 D7~D0 - Flash memory data bus. 87 DTMDAT I DTMF decode IC data input. 88 PF I PF switch input. 89 VOL I Volume level input. 90 BATT I Battery voltage input. 91 ANLSQL I Squelch level input. 92 TEMP I Not used. 93 RSSI I Received signal strength indicator input (RSSI). 94 AVSS - GND. 95 LSDIN I Low speed data input. 96 VREF - +5V 97 AVCC - +5V 98 SFTSTB1 O Shift register data strobe output. 99 W/N O Not used. 100 AFSTB O AF IC data strobe output. Microprocessor : 30622M8A-4F9GP (TX-RX Unit IC15)

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34 TK-480/481 ADJUSTMENT Test Mode  Test mode operating features This transceiver has a test mode. To enter test mode, press [A] key and turn power on. Hold [A] key until test channel No. and test signalling No. appears on LCD. Test mode can be inhibited by programming. To exit test mode, switch the power on again. The following functions are avail- able in test mode. -Controls ControlsFCN appearsFCN not appears [PTT] Used when making a Used when making transmission. a transmission. [AUX] Unused Unused. [MON] Monitor ON and OFF. Monitor ON and OFF. [LAMP] Lights the lamp for five Unused. seconds. Lighting is extended for a further five seconds by pressing any key while the lamp is lit. [S] MSK 1200 bps and Sets to the Tuning 2400 bps mode. [A] Function OFF Function ON. [B] Compander function RF power HIGH and ON and OFF. LOW. [C] Beat shift ON and OFF Changes group. [0] to [9], Used as the DTMF Used as the DTMF and [#], keypad. If a key is keypad. If a key is [ *] pressed during trans- pressed during trans- mission, the DTMF mission, the DTMF corresponding to the corresponding to the key that was pressed key that was pressed is sent. (keypad model) is sent. (keypad model) [ENCODER] Changes system. Changes system. Note : If a [S], [A], [B], [C] key is pressed during transmis- sion, the DTMF corresponding to the key that was pressed is sent. -LCD indicator SCNUnused Lights at Compander ON. LOLights at RF Power Low. PUnused MONLights at moniter ON. SVCUnused Lights at MSK 2400 bps. -LED indicator Red LEDLights during transmission. Blinks at the low battery voltage warning. Green LED Lights when there is a carrier. -Sub LCD indicator FCNAppears at Function ON. Frequency and signalling The set has been adjusted for the frequencies shown in the following table. When required. re-adjust them following the adjustment procedure to obtain the frequencies you want in actual operation. Frequency (MHz) SYS No.TK-480 TK-481 RX (TX : TA) TX RX (TX : TA) TX 1 851.0500 806.0500 935.0250 896.0250 2 851.5500 806.5500 935.0500 896.0500 3 860.0000 815.0000 938.0000 899.0000 4 860.5000 815.5000 938.0250 899.0250 5 865.9875 820.9875 939.9875 900.9875 6 869.4000 824.4000 940.4000 901.4000 7 869.9000 824.9000 940.9000 901.9000 8 855.4000 810.4000 936.2500 897.2500 9 865.6000 820.6000 939.3000 900.3000 10 867.5000 822.5000 936.7500 897.7500 11~16-“ -“-“-“ Signalling Group No. RX TX 1 None None 2 None 100Hz square 3 LTR data LTR data 4 QT 67.0Hz QT 67.0Hz 5 QT 151.4Hz QT 151.4Hz 6 QT 210.7Hz QT 210.7Hz 7 QT 250.3Hz QT 250.3Hz 8 DQT D023N DQT D023N 9 DQT D754I DQT D754I 10 DTMF DEC, (159D) DTMF DEC, (159D) 11 None DTMF tone 9 12 None None 13 Single tone 1200Hz Single tone 1200Hz 14 None MSK 15 MSK code MSK code -Preparations for tuning the transceiver Before attempting to tune the transceiver, connect the unit to a suitable power supply. Whenever the transmitter is turned, the unit must be connected to a suitable dummy load (i.e. power meter). The speaker output connector must be terminated with a 16-„¦ dummy load and connected to an AC voltmeter and an audio distortion meter or a SINAD measurement meter at all times during tuning.

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A B C D E F G H I J K L M N O P Q R S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G ND D2 O PT LO K RX EM AI RX D AU XRX D SB SQ D 1 5C A AC RX W MAO TX D A U XTX D AU DIO BEEP M ONI LA M P DEO D I9 R X AO RX AI PTTO UT TX AO PTTIN T X A I/M UTE D I/A N I RSSI B VC A N T R419 R 420 R 4 R5 R7 R98 R 86 R 57 R 11 R 32 C 58 C 75 C F1 C 79 R 13 R 422 R 148 R 3 C197 C 195 X 2 C92 C 80 C 15 C 60 R 161 C 123 C 111 C 112 C 100 C 196 C 18 C N 2 4 1 1 4 5 8 R87 R 6 R164 1 12 13 24 R 423 R 157 R 122 R 147 R 250 C 138 D 18 D 17 C 188 C 189 C 190 C 199 C F2 R 40 C 61 C 68 C 8 C7 C16 IC 21 34 5 C22 C 19 R 10 Q 5 R 51 C D 1 R417 R 14 R 59 R 162 C 26 C 56 R 56 C 53 R 99 C 156 C 155 R 129 R 136 L27 R 137 R 156 C 3 C2 C1 R128 R 127 C 154 C 175 C 169 L32 L28 D 9 D10 C 167 C 134 C 168 C 176 C 143 C 163 D 6 L4 R 21 R 54 R 16 L1 R 12 R 8 R9 C107 C 9 C5 C28 C 37 IC 14 1 3 4 6 IC 10 IC 4 C6 IC 1 R88 C 120 C 191 C 200 C 201 M ON LA M P PTT G ND C11 Q 7 Q22 + + D D G G S S C 109 C 10 C 263 + + 1 4 4 5 8 1 IC 8 4 5 8 1 5 8IC 3 + CN 3 F1 C N 10 R 25 R 23 + C 62 R 49 C 55 X F1 L 20 L 11 + L 25 C 160 C 173 C 174 C 40 C 166 IC 30 1 2 3 4 D 7 L30 L 31 L 29 C N 1 R2 R1 R17 C 4 C12 IC 5 R103 + D 2 O G I 1 10 E N 1EEN 2EVO L5MS BSB+B+B 1 24 S BM ICM ELB LLGLRA U XPTTN CCSA M5MG NDKI2K I1K RSD TTX DRX DCK P FN CAFEA F J72-0 812-0 2 C 13 C 38 C 30 C 31 IC 6 C20 C N 12 C N 4 CN 11 Q 4 Q14 Q 13 D 4 D 5 Q 6 R36 R 130 R 132 R 133 R 135 R 101 R 170 R 169 R 167 R 168 R 158 C N 5 R151 R 96 R 94 R 100 R 91 C 198 C 135 C 99 C 133 C 125 C 127 C 122 C 209 C 208 R 141 R 15 R 142 R 115 R 108 R 109 R 117 R 152 R 102 R 155 R 97 R 22 R 24 R 26 R 171 R 163 R 160 R 126 R 20 R 28 C 46 C 50 C 47 C 86 C 96 C 97 C 126 C 121 C 114 C 207 C 158 C 162 C 148 C 262 C 115 C 144 L 35 R 93 L17 R 113 R 154 C 153 C 150 L23 L24 C 145 C 140 C 142 C 151 C 187 C 108 C 118 C 183 C 180 C 104 C 178 C 117 C 116 C 179 C 73 C 67 C 76 C 77 C 82 C 83 C 85 C 89 C 103 C 102 C 101 C N 9 L16 C 90 L54 C 66 D 1 C105 C 185 C 186Q 8 Q3 Q23 Q 21 Q 16 C 52 C 98 C 87 C 141 R 121 R 259 R 118 R 67 R 111 R 107 R 200 C 206 C P20 C P22 C P19 C P18 C P17 C P16 C P13 C P12 C P11 C P14 C P15 IC 19 1 8 9 16 IC 18 IC 16 1 1 8 8 9 4 5 16 C N 8 R77 R 35 R 53 R 46 R 45 R 47 R 48 R 50 R 63 R 74 R 84 R 82 R 120 R 211 R 149R 218 C P3 C P5 R 418 R 248 L 26 C N 7 C95 C 88 C 69 C 44 C 24 C 204 IC 231 3 4 5 D 3 D11 C 43 C 59 R 85 R 31 IC 11 1 10 11 20 C 192 C 194 C 131 C 137 C 202 C 36 C 27 C 42 C 33 R 140 R 37 C 17 C 21 C 29 C 25 C 34 L18 L9 L6 L7 IC 7 1 3 4 6 + O I G R134 R 146 R 165 R 143 R 114 R 153 R 65 R 62 R 105 R 145 R 144 R 131 C 165 C 172 C 152 C 164 C 170 C 171 C 149 C 136 C 91 C 94 C 78 C 81 C 63 C 84 C 146 C 193 C 110 C 161 C 132 C 139 C 129 Q 15 Q 18 IC 21 1 4 5 8 DGS DGS DGS DGS DGS Q 2 Q 1 1 Q 1 Q9 Q20 Q 17 Q 10 + L19 L 14 L 15 R 76 D SG 1 G2 S DG2 G1 R60 R 27 Q 12 E C B L21 L 34 L 10 R 38 R 83 R 75 R 78 R 69 R 70 R 42 R 159 R 166 R 43 R 39 R 90 R 79 R 92 R 95 R 72 R 68 C 177 C 182 C 181 C 130 C 119 C 184 C 128 + + + + + + + C 57 L8 L5 L12 D 12 L 13 C 14 C N 6 C35 C 48 C 49 C 45 C 32 C 39 C 54 R 41 C 51 R 18 R 29 R 34 R 19 R 33 IC 9 Q 19 1 8 9 16 L3 X 1 IC 13 1 7 8 14 X 3 C124 C 113 C 106 R 89 C P1 L55 L56 C 72 C 70 C 23 C 93 C 74 C 64 C 203 C 65 C 71 R 55 R 61 R 64 R 66 R 71 R 73 R 80 R 44 R 58 T H 2 D8 C41 R 106 R 110 R 112 C 159 + IC 12 1 1112 2223 3334 44 R 81 R 276 R 421 IC 17 L22 L53 R 408 C 261 1 16 17 32 C P21 R 150 C P10 C P9 C P8 C P7 C P6 C P24 R 297R 298 R 125R 124R 123R 201R 202R 203R 204R 205R 206R 207R 139R 116C 147 IC 15 1 2526 5051 7576 100 C 205R 138 R 104 C 157 X 4 R ef N o. A ddre ss IC 1 4H IC 2 8R IC 3 7F IC 4 5G IC 5 9S IC 6 6R IC 7 7R IC 8 7I IC 9 9K IC 10 7I IC 11 5J IC 12 6F IC 13 3H IC 14 6K IC 15 7C T K -4 80/4 81 5 1 52 T X -R X U NIT ( X 57-5 630-X X) - 1 0 : T K -4 80 - 1 1 : T K -4 81 C om ponen t s id e v ie w + F o il s id e C om po nen t s id e Fo il s id e P atte rn 1 P atte rn 2 P atte rn 3 P atte rn 4 P atte rn 5 P atte rn 6 C on nect 1 a n d 6 R ef N o. A ddre ss IC 16 3B IC 17 5C IC 18 3C IC 19 3D IC 21 5P IC 23 9H IC 30 3O Q1 7O Q2 7O Q3 7K Q4 6Q Q5 9L Q6 8N Q7 5F Q8 6L R ef N o. A ddre ss Q9 7P Q10 7M Q11 6N Q12 5N Q13 5N Q14 6P Q15 5O Q16 8F Q17 7N Q18 6O Q19 8J Q20 7O Q21 7J Q22 6F Q23 8L R ef N o. A ddre ss D1 6I D2 9R D3 8I D4 7O D5 7N D6 5M D7 5P D8 8H D9 6Q D10 6R D11 9F D12 6K D17 9G D18 9F N JM 2904V M 62364FP TA 75W 02FUT C 75W 51FU T D A 7053A T R N 5V L42CTA 75S 01F TA 31136FN LC 73872M

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61 TK-480/481 KNB-16A/17A (Ni-Cd BATTERY) / KPG-36 (PROGRAMMING INTERFACE CABLE) / KSC-19 (CHARGER) KNB-16A KNB-17A External View External View KNB-16A Specifications Voltage ....................................... 7.2V (1.2V x 6) Charging current ........................ 1100mAh Dimensions (mm) ...................... 58 W x 110.8 H x 17.2 D (Projections included) Charger and charging time KSC-19 (Normal Charger) ...... Approx. 8 hours KSC-20 (Rapid charger) ......... Approx. 1 hour Weight ....................................... 180g KNB-17A Specifications Voltage ....................................... 7.2V (1.2V x 6) Charging current ........................ 1500mAh Dimensions (mm) ...................... 58.0 W x 110.8 H x 20.0 D (Projections included) Charger and charging time KSC-19 (Normal Charger) ...... Approx. 8 hours KSC-20 (Rapid charger) ......... Approx. 1.3 hour Weight ....................................... 220g KPG-36 External View KNB-16A KNB-17A Circuit Diagram Circuit Diagram KSC-19 External View KSC-19 Charging KNB-16A Voltage ................................................. 7.2V Battery capacity ................................... 1100mAh Charging time ....................................... Approx. 8 hours KNB-17A Voltage ................................................. 7.2V Battery capacity ................................... 1500mAh Charging time ....................................... Approx. 8 hours + -“ T + -“ Discharge pin side Breaker (80±5°C) Breaker (70±5°C) Diode Thermister Charge pin side + -“ T + -“ Discharge pin side Breaker (80±5°C) Breaker (70±5°C) Diode Thermister Charge pin side