Kenwood TK 862 G Service Manual

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2 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 operators 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

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3 TK-860G/862G 1 3 + -“ 7 6 13 15 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 systems 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 radios 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

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23 TK-860G/862G INSTALLATION 1 2 3 4 5 6 2. Fold the flat cable ( ) in the opposite direction ( ). 3. Rotate the control section ( ) 180 degrees ( ). 4. Insert the flat cable into the control section connector, CN501 ( ). 5. Mount the control section on the transceiver ( ). CN501 1 2 3 4 5 6 Fig. 7 6. External Speaker 6-1. KES-3 : Option The KES-3 is an external speaker for the 3.5-mm-diam- eter speaker jack. -Connection procedure 1. Connect the KES-3 to the 3.5-mm-diameter speaker jack on the rear of the transceiver. KES-3 Fig. 9 6. Rotate the control panel 180 degrees and mount it on the transceiver. Refit the two halves of the case to complete installation. (Fig. 8) Fig. 86-2. KES-4 : Option The KES-4 is an external speaker used with the acces- sory connection cable. -Connection procedure 1. Install the KCT-19 in the transceiver. (See the KCT-19 section.) 2. Insert the crimp terminal into the square plug supplied with the KCT-19. 3. Connect CN8 of the transceiver to connector C of the KCT-19 instead of to the internal speaker connector. KES-4 1 3 6 13 15 12 Crimp terminal (E23-0613-05)Black lead Black/White lead Fig. 10

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31 TK-860G/862G DESCRIPTION OF COMPONENTS Display Unit (X54-3270-10) : TK-860G Ref. No. Use/Function Operation/Condition D801 Reverse current prevention D802~805 Light emission D808 Current stability IC801 LCD driver Q801 DC switch (LED) Display Unit (X54-3280-10) : TK-862G Ref. No. Use/Function Operation/Condition D801 Light emission D802 Reverse current prevention D803,804 Light emission IC801 LCD driver Q801~809 DC switch (LED) TX-RX Unit (X57-5960-XX) -10 : TK-860G K,M -11 : TK-862G K -14 : TK-860G K3 Ref. No. Use/Function Operation/Condition D1 Surge absorption D2 Voltage reference D3~5 Surge absorption D8 IF switch (Wide/Narrow) D9 DC switch D10 IF switch (Wide/Narrow) D11 Noise amp detect D14 Surge absorption D15 OR gate SP mute, AM D16 RF switch (TX/RX) Heterodyne D17 Temperature Drive compensation D18 RF BPF tuning D19 Surge absorption D20 Reverse current prevention D21 Voltage reference D23 RF BPF tuning D24 Voltage reference D25 Surge absorption D27 Reverse current prevention Ref. No. Use/Function Operation/Condition D28 RF BPF tuning D29 Reverse current prevention D30 ANT switch D31 RF BPF tuning D33,34 ANT switch D35,36 APC voltage detect D39 Voltage reference Power protection D40 Charge DEO D41 Temperature APC compensation D42 Voltage drop Charge pump D43 Surge absorption D501 Reverse current KOUT 0 prevention D502 Reverse current KOUT 1 prevention D503 Reverse current KOUT 2 prevention D504 Reverse current KOUT 0 prevention D505 Reverse current KOUT 1 prevention D506 Voltage discharger When powering down D507 Reverse current KOUT 2 prevention D508 Limiter MIC D509~514 Key backlight Active while MBL is H D521 Busy/TX LED Lights green while busy, red while TX D523 OR gate MIC mute, MM, MM2 D524 Surge absorption HOOK/RXD D525 Surge absorption PTT/TXD D526 Current protection D527 Surge absorption CM D528 Surge absorption MBL D529 Limiter QT/DQT decode limiter IC1 Sum amplifier DI, TO mixing IC2 DC amplifier FC, TCXO control IC3 PLL synthesizer Reference 16.8MHz, PLL lock : LD H IC4 Amplifier DEO IC5 AF demodulation Quadrature detector, 2nd mixer, OSC, IF amplifiler, RSSI IC6 D/A converter