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Kenwood TK-860HG Service Manual
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Kenwood TK-860HG Service Manual

Kenwood TK-860HG Service Manual

Uhf fm transceiver
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Document Copyrights
Copyright 2006 by Kenwood Corporation. All rights reserved.
No part of this manual may be reproduced, translated, distributed, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, for
any purpose without the prior written permission of Kenwood.
Disclaimer
While every precaution has been taken in the preparation of this manual, Kenwood
assumes no responsibility for errors or omissions. Neither is any liability assumed for
damages resulting from the use of the information contained herein. Kenwood reserves
the right to make changes to any products herein at any time for improvement purposes.

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Summary of Contents for Kenwood TK-860HG

  • Page 1 Kenwood. Disclaimer While every precaution has been taken in the preparation of this manual, Kenwood assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Kenwood reserves...
  • Page 2 REVISED © 2000-12 PRINTED IN JAPAN B51-8539-10 ( N ) 1350 This service manual is the same as the K and M markets, TK-860HG/ 862HG (B51-8539-00) serviice manual with the exception of the new K2, K3 and M3 markets. TK-860HG (K)

  • Page 3: Table Of Contents

    EXPLODED VIEW ......................18 PACKING ........................20 ADJUSTMENT ....................... 21 PC BOARD VIEWS DISPLAY UNIT (X54-3270-10) : TK-860HG .............. 30 DISPLAY UNIT (X54-3280-10) : TK-862HG .............. 31 PLL/VCO (X58-4670-12) ................... 32 TX-RX UNIT (X57-5960-XX) (A/2) ................33 TX-RX UNIT (X57-5960-XX) (B/2) ................39 SCHEMATIC DIAGRAM ....................

  • Page 4: Operating Features

    After finishing transmission, the transceiver receivers for 5 seconds. The transceiver mutes the speaker while receiv- ing. Following the above sequence, the transceiver contin- ues to transmit and receive. Emergency mode system chart (TK-860HG) Foot switch 1 push (Hold it down for about one second.) Emergency mode...

  • Page 5: Realignment

    REMOTE/TXD HOOK/RXD 1. Turn the master TK-860HG power ON with the [ ] key held down. If the password is set to the TK-860HG, the TK-860HG displays “CLN LOCK”. If the password is not set, the TK-860HG displays “CLONE”.

  • Page 6: Installation

    TK-860HG/862HG INSTALLATION Ignition Sense Cable (KCT-18 : Option) Operation when KCT-18 R134 R135 is connected The KCT-18 is an optional cable for enabling the ignition Enable ← KCT-18 cannot Enable function. The ignition function lets you turn the power to the...
  • Page 7 TK-860HG/862HG INSTALLATION Modifying the Transceiver • Public address • Horn alert The signal from pin 13 of IC9 on the TX-RX unit drives PA relay K1 in the KAP-1 and switches the audio power ampli- The signal from pin 4 of IC9 on the TX-RX unit turns Q5...

  • Page 8: Emergency Mode

    TK-860HG/862HG INSTALLATION Emergency Mode Transceiver Modification Procedure TX-RX unit B/2 Foil side • Install the foot switch Install the foot switch through the KCT-19 and KCT-18. When the switch is treaded on, the radio enters the emer- gency mode. • Change the power switch circuit...

  • Page 9: Parts List

    TK-860HG/862HG PARTS LIST CAPACITORS CC 45 TH 1H 220 J • Capacitor value Color* CC45 010 = 1pF 0 = 22pF 100 = 10pF 1 = Type … ceramic, electrolytic, etc. 4 = Voltage rating Multiplier 101 = 100pF 2 = Shape … round, square, ect.
  • Page 10 Les articles non mentionnes dans le Parts No. ne sont pas fournis. Y : AAFES (Europe) X : Australia M: Other Areas Teile ohne Parts No. werden nicht geliefert. TK-860HG/862HG DISPLAY UNIT (X54-3270-10) : TK-860HG DISPLAY UNIT (X54-3280-10) : TK-862HG Desti- Desti- Ref. No. Address Parts No.
  • Page 11 CHIP C 0.010UF CK73GB1H471K CHIP C 470PF TX-RX UNIT (X57-5960-XX) -15 : TK-860HG K,M CC73GCH1H020B CHIP C 2.0PF -16 : TK-862HG K -17 : TK-860HG K2 -18 : TK-860HG K3,M3 CK73GB1H471K CHIP C 470PF D509-514 B30-2050-05 C92-0555-05 CHIP-TAN 0.047UF 35WV...
  • Page 12 CHIP C 0.010UF C208 CC73GCH1H060D CHIP C 6.0PF K3,M3 C516 CC73GCH1H270J CHIP C 27PF C208 CC73GCH1H070D CHIP C 7.0PF C517 CK73GB1C683K CHIP C 0.068UF C209 CC73FCH1H050C CHIP C 5.0PF K,K3,M C518 CC73GCH1H270J CHIP C 27PF TK-860HG : K,K2,K3,M,M3 TK-862HG : K...
  • Page 13 SMALL FIXED INDUCTOR (18NH) C596 CK73GB1H102K CHIP C 1000PF L40-1075-34 SMALL FIXED INDUCTOR (10NH) C597 CC73GCH1H101J CHIP C 100PF L40-1085-77 SMALL FIXED INDUCTOR (100NH) K3,M3 C598 CK73GB1H102K CHIP C 1000PF L40-4775-77 SMALL FIXED INDUCTOR (47NH) TK-860HG : K,K2,K3,M,M3 TK-862HG : K...
  • Page 14 CHIP R 1.5K 1/16W R105 RK73GB1J101J CHIP R 1/16W RK73GB1J103J CHIP R 1/16W R106 RK73GB1J102J CHIP R 1.0K 1/16W R92-1252-05 CHIP R 0 OHM R107 RK73GB1J473J CHIP R 1/16W R108 RK73GB1J152J CHIP R 1.5K 1/16W TK-860HG : K,K2,K3,M,M3 TK-862HG : K...
  • Page 15 1/16W R166 RK73GB1J151J CHIP R 1/16W R527 R92-1252-05 CHIP R 0 OHM R166 RK73GB1J181J CHIP R 1/16W R528 RK73GB1J472J CHIP R 4.7K 1/16W R169 RK73GB1J103J CHIP R 1/16W R529 RK73GB1J154J CHIP R 150K 1/16W TK-860HG : K,K2,K3,M,M3 TK-862HG : K...
  • Page 16 R92-1252-05 CHIP R 0 OHM MA742 DIODE R588 RK73GB1J103J CHIP R 1/16W 1SS355 DIODE R590 RK73GB1J333J CHIP R 1/16W HZU5ALL DIODE R591 R92-1252-05 CHIP R 0 OHM R592 RK73GB1J103J CHIP R 1/16W HVC131 DIODE TK-860HG : K,K2,K3,M,M3 TK-862HG : K...
  • Page 17 CHIP C 5.0PF TC106 C05-0384-05 CERAMIC TRIMMER CAP (10PF) DTC114EKA DIGITAL TRANSISTOR TC109 C05-0384-05 CERAMIC TRIMMER CAP (10PF) 2SC4093 TRANSISTOR 2SA1641(S,T) TRANSISTOR CN101 E40-6019-05 PIN ASSY DTA114EKA DIGITAL TRANSISTOR 2SC3357 TRANSISTOR F10-2279-04 SHIELDING CASE TK-860HG : K,K2,K3,M,M3 TK-862HG : K...
  • Page 18 RK73GB1J392J CHIP R 3.9K 1/16W R117 RK73GB1J101J CHIP R 1/16W D101-104 1SV283 VARIABLE CAPACITANCE DIODE D105 1SV214 VARIABLE CAPACITANCE DIODE Q101 2SK508NV(K52) Q102 DTC114EUA DIGITAL TRANSISTOR Q103 2SK508NV(K52) Q104,105 2SC4081 TRANSISTOR Q106 2SC4226(R24) TRANSISTOR TK-860HG : K,K2,K3,M,M3 TK-862HG : K...

  • Page 19: Exploded View

    TK-860HG/862HG EXPLODED VIEW (TK-860HG) Parts with the exploded numbers larger than 700 are not supplied.
  • Page 20 TK-860HG/862HG EXPLODED VIEW (TK-862HG) Parts with the exploded numbers larger than 700 are not supplied.

  • Page 21: Packing

    TK-860HG/862HG PACKING 45 Microphone 13 DC cord (T91-0597-25) : K 33 Protection bag (E30-3339-05) (H25-0720-04) 19 Fuse (F51-0017-05) x 2 5 Cap (B09-0235-05) 38 Bracket (J29-0627-23) 32 Inner packing case (H12-1391-03) 36 Holder (J19-1584-05) 42 Screw set (N99-0395-05) 31 Polystyrene foamed fixture (R)

  • Page 22: Adjustment

    TK-860HG/862HG ADJUSTMENT • Signalling Test Mode (TK-860HG Only) Signalling No. Test Mode Operating Features None None This transceiver has a test mode. To enter test mode, press [SCN] key and turn power on. Hold [SCN] key un- None 100Hz square til test channel No.
  • Page 23 TK-860HG/862HG ADJUSTMENT Tuning Mode Display Function name FREQ_ _XX Frequency adj. HPOW_XXX H.POW_XXX H.P.OW_XXX H.P.O.W_XXX H.P.O.W._XXX H.P.O.W._.XXX RF high power Hi power (L) Hi power (L') Hi power (C) Hi power (H') Hi power (H) [D/A] [D/A] [D/A] [D/A] [D/A] LPOW_XXX L.POW_XXX...
  • Page 24 TK-860HG/862HG ADJUSTMENT Test Equipment Required for Alignment Test Equipment Major Specifications 1. Standard Signal Generator Frequency Range 400 to 520MHz (SSG) Modulation Frequency modulation and external modulation Output –127dBm/0.1µV to greater than –7dBm/100mV 2. Power Meter Input Impedance 50Ω Operation Frequency...
  • Page 25 TK-860HG/862HG ADJUSTMENT Adjustment Location Adjustment Point Switch (TK-860HG) Volume Channel Power up/down Display up/down TX-RX UNIT (A/2) MIC jack Programmable function keys Note TC106 • Flash memory PLL/VCO The firmware program (User mode, Test mode, Tuning RSSI TC109 mode, etc.) and the data programmed by the FPU (KPG-56D) for the flash memory, is stored in memory.
  • Page 26 TK-860HG/862HG ADJUSTMENT Common Section Since the TK-862HG cannot be tuned from the panel, the FPU (KPG-56D) should be used for adjustment. Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment ± 0.1V 1. PLL lock 1) Set test mode TX-RX CV TC106 7.5V...
  • Page 27 TK-860HG/862HG ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 2) “S.Q.L.3” Rear Front CH / Adjust to the Adjust [ *** ] panel panel squelch threshold SSG freq’ : 470.050MHz K,M AF VTVM point. : 498.550MHz K2 Distortion (EXT.SP)
  • Page 28 TK-860HG/862HG ADJUSTMENT Transmitter Section Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 1. Frequency 1) Set test mode Power meter Rear Front CH / Check 470.100MHz±100Hz K,M Select “FREQ” in tuning mode. F. counter panel panel 498.600MHz±100Hz K2...
  • Page 29 TK-860HG/862HG ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 6. Modulation 1) Set test mode Power meter Rear Front CH / Make the de- (Wide/Narrow) balanced MIC input : OFF Deviation panel panel modulation • Wide Select “BAL”...
  • Page 30 TK-860HG/862HG ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment ± 50Hz (Wide/Narrow) 2) “_.F.Q.T” Power meter Rear Front CH / 0.75kHz PTT : ON Deviation panel panel Adjust [ *** ] meter Oscilloscope 3) “_.F.Q.T._.”...

  • Page 31: Pc Board Views

    TK-860HG/862HG PC BOARD VIEWS DISPLAY UNIT (X54-3270-10) : TK-860HG DISPLAY UNIT (X54-3270-10) : TK-860HG Component side view Foil side view C806 C806 C807 C807 R808 R808 R809 R809 CN801 CN801 C801 C801 R801 R801 C802 C802 C805 C803 C805 C803...

  • Page 32: Display Unit (X54-3280-10) : Tk-862Hg

    TK-860HG/862HG PC BOARD VIEWS DISPLAY UNIT (X54-3280-10) : TK-862HG DISPLAY UNIT (X54-3280-10) : TK-862HG PLL/VCO (X58-4670-XX) -12 : K,M -13 : K2 -14 : K3,M3 Component side view Foil side view Component side view J72-0676-02 C115 C119 L111 L109 CN101...
  • Page 33 TK-860HG/862HG TX-RX UNIT (X57-5960-XX) (A/2) Component side view PC BOARD VIEW -15 : TK-860HG K,M -16 : TK-862HG K -17 : TK-860HG K2 -18 : TK-860HG K3,M3 Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address IC13...
  • Page 34 TK-860HG/862HG TX-RX UNIT (X57-5960-XX) (A/2) Foil side view PC BOARD VIEW -15 : TK-860HG K,M -16 : TK-862HG K Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address...

  • Page 35: Tx-Rx Unit (X57-5960-Xx) (A/2)

    Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address -16 : TK-862HG K -17 : TK-860HG K2 -18 : TK-860HG K3,M3 IC13 Component side view + Foil side IC14 IC15 Q10 13M...
  • Page 36 TK-860HG/862HG TX-RX UNIT (X57-5960-XX) (B/2) Component side view PC BOARD VIEWS -15 : TK-860HG K,M -16 : TK-862HG K -17 : TK-860HG K2 -18 : TK-860HG K3,M3 D512 J72-0760-12 B/2 D511 R566 C543 C632 L501 R567 R560 C501 C542 R561...
  • Page 37 TK-860HG/862HG PC BOARD VIEW TX-RX UNIT (X57-5960-XX) (B/2) Component side view + Foil side -15 : TK-860HG K,M -16 : TK-862HG K -17 : TK-860HG K2 -18 : TK-860HG K3,M3 J72-0760-12 B/2 D512 R550 D511 R548 R501 R553 R612 C534...

  • Page 38: Schematic Diagram

    TK-860HG SCHEMATIC DIAGRAM Note : Components marked with a dot (·) are parts of patterun 1.
  • Page 39 TK-862HG SCHEMATIC DIAGRAM Note : Components marked with a dot (·) are parts of patterun 1.

  • Page 40: Block Diagram

    TK-860HG/862HG TK-860HG/862HG TK-860HG/862HG BLOCK DIAGRAM...

  • Page 41: Level Diagram

    TK-860HG/862HG TK-860HG/862HG LEVEL DIAGRAM Receiver Section Center Frequency 49.95MHz 450kHz Audio Frequency To make measurements in the RF section, connect the RF level meter. In the RF section, use a 0.01µF coupling capacitor. (The display shows the SSG input value required to obtain 12dB SINAD.)

  • Page 42: Terminal Function

    TK-860HG/862HG TERMINAL FUNCTION CN1 (TX-RX Unit) CN3 (TX-RX Unit) Pin No. Name Function Pin No. Name Function DC 8V output. Horn alert/call output. DC 5V output. Ground. AUX5 SMRD : Reset output. *1 Switched B+, DC 13.6V output, Maximum 1A.

  • Page 43: Specifications

    Frequency Range ........ K,M : 450 to 490MHz K2 : 485 to 512MHz K3,M3 : 400 to 430MHz Number of Channels ......TK-862HG : Maximum 8 channels TK-860HG : Maximum 128 channels Number of Groups ......TK-860HG : Maximum 128 groups Channel Spacing ......... Wide : 25kHz Narrow : 12.5kHz PLL Channel Stepping ......
  • Page 44 Mechelsesteenweg 418 B-1930 Zaventem, Belgium KENWOOD ELECTRONICS FRANCE S.A. 13, Boulevard Ney, 75018 Paris, France KENWOOD ELECTRONICS U.K. LIMITED KENWOOD House, Dwight Road, Watford, Herts., WD1 8EB United Kingdom KENWOOD ELECTRONICS EUROPE B.V. Amsterdamseweg 37, 1422 AC Uithoorn, The Netherlands KENWOOD ELECTRONICS ITALIA S.p.A.

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