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Kenwood TK-863G Service Manual
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Kenwood TK-863G Service Manual

Uhf fm transceiver
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See also: Instruction Manual
UHF FM TRANSCEIVER
TK-863G
SERVICE MANUAL
Cabinet (Upper)
(A01-2165-23)
GENERAL .................................................. 2
SYSTEM SET-UP ...................................... 2
OPERATING FEATURES .......................... 3
REALIGNMENT ......................................... 9
INSTALLATION ....................................... 12
CIRCUIT DESCRIPTION .......................... 18
SEMICONDUCTOR DATA ...................... 23
PARTS LIST ............................................. 27
EXPLODED VIEW .................................... 34
PACKING ................................................. 35
Microphone
(T91-0621-05)
CONTENTS
ADJUSTMENT ........................................ 36
LEVEL DIAGRAM .................................... 45
PLL/VCO (X58-4670-17) ...................... 48
SCHEMATIC DIAGRAM .......................... 59
BLOCK DIAGRAM ................................... 63
TERMINAL FUNCTION ........................... 66
SPECIFICATIONS .................................... 67
© 2002-1 PRINTED IN JAPAN
B51-8617-00 ( N ) 1231
Panel assy
(A62-0642-03)
Key top
(K29-9140-02)

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  • Page 1: Table Of Contents

    UHF FM TRANSCEIVER TK-863G SERVICE MANUAL © 2002-1 PRINTED IN JAPAN B51-8617-00 ( N ) 1231 Microphone (T91-0621-05) Cabinet (Upper) (A01-2165-23) Panel assy (A62-0642-03) Key top (K29-9140-02) CONTENTS GENERAL ..........2 ADJUSTMENT ........36 SYSTEM SET-UP ........2 LEVEL DIAGRAM ........45 OPERATING FEATURES ......

  • Page 2: General

    TK-863G GENERAL / SYSTEM SET-UP INTRODUCTION SERVICE SCOPE OF THIS MANUAL This radio is designed for easy servicing. Refer to the schematic diagrams, printed circuit board views, and align- This manual is intended for use by experienced techni- ment procedures contained in this manual.

  • Page 3: Operating Features

    TK-863G OPERATING FEATURES 1-3. Display 1. Controls and Functions 1-1. Front Panel Indicator Description Appears when the selected group is programmed as priority. Appears when the selected group is 1-2. Microphone programmed as Talk Around. Appears when the key programmed as Monitor is pressed.
  • Page 4 DTMF ID (Begin of TX) will be sent automatically. 2. Operation Features • DTMF ID (EOT) The TK-863G is a UHF FM radio designed to operate in In conventional mode, if you press this key, a predeter- trunking format. The programmable features are summa- mined DTMF ID (End of TX) will be sent automatically.

  • Page 5: Scan Operating

    TK-863G OPERATING FEATURES • Redial Following the above sequence, the transceiver continues to transmit and receive. While in Emergency mode, switch If you press this key when the system/group is displayed, the power OFF or press [Emergency] for longer than the pro- the last transmitted DTMF code will appear on the display.
  • Page 6 TK-863G OPERATING FEATURES • List type system scan • Last used revert A scan list can be set for each system. If a system/group call is received during scanning and the The list to be scanned can be changed by changing the PTT button is pressed for transmission and response within display system.
  • Page 7 TK-863G OPERATING FEATURES The timing when the fixed LTR ID matches is as follows 5. Details of Features (trunking mode); Time-out Timer 0.5s The time-out timer can be programmed in 15 seconds increments from 15 seconds to ten minutes. If the transmit-...

  • Page 8: Audible User Feedback Tones

    TK-863G OPERATING FEATURES Busy Tone If there is no system to be accessed, an intercept tone sounds, the mode is terminated, and the transceiver returns Sounds in LTR mode, when you cannot use a repeater to the first system. If the access is successful, the mode is (system busy or TX inhibit).

  • Page 9: Realignment

    TK-863G OPERATING FEATURES / REALIGNMENT Proceed Tone REALIGNMENT This tone is output when the PTT button is pressed, transmission starts, and the repeater is connected to indi- 1. Modes cate that the user can talk if the clear to talk function has been set.

  • Page 10: Radio Information

    • The data stored in the personal computer must match model type when it is written into the flash memory. 1. Start up the programming software (FPRO EXE.). • Change the TK-863G to PC mode, then attach the inter- 2. Set the communications speed (normally, 57600 bps) face cable.

  • Page 11: Clone Mode

    The operation is as follows (the transmit radio is the master and the receive radio is the slave). 1. Turn the master TK-863G power ON with the [ ] key Cloning cable held down. If the password is set to the TK-863G, the (E30-3382-05) TK-863G displays “CLN LOCK”.

  • Page 12: Installation

    TK-863G INSTALLATION 1-2. KCT-19 Accessory Port Function 1. Accessory Connection Cable Name Function Note (KCT-19 : Option) (A) (B,C,D,E) The KCT-19 is an accessory connection cable for con- Data channel control/ necting external equipment. The connector has 15 pins and the necessary signal lines are selected for use.
  • Page 13 TK-863G INSTALLATION 2. Accessory Terminal (TX-RX Unit) 3. Ignition Sense Cable (KCT-18 : Option) The KCT-18 is an optional cable for enabling the ignition 2-1. External Connector Accessory Terminal Method function. The ignition function lets you turn the power to the...
  • Page 14 TK-863G INSTALLATION 4. PA/HA Unit (KAP-1 : Option) 4-1. Installing the KAP-1 in the Transceiver The Horn Alert (max. 2A drive) and Public Address func- tions are enabled by inserting the KAP-1 W1 (3P; white/ black/red) into CN3 on the TX-RX unit (A/2), inserting W2 (3P;...

  • Page 15: Emergency Mode

    TK-863G INSTALLATION • Others If the PA and HR2 are not necessary and the speaker out- put is output to an external unit through the KCT-19, connect the KCT-19 C connector to CN8 on the TX-RX unit (A/2). KAP-1 (SWITCH UNIT : X41-3380-20)
  • Page 16 Fig. 11 R142 7. Fitting the Control Panel Upside Down The TK-863G control panel can be fitted upside down, so the transceiver can be mounted with its internal speaker (in the upper half of the case) facing down in your car.

  • Page 17: External Speaker

    TK-863G INSTALLATION 2. Fold the flat cable ( ) in the opposite direction ( 8. External Speaker 3. Rotate the control section ( ) 180 degrees ( 8-1. KES-3 : Option 4. Insert the flat cable into the control section connector, The KES-3 is an external speaker for the 3.5-mm-diam-...

  • Page 18: Circuit Description

    TK-863G CIRCUIT DESCRIPTION IF Amplifier Frequency Configuration The first IF signal is amplified by Q13, and the enters IC5 The receiver utilizes double conversion. The first IF is (FM processing IC). The signal is heterodyned again with a 49.95MHz and the second IF is 450kHz. The first local oscil- second local oscillator signal within IC5 to create a 450kHz lator signal is supplied from the PLL circuit.
  • Page 19 VCO to control the oscillator frequency. (See Fig. 6) TX-RX UNIT (B/2) IC508 IC507 IC13 AUDIO The TK-863G has VCO in a Sub-unit (A1) housed in a solid AF PA PROCE. CONV. shielded case and connected to the TX-RX unit (A/2) through CN101. DTMF The operating frequency is generated by Q103 in trans- mit mode and Q101 in receive mode.
  • Page 20 TK-863G CIRCUIT DESCRIPTION PLL/VCO IC3 : PLL IC Q103 TX VCO 10kHz/12.5kHz Q106 BUFF X2 multiply D102,104 Phase Charge Q101 comparator pump DATA RX VCO Q102, 104,105 T/R SW 10kHz/12.5kHz D101,103 16.8MHz Fig. 6 PLL circuit Unlock Circuit Transmitter System...
  • Page 21 TK-863G CIRCUIT DESCRIPTION APC Circuit Memory Circuit The automatic transmission power control (APC) circuit The transceiver has a 2M-bit (256k x 8) flash ROM detects part of a power module output with a diode (D35, (IC501) and an 8k-bit EEPROM (IC505). The flash ROM con- D36) and applies a voltage to IC15.
  • Page 22 TK-863G CIRCUIT DESCRIPTION Encode D/A Converter The LTR, QT and DQT signals are output from TO of the The D/A converter (IC6) is used to adjust TONE and MO CPU (IC502) and summed with the external pin DI line by...

  • Page 23: Semiconductor Data

    TK-863G SEMICONDUCTOR DATA Microprocessor : 30622M4A-410GP (TX-RX Unit IC502) Terminal function Pin No. Name Function Pin No. Name Function EMGT External MIC control. Mobile MIC : H HOLD Not used. DTMF DTMF/BEEP output. 40,41 – – Not used. READ signal.

  • Page 24: Description Of Components

    TK-863G SEMICONDUCTOR DATA / DESCRIPTION OF COMPONENTS Shift Register : BU4094BCFV DESCRIPTION OF COMPONENTS Terminal function (TX-RX unit IC510) Display Unit (X54-3270-10) Pin No. Port Name Function Ref. No. Use/Function Operation/Condition Wide/Narrow SW. Narrow : H D801 Reverse current MUTE MIC mute (M models only).
  • Page 25 TK-863G DESCRIPTION OF COMPONENTS Ref. No. Use/Function Operation/Condition Ref. No. Use/Function Operation/Condition D33,34 ANT switch Shift/Store register HNC, 8RC, 8TC, SPMUTE, RX, D35,36 APC voltage detect PA/LI, AUX5, AUX6 Voltage reference Power protection IC10 5V AVR 5C (TX/RX) Charge IC11...
  • Page 26 TK-863G DESCRIPTION OF COMPONENTS Ref. No. Use/Function Operation/Condition Ref. No. Use/Function Operation/Condition AF mute Active while AF mute is active Q503 Inverter Active while PA2 is H, DC switch 8R, active while RX public address is active Q19,20 DC switch...

  • Page 27: Parts List

    TK-863G PARTS LIST New Parts. indicates safety critical components. L : Scandinavia K : USA P : Canada Parts without Parts No. are not supplied. Y : PX (Far East, Hawaii) T : England E : Europe Les articles non mentionnes dans le Parts No. ne sont pas fournis.
  • Page 28 TK-863G PARTS LIST TX-RX UNIT (X57-6490-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation CK73GB1H103K CHIP C 0.010UF C135 CK73GB1H471K CHIP C 470PF CK73GB1H102K CHIP C 1000PF C138 CK73FB1E104K CHIP C 0.10UF...
  • Page 29 TK-863G PARTS LIST TX-RX UNIT (X57-6490-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C222 CC73GCH1H0R5B CHIP C 0.5PF C557 CK73GB1C104K CHIP C 0.10UF C223 CC73GCH1H020B CHIP C 2.0PF C558...
  • Page 30 TK-863G PARTS LIST TX-RX UNIT (X57-6490-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation F53-0108-05 FUSE RK73GB1J474J CHIP R 470K 1/16W RK73GB1J104J CHIP R 100K 1/16W J31-0543-05 COLLAR RK73GB1J220J CHIP R...
  • Page 31 TK-863G PARTS LIST TX-RX UNIT (X57-6490-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R85,86 RK73GB1J122J CHIP R 1.2K 1/16W R160 RK73FB2A102J CHIP R 1.0K 1/10W RK73GB1J102J CHIP R 1.0K...
  • Page 32 TK-863G PARTS LIST TX-RX UNIT (X57-6490-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R531 RK73GB1J564J CHIP R 560K 1/16W R610,611 RK73GB1J473J CHIP R 1/16W R533 RK73GB1J564J CHIP R 560K...
  • Page 33 TK-863G PARTS LIST TX-RX UNIT (X57-6490-10) PLL/VCO (X58-4670-17) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation BU4094BCF MOS IC 157-153-65001 THERMISTOR IC10 NJM78L05UA BI-POLAR IC IC11 AN8009M MOS IC IC12...

  • Page 34: Exploded View

    TK-863G EXPLODED VIEW Parts with the exploded numbers larger than 700 are not supplied.

  • Page 35: Packing

    TK-863G PACKING 45 Microphone 13 DC cord (T91-0621-05) 33 Protection bag (E30-3339-05) (H25-0720-04) 19 Fuse (10A) (F51-0016-05) x 2 5 Cap (B09-0235-05) 38 Bracket (J29-0627-23) 32 Inner packing case (H12-1391-03) 36 MIC holder (J19-1584-05) 42 Screw set (N99-0395-05) 31 Polystyrene foamed fixture (R)

  • Page 36: Adjustment

    TK-863G ADJUSTMENT • Signalling Test Mode Decode Encode Test Mode Operating Features This transceiver has a test mode. To enter test mode, None None press [SCN] key and turn power on. Hold [SCN] key un- None 100Hz square wave til test channel No. and test signalling No. appears on...
  • Page 37 TK-863G 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 38 TK-863G ADJUSTMENT Test Equipment Required for Alignment Test Equipment Major Specifications 1. Standard Signal Generator Frequency Range 450 to 490MHz (SSG) Modulation Frequency modulation and external modulation Output –127dBm/0.1 V to greater than –7dBm/100mV 2. Power Meter Input Impedance Operation Frequency...
  • Page 39 TK-863G ADJUSTMENT Adjustment Location Adjustment Point Switch Volume System Power up/down Display up/down TX-RX UNIT (A/2) MIC jack Programmable function keys TC106 Note PLL/VCO • Flash memory RSSI TC109 The firmware program (User mode, Test mode, Tuning mode, etc.) and the data programmed by the FPU (KPG-76D) for the flash memory, is stored in memory.
  • Page 40 TK-863G ADJUSTMENT Common Section Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 1. PLL 1) Set test mode TX-RX CV TC106 6.0V 0.1V lock CH : CH3 - Sig1 Power meter (A/2) voltage F. conter 2) PTT : ON (Transmit) TC109 6.5V...
  • Page 41 TK-863G ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 4. Squelch 9 1) Set test mode Rear Front Adjust to the • Wide Select “SQL9” in tuning mode. panel panel squelch threshold “S.QL9” AF VTVM point.
  • Page 42 TK-863G ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 3. High power 1) Set test mode Power meter Rear Front 25.0W 1.0W Select “HPOW” in tuning mode. F. counter panel panel “H.POW” PTT : ON Adjust [ *** ] 2) “H.P.OW”...
  • Page 43 TK-863G ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 2) “_.B.A.L” Power meter Rear Front Make the de- (Wide/Narrow) PTT : ON Deviation panel panel modulation Adjust [ *** ] meter waveform neat. Oscilloscope 3) “_.B.A.L._.”...
  • Page 44 TK-863G ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 10. DQT 1) Set test mode Power meter Rear Front 0.75kHz 50Hz (Wide/Narrow) deviation Select “FDQT” in tuning mode. Deviation panel panel • Wide “F.DQT” meter...

  • Page 45: Level Diagram

    TK-863G TK-863G LEVEL DIAGRAM Receiver Section Center Frequency 49.95MHz 450kHz Audio Frequency W –89.5dBm W –91.0dBm N –85.0dBm N –91.0dBm W –120.0dBm W –122.0dBm W –111.0dBm W –107.5dBm W –115.0dBm W –100.0dBm N –119.5dBm N –122.0dBm N –110.5dBm N –106.5dBm N –114.5dBm...

  • Page 46: Pc Board Views

    TK-863G PC BOARD VIEWS DISPLAY UNIT (X54-3270-10) (J72-0683-02) DISPLAY UNIT (X54-3270-10) (J72-0683-02) PLL/VCO (X58-4670-17) Component side view (J72-0676-02) Component side view Foil side view J72-0676-02 C115 C119 L111 L109 CN101 L103 C104 (ST) 6 C122 Q105 L106 Q106 R109 Q102...
  • Page 47 TK-863G PC BOARD VIEW TX-RX UNIT (X57-6490-10) (A/2) Component side view (J72-0810-02) Ref No. Address Ref No. Address Ref No. Address Ref No. Address IC13 IC400 Component side IC400 Pattern 1 Pattern 2 IC11 Pattern 3 IC12 Pattern 4 Foil side...
  • Page 48 TK-863G PC BOARD VIEW Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address TX-RX UNIT (X57-6490-10) (A/2) Foil side view (J72-0810-02) IC10 IC14 IC400 Component side IC15 Pattern 1...

  • Page 49: Tx-Rx Unit (X57-6490-10) (A/2)

    TK-863G PC BOARD VIEW Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address Ref No. Address TX-RX UNIT (X57-6490-10) (A/2) Component side view + Foil side IC13 (J72-0810-02)

  • Page 50: Tx-Rx Unit (X57-6490-10) (B/2)

    TK-863G PC BOARD VIEWS TX-RX UNIT (X57-6490-10) (B/2) Component side view (J72-0810-02) J72-0810-02 B/2 D512 D511 R566 C543 C632 R567 L501 R560 C501 C542 R561 IC510 IC507 R533 C517 R517 C537 R564 C525 R505 R543 IC513 R563 C541 C527 R520...
  • Page 51 TK-863G PC BOARD VIEW TX-RX UNIT (X57-6490-10) (B/2) Component side view + Foil side (J72-0810-02) J72-0810-02 B/2 D512 R550 D511 R726 R548 R501 R553 R612 C534 R566 C543 C632 R595 L501 R567 C542 R613 R560 C530 C501 C536 R558 R554...

  • Page 52: Schematic Diagram

    TK-863G SCHEMATIC DIAGRAM Note : Components marked with a dot (·) are parts of patterun 1.

  • Page 53: Block Diagram

    TK-863G TK-863G TK-863G BLOCK DIAGRAM...

  • Page 54: Terminal Function

    TK-863G 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 Switched B+, DC 13.6V output, Maximum 1A. AUX6 Auxiliary output. CN4 (TX-RX Unit)

  • Page 55: Specifications

    TK-863G SPECIFICATIONS GENERAL Frequency Range ........ 450 to 490MHz Number of Systems ......Maximum 32 systems Number of Groups ......Maximum 250 groups Channel Spacing ......... Wide : 25kHz Narrow : 12.5kHz PLL Channel Stepping ......5, 6.25kHz Operating Voltage ....... 13.6V DC 15% Current Drain ........
  • Page 56 Leuvensesteenweg 248 J, 1800 Vilvoorde, 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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