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Kenwood TK-780 Service Manual

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See also: Service Manual , Instruction Manual
VHF FM TRANSCEIVER
TK-780
SERVICE MANUAL
REVISED E·E3 versions
GENERAL ................................................................. 2
OPERATING FEATURES ......................................... 3
REALIGNMENT ...................................................... 16
INSTALLATION ...................................................... 19
CIRCUIT DESCRIPTION ......................................... 26
SEMICONDUCTOR DATA ..................................... 31
DESCRIPTION OF COMPONENTS ....................... 32
PARTS LIST ............................................................ 34
EXPLODED VIEW .................................................. 43
PACKING ................................................................ 44
ADJUSTMENT ....................................................... 45
Panel assy
Cabinet (Upper)
(A62-0642-03)
(A01-2165-23)
CONTENTS
© 2002-2 PRINTED IN JAPAN
B51-8523-10 ( N ) 388
This Service Manual was revised based on the service
manual as per parts No. B51-8523-00, in order to include
new variants with the following destination codes : E3.
Key top
(K29-9105-02)
PLL/VCO (X58-4712-70) ................................... 54
SUB UNIT (X58-4850-10) : E3 .......................... 54
TX-RX UNIT (X57-6142-XX) (A/2) ................... 55
TX-RX UNIT (X57-6142-XX) (B/2) .................... 61
SCHEMATIC DIAGRAM ........................................ 65
BLOCK DIAGRAM.................................................. 73
LEVEL DIAGRAM ................................................... 76
TERMINAL FUNCTION ......................................... 78
SPECIFICATIONS ................................................... 79

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  • Page 1: Table Of Contents

    VHF FM TRANSCEIVER TK-780 SERVICE MANUAL REVISED E·E3 versions © 2002-2 PRINTED IN JAPAN B51-8523-10 ( N ) 388 This Service Manual was revised based on the service manual as per parts No. B51-8523-00, in order to include new variants with the following destination codes : E3.

  • Page 2: General

    TK-780 GENERAL 2-2. Testing INTRODUCTION The radio should be tested complete with all cabling and SCOPE OF THIS MANUAL accessories as they will be connected in the final installa- This manual is intended for use by experienced techni- tion. Transmitter frequency, deviation, and power output...

  • Page 3: Operating Features

    4. INSTALLATION PLANNING – CONTROL STATIONS 1. Operation Features 4-1. Antenna system The TK-780 is a VHF FM radio designed in both 5-tone Control station. The antenna system selection depends model and DTMF/2-tone/DMS model. The programmable on many factors and is beyond the scope of this manual.

  • Page 4: Operating Features

    TK-780 OPERATING FEATURES 2-2. Programmable Keys Channel Name The FPU (KPG-60D) enables programmable keys to se- Press this key to switch between the “Channel name” lect the following functions. and “Grp #/Ch #” for the display. If no channel name is pro-...
  • Page 5 TK-780 OPERATING FEATURES Group Up/Down Operator Selectable Tone When this key is pressed each time, the group number to When this key is pressed, the “OST” appears and en- be selected is increased/decreased and repeats if held for code/decode QT/DQT is switched to the OST tone pair. If one second or longer.
  • Page 6 TK-780 OPERATING FEATURES Receive Entry (5-tone) Selcall List Press [Receive entry] key to enter the desired Selcall Press [Selcall list] key to enter Selcall list mode. code you want to receive. This function can be activated • 5-tone only when “RX address” is set to the channel and “select- able receive digit”...
  • Page 7 TK-780 OPERATING FEATURES Status Entry (5-tone) Function Table It allows the operator to input the status and transmit it to Function DTMF/2-tone/DMS 5-tone the base station. None Both TX address and “Selectable status digit” must be Auto dial programmed to perform the operation. Press [Status entry] key to access Status entry mode.

  • Page 8: Scan Operating

    TK-780 OPERATING FEATURES 2-3. Front Panel Displays and Indicators Handset indicator Sub display This icon is not used this transceiver. Displays the system, channel and group numbers. Also MAIL indicator displays various functions, such as TA. Flashes when a status message (5-tone or DMS) is re- P (Priority) indicator ceived.
  • Page 9 TK-780 OPERATING FEATURES Scan channel types Scan end 1) Priority channel is the most important channel for the When you reactivate the key programmed to the scan scan, and always detects a signal during scan and when function during scan mode, the scan ends.
  • Page 10 TK-780 OPERATING FEATURES Com port Radio password • Com 0 When the password is set in the transceiver, user can not use the transceiver unless enter the correct password. This function selects the external serila port function at This code can be up to 6 digits from 0 to 9 and input with the microphone jack (TXD/RXD).
  • Page 11 It is possible to use individual call, group call, stun, kill. The Alphanumeric Two-way Paging Function (DMS) is a Stun and kill are used with DTMF only. Kenwood proprietary protocol. It enables a variety of paging If the option signalling matches, a predetermined action functions.
  • Page 12 TK-780 OPERATING FEATURES Selective Call (SELCALL) Short Messase (Optional) This is a voice call to a particular individual or group of A maximum of 48 characters can be sent (External equip- stations. ment is required). Received Short Messages will be dis- played in the same manner as a Status Message.
  • Page 13 2) MAP HEADER KW1 ($PKLDS) Data TX Modulation Delay Time is the amount of time This is a Kenwood original sentence which consists of from the beginning of transmission to the beginning of a “$GPGLL + Fleet + ID + Status”. This item should be set data modulation.
  • Page 14 TK-780 OPERATING FEATURES Monitor Function Selectable Selcall Digit You can select either QT/DQT or 5-tone decoding to be Select the check box to change selcall code (maximum 8 canceled when [Monitor] or [Monitor momentary] key is digits) manually when transmitting encode code. You can- pressed.

  • Page 15: Audible User Feedback Tones

    TK-780 OPERATING FEATURES Decode Code 8. Audible User Feedback Tones When “Special setting” is disabled, you can select the The transceiver outputs various combinations of tones to decode code setting from #1 to #8. The transceiver tries to notify the user of the transceiver operating state. The main decode the selected decode code setting (maximum 8 dif- tones are listed below.

  • Page 16: Realignment

    • Change the TK-780 to PC mode, then attach the interface cable. PC test mode Used to check the radio using the PC.

  • Page 17: Self Programming Mode

    3. Set the firmware to be updated by File name item. it has been disabled with the KPG-60D. 4. Turn the TK-780 Power ON with the [A] switch held down. Hold the switch down until the display changes to “PROG 57600”. When “PROG 57600” appears, release your finger from the switch.
  • Page 18 TK-780 REALIGNMENT 7-2. Channel Setting Mode 7-3. Flow Chart Each channel can be setup in its action mode by using Self programming the panel keys. mode • Pressing [ ] while “SELF PROG” is displayed will change to channel setting mode.

  • Page 19: Installation

    TK-780 INSTALLATION 1-2. KCT-19 Accessory Port Function 1. Accessory Connection Cable No. (A) No. (B,C,D,E) Name Function Note (KCT-19 : Option) External hook input The KCT-19 is an accessory connection cable for con- Microphone ground necting external equipment. The connector has 15 pins and Speaker audio mute input the necessary signal lines are selected for use.
  • Page 20 TK-780 INSTALLATION 1-3. Data Equipment Connection 2. Accessory Terminal (TX-RX Unit A/2) The jumpers must be set to either one for each function. 2-1. External Connector Accessory Terminal Method Otherwise, the radio will not work properly. Connector Function ME/AM name R12 (0Ω) R167 (0Ω)
  • Page 21 TK-780 INSTALLATION Schematic diagram PC board view Connector Function name Name I/O Function Name Unit Serial data input 1. “Com1” port CODE3 Option code 1 (for voice TX-RX (A/2) must be select “DATA”/“GPS” scrambler code 3) function in the KPG-60D.
  • Page 22 2. Set jumper resistors (0Ω) R151 and R152 of the TX-RX 5-2. Voice Scrambler Board Connection unit (A/2) as shown in Table 1. • Modification 1. Remove the upper half of the case of the TK-780. Operation when KCT-18 is connected R151 R152 2.
  • Page 23 TK-780 INSTALLATION Scrambler board TK-780 6. PA/HA Unit (KAP-1 : Option) Code 4 (C4) (TX-RX A/2 PCB) 6-1. Installing the KAP-1 in the Transceiver Code 3 (C3) (TX-RX A/2 PCB) The Horn Alert (max. 2A drive) and Public Address func-...
  • Page 24 TK-780 INSTALLATION 7. Fitting the Control Panel Upside Down The TK-780 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 25: External Speaker

    TK-780 INSTALLATION 8-2. KES-4 : Option 6. Rotate the control panel 180 degrees and mount it on the transceiver. Refit the two halves of the case to complete The KES-4 is an external speaker used with the acces- installation. (Fig. 11) sory connection cable.

  • Page 26: Circuit Description

    TK-780 CIRCUIT DESCRIPTION an LPF and an attenuator to eliminate unwanted harmonics Frequency Configuration components and implement the optimum input level to the The TX-RX unit (A/2) incorporates a VCO, based on a frac- mixer, then enters IC202. A DBM is used as a mixer to tional N type PLL synthesizer system, that allows a channel achieve a high potential.
  • Page 27 VCO/PLL Circuit unit (A/2) is input to the D/A converter (IC5). The AFO out- The TK-780 has a VCO for the transmitter and a VCO for put level is adjusted by the D/A converter. The signal output the receiver in a sub-unit (A1). They are housed in a solid...
  • Page 28 TK-780 CIRCUIT DESCRIPTION Unlock Circuit Q17 turns the PC signal on or off using 8T so that the circuit works only during transmission. With stability at low During reception, the TR signal goes high, the KEY signal power in mind, Q29 turns off to optimize the detection volt- goes low, and Q10 turns on.
  • Page 29 Key Matrix Circuit through two low-pass filters of IC501, goes to LSDI of the The TK-780 front panel has ten keys. Each of them is CPU (IC511) to decode QT, DQT. The DTMF signal is de- connected to a cross point of a matrix of the KEY1 to KEY7 coded by a dedicated IC (IC507) and the resulting signal is ports of the microprocessor.
  • Page 30 TK-780 CIRCUIT DESCRIPTION Horn Control Power Supply Circuit The horn switch, consisting of Q4, Q5, and Q6, controls When the POWER switch on the control unit is pressed, the horn relay. It is supplied by the dealer to provide the the PSW signal goes low.

  • Page 31: Semiconductor Data

    TK-780 SEMICONDUCTOR DATA Microprocessor : 30620M8A-2K9GP (TX-RX Unit B/2 : Control Section IC511) Terminal function Pin No. Name Function Pin No. Name Function LSDOUT Low speed data output. PLL IC data strobe output. HSDOUT High speed data output. Flash memory chip enable.

  • Page 32: Description Of Components

    TK-780 SEMOCONDUCTOR DATA / DESCRIPTION OF COMPONENTS Terminal function (TX-RX unit A/2 IC8) DESCRIPTION OF COMPONENTS Pin No. Port Name Function Strobe TX-RX Unit (A/2) DATA Ref. No. Use / Function Operation / Condition Clock DC amp FC, TCXO control Audio mute 1.

  • Page 33: Vco Unit

    TK-780 DESCRIPTION OF COMPONENTS Ref. No. Use / Function Operation / Condition Ref. No. Use / Function Operation / Condition W/N switch Wide time on IC506 Analog switch MO, DEO, EMG, MI switch TOF switch Q22 on time on IC507...

  • Page 34: Parts List

    TK-780 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 35 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C92-0719-05 ELECTRO 47UF 25WV C147 CC73FCH1H0R5B CHIP C 0.5PF C92-0044-05 CHIP-ELE 47UF 10WV C148 CK73GB1H102K CHIP C...
  • Page 36 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C256 C93-0557-05 CHIP C 7.0PF C512 CK73GB1H471K CHIP C 470PF C257 C93-0666-05 CERAMIC 24PF C513 CK73GB1H102K...
  • Page 37 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C593 CK73GB1H103K CHIP C 0.010UF L92-0138-05 FERRITE CHIP C594,595 CC73GCH1H270J CHIP C 27PF L40-4775-44 SMALL FIXED INDUCTOR (47.0NH)
  • Page 38 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R92-1252-05 CHIP R 0 OHM J 1/16W R121 RK73GB1J472J CHIP R 4.7K 1/16W RK73GB1J223J CHIP R...
  • Page 39 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R224 R92-1252-05 CHIP R 0 OHM J 1/16W R509 RK73GB1J103J CHIP R 1/16W R225 RK73GB1J820J CHIP R...
  • Page 40 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R584 R92-1252-05 CHIP R 0 OHM J 1/16W R712,713 RK73GB1J473J CHIP R 1/16W R585,586 RK73GB1J473J CHIP R...
  • Page 41 TK-780 PARTS LIST TX-RX UNIT (X57-6142-XX) PLL/VCO (X58-4712-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation TA78L05F MOS IC Q502 DTC144EE DIGITAL TRANSISTOR IC10 LA4422 BI-POLAR IC Q503 2SC4617(S) TRANSISTOR...
  • Page 42 TK-780 PARTS LIST PLL/VCO (X58-4712-70) SUB UNIT (X58-4850-10) : E3 Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R114 RK73GB1J271J CHIP R 1/16W R115,116 RK73GB1J470J CHIP R 1/16W R117 RK73GB1J473J...

  • Page 43: Exploded View

    TK-780 EXPLODED VIEW Parts with the exploded numbers larger than 700 are not supplied.

  • Page 44: Packing

    TK-780 PACKING 36 Protection bag 37 Protection bag (H25-0103-04) (H25-0720-04) 5 Cap (B09-0235-05) 10 DC cord (E30-3438-05) 21 Fuse (F52-0006-05) 40 Bracket 9 Rating label (J29-0627-23) (B42-5999-14) 35 Inner packing case (H12-1391-03) 44 Screw set (N99-0395-05) 34 Polystyrene foamed fixture (B)

  • Page 45: Adjustment

    TK-780 ADJUSTMENT Frequency and Signalling Test Mode The set has been adjusted for the frequencies shown in Test Mode Operating Features the following table. When required, re-adjust them follow- This transceiver has a test mode. To enter test mode, ing the adjustment procedure to obtain the frequencies you press [B] key and turn power on.
  • Page 46 TK-780 ADJUSTMENT • Tuning flow Press [A], now in tuning mode. Use [C] button to write tuning data through tuning modes, and [Channel Up/Down] to adjust tuning requirements (1 to 256 appears on LCD). FREQ xxx Use [D] button to select the adjustment item through tun- ing modes.
  • Page 47 TK-780 ADJUSTMENT Test Equipment Required for Alignment Test Equipment Major Specifications 1. Standard Signal Generator Frequency Range 136 to 174MHz (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 48 Repair Jig (Chassis) • EEPROM Use jig (Part No. : A10-4010-02) for repairing the TK-780. The tuning data (Deviation, Squelch, etc.) for the The jig facilitates the voltage check when the voltage on the EEPROM, is stored in memory. When parts are changed, component side TX-RX unit (A/2) is checked during repairs.
  • Page 49 TK-780 ADJUSTMENT Receiver Section Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 1. Discriminator 1) Set test mode Rear TX-RX L6 AF output voltage CH : CH1 - Sig1 panel (A/2) maximum. SSG output : –53dBm AF VTVM AF : 1.4V/4Ω...
  • Page 50 TK-780 ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 5. Squelch 1) Set test mode Rear Squelch must be (Tight) Select “nL SQLT” in tuning mode. panel closed once. SSG freq’ : 146.050MHz AF VTVM Then adjust for SSG output : –109dBm...
  • Page 51 TK-780 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 Check 160.100MHz±100Hz Select “FREQ” in tuning mode. F. counter panel PTT : ON ± 0.5W E 2.
  • Page 52 TK-780 ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment 7. Maximum 1) Set test mode Power meter Rear 4.1kHz (Wide) +0Hz/–50Hz deviation Connect AG to the MIC Deviation panel 3.3kHz (Semi-wide) (Wide/Semi-wide/Narrow) terminal. meter 2.05kHz (Narrow) Select “MAX”...
  • Page 53 TK-780 ADJUSTMENT Measurement Adjustment Item Condition Specifications/Remarks Test- Unit Terminal Unit Parts Method equipment ± 0.2kHz (Wide/Semi-wide) 11. DTMF 1) Set test mode Power meter Rear 3.0kHz (Wide) ± 0.1kHz (Narrow) deviation Select “n DTMF” in tuning mode. Deviation panel 2.4kHz (Semi-wide)

  • Page 54: Pc Board Views

    TK-780 PC BOARD VIEWS SUB UNIT (X58-4850-10) : E3 PLL/VCO (X58-4712-70) Component side view Component side view (J72-0732-02) (J72-0785-02) J72-0732-02 9C IN CN101 L110 L103 R101 C122 L105 C134 C104 R105 L106 J72-0785-02 C136 R116 Q105 C127 R107 Q106 C138...

  • Page 55: Tx-Rx Unit (X57-6142-Xx) (A/2)

    TK-780 PC BOARD VIEW TX-RX UNIT (X57-6142-XX) (A/2) -70 : E -72 : E3 Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Component side view (J72-0724-22 A/2) Q403 IC10 IC11 D206 IC14 Q300...
  • Page 56 TK-780 PC BOARD VIEW TX-RX UNIT (X57-6142-XX) (A/2) -70 : E -72 : E3 Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Foil side view (J72-0724-22 A/2)
  • Page 57 TK-780 PC BOARD VIEW TX-RX UNIT (X57-6142-XX) (A/2) -70 : E -72 : E3 Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Ref. No. Address Component side view + Foil side (J72-0724-22 A/2)

  • Page 58: Tx-Rx Unit (X57-6142-Xx) (B/2)

    TK-780 PC BOARD VIEWS TX-RX UNIT (X57-6142-XX) (B/2) -70 : E -72 : E3 Component side view (J72-0724-22 B/2) J72-0724-22 B/2 D512 R514 D517 R710 R517 C712 R510 C527 C710 C518 C583 R526 R713 L507 R525 IC710 R682 IC502 C524...
  • Page 59 TK-780 PC BOARD VIEW TX-RX UNIT (X57-6142-XX) (B/2) -70 : E -72 : E3 Component side view + Foil side (J72-0724-22 B/2) J72-0724-22 B/2 D512 R520 R514 D517 R710 C607 R517 C712 MPTT C516 R518 R510 C515 C527 C710 C518...

  • Page 60: Schematic Diagram

    TK-780 SCHEMATIC DIAGRAM Note : Components marked with a dot (·) are parts of layer 1.
  • Page 61 TK-780 Note : Components marked with a dot (·) are parts of layer 1. SCHEMATIC DIAGRAM...

  • Page 62: Block Diagram

    TK-780 TK-780 TK-780 BLOCK DIAGRAM...

  • Page 63: Level Diagram

    TK-780 TK-780 LEVEL DIAGRAM Receiver Section –95.0dBm –99.5dBm SW –94.0dBm SW –98.0dBm –94.5dBm –88.0dBm W/SW/N W/SW/N W/SW/N W/SW/N W/SW/N –118.0dBm –121.0dBm –109.0dBm –106.5dBm –120.5dBm –110.0dBm 62mVrms 30mVrms 0.45Vrms 820mVrms 820mVrms 16mVrms SG input level for 12dB SINAD are obtained measured by AF VTVM connecting SG to each point via a 0.01µF capacitor.

  • Page 64: Terminal Function

    TK-780 TERMINAL FUNCTION CN7 (TX-RX Unit A/2) ← → CN502 (TX-RX Unit B/2) CN101 (VCO) ← → TX-RX Unit A/2 Pin No. Name Function Pin No. Name Function Wide/Narrow. H : Wide Switched transmit input. H : Transmit TX/RX switch. H : Receive RF output.

  • Page 65: Specifications

    TK-780 SPECIFICATIONS GENERAL Frequency Range ........ 146 to 174MHz Number of Channels ......Maximum 250 channels Channel Spacing ......... Narrow : 12.5kHz Wide 4k : 20kHz Wide 5k : 25kHz Input Voltage ........13.2V DC negative ground Current Drain ........0.4A on standby 1.0A on receive...
  • Page 66 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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