Kenwood TK-480 Service Manual

800MHz FM TRANSCEIVER

TK-480

SERVICE MANUAL

M2 Version

Whip antenna
(T90-0636-25)

Knob (ENC)
(K29-5232-03)

© 2003-10 PRINTED IN JAPAN
B51-8665-00 (N) PDF

This service manual has new information that is not
covered by the TK-480/481 (REVISED II) service
manual (B51-8408-20).
Refer to the TK-480/481 (REVISED II) service manual
(B51-8408-20) for items not provided in this service
manual.

Knob (PTT)
(K29-5157-03)

Knob (VOL)
(K29-5231-03)

Panel assy
(A62-0981-04)

Badge
(B43-1139-04)

Cabinet assy
(A02-3659-13)

Packing
(G53-0841-02)

CONTENTS

GENERAL ............................................................ 2

SYSTEM SET-UP ................................................ 2

OPERATING FEATURES .................................... 3

REALIGNMENT................................................... 8

PARTS LIST ....................................................... 10

EXPLODED VIEW ............................................. 16

PACKING ........................................................... 17

ADJUSTMENT .................................................. 18

SPECIFICATIONS.......................... BACK COVER

CAUTION
When using an external power connector,
please use with maximum final module
protection of 9V.

TK-480

GENERAL / SYSTEM SET-UP

INTRODUCTION

SCOPE OF THIS MANUAL

This manual is intended for use by experienced techni­cians familiar with similar types of commercial grade com­munications equipment. It contains all required service in­formation for the equipment and is current as of this publica­tion 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 informa­tion, 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.

Model &

destination

TK-480 M2 X57-5630-10 X54-3210-11 806~870MHz

TX-RX unit DISPLAY unit

Unit

Frequency range Remarks Charger Battery 12 key

PERSONNEL SAFETY

The following precautions are recommended for person-

nel safety :

•DONOT 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 tech­nicians.

SERVICE

This radio is designed for easy servicing. Refer to the

schematic diagrams, printed circuit board views, and align­ment procedures contained within.

IF1 : 44.85MHz

LOC : 44.395MHz

Option ✓✓

Note : X57-5630-10/X54-3210-11 : Produced in Singapore

SYSTEM SET-UP

Merchandise received

Choose the type of transceiver

Transceiver programming

Are you using the speaker microphone?

NO

Frequency range (MHz) RF power Type

TX 806~825 2.5W TK-480 M2

851~870

RX 851~870

A personal computer (IBM PC or compatible), programming
interface (KPG-36), and programming software (KPG-49D (M2)
ver 6.30 or later) 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

KMC-25

Speaker microphone

(Option)

Delivery

2

OPERATING FEATURES

TK-480

1. Operation Features

The TK-480 is an 800MHz band EFJ LTR™-compatible
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

Microphone Speaker

1 2 3

4

5

6

7

8

9

12

10

11

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 param­eters, such as the system and group, are stored in
memory. When the power is switched on again, the sys­tem 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 trans­mission, the brightness of this indicator decreases at in­tervals of about one second, so it can be used as the bat­tery voltage alert function.

S, A, B, and C key (Programmable)

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 ex­plained 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 (M2) ver 6.30 or later) al-

lows selecting between system selector and group se-

lector.

DTMF keypad

Press the keys on the telephone keypad to send DTMF
tones.

Universal connector

Connect the external KMC-25 speaker/ microphone (op­tional) 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 (M2) ver 6.30 or later) enables pro-

grammable keys to select the following functions.

Auto Tel, AUX(only when Voice Scrambler is not se­lected), 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, Moni­tor 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.

3

TK-480

OPERATING FEATURES

■ Auto TEL

Automatically connects available repeaters that are con­nected to telephone circuits when operating as LTR system.
The time allocated to search for available repeaters is 60
seconds, after which connection failure occurs, a DTMF
tone is output and the function terminates.

If connection to an available circuit is made, only ID 253,
EOT or hang-up time-out can terminate the function.

■ AUX

This function can be programmed when the voice scram­bler board is not installed.

If this key is pressed, an underscore (“_”) appears at the
extreme right of the LCD and AUX port which is inside of the
transceiver turns to the active level. If pressed again, the
underscore disappears and the AUX ports turns to the
deactive level.

■ DTMF ID (BOT)

Pressing this key in Conventional mode, automatically
sends the preset Connect ID.

■ DTMF ID (EOT)

Pressing this key in Conventional mode, automatically
sends the preset Disconnect ID.

■ Display character

This key switches the LCD display between the system/
group number and system/group name.

■ Emergency

Pressing this key for longer than the programmed “Emer­gency Key Delay Time” causes the transceiver to enter the
emergency mode. The transceiver jumps to the pro­grammed “Emergency System/Group” and transmits for
the programmed “Active Time”.

The transceiver disables mic mute while transmitting.
After finishing transmission, the transceiver receivers for
the programmed “Interval Time”. The transceiver mutes
the speaker while receiving. Following the above sequence,
the transceiver continues to transmit and receive.

If “Man Down Switch” has been programmed on the ra­dio and the switch is activated, the radio enters Emergency
mode after the specified “Man Down Delay Time” expires.

■ Key lock

Pressing this key causes the transceiver to accept entry
of only the [Function], [Key Lock], [PTT], [Lamp], [Monitor A],
[Monitor B], [Monitor C], [Monitor D], and [Emergency] keys.

The locked keys also include the tuning control.

■ Lamp

This key illuminates the LCD and keys on the front panel.
When the key is pressed, the LED lamp goes on.

When it is released, the lamp goes off after about five
seconds. If any key is pressed while the LED lamp is on, the
lamp is kept on for five seconds.

■ Memory

This key allows DTMF memory data to be recalled; up to
32 memories each with a memory dial of up to 16 digits and
an A/N of up to 10 digits per memory.

■ Monitor

Used to release signalling or squelch when operating as a
conventional. It is also used to reset option signalling.

■ Redial

Pressing this key when System/Group is shown, displays
the previously transmitted DTMF code. Pressing [PTT] at
this time, transmits the code that is currently displayed.

■ RF power low

Used to temporarily switch transmission output to low
power. Turning the function on enables:

Hi→Low, Low→Low

Key states are backed up, except in the PC mode when
they are reset.

■ Scan

Press this key starts scanning. Pressing this key stops
scanning.

■ Scan Del/Add

Used to select whether system scan routines are used
during system scan. Each pressing of the key (to ON)
toggles between lockout and lock. The scan routine is
started when on lock. The DEL indicator flashes when the
system is on lockout.

■ Function

Pressing this key causes the transceiver to display
“FCN”. Then, pressing a DTMF key causes the correspond­ing programmed function to start. This key may be conve­nient when using many functions with the 12-key keypad.

■ Group up/down

When the key is pressed each time, the group number to
be selected is incremented/decremented and repeats if held
for one second or longer.

■ Home group

Each pressing of the key selects a preset system/group.

4

■ Scan temporary delete

This key is temporarily deleted a system being scanned.
If you press this key when scan is stopped (when a call is
being received from another station), the system is tempo­rarily deleted and scanning restarts.

This key operates even when “Scan Type” is set to “List
Type System Scan”.

■ Scrambler

If a scrambler code (1 to 4) has been set in the FPU, an
underscore (“_”) appears at the extreme right of the LCD
display when scrambler is active. Pressing this key changes
ON/OFF of scramble operation.

Holding this key down for 2 seconds sets Scramble Code
Select Mode.

OPERATING FEATURES

TK-480

■ System up/down

When the key is pressed each time, the system number
to be selected is incremented/decremented and repeats if
held for one second or longer.

■ Telephone disconnect

Pressing this key ends an RIC connection (disconnects
the telephone line).

■ None

Sounds error operation beep, and no action will occur.

Use this function when the transceiver is required to be
more simple operated.

2-4. Display

P

9

Sub display

Displays the system and group numbers. Also displays

various functions which have been programmed.

Alphanumeric display

The twelve-character dot matrix alphanumeric display
shows the system and group numbers. You can program
system and group names with up to ten characters in
place of these numbers. The left display is used as a de­lete indicator (

) or scrambler ( _ ) function. The delete/add indica-

call (
tor shows the systems locked out of the scanning se­quence. Selective call and scrambler are optional func­tions that can be programmed. Also displays received
messages when using DMS (Digital Message System).

) and the right is used for the selective

3. Option Signalling

3-1. DTMF

Built-in DTMF decoder is available for option signalling.
It is possible to use individual call, group call, D.B.D.

(Dead Beat Disable). D.B.D. is used with DTMF only.

If the option signalling matches, a predetermined action

will occur.

If option signalling matches on a group which is set up
with option signalling, the option signalling indicator (
flash and option signalling will be released. The transpond
or alert tone will sound.

If the selective call alert LED is set up, the orange LED
will flash.

While option signalling matches (or if option signalling is
deactivated when you are transmitting), you can mute or
unmute ID/QT/DQT/Carrier.

) will

P (Priority) indicator

The P indicator ( ) appears when a selected channel is
programmed as priority, in conventional operation.

MON (Monitor) indicator

The MON indicator appears when the button pro­grammed as MONITOR is pressed.

SVC (Service) indicator

This icon is not used on this transceiver.

SCN (Scan) indicator

The SCN indicator appears when using Scan mode.

LO indicator

Appears when low power is selected.

Handset indicator

The handset indicator ( ) appears when the selected
group is programmed as telephone IDs.

MAIL indicator

Flashes when a status message (DMS) is received.
Lights when a status message is stored in the stack
memory.

■ AND/OR

You can select AND or OR for option signalling match
conditions.

Alert/Transpond

AND QT/DQT/ID+DTMF; Option matches = Action

OR QT/DQT/ID+DTMF; Option matches = Action

AF mute open

AND QT/DQT/ID+DTMF; Option matches = Action

OR QT/DQT/ID; Signalling only matches = Action

With OR set up, alert/transpond will not function with
only DTMF.

With OR set up, AF mute will not release when only
DTMF matches.

With a conventional group not set up with QT or DQT,
only the carrier is considered when signalling matches.

■ Auto Reset

If option signalling matches a group set up with option
signalling, option signalling is released. After matching op­tion signalling, option signalling will temporarily reset auto­matically.

5

TK-480

OPERATING FEATURES

■ Dead Beat Disable

If the D.B.D. code matches, a predetermined action will
occur. Whether option signalling is activated or not, when
D.B.D. matches on any group, the transceiver will become
TX inhibited or TX/RX inhibited. While D.B.D. is active, if the
D.B.D. code + “#” code is received, D.B.D. will disactivate.

When D.B.D. matches, transpond will function. Alert will
not be output, and option signalling match icon will not ap­pear.

3-2. MSK

Built-in MSK (DMS : Fleet-ID) decoder is available for op­tion signalling. When the group ID matches, squelch re­mains muted while the station waits for reception of proper
MSK signal. When MSK signal matches, squelch unmutes.

■ AND/OR

AND : QT/DQT/ID + MSK to unmute. MSK matches =
alert tone

OR : QT/DQT/ID to unmute. MSK matches = alert tone

4.

Alphanumeric Two-way Paging Function

(Digital Message System)

4-1. General

The Alphanumeric Two-way Paging Function (DMS) is a
Kenwood proprietary protocol. It enables a variety of paging
functions.

4-2. ID Construction

A radio unit ID is defined by a combination of 3-digit Fleet
and 4-digit ID numbers. Each radio unit must be assigned its
own Fleet and ID numbers.

4-3. PTT ID

A pre-programmed unique ID can be sent at the begin­ning of transmission and/or the end of transmission to iden­tify which radio unit is on air.

4-4. Selective Call (SELCALL)

This is a voice call to a particular individual or group of
stations.

■ Example of call types;

[100][ALL ] : <Group Call>

All the units whose fleet number is “100” are called.

[100][1000] : <Individual Call>

The unit, whose the fleet number is “100” and ID num-

ber is “1000”, is called.

[ALL][ALL ] : <Broadcast Call>

All the units are called.

[ALL][1000] : <Supervisor Call>

All ID “1000” are called regardless of their fleet number.

■ Unit ID Encode Block

Encode ID Block can be set to limit manual dial ID. The
radio unit will not accept an ID other than these IDs which
are entered from the keypad. If Inter-fleet Call is enabled,
block ID setting affects each fleet group.

6

4-5. Status Message

Using a 2-digit number, you can send and receive a Sta­tus message which may be decided in your talk group. Each
Status may be displayed with 16 alphanumeric characters if
programmed in the radio. A maximum of 9 received mes­sages can be stored in the stack memory, and it can be re­viewed after reception. If the message memory becomes
full, the oldest one will be erased. The stack memory will be
cleared by turning radio power off.

■ Status 80~99 (Special)

Status numbers from 80 to 99 are reserved for special
purposes. Entering these statuses from the DTMF keypad
can be inhibited.

Please notice that the following status numbers are used
for special purposes;

80~89 : Reserved for future use.

90 : Remote stun on. Disable the received radio unit’s

TX.

91 : Remote stun on. Disable the received radio unit’s

TX/RX.

92 : Cancel remote stun. Enable the received radio unit’s

TX/RX.

93 : Acknowledgement status sent when the radio unit is

in stun mode (TX disabled).

94 : Acknowledgement status sent when the radio unit is

in stun mode (TX/RX disabled).

95~98 : Reserved for future use.

99 : Emergency Status.

Note : Remote stun works with DTMF D.B.D. function also.

■ Automatic Status Response

If you pre-select a status number and leave the radio in
the Status Mode, it can automatically respond with the se­lected status number upon request from the base station.
(The request function is initiated by serial control on the
base station (Optional).)

4-6. Short Messase (Optional)

A maximum of 48 characters can be sent (External equip­ment is required). Received Short Messages will be dis­played in the same manner as a Status Message. A maxi­mum of 4 received messages can be stored in the stack
memory. In the Stack Mode, 3-digit LCD indicates the re­ceived Short Message as “M01”~”M04".

4-7. Long Message

A maximum of 1024 characters can be sent (External
equipment is required). Received Long Message will not be
displayed or stacked in the radio memory but is output
through the COM (Data) port.

4-8. Emergency Function

Emergency status 99 will be sent at the beginning of
each emergency transmission.

OPERATING FEATURES

TK-480

■ Emergency Status response

“Alert” can be selected for the called radio unit’s re­sponse to reception of status 99 which is used as an emer­gency status.

4-9. Other Functions

■ Manual Dial

Fleet, ID and Status numbers can be entered from DTMF
keypad.

■ Data TX with QT/DQT

Whether programmed QT/DQT is modulated or not with
a data transmission except for Selcall. A radio unit can re­ceive a data message regardless of QT/DQT if the receiving
unit is not scanning.

■ DMS Baud Rate

MSK data baud rate setting. The same rate must be set
as a communication partner.

1200bps :

Data communication is made in 1200bps. The communi­cation area is much wider than 2400bps. Recommended for
repeater operation.

2400bps :

Data communication is made in 2400bps. The communi­cation area is narrower than 1200bps, but it will decrease
the data traffic. Data rate 2400bps may not work properly
depending on the repeater’s characteristic.

■ Inter-fleet call

Inter-Fleet Calls allow a radio of one Fleet number to call
a radio with a different Fleet number (radio users can manu­ally dial a Unit ID with a different Fleet number).

■ Status/Short/Long Message on Data Group/

Channel

Status/Short/Long Message transmission is made
whether on the Data System/Group.

■ Number of Retries

Number of Retries is the maximum number of retry
transmission when no acknowledgement is received in the
Maximum ACK Wait Time. Increase this item to improve
data communication reliability.

■ TX Busy Wait Time

TX Busy Wait Time is the maximum amount of time be­fore giving up the data transmission when the channel is
busy. Also, this timer affects if it expires during Random
Access period.

■ Maximum ACK Wait Time

Maximum ACK Wait Time is the maximum amount of
time to wait for an acknowledgement from the called radio
unit. It is used as an interval time of retries. It must be set
greater than the ACK Delay Time of the called radio unit.

■ ACK Delay Time

ACK Delay Time is the amount of time from the end of
receiving a data to the beginning of sending an
acknowledgement. It should be adjusted as the repeater’s
hang-up delay time. Also, it must be set less than the Maxi­mum ACK Wait Time of the calling radio unit.

■ TX Delay Time (RX Capture)

TX Delay Time is the amount of unmodulated transmis­sion to let the called unit stop scanning or exit its battery
save mode. It is used only when starting a data communica­tion sequence.

■ Data TX Modulation Delay Time

Data TX Modulation Delay Time is the amount of time
from the beginning of transmission to the beginning of a
data modulation. It is used every time data is transmitted.

■ Status/Short/Unit ID Message Serial Output

Whether a received Status/Short message or PTT ID is

outputed or not to serial port.

4-10. Parameters

■ GTC Count

Number of “Go To data Channel” messages to be sent
before transmitting a data message if it is being made on
Data System/Group. If a radio unit receives a GTC message,
it will move to the Data System/Group of the current sys­tem. Increase this item to make sure the called radio unit
moves to the Data System/Group.

■ Random Access (Contention)

When a channel is busy, radio unit will not transmit (de­pending on its Busy Channel Lockout setting). As soon as a
channel is cleared, some transmissions may crash. Random
access is used to avoid this by employing a random trans­mission sequence.

7

TK-480

REALIGNMENT

1. PC Mode

1-1. Preface

The TK-480 transceiver is programmed by using a per-

sonal computer, programming interface (KPG-36) and pro­gramming software (KPG-49D (M2) ver 6.30 or later).

The programming software can be used with an IBM PC

or compatible. Figure 1 shows the setup of an IBM PC for
programming.

1-2. Connection procedure

1. Connect the TK-480 to the personal computer with the
interface cable.

2. When the POWER switch on, user mode can be entered
immediately. When PC sends command the radio enter
PC mode, and “PROGRAM” is displayed on the LCD.
When data transmitting from transceiver, the red LED is
blinking.
When data receiving to transceiver, the green LED is
blinking.

Notes:

• The data stored in the personal computer must match
model type, when it is written into the flash memory.

• Change the TK-480 to PC mode, then attach the interface
cable.

1-3. KPG-36 description
(PC programming interface cable: Option)

The KPG-36 is required to interface the TK-480 to the

computer. It has a circuit in its D-subconnector (25-pin) case
that converts the RS-232C logic level to the TTL level.

The KPG-36 connects the universal connector of the TK-

480 to the computers RS-232C serial port.

1-4. Programming software description

The KPG-49D (M2) ver 6.30 or later programming disk is

supplied in 3-1/2" disk format. The software on this disk al­lows a user to program TK-480 radio via programming inter­face cable (KPG-36).

1-5. Programming with IBM PC

If data is transferred to the transceiver from an IBM PC

with the KPG-49D (M2) ver 6.30 or later, the destination data
(basic radio information) for each set can be modified. Nor­mally, it is not necessary to modify the destination data be­cause their values are determined automatically when the
frequency range (frequency type) is set.

The values should be modified only if necessary. Data

can be programmed into the flash memory in RS-232C for­mat via the universal connector.

KPG-49D (M2) instruction manual parts No. : B62-1358-

XX

IBM-PC

KPG-36

KPG-49D (M2)
(ver 6.30 or later)

Fig. 1

2. Firmware Programming Mode

2-1. Preface

Flash memory is mounted on the TK-480. This allows the
TK-480 to be upgraded when new features are released in
the future. (For details on how to obtain the firmware, con­tact Customer Service.)

2-2. Connection procedure

Connect the TK-480 to the personal computer (IBM PC or
compatible) with the interface cable (KPG-36). (Connection
is the same as in the PC Mode.)

2-3. Programming

1. Start up the programming software (KPG-49D (M2) ver

6.30 or later), select “firmware program” in the “Pro-

gram” item, and press the Return key on the personal

computer. This starts up the firmware programmer.

2. The top screen is displayed. Press any key to advance to

the next screen.

3. Set the communications speed (normally, 57600 bps)

and communications port in the Setup item.

4. Set the firmware to be updated by File select (=F1).

5. Turn the TK-480 power ON with the [S] switch held

down. Hold the switch down for two seconds until the

display changes to “PROG 57600”. When “PROG

57600” appears, release your finger from the switch.

6. Check the connection between the TK-480 and the per-

sonal computer, and make sure that the TK-480 is in the

Program mode.

7. Press F10 on the personal computer. A window opens on

the display to indicate progress of writing. When the TK-

480 start to receive data. the [P] icon is blinking.

8. If writing ends successfully, the LED on the TK-480 light

and the checksum is displayed.

9. If you want to continue programming other TK-480, re-

peat steps 5 to 8.

8