Kenwood TK-5810, TK-5810H, TK-5810BG, TK-5810HBG Service Manual

UHF P25 TRANSCEIVER

TK-5810(BG TK-5810H(BG

SERVICE MANUAL

TK-5810(BG) with KCH-14

Metallic cabinet (Top) (A01-2161-32)

POWER

GRP

)

Use this service manual together with the KCH-14/15 service manual (B51-8728-00) or KCH-16 service manual (B51-8834-00). As for the hardware of this transceiver, version 3 is used. The programming software must use KPG-95DG.

KCH-14 (Front panel kit)

)

TK-5810H(BG)

BUSY

VOL

Metallic cabinet (Top) (A01-2163-21)

This product complies with the

Metallic cabinet (Bottom) (A01-2164-31)

directive for the European market.

RoHS

This product uses Lead Free solder.

TK-5810(BG)/5810H(BG

)

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

SYSTEM SET-UP ....................................................... 4

REALIGNMENT ......................................................... 5

INSTALLATION ........................................................ 12

DISASSEMBLY FOR REPAIR .................................. 20

CIRCUIT DESCRIPTION .......................................... 24

COMPONENTS DESCRIPTION ............................... 32

PARTS LIST ............................................................. 35

EXPLODED VIEW .................................................... 50

PACKING .................................................................. 52

TROUBLE SHOOTING ............................................ 54

ADJUSTMENT ........................................................ 56

Document Copyrights

served.

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.

TERMINAL FUNCTION ........................................... 75

PC BOARD

FINAL UNIT (X45-3790-XX): TK-5810(BG) ......... 80

FINAL UNIT (X45-3800-XX): TK-5810H(BG) ...... 82

CONTROL UNIT (X53-4400-10) .......................... 86

TX-RX UNIT (X57-7270-XX) ................................ 90

INTERCONNECTION DIAGRAM ............................ 94

SCHEMATIC DIAGRAM .......................................... 96

BLOCK DIAGRAM ................................................. 114

LEVEL DIAGRAM .................................................. 120

SPECIFICATIONS .................................................. 121

Firmware Copyrights

The title to and ownership of copyrights for firmware embedded in Kenwood product memories are reserved for Kenwood Corporation. Any modifying, reverse engineering, copy, reproducing or disclosing on an Internet website of the firmware is strictly prohibited without prior written consent of Kenwood Corporation. Furthermore, any reselling, assigning or transferring of the ﬁ rmware is also strictly prohibited without embedding the firmware in Kenwood product memories.

Transceivers containing AMBE+2™ Vocoder:

The AMBE+2™ voice coding technology is embedded in the ﬁ rmware under the license of Digital Voice Systems, Inc.

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 the publication date. Changes which may occur after publication are covered by either Service Bulletins or Manual Revisions. These are issued as required.

GENERAL

ORDERING REPLACEMENT PARTS

When ordering replacement parts or equipment information, the full part identiﬁ cation 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 sufﬁ cient description of the required component for proper identiﬁ cation.

GENERAL

TK-5810(BG)/5810H(BG

)

PERSONAL SAFETY

The following precautions are recommended for personal

safety:

• DO NOT transmit if someone is within two feet (0.6 meter) of the antenna.

• DO NOT 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.

• All equipment should be properly grounded before power-up for safe operation.

• This equipment should be serviced by only qualified technicians.

PRE-INSTALLATION CONSIDERATIONS

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

radio installation (mobile or base) be obtained by the equipment owner. The licensee is responsible for ensuring transmitter power, frequency, and deviation are within the limits permitted by the station license.

Transmitter adjustments may be performed only by a

licensed technician holding an FCC ﬁ rst, second or general class commercial radiotelephone operator’s license. There is no license required to install or operate the radio.

3. PRE-INSTALLATION CHECKOUT

3-1. Introduction

Each radio is adjusted and tested before shipment. How-

ever, it is recommended that receiver and transmitter operation 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 ﬁ nal installation. Transmitter frequency, deviation, and power output should be checked, as should receiver sensitivity, squelch operation, and audio output. Signaling equipment operation should be veriﬁ ed.

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 radio’s weight. Allow sufﬁ cient 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 instal-

lation 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

recommended.

3. Connect the ground lead directly to the battery negative

terminal.

4. The cable provided with the radio is sufﬁ cient to handle

the maximum radio current demand. If the cable must be

extended, be sure the additional wire is sufﬁ cient for the

current to be carried and length of the added lead.

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 system 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 system’s power supply (which supplies the voltage and current required for your system). Make sure sufﬁ cient air can ﬂ ow 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 alignment procedures contained in this manual.

NOTE

You must use KPG-95DG version 6.10 or later for this transceiver.

TK-5810(BG)/5810H(BG

)

SYSTEM SET-UP

Before Reading About System Set-up

The TK-5810(BG)/5810H(BG) is a transceiver main unit (without a panel or speaker) that you complete by adding options.

The options are classiﬁ ed into three types according to operation and function.

Merchandise received

License and frequency allocated by FCC

Choose the type of transceiver

TK-5810(BG)/5810H(BG) is complete by combining options

with only the transceiver body (without panel)

Are you using the handheld control head?

Are you using the remote kit?

See page 12 Please refer to the KCH-14/15 service manual (B51-8728-00) for serving information, such as circuit diagram, parts list and etc.

KCH-14 (Basic model)

Front panel kit

Are you using the printed keytops?

See page 12

Supplied accessory keytops

YES

See page 12 Please refer to the KCH-14/15 service manual (B51-8728-00) for serving information, such as circuit diagram, parts list and etc.

KCH-15 (Full-featured

model) Front panel kit

YES

1. Install the front panel kit (controller) directly on a radio to operate it. (Form: Radio + KCH-14/15)

2. Remotely control one radio with one controller. (Form: Radio + KRK-5 + KCH-14/15 + KCT-22M/M2/M3)

3. Remotely control one radio with two controllers. (Form: Radio + KRK-6DH + KCH-14/15 (two) + KCT-22M/M2/M3 (two))

Type

TK-5810H(BG) K

TK-5810H(BG) K2

Please refer to the KCH-16 service manual (B51-8834-00) for serving information, such as circuit diagram, installation, adjustment and etc.

Are you using one transceiver

with one controller?

See page 13

YES

Please refer to the KRK-5/6DH service manual (B51-8445-20) for serving information, such as circuit diagram, parts list and etc.

Single control head remote kit

KCH-14 KCH-15

Frequency range RF power

450~520MHz 45W~5WTK-5810(BG) K

400~470MHz 45W~5WTK-5810(BG) K2

450~500MHz 100W~50W

500~520MHz

400~470MHz

Are you using one radio with two controllers?

KRK-5

(Option) (Option)

60W~50W

100W~50W

YES

See page 15 Please refer to the KRK-5/6DH service manual (B51-8445-20) for serving information, such as circuit diagram, parts list and etc.

oror or

KRK-6DH

KCH-14

KCH-15

Dual control head remote kit

KCH-14

KCH-15

Service manual parts No. list

Model Parts No.

KRK-5/6DH B51-8445-20

KCH-14/15 B51-8728-00

KCH-16 B51-8834-00

Transceiver programming

KCT-23 DC cable

Are you using the voice guide & storage unit?

Are you using the external speaker?

Are you using the keypad microphone?

Delivery

KCT-22M/M2/M3

Control cable

See page 5 A personal computer, programming interface (KPG-43/43A), USB adapter (KCT-53U), and programming software (KPG-95DG: ver. 6.10 or later) are required for programming. (The frequency and signaling data are programmed for the transceiver.)

KCT-23 M,M3

YES

VGS-1

KES-5

KMC-28

See pages 14 and 15

See page 17

(Option)

See page 17

(Option)

Desk top microphone KMC-9B

TK-5810(BG)/5810H(BG

REALIGNMENT

)

1. Modes

User mode

Panel test mode

PC mode

Firmware programming mode

Firmware version information

Clock adjustment mode

Transceiver information mode

Clone mode

Self programming mode

Mode Function

User mode For normal use.

Panel test mode

Panel tuning mode Used by the dealer to tune the transceiver.

PC mode

Data programming mode

PC test mode

Firmware programming mode

Firmware version information

Clock adjustment mode

Transceiver information mode

Clone mode

Self programming mode

Used by the dealer to check the fundamental characteristics.

Used for communication between the transceiver and PC.

Used to read and write frequency data and other features to and from the transceiver.

Used to check the transceiver using the PC. This feature is included in the FPU. See panel tuning.

Used when changing the main program of the ﬂ ash memory.

Used to conﬁ rm the internal ﬁ rmware version.

Used by the dealer to adjust date and time.

Used to conﬁ rm the transceiver ﬁ rmware version.

Used to transfer programming data from one transceiver to another.

Frequency, signaling and features write to the transceiver.

Panel tuning mode

Data programming mode

PC test mode

PC tuning mode

2. How to Enter Each Mode

Mode Operation

User mode Power ON

Panel test mode [PF1] + Power ON

PC mode Received commands from PC

Panel tuning mode [Panel test mode] + [GRP

Firmware programming mode [PF2] + Power ON

Firmware version information [PF3] + Power ON

Clock adjustment mode [PF4] + Power ON

Transceiver information mode [PF1] + [PF3] + Power ON

Clone mode [PF5] + Power ON

Self programming mode [GRP ] + Power ON

]

3. Panel Test Mode

Setting method refer to ADJUSTMENT.

4. Panel Tuning Mode

Setting method refer to ADJUSTMENT.

5. PC Mode

5-1. Preface

The transceiver is programmed by using a personal computer, programming interface (KPG-43/43A), USB adapter (KCT-53U) and programming software (KPG-95DG: ver. 6.10 or later).

The programming software can be used with a PC. Figure 1 shows the setup of a PC for programming.

KPG-43 or KPG-43A or KPG-43A + KCT-53U Illustration is KPG-43.

KPG-95DG

(Ver. 6.10 or later)

D-SUB

(25-pin)

KPG-43

Transceiver

D-SUB (9-pin)

KPG-43A

Transceiver

USB

KCT-53U

KPG-43A

Transceiver

Fig. 1

TK-5810(BG)/5810H(BG

)

REALIGNMENT

5-2. Connection procedure

1. Connect the transceiver to the computer using the interface cable and USB adapter (When the interface cable is KPG-43A, the KCT-53U can be used.).

Note:

• You must install the KCT-53U driver in the computer to use the USB adapter (KCT-53U).

• When using the USB adapter (KCT-53U) for the ﬁ rst time, plug the KCT-53U into a USB port on the computer with the computer power ON.

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

Note:

The data stored in the computer must match the “Model

Name and Market Code” when it is written into the ﬂ ash memory.

5-3. KPG-43/KPG-43A description (PC programming interface cable: Option)

The KPG-43/43A is required to interface the transceiver

to the computer. It has a circuit in its D-sub connector (KPG43: 25-pin, KPG-43A: 9-pin) case that converts the RS-232C logic level to the CMOS level.

The KPG-43/43A connects the microphone jack of the

transceiver to the RS-232C serial port of the computer.

6. PC Tuning Mode

When making adjustment while in PC tuning mode, modify the KPG-43/43A programming interface cable as described below.

1. Remove the two screws from the plug cover, then lift

the cover from the plug.

2. Solder the lead wire onto the MIC tab on the PCB, and

the ground wire onto the ME tab.

• KPG-43

MIC

MAX232C

ME TRD

MAXIM

GND

IC1

5-4. KCT-53U description (USB adapter: Option)

The KCT-53U is a cable which connects the KPG-43A to

a USB port on a computer.

When using the KCT-53U, install the supplied CD-ROM (with driver software) in the computer. The KCT-53U driver runs under Windows 2000, XP or Vista (32-bit).

5-5. Programming software KPG-95DG description

The KPG-95DG (ver. 6.10 or later) is the programming software for the transceiver supplied on a CD-ROM. This software runs under Windows 98, ME, Windows NT4.0, 2000, XP or Vista (32-bit) on a PC.

The data can be input to or read from the transceiver and edited on the screen. The programmed or edited data can be printed out. It is also possible to tune the transceiver.

• KPG-43A

MIC ME

CN1

• KPG-43 Create a hole in the casing (as shown in the illustration)

then ﬁ t the cable into the hole. Replace the cover and secure it using the two screws.

MIC

Cable

Create a hole

TK-5810(BG)/5810H(BG

REALIGNMENT

)

• KPG-43A Install the D-SUB socket into the cover after aligning the

lead wire as shown in the ﬁ gure.

Replace the cover and secure it using the two screws.

D-SUB socket

Lead wire

MIC

Cover

7. Firmware Programming Mode

7-1. Preface

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

• These transceivers use firmware versions G5.10 or later. When using ﬁ rmware versions earlier than version G5.10, a “Check connection” error message will appear on the LCD. Firmware versions earlier than version G5.10 will not write to the transceiver.

• While the firmware is being written, if the transceiver resets due to a power supply interruption or other problem, the LCD may not display correctly (for example, “PROGRAM FIRM” may not display).

Additionally, transceiver keys other than the power

switch cannot be operated.

To return to normal operation, click the “Cancel” but-

ton in the firmware programming software, then turn the transceiver power OFF and back ON. “PROGRAM FIRM” reappears on the display and the transceiver keys can be operated. However, the previously written ﬁ rmware data is lost; you must write the ﬁ rmware using the ﬁ rmware programming software again.

8. Firmware Version Information

Press and hold the [PF3] key while turning the transceiv-

er power ON and then keep pressing and holding the [PF3] key, the ﬁ rmware version information appears on the LCD.

7-2. Connection procedure

Connect the transceiver to the personal computer (PC) using the interface cable (KPG-43/43A) and USB adapter (KCT-53U: When the interface cable is KPG-43A, the KCT53U can be used.). (Connection is the same as in the PC Mode.)

7-3. Programming

1. Start up the ﬁ rmware programming software (Fpro.exe).

2. Set the communications speed (normally, 115200 bps)

and communications port in the conﬁ guration item.

3. Set the ﬁ rmware to be updated by File name item.

4. Press and hold the [PF2] key while turning the transceiv-

er power ON. Then, the orange LED on the transceiver

lights and “PROGRAM FIRM” is displayed.

5. Check the connection between the transceiver and the

personal computer, and make sure that the transceiver is

in the Program mode.

6. Press “write” button in the window. When the trans-

ceiver starts to receive data, the [PG] display is blinking.

7. If writing ends successfully, the checksum is calculated

and a result is displayed.

8. If you want to continue programming other transceivers,

repeat steps 4 to 7.

Note:

• This mode cannot be entered if the Firmware Program-

ming mode is set to Disable in the Programming soft-

ware.

9. Clock Adjustment Mode

9-1. Flow chart of operation

[PF4] + Power ON

YEAR

MONTH

DAY

HOUR

MINUTE