Kenwood TK-8162 User Manual

UHF FM TRANSCEIVER

TK-8160/8162

SERVICE MANUAL

TK-8160 E, E3, X2

Modular jack (E08-0877-05)

Key top (K29-9342-01)

TK-8162 E, E3

Modular jack (E08-0877-05)

Key top (K29-9342-01)

CONTENTS

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

SYSTEM SET-UP ...................................... 3

OPERATING FEATURES .......................... 4

REALIGNMENT ......................................... 6

DISASSEMBLY FOR REPAIR ................. 10

CIRCUIT DESCRIPTION .......................... 11

SEMICONDUCTOR DATA ...................... 16

COMPONENTS DESCRIPTION .............. 17

PARTS LIST ............................................. 18

EXPLODED VIEW.................................... 26

PACKING ................................................. 27

Panel assy (A62-1107-13)

Panel assy (A62-1108-03)

ADJUSTMENT ........................................ 28

TERMINAL FUNCTION ........................... 33

PC BOARD

DISPLAY UNIT (X54-3510-10) ............ 34

DISPLAY UNIT (X54-3522-70) ............ 36

TX-RX UNIT (X57-711X-XX)............... 38

SCHEMATIC DIAGRAM.......................... 42

BLOCK DIAGRAM ................................... 48

LEVEL DIAGRAM .................................... 50

SPECIFICATION ................... BACK COVER

This product uses Lead Free solder.

TK-8160/8162

GENERAL

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.

PERSONAL SAFETY

The following precautions are recommended for personal safety :

•DONOT transmit if someone is within two feet (0.6

meter) of the antenna.

•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.

• All equipment should be properly grounded before power-

up for safe operation.

• This equipment should be serviced by only qualified tech-

nicians.

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. PRE-INSTALLATION CHECKOUT 2-1. Introduction

Each radio is adjusted and tested before shipment. However, it is recommended that receiver and transmitter operation be checked for proper operation before installation.

2-2. Testing

The radio should be tested complete with all cabling and accessories as they will be connected in the final installation. Transmitter frequency, deviation, and power output should be checked, as should receiver sensitivity, squelch operation, and audio output. Signalling equipment operation should be verified.

3. PLANNING THE INSTALLATION 3-1. General

Inspect the vehicle and determine how and where the ra-

dio antenna and accessories will be mounted.

Plan cable runs for protection against pinching or crushing

wiring, and radio installation to prevent overheating.

3-2. 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.

3-3. 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 sufficient 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.

3-4. 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 installation

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 rec-

ommended.

3. Connect the ground lead directly to the battery negative

terminal.

4. The cable provided with the radio is sufficient to handle

the maximum radio current demand. If the cable must be

extended, be sure the additional wire is sufficient for the

current to be carried and length of the added lead.

4. INSTALLATION PLANNING – CONTROL STATIONS 4-1. 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.

4-2. 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 sufficient air can flow around the radio and power supply to allow adequate cooling.

TK-8160/8162

GENERAL / SYSTEM SET-UP

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

If you do not intend to use the 3.5-mm jack for the external speaker, fit the supplied speaker-jack cap to stop dust and sand from getting in.

E,E3

Antenna connector

External speaker jack

Power input connector

External speaker jack

Power input connector

SYSTEM SET-UP

Merchandise received

Choose the type of transceiver

Transceiver programming

KES-3

External speaker

(Option) (Option)

Modem GPS receiver or

Modem GPS controller

KCT-39

Connection cable

KCT-36

Extension cable

KGP-2A

KGP-2B

Delivery

Frequency range (MHz) RF power

440~470 25W E

400~430 25W E3

470~512 25W X2

See page 6. A personal computer (IBM PC or compatible), programming interface (KPG-46), and programming software (KPG-99D(E)) are required for programming.

(Option)

Ignition sense cable

KDS-100

Mobile data

terminal

(Option)(Option)

Type

KCT-18

(Option)

TK-8160/8162

OPERATING FEATURES

1. Controls and Functions

1-1. Front Panel

yu i o

1-2. Microphone

q (Power) switch

Press to switch the transceiver ON or OFF.

w / keys

Press to activate their programmable functions (page 5).

e Display

Refer to right or next page.

/ keys

Press to activate their programmable functions (page 5).

t Speaker

Internal speaker.

y Microphone jack

Insert the microphone plug into this jack.

u TX/RX Indicator

Lights red while transmitting. Lights green while receiving a signal.

, , , and keys

Press to activate their programmable functions (page 5).

o key

Press to activate its programmable function (page 5).

!0 PTT switch

Press this switch, then speak into the microphone to call a station.

we rt

1-3. Display (TK-8160)

Indicator Description

Appears when the key programmed as

Monitor or Squelch Off is pressed.

Appears when the DTMF code of a call

matches the code in your transceiver.

Appears while using the Talk Around

function.

The selected zone is added to the

scanning sequence.

Appears while scanning.

Appears when a message is stored in the

transceiver stack memory. Appears and

blinks when a new message has arrived.

Appears when the AUX port has been

activated.

The selected channel is set as a Priority

channel.

Appears when the Horn Alert function

has been activated.

The selected channel is added to the

scanning sequence.

Appears when Scrambler function has

been selected.

This icon is not used on this transceiver.

Displays the currently selected zone and

channel number, or the channel name.

OPERATING FEATURES

TK-8160/8162

1-4. Display (TK-8162)

Indicator Description

Appears when the key programmed as

Monitor or Squelch Off is pressed.

Appears while using the Talk Around

function.

Appears when Scrambler function has

been selected.

The selected channel is set as a Priority

channel.

Appears while scanning.

The selected channel is added to the

scanning sequence.

Displays the currently selected channel

number (max 16 channels).

Appears when the AUX port or

Horn Alert function has been activated.

1-6. Programmable Functions

The , , , , , , , , and keys can be programmed with the functions listed below. Ask your dealer for details on these functions.

• AUX • Operator Selectable Tone

• Call 1~Call 2 • Scan Del/Add

• Channel Down • Scan

• Channel Up • Scrambler

• Digit 1x Down

• Digit 10x Down

• Digit 1x Up

• Digit 10x Up

• Direct CH

2, 3

• Direct Zone-Channel

• Display Character

• Emergency

• Selcall

• Selcall (5-tone)

• Selcall + Status

• Send the GPS data

• Squelch Level

1, 3

• Squelch Off

• Squelch Off Momentary

• Status

• Horn Alert • Talk Around

• Key Lock • Volume Down

• LCD Brightness

• Volume Up

• Lone Worker • Zone Down

• Monitor • Zone Up

• None

1Digit 1x Down, Digit 10x Down, Digit 1x Up, Digit 10x Up,

Direct Zone-Channel, Display Character, LCD Brightness,

Operator Selectable Tone, Selcall, Selcall (5-tone), Selcall

+ Status, Send the GPS data, and Status are available only

on TK-8160 transceivers. 2 Direct CH is available only on TK-8162 transceivers. 3 Direct CH and Direct Zone-Channel can be programmed

only on the 4 Emergency can be programmed only on the

, , , , and keys.

key.

1-5. Rear Panel

E,E3

Antenna connector

External speaker jack

Power input connector

External speaker jack

Power input connector

TK-8160/8162

IBM-PC

KPG-46

TK-8160/TK-8162

KPG-99D(E)

1. Modes

User mode PC mode PC programming mode

REALIGNMENT

Clone mode

∗ Self programming mode

Mode Function

User mode For normal use.

PC mode Used for communication between the

transceiver and PC (IBM compatible).

PC programming Used to read and write frequency data and

mode other features to and from the transceiver.

PC test mode Used to check the transceiver using the PC.

This feature is included in the FPU.

PC tuning mode Used to tune the transceiver using the PC.

Clone mode Used to transfer programming data from

one transceiver to another.

∗

Self programming

mode

∗ : Only TK-8160 transceiver

You can program the frequency, signalling and

other functions using only the transceiver.

PC test mode

PC tuning mode

2. How to Enter Each Mode

Mode Operation

User mode Power ON

PC mode Received commands from PC

Clone mode

* Self programming mode [ ]+Power ON (Two seconds)

∗ : Only TK-8160 transceiver

[ ]+Power ON (Two seconds)

3. PC Mode

3-1. Preface

This transceiver is programmed using a personal computer, a programming interface (KPG-46) and programming software (KPG-99D(E)).

The programming software can be used with an IBM PC or compatible. Figure 1 shows the setup of an IBM PC for programming.

3-2. Connection Procedure

1. Connect the transceiver to the personal computer with

the interface cable.

2. When the Power is switched on, user mode can be en-

tered immediately. When the PC sends a command, the

transceiver enters PC mode.

When data is transmitted from transceiver, the TX indica-

tor blink.

When data is received by the transceiver, the BUSY indi-

cator blink.

In the PC mode, “PROGRAM” (TK-8160) or “P” (TK-8162)

is displayed on the LCD.

Fig. 1

3-3. KPG-46 Description

(PC programming interface cable : Option)

The KPG-46 is required to interface the transceiver 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-46 connects the modular microphone jack of the transceiver to the computers RS-232C serial port.

3-4. Programming Software Description

KPG-99D(E) is the programming software for transceiver supplied on a CD-ROM. This software runs under Windows 98, ME, Windows 2000 or XP on an IBM-PC or compatible machine.

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

4. Clone Mode

Programming data can be transferred from one transceiver to another by connecting them via their modular microphone jacks. The operation is as follows (the transmit transceiver is the master and the receive transceiver is the slave).

Note :

Clone mode should be enabled.

1. Turn the master transceiver power ON with the [

held down (2 seconds), “CLONE” (TK-8160 or “C” (TK-

8162) is displayed on the LCD.

2. Power on the slave transceiver.

3. Connect the cloning cable (No. E30-3382-05) to the modu-

lar microphone jacks on the master and slave.

4. Press the [

the master is sent to the slave. While the master is send-

ing data, red LED blinked. While the slave is receiving the

data, “PROGRAM” (TK-8160) or “P” (TK-8162) is dis-

played and green LED blinked. When cloning of data is

completed, the master displays “END” (TK-8160) or “E”

(TK-8162), and the master red LED turned off, and the

slave automatically operates in the User mode. The slave

can then be operated by the same program as the master.

5. The other slave can be continuously cloned. Carry out the

operation in step 2 to 4.

] key on the master transceiver. The data of

] key

REALIGNMENT

TK-8160/8162

4-1. Adding the data password.

If the Read Authorization password is set in the optional feature menu, you must enter the password (Master transceiver) to activate a clone mode.

You can use 0~9 to configure the password. The maximum length of the password is 6 digits.

]+Power ON.

1. [

2. “CLN LOCK” (TK-8160) or “P” (TK-8162) is displayed on

the LCD.

3. If the [

(TK-8160) or “P” (TK-8162) is displayed, numbers (0 to 9)

are displayed flashing. When you press the [ ] key, the

currently selected number is determined. If you press the

[

“CLONE” (TK-8160) or “C” (TK-8162) is displayed if the

entered password is correct. If the password is incorrect,

“CLN LOCK” (TK-8160) or “P” (TK-8162) is redisplayed.

] and [ ] keys is pressed while “CLN LOCK”

] key after entering the password in this procedure,

Clone cable (E30-3382-05)

Fig, 2

5. Self Programming Mode

Self programming mode operates with only the TK-8160

transceiver.

Write mode for frequency data and signaling, etc. To be used ONLY by the authorized service person maintaining the user’s equipment. After programming, reset the FPU to the “Self- Programming” disabled mode. Radios CANNOT be delivered to the end-user in the self-programming mode.

5-1. Enter to the Self Programming Mode

Hold down the [ ] key 2 seconds and turn the power switch on. When enter the self programming mode, “1- 1” is displayed 2 seconds after “ SELF ” is displayed.

5-2. Adding the Data Password

If the data password is set in the optional feature menu, you must enter the password to activate a self programming mode.

You can use 0~9 to configure the password. The maximum length of the password is 6 digits.

]+Power ON.

1. [

2. “SLF.LOCK.R”* is displayed on the LCD.

3. If the [ ] and [ ] keys is pressed while “SLF.LOCK.R”

is displayed, numbers (0 to 9) are displayed flashing.

When you press the [

number is determined. If you press the [

tering the password in this procedure, “SELF” is dis-

played if the entered password is correct. If the password

is incorrect, “SLF.LOCK.R”* is redisplayed.

] key, the currently selected

] key after en-

■ Flow Chart (Master radio)

Press [ ] key+Power ON for 2 seconds

password*

* Read Authorization password

set?

Start the clone function

Ye s

Shows CLN LOCK or C

Clone mode

Input password if

password is correct

[ ]

* Read authorization password → “SLF.LOCK.R” Overwrite password → “SLF.LOCK.W”

Note :

This mode (self programming mode) cannot be set when it has been disabled with the FPU.

5-3. Channel Setting Mode

Each channel can be setup in its action mode by using the panel keys.

The 5-tone functions cannot be programmed in this mode.

• Pressing [ ] when “1- 1” is displayed, sets channel

setting mode.

• Select an item set using [

with the [

•The data displayed using [

• Pressing [

in the memory.

• Press [ ] to set the display to “ SELF ” and return to

reset (default) status.

] or [ ].

] proceeds to the next item without storing it

] then change the selection

] is stored in the memory.

TK-8160/8162

REALIGNMENT

■ Item Selection Mode ■ Item Setting Mode

[ ] + Power on

Self programming mode

Zone / Channel selection

[ ] [ ]

Zone No. /

Channel No. selection

[ ]

1. RX frequency

[ ] [ ]

[ ]

2. RX signaling

[ ] [ ]

[ ]

3. TX frequency

[ ] [ ]

[ ]

4. TX signaling

[ ] [ ]

5. Channel name

[ ] [ ]

Wide 5k / Wide 4k

[ ]

/ Narrow : E Wide/Narrow : E3,X2

[ ] [ ]

[ ]

7. RF power

[ ] [ ]

8. Scan Del/Add

[ ] [ ]

9. Beat shift on/off

[ ] [ ]

10. Compander on/off

Display

SEL F

[ ]

: Down : Up

[ ]

Refer to the “Item setting mode”.

[ ]

Refer to the “Item setting mode”.

[ ]

Same operation as the “RX frequency”.

[ ]

Same operation as the “RX signaling”.

[ ][ ]

Refer to the “Item setting mode”.

[ ]

→

[ ] / [ ]

1- 1

Zone Channel

[ ] : Stored

Not stored

[ ] :

[ ] : Stored

Not stored

[ ] :

[ ] : Stored

Not stored

[ ] :

[ ] : Stored

Not stored

[ ] :

[ ] : Stored

Not stored

[ ] :

1. RX frequency

[ ]

MHz setting

[ ]

[ ] [ ]

kHz setting

[ ] [ ]

kHz step

[ ] [ ]

Frequency clear

2. RX signaling

[ ]

Signaling setting

[ ] [ ]

QT normal

[ ] [ ]

DQT normal

[ ] [ ]

DQT inverse

Off

Current setting value

Value is not set

[ ] / [ ]

[ ]

: Cleared

[ ]

: Tone off

[ ] / [ ]

[ ]

Display

00000

––––––––

*****

STPD500K

––––––––

*: 440 (E)

400 (E3) 470 (X2)

Display

TONEDOF F

QTDD

****

DQTD

***

DQTD

***

5. Channel name

Display

________

[ ]

Channel name

[ ]

setting

[ ] [ ]

1~8 digit selection

[ ]

: Stored

[ ] / [ ]

Character selection

If the [ ] key held down (2 seconds), the blinking character clears.

13 15

REALIGNMENT

TK-8160/8162

6. Accessory Connection Cable (KCT-39)

The KCT-39 is an accessory connection cable for connecting external equipment. The connector has 15 pins and the necessary signal lines are selected for use.

6-1. Installing the KCT-39 in the Transceiver

1. Lift the DC cord bushing (1) from the chassis. Peel the

pad as shown in Figure 3 (

2. Stick the pad to the DC cord (3) and chassis (4), both

of which are supplied with the KCT-39.

Fig. 3

3. Insert the KCT-39 cable (5) into the chassis (6). The

wire harness band (

) must be inside the chassis and

face down.

4. Connect the KCT-39 to the TX-RX unit as shown in Figure

5 (

Chassis

Cushion

Chassis

End view of this area

Wire harness band (Stopper)

KCT-39 sumi tube

Face down

PCB

CN2

CN3

Fig. 5

5. Connect the KCT-39 to the external accessory by inserting

the crimp terminal (

) into the square plug (10), both of

which are supplied with the KCT-39.

Fig. 4

■ Accessory Port Function

No. Color Internal Name

connector

1 Red CN2-1 SB

2 Pink CN3-1 IGN

3 Black CN2-3 GND

4 Brown CN3-3 DETO

5 Orange CN3-2 DATAI

6 Yellow CN2-8 FNC4

7 Green CN2-7 FNC3

8 Blue CN2-9 FNC5

No. Color Internal Name

connector

9 Purple CN2-12 FNC8

10 Grey CN2-10 FNC6

11 White CN2-11 FNC7

12 NC NC

13 NC NC

Sky blue

Turquoise

CN2-6 FNC2

CN2-5 FNC1

Fig. 6

1471013

2581114

3691215

TK-8160/8162

REALIGNMENT / DISASSEMBLY FOR REPAIR

7. Ignition Sense Cable (KCT-18)

The KCT-18 is an optional cable for enabling the ignition

function. The ignition function lets you turn the power to the transceiver on and off with the car ignition key.

7-2. Connecting the KCT-18 to the Transceiver

1. Install the KCT-39 in the transceiver. (See the KCT-39 section)

2. Insert the KCT-18 lead terminal (

39 (

Fig. 7

) into pin 2 of the KCT-

1. When you remove the panel, turn the transceiver up side down. Detach the panel by lifting the tabs as shown below.

Tabs

Fig. 1

2. To remove the cabinet, first turn the transceiver up side down. Detach the cabinet by prying the tabs as shown below.

7-3. Modifying the Transceiver

Modify the transceiver as follows to turn the power on and

off with the ignition key.

1. Remove the resistor R95 of the TX-RX unit.

■ Setting With the KPG-99D(E)

Select “Function port” from the “Edit” menu and enable

the “Ignition Sense”.

TX-RX UNIT Component side

CN2

R95

Tabs

Fig. 2

3. When mounting the front panel, match the 4 tabs of the chassis with the panel, being sure they attach securely.

Tabs

Fig. 8

Tabs

Fig. 3

CIRCUIT DESCRIPTION

TK-8160/8162

Frequency Configuration

The receiver utilizes double conversion. The first IF is

49.95MHz and the second IF is 450kHz. The first local oscillator signal is supplied from the PLL circuit.

The PLL circuit in the transmitter generates the necessary

frequencies. Figure 1 shows the frequencies.

CF 450kHz

IF SYSTEM

50.4MHz

multiply

TCXO

PLL/VCO

AF PA

16.8MHz

MIC

AMP

MIC

ANT

ANTSWRF

POWER

AMP

1st

MIX

MCF

49.95MHz

Fig. 1 Frequency configuration

Receiver System

The receiver is double conversion superheterodyne. The

frequency configuration is shown in Figure 1.

■ Front-end RF Amplifier Circuit

An incoming signal from the antenna is applied to an RF amplifier (Q353) after passing through a transmit/receive switch circuit (D604 and D605 are off) and a BPF (L359, L358, L360, L361 and varactor diodes : D353, D354, D355). After the signal is amplified (Q353), the signal is filtered by a BPF (L354, L355 and varactor diodes : D351, D352) to eliminate unwanted signals before it is passed to the first mixer.

The voltage of these diodes are controlled by tracking the CPU (IC101) center frequency of the band pass filter. (See Fig. 2)

■ First Mixer Circuit

The signal from the RF amplifier is heterodyned with the first local oscillator signal from the PLL frequency synthesizer circuit at the first mixer (Q352) to create a 49.95MHz first intermediate frequency (1st IF) signal. The first IF signal is then fed through a monolithic crystal filter (MCF : XF351) to further remove spurious signals.

■ IF Amplifier Circuit

The first IF signal is amplified by Q351, and the enters IC321 (FM processing IC). The signal is heterodyned again with a second local oscillator signal within IC321 to create a 450kHz second IF signal. The second IF signal is then fed through a 450kHz ceramic filter (Wide : CF331, Narrow : CF332) to further eliminate unwanted signals before it is amplified and FM detected in IC321.

Item Rating

Nominal center frequency 49.95MHz

Pass bandwidth ±5.0kHz or more at 3dB

35dB stop bandwidth ±20.0kHz or less

Ripple 1.0dB or less

Insertion loss 5.0dB or less

Guaranteed attenuation 80dB or more at fo±1MHz

Spurious : 40dB or more within fo±1MHz

Terminal impedance 350Ω / 5.5pF

Table 1 Crystal filter (L71-0624-05) : XF351

Item Rating

Nominal center frequency 450kHz

6dB bandwidth ±6.0kHz or more

50dB bandwidth ±12.5kHz or less

Ripple 2.0dB or less

Insertion loss 6.0dB or less

Guaranteed attenuation 35.0dB or more within fo±100kHz

Terminal impedance 2.0kΩ

Table 2 Ceramic filter (L72-0993-05) : CF331

Item Rating

Nominal center frequency 450kHz

6dB bandwidth ±4.5kHz or more

50dB bandwidth ±10.0kHz or less

Ripple 2.0dB or less

Insertion loss 6.0dB or less

Guaranteed attenuation 60.0dB or more within fo±100kHz

Terminal impedance 2.0kΩ

Table 3 Ceramic filter (L72-0999-05) : CF332

CF331 (Wide)

ANT

D602 D604 D605

ANT

IC201

D/A

L358~361

D353~355

BPF

CPU

Q353

RF AMP

L354,355 D351,352

Q352

BPF

MIX

1st local

OSC (VCO/PLL)

XF351

MCF

Fig. 2 Receiver system

Q351

IF AMP

X401

TCXO

CF332 (Narrow)

IC321

IF system

Q341

X3 multiply

IC201

D/A CONVERTER

W/NO

TK-8160/8162

CIRCUIT DESCRIPTION

■ Wide/Narrow Switching Circuit

The Wide port (pin 23) and Narrow port (pin 22) of the CPU is used to switch between ceramic filters. When the Wide port is high, the ceramic filter SW diodes (D332, D331) cause CF331 to turn on to receive a Wide signal.

When the Narrow port is high, the ceramic filter SW diodes (D332, D331) cause CF332 to turn on to receive a Narrow signal.

IC321

R334

IF System

R333

R332

Wide IC101 pin 23

Narrow IC101 pin 22

IF_IN MIX_O

CF331

(Wide)

CF332

D332 D331

(Narrow)

R335

Fig. 3 Wide/Narrow switching circuit

■ AF Signal System

The detection signal from IF IC (IC321) goes to D/A converter (IC201) to adjust the gain and is output to AQUA IC (IC241) for characterizing the signal. The AF signal output from IC241 and the DTMF/MSK signal, BEEP signal are summed and the resulting signal goes to the D/A converter (IC201). The AFO output level is adjusted by the D/A converter. The signal output from the D/A converter is input to the audio power amplifier (IC281). The AF signal from IC281 switches between the internal speaker and speaker jack (J1) output.

IC321

IF IC

IC201 IC241

W/NO

D/A

CONV.

AQUA

IC201

D/A

CONV.

IC281 SP

AF PA

Fig. 4 AF signal system

■ Squelch Circuit

The detection output from the FM IF IC (IC321) passes through a noise amplifier (Q301) to detect noise. A voltage is applied to the CPU (IC101). The CPU controls squelch according to the voltage (SQIN) level. The signal from the RSSI pin of IC321 is monitored. The electric field strength of the receive signal can be known before the SQIN voltage is input to the CPU, and the scan stop speed is improved.

SYSTEM

Q301

NOISE AMP

AFO

RSSI

D301IC321 IC101

DET

SQIN

RSSI

CPU

Fig. 5 Squelch circuit

PLL Frequency Synthesizer

The PLL circuit generates the first local oscillator signal for reception and the RF signal for transmission.

■ PLL Circuit

The frequency step of the PLL circuit is 5 or 6.25kHz. A

16.8MHz reference oscillator signal is divided at IC401 by a fixed counter to produce the 5 or 6.25kHz reference frequency. The voltage controlled oscillator (VCO) output signal is buffer amplified by Q446, then divided in IC401 by a dualmodule programmable counter. The divided signal is compared in phase with the 5 or 6.25kHz reference signal in the phase comparator in IC401. The output signal from the phase comparator is filtered through a low-pass filter and passed to the VCO to control the oscillator frequency. (See Fig. 6)

■ VCO Circuit

The operating frequency is generated by Q406 in transmit mode and Q441 in receive mode. The oscillator frequency is controlled by applying the VCO control voltage, obtained from the phase comparator, to the varactor diodes (D443 and D444 in transmit mode and D441 and D442 in receive mode). The TX/RX pin is set low in receive mode causing Q443 and Q442 to turn Q406 off, and turn Q441 on. The TX/RX pin is set high in transmit mode. The outputs from Q441 and Q406 are amplified by Q446 and sent to the RF amplifiers.

PLL

DATA

16.8MHz

IC401 : PLL IC

1/N

REF

OSC

1/M

5kHz/6.25kHz

Phase

comparator

5kHz/6.25kHz

LPF

Charge

pump

Fig. 6 PLL circuit

D443,444

D441,442

Q406

TX VCO

Q441

RX VCO

Q431

AMP Q446 BUFF AMP

Q442,443

T/R SW

CIRCUIT DESCRIPTION

TK-8160/8162

■ Unlock Circuit

During reception, the 8RC signal goes high, the 8TC signal goes low, and Q44 turns on. Q43 turns on and a voltage is applied to the collector (8R). During transmission, the 8RC signal goes low, the 8TC signal goes high and Q46 turns on. Q45 turns on and a voltage is applied to 8T.

The CPU in the control unit monitors the PLL (IC401) LD signal directly. When the PLL is unlocked during transmission, the PLL LD signal goes low. The CPU detects this signal and makes the 8TC signal low. When the 8TC signal goes low, no voltage is applied to 8T, and no signal is transmitted.

8R 8T

Q43

Q44

8RC

IC101

CPU

Q45

Q46

8TC

IC401

PLL

PLL lock : LD “H”

Fig. 7 Unlock circuit

Transmitter System

■ Outline

The transmitter circuit produces and amplifies the desired frequency directly. It FM-modulates the carrier signal by means of a varicap diode.

■ Power Amplifier Circuit

The transmit output signal from the VCO passes through the transmission/reception selection diode (D448) and amplified by Q501 and Q502. The amplified signal goes to the fRF power module (IC502) through a low-pass filter. The lowpass filter removes unwanted high-frequency harmonic components, and the resulting signal is goes the antenna terminal.

■ APC Circuit

The automatic transmission power control (APC) circuit detects part of a final amplifier output with a diode (D606, D607, D608 and D609) and applies a voltage to IC651. IC651 compares the APC control voltage (PC) generated by the D/A converter (IC201) and DC amplifier (IC214) with the detection output voltage. IC651 generates the voltage to control Q502 and IC502 and stabilizes transmission output.

The APC circuit is configured to protect over current of Q502 and IC502 due to fluctuations of the load at the antenna end and to stabilize transmission output at voltage and temperature variations.

IC211MIC

MIC/

IDC

MIC KEY

INPUT

IC201

D/A

CONV.

TCXO

16.8MHz

X401

D448

IC201

pin 3

IC213

CPU

IC101

Q406

VCO

PLL

IC401

Q500

AMP

IC214

AMP

IC241

AQUA

D/A

CONV.

IC201

Q446

BUFF

AMP

Q431

Q447

AMP

Q500

AMP

Fig. 8 Transmitter system

Q501

AMP

Q502

PRE

DRIVE

AMP

IC651

IC502

RF POWER

MODULE

APC

CONTROL

Q501

AMP

D602

D604,D605

ANT

D606 D607 D608

Q502

PRE

DRIVE

AMP

POWER

ANT

IC502

RF POWER

MODULE

ANT

LPF

DET

Fig. 9 APC circuit

TK-8160/8162

CIRCUIT DESCRIPTION

Control Circuit

The CPU carries out the following tasks:

1) Controls the WIDE, NARROW, TX/RX outputs.

2) Controls the AQUA IC (IC241).

3) Controls the PLL (IC401).

4) Controls the D/A converter (IC201) and adjusts the volume, modulation and transmission power.

CK DT

IC101

CPU

PLLE

Fig. 10 Control circuit

■ Memory Circuit

The transceiver has an 64k-bit EEPROM (IC81). The

EEPROM contains adjustment data. The CPU (IC101) controls the EEPROM through three serial data lines.

EEPCK

IC101

CPU

EEPDT

EEPWP

Fig. 11 Memory circuit

■ Display Circuit

The CPU (IC101) controls the display LCD and LEDs.

When power is on, the CPU will use the MBL line to control the LCD illumination and key backlight LEDs.

The dimmer function is controlled by the switch Q1*. The

LCD controller (IC1) controls the functions of the LCD through the DO, CE, CL, DI lines from the CPU.

IC101

CPU

* TK-8160 only

IC1

LCD

driver

BRI

EEPROM

IC201

D/A

converter

IC401

PLL

IC81

(TK-8160)

(TK-8162)

illumination

D1~D6

Key backlit

D7~D18

D7~D12

LCD

■ Key Matrix Circuit

The TK-8160/8162 front panel has function keys. The TK8162 terminal name are parenthese inside. Each of them is connected to a cross point of a matrix of the KMI1 (KI3) to KMO3 (KS4) ports of the IC1 LCD driver. The KMO1 (KS2) to KMO3 (KS4) ports are always high, while the KMI1 (KI3) to KMI3 (KI1) ports are always low.

The microprocessor monitors the status of the KMI1 (KI3) to KMO3 (KS4) ports. If the state of one of the ports changes, the microprocessor assumes that the key at the matrix point corresponding to that port has been pressed.

CH UP

CH DN

IC1

LCD

driver

KMI1 (KI3) KMI2 (KI2) KMI3 (KI1)

KMO3 (KS4) KMO2 (KS3) KMO1 (KS2)

VOL

Fig. 13 Key matrix circuit

Signaling Circuit

■ Encode

• Low-speed data (QT, DQT)

Low -speed data is output from pin 1 of the CPU (IC101). The signal passes through a low-pass CR filter. The signal is mixed with the audio signal and goes to the VCO and TCXO (X401) modulation input after passing through the D/A converter (IC201) for BAL adjustment.

• High-speed data (5-tone, DTMF)

High-speed data (HSD) is output from pin 2 of the CPU. The signal passes through a low-pass CR filter. TX deviation making an adjustment by microprocessor is passed through the switch (IC213) and then applied to the audio processor (IC241). The signal is mixed with the audio signal and goes to the VCO and TCXO.

The RX tone is passed a summing amplifier (IC241). The D/A converter (IC201) for audio control, audio power amplifier and then to the speaker.

• MSK

MSK signal is output from pin 6 of IC241. The signal passes through the D/A converter (IC201) for the MSK deviation adjustment, and is routed to the VCO. When encoding MSK, the microphone-input signal is muted.

Fig. 12 Display circuit

IC241

AQUA IC

EXTLIMIN

CIRCUIT DESCRIPTION

TK-8160/8162

TCXO

MOD

X401

TCXO

IC201

D/A

VCO

MOD

IC401

PLL

VCO

IC101

CPU

LSDO QT/DQT

HSDO DTMF/

5-tone

IC213

IC241

AQUA

IC241

AQUA

MSK

Fig. 14 Encode

■ Decode

• Low-speed data (QT, DQT)

The demodulated signal from the FM IC (IC321) is passed through a low-pass filter (IC211 1/2) to remove frequency of 300Hz or more.

The signal is input to pin 88 of the CPU. The CPU digitizes this signal, performs processing such as DC restoration, and decodes the signal.

• High-speed data (DTMF)

The DTMF input signal from the IF IC is amplified by IC241 and goes to the DTMF decoder in the IC241. The CPU then processes the decoded information.

• High-speed data (5-tone)

The demodulated signal from the IF IC (IC321) is amplified by IC241 and passes through a high-pass filter to remove frequency of 300Hz or less. The CPU digitizes this signal and decodes the signal.

• MSK

The MSK input signal from the IF IC goes to pin 5 of IC241. The signal is demodulated by MSK demodulator in IC241. The demodulated data goes to the CPU for processing.

Fig. 15 Decode

Power Supply Circuit

When the power switch on the display unit is pressed, the power port on the display unit which is connected port 17 (POWER), goes low, then port 78 (SBC) goes high, Q42 turns on, SB SW (Q31) turns on and power (SB) is supplied to the radio.

When the DC power supplied to the radio, the voltage regulator IC (IC43) supply into the CPU VDD and reset voltage detect IC (IC44). IC44 will generate signal (RESET) in to the reset terminal on the CPU (IC101) to carry out a power ON reset. Also, CPU (IC101) is checking on port 91 (BATT). If DC power is less than about 9.5V, the radio is unable to power on.

When the DC power voltage deceases from normal voltage, the INT voltage detector IC (IC45) will set to high on CPU port 18 (INT). If B line becomes less than about 9.5V, CPU will send the backup data to EEPROM (IC81) and go into STOP mode.

This circuit has an overvoltage protection circuit. If a DC voltage of 16V or higher is applied to the base of Q81, this voltage turns Q81 on and sets port 18 (INT) to low. As a result port 78 (SBC) is low, and turns Q42 and Q31 (SB) off.

SBC

Q31 SW

Q42 SW

IC44 RST

Q81

IC43 AVR

IC45 AVR

D81

R49R50

IGN

R93R92

POWER

Q84

IGN

IC101

CPU

BATT

POWER

INT

RESET

Fig. 16 Power supply circuit

TK-8160/8162

SEMICONDUCTOR DATA

Microprocessor : TX-RX unit IC101

■ Pin Function

Pin No. Name I/O Function

1 LSDO O QT/DQT output

2 HSDO O DTMF/5-tone/BEEP output

3 PLLE O PLL IC chip select

4,5 NC O

6 GND - GND

7 CNVSS - CNVss for flash

8 EVLLD O E-Volume LD

9 BSHIFT O Beat shift

10 RESET - RESET

11 XOUT - X’TAL (12MHz)

12 VSS - GND

13 XIN - X’TAL (12 MHz)

14 VCC - +5V

15 GND - GND (Input only)

16 NC I

17 POWER I Power key input

18 INT I µCom stop

19 NC I

20 TX/RX O TX/RX H : RX, L : TX

21 UL I PLL unlock detect

22 NARROW O Wide/Narrow2 H : Narrow

23 WIDE O Wide/Narrow H : Wide

24 HOR O Horn alert

25 PA O Public address

26 EEPWP O EEPROM write protect

27 EEPCK O EEPROM clock (Nch open drain)

28 EEPDT I/O EEPROM Data (Nch open drain)

29 FNC1 I/O Function P1/TxD for flash

30 FNC2 I/O Function P2/RxD for flash

31 CLKFLS I SCLK for flash

32 BSYFLS O Busy for flash

33 TXD O To FPU

34 RXD I From FPU

35 PTT I PTT KEY

36 HOOK I Hook

37 ABS I AQUA clock beat shift

38 NC I

39 EMPFLS I/O EPM for flash

40 SCRSW O For Ext. scrambler

H : No Board, L : Mounted

41 DETSW O For DET H : RX, L : TX

42 HSDSW O For High Speed Data

H : HSD send, L : Others

43 FNC3 I/O Function Port 3

44 CEFLS I/O CE for flash

45~49 FNC4~FNC8 I/O Function Port 4~8

50 AFM O AF Mute H : Mute, L : Unmute

51 SPM O

Speaker mute H : Mute, L : Unmute

Pin No. Name I/O Function

52 AMPSW O

53 DT O Common data

54 CK O Common clock

55,56 NC I

57 DST1 I Destination 1 H : 25W, L : 50W

58 DST2 I Destination 2

59 DST3 I Destination 3

60 VCC - +5V

61 NC I

62 VSS - GND

63,64 NC I

65 MBL O MIC backlight

66 DISPID I Display type information

67 CM I/O From MIC keypad

68 CL O Clock for LCD

69 DO O Transfer data to LCD

70 CE O Chip enable for LCD

71 DI I Transfer data from LCD

72 IGN I Ignition

73 MICMT O MIC 1 mute

74 MICEM O MIC 2 mute

75 MICMT2 I

76 8RC O 8R control

77 8TC O 8T control

78 SBC O Battery switch

79 LIMSW O For limiter

80 DTRLOADN O

81 STD I

84 DI/O I/O

85 RDF/FD I

86 DIR O

87 HSDI I HSD input

88 LSDI I LSD input

89 TEMP2 I Temperature 2

90 TEMP1 I Temperature 1

91 BATT I Battery voltage

92 RSSI I RSSI input

93 SQIN I Squelch input

94 AVSS - GND

95 NC I

96 VREF - +5V

97 AVCC - +5V

98 NC O

99 RXLED O For panel PCB

100 TXLED O For panel PCB

TCLK/DTRDO

TDATA/DTRCLK

AF AMP SW H : SW off, L : SW on

TK-8160/8162

COMPONENTS DESCRIPTION

Display Unit (X54-3510-10) : TK-8160 Display Unit (X54-3522-70) : TK-8162

Ref. No. Parts name Description

IC1 IC LCD controller

Q1 Transistor Dimmer function switch

(TK-8160 only)

Q2 Transistor LCD backlit switch

Q3 Transistor KEY backlit switch

Q4 Transistor DC switch

Q7,8 Transistor DC switch

D1~6 Diode Key backlit

D7~18 Diode LCD backlit

(D13~18 : TK-8160 only)

D20 Diode Surge absorption

D21 Diode DC controller

D22 Diode TX/RX LED

TX-RX Unit (X57-711X-XX)

Ref. No. Parts name Description

IC41 IC Voltage Regulator / 8V

IC42,43 IC Voltage Regulator / 5V

IC44 IC Voltage detector / Reset

IC45 IC Voltage detector / Int

IC81 IC EEPROM

IC101 IC Microprocessor

IC201 IC Digital potentiometer

IC211 IC MIC amplifier

IC213 IC Quad analog switch

IC214,215 IC Dual ground sense op-amplifier

IC241 IC Audio processor

IC281 IC Audio amplifier

IC321 IC FM IF system

IC401 IC PLL system

IC502 IC RF power module

IC651 IC Comparator (APC)

Q31 FET DC switch (SB)

Q42 Transistor DC switch (SB)

Q43,44 Transistor DC switch (8R)

Q45,46 Transistor DC switch (8T)

Q81 Transistor Over voltage detection

Q82,83 Transistor Beat shift

Q84 Transistor Ignition

Q201 Transistor TX AF (DETO)

Q211 Transistor AGC/MIC mute

Ref. No. Parts name Description

Q212 FET Emergency MIC

Q213 FET MIC mute

Q241 Transistor W/N switch / TX

Q281 Digital transistor AF mute

Q282 Transistor AF mute

Q301 Transistor SQL amplifier

Q341 Transistor Buffer amplifier

Q351 Transistor IF amplifier

Q352 FET Mixer

Q353 FET RF amplifier

Q406 FET TX VCO

Q421,422 Transistor Charge pump

Q431 Transistor RF amplifier

Q441 FET RX VCO

Q442 FET T/R switch

Q443 Transistor T/R switch

Q445 Transistor Ripple filter

Q446 Transistor Buffer amplifier

Q447 Transistor RF amplifier

Q500,501 Transistor RF amplifier

Q502 FET Pre drive amplifier

D1~11 Diode Surge absorption

D41 Diode Reverse connection protection

D42 Poly SW Current protection

D81,82 Diode Over voltage detection

D211 Diode AGC

D212 Diode OR gate

D301 Diode Rectification

D331,332 Diode IF switch (Wide/Narrow)

D351~355

D401 Diode Ripple filter

D421 Diode Voltage dropped

D441,442 Varicap RX VCO

D443,444 Varicap TX VCO

D445 Diode Modulation

D446 Diode Ripple filter

D447,448 Diode RF switch (TX/RX)

D502 Diode Temperature compensation

D503 Diode Voltage protection

D602 Diode ANT switch

D604,605 Diode ANT switch

D606~608

D609,910 Diode Temperature compensation

Varicap RF BPF tuning

Diode APC voltage detect

TK-8160/8162

PARTS LIST

✽ New Parts. indicates safety critical components. Parts without Parts No. are not supplied. Les articles non mentionnes dans le Parts No. ne sont pas fournis. Teile ohne Parts No. werden nicht geliefert.

TK-8160/8162 (Y51-507X-XX) DISPLAY UNIT (X54-3510-10)

Ref. No.

Address

New

Parts No. Description

parts

Destination

TK-8160/8162

11BA02-3898-02 PLASTIC CABINET 23A✽ A62-1107-13 PANEL ASSY 23A✽ A62-1108-03 PANEL ASSY 62E,62E3

33AB42-7729-04 STICKER (WEEE) 41C✽ B62-1863-00 INSTRUCTION MANUAL

73BE04-0167-05 RF COAXIAL RECEPTACLE (M) X2 83BE04-0454-05 RF COAXIAL RECEPTACLE (BNC) 60E,60E3 83BE04-0454-05 RF COAXIAL RECEPTACLE (BNC) 62E,62E3 93CE30-3339-05 DC CORD ASSY ACCESSORY X2 10 2B E30-3448-05 DC CORD

11 3C E30-7523-05 DC CORD ASSY ACCESSORY 60E,60E3 11 3C E30-7523-05 DC CORD ASSY ACCESSORY 62E,62E3 12 3A E37-0962-05 SPEAKER CABLE 13 2A E37-1187-05 FLAT CABLE

15 2B ✽ F10-2491-12 SHIELDING COVER (UPPER) 16 3B F10-3011-03 SHIELDING CASE 17 2B F10-3019-03 SHIELDING CASE 18 2B ✽ F10-3047-13 SHIELDING PLATE 19 3C F51-0016-15 FUSE (6X30) ACCESORY X2

60E,60E3,X2

L : Scandinavia K : USA P : Canada Y : PX (Far East, Hawaii) T : England E : Europe Y : AAFES (Europe) X : Australia M :Other Areas

Ref. No.

D1-6 B30-2282-05 LED (Y) D7-18 B30-2281-05 LED (Y) D22 B30-2151-05 LED (RED/GREEN)

C1 CK73GB1H103K CHIP C 0.010UF K C6,7 CK73GB1H102K CHIP C 1000PF K C9 CK73GB1H102K CHIP C 1000PF K C10 CK73GB1H103K CHIP C 0.010UF K C11-14 CK73GB1H102K CHIP C 1000PF K

C15 CK73GB1H471K CHIP C 470PF K C16,17 CK73GB1A105K CHIP C 1.0UF K C18 CK73GB1C104K CHIP C 0.10UF K C19,20 CC73GCH1H101J CHIP C 100PF J C21 CK73GB1H681K CHIP C 680PF K

C22,23 CK73GB1H102K CHIP C 1000PF K C24 CK73GB1H103K CHIP C 0.010UF K C25 CK73GB1H102K CHIP C 1000PF K C27 CC73GCH1H101J CHIP C 100PF J C30 CK73GB1H102K CHIP C 1000PF K

103 2A E29-1206-05 INTER CONNECTOR CN1 E40-6005-05 FLAT CABLE CONNECTOR J1 E08-0877-05 MODULAR JACK

Address

New

Parts No. Description

parts

Destination

20 3C F52-0023-05 FUSE (BLADE TYPE) ACCESSORY 60E,60E3 20 3C F52-0023-05 FUSE (BLADE TYPE) ACCESSORY 62E,62E3

22 2B G02-1825-03 EARTH SPRING 23 3B G02-1826-03 EARTH SPRING 24 2B ✽ G02-1827-14 EARTH SPRING 25 2B G10-0792-14 FIBROUS SHEET 26 2A G10-1324-04 FIBROUS SHEET (DISPLAY)

27 3B G13-2003-04 CUSHION 28 2B ✽ G13-2119-04 CONDUCTIVE CUSHION 29 1B G53-1524-02 PACKING 30 2B G53-1542-03 PACKING 31 3B G53-1664-03 PACKING

33 2C,1D H12-3178-05 PACKING FIXTURE 34 3D H13-1190-02 CARTON BOARD 35 1C H25-2320-04 PROTECTION BAG 36 1C H25-2341-04 PROTECTION BAG 37 2C H52-2090-02 ITEM CARTON CASE

37 2C H52-2091-02 ITEM CARTON CASE 62E,62E3

39 3D J29-0662-03 BRACKET ACCESSORY

41 3A K29-9342-01 KEY TOP

A2BN67-3008-48 PAN HEAD SEMS SCREW B2AN80-2008-48 PAN HEAD TAPTITE SCREW C 2B,3B N87-2606-48 BRAZIER HEAD TAPTITE SCREW D 1B,2B N87-2614-48 BRAZIER HEAD TAPTITE SCREW 43 3D N99-2048-05 SCREW SET

45 3A T07-0753-05 SPEAKER

60E,60E3,X2

104 2A G10-1348-04 FIBROUS SHEET

105 2A J21-8494-03 MOUNTING HARDWARE

- J31-0553-05 COLLAR

L1 L92-0138-05 CHIP FERRITE

CP1 R90-0724-05 MULTI-COMP 1K X4 R1 RK73GB1J101J CHIP R 100 J 1/16W R2 RK73GB1J100J CHIP R 10 J 1/16W R3-5 RK73GB1J102J CHIP R 1.0K J 1/16W R6-8 RK73GB1J103J CHIP R 10K J 1/16W

R9 RK73GB1J563J CHIP R 56K J 1/16W R10,11 RK73FB2A331J CHIP R 330 J 1/10W R14 RK73FB2A473J CHIP R 47K J 1/10W R15,16 RK73FB2A330J CHIP R 33 J 1/10W R17,18 RK73FB2A390J CHIP R 39 J 1/10W

R19 RK73GB1J392J CHIP R 3.9K J 1/16W R20 R92-0670-05 CHIP R 0 OHM R21 R92-1252-05 CHIP R 0 OHM J 1/16W R22 RK73FB2A181J CHIP R 180 J 1/10W R23 RK73FB2A820J CHIP R 82 J 1/10W

R24,25 RK73GB1J103J CHIP R 10K J 1/16W R26,27 RK73GB1J102J CHIP R 1.0K J 1/16W R28-31 RK73GB1J390J CHIP R 39 J 1/16W

D20,21 MC2850 DIODE IC1 PT6554LQ MOS-IC Q1 RN47A4 TRANSISTOR Q2 2SB1132(Q,R) TRANSISTOR Q3 KRA225S DIGITAL TRANSISTOR

DISPLAY UNIT (X54-3510-10) : TK-8160 E,E3,X2

101 2A B11-1829-03 ILLUMINATION GUIDE 102 2A B38-0902-05 LCD

Q4 KRC102S DIGITAL TRANSISTOR Q7,8 2SC3928A TRANSISTOR

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