This service manual mainly covers TK-860G K2, M2 and TK-862G K2.
If information you require is missing from this service manual.
Please refer to the B51-8498-10 service manual.
Pressing this key for longer than 1 second causes the
transceiver to enter the emergency mode. The transceiver
jumps to the programmed "Emergency the group and channel" and transmits for 25 seconds.
The transceiver disables mic mute while transmitting.
After finishing transmission, the transceiver receivers for 5
seconds. The transceiver mutes the speaker while receiving. Following the above sequence, the transceiver continues to transmit and receive.
■ Emergency mode system chart (TK-860G)
Foot switch 1 push(Hold it down for about one second.)
*1 : 3 left most dots light.
*2 : Hold the foot switch again for about one second.
*3 : 2 right most dots light.
LCD dot status change
or
*1 : When the dot indicator is on, it turns off.
*2 : Hold the foot switch again for about one second.
*1
Dot
*1
Dot
*2
When the dot indicator is off, it turns on.
3
TK -860G/862G
MBL
PSB
GND
PTT/TXD
ME
MIC
HOOK/RXD
CM
GND
REMOTE/TXD
PTT/RXD
8
1
1
8
REALIGNMENT
Clone Mode
Programming data can be transferred from one radio to
another by connecting them via their modular microphone
jacks. The operation is as follows (the transmit radio is the
master and the receive radio is the slave).
1. Turn the master TK-860G power ON with the [
held down. If the password is set to the TK-860G, the
TK-860G displays "CLN LOCK". If the password is not
set, the TK-860G displays "CLONE".
2. When "CLN LOCK" is displayed, only the [CH
and [SCN], and [0] to [9] keys can be accepted. When
you enter the correct password, and "CLONE" is displayed, the TK-860G can be used as the cloning master.
The following describes how to enter the password.
3. How to enter the password with the microphone keypad;
If you press a key while "CLN LOCK" is displayed, the
number that was pressed is displayed on the TK-860G.
Each press of the key shifts the display in order to the
left. When you enter the password and press the [SCN]
key, "CLONE" is displayed if the entered password is correct. If the password is incorrect, "CLN LOCK" is
redisplayed.
How to enter the password with the [CH
If the [CH
/ ] key is pressed while "CLN LOCK" is dis-
/ ] key;
played, numbers (0 to 9) are displayed flashing. When
you press the [SCN] key, the currectly selected number is
determined, and the display shifts to the left. If you press
the [SCN] key after entering the password in this procedure, "CLONE" is displayed if the entered password is
correct. If the password is incorrect, "CLN LOCK" is
redisplayed.
4. Power on the slave TK-860G/862G.
5. Connect the cloning cable (No. E30-3382-05) to the
modular microphone jacks on the master and slave.
6. Press the [SCN] key on the master while the master displays "CLONE". The data of the master is sent to the
slave. While the slave is receiving the data, "–PC–" is displayed. When cloning of data is completed, the master
displays "END", and the slave automatically operates in
the User mode. The slave can then be operated by the
same program as the master.
7. The other slave can be continuously cloned. When the
[SCN] key on the master is pressed while the master displays "END", the master displays "CLONE". Carry out the
operation in step 4 to 6.
] key
/] key
Clone cable
E30-3411-05 (TK-860G → TK-360G/370G)
Cloning cable
(E30-3382-05)
Fig. 1
Note :
You can clone the programmed data between the trans-
ceiver frequency version must be same.
4
INSTALLATION
2
3
4
1
3
W1
W2
CN1
CN2
KCT-19
Cushion
(G13-1710-04)
CN3
CN7
1
CN3
TK -860G/862G
Ignition Sense Cable (KCT-18 : Option)
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.
If you use the Horn Alert function or the Manual Relay
function, you can turn the function off while driving with the
ignition key.
■ Connecting the KCT-18 to the Transceiver
1. Install the KCT-19 in the transceiver.
2. Insert the KCT-18 lead terminal () into pin 3 of the
square plug () supplied with the KCT-19, then insert
1
the square plug into the KCT-19 connector ().
KCT-19
3
Fig. 1
2
3
1
3
13
Contact
6
15
1
2
KCT-18
Operation when KCT-18R134R135
is connected
Enable Enable ← KCT-18 cannot
Power on/off and Horn Disable Enable be connected
Alert or AUX-A on/off
Horn Alert or AUX-AEnable Disable
on/off
Disable Disable ← Power cannot
be turned on
Table 1R134 and R135 setup chart
PA/HA Unit (KAP-1 : Option)
■ Installing the KAP-1 in the Transceiver
The Horn Alert (max. 2A drive) and Public Address functions are enabled by inserting the KAP-1 W1 (3P; white/
black/red) into CN3 on the TX-RX unit, inserting W2 (3P;
green) into CN7 on the TX-RX unit, and connecting the KCT19 (option) to CN2 and CN3 of the KAP-1.
• Installation procedure
1. Open the upper case of the transceiver.
2. Insert the two cables () with connectors from the
KAP-1 switch unit into the connectors on the transceiver.
3. Secure the switch unit board to the chassis with a screw
(). The notch () in the board must be placed at the
3
front left side.
4. Attach the cushion on the top of the KAP-1 switch unit.
1
2
■ Modifying the Transceiver
Modify the transceiver as follows to turn the power or
the Horn Alert or Manual Relay function on and off with the
ignition key.
1. Remove the lower half of the transceiver case.
2. Set jumper resistors (0Ω) R134 and R135 of the TX-RX
unit (A/2) as shown in Table 1.
KCT-19
TX-RX UNIT
(A/2)
CN2
R133
R134
R135
Fig. 2
ANT
Fig. 3
5
TK -860G/862G
TX-RX UNIT
(A/2)
ANT
KCT-19
CN2
Q19
R122
R153
INSTALLATION
■ Modifying the Transceiver
• Horn alert
The signal from pin 4 of IC9 on the TX-RX unit turns Q5
and Q1 on and off and drives KAP-1 HA relay K2 to drive the
horn with a maximum of 2A.
The default output is HR1. The relay open output can be
obtained between HR1 and HR2 by removing R1 in the KAP-
1.
R1Output form
HR1 (Default)Enable
HR2Disable
HR1
HR1
HR2
• Public address
The signal from pin 13 of IC9 on the TX-RX unit drives PA
relay K1 in the KAP-1 and switches the audio power amplifier output between the external PA system (through KCT-
19) and internal and external speakers.
To use the PA function, R153 on the TX-RX unit must be
removed.
R153
Use the PA functionDisable
Do not use the PA functionEnable
R1
Fig. 5
Fig. 4 KAP-1 foil side view
TX-RX UNIT
8C
IC9
Shift
register
Q6
13
Audio
power amp
IC13
6
Q5
4
Q1
Q6
IGN
+
R21
Q1
1
2
E
SP
R153
CN8
Internal/External
speaker
CN3
D2
CN7
KAP-1 (SWITCH UNIT : X41-3380-20)
Q1 : DTD114EK
D1,2 : 1SS193
W1
1
HOR
2
E
3
SB
W2
1
PA/LI
2
SPO
3
SPI
■ Others
If the PA and HR2 are not necessary and the speaker output is output to an external unit through the KCT-19, connect
the KCT-19 C connector to CN8 on the TX-RX unit.
HR2
NC
HR1
E
SB
PAO/LIO
E
C
B
C
KCT-19 Terminal
13 101
15
6 : Earth
10 : HR1
12 : PA (HR2)
CN1
1
2
R1 0
C1
1000P
R3 0
R4 0
Q1
C2
1000P
C5 1000P
±
C3 0.01
K1
±
C4 0.01
K2
C6
+
C7
D1
+
D2
1000P
1000P
CN2
1
2
3
CN3
1
2
Fig. 6
GRN
BRN
ORG
YEL
GRN
12
KCT-19
36
INSTALLATION
R142
TX-RX unit A/2
Foil side
Emergency Mode
■ Transceiver Modification Procedure
• Install the foot switch
Install the foot switch through the KCT-19 and KCT-18.
When the switch is treaded on, the radio enters the emergency mode.
TK -860G/862G
TX-RX unit B/2
Foil side
• Change the power switch circuit
TX-RX unit (B/2) : Control section
$R705 : Attach (R92-1252-05, 0Ω)
TX-RX unit (A/2) : RF section
R142 : Remove (RK73GB1J473J, 47kΩ)
Once the transceiver is modified, it cannot be turned on
and off with the power switch. The power switch turns the
LCD backlight and display on and off. (The power is
switched on and off by IGNITION SENSE.)
Q505
SB
MBL
Q506
MBL
TX-RX section
KCT-19 Terminal
131
3615
3 : Ignition sense
6 : Earth
15 : Foot switch
Key
backlight
IC510
6
CN5
1
KCT-19
15 pin
Foot
switch
IC502
Control section
LCD
Attach
CPU
$R705
87
88
2520
3
Remove
KCT-18
Power
switch
0
47K
R142
IC14
Outside
R705
F.RESET
Fig. 8
Fig. 7
7
TK -860G/862G
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-860G/862G
DISPLAY UNIT (X54-3270-10) : TK-860G, DISPLAY UNIT (X54-3280-10) : TK-862G
82GB62-1257-20INSTRUCTION MANUALM,M2
82GB62-1258-10INSTRUCTION MANUALK,K2,K3
91CB72-1692-04MODEL NAME PLATE860K
91CB72-1693-04MODEL NAME PLATE860M
91FB72-1695-04MODEL NAME PLATE862K
91CB72-1743-04MODEL NAME PLATE860K3
91CB72-1808-04MODEL NAME PLATE860K2
91CB72-1809-04MODEL NAME PLATE860M2
91FB72-1810-04MODEL NAME PLATE862K2
A2A,2DN33-2606-45OVAL HEAD MACHINE SCREW
B2C,2FN67-3008-46PAN HEAD SEMS SCREW W
C2B,2EN87-2606-46BRAZIER HEAD TAPTITE SCREW
D2B,2EN87-2612-46BRAZIER HEAD TAPTITE SCREW
422GN99-0395-05SCREW SET
C523CC73GCH1H221JCHIP C220PFJ
C524CK73GB1H103KCHIP C0.010UF K
C525CK73GB1E123KCHIP C0.012UF K
C526CK73GB1C683KCHIP C0.068UF K
C527CK73GB1H222KCHIP C2200PFK
CN7E40-3247-05PIN ASSY
CN8E40-3246-05PIN ASSY
CN501E40-6021-05FLAT CABLE CONNECTOR
J1E11-0442-053.5D PHONE JACK (3P)
J501E08-0877-05MODULAR JACK
F1F53-0108-05FUSE
C564C92-0507-05CHIP-TAN4.7UF6.3WV
C565,566CK73GB1H472KCHIP C4700PF K
C567CC73GCH1H101JCHIP C100PFJ
C568C92-0507-05CHIP-TAN4.7UF6.3WV
C569CK73GB1E223KCHIP C0.022UF K
C570CK73FF1C105ZCHIP C1.0UFZ
C571,572CK73GB1H102KCHIP C1000PF K
C573CK73FB1H563KCHIP C0.056UF K
C574CC73GCH1H470JCHIP C47PFJ
C575CK73GB1H102KCHIP C1000PFK
C582CK73GB1C473KCHIP C0.047UF K
C583C92-0566-05CHIP-TAN10UF6.3WV
C584CK73GB1H103KCHIP C0.010UF K
C585CC73GCH1H101JCHIP C100PFJ
C587CK73GB1H103KCHIP C0.010UF K