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Kenwood TK-8160 Service Manual

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UHF FM TRANSCEIVER
TK-8160
SERVICE MANUAL
Modular jack
(E08-0877-05)
RF coaxial receptacle (M)
(E04-0167-05)
GENERAL .................................................. 2
SYSTEM SET-UP ...................................... 3
OPERATING FEATURES .......................... 4
REALIGNMENT ......................................... 5
INSTALLATION ......................................... 9
DISASSEMBLY FOR REPAIR ................. 11
CIRCUIT DESCRIPTION .......................... 12
SEMICONDUCTOR DATA ...................... 17
COMPONENTS DESCRIPTION .............. 18
PARTS LIST ............................................. 19
EXPLODED VIEW .................................... 26
Key top
Panel assy
(K29-9342-01)
(A62-1107-13)
DC cord
(E30-3448-05)
CONTENTS
PACKING ................................................. 27
ADJUSTMENT ........................................ 28
TERMINAL FUNCTION ........................... 33
TX-RX UNIT (X57-7090-10) ................ 36
SCHEMATIC DIAGRAM .......................... 40
BLOCK DIAGRAM ................................... 44
LEVEL DIAGRAM .................................... 46
SPECIFICATION ................... BACK COVER
© 2004-12 PRINTED IN JAPAN
B51-8707-00 ( N ) 1074
Badge
(B43-1179-04)

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Summary of Contents for Kenwood TK-8160

  • Page 1: Table Of Contents

    UHF FM TRANSCEIVER TK-8160 SERVICE MANUAL © 2004-12 PRINTED IN JAPAN B51-8707-00 ( N ) 1074 Modular jack Key top Panel assy Badge (E08-0877-05) (K29-9342-01) (A62-1107-13) (B43-1179-04) RF coaxial receptacle (M) (E04-0167-05) DC cord (E30-3448-05) CONTENTS PACKING ..........27 GENERAL ..........2 ADJUSTMENT ........

  • Page 2: General

    TK-8160 GENERAL 3. PRE-INSTALLATION CHECKOUT INTRODUCTION 3-1. Introduction SCOPE OF THIS MANUAL Each radio is adjusted and tested before shipment. How- This manual is intended for use by experienced techni- ever, it is recommended that receiver and transmitter opera- cians familiar with similar types of commercial grade commu- tion be checked for proper operation before installation.

  • Page 3: System Set-Up

    Your sand from getting in. 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.

  • Page 4: Operating Features

    TK-8160 OPERATING FEATURES 1. Controls and Functions Press to activate its programmable function. The default 1-1. Front Panel setting is None (no function). !5 PTT switch Press this switch, then speak into the microphone to call a station. 1-3. Display 1-2.

  • Page 5: Realignment

    The data can be input to or read from TK-8160 and edited on the screen. The programmed or edited data can be printed out. It is also possible to tune the transceiver.

  • Page 6: Self Programming Mode

    TK-8160 REALIGNMENT 4-1. Adding the data password. 5. Self Programming Mode If the data password is set in the optional feature menu, Write mode for frequency data and signaling, etc. To be you must enter the password (Master transceiver) to activate used ONLY by the authorized service person maintaining the a clone mode.
  • Page 7 TK-8160 REALIGNMENT ■ Item Selection Mode ■ Item Setting Mode Display [ ] + Power on Display Current → Self programming mode SE L F 1. RX frequency 4 5 0 0 0 0 0 0 setting value Value is not set –...
  • Page 8 TK-8160 REALIGNMENT 3. Insert the KCT-39 cable ( ) into the chassis ( ). The 6. Accessory Connection Cable (KCT-39) wire harness band ( ) must be inside the chassis and The KCT-39 is an accessory connection cable for connect- face down.
  • Page 9 TK-8160 REALIGNMENT / INSTALLATION 7. Ignition Sense Cable (KCT-18) 1. PA/HA Unit (KAP-2 : Option) The KCT-18 is an optional cable for enabling the ignition 1-1. Installing the KAP-2 in the Transceiver function. The ignition function lets you turn the power to the The Horn Alert and Public Address functions are enabled transceiver on and off with the car ignition key.

  • Page 10: Installation

    TK-8160 INSTALLATION 5. Affix the 20 x 20 x 2.5 mm pad to the 40 x 33 mm transpar- 8. Attach the supplied cable to the CN3 connector of the ent sheet, then attach it to the TX-RX unit printed area as KAP-2 unit and the CN6 connector of the TX-RX unit.

  • Page 11: Disassembly For Repair

    TK-8160 INSTALLATION / DISASSEMBLY FOR REPAIR 1. When you remove the panel, turn the transceiver up side 2. External Speaker (Option) down. Detach the panel by lifting the tabs as shown be- 2-1. KES-3 low. The KES-3 is an external speaker for the 3.5-mm-diameter Tabs speaker jack.

  • Page 12: Circuit Description

    TK-8160 CIRCUIT DESCRIPTION ■ IF Amplifier Frequency Configuration The first IF signal is amplified by Q351, and the enters The receiver utilizes double conversion. The first IF is IC321 (FM processing IC). The signal is heterodyned again 49.95MHz and the second IF is 450kHz. The first local oscil- with a second local oscillator signal within IC321 to create a lator signal is supplied from the PLL circuit.
  • Page 13 TK-8160 CIRCUIT DESCRIPTION ■ Wide/Narrow Switching Circuit ■ Squelch Circuit The Wide port (pin 23) and Narrow port (pin 22) of the CPU The detection output from the FM IF IC (IC321) passes is used to switch between ceramic filters. When the Wide through a noise amplifier (Q301) to detect noise.
  • Page 14 TK-8160 CIRCUIT DESCRIPTION ■ Unlock Circuit Transmitter System During reception, the 8RC signal goes high, the 8TC signal ■ Outline goes low, and Q44 turns on. Q43 turns on and a voltage is The transmitter circuit produces and amplifies the desired applied to the collector (8R).
  • Page 15 CIRCUIT DESCRIPTION ■ Key Matrix Circuit Control Circuit The TK-8160 front panel has function keys. Each of them The CPU carries out the following tasks: is connected to a cross point of a matrix of the KMI1 to KMO3 1) Controls the WIDE, NARROW, TX/RX outputs.
  • Page 16 TK-8160 CIRCUIT DESCRIPTION ■ Decode Power Supply Circuit The signal goes to EXTLIMIN (pin 5) of AQUA IC (IC241). When the power switch on the display unit is pressed, the The QT/DQT signal will pass through the low-pass filters in...

  • Page 17: Semiconductor Data

    TK-8160 SEMICONDUCTOR DATA Microprocessor : 30622MEP-A01GP (TX-RX unit IC101) ■ Pin Function Pin No. Name Function Pin No. Name Function AMPSW AF AMP SW H : SW off, L : SW on QT/DQT QT/DQT output DTMF/MSK HSD/MSK/BEEP output Common data...

  • Page 18: Components Description

    TK-8160 COMPONENTS DESCRIPTION Display Unit (X54-3510-10) Ref. No. Parts name Description Ref. No. Parts name Description Q281 Digital transistor AF mute LCD controller Q282 Transistor AF mute Transistor Dimmer function switch Q301 Transistor SQL amplifier Transistor LCD backlit switch Q341...

  • Page 19: Parts List

    Les articles non mentionnes dans le Parts No. ne sont pas fournis. Y : AAFES (Europe) X : Australia M : Other Areas Teile ohne Parts No. werden nicht geliefert. TK-8160 (Y51-5070-XX) DISPLAY UNIT (X54-3510-10) TX-RX UNIT (X57-7090-10) Desti- Desti- Ref.
  • Page 20 TK-8160 PARTS LIST TX-RX UNIT (X57-7090-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C46,47 CK73GB1H221K CHIP C 220PF C260 CK73GB1A474K CHIP C 0.47UF CK73GB1H102K CHIP C 1000PF C261 CK73HB1A104K CHIP C 0.10UF...
  • Page 21 TK-8160 PARTS LIST TX-RX UNIT (X57-7090-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C371 CC73GCH1HR75B CHIP C 0.75PF C471 CC73GCH1H020B CHIP C 2.0PF C372 CC73GCH1H180G CHIP C 18PF C477...
  • Page 22 TK-8160 PARTS LIST TX-RX UNIT (X57-7090-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C652 CK73GB1H471K CHIP C 470PF RK73GB1J472J CHIP R 4.7K 1/16W C672,673 CK73GB1H471K CHIP C 470PF RK73GB1J473J...
  • Page 23 TK-8160 PARTS LIST TX-RX UNIT (X57-7090-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R222 RK73HB1J223J CHIP R 1/16W R341 RK73GB1J101J CHIP R 1/16W R223 RK73GB1J102J CHIP R 1.0K 1/16W...
  • Page 24 TK-8160 PARTS LIST TX-RX UNIT (X57-7090-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation ✽ R458 RK73GB1J101J CHIP R 1/16W D212 MC2858 DIODE R459 RK73GB1J102J CHIP R 1.0K 1/16W D301...
  • Page 25 TK-8160 PARTS LIST TX-RX UNIT (X57-7090-10) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation Q501 2SC3356(R24) TRANSISTOR Q502 RD00HVS1 PREDRIVE FET Q503 PD55008TR DRIVE FET Q504 RD60HUF1-01 FINAL FET TH301...

  • Page 26: Exploded View

    TK-8160 EXPLODED VIEW M2.6 x 8 : N67-2608-48 M2 x 8 : N80-2008-48 M2.6 x 6 (Br-Tap) : N87-2606-48 M2.6 x 14 (Br-Tap) : N87-2614-48 Cx12 Display unit IC281 Q504 19x2 TX-RX unit Chassis Caution sticker (K only) S/No. label Caution sticker Parts with the exploded numbers larger than 700 are not supplied.

  • Page 27: Packing

    TK-8160 PACKING 31 Protection bag (H25-2341-04) 5 Instruction manual Pamphlet (B62-1829-00) 29 Packing fixture (H12-3178-05) 29 Packing fixture (H12-3178-05) 31 Protection bag (H25-2341-04) 42 Microphone (T91-0639-05) : K 32 Item carton case (H52-2089-02) UPC code label 39 Screw set (N99-0395-05)

  • Page 28: Adjustment

    TK-8160 ADJUSTMENT Test Equipment Required for Alignment Test Equipment Major Specifications 1. Standard Signal Generator Frequency Range 400 to 520MHz (SSG) Modulation Frequency modulation and external modulation Output –127dBm/0.1µV to greater than –7dBm/100mV 2. Power Meter Input Impedance 50Ω Operation Frequency...
  • Page 29 TK-8160 ADJUSTMENT ■ Notes Adjustment Location • EEPROM ■ Switch The tuning data (Deviation, Squelch, etc.) for the EEP- ROM, is stored in memory. When parts are changed, re- Volume Channel up/down Display up/down Speaker adjust the transceiver. Power • AF PA IC (IC281) How to mounting the IC281.
  • Page 30 TK-8160 ADJUSTMENT Test Frequency 3 or 5 Reference Level Adjustment Frequency Tuning Channel RX (MHz) TX (MHz) RX (MHz) TX (MHz) point RX (MHz) TX (MHz) RX (MHz) TX (MHz) 470.05 470.10 460.05 460.10 450.05 450.10 440.05 440.10 450.05 450.10 440.05...
  • Page 31 TK-8160 ADJUSTMENT Measurement Adjustment Specifications/ Item Condition Test equipment Terminal Parts Method Remarks 4. RF 1) CH : RX center (Wide) Tra generator PC key Adjust the BPF waveform bandpass CH : RX low (Wide) Spectrum analyzer to Fig. 1...
  • Page 32 TK-8160 ADJUSTMENT Measurement Adjustment Specifications/ Item Condition Test equipment Terminal Parts Method Remarks ± 1.0W 3. High 1) CH : TX low Power meter PC key power CH : TX low’ CH : TX center CH : TX high’ CH : TX high 2) Transmit ±...

  • Page 33: Terminal Function

    TK-8160 TERMINAL FUNCTION Name Function Name Function Battery voltage DC supply Ignition sens input DATAI External transmit signal input Ground DETO FM detector output DETO FM detector output TXAFI TX audio input from scrambler board FNC1 Programable I/O (programmed by FPU)

  • Page 34: Pc Board

    TK-8160 PC BOARD DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) VOL UP POWER VOL DOWN HOOK MIC JACK DISPLAY UNIT (X54-3510-10) Foil side view (J72-0959-09) HOOK...
  • Page 35 TK-8160 PC BOARD DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) Ref. No. Address CH UP CH DOWN Component side Layer 1 J72-0959-09 Layer 2 Foil side DISPLAY UNIT (X54-3510-10) Foil side view (J72-0959-09) Ref. No. Address J72-0959-09 BUSY POWER HOOK...
  • Page 36 TK-8160 TK-8160 PC BOARD PC BOARD DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) Ref. No. Address VOL UP CH UP POWER VOL DOWN CH DOWN HOOK MIC JACK Component side Layer 1 J72-0959-09...

  • Page 37: Tx-Rx Unit (X57-7090-10)

    TK-8160 PC BOARD TX-RX UNIT (X57-7090-10) Component side view (J72-0956-09) EXT. SP C536 C535 Smartrunk C538 C539 – L507 C541 KAP-2 Q503 C543 C528 R536 R535 C534 R534 C527 R526 R521 R524 C113 C116 IC281 R224 CNVSS R101 Q212 Q201...
  • Page 38 TK-8160 PC BOARD TX-RX UNIT (X57-7090-10) Component side view (J72-0956-09) Ref. No. Address IC43 J72-0956-09 IC201 IC211 IC213 IC214 R800 C574 IC215 C616 C575 IC241 C576 IC281 C555 IC401 IC651 C556 C613 Q201 Q211 C609 Q212 Q504 Q213 Q241 Q281...
  • Page 39 TK-8160 TK-8160 PC BOARD PC BOARD TX-RX UNIT (X57-7090-10) Component side view (J72-0956-09) TX-RX UNIT (X57-7090-10) Component side view (J72-0956-09) Ref. No. Address IC43 J72-0956-09 IC201 IC211 EXT. SP IC213 IC214 R800 C574 C536 IC215 C616 C575 IC241 C576 C535...
  • Page 40 TK-8160 PC BOARD TX-RX UNIT (X57-7090-10) Foil side view (J72-0956-09) J72-0956-09 C614 C615 L605 D608 L604 C620 C611 C610 D607 C607 C606 D606 D604 D605 L509 C572 C571 L361 C573 C385 D354 D355 L359 R520 C389 R519 C382 C383 D353...
  • Page 41 TK-8160 PC BOARD TX-RX UNIT (X57-7090-10) Foil side view (J72-0956-09) Ref. No. Address IC41 IC42 IC44 IC45 IC81 R131 IC101 R132 IC321 – Q301 Q351 Q352 Q353 Q406 Q431 Q441 Q442 Q443 Q445 Q446 Q447 Q500 Q501 Q502 D301 D351...
  • Page 42 TK-8160 TK-8160 PC BOARD PC BOARD TX-RX UNIT (X57-7090-10) Foil side view (J72-0956-09) TX-RX UNIT (X57-7090-10) Foil side view (J72-0956-09) Ref. No. Address IC41 J72-0956-09 IC42 IC44 IC45 IC81 R131 IC101 C614 R132 IC321 C615 L605 D608 L604 C620 C611 C610 –...

  • Page 43: Schematic Diagram

    TK-8160 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7090-10) R424 C445 VOLTAGE DROPPED Q421,422 RX VCO D421 R421 R:6.45V R:1.01V CHARGE PUMP RX VCO Q441 Q421 HZU5ALL L441 D442 2SK508NV(K52) R426 R427 R429 L421 C441 C447 2SA1832(GR) L443 Q422 4.7u 1.5k 0.5p MA2S304...
  • Page 44 TK-8160 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7090-10) RF AMP BUFFER AMP 7.07V Q447 6.98V 1.63V Q446 2SC5636 C480 R460 0.76V C469 C470 2SC5636 R522 RF AMP RF AMP DRIVE AMP RF SW Q500 Q501 PRE DRIVE AMP R:0V 2SC5110(O) Q503 (TX/RX) 2SC3356(R24) T:5.49V...
  • Page 45 TK-8160 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7090-10) TEMP1 R:13.6V TEMP2 T:12.6V D601,602 ANT SW D601 C627 C626 R607 MA4PH633 470p 1.5p D602 C541 C570 C603 L603 L604 L507 2.5n 1.5T 1.5T MA4PH633 470p 470p Q504 POWER RD60HUF1-01 T:2.40V FINAL AMP T:0.80V...
  • Page 46 TK-8160 SCHEMATIC DIAGRAM DISPLAY UNIT (X54-3510-10) SURGE ABSORPTION MC2850 HOOK KMO1 <B C> KMO2 KMO3 HOOK POWER SEG26 KMI3 SEG25 KMI2 SEG24 KMI1 SEG23 SEG22 SEG21 BUSY 5.01V SEG20 LCD CONTROLLER SEG19 LC75854W VDD1 SEG18 VDD2 SEG17 SEG16 1k*4 SEG15...
  • Page 47 TX-RX UNIT (X57-7090-10) DISPLAY UNIT (X54-3510-10) R424 TEMP1 C445 R:13.6V TEMP2 T:12.6V VOLTAGE DROPPED RF AMP BUFFER AMP 7.07V Q421,422 RX VCO 6.98V 1.63V Q447 D421 R421 Q446 2SC5636 R460 C480 CHARGE PUMP RX VCO R:6.45V Q441 R:1.01V 0.76V 2SC5636 C469 C470 Q421...

  • Page 48: Block Diagram

    TK-8160 BLOCK DIAGRAM DISPLAY UNIT TX-RX UNIT Q431 2SC4649(N,P) POWER 2SK508 Q421 IC401 PTT(TXD) CHARGE 2SA1832(GR) MB15A02 PUMP PLLE HOOK(RXD) LOOP Q442 PLL IC C> KMO1 FILTER <B 2SJ347 16.8MHz CHARGE Q422 PUMP 2SC4738(GR) 16.8MHz KMO2 TCXO TCXOMOD Q445 X401...
  • Page 49 TK-8160 BLOCK DIAGRAM D601,602 Q504 MA4PH633 Q501 Q502 Q503 RD60HUF Q446 Q447 Q441 Q500 2SC3356 D604,605 RD00HVS1 PD55008 1-01 2SK508NV(K52) 2SC5636 2SC5636 2SC5110(O) (R24) XB15A709 FINAL DRIVE BUFF DRIVE ANT SW Q443 D447,448 Q442 KRX102U HSC277 2SJ347 POW. POW. POW.

  • Page 50: Level Diagram

    TK-8160 LEVEL DIAGRAM Receiver Section Center Frequency 49.95MHz 450kHz W : –79.0dBm N : –76.5dBm W : –120.5dBm W : –121.0dBm W : –108.0dBm W : –111.5dBm W : –111.0dBm W : –100.0dBm CF301 N : –120.0dBm N : –121.0dBm N : –107.0dBm...
  • Page 51 TK-8160 LEVEL DIAGRAM Audio Frequency 450kHz W : –93.5dBm N : –90.0dBm CF301 W : 0.58Vrms /CF302 N : 0.49Vrms 0.28Vrms 0.28Vrms 0.29Vrms 0.28Vrms 15mVrms 0.55Vrms 0.45Vrms IC321 IC201 IC241 IC213 IC241 IC241 IC201 IC281 vel meter. 12dB SINAD.) To make measurements in the AF section, connect the AC level meter.

  • Page 52: Specification

    Leuvensesteenweg 248 J, 1800 Vilvoorde, Belgium KENWOOD ELECTRONICS FRANCE S.A. 13, Boulevard Ney, 75018 Paris, France KENWOOD ELECTRONICS U.K. LIMITED KENWOOD House, Dwight Road, Watford, Herts., WD18 9EB United Kingdom KENWOOD ELECTRONICS EUROPE B.V. Amsterdamseweg 37, 1422 AC Uithoorn, The Netherlands KENWOOD ELECTRONICS ITALIA S.p.A.

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