Kenwood TK-3402U User manual

SERVICE MANUAL
This product complies with the RoHS directive for the European market. This product uses Lead Free solder.
© 2012-11 PRINTED IN JAPAN
B53-7041-00 (Y)669
UHF FM TRANSCEIVER
TK-3402(U)/3402
CONTENTS
GENERAL....................................................2
SYSTEM SET-UP.........................................3
REALIGNMENT...........................................3
DISASSEMBLY FOR REPAIR.....................6
CIRCUIT DESCRIPTION .............................9
SEMICONDUCTOR DATA .........................14
COMPONENTS DESCRIPTION................15
PARTS LIST...............................................16
EXPLODEDVIEW......................................22
PACKING ...................................................23
ADJUSTMENT...........................................25
PC BOARD
TX-RX UNIT (X57-8320-10)....................30
SCHEMATIC DIAGRAM ............................34
BLOCK DIAGRAM.....................................38
LEVEL DIAGRAM......................................40
SPECIFICATIONS......................................41
Button knob
(SIDE1/SIDE2)
(K29-9613-03)
Knob (Selector)
(K29-9615-03)
Knob (Volume)
(K29-9614-03)
Plastic cabinet assy
(A02-4200-03)
Button knob (PTT)
(K29-9612-03)
Whip antenna
(T90-1039-25) :TK-3402(U)
TK-3402
TK-3407

TK-3402(U)/3402/3407
2
GENERAL
INTRODUCTION
SCOPE OFTHIS MANUAL
This manual is intended for use by experienced techni-
cians familiar with similar types of commercial grade com-
munications equipment. It contains all required service
information for the equipment and is current as of the pub-
lication date. Changes which may occur after publication
are covered by either Service Bulletins or Manual Revisions.
These are issued as required.
ORDERING REPLACEMENT PARTS
When ordering replacement parts or equipment informa-
tion, the full part identification 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 sufficient description of the re-
quired component for proper identification.
PERSONAL SAFETY
The following precautions are recommended for personal
safety:
• DO NOT transmit until all RF connectors are verified se-
cure and any open connectors are properly terminated.
• SHUT OFF and DO NOT operate this equipment near
electrical blasting caps or in an explosive atmosphere.
• This equipment should be serviced by a qualified techni-
cian only.
SERVICE
This transceiver is designed for easy servicing. Refer
to the schematic diagrams, printed circuit board views, and
alignment procedures contained within.
Model Type TX-RX unit Frequency
range Remarks
TK-
3402(U) K
X57-8320-10 450~520MHz IF1: 50.85MHz
LOC: 50.4MHz
TK-3402 K
TK-3407 M
Document Copyrights
Copyright 2012 by JVC KENWOOD Corporation. All
rights reserved.
No part of this manual may be reproduced, translated,
distributed, or transmitted in any form or by any means,
electronic, mechanical, photocopying, recording, or other-
wise, for any purpose without the prior written permission of
JVC KENWOOD Corporation.
Disclaimer
While every precaution has been taken in the preparation
of this manual, JVC KENWOOD Corporation assumes no
responsibility for errors or omissions. Neither is any liability
assumed for damages resulting from the use of the informa-
tion contained herein. JVC KENWOOD Corporation reserves
the right to make changes to any products herein at any time
for improvement purposes.

3
TK-3402(U)/3402/3407
SYSTEM SET-UP
REALIGNMENT
Choose the type of transceiver
Transceiver programming
Delivery
Merchandise received
Are you using the speaker microphone?
A personal computer, programming interface (KPG-22A/22U),
and FPU (programming software) are required for programming.
(The frequency, TX power HI/LOW, and signaling data are
programmed for the transceiver.)
YES
NO
KMC-21, KMC-45
Speaker microphone
(Option)
Are you using the optional antenna? YES
NO
KRA-22 or KRA-26
Optional antenna
TX/RX 450~520 5.0W TK-3402(U) K
TK-3402 K
TK-3407 M
Frequency range (MHz) RF power Type
1. Modes
User mode
Data programming mode
PC test mode PC tuning mode
PC mode
Wireless clone mode
Mode Function
User mode For normal use.
PC mode Used for communication between the trans-
ceiver and PC.
Data programming
mode Used to read and write frequency data and 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.
Wireless clone
mode Used to transfer programming data from one transceiver to another.
2. How to Enter Each Mode
Mode Operation
User mode Power ON
PC mode Received commands from PC
Wireless clone mode [PTT] + [Side] + Power ON (Two seconds)
3. PC Mode
3-1. Preface
The transceiver is programmed by using a personal com-
puter, a programming interface (KPG-22A/22U) and FPU
programming software.
The programming software can be used with a PC. Fig-
ure 1 shows the setup of a PC for programming.
3-2. Connection Procedure
1. Connect the transceiver to the personal computer with
the interface cable.
Note:
• You must install the KPG-22U driver in the computer to
use the USB programming interface cable (KPG-22U).

TK-3402(U)/3402/3407
4
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 read from the transceiver, the red LED
lights.
When data is written to by the transceiver, the green LED
lights.
Note:
• The data stored in the personal computer must match
Model Name and Model Type when it is written into EE-
PROM.
• Do not press the [PTT] key during data transmission or
reception.
3-3. KPG-22A Description
(PC programming interface cable: Option)
The KPG-22A is required to interface the transceiver with
the computer.It has a circuit in its D-sub connector (KPG-22A:
9-pin) case that converts the RS-232C logic level to the TTL
level.
The KPG-22A connects the SP/MIC connector of the
transceiver to the RS-232C serial port of the computer.
3-4. KPG-22U Description
(USB programming interface cable: Option)
The KPG-22U is a cable which connects to a USB port
on a computer.
When using the KPG-22U, install the supplied CD-ROM
(with driver software) in the computer. The KPG-22U driver
runs under Windows XP, Vista or 7.
3-5. Programming Software Description
The FPU is the programming software for the transceiver
supplied on a CD-ROM. This software runs under windows
XP, Vista or 7 on a PC. The software on this disk allows a
user to program the transceiver via Programming interface
cable (KPG-22A/22U).
• Use the FPU that matches the market when you first set
the market code and model name/frequency data to the
service unit.The unit set by mistake cannot be restored.
3-6. Programming with PC
If data is transferred to the transceiver from a PC with the
FPU, the data for each set can be modified.
Data can be programmed into the EEPROM in RS-232C
format via the SP/MIC jack.
In this mode the PTT line operate as TXD and RXD data
lines respectively.
Fig. 1
REALIGNMENT
PC KPG-22A or KPG-22U
Illustration is KPG-22A
FPU
Gray
Gray/Black
1.5D-XV Lead wire
1.5D-XV Shield wire
+
–
+
–
SP
MIC
Tuning cable
(E30-3216-05)
TransceiverTransceiver
KPG-22U
PC
D-SUB
(9-pin)
KPG-22A
PC
USB
• List of FPU for transceiver
Model Type FPU
TK-3402(U) K KPG-159DN
TK-3402 K KPG-158D
TK-3407 M

5
TK-3402(U)/3402/3407
REALIGNMENT
4.Wireless Clone Mode
4-1. Outline
“Wireless Clone Mode” copies the transceiver data to an-
other transceiver.
The dealer can copy the transceiver data to another
transceiver even without the use of a personal computer.
4-2. Example
The transceiver can copy the programming data to one or
more transceivers via RF communication.
The clone source and clone target/s must be in wireless
clone mode.
4-3. Operation
1. To switch the clone target/s to Wireless Clone mode,
press and hold the [PTT] and [side2] keys while turning
the transceiver power ON.
2. Wait for 2 seconds. The LED will light orange and the
transceiver will announce “Clone”.
3. Select a channel table number using Side1 (increment
channel table) and Side2 (decrement channnel table)
keys.
4. To switch the clone source to wireless clone mode, press
and hold the [PTT] and [side2] keys while turning the
transceiver power ON.
5. Wait for 2 seconds. The LED will light orange and the
transceiver will announce “Clone”.
6. Select the same channel table number as the clone
target/s.
7. Press [PTT] on the clone source to begin data transmis-
sion.
When the clone target starts to receive data, the LED will
light green.
When the clone source finishes sending data, a “confir-
mation” tone will sound.
If data transmission fails while cloning, an “error” tone will
sound from the target unit.
8. If the cloning fails, no data will be available in the target
unit when it is returned to User mode.
9. When the cloning is successful, the target unit’s “Scan”
and “Key lock” functions will return to their default values
(Scan = OFF, Key lock = OFF).
Note:
• The dealer can clone data to two or more transceivers by
repeating the above procedures.
• If the transceivers wireless clone Mode is configured as
“Disabled”, the transceiver cannot enter Clone mode.
• The table shown below will cover the frequency tables
used for wireless cloning.
• Wireless clone mode cannot be entered in battery low
state.
• A unit cannot be a “Source Unit” if it is unprogrammed. If
[PTT] is pressed, an “error” tone will sound.
• The language used in cloning depends on the “Model
type” setting, not the FPU setting.
• Once a unit is set to be the source, it cannot be a target
after the data has been transmitted. This protects the
data in the source unit.
• Electronic interface may cause a failure in data transfer
during Wireless Clone, such as when waveforms or elec-
tromagnetics are being performed at the workbench.
• Wireless clone mode can be used ONLY by the au-
thorized service personnel.
• The wireless clone mode setting must be configured
as“Disable”before being delivered to the end-user.
• To clone, replace the antenna from both the source
transceiver and the target transceiver with a dummy
load.
• The transmit output power is automatically set to
Low in clone mode.
• Clone frequency table
No. Operating frequency 450~520 (MHz)
1 450.000
2 452.000
3 454.000
4 456.000
5 458.000
6 460.000
7 462.000
8 464.000
9 466.000
10 468.000
11 470.000
12 472.000
13 474.000
14 476.000
15 478.000
16 480.000
17 482.000
18 484.000
19 486.000
20 488.000

TK-3402(U)/3402/3407
6
DISASSEMBLY FOR REPAIR
1. Removing the Case Assembly from the
Chassis
1. Remove the selector knob aand volume knob b.
2. Remove the two screws c.
3. Lift and remove the chassis from the case assembly d.
(Use a flat-blade screwdriver to easily lift the chassis.)
a
b
c
c
d
2. Removing the Holder Assembly from
the Chassis
1. Remove the packing efrom the SMA, volume and selec-
tor.
2. Remove the holder from the chassis.
Note: Taking care not to cut the speaker and microphone
lead.
3. Detach the solder of speaker and microphone lead from
the PCB beforehand.
4. Remove the packing ffrom the SP/MIC jack of the TX-
RX unit.
0 0
㸩
㹑
㹑
RED
BROWN
RED
BLACK
Note: To remove the Holder Assy from
the Chassis,useaflat-head screwdriver
and insert to this hole.
e
f
3. Removing theTX-RX unit from the
Chassis
1. Remove the eleven screws gfixing the TX-RX unit.
2. Remove the solder of the antenna terminal with a solder-
ing iron h.
3. Remove the solder of the positive terminal with a solder-
ing iron i.
Note: You can remove the TX-RX unit from the chassis
without removing the solder at the positive terminal.
However, in this case, you can not attach the packing
(G53-2218-03) that is on the positive terminal to the
chassis in assembling. So, it is advisable to remove the
solder on the positive terminal first.
4. Remove the FPC from the flat cable connector j.
5. Lift and remove the TX-RX unit from the chassis k.
g
j
h
x2
x4 x2
g
g
g
g
g
g
i
k
4. Removing the Battery Release Lever
from the Case Assembly
1. Press the upper part of the lever toward the inside of the
case assembly. One side of the shaft will be removed a.
2. Lift and remove the battery release lever from the case
assembly b.
Note: Scratch and widen the glue hole if there is difficulty
in removing the other end of the shaft.
No glue is required when you reassemble the battery re-
lease lever.
b
a

7
TK-3402(U)/3402/3407
5. Attaching the Battery Release Lever to
the Case Assembly
1. Insert one side of the shaft into the hole at the lever fitting
section on the case assembly a.
Caution: The thin spring (G01-4543-14) should be posi-
tioned above the two tabs of the lever.
2. Tilt the battery release lever slightly forward b, so that
the thick spring (G01-4542-04) is positioned below the
case surface.
3. With the thick spring positioned below the case surface,
attach the other side of the shaft to the case assembly
by pressing the battery release lever cuntil it snaps into
place d.
Caution: Be careful not to tilt the battery release lever
too forward.
If the battery release lever is pushed in this state where
the two tabs come below the case surface, there is a
possibility of damaging the two tabs.
A thin spring
Shaft
Tow tabs
A thick spring
ab
d
c
6. Assembling the Battery Release Lever
1. Place the lever bonto the stopper a.
2. Place the thick spring conto the lever.
3. Hook the right and left ends of the thin spring donto the
tabs of the stopper, then place the thin spring onto the
lever e.
4. Slide the shaft through the hole of the stopper and lever f.
a
b
c
d
e
f
7. Attaching the PositiveTerminal to the
Chassis
Always attach the positive terminal to the chassis, using
the following procedures, before mounting the TX-RX unit
onto the chassis.
1. Remove the holder assembly bfrom the packing aof
the positive terminal.
2. Mount the packing of the positive terminal into the chas-
sis hole c.
3. Mount the holder assembly into the packing of the posi-
tive terminal d.
a
c
bd

TK-3402(U)/3402/3407
8
DISASSEMBLY FOR REPAIR
8. Mounting the Chassis to the Case
Assembly
1. Confirm that the waterproof packing attached to the
circumference of the chassis is securely inserted in the
groove of the chassis a.
2. Insert the upper part of the chassis into the case assem-
bly b.
3. Press the chassis cand the case assembly together to
attach them.
Caution: If the packing of the SP/MIC does not come
to the correct position after attaching the chassis to the
case assembly, reposition the packing with your fingers.
a
b
c
c
9. Attaching the Antenna Receptacle to
the Chassis
Screw the antenna receptacle to the chassis in the or-
der shown in the drawing so that the antenna receptacle
comes to the center of the case hole.
Tighten this screw second.
Ti
g
hten this screw first.
10.The Nuts of theVolume Knob and
Channel Knob
Note that the shapes, colors and heights of nuts of the
volume knob and channel knob are different from one
another. (The nut of volume knob is silver, and the nut of
channel knob is gold.)
Use the following jig when removing the nuts of the vol-
ume knob and channel knob.
• Jig (Part No.:W05-1012-00)
for Volume knob
(Long) for Selector knob (Short)

9
TK-3402(U)/3402/3407
CIRCUIT DESCRIPTION
1. Frequency Configuration
The receiver utilizes double conversion. The first IF is
50.85MHz and the second IF is 450kHz. The first Local os-
cillator is supplied from the PLL circuit.
The PLL circuit in the transmitter generates the neces-
sary frequencies. Figure 1 shows the frequencies
2. Receiver System
The receiver system is shown in Figure 2.
Fig. 1 Frequency configuration
Fig. 2 Receiver system
TX/RX: 450~520MHz
399.15~
469.15MHz
450~520MHz
1st MIX MCF SP
MIC
CF
450kHz
ANT
ANT
SW RF AMP IF System
X3
Tripler
PLL
VCO
50.85MHz 50.4MHz
TX
AMP RF AMP
AF
AMP
MIC
AMP
Baseband
TCXO 16.8MHz
SP
ANT
IC400
IF,MIX,DET
Q404
1st MIX
ANT
SW
Q400
X3 Tripler
2nd Local
X1
TCXO
16.8Hz
Baseband
IC705
BPF1
BPF Q405 RF AMP XF400
MCF
Q403
IF AMP
IC709
AF PA
(INT)
BPF1 1st Local
BPF
CF401
2-1. Front End (RF Amplifier) Circuit
The signal coming from the antenna passes through the
transmit/receive switching diode circuit (D201, D202, D203
and D204) and a BPF (L415 and L416), and is then ampli-
fied by the RF amplifier (Q405).
The resulting signal passes through a BPF (L410,L411
and L413) and goes to the mixer.These BPF are adjusted by
variable capacitance diodes (D400, D401, D402, D403 and
D404).The input voltage to the variable capacitance diode is
a regulated voltage output from the DC amplifier (IC704).
2-2. First Mixer
The signal from the front end is mixed with the first local
oscillator signal generated in the PLL circuit by Q404 to pro-
duce a first IF frequency of 50.85MHz.
The resulting signal passes through the XF400 MCF to
cut the adjacent spurious and provide the optimum charac-
teristics, such as adjacent frequency selectivity.

TK-3402(U)/3402/3407
10
CIRCUIT DESCRIPTION
2-3. IF Amplifier Circuit
The first IF signal is passed through a four-pole mono-
lithic crystal filter (XF400) to remove the adjacent channel
signal. The filtered first IF signal is amplified by the first IF
amplifier (Q403) and is then applied to the IF system IC
(IC400).
The IF system IC provides a second mixer, limiting
amplifier, quadrature detector and RSSI (Received Signal
Strength Indicator). The second mixer mixes the first IF sig-
nal with the 50.85MHz signal of the second local oscillator
output (Q403) and produces the second IF signal of 450kHz.
The second IF signal is passed through the ceramic filter
(CF401) to remove the adjacent channel signal. The filtered
second IF signal is amplified by the limiting amplifier and
demodulated by the quadrature detector with the ceramic
discriminator (CD400). The demodulated signal is routed to
the audio circuit.
2-4. Audio Amplifier Circuit
The demodulated signal from IC400 is sent to an AF am-
plifier through IC705, and is routed to an audio power ampli-
fier (INT:IC709,EXT:IC707) where it is amplified and output
to the speaker.
Baseband
IC
IC705 AF PA
(INT)
IC709INT
SP
FM IC
IC400
AF PA
(EXT)
IC707 EXT
SP
SPO
Fig. 3 Audio Amplifier circuit
2-5. Squelch Circuit
Part of the AF signal from the IC400 enters the FM IC
(IC400) again, and the noise component is amplified and
rectified by a filter and an amplifier to produce a DC voltage
corresponding to the noise level.
The DC signal from the FM IC goes to the analog port of
the MCU (IC702). IC702 determines whether or not to output
sounds from the speaker by checking if the input voltage is
higher or lower than the preset value.
To output sounds from the speaker, IC702 sends a high
signal to the AFSW line and turns IC707 on through Q709,
Q710, Q713 and Q716. This explanation is a case of exter-
nal speaker amplifier. In the case of internal loudspeaker
amplifier, IC702 sends a high signal to the AFSW line and
turns IC709 on through Q711 and Q714.
3.Transmitter System
3-1. Microphone Amplifier Circuit
The signal from the microphone is limited by the AGC
circuit, which is composed of D700, D701, Q705, Q706 and
the mute switch (Q704). IC705 is composed of a high-pass
filter, low-pass filter and pre-emphasis/IDC circuit.
The signal from the microphone and the low speed data
from the MCU (IC702) enter the baseband IC (IC705) and
pass through each path and are mixed inside the IC.
The output signal from the audio processor goes to the
VCO modulation input. The other output signal goes to the
TCXO modulation input.
AGC
SW
D702,703
Q705,706
MICM
X1
TCXO
VCO
LSD
OUT
IC705
Q704
MIC
Baseband
MOD1
Fig. 4 Microphone amplifier circuit
3-2. Drive and Final Amplifier Circuit
The signal from the T/R switch (D15 is on) is amplified by
the pre-drive amplifier (Q201) to 20mW.
The output of the pre-drive amplifier is amplified by the
drive amplifier (Q206) and the RF final amplifier (Q208) to
5.0W (1W when the power is low).
The drive amplifier and the RF final amplifier consist of
two MOS FET stages.
The output of the RF final amplifier is then passed
through the harmonic filter (LPF) and antenna switch (D203
and D204) and is applied to the antenna terminal.
3-3. APC Circuit
The APC circuit always monitors the current flowing
through the drive amplifier (Q206) and the RF power ampli-
fier (Q208) and keeps a constant current. The voltage drop
at R230, R231 and R233 is caused by the current flowing
through the RF final amplifier. This voltage is applied to the
differential amplifier IC200 (1/2).
IC200 (2/2) compares the output voltage of IC200 (1/2)
with the reference voltage from IC705(32pin:AUXDAC1).The
output of IC200 (2/2) controls the gate bias voltage of the
RF power amplifier and the drive amplifier to make both volt-
ages the same.
The change of power high/low is carried out by the
change of the reference voltage.