Kenwood TK-480 User manual

SERVICE MANUAL
This product complies with the RoHS directive for the European market.This product uses Lead Free solder.
© 2012-4 PRINTED IN JAPAN
B53-7022-00 (Y)PDF
800MHz/900MHz FM TRANSCEIVER
TK-480/481
CONTENTS
GENERAL....................................................2
DISASSEMBLY FOR REPAIR .....................3
PARTS LIST .................................................4
EXPLODED VIEW......................................11
PC BOARD
TX-RX UNIT (X57-5630-XX) ...................12
SCHEMATIC DIAGRAM ............................16
SUPPLEMENT II
Whip antenna
(T90-0636-25) : TK-480
(T90-0640-25) : TK-481
Knob (Selector)
(K29-5232-03)
Knob (VOL)
(K29-5231-03)
Badge
(B43-1139-04)
Knob (PTT)
(K29-5157-03)
Packing
(G53-0841-22) : K4
Cabinet assy
(A02-3659-23) : K4
Panel assy
(A62-0981-04)
This service manual has been revised due to the modification of the LCD ASSY and is-
sues it as a supplemental manual.
This service manual applies to products with B2200001 (TK-480), B2200001 (TK-481)
or subsequent serial numbers. Refer to the TK-480/481 series service manual for any
information which has not been covered in this manual.
Illustration is TK-480/481 K4 type.
K3, K4, M4 versions
CAUTION
When using an external power connector,
please use with maximum final module protec-
tion of 9V.

TK-480/481
2
GENERAL
Title Part number Remarks Unit number PCB number
TK-480/481 B51-8408-00 Hardware Ver. 1.0
~ S/No. 212xxxxx
X57-5370-10: J
X57-5630-10: S
J72-0516-12
J72-0516-22
TK-480/481 Revised B51-8408-10 X57-5370-10: J
X57-5630-10: S
J72-0516-32
J72-0516-32
TK-480/481 Revised II B51-8408-20 Hardware Ver. 2.0
~ S/No. 313xxxxx X57-5630-10: S J72-0812-02 J72-1006-09
TK-480 M2 Version B51-8665-00
(PDF ONLY)
For TK-480 M2
Hardware Ver. 2.0 X57-5630-10: S J72-0812-02 J72-1006-09
TK-480/481 Supplement
K3, K4, M4 Versions
B51-8977-00
(PDF ONLY)
The modification of
the PLL IC X57-5630-10: S J79-0201-09
TK-480/481 Supplement II
K3, K4, M4 Versions
B53-7022-00
This service manual
(PDF ONLY)
The modification of
the LCD ASSY X57-5630-10: S J79-0201-19
Note: X57-5370-XX: Produced in Japan
X57-5630-XX: Produced in Singapore
SERVICE MANUAL LIST
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.
Firmware Copyrights
The title to and ownership of copyrights for firmware em-
bedded in KENWOOD product memories are reserved for
JVC KENWOOD Corporation. Any modifying, reverse en-
gineering, copy, reproducing or disclosing on an Internet
website of the firmware is strictly prohibited without prior
written consent of JVC KENWOOD Corporation. Further-
more, any reselling, assigning or transferring of the firmware
is also strictly prohibited without embedding the firmware in
KENWOOD product memories.

TK-480/481
3
DISASSEMBLY FOR REPAIR
Compatibility information
The LCD ASSY (B38-0892-15) has been discontinued by the supplier. A new LCD ASSY (B38-0951-05) has been applied to
the X57-5630-XX and X54-3210-XX production.
TK-480 K3, K4, M4/ TK-481 K3, K4
TX-RX UNIT(X57-5630-XX), DISPLAY UNIT(X54-3210-XX)
OLD NEW
TX-RX UNIT: X57-5630-10/-11/-21
DISPLAY UNIT: X54-3210-10/-11 *1
(TK-480: S/No.B21xxxxx and earlier,
TK-481: S/No.B21xxxxx and earlier)
TX-RX UNIT: X57-5630-12/-13/-22
DISPLAY UNIT: X54-3210-10/-11 *1
(TK-480: S/No.B2200001~,
TK-481: S/No.B2200001~)
LCD ASSY B38-0892-15 B38-0951-05
Microprocessor 30622MEP589GU 30622MEP599GU
Firmware
Version Ver. 2.xx Ver. 3.xx
Checksum (K3, K4 type) 0AF3
(When the firmware version is Ver. 2.09.)
47C6
(When the firmware version is Ver. 3.09.)
Checksum (M4 type) D179
(When the firmware version is Ver. 2.28.)
DED7
(When the firmware version is Ver. 3.28.)
PC board
TX-RX (X57-5630-XX) J79-0201-09 J79-0201-09
J79-0201-19
DISPLAY (X54-3210-XX) J72-0517-22 J72-0517-22
Compatibility Chart
LCD ASSY
OLD NEW
B38-0892-15 B38-0951-05
Unit
OLD *2
TX-RX: X57-5630-10/-11/-21
DISPLAY: X54-3210-10/-11 *1
Available NOT available
(The character does not appear.)
NEW
TX-RX: X57-5630-12/-13/-22
DISPLAY: X54-3210-10/-11 *1
NOT available
(The character does not appear.) Available
*1: The circuit fixed number of the LCD VCI section differs between the old Display unit (X54-3210-10/-11) and the new Display
unit (X54-3210-10/-11).
*2: The following units were added as an object for service of old Display units.
OLD Display Unit Display Unit for Service
X54-3210-10 X54-3210-14
X54-3210-11 X54-3210-15

TK-480/481
4
Chip capacitor
Code L W T
Empty 5.6±0.5 5.0±0.5 Less than 2.0
A 4.5±0.5 3.2±0.4 Less than 2.0
B 4.5±0.5 2.0±0.3 Less than 2.0
C 4.5±0.5 1.25±0.2 Less than 1.25
D 3.2±0.4 2.5±0.3 Less than 1.5
E 3.2±0.2 1.6±0.2 Less than 1.25
F 2.0±0.3 1.25±0.2 Less than 1.25
G 1.6±0.2 0.8±0.2 Less than 1.0
H 1.0±0.05 0.5±0.05 0.5±0.05
Chip resistor
Code L W T
E 3.2±0.2 1.6±0.2 1.0
F 2.0±0.3 1.25±0.2 1.0
G 1.6±0.2 0.8±0.2 0.5±0.1
H 1.0±0.05 0.5±0.05 0.35±0.05
฀฀Code Wattage Code Wattage Code Wattage
1J 1/16W 2C 1/6W 3A 1W
2A 1/10W 2E 1/4W 3D 2W
2B 1/8W 2H 1/2W
฀฀
Code B C D F G
(pF) ±0.1 ±0.25 ±0.5 ±1 ±2
C C 4 5 T H 1 H 2 2 0 J
1 2 3 4 5 6
1 = Type ... ceramic, electrolytic, etc. 4 = Voltage rating
2 = Shape ... round, square, etc. 5 = Value
3 = Temp. coefficient 6 = Tolerance
฀฀1st Word C L P R S T U
Color* Black Red Orange Yellow Green Blue Violet
ppm/°C 0 –80 –150 –220 –330 –470 –750
฀฀฀฀Code C D G J K M X Z P No code
(%) ±0.25 ±0.5 ±2 ±5 ±10 ±20 +40 +80 +100 More than 10µF : –10~+50
–20 –20 –0 Less than 4.7µF : –10~+75
฀฀
2nd word A B C D E F G H J K V
1st word
0 1.0 1.25 1.6 2.0 2.5 3.15 4.0 5.0 6.3 8.0 –
1 10 12.5 16 20 25 31.5 40 50 63 80 35
2 100 125 160 200 250 315 400 500 630 800 –
3 1000 1250 1600 2000 2500 2150 4000 5000 6300 8000 –
฀฀(EX) C C 7 3 F S L 1 H 0 0 0 J Refer to the table above.
1 2 3 4 5 6 7 1 = Type
(Chip) (CH, RH, UJ, SL) 2 = Shape
3 = Dimension
(EX) C K 7 3 F F 1 H 0 0 0 Z 4 = Temp. coefficient
1 2 3 4 5 6 7 5 = Voltage rating
(Chip) (B, F) 6 = Value
7 = Tolerance
฀฀฀(EX) R D 7 3 E B 2 B 0 0 0 J
1 2 3 4 5 6 7
(Chip) (B, F)
฀฀฀฀
(EX) R D 1 4 B B 2 C 0 0 0 J
1 2 3 4 5 6 7
1 = Type 5 = Rating wattage
2 = Shape 6 = Value
3 = Dimension 7 = Tolerance
4 = Temp. coefficient
CC45 Color*
2nd Word G H J K L
ppm/°C ±30 ±60 ±120 ±250 ±500
Example : CC45TH = –470±60ppm/°C
฀฀010 = 1pF 2 2 0 = 22pF
100 = 10pF
101 = 100pF Multiplier
102 = 1000pF = 0.001µF 2nd number
103 = 0.01µF 1st number
L
W
T
฀PARTS LIST

TK-480/481
✽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.
L: Scandinavia K: USA P: Canada
Y: PX (Far East, Hawaii) T: England E: Europe
C: China X: Australia M: Other Areas
5
Ref. No. Address Parts No. Description Desti-
nation
New
parts
Ref. No. Address Parts No. Description Desti-
nation
New
parts
PARTS LIST
1 1A A02-3658-23 PLASTIC CABINET ASSY(4KEY) K5,K7
1 1A A02-3659-23 PLASTIC CABINET ASSY(16KEY) K6,M4,K8
2 2B A62-0981-04 PANEL ASSY
4 2C B09-0363-03 CAP(SP/MIC) ACCESSORY
5 2A
✽B38-0951-05 LCD ASSY
6 1B B43-1139-04 BADGE(KENWOOD)
9 2C
✽B62-1483-10 INSTRUCTION MANUAL K5,K6,K7
9 2C
✽B62-1483-10 INSTRUCTION MANUAL K8
9 2C
✽B62-1771-20 INSTRUCTION MANUAL M4
9 2C
✽B62-1877-10 INSTRUCTION MANUAL K5,K6,K7
9 2C
✽B62-1877-10 INSTRUCTION MANUAL K8
10 3A
✽B72-1968-14 MODEL NAME-PLATE K5,K6
10 3A
✽B72-2244-14 MODEL NAME-PLATE M4
10 3A
✽B72-2668-04 MODEL NAME-PLATE K7
10 3A
✽B72-2669-04 MODEL NAME-PLATE K8
12 3B E04-0406-05 RF COAXIAL RECEPTACLE(SMA)
15 2B E23-1049-04 TERMINAL(ANT)
51 3A E23-1166-04 RELAY TERMINAL
17 3A E37-0673-05
LEAD WIRE WITH CONNECTOR(PTT)
18 1A E37-0674-15
LEAD WIRE WITH CONNECTOR(SP)
16 2A E37-1537-05 FLAT CABLE(CONT-TX-RX)
19 3B E58-0440-15
RECTANGULAR RECEPTACLE(SP/MIC)
52 3A E72-0412-13 TERMINAL BLOCK
54 2A F10-2248-13 SHIELDING CASE(VCO)
56 2A F10-2255-04 SHIELDING PLATE(P-MODULE)
57 2A F10-2310-13 SHIELDING PLATE(LCD)
55 2A
✽F10-3100-03 SHIELDING PLATE(BAND PASS)
-
✽F12-0494-04 SHIELDING SHEET(CHASSIS) K7,K8
- F20-1192-04
INSULATING SHEET(SHIELD CASE)
- F20-3303-04 INSULATING SHEET(MIC/GND)
21 1A G01-0881-04 COIL SPRING
22 1B G09-0418-05 KNOB SPRING(VOL,SELECTOR)
23 1B G10-0799-04 FIBROUS SHEET(SP)
24 3A G11-0800-04 SHEET(PTT)
61 3A G11-2544-04 SHEET(CHASSIS)
- G11-4402-04 SHEET(CASE BOTTOM)
62 2A G13-1731-04 CUSHION(LCD)
63 3A,3B G13-1762-04 CUSHION(VOL/CHASSIS)
64 3A G13-1834-04 CUSHION(TERMINAL)
26 3B G53-0811-03 PACKING(TOP)
25 1A G53-0840-22 PACKING(4KEY) K5,K7
25 1A G53-0841-22 PACKING(16KEY) K6,M4,K8
65 3A G53-1510-04 PACKING(BATT+)
66 3A G53-1520-24 PACKING(TERMINAL)
67 3B G53-1619-04 PACKING(SMA)
- H13-1072-04
CARTON BOARD(PACKING FIXTURE)
29 3D
✽H52-1096-22 ITEM CARTON CASE K5,M4,K6
29 3D H52-1097-12 ITEM CARTON CASE K7,K8
28 2D H12-3014-02 PACKING FIXTURE
31 1A J19-1572-04 HOLDER
68 2A J21-8321-03
MOUNTING HARDWARE(P-MODULE)
32 2C J29-0734-05 BELT HOOK ASSY
34 3B J82-0066-15 FPC(SOCKET)
33 3B J87-0017-05 FPC(VOL,SELECTOR)
38 1B K29-5157-03 KNOB(PTT)
39 1B K29-5158-03 KEY TOP(PTT)
36 1B K29-5231-03 KNOB(VOL)
37 1B K29-5232-03 KNOB(SELECTOR)
40 1A K29-9251-03 LEVER KNOB
A 2B N14-0834-04
CIRCULAR NUT(VOL,SELECTOR)
B 3B
✽N30-2605-48
PAN HEAD MACHINE SCREW(ANT)
C 3A N30-2610-48
PAN HEAD MACHINE SCREW(CASE)
D 2A N67-2606-48
PAN HEAD SEMS SCREW(P-MODULE)
E 2A,1B N83-2005-48 PAN HEAD TAPTITE SCREW(UNIT)
F 3A
✽N09-6616-05 TAPTITE SCREW(TERMINAL)
42 2C N99-2004-15 SCREW SET ACCESSORY
44 3B R31-0617-05 VARIABLE RESISTOR
S300 - S70-0414-05 TACT SWITCH
46 1A T07-0714-15 SPEAKER
47 2C T90-0636-25
WHIP ANTENNA(800MHZ) ACCESSORY K5,M4,K6
47 2C T90-0640-25
WHIP ANTENNA(900MHZ) ACCESSORY K7,K8
MIC300 1A T91-0579-05 MIC ELEMENT
49 2B W02-1814-05 ENCODER
D301 B30-2019-05 LED(RED/GREEN) BUSY/TX
D305-310 B30-2171-05 LED(ORANGE) BACKLIGHT K6,M4,K8
D305,306 B30-2171-05 LED(ORANGE) BACKLIGHT K5,K7
C301 CC73GCH1H470J CHIP C 47PF J
C302 CS77BA0J100M CHIP TNTL 10UF 6.3WV
C304 CK73FB1C474K CHIP C 0.47UF K
C305 CC73GCH1H101J CHIP C 100PF J
C307 CK73GB1C104K CHIP C 0.10UF K
C308 CC73GCH1H101J CHIP C 100PF J
C309 CK73FB1C474K CHIP C 0.47UF K
C310 CK73GB1C104K CHIP C 0.10UF K
C311 CC73GCH1H470J CHIP C 47PF J
C312 CK73GB1C104K CHIP C 0.10UF K
C313 CS77BA1A100M CHIP TNTL 10UF 10WV
C314 ✽CS77MP0G3R3M CHIP TNTL 3.3UF 4WV
C315 CC73GCH1H101J CHIP C 100PF J
C316,317 CC73GCH1H470J CHIP C 47PF J
C318 CC73GCH1H101J CHIP C 100PF J
C321-333 CC73GCH1H470J CHIP C 47PF J
C335-339 CC73GCH1H470J CHIP C 47PF J
C340 CK73GB1E153K CHIP C 0.015UF K
C341-344 CC73GCH1H470J CHIP C 47PF J
CN300 ✽E40-6948-05 FLAT CABLE CONNECTOR(24P)
CN301 ✽E40-5892-15 FLAT CABLE CONNECTOR(14P)
CN302 E41-2539-05 PIN ASSY(SP)
CN303 E41-3086-05 PIN ASSY(PTT)
CN304 E40-6452-05 FLAT CABLE CONNECTOR(LCD)
TK-480/481
K5:TK-480(K3), K6:TK-480(K4),
K7:TK-481(K3), K8:TK-481(K4),
M4:TK-480(M4)
L: Scandinavia K: USA P: Canada
Y: PX (Far East, Hawaii) T: England E: Europe
C: China X: Australia M: Other Areas
DISPLAY UNIT (X54-3210-XX) -10: K3 -11: K4, M4
TK-480/481
DISPLAY UNIT (X54-3210-XX)