Kenwood TK-868G User manual

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UHF FM TRANSCEIVER / UHF
© 2001-3
B51-8566-00 (N)617
TK-868G
SERVICE MANUAL /
Panel assy
(A62-0642-03)
Key top
(K29-5343-02)
128 channels / 128
GENERAL ................................................................. 2
INSTALLATION........................................................ 3
PARTS LIST .............................................................. 8
EXPLODED VIEW .................................................. 17
PACKING ................................................................ 18
ADJUSTMENT ....................................................... 19
LEVEL DIAGRAM ................................................... 35
PC BOARD VIEWS
DISPLAY UNIT (X54-3270-10) .......................... 37
PLL/VCO (X58-4670-16) ................................... 38
TX-RX UNIT (X57-5963-09) (A/2) ..................... 39
TX-RX UNIT (X57-5963-09) (B/2) ..................... 45
SCHEMATIC DIAGRAM ........................................ 49
BLOCK DIAGRAM .................................................. 53
SPECIFICATIONS................................................... 56
CONTENTS
SUPPLEMENT / This TK-868G service manual contains a number of sec-
tions which differ from the service manual (B51-8500-00)
for the TK-868G.
For items other than those in this TK-868G service
manual please refer to the service manual (B51-8500-00)
for the TK-868G.

2
TK-868G
Self Programming Mode
Write mode for frequency data and signalling etc. Mainly
used by the person maintaining the user equipment.
■Enter to the Self Programming Mode
Hold down the [A] key and turn the power switch on. When
enter the self programming mode, “SELF” is displayed.
Flow chart 
REALIGNMENT /
Service Manual List
Title Parts number Remarks Destination TX-RX unit
PCB number
TK-868G B51-8500-00 C,C3 J72-0678-02
TK-868G B51-8502-00 M,M3 J72-0678-02
TK-868HG B51-8541-00 SUPPLEMENT C J72-0760-02
TK-868HG B51-8541-10 REVISED C,C3 J72-0760-12
TK-868G B51-8566-00 SUPPLEMENT C6 J72-0760-22
This Service manual
Frequency range C,M : 450~490MHz
C3,M3 : 400~430MHz
C6 : 350~390MHz
[]
[MON]
Channel set mode Function set mode
Self programming mode
Note :
This mode (self programming mode) cannot be set when
it has been disabled with the FPU.

3
TK-868G
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 the square
plug into the KCT-19 connector ( ).
2
3
1
1
3
6
13
15
KCT-18
KCT-19
Contact /
12
3
2
3
1
Fig. 1 /
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 igni-
tion 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.
TX-RX UNIT
(A/2)
ANT
KCT-19 CN2
R134
R133
R135
Fig. 2 /
Operation when KCT-18 R134 R135
is connected
Yes Yes KCT-18 cannot
Power on/off and Horn No Yes be connected
Alert or AUX-A on/off
Horn Alert or AUX-A Yes No
on/off
No No Power cannot
be turned on
Table 1 R134 and R135 setup chart
INSTALLATION /

4
TK-868G
INSTALLATION /

1
3
2
2
3
4
1
3
W1
W2
CN1
CN2
KCT-19
Cushion /
(G13-1710-04)
CN3
CN7
1
CN3
Fig. 3 /
PA/HA Unit (KAP-1 : Option)
Installing the KAP-1 in the Transceiver
The Horn Alert (max. 2A drive) and Public Address func-
tions 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 KCT-19 (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
front left side.
4. Attach the cushion on the top of the KAP-1 switch unit.
1
3 2
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.
R1 Output form
HR1 (Default) Yes
HR2 No
HR1
HR1
HR2
R1
Fig. 4 KAP-1 foil side view

HR1
HR1
HR2

5
TK-868G
INSTALLATION /
Public address
The signal from pin 13 of IC9 on the TX-RX unit drives PA
relay 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 function No
Do not use the PA function Yes
TX-RX UNIT
(A/2)
KCT-19 CN2
Q19
R122
R153
ANT
Fig. 5 /

Others
If the PA and HR2 are not necessary and the speaker out-
put is output to an external unit through the KCT-19, connect
the KCT-19 C connector to CN8 on the TX-RX unit.
8C
R21
Q5
Q1
D2
Q6
Q1
Q6
4
IC9
Shift
register
IGN
±+
±+
KAP-1 (SWITCH UNIT : X41-3380-20)
W1 1
2
3
HOR
E
SB
W2 1
2
3
PA/LI
SPO
SPI
CN1
1
2HR2
NC
CN2
1
2
3
HR1
E
SB
CN3
1
2PAO/LIO
E
R1 0
C5 1000P
C6
1000P
C7
1000P
K2
D1
C3 0.01
C1
1000P
R3 0
R4 0
C2
1000P
D2
K1
C4 0.01
Q1
Q1 : DTD114EK
D1,2 : 1SS193
CN3
CN7
13
+
R153
Audio
power amp
IC13
CN8
1 2
SP
E
Internal/External
speaker
TX-RX UNIT
B
BRN
ORG
YEL
C
C
GRN
GRN
KCT-19
13 10 1
36
12
15
KCT-19 Terminal
6 : Earth
10 : HR1
12 : PA (HR2)
Fig. 6 /

6
TK-868G
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 emer-
gency mode.
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.)


IC502
CPU
6
Q506
87
88
25 20
$R705
Attach
0
Power
switch
MBL
MBL
SB Q505
Key
backlight
LCD
IC510
13
CN5
R142
47K
Remove
IC14
KCT-19
15 pin
KCT-18
Foot
switch
Control section
TX-RX section
Outside
13 1
3615
KCT-19 Terminal
3 : Ignition sense
6 : Earth
15 : Foot switch
F.RESET
R705
TX-RX unit B/2
Foil side
R142
TX-RX unit A/2
Foil side
Fig. 7 /
Fig. 8 /
INSTALLATION /

7
TK-868G
INSTALLATION /
Emergency Mode System Chart
Press the Foot switch once
Emergency mode
Emergency channel LCD dots light
TX 25 sec. ←→ RX 5 sec.
Emergency ACK code receive
Foot switch 1 push
Horn/Light operation stop
Horn/Light operation
[D/A] key 1 push
Emergency reset code receive [MON] key + Foot SW 1 push
Emergency mode reset
Normal operation
After 1 min.
*1
*4
*2
Dots
Dots
LCD dots light
*3
or
or
*1 : Press and hold the foot switch for about one
second.
*2 : 3 left most dots light.
*3 : 2 right most dots light.
*4 : While pressing [MON] key, push foot switch
for about one second.
←→
*1
*4
*2
*3

8
TK-868G
2nd Word G H J K L
ppm/°C±30 ±60 ±120 ±250 ±500
Example : CC45TH = –470 ±60ppm/°C
Multiplier
2nd number
1st number
2 2 0 = 22pF
CAPACITORS CC 45 TH 1H 220 J
12 3 4 56
1 = Type … ceramic, electrolytic, etc. 4 = Voltage rating
2 = Shape … round, square, ect. 5 = Value
3 = Temp. coefficient 6 = Tolerance
• Temperature coefficient
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
• Tolerance (More than 10pF)
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
• Voltage rating
ABCDE FGHJKV
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 3150 4000 5000 6300 8000 –
• Chip capacitors
(EX) C C 7 3 F S L 1 H 0 0 0 J
1 234 5 6 7
(Chip) (CH, RH, UJ, SL)
(EX) C K 7 3 F F 1 H 0 0 0 Z
1 234 5 6 7
(Chip) (B, F)
RESISTORS
• Chip resistor (Carbon)
(EX) R D 7 3 E B 2 B 0 0 0 J
1 234 5 6 7
(Chip) (B,F)
• Carbon resistor (Normal type)
(EX) R D 1 4 B B 2 C 0 0 0 J
1 234 5 6 7
1 = Type … ceramic, electrolytic, etc. 5 = Voltage rating
2 = Shape … round, square, ect. 6 = Value
3 = Dimension 7 = Tolerance
4 = Temp. coefficient
• Capacitor value
010 = 1pF
100 = 10pF
101 = 100pF
102 = 1000pF = 0.001µF
103 = 0.01µF
(Less than 10pF)
Code B C D F G
(pF) ±0.1 ±0.25 ±0.5 ±1±2
1st word
2nd word
Refer to the table above.
Dimension (Chip capacitors)
Dimension 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
Dimension
Dimension (Chip resistor)
Dimension 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
Rating wattage
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
1 = Type
2 = Shape
3 = Dimension
4 = Temp. coefficient
5 = Voltage rating
6 = Value
7 = Tolerance
CC45 Color*
T
W
L
PARTS LIST /

TK-868G
PARTS LIST /
9
*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
Y: AAFES (Europe) X: Australia M: Other Areas
TK-868G
DISPLAY UNIT (X54-3270-10)
TX-RX UNIT (X57-5963-09)
New Desti-
parts nation
Ref. No. Address Parts No. Description
New Desti-
parts nation
Ref. No.
Address Parts No. Description
1 1B A01-2165-13 CABINET UPPER
2 2A A01-2166-13 CABINET BOTTOM
3 2A A62-0642-03 PANEL ASSY
6 2B B11-1226-03 ILLUMINATION GUIDE
7 2A B38-0824-05 LCD
82D
*B62-1259-20 INSTRUCTION MANUAL
9 1C B72-1951-04 MODEL NAME PLATE
11 2B E29-1179-04 INTER CONNECTOR
12 1C E30-2145-15 ANTENNA CABLE RADIO
14 1C E30-3340-05 DC CORD
- E30-3404-05 EXTENSION CABLE
16 1C E37-0790-25 LEAD WIRE WITH CONNECTOR (SP)
17 2B E37-0815-05 FLAT CABLE
- E37-0852-05 LEAD WIRE WITH CONNECTOR (15P)
- E37-0853-05 LEAD WIRE WITH CONNECTOR (10P)
- E37-0854-05 LEAD WIRE WITH CONNECTOR (8P)
- E37-0855-05 LEAD WIRE WITH CONNECTOR (3P)
18 2B F12-0435-04 CONDUCTIVE SHEET
21 1C G02-0791-04 FLAT SPRING AF, APC
22 1B,1C G10-1221-04 FIBROUS SHEET SIDE
23 1B G10-1222-14 FIBROUS SHEET UP, DOWN
24 1A,2C G10-1223-14 FIBROUS SHEET SHIELD
25 1C G13-1468-04 CUSHION DC CORD
26 1B G13-1759-04 CUSHION SP
27 2C G53-0796-04 PACKING PHONE JACK
30 2D H10-6618-12 POLYSTYRENE FOAMED FIXTURE (F)
31 1E H10-6619-12 POLYSTYRENE FOAMED FIXTURE (R)
33 2E H25-0720-04 PROTECTION BAG (200X350)
34 3E H52-1520-02 ITEM CARTON CASE
37 2A J21-8382-03 HARDWARE FIXTURE
40 2A K29-5343-02 KEY TOP
A 2A,1B N33-2606-45 OVAL HEAD MACHINE SCREW
B 2C N67-3008-46 PAN HEAD SEMS SCREW W
C 2B,1C N87-2606-46 BRAZIER HEAD TAPTITE SCREW
D 2B N87-2612-46 BRAZIER HEAD TAPTITE SCREW
44 1B T07-0368-05 SPEAKER
D802-805 B30-2220-05 LED (YELLOW)
C801-803 CC73GCH1H101J CHIP C 100PF J
C804 CK73GF1A105Z CHIP C 1.0UF Z
C805 CK73GB1H102K CHIP C 1000PF K
C806,807 CK73GB1H471K CHIP C 470PF K
CN801 E40-6020-05 PIN ASSY
L801 L92-0138-05 FERRITE CHIP
TK-868G R801-803 RK73GB1J103J CHIP R 10K J 1/16W
R804 RK73GB1J473J CHIP R 47K J 1/16W
R805 RK73GB1J474J CHIP R 470K J 1/16W
R806 R92-1252-05 CHIP R 0 OHM
R808 RK73GB1J392J CHIP R 3.9K J 1/16W
R809 RK73FB2A270J CHIP R 27 J 1/10W
D801 MA2S111 DIODE
D808 DA204U DIODE
D808 HSB123 DIODE
IC801 LC75823W IC (LCD DRIVER)
Q801 2SB1132(Q,R) TRANSISTOR
D509-514 B30-2050-05 LED
D521 B30-2151-05 LED (RED/GREEN)
C1-11 CK73GB1H471K CHIP C 470PF K
C13-19 CK73GB1H471K CHIP C 470PF K
C20 C92-0507-05 CHIP-TAN 4.7UF 6.3WV
C21 CK73GB1H471K CHIP C 470PF K
C22 CK73GB1C104K CHIP C 0.10UF K
C23,24 C92-0507-05 CHIP-TAN 4.7UF 6.3WV
C26 CK73GB1H471K CHIP C 470PF K
C29 C92-0507-05 CHIP-TAN 4.7UF 6.3WV
C30 CC73GCH1H030C CHIP C 3.0PF C
C31 CK73GB1H102K CHIP C 1000PF K
C32 C92-0662-05 CHIP-TAN 15UF 6.3WV
C33 CC73GCH1H220J CHIP C 22PF J
C35 CK73GB1C104K CHIP C 0.10UF K
C36 CK73GB1H102K CHIP C 1000PF K
C37 CK73FB1C334K CHIP C 0.33UF K
C40,41 CK73GB1H103K CHIP C 0.010UF K
C43 C92-0507-05 CHIP-TAN 4.7UF 6.3WV
C44 CK73GB1H331K CHIP C 330PF K
C45 CK73GB1H102K CHIP C 1000PF K
C46 CK73GB1H103K CHIP C 0.010UF K
C47 C92-0561-05 CHIP-ELE 22UF 16WV
C49 CK73GB1H102K CHIP C 1000PF K
C51 CK73GB1C104K CHIP C 0.10UF K
C52 CC73GCH1H680J CHIP C 68PF J
C53 CK73GB1C104K CHIP C 0.10UF K
C54 CK73GB1H103K CHIP C 0.010UF K
C56 CC73GCH1H220J CHIP C 22PF J
C58 CK73GB1E223K CHIP C 0.022UF K
C60,61 CK73GB1H102K CHIP C 1000PF K
C62 CC73GCH1H101J CHIP C 100PF J
C63 CK73GB1C104K CHIP C 0.10UF K
C64 CK73GB1H103K CHIP C 0.010UF K
C66 CK73GB1H102K CHIP C 1000PF K
C67 CK73GB1H471K CHIP C 470PF K
C68 CC73GCH1H101J CHIP C 100PF J
C69 CK73GB1E223K CHIP C 0.022UF K
C70 C92-0507-05 CHIP-TAN 4.7UF 6.3WV
C71 CC73GCH1H101J CHIP C 100PF J
DISPLAY UNIT (X54-3270-10)
TX-RX UNIT (X57-5963-09)