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Kenwood TK-5810 User Manual

Kenwood TK-5810
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This product uses Lead Free solder.
This product complies with the
RoHS
directive for the European market.
© 2010-3 PRINTED IN JA PAN
B51-8913-00
(
N
)
TK-5810
(
BG
)
TK-5810H
(
BG
)
SERVICE MANUAL
UHF P25 TRANSCEIVER
TK-5810(BG) with KCH-14
TK-5810H(BG)
Use this service manual together with the KCH-14/15 service
manual (B51-8728-00) or KCH-16 service manual (B51-8834-00).
As for the hardware of this transceiver, version 3 is used.
The programming software must use KPG-95DG.
GRP
VOL
CH
POWER
TX
BUSY
Metallic cabinet (Top)
(A01-2161-32)
Metallic cabinet (Top)
(A01-2163-21)
Metallic cabinet (Bottom)
(A01-2164-31)
KCH-14
(Front panel kit)

Questions and Answers:

Kenwood TK-5810 Specifications

General IconGeneral
Channel Capacity128 channels
Weight300 g
Channel Spacing12.5 / 25 kHz
Power Output5 W
Modulation16K0F3E, 11K0F3E
Frequency Range136-174 MHz

Summary

GENERAL

PERSONAL SAFETY

Recommended precautions for user safety during operation and service.

PRE-INSTALLATION CONSIDERATIONS

Steps and checks to perform before installing the transceiver.

PLANNING THE INSTALLATION

Considerations for mounting the radio and routing cables.

SERVICE

Notes on servicing the transceiver using manual diagrams and procedures.

SYSTEM SET-UP

REALIGNMENT

MODES

Describes the various operating and test modes of the transceiver.

ENTERING MODES

Instructions on how to access different operational modes.

PANEL TEST MODE

Details on how to use the panel test mode for diagnostics.

PANEL TUNING MODE

Explains the procedure for tuning the transceiver via the panel.

PC MODE

Covers communication and programming using a PC.

CONNECTION PROCEDURE

Steps for connecting the transceiver to a computer for programming.

PROGRAMMING INTERFACE CABLES

Description of KPG-43/43A and KCT-53U cables.

PROGRAMMING SOFTWARE

Overview of the KPG-95DG programming software.

PC TUNING MODE

Details on making adjustments using PC tuning mode.

FIRMWARE PROGRAMMING MODE

Procedure for updating transceiver firmware.

FIRMWARE VERSION INFORMATION

Instructions on how to check the firmware version.

CLOCK ADJUSTMENT MODE

Procedure for adjusting the transceiver's clock and date.

TRANSCEIVER INFORMATION MODE

How to view transceiver information.

CLONE MODE

Explains data transfer between transceivers.

SELF PROGRAMMING MODE

Details on programming via FPU.

SETUP ITEMS FOR SELF PROGRAMMING

Lists programmable items for self-programming.

KEY OPERATION

Describes key functions in different modes.

SELF PROGRAMMING MODE FLOW CHART

Visual guide for self programming steps.

INSTALLATION

FRONT PANEL KIT (KCH-14/15: OPTION)

Covers installation of KCH-14/15 front panel kits.

INSTALLING THE FRONT PANEL KIT

Step-by-step guide for mounting the KCH-14/15 panel.

INSTALLING ACCESSORY KEYTOPS

Describes keytop installation for customization.

REMOTE KIT (KRK-5: OPTION)

Covers installation of KRK-5 remote control kit.

INSTALLING THE KRK-5 MAIN PANEL

Step-by-step guide for mounting the KRK-5 main panel.

INSTALLING KRK-5 REAR PANEL

Guide for attaching the rear panel to the front kit.

CONTROL CABLE CONNECTION

Instructions for connecting the KCT-22 cable.

DISPLAY INSTALLATION

Steps for installing the display unit with bracket.

DUAL CONTROL HEAD REMOTE KIT (KRK-6DH: OPTION)

Covers installation of KRK-6DH dual control system.

INSTALLING KRK-6DH MAIN PANEL

Guide for mounting the main panel of the dual control kit.

INSTALLING KRK-6DH REAR PANELS

Instructions for attaching rear panels to front kits.

CONTROL CABLE CONNECTION

Steps for connecting KCT-22 cables for dual displays.

IGNITION SENSE CABLE (KCT-18: OPTION)

Optional cable for ignition and timed power-off functions.

CONNECTING KCT-18 TO TRANSCEIVER

Steps to connect the ignition sense cable to the transceiver.

CONNECTING KCT-18 TO REMOTE KIT

Instructions for connecting the cable to KRK-5/6DH kits.

VOICE GUIDE & STORAGE UNIT (VGS-1: OPTION)

Details installation of the VGS-1 unit.

INSTALLING VGS-1 UNIT

Step-by-step guide for installing the VGS-1 unit.

EXTERNAL SPEAKER (KES-5: OPTION)

Information on using an external speaker.

CONNECTING KES-5 EXTERNAL SPEAKER

Instructions for connecting the KES-5 speaker.

CONNECTING KES-5 SPEAKER TO REMOTE KIT

Guide for connecting speaker to KRK-5/6DH kits.

MODIFYING AUDIO OUTPUT

Steps to increase control head audio output.

USE AS PUBLIC ADDRESS SPEAKER

Instructions for using the transceiver for public address.

HORN ALERT FUNCTION

Details the horn alert function and modification.

HANDHELD CONTROL HEAD (KCH-16: OPTION)

Information about the KCH-16 handheld control head.

DISASSEMBLY FOR REPAIR

DISASSEMBLY PROCEDURE (TK-5810(BG))

Steps to disassemble the TK-5810(BG) model.

REMOVING CASE AND SHIELDING COVER

Instructions for removing the outer case components.

REMOVING TX-RX UNIT

Steps to remove the TX-RX unit.

REMOVING FINAL UNIT

Guide for disassembling the final unit.

DISASSEMBLY FOR REPAIR

DISASSEMBLY PROCEDURE (TK-5810H(BG))

Steps to disassemble the TK-5810H(BG) model.

REMOVING CASE AND SHIELDING COVER

Instructions for removing outer case components.

REMOVING TX-RX UNIT

Steps to remove the TX-RX unit.

REMOVING FINAL UNIT

Guide for disassembling the final unit.

DISASSEMBLY FOR REPAIR

REMOVING CONTROL UNIT

Instructions for removing the control unit.

REMOVING ACCESSORY AND POWER CABLES

Steps to disconnect cables.

REASSEMBLY PRECAUTIONS

Important notes for reassembling the unit.

DISASSEMBLY FOR REPAIR

CABLE ALIGNMENT (W2 TERMINAL)

Cable connection alignment for TK-5810H(BG).

CASE PACKING INSTALLATION CHECK

Verifying case packing fit.

SCREW TIGHTENING SEQUENCE

Recommended order for tightening case screws.

CIRCUIT DESCRIPTION

OVERVIEW

General overview of the transceiver's function and range.

FREQUENCY CONFIGURATION

Explains frequency mixing and conversion.

RECEIVER SYSTEM

Details the receiver circuitry stages.

FRONT-END RF AMPLIFIER

Description of the RF amplifier circuit.

1ST LOCAL

Explanation of the first local oscillator stage.

CIRCUIT DESCRIPTION

1ST IF STAGE

Describes the first IF signal processing path.

2ND LOCAL OSCILLATOR

Details the second local oscillator circuit.

2ND IF STAGE

Explains the second IF signal processing.

CIRCUIT DESCRIPTION

AUDIO AMPLIFIER CIRCUIT

Explains audio signal processing and amplification.

SQUELCH CIRCUIT

Details the squelch circuit operation.

TRANSMITTER SYSTEM

Overview of the transmitter circuitry.

AUDIO BAND CIRCUIT

Describes the audio path for the transmitter.

CIRCUIT DESCRIPTION

BASE BAND CIRCUIT

Explains baseband signal processing for FM and P25 modes.

DRIVE AMPLIFIER CIRCUIT

Describes the drive amplifier stage.

FINAL AMPLIFIER CIRCUIT (TK-5810(BG))

Details the final amplifier for the TK-5810(BG).

FINAL AMPLIFIER CIRCUIT (TK-5810H(BG))

Details the final amplifier for the TK-5810H(BG).

CIRCUIT DESCRIPTION

AUTOMATIC POWER CONTROL (APC) CIRCUIT

Explains APC circuit for power stabilization.

TEMPERATURE PROTECTION CIRCUIT (TK-5810(BG))

Details thermal protection for TK-5810(BG).

TEMPERATURE PROTECTION CIRCUIT (TK-5810H(BG))

Details thermal protection for TK-5810H(BG).

PLL FREQUENCY SYNTHESIZER

Overview of PLL components.

VCXO (X400)

Description of the Voltage Controlled Crystal Oscillator.

VCO

Description of Voltage Controlled Oscillators.

CIRCUIT DESCRIPTION

POTENTIOMETER IC (IC401)

Details the function of the potentiometer IC.

LOCKUP ACCELERATOR

Explains the circuit for VCO frequency convergence.

PLL IC (IC400)

Describes the Phase Locked Loop IC.

LOCAL SWITCH (D419, D420)

Explains the function of the local switches.

CIRCUIT DESCRIPTION

CONTROL CIRCUIT

Explains the control circuit functions.

ASIC

Details the ASIC processor functions.

MEMORY CIRCUIT

Describes flash memory, SRAM, and RTC.

FLASH MEMORY

Details of flash memory contents and usage.

SRAM (STATIC MEMORY)

Details of SRAM usage and backup.

REAL-TIME CLOCK

Details of the real-time clock functionality.

DISPLAY UNIT

Overview of the display unit components.

TEMPERATURE DETECTION CIRCUIT

Explains temperature monitoring and correction.

DSP

Details the Digital Signal Processor functions.

POWER SUPPLY CIRCUIT

Describes the power supply system.

COMPONENTS DESCRIPTION

FINAL UNIT COMPONENTS (TK-5810(BG))

Lists components for the TK-5810(BG) final unit.

FINAL UNIT COMPONENTS (TK-5810H(BG))

Lists components for the TK-5810H(BG) final unit.

CONTROL UNIT COMPONENTS

Lists components for the control unit.

COMPONENTS DESCRIPTION

TX-RX UNIT COMPONENTS (X57-7270-XX)

Lists components for the TX-RX unit.

PARTS LIST

CAPACITORS

Details capacitor types, sizes, and values.

RESISTORS

Details resistor types, sizes, and power ratings.

PARTS LIST

FINAL UNIT PARTS (TK-5810(BG))

Lists components for the final unit, including cabinets and chassis.

PARTS LIST

FINAL UNIT PARTS (TK-5810H(BG))

Lists components for the TK-5810H(BG) final unit.

PARTS LIST

CONTROL UNIT PARTS (X53-4400-10)

Lists components for the control unit.

PARTS LIST

TX-RX UNIT PARTS (X57-7270-XX)

Lists components for the TX-RX unit.

PARTS LIST

TX-RX UNIT PARTS (X57-7270-XX)

Lists components for the TX-RX unit.

EXPLODED VIEW (TK-5810(BG))

EXPLODED VIEW (TK-5810H(BG))

PACKING (TK-5810(BG))

PACKING (TK-5810H(BG))

TROUBLE SHOOTING

OVERVIEW

Introduction to troubleshooting flowchart.

BGA PARTS IDENTIFICATION

Lists critical BGA components for diagnosis.

DIAGNOSIS CHECKLIST

Steps for checking voltage, clock, and signals.

IDENTIFYING ABNORMAL POINTS

Guides on pinpointing faulty components.

TROUBLE SHOOTING

ASIC SOFTWARE CONTROL OUTPUT CHECK

Verifying ASIC output signals.

PANEL CONTROL DIAGNOSIS

Troubleshooting panel controls for unit and KCH.

CLOCK AND CONTROL SIGNAL CHECKS

Checking clock and control signals.

LCD ERROR DISPLAYS

Troubleshooting specific LCD error messages.

REPLACING CONTROL UNIT

Guidance on replacing the control unit.

ADJUSTMENT

CONTROL LAYOUTS

Overview of KCH-14 and KCH-15 panel controls.

PANEL TEST MODE

Explains how to enter and use panel test mode.

KEY OPERATION

Describes key functions in different modes.

ADJUSTMENT

INDICATORS AND DISPLAYS

Explanation of LED indicators and LCD in test mode.

FILTER MODES

Details available filter modes.

FREQUENCY AND SIGNALING TESTS

Lists test frequencies and signaling parameters.

ADJUSTMENT

PANEL TUNING MODE

Procedures for panel tuning.

TUNING PREPARATIONS

Setup required before transceiver tuning.

ENTERING TUNING MODE

Steps to access tuning mode.

PANEL TUNING MODE LCD DISPLAY

Description of the LCD during tuning.

PANEL TUNING MODE KEY OPERATIONS

Key functions for tuning adjustments.

FREQUENCY REFERENCE LEVEL ADJUSTMENTS

Adjusting frequency reference levels.

ASSIST VOLTAGE ADJUSTMENTS

Adjusting assist voltages.

OTHER ADJUSTMENT ITEMS

Other tuning parameters.

ADJUSTMENT

ADJUSTABLE ITEMS AND DISPLAY

Lists all adjustable parameters and their display codes.

ADJUSTMENT

ADJUSTMENT FLOW CHARTS

Visual guides for performing various adjustments.

ADJUSTMENT

BIT ERROR RATE (BER) MEASUREMENT

Steps to measure BER using panel test mode.

C4FM (P25) DEVIATION ADJUSTMENT

Procedure for adjusting C4FM deviation.

ADJUSTMENT

TEST EQUIPMENT REQUIRED FOR ALIGNMENT

Lists essential test equipment for calibration.

CONNECTOR AND CABLE DESCRIPTIONS

Details MIC connector, input, and output cables.

ADJUSTMENT

COMMON ADJUSTMENT ITEMS

General calibration procedures.

SETTING (DC VOLTAGE & MODULATION)

Setup for DC voltage and SSG modulation.

TRANSMIT ASSIST VOLTAGE ADJUSTMENT

Procedure for adjusting transmit assist voltage.

RECEIVE ASSIST VOLTAGE ADJUSTMENT

Steps for adjusting lower and upper RX assist voltages.

ADJUSTMENT

MCF (WIDE) ADJUSTMENT

Coil adjustment for wide band MCF.

2ND LOCAL ADJUSTMENT

Adjusting the second local oscillator frequency.

QUADRATURE COIL ADJUSTMENT

Adjusting the quadrature coil.

RTC OSCILLATION ADJUSTMENT

Adjusting the transceiver's internal clock.

ADJUSTMENT

FREQUENCY ADJUSTMENT

Steps for adjusting transmit frequency.

TRANSMITTER SECTION ADJUSTMENTS

Covers transmitter calibration.

FREQUENCY CHECK

Verifying operational frequencies.

MAXIMUM TRANSMIT POWER ADJUSTMENT

Adjusting maximum output power.

HIGH TRANSMIT POWER ADJUSTMENT

Adjusting high power output.

LOW TRANSMIT POWER ADJUSTMENT

Adjusting low power output.

ADJUSTMENT

BALANCE ADJUSTMENT

Procedure for adjusting signal balance.

MAXIMUM DEVIATION ADJUSTMENT

Adjusting maximum deviation for wide and narrow modes.

P25 HIGH DEVIATION ADJUSTMENT

Adjusting high deviation for P25 mode.

ADJUSTMENT

MIC SENSITIVITY CHECK

Procedure for adjusting MIC sensitivity.

QT FINE DEVIATION ADJUSTMENT

Adjusting QT fine deviation for wide and narrow.

DQT FINE DEVIATION ADJUSTMENT

Adjusting DQT fine deviation for wide and narrow.

ADJUSTMENT

DTMF DEVIATION ADJUSTMENT

Adjusting DTMF deviation for wide and narrow.

SINGLE TONE DEVIATION ADJUSTMENT

Adjusting single tone deviation for wide and narrow.

MSK DEVIATION ADJUSTMENT

Adjusting MSK deviation for wide.

ADJUSTMENT

MSK DEVIATION ADJUSTMENT (NARROW)

Continues MSK deviation adjustment for narrow.

NECESSARY DEVIATION ADJUSTMENT ITEMS

Table detailing deviation adjustments by mode.

RECEIVER SECTION ADJUSTMENTS

Calibration steps for the receiver section.

RX FRONT END WRITE

Procedure for adjusting RX front end.

ADJUSTMENT

AF LEVEL SETTING

Procedure to set audio frequency level.

SENSITIVITY CHECK

Steps to check receiver sensitivity.

SQUELCH OPEN ADJUSTMENT

Adjusting squelch open level for wide and narrow.

ADJUSTMENT

SQUELCH OPEN ADJUSTMENT (P25)

Continues squelch open adjustment for P25.

SQUELCH TIGHT ADJUSTMENT

Adjusting squelch tight level for wide and narrow.

RSSI REFERENCE ADJUSTMENT

Adjusting RSSI reference for wide and narrow.

ADJUSTMENT

RSSI REFERENCE ADJUSTMENT (P25)

Continues RSSI reference adjustment for P25.

RSSI (–120dBm) ADJUSTMENT

Adjusting RSSI for –120dBm across modes.

RSSI (–70dBm) ADJUSTMENT

Adjusting RSSI for –70dBm across modes.

ADJUSTMENT

RSSI (–70dBm) ADJUSTMENT (P25)

Continues RSSI adjustment for P25.

RADIO CHECK SECTION

Procedures for verifying radio performance.

FREQUENCY CHECK

Verifying operational frequencies.

HIGH POWER CHECK

Measuring high transmit power.

LOW POWER CHECK

Measuring low transmit power.

ADJUSTMENT

SENSITIVITY CHECK

Steps to check receiver sensitivity.

ADJUSTMENT POINTS

Locations on PC boards for specific adjustments.

TERMINAL FUNCTION

FINAL UNIT TERMINALS (TK-5810(BG))

Pinout and function for TK-5810(BG) final unit.

FINAL UNIT TERMINALS (TK-5810H(BG))

Pinout and function for TK-5810H(BG) final unit.

CONTROL UNIT TERMINALS

Pinout and function for the control unit.

TERMINAL FUNCTION

CONTROL UNIT TERMINALS (Continued)

Pinouts for CN444, CN457, and CN459.

TERMINAL FUNCTION

CONNECTOR TERMINALS (CN501, CN502, CN503, CN504)

Pinouts for various connectors including TX-RX, ACC, KRK, and Display units.

TERMINAL FUNCTION

TX-RX UNIT TERMINALS

Pinout and function for the TX-RX unit.

D-SUB 25PIN CONNECTOR

Pinout and function for the D-SUB connector.

TERMINAL FUNCTION

ACCESSORY 9-PIN CONNECTOR

Pinout and function for the 9-pin accessory connector.

ACCESSORY 12-PIN CONNECTOR (HEAD)

Pinout and function for the 12-pin head accessory connector.

PC BOARD

FINAL UNIT PC BOARD (TK-5810(BG))

Component and foil side views of the TK-5810(BG) final unit.

PC BOARD

FINAL UNIT PC BOARD (TK-5810(BG))

Component and foil side views of the TK-5810(BG) final unit.

PC BOARD

FINAL UNIT PC BOARD (TK-5810H(BG))

Component side view of the TK-5810H(BG) final unit.

PC BOARD

FINAL UNIT PC BOARD (TK-5810H(BG))

Foil side view of the TK-5810H(BG) final unit.

PC BOARD

FINAL UNIT PC BOARD (TK-5810H(BG))

Foil side view of the TK-5810H(BG) final unit.

PC BOARD

FINAL UNIT PC BOARD (TK-5810H(BG))

Foil side view of the TK-5810H(BG) final unit.

PC BOARD

CONTROL UNIT PC BOARD

Component side view of the Control Unit PC Board.

PC BOARD

CONTROL UNIT PC BOARD

Component side view of the Control Unit PC Board.

PC BOARD

CONTROL UNIT PC BOARD

Foil side view of the Control Unit PC Board.

PC BOARD

CONTROL UNIT PC BOARD

Foil side view of the Control Unit PC Board.

PC BOARD

TX-RX UNIT PC BOARD

Component side view of the TX-RX Unit PC Board.

PC BOARD

TX-RX UNIT PC BOARD

Foil side view of the TX-RX Unit PC Board.

PC BOARD

TX-RX UNIT PC BOARD

Foil side view of the TX-RX Unit PC Board.

PC BOARD

TX-RX UNIT PC BOARD

Foil side view of the TX-RX Unit PC Board.

INTERCONNECTION DIAGRAM

SCHEMATIC DIAGRAM

FINAL UNIT SCHEMATIC

Circuit diagram for the final unit.

SCHEMATIC DIAGRAM

FINAL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the final unit.

SCHEMATIC DIAGRAM

FINAL UNIT SCHEMATIC (TK-5810H(BG))

Circuit diagram for the TK-5810H(BG) final unit.

SCHEMATIC DIAGRAM

FINAL UNIT SCHEMATIC (TK-5810H(BG)) (Continued)

Continuation of the circuit diagram for the TK-5810H(BG) final unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC

Circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

CONTROL UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the control unit.

SCHEMATIC DIAGRAM

TX-RX UNIT SCHEMATIC

Circuit diagram for the TX-RX unit.

SCHEMATIC DIAGRAM

TX-RX UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the TX-RX unit.

SCHEMATIC DIAGRAM

TX-RX UNIT SCHEMATIC (Continued)

Continuation of the circuit diagram for the TX-RX unit.

BLOCK DIAGRAM

BLOCK DIAGRAM (TK-5810(BG))

BLOCK DIAGRAM (TK-5810H(BG))

LEVEL DIAGRAM

SPECIFICATIONS

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