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Kenwood TK-7180 Service Manual

Kenwood TK-7180
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© 2005-1 PRINTED IN JAPAN
B51-8713-00
(
N
)
556
VHF FM TRANSCEIVER
TK-7180/7189
SERVICE MANUAL
TK-7180 E
TK-7189 E
This product uses Lead Free solder.
Panel assy
(A62-1094-23)
Modular jack
(E08-0877-05)
Key top
(K29-9349-01)
Cabinet
(A01-2194-11)
Panel assy
(A62-1095-03)
Modular jack
(E08-0877-05)
Key top
(K29-9313-01)
Cabinet
(A01-2194-11)

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Kenwood TK-7180 Specifications

General Specifications IconGeneral Specifications
frequency range136~174MHz
number of channelsMax. 512
channel spacing (wide)25, 30kHz
channel spacing (narrow)12.5, 15kHz
operating voltage13.6V DC ± 15%
Current Drain IconCurrent Drain
standby current drain0.4A
receive current drain1.0A
transmit current drain9.0A
Operating Environment IconOperating Environment
duty cycleTransmit : 20%
operating temperature range–22°F~+140°F (–30°C~+60°C)
frequency stability± 0.00025% (–22°F~+140°F)
Receiver IconReceiver
sensitivity (12dB SINAD) wide0.25µV
sensitivity (12dB SINAD) narrow0.28µV
selectivity wide80dB
Transmitter IconTransmitter
RF power output30 to 1W
spurious response70dB
microphone impedance600Ω
Weight and Dimensions IconWeight and Dimensions
antenna impedance50Ω
dimensions (W x H x D)6-5/16 x 1-3/4 x 6-3/16 in. (160 x 45 x 157 mm)
weight3.31lbs. (1.5kg)

Summary

General Installation Planning

Planning the Installation

Guidance on mounting radio and accessories, and cable routing.

Antenna Installation Considerations

Recommended locations for vehicle antenna mounting.

Radio Mounting Guidelines

Considerations for positioning the radio unit for access and cooling.

DC Power and Wiring Instructions

Instructions for connecting the DC power leads and wiring.

Control Station Installation Planning

Planning for control station radio location and antenna systems.

Service Information

System Setup Procedures

Transceiver Programming Requirements

Requirements and procedure for programming the transceiver.

Remote Kit Setup (KRK-10)

Setup guide for the KRK-10 remote kit.

Ignition Sense Cable Setup (KCT-46)

Setup guide for the KCT-46 ignition sense cable.

Radio Interface Cable Setup (KCT-40)

Setup guide for the KCT-40 radio interface cable.

GPS Receiver/Controller Setup (KGP-2A/2B)

Setup for GPS receiver and controller.

Mobile Data Terminal Setup (KDS-100)

Setup for the KDS-100 mobile data terminal.

Public Address/Horn Alert Setup (KAP-2)

Setup guide for the KAP-2 accessory.

Voice Guide & Storage Unit Setup (VGS-1)

Setup guide for the VGS-1 voice guide unit.

External Speaker Setup (KES-3/5)

Setup for KES-3 and KES-5 external speakers.

Keypad Microphone Setup (KMC-32/36)

Setup for KMC-32 and KMC-36 keypad microphones.

Realignment Procedures

Operating Modes Overview

Description of different operating modes for realignment.

Entering Operating Modes

Procedures for entering various operating modes.

Panel Test Mode Details

Details on entering and using Panel Test Mode.

Panel Tuning Mode Details

Details on entering and using Panel Tuning Mode.

PC Mode for Configuration

Using PC Mode for programming and tuning.

PC Mode Setup Preface

Introduction to PC Mode setup and requirements.

PC Mode Connection and Programming

PC Mode Connection Procedure

Steps to connect the transceiver for PC communication.

KPG-46 Cable Description

Description of the KPG-46 PC programming interface cable.

KPG-92D Software Description

Description of the KPG-92D programming software.

Firmware Programming Mode

Procedures for updating transceiver firmware.

Firmware Programming Preface

Preface on firmware programming capabilities.

Firmware Programming Connection

Connecting for firmware programming.

Firmware Programming Steps

Step-by-step guide for firmware programming.

Firmware Programming Functions

Functions and settings within firmware programming.

Clone Mode Procedure

Transferring settings between transceivers.

Clone Mode and Clock Adjustment

Clone Mode Password Entry

How to enter passwords for clone mode.

Firmware Version Information

Procedure to check firmware version.

Clock Adjustment Mode

Procedure for adjusting the clock.

Clock Adjustment Flowchart

Flowchart for clock adjustment steps.

Installation Procedures

Ignition Sense Cable Installation (KCT-46)

Installing the ignition sense cable for power control.

KCT-46 Cable Connection

Step-by-step connection of the KCT-46.

Radio Interface Cable Installation (KCT-40)

Connecting the KCT-40 for data/terminal interface.

KCT-40 Cable Connection

Step-by-step connection of the KCT-40.

Terminal Function Reference

Table detailing terminal functions for various connectors.

Accessory Installation

Horn Alert/P.A. Relay Unit Installation (KAP-2)

Installing the KAP-2 for horn alert/PA functions.

KAP-2 Unit Installation Steps

Step-by-step installation of the KAP-2 unit.

Control Head Remote Kit Installation (KRK-10)

KRK-10 Kit Installation

Installing the KRK-10 remote control kit.

Front Panel Removal

Procedure for removing the front panel.

Main Panel Installation

Installing the main panel of the KRK-10.

Rear Panel Installation

Installing the rear panel of the KRK-10.

Additional Accessory Installation

KRK-10 Panel Connection

Connecting KRK-10 panels with the cable.

Voice Guide & Storage Unit Installation (VGS-1)

Installing the VGS-1 unit for voice guidance.

VGS-1 Unit Installation Steps

Step-by-step installation of the VGS-1 unit.

External Speaker Installation

External Speaker Options (KES-3/5)

Connecting external speakers.

KES-3 Speaker Connection

Connecting the KES-3 external speaker.

KES-3 Connection Procedure

Procedure to connect KES-3 speaker.

KES-5 Speaker Installation

Installing and configuring the KES-5 external speaker.

KAP-2 Cable Connector Information

Pinout for the KAP-2 cable connector.

Internal Board Connections

Voice Scrambler Board Connection

Connecting the voice scrambler board.

ANI Board Connection

Connecting the ANI board.

GPS Receiver Installation

GPS Receiver Connection

Connecting the GPS receiver.

GPS Receiver Installation Steps

Step-by-step installation of the GPS receiver.

GPS Receiver and VGS-1 Installation

Installing GPS receiver and VGS-1 together.

Disassembly Precautions and Procedures

TX-RX PCB Disassembly Precautions

Precautions and steps for disassembling the TX-RX PCB.

Disassembly Precautions

General precautions before starting disassembly.

Disassembly and Reassembly Guide

TK-7180 Speaker Fixture Removal

Removing speaker hardware and holder for TK-7180.

TK-7189 Holder Removal

Removing the holder for TK-7189.

Reassembly Precautions

Precautions to follow when reassembling components.

TX-RX PCB Reassembly

Steps for reassembling the TX-RX PCB.

Audio IC Screw Securing Note

Note on securing the Audio IC with correct screws.

Installation and Reassembly Steps

Final Shield Case Installation

Procedure for installing the final shield case.

Power Supply Cable Installation

Procedure for installing the power supply cable.

Top Packing Installation

Procedure for installing the top packing.

D-Sub Cap Installation

Procedure for installing the D-sub cap for water resistance.

Reassembly of Unit Components

TK-7180 Holder and Fixture Installation

Installing the holder and speaker fixture for TK-7180.

TK-7189 Holder Installation

Installing the holder for TK-7189.

Packing Installation for Waterproofing

Procedure for installing the packing for waterproofing.

Circuit Description Overview

Transceiver Outline

Overview of the transceiver's features and capabilities.

Receiver Circuit Details

Description of the double conversion superheterodyne receiver.

Receiver Front-End Circuit

Details of the receiver's front-end circuitry.

Receiver First Mixer Stage

Description of the first mixer stage in the receiver.

Receiver IF Amplifier Stages

Description of the IF amplifier stages in the receiver.

Receiver Audio Amplifier Circuit

Description of the audio amplifier circuit.

Circuit Description: Receiver and Transmitter

Receiver Squelch Circuit

Description of the squelch circuit operation.

Transmitter Circuit Overview

Description of the transmitter's functional circuits.

Transmitter Microphone Circuit

Description of the microphone input and signal path.

Modulation Level Adjustment Circuit

Description of the modulation level adjustment circuit.

Drive and Final Power Amplifier

Description of the drive and final power amplifier stages.

Automatic Power Control Circuit

Description of the automatic power control circuit.

Circuit Description: Synthesizer and Control

Frequency Synthesizer Unit

Description of the frequency synthesizer unit.

Frequency Synthesizer Details

Details on the frequency synthesizer's components and operation.

Control Circuit Description

Description of the control circuit and CPU.

Circuit Description: Power Supply and Display

Power Supply Circuit Description

Description of the power supply circuit and its components.

Display Circuit Description

Description of the transceiver's display unit and controls.

Semiconductor Data Reference

Microprocessor IC404 Pinout

Pinout and function for the microprocessor IC404.

Microprocessor and Shift Register Data

Microprocessor IC902 Pinout

Pinout and function for the display unit microprocessor IC902.

Shift Register IC403 Pinout

Pinout and function for the shift register IC403.

Component Descriptions

Switch Unit (X41-3682-70) Components

List of components for the switch unit.

Display Unit (X54-348X-XX) Components

List of components for the display unit.

TX-RX Unit (X57-6982-71) Components

List of components for the TX-RX unit.

Parts List

General Parts List (TK-7180/7189)

General parts list for the TK-7180/7189.

Switch Unit Parts List (TK-7189)

Parts list for the TK-7189 switch unit.

Display Unit Parts List

Parts list for the display unit, covering TK-7180 and TK-7189.

Parts List Continuation

Display Unit Parts List (Continued)

Parts list for the display unit.

TX-RX Unit Parts List

Parts list for the TX-RX unit.

TX-RX Unit Parts List

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List Details

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List - Capacitors

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List - Resistors

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List - Resistors

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List - Resistors

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List - Diodes and ICs

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

TX-RX Unit Parts List - Transistors

TX-RX Unit Parts List (Continued)

Parts list for the TX-RX unit (continued).

Exploded View (TK-7180)

Exploded View (TK-7189)

Packing Instructions

Adjustment Procedures Overview

Transceiver Controls

Overview of the transceiver's controls.

Panel Test Mode Operation

Operation features and entry for Panel Test Mode.

Frequency and Signaling Reference

Table of frequencies and adjustment requirements.

Test Frequency List

List of test frequencies for alignment.

Adjustment Procedures: Signaling and Tuning

Test Signaling Procedures

Procedures for test signaling and parameter adjustments.

Panel Tuning Mode Preparation

Preparations and steps for transceiver tuning.

Transceiver Tuning Mode Entry

Guide to placing the transceiver in tuning mode.

Level Adjustment Reference Frequencies

Reference frequencies for level adjustments.

Adjustable Item Display Format

List of adjustable items and their display format.

Adjustment Flowchart

Adjustment Procedure Flowchart

Flowchart detailing the adjustment procedures.

Alignment Test Equipment and Accessories

Required Test Equipment List

List of required test equipment and major specifications.

Microphone Test Cable Details

Details and diagram for the microphone test cable.

VGS-1 Check Jig Information

Information about the VGS-1 check jig.

Common and Transmitter Adjustments

Common Section Adjustment Procedures

General adjustment procedures applicable to common settings.

Initial Setting Adjustments

Adjusting power supply voltage and modulation.

VCO Lock Voltage Adjustment

Adjusting VCO lock voltage in Panel Test Mode and Tuning Mode.

Transmitter Section Adjustments

Adjustments specific to the transmitter section.

Frequency Adjustment Procedure

Procedure to adjust the transceiver's frequency.

Frequency Shift 1 Adjustment

Procedure to adjust frequency shift 1.

Frequency Shift 2 Adjustment

Procedure to adjust frequency shift 2.

Max High Power Adjustment

Procedure to adjust maximum high power output.

Power and Deviation Adjustments

Max Low Power Adjustment

Procedure to adjust maximum low power output.

High Power Adjustment

Procedure to adjust high power output.

High Power Check

Checking high power output in Panel Test Mode.

Low Power Adjustment

Procedure to adjust low power output.

Low Power Check

Checking low power output in Panel Test Mode.

DQT Balance Adjustment

Adjusting DQT balance for different channel bandwidths.

Deviation and Sensitivity Adjustments

Max Deviation (DEV) Adjustment

Adjusting maximum deviation for different bandwidths.

Microphone Sensitivity Check

Checking microphone sensitivity in Panel Test Mode.

QT Deviation Adjustment

Adjusting QT deviation for different bandwidths.

DQT Deviation Adjustment

Adjusting DQT deviation for different bandwidths.

Deviation Adjustments: LTR, DTMF, MSK, TONE

LTR Deviation Adjustment

Adjusting LTR deviation for different bandwidths.

DTMF Deviation Adjustment

Adjusting DTMF deviation for different bandwidths.

MSK Deviation Adjustment

Adjusting MSK deviation for different bandwidths.

TONE Deviation Adjustment

Adjusting TONE deviation for different bandwidths.

Receiver Section Adjustments

Receiver Sensitivity Adjustment

Adjusting receiver sensitivity levels.

Receiver Sensitivity Check

Checking receiver sensitivity in Panel Test Mode.

Squelch (Preset) Adjustment

Adjusting squelch levels for different bandwidths.

RSSI and Squelch Adjustments

Low RSSI Adjustment

Adjusting low RSSI for different bandwidths.

Squelch (Tight) Adjustment

Adjusting tight squelch for different bandwidths.

High RSSI Adjustment and PCB Points

High RSSI Adjustment

Adjusting high RSSI for different bandwidths.

PCB Adjustment Points Diagram

Diagram showing adjustment points on PCBs.

Terminal Function Reference

Switch Unit Terminal Functions (TK-7189)

Terminal functions for the TK-7189 switch unit.

Display Unit Terminal Functions

Terminal functions for the display unit.

TX-RX Unit (A/3) Terminal Functions

Terminal functions for TX-RX unit A/3.

Terminal Function Details

TX-RX Unit (B/3) Terminal Functions

Terminal functions for TX-RX unit B/3.

Connector Terminal Functions

CN427 Connector Terminal Functions

Terminal functions for CN427 connector.

CN429 Connector Terminal Functions

Terminal functions for CN429 connector.

Terminal Function and Solder Land Reference

Solder Land Details for ANI Board

Solder land details for the ANI board.

PC Board Layouts

Switch Unit PCB Layout (TK-7189)

Component and foil side views of the TK-7189 switch unit PCB.

Switch Unit PCB Layout (TK-7189) Continued

Component and foil side views of the TK-7189 switch unit PCB (continued).

Display Unit PC Board Layouts

Display Unit PCB Layouts (TK-7180/7189)

Component and foil side views of the display unit PCB.

Display Unit PC Board Layouts

Display Unit PCB Layouts (Continued)

Component and foil side views of the display unit PCB (continued).

Display Unit PC Board Layouts

Display Unit PCB Layouts (Continued)

Component and foil side views of the display unit PCB (continued).

TX-RX Unit (A/3) PCB Layouts

TX-RX Unit (A/3) Component Side View

Component side view of the TX-RX unit (A/3) PCB.

TX-RX Unit (C/3) Component Side View

Component side view of the TX-RX unit (C/3) PCB.

TX-RX Unit (A/3 & C/3) PCB Layouts

TX-RX Unit (A/3) Foil Side View

Foil side view of the TX-RX unit (A/3) PCB.

TX-RX Unit (C/3) Foil Side View

Foil side view of the TX-RX unit (C/3) PCB.

TX-RX Unit (B/3) Component Side PCB Layout

TX-RX Unit (B/3) Component Side View

Component side view of the TX-RX unit (B/3) PCB.

TX-RX Unit (B/3) Component Side PCB Layout

TX-RX Unit (B/3) Component Side View (Continued)

Component side view of the TX-RX unit (B/3) PCB (continued).

TX-RX Unit (B/3) Foil Side PCB Layout

TX-RX Unit (B/3) Foil Side View

Foil side view of the TX-RX unit (B/3) PCB.

TX-RX Unit (B/3) Foil Side PCB Layout

TX-RX Unit (B/3) Foil Side View (Continued)

Foil side view of the TX-RX unit (B/3) PCB (continued).

TX-RX Unit (B/3) Foil Side PCB Layout

TX-RX Unit (B/3) Foil Side View (Continued)

Foil side view of the TX-RX unit (B/3) PCB (continued).

Schematic Diagrams

Switch Unit Schematic

Schematic diagram for the switch unit.

Display Unit Schematic

Schematic diagram for the display unit.

TX-RX Unit (B/3) Schematic

Schematic diagram for the TX-RX unit (B/3).

TX-RX Unit (B/3) Schematic Continued

Schematic diagram for the TX-RX unit (B/3) (continued).

TX-RX Unit (B/3) Schematic Continued

Schematic diagram for the TX-RX unit (B/3) (continued).

TX-RX Unit (C/3) Schematic

Schematic diagram for the TX-RX unit (C/3).

TX-RX Unit (B/3) Schematic Continued

Schematic diagram for the TX-RX unit (B/3) (continued).

TX-RX Unit (B/3) Schematic Continued

Schematic diagram for the TX-RX unit (B/3) (continued).

TX-RX Unit (B/3) Schematic Continued

Schematic diagram for the TX-RX unit (B/3) (continued).

TX-RX Unit (B/3) Schematic Continued

Schematic diagram for the TX-RX unit (B/3) (continued).

Interconnection Diagram

Block Diagrams

Level Diagrams

Receiver Section Signal Levels

Signal levels within the receiver section.

Transmitter Section Signal Levels

Signal levels within the transmitter section.

Optional Accessories: KRK-10

KRK-10 External View

External view of the KRK-10 kit.

KRK-10 Components Description

Description of KRK-10 components.

KRK-10 Parts List

Parts list for the KRK-10 kit.

KRK-10 Unit Parts List

Parts list for the KRK-10 unit.

KRK-10 Interface Unit Parts List

Parts list for the KRK-10 interface unit.

KRK-10 Exploded View and Packing

KRK-10 Exploded View and Packing

Exploded view and packing details for the KRK-10 kit.

KRK-10 Interface Unit PC Board Layouts

Interface Unit PCB Component Side View

Component side view of the KRK-10 interface unit PCB.

Interface Unit PCB Foil Side View

Foil side view of the KRK-10 interface unit PCB.

KRK-10 Interface Unit Schematic Diagrams

Interface Unit (A/2) Schematic

Schematic for the KRK-10 interface unit (A/2).

Interface Unit (B/2) Schematic

Schematic for the KRK-10 interface unit (B/2).

KRK-10 Terminal Functions

CN1 Connector Terminal Functions (Radio Side)

Terminal functions for CN1 connector (radio side).

CN3 Connector Terminal Functions (Radio Side)

Terminal functions for CN3 connector (radio side).

CN2 Connector Terminal Functions (Display Side)

Terminal functions for CN2 connector (display side).

CN4 Connector Terminal Functions (Display Side)

Terminal functions for CN4 connector (display side).

Optional Accessories Overview

KAP-2 (Horn Alert/P.A. Relay Unit) Overview

Overview of the KAP-2 accessory.

KCT-40 (Radio Interface Cable) Overview

Overview of the KCT-40 accessory.

KMC-35 (Microphone) Overview

Overview of the KMC-35 microphone.

KMC-36 (Keypad Microphone) Overview

Overview of the KMC-36 keypad microphone.

KCT-46 (Ignition Sense Cable) Overview

Overview of the KCT-46 accessory.

KRK-10 Exploded View and Packing

KRK-10 Exploded View and Packing

Exploded view and packing details for the KRK-10 kit.

KRK-10 Interface Unit PC Board Layouts

KRK-10 Interface Unit Component Side PCB

Component side view of the KRK-10 interface unit PCB.

KRK-10 Interface Unit Foil Side PCB

Foil side view of the KRK-10 interface unit PCB.

KRK-10 Interface Unit Schematic Diagrams

KRK-10 Interface Unit (A/2) Schematic

Schematic for the KRK-10 interface unit (A/2).

KRK-10 Interface Unit (B/2) Schematic

Schematic for the KRK-10 interface unit (B/2).

KRK-10 Terminal Functions

CN1 Terminal Functions (Radio Side)

Terminal functions for CN1 connector (radio side).

CN3 Terminal Functions (Radio Side)

Terminal functions for CN3 connector (radio side).

CN2 Terminal Functions (Display Side)

Terminal functions for CN2 connector (display side).

CN4 Terminal Functions (Display Side)

Terminal functions for CN4 connector (display side).

Specifications

General Specifications

General specifications of the transceiver.

Receiver Performance Specifications

Receiver performance specifications according to EN standard.

Transmitter Performance Specifications

Transmitter performance specifications according to EN standard.

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