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© 2000-1 PRINTED IN JAPAN
B51-8498-10 (N) 1268
UHF FM TRANSCEIVER
TK-860G/862G
SERVICE MANUAL
REVISED
Microphone
(T91-0597-15)
Cabinet (Upper)
(A01-2165-13)
Panel assy
(A62-0642-03)
Key top
(K29-5343-02)
Microphone
(T91-0597-15)
Cabinet (Upper)
(A01-2165-13)
Panel assy
(A62-0731-03)
Key top
(K29-5344-02)
TK-860G (K)
TK-862G (K)
Please use this manual in place of the service manual (preliminary version), B51-8498-00.
We have added the information on the circuit description, specifications, and K3 version specifications to the service
manual (preliminary version), B51-8498-00.


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2
TK-860G/862G
CONTENTS / GENERAL
GENERAL
INTRODUCTION
SCOPE OF THIS 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 in-
formation for the equipment and is current as of the publica-
tion data. 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.
PERSONNEL SAFETY
The following precautions are recommended for person-
nel safety :
· DO NOT transmit if someone is within two feet (0.6
meter) of the antenna.
· 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.
· All equipment should be properly grounded before
power-up for safe operation.
· This equipment should be serviced by a qualified techni-
cian only.
PRE-INSTALLATION CONSIDERNATIONS
1. UNPACKING
Unpack the radio from its shipping container and check
for accessory items. If any item is missing, please contact
KENWOOD immediately.
2. LICENSING REQUIREMENTS
Federal regulations require a station license for each ra-
dio installation (mobile or base) be obtained by the equip-
ment owner. The licensee is responsible for ensuring trans-
mitter power, frequency, and deviation are within the limits
permitted by the station license.
Transmitter adjustments may be performed only by a li-
censed technician holding an FCC first, second or general
class commercial radiotelephone operator's license. There
is no license required to install or operate the radio.
CONTENTS
GENERAL ................................................................. 2
SYSTEM SET-UP ..................................................... 4
OPERATING FEATURES ......................................... 5
REALIGNMENT ...................................................... 10
INSTALLATION ...................................................... 20
CIRCUIT DESCRIPTION ......................................... 24
SEMICONDUCTOR DATA ..................................... 29
DESCRIPTION OF COMPONENTS ....................... 31
PARTS LIST ............................................................ 33
EXPLODED VIEW .................................................. 42
PACKING ................................................................ 44
ADJUSTMENT ....................................................... 45
PC BOARD VIEWS
DISPLAY UNIT (X54-3270-10) : TK-860G ........ 54
DISPLAY UNIT (X54-3280-10) : TK-862G ........ 55
PLL/VCO (X58-4670-XX) .................................. 56
TX-RX UNIT (X57-5960-XX) (A/2) ................... 57
TX-RX UNIT (X57-5960-XX) (B/2) .................... 63
SCHEMATIC DIAGRAM ........................................ 67
BLOCK DIAGRAM .................................................. 75
LEVEL DIAGRAM ................................................... 78
TERMINAL FUNCTION ......................................... 80
SPECIFICATIONS ................................................... 81


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3
TK-860G/862G
1
3
+
­
7
6
13
15
5. INSTALLATION PLANNING ­ CONTROL STATIONS
5-1. Antenna system
Control station. The antenna system selection depends
on many factors and is beyond the scope of this manual.
Your KENWOOD dealer can help you select an antenna sys-
tem that will best serve your particular needs.
5-2. Radio location
Select a convenient location for your control station radio
which is as close as practical to the antenna cable entry
point. Secondly, use your system's power supply (which
supplies the voltage and current required for your system).
Make sure sufficient air can flow around the radio and power
supply to allow adequate cooling.
SERVICE
This radio is designed for easy servicing. Refer to the
schematic diagrams, printed circuit board views, and align-
ment procedures contained in this manual.
Note
When you modify your radio as described in system set-
up, take the following precaution.
The rating of pin 7 (SB) of the accessory connector cable
(KCT-19) on the rear of the radio is 13.6V (1A). Insert a 1A
fuse if you use the SB pin for external equipment.
Accessory connector
cable (KCT-19)
If you do not intend to use the 3.5-mm jack for the exter-
nal speaker, fit the supplied speaker-jack cap (B09-0235-05)
to stop dust and sand getting in.
Speaker-jack cap
(B09-0235-05)
3. PRE-INSTALLATION CHECKOUT
3-1. Introduction
Each radio is adjusted and tested before shipment. How-
ever, it is recommended that receiver and transmitter opera-
tion be checked for proper operation before installation.
3-2. Testing
The radio should be tested complete with all cabling and
accessories as they will be connected in the final installa-
tion. Transmitter frequency, deviation, and power output
should be checked, as should receiver sensitivity, squelch
operation, and audio output. QT equipment operation
should be verified.
4. PLANNING THE INSTALLATION
4-1. General
Inspect the vehicle and determine how and where the
radio antenna and accessories will be mounted.
Plan cable runs for protection against pinching or crush-
ing wiring, and radio installation to prevent overheating.
4-2. Antenna
The favored location for an antenna is in the center of a
large, flat conductive area, usually at the roof center. The
trunk lid is preferred, bond the trunk lid and vehicle chassis
using ground straps to ensure the lid is at chassis ground.
4-3. Radio
The universal mount bracket allows the radio to be
mounted in a variety of ways. Be sure the mounting surface
is adequate to support the radio's weight. Allow sufficient
space around the radio for air cooling. Position the radio
close enough to the vehicle operator to permit easy access
to the controls when driving.
4-4. DC Power and wiring
1. This radio may be installed in negative ground electrical
systems only. Reverse polarity will cause the cable fuse
to blow. Check the vehicle ground polarity before installa-
tion to prevent wasted time and effort.
2. Connect the positive power lead directly to the vehicle
battery positive terminal. Connecting the Positive lead to
any other positive voltage source in the vehicle is not rec-
ommended.
CAUTION
If DC power is to be controlled by the vehicle ignition
switch, a switching relay should be used to switch the posi-
tive power lead. The vehicle ignition switch then controls
DC to the relay coil.
3. Connect the ground lead directly to the battery negative
terminal.
4. The cable provided with the radio is sufficient to handle
the maximum radio current demand. If the cable must be
extended, be sure the additional wire is sufficient for the
current to be carried and length of the added lead.
GENERAL


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4
TK-860G/862G
SYSTEM SET-UP
Merchandise received
License and frequency allocated by FCC
Choose the type of transceiver
Are you using the public address?
Are you using the external speaker?
Are you using ignition sense cable?
Delivery
Are you using the KGP-1A Modem GPS receiver
or the KGP-1B Modem GPS controller?
Transceiver programming (Option)
8ch models
TK-862G
128ch models
TK-860G
Frequency range (MHz)
450~490
400~430
RF power
25W
25W
Type
K,M
K3
KAP-1
PA/HA unit
KCT-20
Connection cable
KES-3
External speaker
KCT-19
Accessory connector cable
KCT-18
Ignition sense cable
Frequency range (MHz)
450~490
RF power
25W
Type
K
See page 11.
A personal computer (IBM PC or compatible), programming interface (KPG-22),
and programming software (KPG-56D) are required for programming.
(The frequency and signalling (option) data are programmed for the transceiver.)
(Option)
(Option)
(Option)
(Option)
(Option)
See page 22.
Installation the TX-RX unit when used KAP-1.
YES
YES
YES
YES
NO
NO
NO
NO
See page 21.
See page 20.
See page 23.
See the KCT-20 instruction manual
(B62-0733-11).
* : You can install either KCT-19 or KCT-20 to the
TK-860G/862G transceiver
*
*


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5
TK-860G/862G
1. Controls and Functions
1-1. TK-860G Front Panel
IO (Power) switch
Press to switch the transceiver ON (or OFF).
LED indicator
Lights red while transmitting. Lights green while receiv-
ing. Flashes orange while receiving a Code Squelch or
Selective Call code, or a 2-Tone code that matches the
one set up in your transceiver.
/
keys
These are PF (Programmable Function) keys. Press each
key to activate its auxiliary function. The default settings
are Volume Up and Volume Down.
Display
See right.
/
keys
These are PF (Programmable Function) keys. Press each
key to activate its auxiliary function. The default settings
are Channel Up and Channel Down.
Microphone jack
Insert the microphone plug into this connector.
MON, A, D/A,
,
, and SCN keys (TK-860G)
MON, ,
, and A keys (TK-862G)
These are PF (Programmable Function) keys. Press each
key to activate its auxiliary function.
PTT (Push-to-Talk) switch
Press this switch, then speak into the microphone to call
a station.
1
2
3
4
5
7
6
8
1
2
3
4
5
7
6
1-2. TK-862G Front Panel
1-3. Microphone
1
2
3
4
5
6
7
8
1-4. Display
s TK-860G
Indicator
Description
Appears while using SmarTrunk.
Appears when the selected channel
in busy.
Appears when QT, DQT, DTMF, or
2-Tone decoding is deactivated (by
pressing the Monitor key).
Appears when you receive a Code
Squelch, Selective Call, 2-Tone code.
Also appears when you transmit
using Code Squelch or Selective Call.
Appears while scanning.
Appears when the AUX port is
activated.
Appears when the selected channel
is included in the scanning sequence.
Displays the selected channel
number (or name), DTMF digits
(when entering digits, confirming
digits, or making a call), and mes-
sages received via Selective Call.
s TK-862G
Indicator
Description
Appears when QT, DQT, DTMF, or
2-Tone decoding is deactivated (by
pressing the Monitor key).
Appears when the AUX port is
activated.
Displays the selected channel
number.
OPERATING FEATURES