Kenwood TK-7160 Service Manual
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Kenwood TK-7160 Service Manual

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VHF FM TRANSCEIVER
TK-7160/7162
SERVICE MANUAL
TK-7160 E
Modular jack
(E08-0877-05)
TK-7162 E
Modular jack
(E08-0877-05)
GENERAL .................................................. 2
SYSTEM SET-UP ...................................... 3
OPERATING FEATURES .......................... 4
REALIGNMENT ......................................... 6
DISASSEMBLY FOR REPAIR ................. 10
CIRCUIT DESCRIPTION .......................... 11
SEMICONDUCTOR DATA ...................... 16
COMPONENTS DESCRIPTION .............. 17
PARTS LIST ............................................. 18
EXPLODED VIEW .................................... 26
PACKING ................................................. 27
Key top
Panel assy
(K29-9342-01)
(A62-1107-13)
Key top
Panel assy
(K29-9342-01)
(A62-1108-03)
CONTENTS
ADJUSTMENT ........................................ 28
TERMINAL FUNCTION ........................... 33
TX-RX UNIT (X57-7102-70) ................ 38
SCHEMATIC DIAGRAM .......................... 42
BLOCK DIAGRAM ................................... 48
LEVEL DIAGRAM .................................... 50
SPECIFICATION ................... BACK COVER
© 2005-7 PRINTED IN JAPAN
B51-8722-00 ( N ) 375
This product uses Lead Free solder.

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  • Page 1: Table Of Contents

    VHF FM TRANSCEIVER TK-7160/7162 SERVICE MANUAL © 2005-7 PRINTED IN JAPAN B51-8722-00 ( N ) 375 TK-7160 E Modular jack Key top Panel assy (E08-0877-05) (K29-9342-01) (A62-1107-13) TK-7162 E Modular jack Key top Panel assy (E08-0877-05) (K29-9342-01) (A62-1108-03) CONTENTS ADJUSTMENT ........28 GENERAL ..........

  • Page 2: General

    Control station. The antenna system selection depends on many factors and is beyond the scope of this manual. Your 2. PRE-INSTALLATION CHECKOUT KENWOOD dealer can help you select an antenna system 2-1. Introduction that will best serve your particular needs.

  • Page 3: System Set-Up

    TK-7160/7162 GENERAL / SYSTEM SET-UP SERVICE NOTE This radio is designed for easy servicing. Refer to the If you do not intend to use the 3.5-mm jack for the external schematic diagrams, printed circuit board views, and align- speaker, fit the supplied speaker-jack cap to stop dust and ment procedures contained in this manual.

  • Page 4: Operating Features

    TK-7160/7162 OPERATING FEATURES 1-3. Display (TK-7160) 1. Controls and Functions 1-1. Front Panel Indicator Description Appears when the key programmed as Monitor or Squelch Off is pressed. Appears when the DTMF code of a call 1-2. Microphone matches the code in your transceiver.
  • Page 5 Direct Zone-Channel, Display Character, LCD Brightness, Operator Selectable Tone, Selcall, Selcall (5-tone), Selcall + Status, Send the GPS data, and Status are available only on TK-7160 transceivers. 2 Direct CH is available only on TK-7162 transceivers. 3 Direct CH and Direct Zone-Channel can be programmed...

  • Page 6: Realignment

    1. Turn the master transceiver power ON with the [ ] key The programming software can be used with an IBM PC held down (2 seconds), “CLONE” (TK-7160) or “C” (TK- or compatible. Figure 1 shows the setup of an IBM PC for 7162) is displayed on the LCD.

  • Page 7: Self Programming Mode

    “Self- Programming” disabled mode. Radios CANNOT be 1. [ ]+Power ON. delivered to the end-user in the self-programming mode. 2. “CLN LOCK” (TK-7160) or “P” (TK-7162) is displayed on the LCD. 5-1. Enter to the Self Programming Mode 3. If the [ ] and [ ] keys is pressed while “CLN LOCK”...
  • Page 8 TK-7160/7162 REALIGNMENT ■ Item Selection Mode ■ Item Setting Mode Display [ ] + Power on Display Current → Self programming mode SE L F 1. RX frequency 1 3 6 0 0 0 0 0 setting value Value is not set –...
  • Page 9 TK-7160/7162 REALIGNMENT 3. Insert the KCT-39 cable ( ) into the chassis ( ). The 6. Accessory Connection Cable (KCT-39) wire harness band ( ) must be inside the chassis and The KCT-39 is an accessory connection cable for connect- face down.

  • Page 10: Disassembly For Repair

    TK-7160/7162 REALIGNMENT / DISASSEMBLY FOR REPAIR 1. When you remove the panel, turn the transceiver up side 7. Ignition Sense Cable (KCT-18) down. Detach the panel by lifting the tabs as shown be- The KCT-18 is an optional cable for enabling the ignition low.

  • Page 11: Circuit Description

    TK-7160/7162 CIRCUIT DESCRIPTION ■ IF Amplifier Circuit Frequency Configuration The first IF signal is amplified by Q351, and the enters The receiver utilizes double conversion. The first IF is IC321 (FM processing IC). The signal is heterodyned again 49.95MHz and the second IF is 450kHz. The first local oscil- with a second local oscillator signal within IC321 to create a lator signal is supplied from the PLL circuit.
  • Page 12 TK-7160/7162 CIRCUIT DESCRIPTION ■ Wide/Narrow Switching Circuit ■ Squelch Circuit The Wide port (pin 23) and Narrow port (pin 22) of the CPU The detection output from the FM IF IC (IC321) passes is used to switch between ceramic filters. When the Wide through a noise amplifier (Q301) to detect noise.
  • Page 13 TK-7160/7162 CIRCUIT DESCRIPTION ■ Unlock Circuit Transmitter System During reception, the 8RC signal goes high, the 8TC signal ■ Outline goes low, and Q44 turns on. Q43 turns on and a voltage is The transmitter circuit produces and amplifies the desired applied to the collector (8R).
  • Page 14 CIRCUIT DESCRIPTION ■ Key Matrix Circuit Control Circuit The TK-7160/7162 front panel has function keys. the TK- The CPU carries out the following tasks: 7162 terminal name are parenthese inside. Each of them is 1) Controls the WIDE, NARROW, TX/RX outputs.
  • Page 15 TK-7160/7162 CIRCUIT DESCRIPTION • MSK TCXO IC241 LSDO X401 IC401 The MSK input signal from the IF IC goes to pin 5 of IC241. AQUA TCXO QT/DQT The signal is demodulated by MSK demodulator in IC241. The demodulated data goes to the CPU for processing.

  • Page 16: Semiconductor Data

    TK-7160/7162 SEMICONDUCTOR DATA Microprocessor : TX-RX unit IC101 ■ Pin Function Pin No. Name Function Pin No. Name Function AMPSW AF AMP SW H : SW off, L : SW on LSDO QT/DQT output HSDO DTMF/5-tone/BEEP output Common data PLLE...

  • Page 17: Components Description

    TK-7160/7162 COMPONENTS DESCRIPTION Display Unit (X54-3510-10) : TK-7160 Ref. No. Parts name Description Display Unit (X54-3522-70) : TK-7162 Q212 Emergency MIC Ref. No. Parts name Description Q213 MIC mute LCD controller Q241 Transistor W/N switch / TX Transistor Dimmer function switch...

  • Page 18: Parts List

    TK-7160/7162 PARTS LIST CAPACITORS 2 2 0 • Capacitor value CC45 Color* 010 = 1pF 0 = 22pF 1 = Type ... ceramic, electrolytic, etc. 4 = Voltage rating 100 = 10pF 2 = Shape ... round, square, etc. 5 = Value...
  • Page 19 RN47A4 TRANSISTOR T07-0753-05 SPEAKER 2SB1132(Q,R) TRANSISTOR KRA225S DIGITAL TRANSISTOR KRC102S DIGITAL TRANSISTOR Q7,8 2SC3928A TRANSISTOR DISPLAY UNIT (X54-3510-10) : TK-7160 B11-1829-03 ILLUMINATION GUIDE B38-0902-05 D1-6 B30-2282-05 LED (Y) D7-18 B30-2281-05 LED (Y) DISPLAY UNIT (X54-3522-70) : TK-7162 B30-2151-05 LED (RED/GREEN)
  • Page 20 TK-7160/7162 PARTS LIST DISPLAY UNIT (X54-3522-70) TX-RX UNIT (X57-7102-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation CK73GB1H103K CHIP C 0.010UF CK73GB1H102K CHIP C 1000PF C6,7 CK73GB1H102K CHIP C 1000PF...
  • Page 21 TK-7160/7162 PARTS LIST TX-RX UNIT (X57-7102-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C252 CK73HB1A104K CHIP C 0.10UF C359 CC73GCH1H080B CHIP C 8.0PF C253 CK73GB1H102K CHIP C 1000PF C360-362...
  • Page 22 TK-7160/7162 PARTS LIST TX-RX UNIT (X57-7102-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation C463,464 CK73GB1H471K CHIP C 470PF E40-5702-05 PIN ASSY C465 C92-0795-05 CHIP-TAN 22UF 10WV E40-6292-05 PIN ASSY...
  • Page 23 TK-7160/7162 PARTS LIST TX-RX UNIT (X57-7102-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation RK73GB1J152J CHIP R 1.5K 1/16W R225-228 RK73GB1J223J CHIP R 1/16W RK73GB1J103J CHIP R 1/16W R229 RK73HB1J104J...
  • Page 24 TK-7160/7162 PARTS LIST TX-RX UNIT (X57-7102-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation R323 RK73GB1J222J CHIP R 2.2K 1/16W R450 RK73GB1J473J CHIP R 1/16W R324 R92-1252-05 CHIP R 0 OHM J...
  • Page 25 TK-7160/7162 PARTS LIST TX-RX UNIT (X57-7102-70) Desti- Desti- Ref. No. Address Parts No. Description Ref. No. Address Parts No. Description parts nation parts nation D401 1SS355 DIODE Q502 RD00HVS1 D421 HZU5ALL DIODE TH301 B57331V2104J THERMISTOR D441-444 MA2S304 VARIABLE CAPACITANCE DIODE...

  • Page 26: Exploded View

    TK-7160/7162 EXPLODED VIEW A M3 x 8 : N67-3008-48 B M2 x 8 : N80-2008-48 C M2.6 x 6 (Br-Tap) : N87-2606-48 D M2.6 x 14 (Br-Tap) : N87-2614-48 Note : 1. Apply the silicon grease to the power-module clamp face of the chassis (701) and the base of the power-module (IC502).

  • Page 27: Packing

    (B62-1863-00) 33 Packing fixture (H12-3178-05) 35 Protection bag (H25-2320-04) 33 Packing fixture (H12-3178-05) 37 Item carton case (H52-2078-02) : TK-7160 (H52-2087-02) : TK-7162 43 Screw set (N99-2048-05) 20 Fuse (Blade type) 10A (F52-0023-05) x 2 39 Bracket (J29-0662-03) 11 DC cord assy...

  • Page 28: Adjustment

    TK-7160/7162 ADJUSTMENT Test Equipment Required for Alignment Test Equipment Major Specifications 1. Standard Signal Generator Frequency Range 136 to 175MHz (SSG) Modulation Frequency modulation and external modulation Output –127dBm/0.1µV to greater than –7dBm/100mV 2. Power Meter Input Impedance 50Ω Operation Frequency...
  • Page 29 TK-7160/7162 ADJUSTMENT • Speaker Cable Adjustment Location The speaker cable should be formed before mounting the ■ Adjustment Points shield cover as below. IC502 – TEMP1 Speaker cable TEMP2 CNVSS RESET Locator TX-RX UNIT POWER Component side – Test Frequency...
  • Page 30 TK-7160/7162 ADJUSTMENT Ref –20 dBm Atten 0 dB 3 or 5 Reference Level Adjustment Frequency Peak 136.1MHz 155.1MHz Tuning point RX (MHz) TX (MHz) 174.0MHz –40.5dBm –40.58dBm –42.81dBm 136.05 136.10 Low’ 145.55 145.60 Center 155.05 155.10 High’ 164.55 164.60 High 173.95...
  • Page 31 TK-7160/7162 ADJUSTMENT Measurement Adjustment Specifications/ Item Condition Test equipment Terminal Parts Method Remarks 2. Squelch 9 1) CH : RX low (Wide) PC key Adjust to open the squelch CH : RX center (Wide/Wide 4k/Narrow) CH : RX high (Wide)
  • Page 32 TK-7160/7162 ADJUSTMENT Measurement Adjustment Specifications/ Item Condition Test equipment Terminal Parts Method Remarks ± 1.0W 4. Low 1) CH : TX low Power meter PC key power CH : TX low’ CH : TX center CH : TX high’ CH : TX high 2) Transmit 5.

  • Page 33: Terminal Function

    FNC3 FNC4 Scrambler FNC4 FNC5 Scrambler Code1 (1) FNC5 FNC6 Scrambler Code2 (2) FNC6 FNC7 Scrambler Code3 (4) FNC7 FNC8 Scrambler Code4 (8) FNC8 Port Function is Low Active. (Exclude : Scrambler Code) * GPS (NMEA Input) is TK-7160 only.

  • Page 34: Pc Board

    TK-7160 PC BOARD DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) VOL UP POWER VOL DOWN HOOK MIC JACK DISPLAY UNIT (X54-3510-10) Foil side view (J72-0959-09) HOOK...
  • Page 35 TK-7160 PC BOARD DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) Ref. No. Address CH UP CH DOWN Component side Layer 1 J72-0959-09 Layer 2 Foil side DISPLAY UNIT (X54-3510-10) Foil side view (J72-0959-09) Ref. No. Address J72-0959-09 BUSY POWER HOOK...
  • Page 36 TK-7160 TK-7160 PC BOARD PC BOARD DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) DISPLAY UNIT (X54-3510-10) Component side view (J72-0959-09) Ref. No. Address VOL UP CH UP POWER VOL DOWN CH DOWN HOOK MIC JACK Component side Layer 1 J72-0959-09...
  • Page 37 TK-7162 PC BOARD DISPLAY UNIT (X54-3522-70) Component side view (J72-0960-09) VOL UP POWER VOL DOWN HOOK COM2 COM1 COM0 SEG4 SEG3 SEG2 MIC JACK DISPLAY UNIT (X54-3522-70) Foil side view (J72-0960-09) HOOK...

  • Page 38: Display Unit (X54-3522-70)

    TK-7162 PC BOARD DISPLAY UNIT (X54-3522-70) Component side view (J72-0960-09) Ref. No. Address CH UP CH DOWN SEG2 SEG1 SEG0 Component side Layer 1 J72-0960-09 Layer 2 Foil side DISPLAY UNIT (X54-3522-70) Foil side view (J72-0960-09) Ref. No. Address J72-0960-09 BUSY POWER HOOK...
  • Page 39 TK-7162 TK-7162 PC BOARD PC BOARD DISPLAY UNIT (X54-3522-70) Component side view (J72-0960-09) DISPLAY UNIT (X54-3522-70) Component side view (J72-0960-09) Ref. No. Address VOL UP CH UP POWER VOL DOWN CH DOWN HOOK COM2 COM1 COM0 SEG4 SEG3 SEG2 SEG1 SEG0 MIC JACK Component side...
  • Page 40 TK-7160/7162 PC BOARD TX-RX UNIT (X57-7102-70) Component side view (J72-0957-09) J72-0957-09 EXT. SP – R105 C519 C518 C517 CN506 TEMP2 C113 C116 CNVSS IC281 R101 Q212 C281 RESET R223 R221 Q281 D211 R283 DETO R277 R208 FNC1 C227 R276 FNC2...
  • Page 41 TK-7160/7162 PC BOARD TX-RX UNIT (X57-7102-70) Component side view (J72-0957-09) R800 C614 C613 IC502 C607 D608 D609 R603 R601 C620 D606 R655 R653 R654 R662 R661 TEMP1 L504 C556 C529 C555 C531 C532 Scrambler C222 R381 C204 R266 IC213 R255...
  • Page 42 TK-7160/7162 TK-7160/7162 PC BOARD PC BOARD TX-RX UNIT (X57-7102-70) Component side view (J72-0957-09) TX-RX UNIT (X57-7102-70) Component side view (J72-0957-09) J72-0957-09 EXT. SP R800 C614 C613 IC502 C607 D608 D609 R603 R601 C620 – D606 R655 R653 R654 R105 R662...
  • Page 43 TK-7160/7162 PC BOARD TX-RX UNIT (X57-7102-70) Foil side view (J72-0957-09) L604 C387 R376 C388 D354 R378 C385 L601 L357 L503 D603 C533 C381 C384 CN301 CN503 D352 C360 C377 C370 R359 R370 R374 C367 C373 C368 Q353 R503 C503 R360...
  • Page 44 TK-7160/7162 PC BOARD TX-RX UNIT (X57-7102-70) Foil side view (J72-0957-09) J72-0957-09 C290 R285 C291 – R521 R518 C527 R516 C516 CN502 CN501 C509 L502 R514 R509 R104 R100 R103 R102 C106 R130 C446 D442 R111 IC81 IC101 L444 C441 L441...
  • Page 45 TK-7160/7162 TK-7160/7162 PC BOARD PC BOARD TX-RX UNIT (X57-7102-70) Foil side view (J72-0957-09) TX-RX UNIT (X57-7102-70) Foil side view (J72-0957-09) J72-0957-09 C290 R285 C291 L604 C387 R376 C388 D354 R378 – C385 L601 L357 L503 D603 R521 R518 C533 C527...

  • Page 46: Tx-Rx Unit (X57-7102-70)

    TK-7160/7162 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7102-70) R424 C445 VOLTAGE DROPPED 4.5p Q421,422 RX VCO D421 R421 R:5.98V R:1.15V RX VCO CHARGE PUMP Q441 Q421 8.2k HZU5ALL D442 2SK508NV(K52) C447 L421 L441 C441 L443 2SA1832(GR) R426 R427 R429 Q422 2.7k 1.5k 270n 0.3p...

  • Page 47: Schematic Diagram

    TK-7160/7162 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7102-70) VCO 1/2 DIVIDER 5.01V RF SW IC402 PRE DRIVE AMP UPB1509GV (TX/RX) R:0V RF AMP Q501 BUFFER AMP 4.86V T:5.61V T:1.21V 7.40V Q447 D448 2SC3357(RF) 5.92V 1.2V Q446 HSC277 VCC1 VCC2 2SC4649(N,P) L457 C480...
  • Page 48 TK-7160/7162 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7102-70) POWER MODULE IC502 RA30H1317M-31 PRE DRIVE AMP C555 Q502 T:7.6V RD00HVS1 C509 C516 R517 L503 R521 COMPARATOR(APC) IC651 TA75W01FU R523 T:7.94V R653 TEMP1 R652 TEMP2 VOLTAGE PROTECTION R659 R522 R661 R662 D610 1SS355 TEMP DTECT...
  • Page 49 TK-7160/7162 SCHEMATIC DIAGRAM TX-RX UNIT (X57-7102-70) C626 C613 ANT SW C603 D602 L603 L604 MA4PH633 1000p E40-6268-05 T:0.9V VOLTAGE 3.3k VOLTAGE DETECT DETECT ANT SW D606 D608 MA742 MA742 BSYLED TXLED DISPID D609 R655 1SS355 T:9.0V(Hi) POWER :3.6V(Lo) TEMPERATURE HOOK...
  • Page 50 TK-7160/7162 SCHEMATIC DIAGRAM DISPLAY UNIT (X54-3510-10) E08-0877-05 SURGE ABSORPTION MC2850 HOOK KMO1 <B C> KMO2 KMO3 HOOK POWER SEG26 KMI3 SEG25 KMI2 SEG24 KMI1 SEG23 SEG22 SEG21 BUSY 5.01V SEG20 LCD CONTROLLER SEG19 VDD1 LC75854W SEG18 VDD2 SEG17 SEG16 SEG15...
  • Page 51 TK-7160/7162 SCHEMATIC DIAGRAM DISPLAY UNIT (X54-3522-70) E08-0877-05 SURGE ABSORPTION MC2850 HOOK <B C> LCD CONTROLLER LC75893M KS2/S16 KS1/S15 HOOK CoM3 POWER CoM2 CoM1 BUSY 5.01V TEST VDD1 VDD2 R90-0724-05 P4/S4 P3/S3 CN1 E40-6005-05 DC SW DC SW P2/S2 2SC3928A 2SC3928A P1/S1 T:3.71V...
  • Page 52 TX-RX UNIT (X57-7102-70) DISPLAY UNIT (X54-3510-10) DISPLAY UNIT (X54-3522-70) R424 VCO 1/2 DIVIDER 5.01V C445 IC402 RF SW POWER MODULE VOLTAGE UPB1509GV (TX/RX) R:0V PRE DRIVE AMP IC502 DROPPED 4.5p BUFFER AMP RF AMP 7.40V 4.86V T:5.61V T:1.21V Q501 D421 R421 Q421,422 RX VCO...

  • Page 53: Block Diagram

    TK-7160/7162 BLOCK DIAGRAM DISPLAY UNIT : TK-7160 TX-RX UNIT Q431 2SC4649(N,P) POWER 2SK508 Q421 IC401 PTT(TXD) CHARGE 2SA1832(GR) KMO1 <B C> MB15A02 PUMP PLLE HOOK(RXD) LOOP Q442 PLL IC FILTER 2SJ347 KMO2 16.8MHz CHARGE Q422 PUMP 2SC4738(GR) 16.8MHz KMO3 TCXO...
  • Page 54 TK-7160/7162 BLOCK DIAGRAM D602 Q501 MA4PH633 Q502 2SC3357 Q441 Q446 IC402 Q447 IC502 D603 RD00HVS1 (RF) 2SK508NV(K52) 2SC5108(Y) UPB1509GV 2SC4649(N,P) RA30H1317M-31 XB15A709 BUFF DIVIDER DRIVE POWER MODULE ANT SW Q443 Q442 D447,448 KRX102U 2SJ347 HSC277 POW. POW. Q341 2SC3928A D606...

  • Page 55: Level Diagram

    TK-7160/7162 LEVEL DIAGRAM Receiver Section Center Frequency 49.95MHz 450kHz W : –78.5dBm N : –76.5dBm W : –121.5dBm W : –120.0dBm W : –106.5dBm W : –111.0dBm W : –110.5dBm W : –99.0dBm CF331 N : –121.5dBm N : –120.5dBm N : –106.5dBm...
  • Page 56 TK-7160/7162 LEVEL DIAGRAM Audio Frequency 450kHz W : –93.5dBm N : –90.0dBm CF331 W : 0.58Vrms /CF332 N : 0.49Vrms 0.28Vrms 0.28Vrms 0.29Vrms 0.28Vrms 15mVrms 0.55Vrms 0.45Vrms IC321 IC201 IC241 IC213 IC241 IC241 IC201 IC281 vel meter. 2dB SINAD.) To make measurements in the AF section, connect the AC level meter.

  • Page 57: Specification

    GENERAL (Applicable standards : EN standard, AS-4295) Frequency range .............. 136~174MHz Number of channels TK-7160 ................ Max. 128 Channels total per radio Zone : Max. 128 per radio Channel : Max. 128 per zone TK-7162 ................ Max. 16 Channels Channel spacing ............... Wide 5k : 25kHz Wide 4k : 20kHz Narrow : 12.5kHz...

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