Model 70-1545 Mobile Transceiver SERVICE MANUAL 6KEN SOFTWARE VERSION Manual # KW208SM-6KEN
SCOPE OF THIS MANUAL This manual covers the KG208 Series for the following bands: KG208-08A…. 66-88 MHz. KG208-15A…. KG208-15B…. 134-162 MHz. 146-174 MHz. KG208-20A…. KG208-20B…. KG208-20C…. 176-208 MHz 208-245 MHz. 240-276 MHz. KG208-40SA…. KG208-40A…. KG208-40B…. KG208-40C…. KG208-40DS…. KG208-40D…. KG208-40E…. KG208-40F…. 300-335 MHz 335-365 MHz 365-400 MHz 400-435 MHz. 420-455 MHz 440-475 MHz 465-500 MHz 485-520 MHz The KG208-03, 30 –50 MHz band will be covered in an addendum to this manual.
INDEX SUBJECT PAGE SCOPE OF MANUAL INDEX (THIS PAGE) DRAWING INDEX SPECIFICATIONS 2 3 4 5 SECTION 1: INTRODUCTION 6 Applications Radio Features Safety Information Model Number Coding Initial inspection Standard Package Contents / Drawing 6 6 6 7 8 8 SECTION 2: INSTALLATION 9 SECTION 3: OPERATION 11 Control Functions, Control panel Drawing Display ICONS Operating the Radio Advanced Features Special Keypad Functions SECTION 4: CIRCUIT DESCRIPTION Operating Voltage Control Receiver Transmitter PLL
DRAWING INDEX DRAWING 4 PAGE EXPLODED VIEW 33 MAIN UNIT SCHEMATIC 66-88 MHZ 35 MAIN UNIT SCHEMATIC 134-174 MHZ 36 MAIN UNIT PCB LAYOUT 37 MAIN UNIT SCHEMATIC 176-276 MHZ 38 MAIN UNIT SCHEMATIC 300-520 MHZ 39 CONTROL UNIT SCHEMATIC 40 CONTROL UNIT PCB LAYOUT 41 LOGIC UNIT PCB LAYOUT 42 LOGIC UNIT SCHEMATIC 43 VCO UNIT SCHEMATIC 66-88 MHZ 44 VCO UNIT SCHEMATIC 134-174 MHZ 45 VCO UNIT SCHEMATIC 176-276 MHZ 46 VCO UNIT SCHEMATIC 300-520 MHZ 47 VCO UNIT PCB LAYOUT 48 DCS UNIT SCH
SPECIFICATIONS KG208 Mobile Transceiver GENERAL Frequency Range 30 MHz Band (1) Designated 03 80 MHz Band Designated 08 VHF Band Designated 15 200 MHz Band Designated 20 UHF Band Designated 40 A: 30 - 40 MHz B: 40 - 50 MHz C: 45 - 55 MHz* A: 66 - 88 MHz A: 134-162 MHz B: 146-174 MHz A: 176-208MHz B: 208-245 MHz C: 240-276 MHz SA: 300-335 MHz A: 335-370 MHz B: 365-400 MHz C: 400-435 MHz DS: 420-455 MHz D: 440-475 MHz E: 465-500 MHz F: 485-520 MHz * Special Order (1) This band will be covered in an
SECTION 1. INTRODUCTION 1.1 INTRODUCTION 1.1.1 APPLICATIONS The KG208 Series mobile radio transceivers provide professional communications for a wide variety of applications. Government agencies, police departments, security and public safety agencies, courier and freight companies, construction, airport ground services, petroleum and utility industries may use the radio for reliable communications.
1.1.3 IMPORTANT SAFETY INFORMATION The Federal Communications Commission (FCC) of the United States in General Docket 79-144 adopted a safety standard for human exposure to radio frequency energy. Proper operation of this FCC regulated equipment will result in exposure significantly below FCC recommended limits. DO NOT transmit if someone is within .6 meters of the radio antenna. DO NOT press the transmit switch unless you actually want to transmit.
1.1.5 INITIAL INSPECTION When you receive your radio, inspect the carton for any signs of shipping damage. Report any damage to the carrier immediately. Then remove and check the contents to be sure all items have been included. 1.1.6 STANDARD PACKAGE See listing at right and drawing below. 1.1.7 OPTIONAL ITEMS Check your order or packing list for the items to be supplied.
SECTION 2. INSTALLATION 2.1 RADIO INSTALLATION Note: It is highly recommended that a qualified technician or engineer perform installation. Special equipment is required to properly install and tune the antenna. 2.1.1 LOCATION The recommended location is under the dash or near the console area within reach of the operator. Do not mount the radio near heat vents or where it will be exposed to direct sunlight.
4. Mount the bracket using two self-tapping screws and flat washers. 5. Mount the speaker into the bracket using the mounting knobs removed in step 1. 6. Remove the white connector on the rear of the radio. Note that this is a jumper to connect the internal speaker. Use tape or a nylon strap to attach this connector to one of the cables on the radio to avoid losing it. It is required to reconnect the internal speaker if the radio is removed for testing. 2.1.
SECTION 3. OPERATION 3.1 CONTROL FUNCTIONS CONTROL PANEL 3.1.1 OFF/VOLUME Switch the radio on by rotating the VOLUME knob clockwise ½ turn. The volume may be adjusted later when you receive a message. 3.1.2 CHANNEL/SQUELCH KNOB Select the desired channel by rotating the CHANNEL knob. The channel number will appear in the display. Either 1 or CH-1 may appear depending on other program features used. If using the Channel Name feature, the name will appear after a short time.
3.2 DISPLAY ICONS The drawing below shows all of the ICONS and characters that are used to indicate radio operation. The function of each icon will be discussed here, and again as we cover the operation and features. LCD DISPLAY Top row 3.2.1 PRIO Indicates that the radio is in one of the priority scan modes. 3.2.2 6 ARROWS There are six (6) arrows along the top of the display. The first indicates that the shift button has been pressed.
3.3 OPERATING THE RADIO This section discusses the actual use of all controls while operating the radio. 3.3.1 POWER ON/OFF, VOLUME Rotate the OFF/VOLUME knob ½ turn to the right. Volume may be adjusted when a signal is received. 3.3.2 SQUELCH ADJUSTMENT Press the SHIFT on the radio panel. The first arrow will appear at the top of the display. The CHANNEL knob now becomes the SQUELCH control. While turning the knob, the display will show SQ-0 through SQ-7.
resumes scanning, you cannot transmit without first exiting the scan mode and selecting the proper channel. If the radio is programmed for selective call, scan capability is limited. The radio will not scan unless the decoder is set ( icon is present). Then, the scan will stop only when the correct decode select call number is received. 3.3.5.
To switch to the Program Scan HIGH Priority channel, press B (no SHIFT). Pressing B again will select the Program Scan LOW Priority channel. Repeated pressing will toggle between the two channels. 3.4 ADVANCED FEATURES Your new Model KG208 contains many advanced features that may be used to suit your individual system needs. Some are available at all times while others may be programmed as needed. Your system engineer may provide additional instructions about specific features used in your system. 3.4.
If the control point is using a KG208 or KG510, it may be programmed to display the ANI of any radio on the channel. With another type of base station, equipment is available to display the ANI. In either case, the operator at the control point will know which radio is transmitting. 3.4.8 KILL MODE If this feature is programmed, the radio may be disabled or “killed” by another operator in the system if he knows the proper kill code and kill password.
3.4.13 PLACING A CALL, 5Tone Mode In 5Tone mode, enter the digits in the field indicated by the arrow at the top of the display. To clear the display, hold the SHIFT key and press the PTT. However, it is not necessary to clear the display. New numbers entered will replace existing digits. Only digits 1 through 9, 0 and A may be used. Other keys have specific functions when entered alone or with the SHIFT key.
SHIFT, 5 Transfer Mode (Call Forwarding) Toggles the Transfer Mode ON or OFF. Upon receipt and decoding of a valid number, this feature allows the radio to retransmit (forward) a number on the same or different channel. SHIFT, 6 Kill Password Permits entry of a password to use the Kill function. This function allows you to disable (kill) another radio by sending that radio its proper kill code. Details of this feature may not be made available to every user.
SHIFT, C DTMF Clear Clears any new DTMF entry that may have been entered in error. Example, if the desired number is 12345 and you have entered 13345, press SHIFT, C to erase 13345, then enter the correct number 12345. C (no SHIFT) Instant Channel Selection C, followed by keypad entry of a channel number followed by C again will instantly select that channel. Example: C 1 2 C will select channel 12. The display will flash the new channel several times before switching.
SECTION 4 CIRCUIT DESCRIPTION 4.1 OPERATING VOLTAGE CONTROL There is a programmable, Power-Off Feature which turns off the radio after a preset time of non-activity to prevent discharging of the vehicle battery. This feature is mentioned in the discussion of each circuit under its control. Battery voltage enters the radio on the RED/BLUE battery cable. Fuses are located in this cable. D22 protects the radio from reverse voltage by causing the fuses to blow.
4.2.3 HIGH IF (48.5 MHz) The IF passes through Crystal Filter XF1, IF Amplifier Q3, IF Transformer T3, Crystal Filter XF2, Amplifier Q4 and on to the input of IC1 -20. IC1 uses crystal X1 to generate 45.045 MHz to convert the 1st IF of 48.5 MHz to the 2nd IF of 455 kHz. 4.2.4 LOW IF (455 kHz) The 455 kHz IF is filtered by Ceramic Filters CF1 & CF2.
4.3 TRANSMITTER 4.3.1 TRANSMITTER AUDIO Microphone audio enters the control unit at the microphone connector, pin 1, passes through preamplifier IC403 and out to the main board on CN4-5. Transmit audio from an external device may be input to the interface connector on the back of the radio, CN10-6. Resistor R103 provides microphone bias if required. External audio is combined with the mic audio and enters the Audio Processor IC8-2 TX IN.
Operating voltage for IC15 is controlled as follows. During transmit, an active high signal from the logic board, TX2 IN, CN6-6, turns on the top half of Q11 which turns on Q21 applying voltage to IC15. An UNLOCK active high signal from the PLL circuit Q7-C controls the lower half of Q11. When the PLLNCO is out of lock, the top half is prevented from turning on. This disables the transmitter. The power output section of PM-1 operates directly from un-switched battery voltage.
IC402 supplies regulated 5 V to mic preamplifier IC403. If the radio is in the transmit mode, Q403 and Q402 hold the radio power on until the PTT is released in the event the power switch is turned off. The keypad permits entry of DTMF or 5-Tone encode messages and various control functions. Other controls include the SHIFT which is used to change the function of various buttons, SCAN which activates the scan function and MUTE (MONITOR) which controls the decoder.
SECTION 5. SERVICING INFORMATION CAUTION: This radio uses surface mount construction. It is recommended that servicing may be limited to replacement of complete modules and non-surface mount components. Component level servicing should not be attempted unless the engineer or technician is very familiar with surface mount repair techniques and has all of the necessary specialized tools and equipment. 5.1 TEST EQUIPMENT AND TOOLS ITEM DESCRIPTION 1. DMM (Digital Multi-meter) 2.
is completed and program customer frequencies. Use the low power channels for all VCO tests to minimize overheating of the radio. The VCO must be adjusted so that the phase detector voltage remains between 1V and 5 V over the entire range of frequencies used. 1. To access the VCO, remove the top cover, 2 black screws, and the VCO shield, 5 brass screws. 2. Select the center channel which was programmed for tuning adjustments. Connect DMM to TP2 located on the left edge of the main board. 3.
1. Connect wattmeter and load to antenna connector. 2. Select high power center channel and adjust the PWR HIGH (FVR8) for 25 Watts (40 Watts on high power models) or other desired power below maximum rated power. 3. Adjust FVC1 (FVC3) for maximum power and repeat step 2. 4. Check power at highest and lowest frequency and readjust FVC1 to balance the power. Power may be slightly lower at band extremes but should not exceed -1 dB. 5.
5.3.2 BOTTOM COVER REMOVAL 1. Remove two black screws (36) from bottom cover (73). 2. Remove bottom cover (73). 5.3.3 LOGIC UNIT REMOVAL 1. Remove top cover (35). 2. Remove two screws (32) from left side of logic unit (33). 3. Gently lift up on logic unit (33) and unplug from main unit (58). 4. Unplug CN9S socket (45) from CN9P on logic unit (33). 5. Remove logic unit (33) 6. Install logic unit and reverse the steps above to reassemble. 5.3.4 VCO UNIT REMOVAL 1. Remove top cover (35). 2.
9. Install bushing (49) on new antenna cable. 10. Install clamp (50) on new antenna cable. 11. Slide new antenna cable, bushing (49), and clamp (50) into place using screw (32). 12. Attach bushing (49) to main chassis (29) with one black screw (67). 13. Solder new antenna cable to main unit (58). 14. Solder clamp (50) to main unit (58). 15. Reverse the steps above to reassemble. 5.3.7 MAIN UNIT REPLACEMENT 1. Remove bottom cover (73). 2. Remove six screws (71) from TX/PA cover (70). 3.
5.3.9 CONTROL UNIT REMOVAL 1. Remove two oval screws (7) from each side of control unit (8). 2. Separate control unit (8) from main chassis (29). 3. Disconnect red keypad cable assembly (57) from CN3P plug on control unit (14). 4. Disconnect blue microphone cable assembly (56) from CN4P plug on control unit (14). 5.3.10 CONTROL UNIT CIRCUIT BOARD REPLACEMENT I. Remove control unit (8). 2. Disconnect volume cable assembly (16) from CN4O2P plug on control unit (14). 3.
5.3.13 SPEAKER REPLACEMENT 1. Remove control panel (8). 2. Disconnect speaker cable assembly (23) from CN401P plug on control unit (14). 3. Disconnect volume cable assembly (16) from CN402P plug on control unit (14). 4. Remove two screws (27) from speaker housing (26). 5. Remove speaker housing (26). 6. Pull speaker cap (24) off of speaker (22). 7. Desolder speaker cable assembly (23) from speaker (22). 8. Remove speaker (22). 9. Install new speaker and reverse the steps above to reassemble. 5.3.
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