Modifying Kenwood TK-760(H)G/762(H)G/860(H)G/862(H)G/863G for Packet Service - Revision history

Opadmin at 22:20, 4 July 2021

2021-07-04T22:20:37Z

Opadmin at 19:06, 30 June 2021

2021-06-30T19:06:09Z

← Older revision		Revision as of 15:06, 30 June 2021
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	'''Modification Process'''		'''Modification Process'''

	Prior to beginning any modification, it is best to test the radio for proper functionality. If the radio was purchased used, there is a fair chance it is programmed to commercial frequencies. Reprogramming into the amateur bands is possible for the TK-760(H)G/762(H)G/860(H)G/862(H)G using the KPG-56D software which is available in both DOS and Windows. The TK-863G requires KPG-76D and is available only for Windows. In general, the VHF high band versions will work well into the 2m band with little or no adjustments needed to the VCO or receiver. The UHF versions (K split, 450-490 MHz) will often work without modification in the upper 10 MHz (~~440~~-450 MHz) and sometimes lower. Many of the UHF versions can go lower into the 70cm band by adjusting the VCO circuits. Some may go down as low as 433 MHz or possibly lower. It should be possible to add small amounts of parallel capacitance across the trimmer capacitors in the VCO section to pull it's range lower in frequency. This will likely be explored in the future.		Prior to beginning any modification, it is best to test the radio for proper functionality. If the radio was purchased used, there is a fair chance it is programmed to commercial frequencies. Reprogramming into the amateur bands is possible for the TK-760(H)G/762(H)G/860(H)G/862(H)G using the KPG-56D software which is available in both DOS and Windows. The TK-863G requires KPG-76D and is available only for Windows. In general, the VHF high band versions will work well into the 2m band with little or no adjustments needed to the VCO or receiver. The UHF versions (K split, 450-490 MHz) will often work without modification in the upper 9-10 MHz (441-450 MHz) and sometimes lower. Many of the UHF versions can go lower into the 70cm band by adjusting the VCO circuits. Some may go down as low as 433 MHz or possibly lower. It should be possible to add small amounts of parallel capacitance across the trimmer capacitors in the VCO section to pull it's range lower in frequency. This will likely be explored in the future.

	1) Open the top cover by removing the two rear screws near the heatsink		1) Open the top cover by removing the two rear screws near the heatsink

Opadmin at 19:04, 30 June 2021

2021-06-30T19:04:55Z

← Older revision		Revision as of 15:04, 30 June 2021
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	K3 = 3<br>		K3 = 3<br>

	For VHF, the K(1) is the most common split, but both the K(1) and K2 splits cover all of 2m (144-148 MHz) without issue. For UHF, the K(1) split is also the most common split (450-490 MHz) and can usually cover at least ~~438~~-450 MHz, some of them will go down as low as 433 MHz with a simple VCO adjustment. The less common K2 split (485-512 MHz) is too far away from the 70cm band to be used and should be avoided except for part donors. The least common K3 split (400-430 MHz) can probably cover the lower portions of the 70cm band, possibly up to 440 or higher. We have not been able to obtain any of these to test, though they be may more available in proximity to [https://www.fcc.gov/engineering-technology/electromagnetic-compatibility-division/frequency-coordination-canada-below Line A] along the northern border of the USA and up in Canada where it is a commercial band. If you do end up with a K3 split and want a K split, please [mailto:kb8uvn@ohiopacket.org contact us] to arrange a trade, we will cover shipping in both directions.		For VHF, the K(1) is the most common split, but both the K(1) and K2 splits cover all of 2m (144-148 MHz) without issue. For UHF, the K(1) split is also the most common split (450-490 MHz) and can usually cover at least 439-450 MHz, some of them will go down as low as 433 MHz with a simple VCO adjustment. The less common K2 split (485-512 MHz) is too far away from the 70cm band to be used and should be avoided except for part donors. The least common K3 split (400-430 MHz) can probably cover the lower portions of the 70cm band, possibly up to 440 or higher. We have not been able to obtain any of these to test, though they be may more available in proximity to [https://www.fcc.gov/engineering-technology/electromagnetic-compatibility-division/frequency-coordination-canada-below Line A] along the northern border of the USA and up in Canada where it is a commercial band. If you do end up with a K3 split and want a K split, please [mailto:kb8uvn@ohiopacket.org contact us] to arrange a trade, we will cover shipping in both directions.

	----		----

Opadmin at 22:18, 27 June 2021

2021-06-27T22:18:51Z

← Older revision		Revision as of 18:18, 27 June 2021
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	42) Solder the COR logic inverter 5v input to the 10k resistor.		42) Solder the COR logic inverter 5v input to the 10k resistor.

	[[File:~~TKn6n~~-COR_5v_to_10k_resistor.jpg\|320px]]		[[File:TK-n6n-COR_5v_to_10k_resistor.jpg\|320px]]

	43) Take about 3" of single wire from the ribbon cable to be used for the COR signal feed, strip back about 1/4" and tin. In this build we will use a red wire.		43) Take about 3" of single wire from the ribbon cable to be used for the COR signal feed, strip back about 1/4" and tin. In this build we will use a red wire.

Opadmin at 22:17, 27 June 2021

2021-06-27T22:17:53Z

← Older revision		Revision as of 18:17, 27 June 2021
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	41) Take about 2" of single wire from the ribbon cable to be used for the 5VDC feed, strip back about 1/4" and tin. In this build we will use a purple wire.		41) Take about 2" of single wire from the ribbon cable to be used for the 5VDC feed, strip back about 1/4" and tin. In this build we will use a purple wire.

	[[File:~~TKn6ng~~-COR_5v_wire_strip_tin.jpg\|320px]]		[[File:TK-n6ng-COR_5v_wire_strip_tin.jpg\|320px]]

	42) Solder the COR logic inverter 5v input to the 10k resistor.		42) Solder the COR logic inverter 5v input to the 10k resistor.

Opadmin at 22:16, 27 June 2021

2021-06-27T22:16:13Z

← Older revision		Revision as of 18:16, 27 June 2021
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	34) Solder the 50k resistor to the base (center wire) of the 2n2222.		34) Solder the 50k resistor to the base (center wire) of the 2n2222.

	[[File:~~TK_n6ng_COR_50k_to_2n2222~~.jpg\|320px]]		[[File:TK-n6ng_COR_50k_to_2n2222.jpg\|320px]]

	35) Trim one of the leads on the 10k resistor about 1/4" and tin the lead.		35) Trim one of the leads on the 10k resistor about 1/4" and tin the lead.

Opadmin at 17:16, 27 June 2021

2021-06-27T17:16:23Z

← Older revision		Revision as of 13:16, 27 June 2021
Line 118:		Line 118:
	'''Modification Process'''		'''Modification Process'''

	Prior to beginning any modification, it is best to test the radio for proper functionality. If ~~this service~~ was purchased used, there is a fair chance it is programmed to commercial frequencies. Reprogramming into the amateur bands is possible for the TK-760(H)G/762(H)G/860(H)G/862(H)G using the KPG-56D software which is available in both DOS and Windows. The TK-863G requires KPG-76D and is available only for Windows. In general, the VHF high band versions will work well into the 2m band with little or no adjustments needed to the VCO or receiver. The UHF versions (K split, 450-490 MHz) will often work without modification in the upper 10 MHz (440-450 MHz) and sometimes lower. Many of the UHF versions can go lower into the 70cm band by adjusting the VCO circuits. Some may go down as low as 433 MHz or possibly lower. It should be possible to add small amounts of parallel capacitance across the trimmer capacitors in the VCO section to pull it's range lower in frequency. This will likely be explored in the future.		Prior to beginning any modification, it is best to test the radio for proper functionality. If the radio was purchased used, there is a fair chance it is programmed to commercial frequencies. Reprogramming into the amateur bands is possible for the TK-760(H)G/762(H)G/860(H)G/862(H)G using the KPG-56D software which is available in both DOS and Windows. The TK-863G requires KPG-76D and is available only for Windows. In general, the VHF high band versions will work well into the 2m band with little or no adjustments needed to the VCO or receiver. The UHF versions (K split, 450-490 MHz) will often work without modification in the upper 10 MHz (440-450 MHz) and sometimes lower. Many of the UHF versions can go lower into the 70cm band by adjusting the VCO circuits. Some may go down as low as 433 MHz or possibly lower. It should be possible to add small amounts of parallel capacitance across the trimmer capacitors in the VCO section to pull it's range lower in frequency. This will likely be explored in the future.

	1) Open the top cover by removing the two rear screws near the heatsink		1) Open the top cover by removing the two rear screws near the heatsink

Opadmin at 19:32, 24 June 2021

2021-06-24T19:32:59Z

← Older revision		Revision as of 15:32, 24 June 2021
Line 1:		Line 1:
	The Kenwood TK-760(H)G/762(H)G/860(H)G/862(H)G/863G are relatively low cost commercial radios that can be reprogrammed to work in the 2m and 70cm bands and depending on band and model are rated for 25-50w output. With a steady hand and fine tipped soldering iron, they can be modified for 1200-9600 baud service, [https://rosmodem.wordpress.com/ VARA FM/FM Wide], including optional COR/COS signaling for hardware carrier detect or use in other services like [https://www.allstarlink.org Allstarlink], [http://www.echolink.org Echolink], [https://www.svxlink.org/ SVXLink], Repeater controllers/remote base, etc. This guide wires them to the [https://www.ohiopacket.org/files/wiring_diagrams/KPC-3_Pinout.jpg Kantronics DB-9] standard and is compatible with the [http://www.ohiopacket.org/index.php/Building_a_4_Port_Packet_Controller 4 Port packet controller] and [http://tarpn.net/t/nino-tnc/nino-tnc.html NinoTNC], details to support adaptation to other interfaces ~~to other interfaces~~ is included.		The Kenwood TK-760(H)G/762(H)G/860(H)G/862(H)G/863G are relatively low cost commercial radios that can be reprogrammed to work in the 2m and 70cm bands and depending on band and model are rated for 25-50w output. With a steady hand and fine tipped soldering iron, they can be modified for 1200-9600 baud service, [https://rosmodem.wordpress.com/ VARA FM/FM Wide], including optional COR/COS signaling for hardware carrier detect or use in other services like [https://www.allstarlink.org Allstarlink], [http://www.echolink.org Echolink], [https://www.svxlink.org/ SVXLink], Repeater controllers/remote base, etc. This guide wires them to the [https://www.ohiopacket.org/files/wiring_diagrams/KPC-3_Pinout.jpg Kantronics DB-9] standard and is compatible with the [http://www.ohiopacket.org/index.php/Building_a_4_Port_Packet_Controller 4 Port packet controller] and [http://tarpn.net/t/nino-tnc/nino-tnc.html NinoTNC], details to support adaptation to other interfaces/TNCs/controllers is included.

	[[File:TK-760HG_TK-862G_TK-863.jpg\|640px]]		[[File:TK-760HG_TK-862G_TK-863.jpg\|640px]]

Opadmin at 16:54, 23 June 2021

2021-06-23T16:54:22Z

← Older revision		Revision as of 12:54, 23 June 2021
Line 390:		Line 390:
	[[File: TK-n6n_COR_logic_output_heatshrink2.jpg\|320px]]		[[File: TK-n6n_COR_logic_output_heatshrink2.jpg\|320px]]

	62) If you want to be able to enable or disable COR signaling via hardware jumper, take a single row of 2.54mm header pins and tin 3 consecutive pins. This is needed if you want to use this radio with a CM108/RA/URI type interface that supports COR signaling on Windows. With the COR connected all the time to that type interface, the COR signal will mute the ~~microphone input~~ whenever a signal is present.		62) If you want to be able to enable or disable COR signaling via hardware jumper, take a single row of 2.54mm header pins and tin 3 consecutive pins. This is needed if you want to use this radio with a CM108/RA/URI type interface that supports COR signaling on Windows. With the COR connected all the time to that type interface, the COR signal will mute the speaker output whenever a signal is present and have to manually be reenabled.

	[[File: TK-n6n_COR_logic_header_prep.jpg\|320px]]		[[File: TK-n6n_COR_logic_header_prep.jpg\|320px]]

Opadmin at 20:17, 18 June 2021

2021-06-18T20:17:05Z

← Older revision		Revision as of 16:17, 18 June 2021
Line 346:		Line 346:
	[[File:TK-n6ng_COR_circuit_heatshrink6.jpg\|320px]]		[[File:TK-n6ng_COR_circuit_heatshrink6.jpg\|320px]]

	52) Returning to the radio, apply a small amount of solder to the left most/output leg of ~~IC10~~ near the 5C label, in the center of the main board next to the ribbon cable.		52) Returning to the radio, apply a small amount of solder to the left most/output leg of IC10NJM78L05UA 5V regulator's output near the 5C label, in the center of the main board next to the ribbon cable.

	[[File:TK-n6ng_COR_5v_schematic.jpg\|320px]]		[[File:TK-n6ng_COR_5v_schematic.jpg\|320px]]
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	[[File:TK-n6ng_COR_5v_source_tin2.jpg\|320px]]		[[File:TK-n6ng_COR_5v_source_tin2.jpg\|320px]]

	53) Apply a small amount of solder to the left anode of D15 near the outside of the radio.		53) Apply a small amount of solder to the left anode of D15/DAN235K near the outside of the radio.

	[[File:TK-n6ng_COR_signal_schematic.jpg\|320px]]		[[File:TK-n6ng_COR_signal_schematic.jpg\|320px]]

← Older revision		Revision as of 18:20, 4 July 2021
Line 101:		Line 101:
	5) 50K resistor (Optional for COR logic inverter)<br>		5) 50K resistor (Optional for COR logic inverter)<br>
	6) 1-2x 3 pin 2.54mm header, commonly available for Raspberry Pi and Arduino projects (Optional 1 for COR logic signaling enable/disable and/or changing TX audio between mic and modulator input)<br>		6) 1-2x 3 pin 2.54mm header, commonly available for Raspberry Pi and Arduino projects (Optional 1 for COR logic signaling enable/disable and/or changing TX audio between mic and modulator input)<br>
	7) 1-2x 2.54mm jumper (Optional for connections on item 6<br>		7) 1-2x 2.54mm jumper (Optional for connections on item 6)<br>
	8) 1/8" heatshrink tubing<br>		8) 1/8" heatshrink tubing<br>
	9) 1/4" heatshrink tubing<br>		9) 1/4" heatshrink tubing<br>
Line 411:		Line 411:
	[[File:TK-n6ng_COR_logic_header_heatshrink1.jpg\|320px]]		[[File:TK-n6ng_COR_logic_header_heatshrink1.jpg\|320px]]

	67) Take a 2.54mm jumper (this can be ~~scavanged~~ from old computer harddrives and other devices) and place it over the pins connected to the COR logic output and front wires and apply heat.		67) Take a 2.54mm jumper (this can be scavenged from old computer harddrives and other devices) and place it over the pins connected to the COR logic output and front wires and apply heat.

	[[File:TK-n6ng_COR_logic_header_heatshrink2.jpg\|320px]]		[[File:TK-n6ng_COR_logic_header_heatshrink2.jpg\|320px]]
Line 490:		Line 490:
	[[File:TK-n6ng_CN4_jack.jpg\|320px]]		[[File:TK-n6ng_CN4_jack.jpg\|320px]]

	83) Carefully take a soldering iron and solder and create solder bridge between the pin on the connector and surface mount ~~capacitor~~. These two components are already shorted, this bridge gives a larger area to solder the wire to be brought out of the radio.		83) Carefully take a soldering iron and solder and create solder bridge between the pin on the connector and surface mount resistor. These two components are already shorted, this bridge gives a larger area to solder the wire to be brought out of the radio.

	[[File:TK-n6ng_CN4_jack_solder_bridge.jpg\|320px]]		[[File:TK-n6ng_CN4_jack_solder_bridge.jpg\|320px]]
Line 498:		Line 498:
	[[File:TK-n6ng_modulator_wire_strip_tin.jpg\|320px]]		[[File:TK-n6ng_modulator_wire_strip_tin.jpg\|320px]]

	85) Carefully solder the ~~modultor~~ input wire to the solder bridge created in step 83.		85) Carefully solder the modulator input wire to the solder bridge created in step 83.

	[[File:TK-n6ng_modulator_wire_connected.jpg\|320px]]		[[File:TK-n6ng_modulator_wire_connected.jpg\|320px]]
Line 624:		Line 624:
	[[File:TK-n6ng_devicnet_to_ribbon_heatshrink_applied.jpg\|320px]]		[[File:TK-n6ng_devicnet_to_ribbon_heatshrink_applied.jpg\|320px]]

	115) Carefully slide the 1/4" heatshrink tubing up the ribbon cable and over the soldered/heatshrink bundle. This may be a tight fit, it is possible to slightly ~~strech~~ the heatshrink using needle nose pliers or similar method. Ideally the outer 1/4" heatshrink sould cover all the other pieces of heatshrink.		115) Carefully slide the 1/4" heatshrink tubing up the ribbon cable and over the soldered/heatshrink bundle. This may be a tight fit, it is possible to slightly stretch the heatshrink using needle nose pliers or similar method. Ideally the outer 1/4" heatshrink sould cover all the other pieces of heatshrink.

	[[File:TK-n6ng_outer_heatshrink_slide1.jpg\|320px]]		[[File:TK-n6ng_outer_heatshrink_slide1.jpg\|320px]]
Line 645:		Line 645:
	[[File:TK-n6ng_devicenet_to_groove.jpg\|320px]]		[[File:TK-n6ng_devicenet_to_groove.jpg\|320px]]

	120) It may be ~~nessesary~~ to reroute the speaker wire from in between the capacitors to around the front to allow clearance for the devicenet cable.		120) It may be necessary to reroute the speaker wire from in between the capacitors to around the front to allow clearance for the devicenet cable.

	[[File:TK-n6ng_devicenet_speakerwire_moved.jpg\|320px]]		[[File:TK-n6ng_devicenet_speakerwire_moved.jpg\|320px]]