KB2LJJ Radio Mods Database and Manuals
Contents
1. TS 450S TX frequency response Service Bulletin no 1004 We have received several reports concerning the transmit audio quality of this unit Several reporters noted that the signal sounded hard or had a reduced bandwidth while others noted a difference in the noise quality when switching between USB and LSB We noticed a significant difference between the output power in LSB and USB on some of these sets Cause Improper adjustment of the 8 83 MHz tuning coils L73 L76 on the RF unit X44 3130 00 can cause these symptoms The coils have two tuning points One is reached when the tuning slug project above the surface of the coilk form When tuned in this manner the bandwidth becomes narrow then normal and causes the symptoms noted above Alignment procedure Adjustment should be performed with the YK 88S1 2 4 KHz filter in line If this filter is not preset you should select the THRU position for the 8 83 MHz IF Adjust L73 and L76 according to the instructions provided in the service manual Item 6 of the Receiver adjustment Ensure that the slug are preset well down in the coil form then adjust for peak You should reach this point before the top of the slug exist the coil form Next readjust L74 and L75 Item 8 of the Receiver adjustment Select the 6 KHz filter for both the 8 83 MHz IF and the 455 KHz IF http www kb21jj com data kenwood ts 450 htm 4 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and2. 18 Kohm RK73FB2A183J Change chip resistor R234 from 1 Kohm to 8 2 Kohm RK73FB2A822 J Delete chip capacitor C173 100 pF and add chip resistor R299 1 5 Kohm RK73FB2A152J Add the following note to page 35 and 37 of the Instruction manual When adjusting for proper ALC levels with an AFSK RTTY terminal or Packet TNC terminal you should adjust VR 13 on the IF Unit for a reading similar to the one shown in the accompanying diagram Note The transceiver and RTTY or TNC terminal should use separate power supplies in order to prevent RFI Radio Frequency Interference Caution This modification requires soldering equipment rated for CMOS type circuits It also requires familiarity with surface mount soldering techniques If you do not have the proper equipment or knowledge do not attempt this modification yourself Seek qualified assistance http www kb21jj com data kenwood ts 450 htm 3 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals Change to 18 EK ohm Mounted on Component Side AS EMS felis Mounted on Component Side Remove C173 Replace with R299 Part of IF Unit X48 3090 XX Foil Side View a o oS 9 20 AQ 6008 HOODOO COUOODOUOB EEO i 0 2 5 5 0 10 0 J PWR l j ALC SWR GEGEBODDOOODOOOOOODOOOOROOoOOoOoO dB 1 20 45 2 id Dont make initial SLO adjustments For Packet etc over this level Adjust higher only ifyou can do this without distortion
3. Manuals Select a dial frequency of 14 100 4 MHz Select the USB mode Adjust L74 and L75 for maximum Select the LSB mode Readjust L74 and L75 for maximum Repeat steps 3c 3f several times until you obtain a difference of 2 dB or less in the AF output when switching between USB and LSB Check Item 14 CAR point adjustment Transmitter section Menu items 11 and 12 and confirm that the transmitter power is equal for USB and LSB TS 450 690 Calibration cable change Service Bulletin no 995 The TS 450 690 may not calibrate properly against WWW JJY when using the calibration cable that is supplied with early versions of these sets serial numbers below 311xxxx and when an antenna that is shorted for DC is used A dipole with a balun is a prime example of a DC shorted wire A minor circuit modification that adds a 100 pF isolation capacitor should also be performed Please refer to the diagrams below for modification notes Parts required E37 0280 05 Calibration cable assembly 1 Ea CK73FCHIHIOIJ 100 pF capacitor 1 Ea Red Cable co iy es l l White Cable Mew Calibration Cable E37 0280 05 PLL Divider Output Cut the foll pattern ji at this Lia and CAL Terminal 4Pacitor PLL Unit XB0 0150 4X Micro input RFI modification TS450 TS690 Kenwood http www kb21jj com data kenwood ts 450 htm 5 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals By Pedro M J Wyns RF
4. and biomedical engineer History After buying a ts690 I got considerable trouble with the vox circuitry The Vox gain was always too high due to an excessive feedback resistance in the vox amplfier Apparently a PCB mounting failure as the schematic carried the right value After correcting this problem I still got RF problems with nearby antennas blocking the transmitter in TX Problem lack of decent RF filtering on the micro input circuitry Solution adding ferromagnetic cores and adjusting rc filters on the IF board Action remove the connectors on the right hand side of the IF board underside transceiver front towards you Unscrew the board and fold over to the left Add 22 nF parallel to R282 1k on t he micro entry close to Connector 6 Add InF parallel to C177 close to the IC 15 input Add InF parall el to C217 close to the vox amplifier Remove te micro in and ground from the number 6 connector Feed the white micro wire through a two hole ferrite core Feed the inner conductor through a small ferrite core as well Reconnect If you might be using an MFJ major fucking junk voice keyer disconnect the shit unshielded micro cable and replace by high quality twin balanced micro cable Only use PTT Mic and GND This concludes the mod Don t even think of doing this without the service man ual and some smd practice Good Luck Pedro M J Wyns Pedro Wyns emmaus be Moutstraat 7 B 2220 Hallaar Belgium Europe Fax 32 15
5. t plugged in it s happened If you don t find anything obvious then recheck your solder connections checking for possible bridged connections hen the modification is done correctly you will see about a 4 S Unit increase at SOOKHz I hope this information is useful to many 73 Andy KU4XR ATTENTION The KB2LJJ takes no responsibility for any damage during the modification or for any wrong information made on this modification http www kb21jj com data kenwood ts 450 htm 11 di 11 01 09 2009 0 07 51
6. the TS 450S If someone knows how to do this plaese let me know TS 450S and KAM Plus info Hi just found out a KINK in hooking up the TS450S to a KAM Plus for AMTOR op You have to turn ur Delay and CAR control to 0 to get it to work mode A Neither control should be active when running AMTOR LSB but they are TRUST ME TS 450S BCB Attenuator Circuit This modification will bypass the BCB attenuator in the RF section of the TS450 series radio Although similar in many aspects to the TS850 there are circuit differences And as anyone who has tried the TS850 mod on the TS450 quickly found out that it won t work TS4508S Bypassing The DS L L9 Attenuater oe A NN PY W d RF Board RLS135 xaqqg 3130 01 Edited Schematic Cireuit Only Ga 5 wu Oas Ori Ji OOs d i ual Pin 2 Tract from IC 2 BAND SELECT CHIP http www kb21jj com data kenwood ts 450 htm 8 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals ROP 10h C162 he A Crude drawing oF appre maiz Ta EF Beard ne he firts hay euT for The eens Gee ne Aperivotor crenta p Az eo 2 Emke bottom side oF Zea a s pF B SmD FcesrsvYors ce here will be A Pex z wa i ene For gach Pin of TES wrth RF Board upsal ee rit Pina 1 oO The leftside oF T l ge thest i rom You ba PAYOR TT aE ov E EER i A ee Tes fer Te eA seca me Set Aan 4 smD Compowenwt S located T
7. work will be done on the underside of the RF Board First for safety disconnect all power and cables turn the radio upside down with the front facing you and remove the bottom cover Once done you will see 2 circuit boards The one on the right is the IF board The one on the left is the RF board This is the board you will be working on First examine the top side of the board the circuit traces are labeled on the board find IC 2 Pin 2 and you can visiually follow the trace to the section to work on Once this is done remove the screws from the board so you can turn it over to work on the back side To turn the board over you will need to unplug the 2 pin plug located at the back of the board in a cut out section You will need to unplug the green mini coax type plug located in the middle of the board next to where the optional CW filter installs At the front of the board you will need to unplug the 2 pin Blue wire plug located close to the left side of the board and almost directly above the plug is a 1 inch wide ribbon cable about 3 inches long Unplug one end This should allow you to turn the board over not actually removing it from the radio If you ve never had the board out before it takes a little sliding and pulling to get the left front corner lifted up and forward to be able to flip it over The wires are getting old and stiff and on the plugs can break off sometimes The wiring harness will need to be moved around to ge
8. 303115 KAM PLUS Problems with TS 450 amp 850 A common problem when using a KAM Plus multimode with the Kenwood TS 850 or TS 450 occurs when the KAM Plus is coupled to the Accessory 2 socket on the back of the transceiver producing noticable distortion of the transmitted audio when using the microphone in SSB mode The problem is easy to cure by disconnecting the Accessory 2 plug from the back of the tranceiver but this meant moving the transceiver around every time one wished to operate on SSB The problem is caused by the input sensitivity of the rear Accessory 2 socket being set to high so that it picks up very low level noise from the KAM Plus and associated computer wiring this mixes with the microphone signal to produce the distortion The cure is to reduce the input sensitivity of the radio thus reducing the chance of distortion also it goes without saying that the output from the KAM Plus must be increased to compensate for this ith both the TS 450 and TS 850 adjusting the input sensitivity is straight forward and the transceiver manuals show you the appropriate control and its location This is in both cases VR18 to be found on the main board of the radio refer to manual in practice I found that it was best to adjust this control fully counterclockwise Then we need to adjust the output from the KAM Plus by varying potentiometer R28 and setting removable link K9 this link is factory set on one post only in the op
9. 9 0 07 51 KB2LJJ Radio Mods Database and Manuals Replace with R300 bes sisi R92 0670 05 DSP 3 Connector L i m T a r z Ma a maea m ma ee ee ee e m m mn IF Unit 48 3090 XX Foil Side View Caution This modification requires soldering equipment rated for CMOS type circuits It also requires familiarity with surface mount soldering techniques If you do not have the proper equipment or knowledge do not attempt this modification yourself Seek qualified assistance TS 450S Parts change Service Bulletin no 1036 The 2SC2509 driver transistor are no longer available They have been discontinued by the manufacturer A substitute transistor 2SC3133 is available but requires some minor circuit changes These changes are detailed below Parts required Qty Description Kenwood Part No Circuit description 2 Driver transistor 20G3133 Q2 Q3 2 330 ohm 1 watt carbon resistor RC05GF2H331J R8 R9 1 047 uF ceramic capacitor C91 0119 05 C2 2 220 pF ceramic capacitor CC45SL2H221J C64 C65 1 560 pF ceramic capacitor CC45SL2HS561J C63 Note C64 and C65 should be soldered directly to the collector and emitter pins of the final transistor Q4 and Q5 http www kb21jj com data kenwood ts 450 htm 2 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals TS 450S 690S Noisy encoder Service Bulletin no 1059 Symptom When tuning the Main Encoder of the TS 450S 690S with bare hands you may encoun
10. KB2LJJ Radio Mods Database and Manuals Contact Downloads Radio Niods Database NMiods Manuals anc Circuits B2 i JJ hittp Jwww kdb ali com TS 450 Expand RF M C General coverage transmission modification for the TS 450 and TS 690 1 Disconnect the power and antenna 2 Remove the top and bottom covers from the radio Take all 14 Screws 3 Remove the top screws countersunk from each side of the front panel 4 Loosen the bottom screws countersunk from each side of the panel 5 Carefully pull the top front panel forward to expose the digital beard 6 Remove the 7 screws from the digital board 7 Disconnect the 5 cables from the digital board 8 Rotate the board towards the front panel to gain access to the back side of the board 9 Locate and remove Diode D 27 Do not pry up the diode The traces will rip apart 10 Reassemble the radio TS 450 690 Low mic gain w DSP 100 Service Bulletin no 1032 Symptom Proper microphone gain ALC readings cannot be obtained unless the user adjusts the TX GAIN potentiometer on the rear of the DSP 100 This irregularity is caused of the DSP 100 MIC amplifier IC 5 Corrective action Remove capacitor C200 from the IF unit on the transceiver and replace it with R300 a chip jumper wire Parts required Qty Description Kenwood Part No Circuit description 1 Chip jumper R92 0670 05 R300 http www kb21jj com data kenwood ts 450 htm 1 di 11 01 09 200
11. e This A Point ee Bottemer RF Beard 1 Re A OSL Be are ful Net to Byfiss Ci eao SMP Cafaciters ere Seid apt HT AHS Seen B hight rou Brown TAN Cour Tire The Bertom OF Sm p Pes asters are vhe Boar d Usugily Black 1S Lateled pup oF EF porn the Civenif Traces Fee Be s3 lm Erewt are labeled a the Bp oF the RF Poard 4 USe your Ohm Meter Continut Setting Te Trace points Erem 7 Mig T Exton http www kb21jj com data kenwood ts 450 htm 9 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals GIVE CREDIT WHERE CREDIT IS DUE after months of Googleing I wasn t able to find any info on this mod on the internet A fellow who I only know as Jordan in Canada emailed me the component values and numbers to bypass Then after locating a readable schematic of the RF Board I was able to blow it up and see schematically where I needed to work It was a little more difficult actually finding the parts on the circuit board Once I did I was able to bypass the attenuator circuit It gave a marked improvement in reception from SOOKHz to 1705KHz Allow me to caution you the work is a little tedious Extremely small components and very close spaced The area on the board you ll be working in is probably 4 inches square so TAKE YOUR TIME double and triple check each component to make sure it is the right one before soldering on it KE AI soldering
12. en position this should be connected shorting the two posts thus putting the KAM Plus into the high output position and then potentiometer R 28 is adjusted to give full power out from your HF radio with very little ALC deflection when the MIC gain is in the normal operating position Then I am sure you will find that your problem is over you can now simply change from digital modes to SSB Remember if you have your Beacon activated to turn it OFF or it could cause a few comments when operating SSB TS 450S Intermittent receive fixed http www kb21jj com data kenwood ts 450 htm 6 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals After making a careful mobile installation WBOBQV found his TS450S to have intermittent receive He removed the screw that was going through the coax in his car and made a second installation in his truck More intermittent With some careful diagnosis he found that moving the coax connector up and down caused the change in signal With the radio opened up I found that moving the coax connector was breaking the contact between the wire from the center conductor and the board W1 in the schematic To save on pulling the filter board I used a short piece of very flexible test prod wire to connect from the center of the UHF connector to W6 on the top of the PC board W6 jumps over the contacts of a relay used only in the TS 690S For added security I also added another wire of the same material fro
13. inhead with a crowbar It is recommended that you use a 15 watt grounded iron to do the soldering with and ground yourself against static discharge I used pre tinned lead wire cut from excess lead length from previous work TAKE YOUR TIME it will be very easy to accidentally bridge components with a solder joint Use a pair of needle nose pliers to bend the end of the lead wire into a L shape as long as the resistor is about 1 16th inch Preheat the wire to melt the solder I used silver solder low melting temp works faster with less heat Put a drop of solder on the tip of the iron and touch each end of the resistor to melt the solder for a fresh joint Using your needle nose pliers hold the wire on the resistor and heat each end to make the bridge connection If you can gently tug at the wire and it dosen t come loose then your connection is successful After you have bypassed R6 and R7 the Modification is done You can now begin the process of putting the board back in the radio Again TAKE YOUR TIME It s easy to miss a cable or plug and go through the process of putting the radio together only to have it not work Your first thought will probably be Oh man the mod didn t work it killed the radio Back up Take a breath and of course take the radio back apart But before you try to undo the mod check for the obvious Loose or disconnected cable maybe a broken wire on a plug Even a bent pin on a plug or the antenna isn
14. is possible to configure the set to personel needs by hold down some buttons during Power on There are three buttons listed in the manual The menu of Power ON LSB USB is listed on page 54 from the manual The menu of Power ON M IN is listed on page 55 The menu of Power ON ENT is listed on page 83 As often usual in microprocessor controled equipment there are hidden keyboard combinations who make it possible to configure more functions then is listed in the manual At Power on CLR ENT a reset to factory defaults is taken place All memory programming is lost All filters are available also these who are not fitted But there is something more The receiver is able to receive from 30 kHz to 40 MHz Transmitting is possible on 1620 kHz to 2000 kHz 3500 kHz to 4000 kHz 7000 kHz to 7500 kHz 10 0 MHz to 10 5 MHz 14 0 MHz to 14 5 MHz 18 0 MHz to 19 0 MHZ 21 0 MHz to 21 5 MHz http www kb21jj com data kenwood ts 450 htm 7 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals 24 5 MHz to 25 0 MHz 28 0 MHz to 30 0 MHz Unfortunately after power off and switching on the programming is returnd to the most of the old values but the 100 memory places are still empty So one advice before start of experimenting note the contens of the memory places and configuration on a piece of paper and read the F manual Until now I do not have a method to program the expanded receiving and transmitting frequencys into
15. m the ground lug on the UHF connector to the end of D1 1 away from the coax connector So now if the flexible back panel breaks the other wire too it won t have so much effect The coax connector is mounted on a 1 32 plated steel panel so is excessively flexible in mounting Ideally that connector should be mounted far more stiffly for those that use real RG 8 coax TS 450 TS 850 feedback ACC 2 Conn Hi if you are using the ACC 2 connector to interface with your multi mode controller you may have had a problem with your transmitted audio signal being distorted to eliminate this see bellow Set your meter on the radio to read ALC PK232 OWNERS if alsso using a VHF tranceiver adjust the AFSK level for proper VHF operation as expalained in chapter 3 of the operating manual If not adjust for proper SSB operation DSP 1232 DSP 2232 Owners Adjust the appropriate AFSK level control for proper SSB operation as expalined in chapter 3 of the operating manual Place the TNC in calibrate mode and press K to key the radio Adjust VR 13 on the TS 450 or VR 18 on the TS 850 so that the meter Just comes off the peg as described in the section titled SSB Tranciever Final Adjustments in the TNC operating manual Press Q to quit the CALIBRATE mode This modification should not affect any of the other normal operations of the radio Copy of service bulletin from AEA TS 450 hidden functions As users of the Kenwood TS 450S already known it
16. t some of the screws out of the board Once the board is loose you can stand it on its side and use you ohm meter to trace from the top of the board to the bottom side Locate Pin 2 on IC 2 on the bottom side Lay the board over on its top and follow the trace to the point where it is marked 5 1 6 on the top side At that point there will be a SMD resistor located about 1 8th inch to the left This should be R35 the 68 Ohm resistor Check its value to confirm it is Next in the line you ll see 2 tan colored SMD s these should be C19 C20 You should not be able to read resistance on these of course Following the circuit on around the next component should be R8 a 10 Ohm resistor Confirm this with your meter You re getting close Follow the trace to the next SMD This should be R7 a black 39 Ohm resistor part of the attenuator Confirm this with your meter follow the trace to the next SMD which should be R6 a black 39 Ohm resistor part 2 of the attenuator Confirm this with http www kb21jj com data kenwood ts 450 htm 10 di 11 01 09 2009 0 07 51 KB2LJJ Radio Mods Database and Manuals your meter When you are sure you are in the right section especially 5 1 6 section you can proceed with the modification It is as simple as soldering a very small piece of wire lead across each of the resistors R6 R7 But as simple as it is to say it certainly isn t as simple to do It s kind of like trying to solder a p
17. ter a scratching noise in the speaker if an antenna with a high SWR is used If gloves are worn no problem is encountered This occurs because the shaft of the encoder is not grounded Countermeasure Replace the Main Encoder with one that has a grounded shaft Parts required Qty Description Part No 1 Main encoder W02 1836 05 2 Mounting screws N90 3006 46 Note You must use the new mounting screws listed above with the replacement encoder TS 450 690 Distorted TX w TNC Service Bulletin no 1002 Note This bulletin supercedes bulletin ASB 994 dated 10 April 1992 We have received several reports of distorted transmitter audio when using a TNC controller such as the AEA PK 232 or Kantronic KAM etc The symptom will generally disappear if the transceiver and TNC units are powered from different sources Cause The audio output level form the TNC is generally too high and causes overload of the microphone amplifier circuit In previous models such as the TS 440S the incoming TNC audio was inserted after the microphone amplifier With the TS 850S it is inserted before the microphone amplifier Just moving the insertion point to the output of the circuit is satisfactory since the drive level for FM packet is higher then that required for SSB Procedure Add a 10 dB attenuator to the PKD line on the IF unit X48 3090 XX This will prevent overmodulation of the microphone input circuit Change chip resistor R233 from 10 Kohm to
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