B&B Tech: Full Monte TS-440S/AT

"FULL MONTY" TREATMENT FOR THE TS-440S(AT)

The TS-440S(AT) is the "workhorse" of Kenwood's old-line solid state rigs, and certainly one of the most popular. To date we have done over 250 of these. Please note when purchasing a TS-440S(AT) on the used market: Virtually every TS-440S(AT) either HAD, HAS, or WILL HAVE problems with the PLL/VCO circuitry. This is evidenced by distortion on receive and/or transmit, "all dots" on the display (which temporarily go away when the dial is spun), or intermittant transmit output. If you have a TS-440S(AT) that exhibits any of these problems at any time, your rig needs the FULL MONTE treatment!

Here's what you get for your money:

	r&r (remove/replace) the RF unit and clean and resolder around the VCO-1 area (this alone can take up to 6 hours)
	r&r the PLL unit and clean and resolder around VCO-5 area, and others as needed.
	realign all 5 PLLs as needed
	replace the memory battery
	replace audio output cap
	replace meter lamp, if needed
	lube VFO shaft
	align RF and IF stages
	60M transmit mod
	set final and driver bias per factory spec
	clean controls as needed
	any other minor repairs needed
	on-air check, receive and transmit

All this for a Full Monte rate of only $189 (major parts and shipping extra).

IMPORTANT NOTE: FOLLOW OUR SHIPPING ADVICE! THE MIC/CAR CONTROL IS NO LONGER AVAILABLE FROM KENWOOD. IF YOURS IS DAMAGED IN SHIPPING, WE WILL NOT BE ABLE TO REPAIR IT. SEE THE SHIPPING PAGE FOR PACKING INSTRUCTIONS. DO NOT USE THE ORIGINAL BOX.

Additional notes on the TS-440S
If you '440 is experiencing keypad bounce (as evidenced by repeating digits with only one keypress), your keypad is dirty. While we have had some success in cleaning these, it is very labor intensive, and due to the age of the adhesive used on the plastic covering, these are starting to split when taken apart. Adding this labor to the "full Monte" repair would be cost-prohibitive. Also, given the chance that we may not be able to restore functionality to the keypad, we are electing not to do this particular repair. For direct entry frequency control, we recommend exploring a PC link to the 440. The best way to keep your keypad clean is to USE IT at least once a week; run through all digits, all modes and all VFO functions often. This will burnish the contacts over time and may actually help correct the problem.

An additional issue of "all 8's" on the display (usually also accompanied by excessive brightness of the display) can sometimes be corrected with a simple reset (a=b, power on). If that does not work, the 8255 "I/O expander" chip is bad on the control unit. We may be able to bring it back with a new chip; we will contact you if this is the case. This repair would be in addition to the Full Monte charge (about another $50).

If your autotuner (AT) unit has ceased working on one or more bands (usually it will either NOT work on 10M, or it will ONLY work on 10M!), the cause is a burned AT unit relay. This will also add about $50 to the Full Monte price, including the relay.

SHOULD I FIX IT, OR REPLACE IT?
When deciding whether to "fix or replace" any rig, keep in mind the replacement cost of an HF rig with built-in autotuner, usually around $900 and up. Please contact us if you need help deciding which way to go. We want you to be happy, regardless.