APX™ TWO-WAY RADIOS APX MOBILES O2, O3, O5, O7 & O9 CONTROL HEAD INSTALLATION MANUAL
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Foreword This manual covers the O2, O3, O5, O7 and O9 models of the ASTRO® APX™ mobile radios. It includes all the information necessary to install mid power and high power radios, and configure radio installation inside vehicles. For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A list of related publications is provided in the section “Related Publications,” on page vi.
Installation Requirements for Compliance with Radio Frequency (RF) Energy Exposure Safety Standards ATTENTION! This radio is intended for use in occupational/controlled conditions, where users have full knowledge of their exposure and can exercise control over their exposure to meet FCC limits. This radio device is NOT authorized for general population, consumer, or any other use.
Table of Contents iii Table of Contents Foreword ..........................................................................................................i RF Energy Exposure and Product Safety Guide for Mobile Two-way Radios..............................................i Manual Revisions .........................................................................................................................................i Parts Ordering .................................................................
iv Table of Contents 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Radio Mounting ........................................................................................................................... 2-19 2.2.2 Remote Mount with Trunnion.......................................................................................... 2-23 2.2.2.1 100W Radios Only................................................................................................. 2-24 2.2.2.2 Remote Mount Control Head Installation...........
Table of Contents 4.3 4.4 4.5 4.6 Vehicle Interface Port Overview .................................................................................................... 4-6 4.3.1 VIP Output Connections ................................................................................................... 4-7 4.3.2 VIP Input Connections ...................................................................................................... 4-8 Compatibility of Emergency when Attaching a Siren ...................
vi Table of Contents Chapter 6 6.1 6.2 6.3 Cable Connection .......................................................................................................................... 6-1 6.1.1 O2 Control Head............................................................................................................... 6-1 6.1.2 O3 Control Head............................................................................................................... 6-1 6.1.3 O5 Control Head..........................
List of Figures vii List of Figures Figure 1-1. Figure 1-2. Figure 1-3. Figure 1-4. Figure 1-5. Figure 1-6. Figure 1-7. Front View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion ....................... 1-1 Side View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion......................... 1-1 Front View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion .............. 1-1 Side View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion................
viii List of Figures Figure 1-35. Remote Mount Configuration with High Power (100W) Radio Transceiver and O7 Control Head................................................................................................................. 1-10 Figure 1-36. Remote Mount Configuration with High Power (100W) Radio Transceiver and O9 Control Head................................................................................................................. 1-10 Figure 1-37.
List of Figures ix Figure 2-37. O3 Control Head Rear View ............................................................................................... 2-31 Figure 2-38. Hang-Up Clip Installation Exploded View ........................................................................... 2-31 Figure 2-39. Locking Kit (Optional) (Cannot Be Used for 100W Radios) ................................................ 2-32 Figure 2-40. Lock Supplied with 100W Quick Release Trunnion ..................................
x List of Figures Figure 4-12. Rear Accessory Connector Audio Configuration ................................................................ 4-12 Figure 4-13. Rear Accessory Connector Data Configuration.................................................................. 4-12 Figure 5-1. Identification of a Motorcycle Radio by Using a Label .......................................................... 5-1 Figure 5-2. Universal Mounting Plate Installation (Part of Radio Enclosure Kit) ...........................
List of Tables List of Tables Table 2-1. Table 2-2. Dash O2, O5 or O7 Radio Operations Dependent Upon A+ and Ignition Connections. 2-16 Remote O2, O5, O7, or O9 Radio Operations Dependent Upon A+ and Ignition Connections ...................................................................................................... 2-16 Table 2-3. Remote O2, O5, O7 or O9 Radio Operations Dependent Upon A+ and Ignition Connections ..................................................................................
xii List of Tables Notes 6878215A01
Mobile Radio Model Numbering Scheme xiii Mobile Radio Model Numbering Scheme Typical Model Number: M Position: 1 3 2 0 3 U 4 R 5 Position 1 - Type of Unit M = Mobile L = Table Top Station Positions 2 & 3 - Model Series 30 = APX 7500 24 = APX 2500 25 = APX 6500 22 = APX 4500 Position 4 - Frequency Band N = 330 to 370MHz A = Less than 29.7MHz P = 366 to 410MHz B = 29.7 to 35.
xiv Mobile Radio Model Numbering Scheme Notes 6878215A01
Commercial Warranty xv Commercial Warranty Limited Warranty MOTOROLA COMMUNICATION PRODUCTS I. What This Warranty Covers And For How Long MOTOROLA SOLUTIONS INC.
xvi Commercial Warranty III. State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY. This warranty gives specific legal rights, and there may be other rights which may vary from state to state. IV.
Commercial Warranty xvii VI. Patent And Software Provisions MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the extent that it is based on a claim that the Product or parts infringe a United States patent, and MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following: A.
xviii Commercial Warranty Notes 6878215A01
Chapter 1 Introduction This manual covers the installation procedures for ASTRO APX mobile and motorcycle radios with O2, O3, O5, O7 and O9 control heads, and accessories required to complete the radio system. The radio system consists of a control head, radio, antenna, microphone, speaker, cabling, Universal Relay Controller (URC), and accessories. 1.1 Mobile Radio Description 1.1.
1-2 Introduction Mobile Radio Description NOTE: The rear accessory connector adds 0.75 in to the overall length. The remote mount length is 194mm. 223 293 74 90 Figure 1-5. Front View of APX 7500 High Power (100W) Transceiver and Trunnion Figure 1-6. Side View of APX 7500 High Power (100W) Transceiver and Trunnion 278 206 269 69 92 Figure 1-7. Front View of O2 Control Head Attached to APX 7500 Mid Power Dash Mount Transceiver and Trunnion Figure 1-8.
Introduction Mobile Radio Description 1-3 61 38 153 Figure 1-11. Front View of O3 Control Head with Coiled Cable Figure 1-12. Side View of O3 Control Head with Coiled Cable 209 123 97 99 Figure 1-13. Front View of O2 Control Head with Remote Mount and Trunnion Figure 1-14. Side View of O2 Control Head with Remote Mount and Trunnion 75 180 51 Figure 1-15. Front View of O5 Control Head with Remote Mount and Trunnion 6878215A01 Figure 1-16.
1-4 Introduction Mobile Radio Description 209 108 178 82 91 Figure 1-17. Front View of O7 Control Head with Remote Mount and Trunnion Figure 1-18. Side View of O7 Control Head with Remote Mount and Trunnion 83 190 178 Figure 1-19. Front View of O9 Control Head with Trunnion Figure 1-20. Side View of O9 Control Head with Trunnion 185 61.5 210 Figure 1-21. Top View of O9 Universal Relay Controller with Trunnion (URC is an orderable accessory.) Figure 1-22.
Introduction Standard Configurations 1.2 Standard Configurations 1.2.1 Dash Mount Configuration 1-5 NOTE: The dash mount configuration is not applicable for 100W radios and O9 control heads. There are two versions of the APX mobile dash mount. The first are the O2, O5 and O7 control heads which are mounted on the front of the transceiver housing. The second is the O3 control head which is connected to the transceiver via a coiled cable, which is plugged into the CAN connector on the transceiver.
1-6 Introduction Standard Configurations ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile Figure 1-25. Dash Mount Configuration for O5 Control Head (Only Applicable for ASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li Mobile) ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile ASTRO 25 Subscribers APX 2500 Figure 1-26. Dash Mount Configuration for O7 Control Head For details on this configuration, see Section 2.2.1 on page 2-21.
Introduction Standard Configurations 1.2.2 1-7 Remote Mount Configuration In the remote control version, the transceiver and the control head are mounted separately in the vehicle. The O2, O5 and O7 control heads are mounted in remote trunnions near the operator.The O3 and O9 control heads are also mounted near the operator using extension cables. The transceiver and control head are mounted using a trunnion or other mounting hardware.
1-8 Introduction Standard Configurations ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile MMP MMP Figure 1-29. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O5 Control Head ASTRO 25 Subscribers APX 2500 ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile MMP MMP Figure 1-30.
Introduction Standard Configurations 1-9 Figure 1-32. Remote Mount Configuration with High Power (100W) Radio Transceiver and O2 Control Head 5 m (17 ft) Extension Cable Figure 1-33. Remote Mount Configuration with High Power (100W) Radio Transceiver and O3 Control Head Figure 1-34.
1-10 Introduction Standard Configurations Figure 1-35. Remote Mount Configuration with High Power (100W) Radio Transceiver and O7 Control Head Figure 1-36.
Introduction Standard Configurations 1-11 17 ft Extension Cable O7 to URC Cable Figure 1-37. Remote Mount Configuration with Mid Power Radio Transceiver, Universal Relay Controller and O7 Control Head (URC is optional.) 17 ft Extension Cable O9 to URC Cable Figure 1-38. Remote Mount Configuration with Mid Power Radio Transceiver, Universal Relay Controller and O9 Control Head (URC is optional.
1-12 Introduction Standard Configurations O7 to URC Cable 17 ft Extension Cable Figure 1-39. Remote Mount Configuration with High Power (100W) Radio Transceiver, Universal Relay Controller and O7 Control Head (URC is optional.) O9 to URC Cable 17 ft Extension Cable Figure 1-40. Remote Mount Configuration with High Power (100W) Radio Transceiver, Universal Relay Controller and O9 Control Head (URC is optional.) For details on these configurations, see Section 2.2.2 on page 2-23.
Introduction Standard Configurations 1.2.3 1-13 Multi Control Head The multi control head option allows separate, remotely operated control heads to operate and control the radio. For example, a fire truck could have a control head located in the cab and on the rear of the truck so that the radio could be operated from outside the vehicle. NOTE: The dual control head can be used together in the future.
1-14 1.3 Introduction Motorcycle Configurations Motorcycle Configurations NOTE: The motorcycle configurations are not applicable for 100W radios and O9 control heads. The ASTRO APX mobile motorcycle radio models provide most of the equipment needed for installing a standard ASTRO APX mobile radio on a motorcycle. Most of this radio system is standard equipment. See Chapter 5: Motorcycle Radio Installation for further information. 1.
Chapter 2 Standard Configurations 2.1 Planning the Installation The APX mobile radio operates only in negative ground electrical systems with a valid operating range of 10.8VDC to 16.3VDC. Before starting the radio installation, make sure that the ground polarity of the vehicle is correct. Accidentally reversing the polarity will not damage the radio, but will cause the cable fuses to blow. Planning is the key to fast, easy radio installation.
2-2 2.1.1 Standard Configurations Planning the Installation Installation Examples The mobile two-way radio offers various methods of installation, with accessories placed to the vehicle as desired. The radio can be a dash or remote mount except for the 100W radio or with 09 control head, which can only be mounted remotely. The O9 control head with the radio and the URC can only be mounted remotely (see Figure 2-3). Speaker Antenna 1/4-Wavelength Radio 911 Battery Radio Figure 2-1.
2-14 2.1.3 Standard Configurations Planning the Installation Radio Operation Wiring for Dash and Remote Configurations Determine from Table 2-1, Table 2-2, or Table 2-3 the radio functionality you wish to achieve, which is controlled by the vehicle’s ignition switch state, the physical wiring of the radio’s ignition sense (ACC) wire, and by the programmed CPS setting. For additional radio functionality as determined by the programming of the ignition switch in CPS, refer to the HELP menu in your CPS (i.
Standard Configurations Planning the Installation 2-15 2.1.3.2 Remote Mount: Power, Ignition, and Emergency Cable Installation The single control head O2, O5, O7 or O9 remote mount configurations receive power from the J200 connector’s red and black wires. The yellow wire at J200 is one ignition sense wire. On mid power radios, the J2 and J600 connectors can also be used for ignition sense. On high power radios, the J200 yellow wire or the J600 connector can be used for ignition sense.
2-16 Standard Configurations Planning the Installation Table 2-1. Dash O2, O5 or O7 Radio Operations Dependent Upon A+ and Ignition Connections Dash Mount Connected to battery Transceiver Red Power Wire HLN6863 Thin Red Wire Transceiver Red Power Wire X X X No ignition switch control. Transceiver Red Power Wire HLN6863 Thin Red Wire X X Connected to ignition switch Ignition switch controls HLN6863 Thin Red Wire Enables ignition switch functionality as programmed in the codeplug.
Standard Configurations Planning the Installation 2.1.4 2-17 Ignition Sense Switch (Radio Wide Advance) CPS selectable settings to control the radio’s functionality based on the state of the vehicle’s Ignition status. Table 2-4. Ignition Sense Switch Settings in CPS Feature Blank Description • Radio POWERS ON when the Power Button is pressed or with the emergency power up feature. • Radio POWERS OFF when the Power Button is pressed.
2-18 2.1.5 Standard Configurations Planning the Installation Siren/PA Configuration/Programming The Siren/PA is shipped pre-wired for 100W operation. It can be rewired for 65W, 75W, or 130W power levels. To change to another power level, perform the following: 1. Open the Siren/PA connector cover to gain access to the two-connector speaker leads. Do not change the speaker common lead (pin 20). The other lead is connected to pin 35 (for 100W operation). 2.
Standard Configurations Radio Mounting 2.2 2-19 Radio Mounting ! Caution DO NOT mount the radio on a plastic mounting surface without first reinforcing the mounting surface; the weight of the radio may crack or break the mounting surface. DO NOT mount the radio on a flat or concave surface where the radio could be partially submersed in water. This is especially important if the cab area of the vehicle is cleaned by spraying with water.
2-20 Standard Configurations Radio Mounting RADIO FRONT Figure 2-23. APX 2500/APX4500 Mid Power Trunnion Orientation (Cannot Be Used for 100W Radios) Figure 2-24.
Standard Configurations Radio Mounting 2.2.1 2-21 Dash Mount with Trunnion NOTE: This configuration is not applicable for 100W radios. 1. Referring to Figure 2-6, select the suitable trunnion kit per the type of mid power transceiver. 2. Select the location to mount your radio on the transmission hump (see Figure 2-25) or under the dash (see Figure 2-26). NOTE: When mounting the trunnion on the transmission hump take care the transmission housing is not affected.
2-22 Standard Configurations Radio Mounting 3 1 1 Figure 2-25. Transmission Hump Trunnion Mounting 1 3 2 Tabs Plastic Guides 1 Groove Threaded Hole for Screw Figure 2-26. Below Dash Trunnion Mounting 7. Secure the radio with two screws provided (Item 1 in Table 2-6). The torque down force for 0371859H01 should be between 50in-lbf to 52in-lbf. 8. For screw 0305760W02, the wing screw torque tool (HLN6970_) is designed to securely tighten the trunnion wing screws while installing the radio.
Standard Configurations Radio Mounting 2.2.2 2-23 Remote Mount with Trunnion ! Caution Before installing any electrical equipment, check the vehicle manufacturer’s user manual. The installation of this device should be completed by an authorized servicer or installer. Before making any holes in the trunk for radio mounting, check the vehicle manufacturer's user manual for restrictions (e.g. due to the gas tank location).
2-24 Standard Configurations Radio Mounting 2.2.2.1 100W Radios Only NOTE: Cabling to the front of the radio (TIB) should not be completed with the handle opened as it is needed to be removed to close the handle. It is suggested that the cabling is to be attached to the front of the radio after the radio is assembled into the trunnion. 1. After selecting the mounting location, use the trunnion mounting bracket as a template and mark the positions of the holes on the mounting surface. 2.
Standard Configurations Radio Mounting 2-25 An adjustable trunnion, which allows a number of mounting positions, is supplied for mounting the control unit. The installation must not interfere with the operation of the vehicle or its accessories, nor disturb passenger seating or leg room. The control head must be within convenient reach and viewing of the user. If the trunnion is mounted on a plastic mounting surface, all four mounting screws should penetrate the mounting surface’s supporting metal frame.
2-26 Standard Configurations Radio Mounting ADJUST THE CONTROL HEAD TO DESIRED ANGLE AND SECURE WITH WING SCREWS USE FOUR MOUNTING SCREWS ON ALL INSTALLATIONS TRUNNION MOUNTING SURFACE IMPORTANT USE A METAL BACKING PLATE (NOT SUPPLIED) IF MOUNTING TRUNNION ON PLASTIC OR UNSTABLE SURFACE DRILL FOUR 5/32'' HOLES IN MOUNTING SURFACE Figure 2-29. O9 Control Head Installation Exploded View Figure 2-30.
Standard Configurations Radio Mounting 2-27 Figure 2-31. O9 Control Head Rear View 2.2.2.3 Multiple Control Head Installation Control heads in a multiple control head configuration should be installed per the steps detailed in Section 2.2.2.2: “Remote Mount Control Head Installation” on page 2-24. Two heads can be connected to each of the two CAN connectors on the transceiver, with the remaining heads connected to one or both of the first two.
2-28 Standard Configurations Radio Mounting FUSE J300R J300L FUSE J200 J300R J300L J200 RED LEAD )+( Control Head 1 Control Head 2 )-( BATTERY FUSE J300R J300L Control Head 3 J200 FUSE J300R J200 Control Head 4 Figure 2-32. Multiple Control Heads Example Configurations NOTE: In Multiple Control Head (MCH) installations, the yellow ignition sense wire must be connected to the head assigned ID # 1. See Section 2.2.2.
Standard Configurations Radio Mounting 2-29 Table 2-8. Ignition Interface Cables Part Number HLN6863_ PMLN4959_ Description Cable, M.A.P. 26pin with Only Ignition and SPK Cable, Y-Splitter with DB-25 and M.A.P. Interface 2.2.2.4 Cable Installation Route the cables where they are protected from pinching, sharp edges or crushing. Use grommets in any holes where the cable passes through metal panels. Figure 2-19 shows how the cables and components are connected.
2-30 Standard Configurations Radio Mounting O5 Mode Knob Figure 2-35. APX Mobile O5 Control Head Front View – Mode Knob 5. Repeat steps 1 to 4 above to set the ID of the remaining control heads. NOTE: In Multiple Control Head (MCH) installations, the yellow ignition sense wire must be connected to the head assigned ID # 1. 2.2.2.6 O3 Control Head and Remote Mount Cabling Choose a mounting location for the radio, considering accessibility, and control and antenna cable lengths.
Standard Configurations Radio Mounting 2-31 A mounting clip, which allows the control head to be mounted, is supplied together with the control head. The installation must not interfere with the operation of the vehicle or its accessories, nor disturb the passenger seating. The control head must be within convenient reach and viewing of the user. Install the mounting clip as follows: 1. Use the provided mounting clip to determine the location of the two screw holes. 2.
2-38 Standard Configurations Antenna Installation 2.4 Antenna Installation IMPORTANT: To assure optimum performance and compliance with RF Energy Safety standards, these antenna installation guidelines and instructions are limited to metal-body vehicles with appropriate ground planes and take into account the potential exposure of back seat passengers and bystanders outside the vehicle.
Standard Configurations Antenna Installation 2-39 7. Ensure that any transmitting radio antennas on this vehicle are separated from each other by at least 3 feet (0.9 meter). See Figure 2-49. 8. The minimum distance between the antenna and the radio/accessories should be at least 3 feet (91.44 cm). NOTE: Any two metal pieces rubbing against each other (such as seat springs, shift levers, trunk and hood lids, exhaust pipes, etc.) in close proximity to the antenna can cause severe receiver interference.
2-40 2.4.2 Standard Configurations Antenna Installation Mini-UHF Connection To help aid in the installation of the radio antenna(s), there are labels indicating the frequency. The first is on the FCC label at the top of the radio which calls out the frequency and by using arrow points, which side the RF connector of the frequency is located at the back of the radio. The second is located at the back of the radio, next to the RF connector(s) (see Figure 2-50).
Standard Configurations Antenna Installation 2-41 4. Slide the collar back against the flange. Insert the antenna cable plug’s pin fully into the radio jack, but do not engage the threads. 5. Ensure that the plug’s and jack’s interlocking features are fully seated. Check this by grasping the crimp on the cable jack, rotating the cable, and noting any movement. If the features are seated correctly, there should be NO movement. 6. Finger-tighten the antenna cable plug’s collar onto the radio’s jack. 7.
2-42 2.4.3 Standard Configurations Antenna Installation GPS Antenna Placement The GPS antenna (excluding the Motorcycle GPS antenna) must be placed at least, 3 feet (0.9 meters) away from any transmitting antenna, and the antenna must have a clear, unobstructed view of the sky for best performance. The length of the cabling must be taken into consideration before the installation is started. 2.4.
Standard Configurations Speaker 2.5 2-43 Speaker ! Caution DO NOT ground the radio's speaker leads. This system has a floating speaker output (DC voltage on both leads); damage to the audio circuit will result if either lead is grounded or if they are shorted together. The speaker kit includes a trunnion bracket that allows the speaker to be mounted in a variety of ways. With the trunnion bracket, the speaker can mount permanently on the mounting surface or in accessible firewall areas.
2-44 2.5.1 Standard Configurations Speaker Internal Speaker Disassembly NOTE: This configuration is only applicable for O2 Control Heads. You can disable the internal speaker of your radio by following the instructions below. Use the following procedure to disassemble your radio: 1. Unplug power, antenna, microphone and all accessories connections. If the radio is a remote-mount radio, disconnect the remote-mount control cable from the front of the transceiver. 2.
Standard Configurations Speaker 2-45 4. Put the control head face down on a clean, flat surface to avoid damaging it. Do not touch the o-ring on the back housing. 5. Carefully disconnect the speaker connector from the circuit board as shown in Figure 2-59. Figure 2-59. Disconnecting the Speaker Connector 6. Reattach the front housing assembly to the back housing assembly as shown in Figure 2-60.
2-46 Standard Configurations Microphone Hang-Up Clip 2.6 Microphone Hang-Up Clip 2.6.1 Standard or O3 Control Head Hang-Up Clip The hang-up clip must be within reach of the operator(s) and close enough to the control head to prevent cable strain. Measure this distance before actually mounting the bracket. Since the bracket has a positive-detent action, the microphone can be mounted in any position. Use the hang-up clip as a template to locate the mounting holes.
Standard Configurations RFID (Option) 2-47 RFID Tag Figure 2-63.
2-48 2.7.1 Standard Configurations RFID (Option) RFID Reading To read an RFID tag using a UHF Gen 2 RFID reader (e.g. Motorola’s MC9090-G), open an appropriate RFID read application, point the RFID reader at the tag and activate the reader's RFID antenna (e.g. pull Motorola’s MC9090-G scanning trigger). RFID reader must be within 1 foot from tag in order to read. Two variables, Read Angle and Reader Orientation, aid in the distance needed to read and write to the RFID Tag.
Standard Configurations RFID (Option) 2-49 Read Angle RFID Tag Figure 2-66. Read Angle for APX 2500/APX 4500 Mid Power Radio Tag Angle RFID Tag Figure 2-67. Tag Angle for APX 2500/APX 4500 Mid Power Radio Read Angle RFID Tag Figure 2-68. Read Angle for High Power Radio NOTE: APX high power mobile radio is shown without handle to allow visibility of RFID tag.
2-50 Standard Configurations RFID (Option) Tag Angle RFID Tag Figure 2-69. Tag Angle for High Power Radio Reader Reader Tag Tag Figure 2-70. Examples of Reader and Tag Aligned (Reader Orientation) Reader Tag Figure 2-71.
Standard Configurations RFID (Option) 2.7.2 2-51 Programming RFID (If Equipped) The user can reprogram the tag (up to 12 ASCII characters when encoded to hexadecimal format) using any UHF Gen 2 capable RFID writer (e.g. Motorola’s MC9090-G). NOTE: Follow read direction in Section 2.7.1 to optimized reprogramming. Table 2-10.
2-52 Standard Configurations Completing the Installation Table 2-11. Serial Number with Radio Band/Tier/Power 2.
Chapter 3 Universal Relay Controller Installation The Universal Relay Controller (URC) is an extension of and an orderable accessory for O7 or O9 control head. URC is used to control high power switching peripherals, e.g. lightbar. URC works on all lightbars which can be controlled by power application. URC is connected to the transceiver's GCAI port. The URC design consists of a microcontroller and uses 10 relays to control the switching device.
3-2 Universal Relay Controller Installation Universal Relay Controller Mounting Install the URC as follows: 1. Use the URC trunnion as a template to mark the mounting holes; drill 5/32" holes. If mounting on a plastic surface, use a metal backing plate. 2. Attach the trunnion bracket using all four 10 – 16" x 5/8" self-tapping screws provided. 3. Temporarily install the URC (adjust for proper viewing angle) and fasten it to the trunnion with two wing screws.
Universal Relay Controller Installation O7/O9 Universal Relay Controller Cable Assembly 3.2 O7/O9 Universal Relay Controller Cable Assembly 3.2.1 Power Cable 3-3 1. Remove the cap nut of power cable gland assembly, and insert the power cable through the cap nut and neoprene seal in the cable gland body. Use power cable with either AWG 6 or AWG 8 only (recommended OD range of cable is 5.5 mm to 9 mm) that is able to withstand 80 A and 50 A respectively, to ensure water sealing of the controller.
3-4 Universal Relay Controller Installation O7/O9 Universal Relay Controller Cable Assembly Counter Nut Cable Gland Body Gasket, Cable Gland Neoprene Seal Cap Nut Figure 3-4. Cable Gland Assembly with Gasket 3.2.3 Wires 1. Assemble the wires into the lightbar gasket retainer and lightbar gasket. The URC can support lightbars through control wires with outer diameter ranging from 1.52 mm to 3.77 mm (0.06” to 0.148”), with wire gages ranging from AWG 12 – 20. 2.
Universal Relay Controller Installation O7/O9 Universal Relay Controller Cable Assembly 3-5 Black Stick Figure 3-6. Wire Installation with Black Stick 5. The lightbar gasket should be replaced at each reassembly of the wire. NOTE: Use of other cable gages except as recommended in this manual may result in water intrusion. Any reassembly of wire needs a new lightbar gasket replaced.
3-6 Universal Relay Controller Installation Notes 6878215A01
Chapter 4 Options and Accessories Installation 4.1 Dash-Mount Accessory Installation NOTE: This configuration is not applicable for 100W radios. For dash-mounted configurations, the accessories must be installed through the accessory connector assembly that is located on the rear of the radio, adjacent to the power connector. Motorola-approved accessories are supplied with male terminals crimped to a 20-gauge wire specifically designed to fit the plug of the accessory connector assembly.
4-2 Options and Accessories Installation Remote-Mount Accessory Installation 4.1.2 Dash-Mount Horn and Lights (External Alarms) Relays NOTE: For installations that use the horn/lights option, select a suitable location for mounting (normally under the dash) and, referring to Figure 4-2, perform the following procedure: 1. Horn Relay – Connect the relay contacts across the horn ring switch, typically found in the steering column.
Options and Accessories Installation Remote-Mount Accessory Installation 4.2.1 4-3 Emergency Pushbutton or Footswitch Installation Mount the switch using the hardware that comes with the kit. Connect the button/switch wires to a ground pin and the emergency pin, removing the default jumper wire in the rear accessory cable. The button/switch will short the pins when in-active.
4-4 4.2.2 Options and Accessories Installation Remote-Mount Accessory Installation Horn (External Alarm) Relay Installation Mount the horn relay in a suitable location (normally under the dash). Connect the relay contacts across the horn ring switch, typically found in the steering column. Connect the two control wires to a SW B+ pin and a VIP OUT pin on the VIP connector. 4.2.3 Lights (External Alarm) Relay Installation Mount the light relay in a suitable location (normally under the dash).
Options and Accessories Installation Remote-Mount Accessory Installation 4.2.5 4-5 Horn-Ring Transfer Configure the Horn Relay for either Negative Contact or Positive Contact as shown in section 6.3 of the siren/PA manual (6881093C18). Program the designated VIP-OUT line for “Horn-Ring Transfer” and program the designated VIP-IN line for “Horn-Ring”. Figure 4-5 shows wiring diagrams for connecting the Horn-Ring via a transfer relay for both negative and positive ground systems.
4-6 4.2.8 Options and Accessories Installation Vehicle Interface Port Overview USB Data Cables It is recommended that the USB 1.5 meter data cable HKN6163_ is used for both dash mount configurations (at J2 connector) and for remote mount configurations (at J100 connector). This is because the HKN6163_ has the emergency jumper present, which is necessary for correct dash mount configurations. For interfacing at the MMP port, use Cable HKN6184_ which is a USB device cable.
Options and Accessories Installation Vehicle Interface Port Overview 4.3.1 4-7 VIP Output Connections The VIP output pins are on the back of the control head (J100 and J400), or the rear accessory port (J2), as shown in Figure 2-10, Figure 4-12 and Figure 4-13, respectively. Use these connections to wire control relays. One end of the relay should connect to switched B+ voltage, while the other side connects to a software controlled ON/OFF switch inside the control head.
4-8 Options and Accessories Installation Vehicle Interface Port Overview 4.3.2 VIP Input Connections The VIP input pins are only available on the back of the control head (remote mount). These connections control inputs from switches. One side of the switch connects to ground while the other side connects to a buffered input on the control head. The switch can be normally closed (NC) or normally open (NO) depending on the configuration of the VIP inputs.
Options and Accessories Installation Compatibility of Emergency when Attaching a Siren 4.4 Compatibility of Emergency when Attaching a Siren When using emergency footswitch or pushbutton with siren/PA configuration, REMOVE pin 8 (emergency) from the siren connector of the HKN4363_ siren cable as follows: Siren Cable Figure 4-9. Field adjustment for Emergency Operation with Siren Accessory 1. Remove the knob from the siren/PA cable connector. 2.
4-10 Options and Accessories Installation Accessory Connector Assembly Details (P2) (All Models Except 100W) 4.5 Accessory Connector Assembly Details (P2) (All Models Except 100W) The APX mobile accessory connector assembly is mounted on the right rear of the radio, opposite the antenna and adjacent to the power connector. It is fastened to the radio via jackscrews and held together by the two cover screws. It is a multi-functional connector that allows for many different types of adaptations.
Options and Accessories Installation Accessory Connector Assembly Details (P2) (All Models Except 100W) 4-11 4.5.1.2 Assembly 1. Place the plug in one cover. Be sure that the flange of the plug is in the slot of the cover. See Figure 4-11. 2. Push the jackscrew through the plug to hold it in. 3. Position each wire across the strain-relief features in the cover. Avoid damaging loads on the plug by allowing some slack in each wire in the accessory connector assembly’s wire chamber. 4.
4-12 4.5.2 Options and Accessories Installation Memory and Three-Day Secure Key Retention Option Adapter Cable If you are planning on installing an APX mobile radio as a replacement for an ASTRO Spectra radio, the following adapter cables are available: Part Number Description HKN6158_ Cable, Audio Adapter Kit HKN6159_ Cable, Data Adapter Kit NOTE: The adaptor cables can only be connected to J2 in the rear of the transceiver.
Chapter 5 Motorcycle Radio Installation NOTE: The motorcycle radio installation is not applicable for 100W radios, APX 4500 radios and O9 control heads. 5.1 Motorcycle Radio Description The motorcycle model includes all the same components in the standard radio, with the exceptions listed in the model charts in the APX Mobile Basic Service Manual (6875964M01). The following paragraphs describe the unique items provided with the motorcycle models.
5-2 Motorcycle Radio Installation Motorcycle Radio Description 5.1.3 Control Head Cable The control-head cable connects the control head to the transceiver. The cable is routed along the motorcycle’s frame and has weather-resistant connections at both ends. Excess cable is coiled under the transceiver inside the weather-resistant enclosure. Each end of the cable is strain-relieved with jackscrews at the control head and the transceiver.
Motorcycle Radio Installation Installation Overview 5.2 Installation Overview 5.2.1 General 5-3 All APX mobile radios are tested and inspected before shipment. It is, however, suggested that the transmitter frequency, deviation, and power output be checked at the time of installation. It is the license holder’s responsibility to ensure that the operating parameters of his station comply with applicable laws governing radio communications equipment.
5-4 5.2.2 Motorcycle Radio Installation Installation Overview Important Installation Hints Consider the following when mounting the radio components: • Excess lengths of control-head, power, ignition sense, and speaker cables must be routed in the enclosure as shown in Figure 5-16. • All components must be mounted securely in order to withstand the constant and sometimes severe vibration experienced on a motorcycle.
Motorcycle Radio Installation Installation Overview 5.2.3 5-5 Parts Identification The following installation procedures refer to Figure 5-2 through Figure 5-17. Detailed descriptions of the mounting hardware used in each procedure are provided in parts lists located in the exploded views located in the APX Mobile Basic Service Manual (Motorola publication part number 6881096C73).
5-6 5.3 Motorcycle Radio Installation Installing the Universal Mounting Plate Installing the Universal Mounting Plate The universal mounting plate, supplied with the motorcycle radio, must be mounted on the motorcycle first. It provides the base on which the weather-resistant enclosure is to be mounted. The method used for mounting the plate depends on the make and model of the motorcycle and whether the plate is mounted to a carrier or to the motorcycle chassis.
Motorcycle Radio Installation Installing the Speaker and Control Head 5.4 5-7 Installing the Speaker and Control Head NOTE: To disable the internal speaker of the O2 Control Head, please refer to Section 2.5.1: “Internal Speaker Disassembly” on page 2-44. The control head mounting location and configuration is determined largely by the make and model of motorcycle. Two different mounting configurations are described below.
5-8 5.4.1 Motorcycle Radio Installation Installing the Speaker and Control Head Handlebar Installation with Speaker and Control Head Mounted Together Figure 5-4 illustrates the combination speaker/control head bracket. This combination bracket is used only when the control head and speaker are to be mounted as a unit. Also illustrated in Figure 5-4 is a handlebar-mounting bracket which may be required if the combination speaker/ control-head bracket cannot be easily mounted to the motorcycle.
Motorcycle Radio Installation Installing the Speaker and Control Head 5-9 Provision has been made on the combination speaker/control-head bracket for mounting the microphone hang-up clip. If that mounting is desired, the hang-up clip must be attached to the bracket before installing the control head and speaker. See Section 5.6: “Installing the Microphone Hang-Up Clip” on page 5-14 for the hang-up clip procedure. Install the speaker and control head as described below. 1.
5-10 Motorcycle Radio Installation Installing the Speaker and Control Head Figure 5-5.
Motorcycle Radio Installation Installing the Speaker and Control Head 5.4.3 5-11 Handlebar Installation with Speaker and Control Head Mounted Separately It may be necessary to use the smaller control head bracket (part number 07-80127N02) and mount the speaker and microphone hang-up clip in another location on the motorcycle.
5-12 Motorcycle Radio Installation Installing the Speaker and Control Head Figure 5-6. Handlebar Installation with Speaker and Control Head Mounted Separately 5.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted Separately The control head may be mounted to the fuel tank console using the smaller control-head bracket and spacers/hardware. In this configuration, the microphone cable connector may be attached directly to the console, eliminating the need for a custom bracket.
Motorcycle Radio Installation Installing the Speaker and Control Head 5-13 Figure 5-7. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately Installation is the same as detailed in Section 5.4.2: “Fuel Tank Console Installation with Speaker and Control Head Mounted Together” on page 5-9 and Section 5.4.3: “Handlebar Installation with Speaker and Control Head Mounted Separately” on page 5-11.
5-14 5.5 Motorcycle Radio Installation Installing the Speaker Installing the Speaker NOTE: To disable the internal speaker of the O2 Control Head, please refer to Section 2.5.1: “Internal Speaker Disassembly” on page 2-44. Use the following procedure when the speaker is mounted separate from the control head. The speaker bracket supplied with the speaker may be used alone if a suitable location can be found, or if necessary, a customer-supplied bracket may be fabricated for mounting the speaker. 1.
Motorcycle Radio Installation Installing Antenna Base and Cables 5.6.3 5-15 Other Hang-Up Clip Mounting To mount the microphone hang-up clip in another location, a customer-supplied bracket may be used. Suggested locations include the handlebars, fuel-tank console, or any location which provides easy access to the microphone without blocking controls and indicators and without interfering with motorcycle handling.
5-16 Motorcycle Radio Installation Installing Antenna Base and Cables 6. These holes in the metal liner is used as a template to mark the position of the hole(s) to be drilled at the top cover. Follow the below guidelines for the various options. - Single Band – Refer to your APX radio (see Figure 5-9 or Figure 5-10) and see if your single band antenna is in the position of Band 1 or 2. Depending on which location your antenna port is mark a hole in the appropriate antenna position only.
Motorcycle Radio Installation Installing Antenna Base and Cables 5-17 Cable Clamp Coaxial Cable Connector Figure 5-11. Routing the Coaxial Cable for GPS 12. Attach the 7/800, VHF or UHF antenna base per Antenna Installation Manual. IMPORTANT: Antenna Placement and Cable Routing in the Antenna Installation Manual is not applicable for the APX series. 13. Route the coaxial cable for the 7/800, VHF or UHF antenna(s) through the cable clamps per Figure 5-12 for Band 1 and Figure 5-13 for Band 2.
5-18 Motorcycle Radio Installation Installing the Antenna Cable Clamp Coaxial Cable Attach to Antenna Connector on Radio Band 2 Figure 5-13. Routing the Coaxial Cable for Band 2 14. After routing cable, allow enough of the cable to reach the radio’s antenna connector and cut off any excess length of the cable. 15. Install the connector per Antenna Installation Manual. 5.
Motorcycle Radio Installation Cable Routing 5-19 SPEAKER/ CONTROL HEAD CONTROL HEAD CABLE SPEAKER CABLE MICROPHONE ACCESSORY CONTROL HEAD CABLE CABLE POWER ANTENNA CABLE CABLE BATTERY FUSE BLOCK IGNITION CABLE SPEAKER CABLE CHASSIS GROUND FUSED POWER CABLE Figure 5-14. Cable Routing 1. Speaker Cable – runs from the speaker to the accessory-cable connector inside the weather-resistant enclosure. 2.
5-20 Motorcycle Radio Installation Cable Routing 3. Take care to position cables away from parts of the motorcycle that get hot. Bundle excess cable length inside the weather-resistant enclosure as discussed later in Section 5.11: “Transceiver and Cabling Installation” on page 5-22. The fifth cable is the microphone with coiled cord. Plug the 9-pin D-connector end of the coiled cord into its mating connector, which was attached near the control head discussed in an earlier paragraph.
Motorcycle Radio Installation Installing the Weather-Resistant Enclosure 5-21 5.10 Installing the Weather-Resistant Enclosure 7 7 2 3 4 8 5 6 1 TO MOTORCYCLE CHASSIS GROUND Item No. Description Item No. Description 1 Universal Mounting Plate 5 Flat Rubber Washer 2 Machine Screw 6 Shouldered Rubber Washer 3 Lockwasher 7 7-1/2-inch Ground Strap 4 Flat Washer 8 Ground Strap Figure 5-15. Weather-Resistant Enclosure Installation 1.
5-22 Motorcycle Radio Installation Transceiver and Cabling Installation 5. The diagram of the shock mount is shown loosely assembled. After the hex screws are tightened, the rubber washers are compressed to fasten the weather- resistant enclosure securely to the universal mounting plate. 6. Figure 5-17 is an exploded view of the enclosure; it shows details that will help to understand how the enclosure is mounted.
Motorcycle Radio Installation Transceiver and Cabling Installation ACCESSORY CABLE EMERGENCY AND EXTERNAL ALARM CONNETOR 5-23 ACCESSORY CABLE HEADSET CONNECTOR HEADSET SPORTING PLUG TRANSCEIVER POWER CABLE EMERGENCY CABLE SHORTING PLUG ACCESSORY CABLE IGNITION SENSE (ACC) CONTROL CABLE (CAN) CONTROL HEAD GROUND (BLACK) CONTROL HEAD POWER (RED) CONTROL HEAD POWER FUSE Figure 5-16. Installing Cables 5.11.
5-24 Motorcycle Radio Installation Transceiver and Cabling Installation 15 3 2 18 17 16 4 1 2 8 10 13 12 9 6 14 11 6 7 Figure 5-17. Installing the Transceiver Table 5-1. Transceiver Installation Parts List Item No. 1 2 3 4 5 6 7 8 9 Description Lock washer Flat washer (8 used) Screw Screw Grommet Screw Lock catch Radio mounting plate Bottom housing Item No.
Motorcycle Radio Installation Installing the Emergency Switch Option 5-25 5.12 Installing the Emergency Switch Option Use the two-conductor, green/black cable which has as one end terminated with two contacts (part number 3080221P02) and which is supplied with this W688 Motorcycle Emergency Push Button. Disconnect the emergency switch shorting plug from the accessory cable. Replace the shorting wire of the shorting plug with the terminated end of the green/black emergency cable.
5-26 Motorcycle Radio Installation Installing the O5 Control Head Sunshield 5.15 Installing the O5 Control Head Sunshield Install the sunshield (part number NNTN7279_) to the O5 control head as follows. 1. Assemble the sunshield to the remote mount trunnion as shown in Figure 5-19. The same process can be used for the motorcycle trunnion. Figure 5-19. Remote Mount Trunnion with Sunshield 2. Position the sunshield as shown in Figure 5-20 and remove the Velcro adhesive backing.
Motorcycle Radio Installation Installing the O5 Control Head Sunshield 5-27 3. Slide the control head onto the trunnion while aligning the edge of the control head with the edge of the sunshield as shown in Figure 5-21. Make sure the Velcro properly adheres to the control head. Figure 5-21. Slide the Control Head onto Trunnion 4. Position control head as desired and install screws as shown in Figure 5-22. Figure 5-22.
5-28 Motorcycle Radio Installation 5.16 Horn/Lights Wiring Figure 5-23. Horn/Lights Wiring Diagram 5.17 Emergency Switch Wiring Figure 5-24. Emergency Switch Wiring Diagram ! WARNING Motorcycle products must have pins 1 and 2 connected together to allow the radio to power down. Opening this connection by REMOVING the emergency shorting plug, or pressing the emergency switch, will turn on the radio. Failure to maintain a normally-closed path could drain the vehicle battery if left unchecked.
Chapter 6 Finishing the Installation 6.1 Cable Connection 6.1.1 O2 Control Head Perform the following if it has not been previously done: 1. Remove the control head from its mounthing trunnion. Plug the radio’s CAN cable into the proper location on the back of the control head (see Figure 2-28 and Figure 2-30 in Chapter 2). The connectors “click” when snapped into place. The control head model can have the microphone plugged into the lower left corner of the control head front panel. 2.
6-2 Finishing the Installation Cable Connection 3. Plug the VIP connector into the correct location on the back of the control head. 4. Connect the CAN cable to the proper location on the transceiver. 6.1.4 O7 Control Head Perform the following if it has not been previously done: 1. Remove the control head from its mounting trunnion. Plug the radio's CAN cable into the proper location on the back of the control head (see Figure 2-28 and Figure 2-30 in Chapter 2).
Finishing the Installation Dust Cover Installation 6.2 6-3 Dust Cover Installation To help protect and ensure debris does not effect or damage your unused connectors, please use the provided dust covers. Refer to Figure 6-1 to determine which cover is for which connector.
6-4 Finishing the Installation Miscellaneous Information NOTE: Parts B and F require inserting then turning approximately 1/3 turn using a coin as a tool until it contacts the stop. Parts C and/or D shall be installed onto DB25 accessory cable assembly when the corresponding cable assembly connections are not in use. Part G is not used on single band transceivers. 6.
Chapter 7 Best Practices: Installation & Troubleshooting In this section are Motorola recommended vehicle installation practices that can address or prevent many issues, including: • Radio circuit damage due to over voltage condition • Radio/Accessories "lock up" • Radio/Accessories change state/lock-up when radio PTT is depressed • Radio powers up in the FL 01/90 state (general communication error code) • Radio intermittently resets • Radio loses secure key • Transmit audio distortion on motorcycle radio
7-2 7.2 Best Practices: Installation & Troubleshooting Check Physical Installation of Radio Ground and Radio Accessory Wiring Check Physical Installation of Radio Ground and Radio Accessory Wiring • Take care to scrape away paint on the chassis at the place where the ground connection is to be made, and try to keep the ground lead as short as possible.
Best Practices: Installation & Troubleshooting Minimize the Effect of Poorly Grounded Antennas 7.4 7-3 Minimize the Effect of Poorly Grounded Antennas • For vehicles with high power (100W) radios that use glass mount antennas, care must be taken to keep the radio and antenna cable as far as possible from the radiating element of the antenna.
7-4 Best Practices: Installation & Troubleshooting Notes 6878215A01
Appendix A A.1 Replacement Parts Ordering Basic Ordering Information When ordering replacement parts or equipment information, the complete identification number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufficient description of the desired component to identify it.
A-2 A.4 Replacement Parts Ordering Telephone Orders Telephone Orders Radio Products and Services Division* (United States and Canada) 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday (Chicago, U.S.A.) 1-800-422-4210 1-847-538-8023 (International Orders) U.S. Federal Government Markets Division (USFGMD) 1-800-826-1913 Federal Government Parts - Credit Cards Only 8:30 AM to 5:00 PM (Eastern Standard Time) A.
Index Index Numerics 100W radios antenna connection ............................................. 2-40 configurations ........................................................ 1-9 installation ........................................................... 2-24 lock ...................................................................... 2-32 trunnions ............................................................. 2-20 100W radios .......................................................... 1-9 dash mount ........
Index-2 L leads black ..................................................2-33, 5-19, 5-25 green ................................................................... 5-25 light relay ................................. 4-2, 4-3, 4-4, 5-25, 5-28 locking kit, installing ................................................ 2-32 pin ground ................................................................... 4-3 SW B+ ..................................................... 4-4, 4-7, 4-8 VIP in ............................
Index-3 W wiring diagrams .........................................................
Index-4 Notes 6878215A01
Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to the ASTRO radio. Term Definition analog Refers to a continuously variable signal or a circuit or device designed to handle such signals. See also digital. band Frequencies allowed for a specific purpose. CPS See Customer Programming Software. Customer Programming Software Software with a graphical user interface containing the feature set of an ASTRO radio.
Glossary-2 Term Definition Megahertz One million cycles per second. Used especially as a radio-frequency unit. microcontroller unit Also written as μC. A microprocessor that contains RAM and ROM components, as well as communications and programming components and peripherals. PA Power amplifier. paging One-way communication that alerts the receiver to retrieve a message. PTT See Push-to-Talk.
Glossary-3 Term Definition TX Transmit. UHF Ultra-High Frequency. Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps. USB See Universal Serial Bus. VHF Very-High Frequency.
Glossary-4 Notes 6878215A01
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