zTitle Page ® XTL™ 5000 Digital Mobile Radio Installation Manual (Mid-Power and 100W Radios) Motorola, Inc.
Foreword This manual covers all models of the ASTRO® XTL™ 5000 digital mobile radios (models W3, W4, W5, W7, and W9), unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.
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.
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Table of Contents v Table of Contents Foreword .........................................................................................................ii Product Safety and RF Exposure Compliance ............................................................................................ii Manual Revisions ........................................................................................................................................ii Parts Ordering ...............................................
Table of Contents vi 2.3 2.4 2.5 2.6 2.7 2.8 2.2.3.2 100W Radios ......................................................................................................... 2-18 Power Cable ................................................................................................................................ 2-18 Ignition Sense Cable ................................................................................................................... 2-21 Antenna Installation ......................
Table of Contents 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 vii 4.2.3 Parts Identification ............................................................................................................ 4-3 4.2.4 Order of Installation .......................................................................................................... 4-4 Installing the Universal Mounting Plate..........................................................................................
List of Figures viii List of Figures Figure 1-1. Front View of Dash Mount Radio (All but 100W Radios) ...................................................... 1-1 Figure 1-2. Side View of Dash Mount Radio (All but 100W Radios) ....................................................... 1-1 Figure 1-3. Front View of 100W Radio.................................................................................................... 1-1 Figure 1-4. Side View of 100W Radio ................................................
List of Figures ix Figure 3-8. Rear Accessory Connector Data Configuration .................................................................. 3-10 Figure 3-9. Rear Accessory Jack Pin Configuration (J2) (Radio Side) ................................................. 3-11 Figure 4-1. Universal Mounting Plate Installation (Part of Radio Enclosure Kit) ..................................... 4-5 Figure 4-2. Handlebar Installation with Speaker and Control Head Mounted Together ..........................
x List of Tables Table 2-1. Table 2-2. Table 3-1. Table 3-2. Table 3-3. Table 3-4. Table 3-5. Table 4-1. Radio Functions Connections .................................................................................. 2-16 Fuse Assembly for Orange and Green Leads Parts List.......................................... 2-17 VIP Output Connections ............................................................................................ 3-1 VIP Input Connections ................................................
Mobile Radio Model Numbering Scheme xi Mobile Radio Model Numbering Scheme Typical Model Number: M Position: 1 2 2 0 3 U 4 R 5 Position 1 - Type of Unit M = Mobile L = Table Top Station 9 7 P 8 W 9 1 10 A 11 N 12 S 13 P 14 0 15 1 16 Positions 13 - 16 SP Model Suffix Position 12 Unique Model Variations C = Cenelec N = Standard Package Positions 2 & 3 - Model Series 20 = XTL 5000 Position 4 - Frequency Band A = Less than 29.7MHz N= B = 29.7 to 35.
Mobile Radio Model Numbering Scheme xii Notes September 17, 2004 6881098C38-O
Commercial Warranty xiii Commercial Warranty Limited Warranty MOTOROLA COMMUNICATION PRODUCTS I. What This Warranty Covers And For How Long MOTOROLA INC.
Commercial Warranty xiv 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 xv 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.
Commercial Warranty xvi Notes September 17, 2004 6881098C38-O
Chapter 1 Introduction This manual covers the installation procedures for ASTRO XTL 5000 mobile and motorcycle radios and accessories required to complete the radio system. The radio system consists of a control head, radio, antenna, microphone, speaker, cabling, and accessories. 1.1 Mobile Radio Description 1.1.
Introduction: Standard Configurations 1-2 1.2 Standard Configurations 1.2.1 Dash Mount Configuration NOTE: The dash mount configuration is not applicable for 100W radios. In the dash mounting version of the XTL 5000, the control head is mounted on the front of the transceiver housing. Electrical connection between the two takes place within the radio via a flexible circuit board between the connectors on the front of the transceiver and at the back of the control head. Figure 1-5.
Introduction: Motorcycle Configurations 1-3 PWR Mode 0 Vol Phon DIM Scan Call Sel 1 HOME XMIT BUSY 4 Sts 7H/L Rcl 2 5 8 Mon 3 6 Msg 9 Dir 0 Del MAEPF-28156-O Figure 1-7. Remote Mount Configuration (100W Only) For details on these configurations, see Section 2.2.2 on page 2-10. 1.2.3 Dual Control Configuration The dual control head option allows two, separate, remotely operated control heads to operate and control the radio.
Introduction 1-4 1.
Chapter 2 Standard Configurations 2.1 Planning the Installation The XTL 5000 radio operates only in negative ground electrical systems. 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.
Standard Configurations: Planning the Installation 2-2 2.1.1 Installation Examples Your mobile two-way radio offers various methods of installation, including dash or remote mount. Except for 100W radios, all versions of the XTL 5000 can be either dash or remote mounted (see Figure 2-1 through Figure 2-6).100W radios can only be mounted remotely (see Figure 2-3, Figure 2-5, and Figure 2-6). Speaker Radio Antenna 1/4-Wavelength Speaker Radio Battery Radio Battery Figure 2-1.
Standard Configurations: Planning the Installation 2.1.2 2-3 Wiring Diagrams Figure 2-7 through Figure 2-11 show the wiring diagrams for all the possible configurations. The title under each figure identifies which model control head is being shown. Identify which of these figures shows the configuration that you are installing, and use the diagram when planning the installation.
Standard Configurations: Planning the Installation 2-4 FUSE BATTERY (+) J0103 PORT ON BACK OF CONTROL HEAD GRN LEAD FUSE (-) VIP FUSE BLOCK 1 2 3 MIC 4 5 ORG LEAD 18 19 20 21 FUSE 34 35 36 37 38 REMOTE MOUNT CONTROL CABLE HORN RELAY LIGHT RELAY PWR Mode MIC CLIP Phon Scan Call Vol 1 2 3 4 Sts 5 6 Msg BUSY DIM 7H/L 8 Mon 9 Dir Rcl HOME CONTROL HEAD* MIC 0 23 24 26 27 28 29 30 31 32 33 43 44 45 46 47 48 49 50 40 41 VIP SECTION PIN OUT 1 VIP OUT - 2 18 SWB + 34 VIP
Standard Configurations: Planning the Installation BATTERY (+) 2-5 FUSE ANTENNA (-) FUSE BLOCK FIREWALL HOLE J2 REAR ACCESSORY CONNECTOR 20 IGNITION CABLE LIGHT OR HORN RELAY FUSE DC POWER CABLE P2 (SEE J2 PINOUT) HANG-UP BOX ANTENNA CONNECTION TRUNNION P506 J6 SPEAKER 26 J5 SPKR+ 7 13 SPKR- VIPOUT 2 12V (RELAY) IGNITION VIPOUT 1 12V (RELAY) MOUNTING SCREW CONTROL HEAD HANDHELD CONTROL HEAD EMERGENCY 21 GROUND 14 8 1 EMERGENCY SWITCH MAEPF-27614-O Figure 2-10.
Standard Configurations: Planning the Installation 2-6 BATTERY (+) J3 REMOTE MOUNT ACCESSORY CONNECTOR FUSE VIP SPKR NOTE 1 IGNITION OUT 2 LO DIG SPKR EMER SWB+ GND HI (-) FUSE BLOCK IGNITION CABLE LIGHT OR HORN RELAY 7 8 FUSE 15 J3 PINOUT REMOTE MOUNT CONTROL CABLE HANG-UP BOX SPEAKER 5 6 14 4 12 13 NC NC BUS+ 3 2 11 10 BUSY NOTE 2 VIP OUT 1 1 9 BUS- NOTES: 1. TX AUDIO IN SP CUSTOMER APPLICATIONS. 2. DET AUDIO IN SP CUSTOMER APPLICATIONS.
Standard Configurations: Radio Mounting 2.2 2-7 Radio Mounting ! Caution CAUTION: DO NOT mount the radio on a plastic dashboard without first reinforcing the dashboard; the weight of the radio may crack or break the dashboard. CAUTION: 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.
Standard Configurations: Radio Mounting 2-8 TOP BOTTOM Figure 2-14. Trunnion Orientation for 100W Radios (Quick Release Trunnion) TOP BOTTOM Figure 2-15.
Standard Configurations: Radio Mounting 2.2.1 2-9 Dash Mount with Trunnion NOTE: This configuration is not applicable for 100W radios. 1. Select the location to mount your radio on the transmission hump (see Figure 2-16) or under the dash (see Figure 2-17). When mounting the trunnion on the transmission hump take care the transmission housing is not affected. 2. Using the trunnion mounting bracket as a template, mark the positions of the holes on the mounting surface.
Standard Configurations: Radio Mounting 2-10 Trunnion Holes for Microphone S-Hook Wing Screw Wing Screw Figure 2-17. Below Dash Trunnion Mounting 2.2.2 Remote Mount with Trunnion 2.2.2.1 Transceiver 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.
Standard Configurations: Radio Mounting 2-11 Figure 2-18. 100W Radio Mounting into Quick Release Trunnion B. Screw-mounted trunnion (HLN6910_): See Figure 2-19. After mounting the trunnion to the vehicle using the screws provided, insert the rear of the radio into the rear catches of the trunnion and rotate the radio down into place. Secure the radio by installing the four wing screws provided. Figure 2-19.
Standard Configurations: Radio Mounting 2-12 2.2.2.2 Control Head and Remote Mount Cabling For radios equipped with optional remote mount control heads, see Figure 2-8 or Figure 2-9. For radios equipped with remote handheld control heads, see Figure 2-11 or Figure 2-12. Choose a mounting location for the radio, considering accessibility, and control and antenna cable lengths. 2.2.2.2.1 Remote W4, W5, W7, and W9 Model Control Head Installation Figure 2-20 shows each of the control head models.
Standard Configurations: Radio Mounting 2-13 2. Attach the trunnion bracket using all four 10-16" x 5/8" self-tapping screws provided. 3. Temporarily install the control head (adjusting for proper viewing angle) and fasten it to the trunnion with two wing screws. Test the installation to be sure the unit does not wobble or feel “spongy” when you press the buttons. NOTE: Use all four mounting screws and be sure they are tightly screwed into metal — either a dashboard support bracket or a backing plate.
Standard Configurations: Radio Mounting 2-14 IMPORTANT USE A METAL BACKING PLATE (NOT SUPPLIED) IF MOUNTING TRUNNION ON A PLASTIC DASHBOARD DRILL FOUR 5/32" HOLES IN DASHBOARD DASHBOARD TRUNNION 03-00136756 USE FOUR MOUNTING SCREWS ON ALL INSTALLATIONS ADJUST THE CONTROL HEAD TO DESIRED ANGLE AND SECURE WITH WING SCREWS VIP CONNECTOR TO RADIO ORANGE AND GREEN LEADS TO SPEAKER MAEPF-21373-0 TO MICROPHONE TECHNICAL PUBLICATIONS DEPT. DESCRIPTION DWG. NO. MAEPF 21373 Figure 2-22.
Standard Configurations: Radio Mounting 2-15 2.2.2.2.2 Remote W3 Model Control Head Installation Figure 2-24 shows the W3 control head model. Figure 2-24. W3 Control Head For the remote handheld control unit, mount the control cable with the screws provided. Connect the control cable as shown in Figure 2-11 or Figure 2-12. Connect the speaker to the accessory cable harness. 2.2.2.2.3 Remote Radio Control Cable Installation The radio control cable should go from the rear of the control head to the radio.
Standard Configurations: Radio Mounting 2-16 ! Caution CAUTION: DO NOT connect either lead to the ungrounded terminal of the battery until you have finalized the installation and have been instructed to do so. Table 2-1.
Standard Configurations: Radio Mounting 2-17 • Slide the plastic insulator fuseholder over the end of the wire that is connected to the cable kit. Insert the stripped end of that wire into one of the metal fuse clips, and crimp it closed onto the exposed wire. Solder it for a better electrical contact. • On the end of the loose wire, repeat the above crimping and soldering process with the remaining metal fuse clip. • Temporarily, install the fuse into the fuse clips onto both sides of the fuse.
Standard Configurations 2-18 2.2.3 Locking Kit (Optional) 2.2.3.1 All Radios Except 100W If an optional locking kit is used (shown in Figure 2-26), position the lock bottom housing on the trunnion before installing the radio mounting screws. Then slip the top lock housing on and remove the key. You can install the lock on either side of the radio, and by rotating it 180°, you can also install it on dash installations. Existing Mounting Screw Lock Housing Lock HLN6372_ Locking Kit Figure 2-26.
6881098C38-O I.B. GROMMET VIP RADIO CONTROL CABLE (BLK/MULTICONDUCTOR) SPEAKER RADIO (ORG) (GRN) MIC MICROPHONE RECEIVER CONTROL CABLE (GRN) RADIO POWER CABLE (RED/BATTERY HOT) SEE NOTE ON/ACC 3A OR 4A FUSE TRANSMITTER CONTROL CABLE (ORG) VEHICLE IGNITION SWITCH OPERATOR COMPARTMENT 15A OR 20A FUSE GROMMET (-) Figure 2-28.
September 17, 2004 CH SPEAKER MICROPHONE SEE NOTE ON/ACC 3A OR 4A FUSE RADIO POWER CABLE (RED/BATTERY HOT) RADIO IGNITION CABLE (thin RED) VEHICLE IGNITION SWITCH 15A OR 20A FUSE GROMMET (-) VEHICLE BATTERY (+) PART OF VEHICLE WIRING VEHICLE BATTERY COMPARTMENT Figure 2-29. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios) If the radio's IGNITION line is wired to the car's ignition switch, the radio will only function when the car's ignition switch is turned ON.
Standard Configurations: Ignition Sense Cable 2.4 2-21 Ignition Sense Cable Motorola supplies an ignition sense cable and recommends that it be used with every mobile installation. The ignition sense cable allows the radio to be turned on and off with the vehicle ignition switch, and allows the radio to “remember” the state of the radio on/off switch, even if it is changed while the vehicle is off.
Standard Configurations: Antenna Installation 2-22 4. Mounting restrictions for certain radio models For 40 Watt UHF models and all 100W models, the 1/4 wave antenna should be mounted only in the center area of the roof, not on the trunk lid, to assure compliance with RF Energy Safety standards. 5. Ensure that the antenna cable can be easily routed to the radio. Route the antenna cable as far away as possible from any vehicle electronic control units and associated wiring. 6.
Standard Configurations: Antenna Installation 2-23 1. Make sure that there is sufficient slack in the antenna cable. 2. Make sure that the collar of the antenna cable plug is loose and does not bind. 3. Make sure that the mini-UHF jack is tight in the radio housing. 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.
Standard Configurations: Speaker 2-24 2.6 Speaker ! Caution 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 dashboard or in accessible firewall areas.
Standard Configurations: Completing the Installation 2-25 Use the hang-up clip as a template to locate the mounting holes. To avoid interference when removing the microphone, install the flathead screw in the top clip hole. 2.7.2 Handheld Hang-Up Box (W3 Model) Use the hang-up box (HUB) as a template to locate the mounting holes. Be sure the HUB will be within easy reach of the operator.
Standard Configurations: Completing the Installation 2-26 Notes September 17, 2004 6881098C38-O
Chapter 3 Options and Accessories Installation 3.1 VIP Overview The vehicle interface port (VIP) allows the control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs which are used for relay control. There are also three VIP inputs which accept inputs from switches. 3.1.1 VIP Output Connections The VIP output pins are on the back of the control head (J0103), or the rear accessory panel (J2).
Options and Accessories Installation: Remote-Mount Accessory Installations for W4/5/7/9 Models 3-2 3.1.2 VIP Input Connections The VIP input pins are only available on the back of the control head. 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: Remote-Mount Accessory Installations for W4/5/7/9 Models 3-3 b. Secure all wires using tie straps or appropriate electrical tape to insure the wire’s safety. Any wires passing through the vehicle’s metal panels must be protected with grommets. This will prevent the shaving of the wire’s protective jacket, which will result in a short. 2. The second method is to use the accessory connector assembly (not supplied with the remote mount configuration).
Options and Accessories Installation: Dash-Mount Accessory Installations for W4/5/7/9 Models 3-4 3.2.1.1.2 W4/5/7 Control Head 1. Remove JU1008 (emergency to ground) from the control head remote back housing (HLN6432_). 2. Place JU1007 (emergency to VIP IN 2) on the control head remote back housing (HLN6432_). 3. Remove R84 (if installed) from the W4/5/7 control head. 4. Install the emergency switch between pins 3 (VIP IN 2) and 20 (ground) of the control head back connector. 3.2.1.
Options and Accessories Installation: Dash-Mount Accessory Installations for W4/5/7/9 Models 3.3.1 3-5 MDC Emergency Pushbutton or Footswitch Installation Mount the footswitch using the hardware that comes with the kit. Open the accessory cable connector housing; remove the jumper wire. Connect the emergency switch wires to pins 14 and 15 (see Figure 3-2). Close the connector housing; route the finished cable from the switch location to the control head location.
3-6 3.4 Options and Accessories Installation: Remote-Mount Accessory Installations for W3 Model Remote-Mount Accessory Installations for W3 Model Accessories for the W3 remote mount handheld control head are connected through the J3 connector located in the remote cable assembly. It requires a different P3 connector (supplied). This P3 connector is a 15 pin D-sub (see Figure 2-11 in Chapter 2), unlike the 26-pin accessory connector assembly (see Figure 3-9).
Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-7 1. Horn Relay—Connect the relay contacts across the horn ring switch, typically found in the steering column. Open the accessory cable connector and connect the two control wires (male pins) into locations 12 and 4 of the connector. 2. Lights Relay—Connect the relay across the headlamp ON/OFF switch, typically found in the steering column.
Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-8 3. Route the ignition wire to either an ignition switch circuit or a power source that is always hot (see Section 2.4 on page 2-21). In either case, verify that the source will be capable of withstanding a load of 4 amps (see the wiring diagrams in the vehicle manufacturer’s service manual). Always use the supplied fuse holder to prevent damage to the radio. 4.
Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3.5.3 3-9 Disassembly and Assembly 3.5.3.1 Disassembly 1. Disconnect the negative terminal from the vehicle’s battery. Make sure that the battery cable is secured such that it will not power the vehicle’s electrical system. See Figure 3-6. 2. Unscrew both jackscrews completely. 3. Pull the accessory connector assembly out from the radio. 4. Loosen both cover screws, but do not remove them completely. 5.
Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-10 5. Squeeze the covers together bending the wires in the strain-relief features. You may need a pair of pliers to seat the assembly covers. 6. Once the covers are fully seated, fasten them with the cover screws. Tighten the screws firmly but do not over-tighten them. Be sure none of the wires are pinched. 7.
Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3.5.5 3-11 Rear Accessory Jack Connection Figure 3-9 shows the complete pin configuration for the J2 rear accessory jack, and Table 3-3 explains the functions of each of the pins. 7 20 26 SPKR+ 13 CHAN ACT SPKRVIP OUT 2 USBUSB PWR IGNITION VIP OUT 1 SWB+ RXD RTS ONE WIRE AUX MIC TXD CTS PTT MONITOR BUSBUSY EMERGENCY RX FILT AUDIO 21 USB+ BUS+ RESET GROUND 14 8 GROUND 1 MAEPF-27619-O Figure 3-9.
Options and Accessories Installation 3-12 Table 3-3. Rear Accessory Jack Pin Functions Pin No. 1 2 3 4 5 6 Pin Name Pin Function Pin No.
Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-13 Table 3-4. Rear Connector and Front Connector Naming Schemes J2 Pin Name1 J2 Pin Number 1 2 Pin Alternate Name EIA Compatible Name at Rear Connector J22 J2-4 UARTA_TX No change TX_DCE J2-5 UARTA_RX No change RX_DCE J2-10 UARTA_CTS Becomes RTS RTS_DCE J2-11 UARTA_RTS Becomes CTS CTS_DCE As indicated for front and rear connectors Pin function as a true “DCE” device according to EIA standard Table 3-5.
3-14 Options and Accessories Installation: Accessory Connector Assembly Details (P2) Notes September 17, 2004 6881098C38-O
Chapter 4 Motorcycle Radio Installation NOTE: This installation is not applicable for 100W radios. 4.1 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 XTL 5000 Basic Service Manual (Motorola publication part number 6881096C73). The following paragraphs describe the unique items provided with the motorcycle models.
Motorcycle Radio Installation: Installation Overview 4-2 4.1.5 External Speaker A 3.2-ohm, 10-watt-rated-audio-power, external speaker is mounted on the front of the motorcycle. The speaker cable is routed along the motorcycle frame to the transceiver’s rear accessory connector. A sealed, weather-resistant, speaker-muting (toggle) switch is mounted on top of the speaker. The external speaker connects to the rear accessory connector of the transceiver. 4.1.
Motorcycle Radio Installation: Installation Overview 4-3 The control head, speaker, and microphone are mounted forward on the motorcycle, on or near the steering column. There are several possible mounting configurations which use a combination of Motorola and customer-built brackets. These configurations are outlined in this manual.
Motorcycle Radio Installation: Installing the Universal Mounting Plate 4-4 • Motorcycle Power Cable Kit • Motorcycle Mounting Kit • Weather-Resistant Enclosure (White) • Weather-Resistant Enclosure (Black) 4.2.4 Order of Installation Before starting the installation, familiarize yourself with the mounting hardware (see Figure 4-1 through Figure 4-9). Perform the installation procedures in the order that follows. 1. Install the universal mounting plate on the motorcycle. 2.
Motorcycle Radio Installation: Installing the Speaker and Control Head 4-5 Figure 4-1. Universal Mounting Plate Installation (Part of Radio Enclosure Kit) Follow the procedures below to mount the universal mounting plate to the motorcycle (see Figure 4-1). 1. Determine the mounting position for the mounting plate. 2. Determine whether stainless steel spacers are required for clearance in mounting the plate. 3.
Motorcycle Radio Installation: Installing the Speaker and Control Head 4-6 4.4.1 Handlebar Installation with Speaker and Control Head Mounted Together Figure 4-2 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 4-2 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 4-7 3. Mount the speaker/control-head bracket, either directly to the motorcycle, or, if used, to the handlebar-mounting bracket, using four stainless-steel machine screws, lockwashers, and nuts. 4. Mount the 9-pin D-connector end of the motorcycle control-head cable to the speaker/controlhead bracket, using two machine screws, flat washers, and nuts. (Cable routing directions appear later in this section.) 5.
Motorcycle Radio Installation: Installing the Speaker and Control Head 4-8 Figure 4-3.
Motorcycle Radio Installation: Installing the Speaker and Control Head 4.4.3 4-9 Handlebar Installation with Speaker and Control Head Mounted Separately It may be necessary to use the smaller control head bracket (part no. 07-80127N02) and mount the speaker and microphone hang-up clip in another location on the motorcycle.
Motorcycle Radio Installation: Installing the Speaker 4-10 4.4.4 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. Figure 4-5.
Motorcycle Radio Installation: Installing the Microphone Hang-Up Clip 4-11 2. Fabricate a bracket if required. Use the Motorola-supplied speaker bracket as a template for drilling mounting holes. Also drill holes in the fabricated bracket for mounting to the motorcycle. 3. Mount the fabricated bracket to the motorcycle chassis. 4. Mount the Motorola-supplied bracket to the fabricated bracket using two machine screws, flat washers, lockwashers, and nuts. 5.
Motorcycle Radio Installation: Installing Cables 4-12 4.7 Installing Cables Five cables must be installed to interconnect the components of the radio system as shown in Figure 4-6. The antenna cable is routed away from the other cables inside the enclosure’s hinged cover. (See the antenna installation instructions shipped with the antenna option for more antennarouting information.) The four remaining cables, routed along the motorcycle frame, are described in the following paragraphs.
Motorcycle Radio Installation: Installing the Weather-Resistant Enclosure 4-13 You may route the cables in any order. As you route each cable, temporarily fasten it at both ends. When all cables have been run, permanently fasten the cables with appropriate cable tie wraps. Observe the following during routing and hook-up: 1. Route the cables so that none interfere with motorcycle operation. 2. Fasten the cables with supplied nylon tie wraps.
Motorcycle Radio Installation: Transceiver and Cabling Installation 4-14 NOTE: Grounding through the power-supply cable is NOT sufficient. Whether the radio transceiver is mounted to a carrier or the chassis itself, the transceiver MUST be properly grounded to the motorcycle chassis. The ground strap supplied with the installation kit may have to be used to ensure a good RF ground path from the radio transceiver to the motorcycle chassis. 4.
Motorcycle Radio Installation: Transceiver and Cabling Installation 4-15 Figure 4-8. Installing Cables 4.9.2 Installing the Transceiver Install the transceiver in the weather-resistant enclosure as follows (see Figure 4-9). NOTE: For new or existing installations, use only the XTL 5000 trunnion (kit number: HLN6861_). 1. Install the mounting trunnion and loose ends of the four ground straps to the radio-mounting plate, using four screws, flat washers, and external-tooth lockwashers (see Figure 4-9).
Motorcycle Radio Installation: Transceiver and Cabling Installation 4-16 Table 4-1.
Motorcycle Radio Installation: Transceiver and Cabling Installation 4-17 Figure 4-9.
Motorcycle Radio Installation: Installing the Antenna 4-18 4.10 Installing the Antenna Refer to the antenna installation instructions in the antenna option package. 4.11 Installing the Emergency Switch Option Use the two-conductor, green/black cable which has as one end terminated with two contacts (part no. 3080221P02) and which is supplied with this W688 Motorcycle Emergency Push Button. Disconnect the emergency switch shorting plug from the accessory cable.
Motorcycle Radio Installation: Emergency Switch Wiring 4-19 4.15 Emergency Switch Wiring Figure 4-11. Emergency Switch Wiring Diagram ! WARNING ! WARNING 6881098C38-O 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.
Motorcycle Radio Installation 4-20 Notes September 17, 2004 6881098C38-O
Chapter 5 Finishing the Installation: Cable Connection Perform the following if it has not been previously done: 1. For all models except W3, remove the control head from its mounting trunnion. Plug the radio’s control cable into the proper location on the back of the control head (see Figure 2-21 and Figure 2-22 in Chapter 2). The connectors “click” when snapped into place.
Finishing the Installation: Cable Connection 5-2 Notes September 17, 2004 6881098C38-O
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.
Replacement Parts Ordering: Telephone Orders A-2 A.4 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.
Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products. Term Definition A/D See analog-to-digital conversion. Abacus IC A custom integrated circuit providing a digital receiver intermediate frequency (IF) backend. ADC See analog-to-digital converter. ADDAG See Analog-to-Digital, Digital-to-Analog and Glue. ALC See automatic level control.
Glossary-2 Term Definition BBP See baseband interface port. baseband interface port Synchronous serial interface to the transceiver board used to transfer transmit and receive audio data. BGA See ball grid array. ball grid array A type of IC package characterized by solder balls arranged in a grid that are located on the underside of the package. CODEC See coder/decoder. coder/decoder A device that encodes or decodes a signal. CPS See Customer Programming Software.
Glossary-3 Term Definition digital signal processor code Object code executed by the Digital Signal Processor in an ASTRO subscriber radio. The DSP is responsible for computation-intensive tasks, such as decoding ASTRO signaling. DPL See Digital Private-Line. See also PL. DSP See digital signal processor. DSP code See digital signal processor code. DTE Data terminal equipment: i.e., a computer. DTMF See dual tone multi-frequency.
Glossary-4 Term Definition frequency Number of times a complete electromagnetic-wave cycle occurs in a fixed unit of time (usually one second). frequency generation unit This unit generates ultra-stable, low-phase noise master clock and other derived synchronization clocks that are distributed throughout the communication network. General-Purpose Input/Output Pins whose function is programmable. GPIO See General-Purpose Input/Output.
Glossary-5 Term Definition LSH See low-speed handshake. Master In Slave Out SPI data line from a peripheral to the MCU. Master Out Slave In SPI data line from the MCU to a peripheral. MCU See microcontroller unit. MDC Motorola Digital Communications. MDI MCU/DSP Interface internal to the Patriot IC. MHz See Megahertz. Megahertz One million cycles per second. Used especially as a radio-frequency unit. microcontroller unit Also written as µC.
Glossary-6 Term Definition paging One-way communication that alerts the receiver to retrieve a message. Patriot IC A dual-core processor that contains an MCU and a DSP in one IC package. PC Board Printed Circuit Board. Also referred to as a PCB. phase-locked loop A circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider. PL See private-line tone squelch. PLL See phase-locked loop.
Glossary-7 Term Definition real-time clock A module that keeps track of elapsed time even when a computer is turned off. receiver Electronic device that amplifies RF signals. A receiver separates the audio signal from the RF carrier, amplifies it, and converts it back to the original sound waves. registers Short-term data-storage circuits within the microcontroller unit or programmable logic IC.
Glossary-8 Term Definition Serial Peripheral Interface How the microcontroller communicates to modules and ICs through the CLOCK and DATA lines. signal An electrically transmitted electromagnetic wave. Signal Qualifier mode An operating mode in which the radio is muted, but still continues to analyze receive data to determine RX signal type. softpot See software potentiometer. software Computer programs, procedures, rules, documentation, and data pertaining to the operation of a system.
Glossary-9 Term Definition transmitter Electronic equipment that generates and amplifies an RF carrier signal, modulates the signal, and then radiates it into space. TSOP See thin small-outline package. TX Transmit. UART See also Universal Asynchronous Receiver Transmitter. UHF Ultra-High Frequency. Universal Asynchronous Receiver Transmitter A microchip with programming that controls a computer's interface to its attached serial devices.
Glossary-10 Notes September 17, 2004 6881098C38-O
Index Index Numerics 100W radios antenna connection .............................................2-22 configurations ........................................................1-3 dimensions .............................................................1-1 installation ............................................. 2-4, 2-6, 2-10 lock ......................................................................2-18 trunnions ................................................................
Index-2 F footswitch, emergency ................................3-3, 3-5, 3-6 G green lead .......................... 2-15, 2-16, 2-17, 2-21, 4-18 H high power, see 100W radios ................................... 1-1 horn relay ............................ 3-3, 3-4, 3-5, 3-6, 3-7, 4-18 I ignition cable ............................................................. 2-21, 3-7 switch ................................................2-15, 2-16, 2-17 wire .......................................................
Index-3 cabling ................................................................. 2-12 configuration .......................................................... 1-2 control cable installation ...................................... 2-15 control head installation .............................. 2-12, 2-15 installation ...................................................... 2-4, 2-6 installation examples ............................................. 2-2 transmit/receive control cable installation ............
Index-4 Notes September 17, 2004 6881098C38-O
