Standard Configurations: Completing the Installation 2.8 2-43 Completing the Installation Complete the installation by connecting the speaker to the accessory cable; verify the ignition sense wire is attached according to planned ignition sense; attach the accessory cable into J600; verify the control head is attached to either the TIB or the CAN extension cable; and then attach the power cable to the back of the transceiver.
-44 Standard Configurations Notes 6878215A01
Chapter 3 Universal Relay Controller Installation The Universal Relay Controller (URC) is an extension of and an orderable accessory for 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: O9 Universal Relay Controller Cable Assembly 3.2 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: 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: 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 2-6, 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 7500 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 7500 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 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 7500 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 7500 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 5-15. • 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 5-16. Detailed descriptions of the mounting hardware used in each procedure are provided in parts lists located in the exploded views located in the APX 7500 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 The control head mounting location and configuration is determined largely by the make and model of motorcycle. Two different mounting configurations are described below. One involves mounting the speaker and control head together as a unit using the combination speaker/control-head bracket (shown in Figure 5-4) supplied by Motorola.
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 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. Determine the location in which the speaker is to be mounted and whether there is a requirement for a customer-supplied bracket. 2.
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) 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. Refer to Figure 5-8.
Motorcycle Radio Installation: Installing Antenna Base and Cables 5-17 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 5-11 for Band 1 and Figure 5-12 for Band 2. ! Be sure to observe the correct routing of the antenna cable.
5-18 5.8 Motorcycle Radio Installation: Installing the Antenna Installing the Antenna IMPORTANT: Antenna Placement and Cable Routing as described inside the Antenna Installation Manual is not applicable for the APX radio series. Refer to information listed below. • Connect the appropriate antenna connectors to the antenna receptacles on the radio. Tighten the coupling until fully engaged. 5.
Motorcycle Radio Installation: Cable Routing 5-19 1. Speaker Cable – runs from the speaker to the accessory-cable connector inside the weather-resistant enclosure. 2. Control Cable – runs from the rear of the control head to the front of the transceiver inside the enclosure. 3. Ignition Sense (Red) Wire Portion of Accessory Cable – runs from the ignition sense fuse terminal of the fuse box to the rear area inside the enclosure.
5-20 Motorcycle Radio Installation: Installing the Weather-Resistant Enclosure 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 5-14. Weather-Resistant Enclosure Installation 1.
Motorcycle Radio Installation: Transceiver and Cabling Installation 5-21 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 5-16 is an exploded view of the enclosure; it shows details that will help to understand how the enclosure is mounted.
5-22 Motorcycle Radio Installation: Transceiver and Cabling Installation ACCESSORY CABLE EMERGENCY AND EXTERNAL ALARM CONNETOR ACCESSORY CABLE HEADSET CONNECTOR TRANSCEIVER POWER CABLE HEADSET SPORTING PLUG EMERGENCY CABLE SHORTING PLUG ACCESSORY CABLE IGNITION SENSE (ACC) CONTROL HEAD GROUND (BLACK) CONTROL CABLE (CAN) CONTROL HEAD POWER (RED) CONTROL HEAD POWER FUSE Figure 5-15. Installing Cables 5.11.
Motorcycle Radio Installation: Transceiver and Cabling Installation 5-23 15 3 2 18 17 16 4 1 2 8 10 13 12 9 6 14 11 6 7 Figure 5-16. Installing the Transceiver Table 5-1. Transceiver Installation Parts List Item No. 1 2 3 4 5 6 7 8 9 6878215A01 Description Lock washer Flat washer (8 used) Screw Screw Grommet Screw Lock catch Radio mounting plate Bottom housing Item No.
5-24 Motorcycle Radio Installation: Installing the Emergency Switch Option 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.
Motorcycle Radio Installation: Installing the Control Head Sunshield 5-25 5.15 Installing the Control Head Sunshield Install the sunshield (part number NNTN7279_) to the control head as follows. 1. Assemble the sunshield to the remote mount trunnion as shown in Figure 5-18. The same process can be used for the motorcycle trunnion. Figure 5-18. Remote Mount Trunnion with Sunshield 2. Position the sunshield as shown in Figure 5-19 and remove the Velcro adhesive backing.
5-26 Motorcycle Radio Installation: Installing the Control Head Sunshield 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 5-20. Make sure the Velcro properly adheres to the control head. Figure 5-20. Slide the Control Head onto Trunnion 4. Position control head as desired and install screws as shown in Figure 5-21. Figure 5-21.
Motorcycle Radio Installation: Horn/Lights Wiring 5.16 Horn/Lights Wiring Figure 5-22. Horn/Lights Wiring Diagram 5.17 Emergency Switch Wiring Figure 5-23. 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.
5-28 Motorcycle Radio Installation Notes 6878215A01
Chapter 6 Finishing the Installation 6.1 Cable Connection 6.1.1 O9 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 2-22 and Figure 2-24 in Chapter 2). The connectors “click” when snapped into place. The control head model can have the microphone plugged into the CGAI connection on the control head back panel. 2.
6-2 6.1.3 Finishing the Installation: Cable Connection O3 Control Head Perform the following if it has not been previously done: 1. Unplug the CAN coiled cable connector on the Transceiver Interface. Plug in the connector again. A “click” sound should be heard. Ensure location of CAN connector is correct (i.e. J800L or J800R) on the transceiver interface. 2. Connect the plug from the speaker lead to the mating connector of either J2 or J626 (refer cabling diagram for detail).
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 6.3 Finishing the Installation: Miscellaneous Information Miscellaneous Information On the mid power and 100W radios, there are rubber port plug which seals an opening which is used for a future antenna connection. On the mid power, the port plug is located at the bottom of the radio behind the control head or TIB. On the high power, the port plug is located at the TIB.
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 100W radios antenna connection ............................................. 2-35 configurations ........................................................ 1-6 installation ........................................................... 2-18 lock ...................................................................... 2-27 trunnions ............................................................. 2-15 configurations 100W radios .......................................................... 1-6 dash mount ..
Index-2 J O J2 ....................................................................... 4-7, 4-8 ordering replacement parts ....................................... A-1 L P leads black ..................................................2-28, 5-19, 5-24 green ................................................................... 5-24 light relay ................................. 4-2, 4-3, 4-4, 5-24, 5-27 locking kit, installing ................................................
Index-3 V W VIP connector ....................................................... 4-2, 6-1 input connections .................................................. 4-8 output connections ................................................ 4-7 wiring diagrams ........................................................
