Motorola 92FT3826 Users Manual

Download

APX™ TWO-WAY RADIOS

APX MOBILES O2, O3, O5, O7 & O9 CONTROL HEAD

INSTALLATION MANUAL

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

RF Energy Exposure and Product Safety Guide for Mobile Two-way Radios

See “Installation Requirements for Compliance with Radio Frequency (RF) Energy Exposure Safety Standards,” on page ii.

Manual Revisions

Changes which occur after this manual is printed are described in PMRs (Publication Manual Revisions). These PMRs provide complete replacement pages for all added, changed, and deleted items.  To obtain PMRs, go to https://businessonline.motorola.com.

Parts Ordering

See Appendix A: Replacement Parts Ordering for information on how to obtain replacement parts. For part numbers, refer to the ASTRO APX Mobile Radio Basic Service Manual (Motorola publication part number 6875964M01).

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the sale of a product.

“Related Publications,” on page vi.

Document Copyrights

No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

Disclaimer

The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.

Trademarks

MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective owners.

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.

To ensure compliance to RF Energy Safety Standards:

• Install only Motorola approved antennas and accessories

• Be sure that antenna installation is per

• Be sure that Product Safety and RF Safety Booklet enclosed with this radio is available to the end user upon completion of the installation of this radio

Before using this product, read the guide enclosed with your radio which contains important operating instructions for safe usage and RF energy awareness and control for compliance with applicable standards and regulations.

“Antenna Installation,” on page 2-38 of this manual

For a list of Motorola-approved antennas and other accessories, visit the following web site which lists approved accessories for your radio model: http://www.motorolasolutions.com.

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 ..............................................................................................................................................i

Computer Software Copyrights ....................................................................................................................i

Document Copyrights ...................................................................................................................................i

Disclaimer.....................................................................................................................................................i

Trademarks ..................................................................................................................................................i

Installation Requirements for Compliance with

Radio Frequency (RF) Energy Exposure Safety Standards.......................ii

Mobile Radio Model Numbering Scheme..................................................xiii

Commercial Warranty ..................................................................................xv

Limited Warranty .......................................................................................................................................xv

MOTOROLA COMMUNICATION PRODUCTS ...............................................................................xv

I. What This Warranty Covers And For How Long ....................................................................xv

II. General Provisions ................................................................................................................xv

III. State Law Rights ................................................................................................................. xvi

IV. How To Get Warranty Service ............................................................................................ xvi

V. What This Warranty Does Not Cover................................................................................... xvi

VI. Patent And Software Provisions ........................................................................................ xvii

VII. Governing Law.................................................................................................................. xvii

Chapter 1 Introduction ......................................................................... 1-1

1.1 Mobile Radio Description............................................................................................................... 1-1

1.1.1 Dimensions ....................................................................................................................... 1-1

1.2 Standard Configurations................................................................................................................ 1-5

1.2.1 Dash Mount Configuration ................................................................................................ 1-5

1.2.2 Remote Mount Configuration ............................................................................................ 1-7

1.2.3 Multi Control Head .......................................................................................................... 1-13

1.3 Motorcycle Configurations ........................................................................................................... 1-14

1.4 Base/Control Stations.................................................................................................................. 1-14

1.5 Tools Required for APX Mobile Installations ............................................................................... 1-14

Chapter 2 Standard Configurations .................................................... 2-1

2.1 Planning the Installation................................................................................................................. 2-1

2.1.3 Radio Operation Wiring for Dash and Remote Configurations ....................................... 2-14

2.1.3.1 Dash Mount: Power, Ignition, and Emergency Cable Installation.......................... 2-14

2.1.3.2 Remote Mount: Power, Ignition, and Emergency Cable Installation...................... 2-15

2.1.4 Ignition Sense Switch (Radio Wide Advance) ................................................................ 2-17

2.1.5 Siren/PA Configuration/Programming............................................................................. 2-18

6878215A01

iv Table of Contents

2.2 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............................................................... 2-24

2.2.2.3 Multiple Control Head Installation.......................................................................... 2-27

2.2.2.4 Cable Installation ................................................................................................... 2-29

2.2.2.5 Setting the Initial Control Head ID ......................................................................... 2-29

2.2.2.6 O3 Control Head and Remote Mount Cabling ....................................................... 2-30

2.2.3 Locking Kit (Optional) .....................................................................................................2-32

2.2.3.1 All Radios Except 100W ........................................................................................ 2-32

2.2.3.2 100W Radios ......................................................................................................... 2-32

2.3 Power Cables (Transceiver and Control Head)........................................................................... 2-33

2.3.1 Optional Locking Feature for High Power Chassis Power Cables.................................. 2-33

2.3.2 O2, O5, O7 or O9 Control Head Power Cables.............................................................. 2-36

2.3.3 Battery Selector Switch................................................................................................... 2-37

2.4 Antenna Installation ..................................................................................................................... 2-38

2.4.1 Selecting an Antenna Site/Location on a Metal Body Vehicle ........................................ 2-38

2.4.2 Mini-UHF Connection ..................................................................................................... 2-40

2.4.3 GPS Antenna Placement................................................................................................ 2-42

2.4.4 GPS Connection .............................................................................................................2-42

2.5 Speaker ....................................................................................................................................... 2-43

2.5.1 Internal Speaker Disassembly ........................................................................................ 2-44

2.6 Microphone Hang-Up Clip ........................................................................................................... 2-46

2.6.1 Standard or O3 Control Head Hang-Up Clip .................................................................. 2-46

2.7 RFID (Option) .............................................................................................................................. 2-46

2.7.1 RFID Reading ................................................................................................................. 2-48

2.7.2 Programming RFID (If Equipped) ................................................................................... 2-51

2.8 Completing the Installation .......................................................................................................... 2-52

Chapter 3 Universal Relay Controller Installation ............................. 3-1

3.1 Universal Relay Controller Mounting ............................................................................................. 3-1

3.2 O7/O9 Universal Relay Controller Cable Assembly ...................................................................... 3-3

3.2.1 Power Cable ..................................................................................................................... 3-3

3.2.2 Ground Cable ................................................................................................................... 3-3

3.2.3 Wires ................................................................................................................................ 3-4

3.2.4 O7/O9 to URC Cable ........................................................................................................ 3-5

Chapter 4 Options and Accessories Installation ............................... 4-1

4.1 Dash-Mount Accessory Installation ............................................................................................... 4-1

4.1.1 Dash-Mount Emergency Pushbutton or Footswitch Installation ....................................... 4-1

4.1.2 Dash-Mount Horn and Lights (External Alarms) Relays ................................................... 4-2

4.2 Remote-Mount Accessory Installation ........................................................................................... 4-2

4.2.1 Emergency Pushbutton or Footswitch Installation............................................................ 4-3

4.2.2 Horn (External Alarm) Relay Installation........................................................................... 4-4

4.2.3 Lights (External Alarm) Relay Installation......................................................................... 4-4

4.2.4 Gunlock Installation .......................................................................................................... 4-4

4.2.5 Horn-Ring Transfer ........................................................................................................... 4-5

4.2.6 Record Audio Out Jack of Transmit and Receive Audio................................................... 4-5

4.2.7 Earphone Jack.................................................................................................................. 4-5

4.2.8 USB Data Cables.............................................................................................................. 4-6

4.2.9 RS232 Cables .................................................................................................................. 4-6

6878215A01

Table of Contents v

4.3 Vehicle Interface Port Overview .................................................................................................... 4-6

4.3.1 VIP Output Connections ................................................................................................... 4-7

4.3.2 VIP Input Connections ......................................................................................................4-8

4.4 Compatibility of Emergency when Attaching a Siren ..................................................................... 4-9

4.5 Accessory Connector Assembly Details (P2) (All Models Except 100W).................................... 4-10

4.5.1 Disassembly and Assembly ............................................................................................ 4-10

4.5.1.1 Disassembly .......................................................................................................... 4-10

4.5.1.2 Assembly ............................................................................................................... 4-11

4.5.2 Adapter Cable................................................................................................................. 4-12

4.6 Memory and Three-Day Secure Key Retention Option ............................................................... 4-12

Chapter 5 Motorcycle Radio Installation ............................................ 5-1

5.1 Motorcycle Radio Description ........................................................................................................ 5-1

5.1.1 Transceiver Enclosure ......................................................................................................5-1

5.1.2 Control/Display Unit .......................................................................................................... 5-1

5.1.3 Control Head Cable .......................................................................................................... 5-2

5.1.4 Microphone ....................................................................................................................... 5-2

5.1.5 Keypad Mic ....................................................................................................................... 5-2

5.1.6 External Speaker .............................................................................................................. 5-2

5.1.7 Headset Capability............................................................................................................ 5-2

5.1.8 Antenna ............................................................................................................................ 5-2

5.1.9 Ignition Sense (ACC) Wire................................................................................................ 5-2

5.2 Installation Overview...................................................................................................................... 5-3

5.2.1 General ............................................................................................................................. 5-3

5.2.2 Important Installation Hints ...............................................................................................5-4

5.2.3 Parts Identification ............................................................................................................ 5-5

5.2.4 Order of Installation .......................................................................................................... 5-5

5.3 Installing the Universal Mounting Plate.......................................................................................... 5-6

5.4 Installing the Speaker and Control Head ....................................................................................... 5-7

5.4.1 Handlebar Installation with Speaker and Control Head Mounted Together...................... 5-8

5.4.2 Fuel Tank Console Installation with Speaker and Control Head Mounted Together ........ 5-9

5.4.3 Handlebar Installation with Speaker and Control Head Mounted Separately ................. 5-11

5.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted Separately ... 5-12

5.5 Installing the Speaker .................................................................................................................. 5-14

5.6 Installing the Microphone Hang-Up Clip ...................................................................................... 5-14

5.6.1 Extension Bracket Mounting ........................................................................................... 5-14

5.6.2 Speaker/Control Head Bracket Side Mounting ............................................................... 5-14

5.6.3 Other Hang-Up Clip Mounting ........................................................................................ 5-15

5.7 Installing Antenna Base and Cables............................................................................................ 5-15

5.8 Installing the Antenna .................................................................................................................. 5-18

5.9 Cable Routing .............................................................................................................................. 5-18

5.10 Installing the Weather-Resistant Enclosure ................................................................................. 5-21

5.11 Transceiver and Cabling Installation............................................................................................ 5-22

5.11.1 Installing Cabling in the Enclosure.................................................................................. 5-22

5.11.2 Installing the Transceiver................................................................................................5-23

5.12 Installing the Emergency Switch Option ......................................................................................5-25

5.13 Installing the External Alarm Relay Option ..................................................................................5-25

5.14 Installing the Headset Accessory................................................................................................. 5-25

5.15 Installing the O5 Control Head Sunshield ....................................................................................5-26

5.16 Horn/Lights Wiring ....................................................................................................................... 5-28

5.17 Emergency Switch Wiring............................................................................................................ 5-28

6878215A01

vi Table of Contents

Chapter 6 Finishing the Installation .................................................... 6-1

6.1 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............................................................................................................... 6-1

6.1.4 O7 Control Head............................................................................................................... 6-2

6.1.5 O9 Control Head............................................................................................................... 6-2

6.2 Dust Cover Installation .................................................................................................................. 6-3

6.3 Miscellaneous Information ............................................................................................................. 6-4

Chapter 7 Best Practices: Installation & Troubleshooting ............... 7-1

7.1 Check Wiring of Ignition and Radio Ignition Sensing..................................................................... 7-1

7.2 Check Physical Installation of Radio Ground and Radio Accessory Wiring .................................. 7-2

7.3 Improve the Electrical Quality of the Power and Ignition Lines ..................................................... 7-2

7.4 Minimize the Effect of Poorly Grounded Antennas ........................................................................ 7-3

7.5 Jump-Start the Vehicle .................................................................................................................. 7-3

7.6 Eliminate Noise/Howling from PA Speaker ................................................................................... 7-3

Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information............................................................................................................A-1

A.2 Motorola Online ............................................................................................................................. A-1

A.3 Mail Orders.................................................................................................................................... A-1

A.5 Fax Orders..................................................................................................................................... A-2

A.6 Parts Identification......................................................................................................................... A-2

A.7 Product Customer Service............................................................................................................. A-2

A.8 Asia Pacific Service Centers ......................................................................................................... A-2

Index .....................................................................................................Index-1

Glossary .........................................................................................Glossary-1

Related Publications

ASTRO APX Mobile Radio O2 Control Head User Guide.......................................................... 68012006035

ASTRO APX Mobile Radio O3 Control Head User Guide .......................................................... 6875946M01

ASTRO APX Mobile Radio O5 Control Head User Guide .......................................................... 6875947M01

ASTRO APX Mobile Radio O7 Control Head User Guide.......................................................... 68012006034

ASTRO APX Mobile Radio O9 Control Head User Guide ......................................................... 68007024014

ASTRO APX Mobile Radio Basic Service Manual .....................................................................6875964M01

ASTRO APX Mobile Radio Detailed Service Manual ................................................................. 6875963M01

6878215A01

List of Figures vii

List of Figures

Figure 1-1. Front View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion ....................... 1-1

Figure 1-2. Side View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion......................... 1-1

Figure 1-3. Front View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion .............. 1-1

Figure 1-4. Side View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion................ 1-1

Figure 1-5. Front View of APX 7500 High Power (100W) Transceiver and Trunnion ............................. 1-2

Figure 1-6. Side View of APX 7500 High Power (100W) Transceiver and Trunnion............................... 1-2

Figure 1-7. Front View of O2 Control Head Attached to APX 7500 Mid Power Dash Mount 

Transceiver and Trunnion ..................................................................................................... 1-2

Figure 1-8. Side View of O2 Control Head Attached to APX7500 Mid Power Dash Mount Transceiver 

and Trunnion......................................................................................................................... 1-2

Figure 1-9. Front View of O7 Control Head Attached to APX 2500 Mid Power Dash Mount 

Transceiver and Trunnion ..................................................................................................... 1-2

Figure 1-10. Side View of O7 Control Head Attached to APX 2500 Mid Power Dash Mount Transceiver 

and Trunnion......................................................................................................................... 1-2

Figure 1-11. Front View of O3 Control Head with Coiled Cable................................................................ 1-3

Figure 1-12. Side View of O3 Control Head with Coiled Cable ................................................................. 1-3

Figure 1-13. Front View of O2 Control Head with Remote Mount and Trunnion....................................... 1-3

Figure 1-14. Side View of O2 Control Head with Remote Mount and Trunnion ........................................ 1-3

Figure 1-15. Front View of O5 Control Head with Remote Mount and Trunnion....................................... 1-3

Figure 1-16. Side View of O5 Control Head with Remote Mount and Trunnion ........................................ 1-3

Figure 1-17. Front View of O7 Control Head with Remote Mount and Trunnion....................................... 1-4

Figure 1-18. Side View of O7 Control Head with Remote Mount and Trunnion ........................................ 1-4

Figure 1-19. Front View of O9 Control Head with Trunnion ...................................................................... 1-4

Figure 1-20. Side View of O9 Control Head with Trunnion........................................................................ 1-4

Figure 1-21. Top View of O9 Universal Relay Controller with Trunnion

(URC is an orderable accessory.)......................................................................................... 1-4

Figure 1-22. Side View of O9 Universal Relay Controller with Trunnion

(URC is an orderable accessory.)......................................................................................... 1-4

Figure 1-23. Dash Mount Configuration for O2 Control Head ................................................................... 1-5

Figure 1-24. Dash Mount Configuration for O3 Control Head ................................................................... 1-5

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) ................... 1-6

Figure 1-26. Dash Mount Configuration for O7 Control Head ................................................................... 1-6

Figure 1-27. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, 

CHIB Rear Assembly and O2 Control Head ......................................................................... 1-7

Figure 1-28. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board 

and O3 Control Head ............................................................................................................ 1-7

Figure 1-29. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, 

CHIB Rear Assembly and O5 Control Head ......................................................................... 1-8

Figure 1-30. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, 

CHIB Rear Assembly and O7 Control Head ......................................................................... 1-8

Figure 1-31. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board 

and O9 Control Head ............................................................................................................ 1-8

Figure 1-32. Remote Mount Configuration with High Power (100W) Radio Transceiver and 

O2 Control Head ................................................................................................................... 1-9

Figure 1-33. Remote Mount Configuration with High Power (100W) Radio Transceiver and 

O3 Control Head ................................................................................................................... 1-9

Figure 1-34. Remote Mount Configuration with High Power (100W) Radio Transceiver and 

O5 Control Head ................................................................................................................... 1-9

6878215A01

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. Remote Mount Configuration with Mid Power Radio Transceiver, 

Universal Relay Controller and O7 Control Head (URC is optional.)...................................1-11

Figure 1-38. Remote Mount Configuration with Mid Power Radio Transceiver, 

Universal Relay Controller and O9 Control Head (URC is optional.)...................................1-11

Figure 1-39. Remote Mount Configuration with High Power (100W) Radio Transceiver,

Universal Relay Controller and O7 Control Head (URC is optional.).................................. 1-12

Figure 1-40. Remote Mount Configuration with High Power (100W) Radio Transceiver,

Universal Relay Controller and O9 Control Head (URC is optional.).................................. 1-12

Figure 2-1. Dash Mount Radios Can Be Located in the Middle Console, on the

Transmission Hump, or Under the Dash (See

Figure 2-2 for 100W Radio Install) ............... 2-2

Figure 2-2. Remote Mount Radio Control Heads Can Be Located in the Middle

Console, on the Transmission Hump, or Under the Dash .................................................... 2-2

Figure 2-3. Remote Mount of the Radio, O9 Control Head

and Universal Relay Controller (URC is optional.)................................................................ 2-2

Figure 2-4. Radio Installation (O2 Mid Power Dash Mount).................................................................... 2-3

Figure 2-5. Radio Installation (O3 Mid Power Dash Mount).................................................................... 2-3

Figure 2-6. Radio Installation (O5 Mid Power Dash Mount).................................................................... 2-4

Figure 2-7. Radio Installation (O7 Mid Power Dash Mount).................................................................... 2-4

Figure 2-8. Radio Installation (O2 Mid Power Remote Mount) ............................................................... 2-5

Figure 2-9. Radio Installation (O3 Mid Power Remote Mount) ............................................................... 2-6

Figure 2-10. Radio Installation (O5 Mid Power Remote Mount) ............................................................... 2-6

Figure 2-11. Radio Installation (O7 Mid Power Remote Mount) ............................................................... 2-7

Figure 2-12. Radio Installation (O2 High Power Remote Mount).............................................................. 2-7

Figure 2-13. Radio Installation (O3 High Power Remote Mount).............................................................. 2-8

Figure 2-14. Radio Installation (O5 High Power Remote Mount).............................................................. 2-8

Figure 2-15. Radio Installation (O7 High Power Remote Mount).............................................................. 2-9

Figure 2-16. Radio Installation of O9 Remote Mount with Transceiver (URC is optional.) ....................... 2-9

Figure 2-17. Radio Installation (O9 Remote Mount with Pinouts) ........................................................... 2-10

Figure 2-18. Remote Control Head Pinouts ............................................................................................ 2-10

Figure 2-19. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios) ..........2-11

Figure 2-20. Cabling Interconnect Diagram for Remote Mount .............................................................. 2-12

Figure 2-21. Cabling Interconnect Diagram for 09 Remote Mount (URC is optional.) ............................ 2-13

Figure 2-22. APX 7500/ APX6500/ APX5500/ APX6500Li Mid Power Trunnion Orientation 

(Cannot Be Used for 100W Radios) ................................................................................... 2-19

Figure 2-23. APX 2500/APX4500 Mid Power Trunnion 

Orientation (Cannot Be Used for 100W Radios)................................................................. 2-20

Figure 2-24. Trunnion Orientation for 100W Radios ............................................................................... 2-20

Figure 2-25. Transmission Hump Trunnion Mounting ............................................................................. 2-22

Figure 2-26. Below Dash Trunnion Mounting.......................................................................................... 2-22

Figure 2-27. 100W Radio Mounting into Quick Release Trunnion.......................................................... 2-24

Figure 2-28. O5 Control Head Installation Exploded View 

(Also applicable for O2 and O7 Control Heads) ................................................................. 2-25

Figure 2-29. O9 Control Head Installation Exploded View...................................................................... 2-26

Figure 2-30. O5 Control Head Rear View (Also applicable for O2 and O7 Control Heads) .................... 2-26

Figure 2-31. O9 Control Head Rear View ............................................................................................... 2-27

Figure 2-32. Multiple Control Heads Example Configurations ................................................................ 2-28

Figure 2-33. APX Mobile O5 Control Head Front View........................................................................... 2-29

Figure 2-34. Radio Display with Current Control Head ID ...................................................................... 2-29

Figure 2-35. APX Mobile O5 Control Head Front View – Mode Knob .................................................... 2-30

Figure 2-36. O3 Control Head................................................................................................................. 2-30

6878215A01

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............................................................ 2-32

Figure 2-41. Bracket Installation.............................................................................................................. 2-33

Figure 2-42. Bracket Installation.............................................................................................................. 2-34

Figure 2-43. Bracket Installation (Assembled State) ............................................................................... 2-34

Figure 2-44. Bracket Uninstallation ......................................................................................................... 2-35

Figure 2-45. Bracket Uninstallation ......................................................................................................... 2-35

Figure 2-46. HKN6188_ Power Cable with External Speaker Connector ............................................... 2-36

Figure 2-47. HKN6187_ Power Cable with External Speaker Connector, Record Audio Output Jack 

(2.5 mm) and Earphone Jack (2.5 mm) .............................................................................. 2-36

Figure 2-48. Battery Selector Switch....................................................................................................... 2-37

Figure 2-49. Multiple Antennas Separation ............................................................................................. 2-39

Figure 2-50. Mini-UHF Connection (As Shown on Mid Power) ............................................................... 2-40

Figure 2-51. Mini-UHF Connection (100W Radios Only) ........................................................................ 2-40

Figure 2-52. Mini-UHF Connector Tool (As Shown on Mid Power) ......................................................... 2-41

Figure 2-53. Mini-UHF Connector Tool (100W Radios Only) .................................................................. 2-41

Figure 2-54. GPS Antenna Connector on the Back of the Mid Power Radio .......................................... 2-42

Figure 2-55. GPS Antenna Connector on the Front of the 100W Radio ................................................. 2-42

Figure 2-56. Speaker Mounting............................................................................................................... 2-43

Figure 2-57. Removing the screws on the Control Head ........................................................................ 2-44

Figure 2-58. Removing the Control Head................................................................................................ 2-44

Figure 2-59. Disconnecting the Speaker Connector ............................................................................... 2-45

Figure 2-60. Reattaching the Control Head............................................................................................. 2-45

Figure 2-61. RFID Location on Mid Power Radio....................................................................................2-46

Figure 2-62. RFID Location on APX 2500/APX 4500 Mid Power Radio ................................................. 2-46

Figure 2-63. RFID Location on High Power Radio .................................................................................. 2-47

Figure 2-64. Read Angle for Mid Power Radio........................................................................................ 2-48

Figure 2-65. Tag Angle for Mid Power Radio .......................................................................................... 2-48

Figure 2-66. Read Angle for APX 2500/APX 4500 Mid Power Radio ..................................................... 2-49

Figure 2-67. Tag Angle for APX 2500/APX 4500 Mid Power Radio ........................................................ 2-49

Figure 2-68. Read Angle for High Power Radio...................................................................................... 2-49

Figure 2-69. Tag Angle for High Power Radio......................................................................................... 2-50

Figure 2-70. Examples of Reader and Tag Aligned (Reader Orientation)............................................... 2-50

Figure 2-71. Example of Reader and Tag Misaligned (Reader Orientation) ........................................... 2-50

Figure 3-1. Universal Relay Controller Orientation.................................................................................. 3-1

Figure 3-2. Universal Relay Controller Installation Exploded View ......................................................... 3-2

Figure 3-3. Power and Ground Cable Glands ......................................................................................... 3-3

Figure 3-4. Cable Gland Assembly with Gasket...................................................................................... 3-4

Figure 3-5. Wires Installation................................................................................................................... 3-4

Figure 3-6. Wire Installation with Black Stick........................................................................................... 3-5

Figure 3-7. O7/O9 to URC Cable Installation .......................................................................................... 3-5

Figure 4-1. Emergency Switch Wiring Diagram ......................................................................................4-1

Figure 4-2. Horn/Light Wiring Diagram.................................................................................................... 4-2

Figure 4-3. Emergency Jumper Removal in Remote Mount ................................................................... 4-3

Figure 4-4. Gunlock Switch Redundancy Diagram ................................................................................. 4-4

Figure 4-5. Siren/PA Horn-Ring Connections.......................................................................................... 4-5

Figure 4-6. Remote Control Head Pinouts .............................................................................................. 4-6

Figure 4-7. HKN6196_ VIP Connector Detail.......................................................................................

... 4-6

Figure 4-8. Relay Coil.............................................................................................................................. 4-7

Figure 4-9. Field adjustment for Emergency Operation with Siren Accessory ........................................ 4-9

Figure 4-10. Location for Pin 8 .................................................................................................................. 4-9

Figure 4-11. Exploded View of Accessory Connector Assembly (HLN6863_) ........................................ 4-11

6878215A01

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) ..................................... 5-6

Figure 5-3. Motorcycle Control Head Cabling (3075217A01) ................................................................. 5-7

Figure 5-4. Handlebar Installation with Speaker and Control Head Mounted Together .......................... 5-8

Figure 5-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Together ........... 5-10

Figure 5-6. Handlebar Installation with Speaker and Control Head Mounted Separately..................... 5-12

Figure 5-7. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately........ 5-13

Figure 5-8. Location of Band 1 or Band 2 (Depending on the Antenna Port They Align to) ................. 5-15

Figure 5-9. Antenna Band Identification................................................................................................ 5-16

Figure 5-10. APX 2500/APX 4500 Antenna Band Identification ............................................................. 5-16

Figure 5-11. Routing the Coaxial Cable for GPS .................................................................................... 5-17

Figure 5-12. Routing the Coaxial Cable for Band 1 ................................................................................5-17

Figure 5-13. Routing the Coaxial Cable for Band 2 ................................................................................5-18

Figure 5-14. Cable Routing ..................................................................................................................... 5-19

Figure 5-15. Weather-Resistant Enclosure Installation........................................................................... 5-21

Figure 5-16. Installing Cables ................................................................................................................. 5-23

Figure 5-17. Installing the Transceiver.................................................................................................... 5-24

Figure 5-18. Motorcycle Wiring Harness Rework....................................................................................5-25

Figure 5-19. Remote Mount Trunnion with Sunshield............................................................................. 5-26

Figure 5-20. Position the Sunshield ........................................................................................................ 5-26

Figure 5-21. Slide the Control Head onto Trunnion ................................................................................5-27

Figure 5-22. Position Control Head as Desired....................................................................................... 5-27

Figure 5-23. Horn/Lights Wiring Diagram................................................................................................ 5-28

Figure 5-24. Emergency Switch Wiring Diagram .................................................................................... 5-28

Figure 6-1. Dust Cover Installation Locations ......................................................................................... 6-3

6878215A01

List of Tables xi

List of Tables

Table 2-1. Dash O2, O5 or O7 Radio Operations Dependent Upon A+ and Ignition Connections. 2-16 Table 2-2. 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 ...................................................................................................... 2-16

Table 2-4. Ignition Sense Switch Settings in CPS .......................................................................... 2-17

Table 2-5. Power Level Configurations ........................................................................................... 2-18

Table 2-6. Mid Power Trunnion Kit.................................................................................................. 2-21

Table 2-7. Available CAN Cables.................................................................................................... 2-28

Table 2-8. Ignition Interface Cables ................................................................................................ 2-29

Table 2-9. Power Cables................................................................................................................. 2-33

Table 2-10. Model Number Chart in 12-Digit ASCII Format.............................................................. 2-51

Table 2-11. Serial Number with Radio Band/Tier/Power .................................................................. 2-51

Table 4-1. VIP Output Connections .................................................................................................. 4-7

Table 4-2. VIP Input Connections ..................................................................................................... 4-8

Table 5-1. Transceiver Installation Parts List .................................................................................. 5-24

6878215A01

xii List of Tables

Notes

6878215A01

Mobile Radio Model Numbering Scheme xiii

Mobile Radio Model Numbering Scheme

Typical Model Number:

Position:

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

Less than 29.7MHz

= =

29.7 to 35.99MHz

36 to 41MHz

42 to 50MHz

300 to 345MHz

66 to 80MHz

74 to 90MHz

Product Specific

VHF Range

136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

* For APX 7500 "K" in Position 4 represents 136-174MHz. * For APX 7500 "Q" in Position 4 represents 380-470MHz. * For APX 7500 "S" in Position 4 represent 470-520MHz. * For APX 7500 "U" in Position 4 represent 762-870MHz.

Note: Values represented are not absolute, and are given to indicate range only.

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

10.1 to 15 Watts

16 to 25 Watts

26 to 35 Watts

Note: Values represented are not absolute, and are given to indicate range only.

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Tranceiver with Selectable Control Head

VDV Control Head

Control Head #2

Position 7 - Channel Spacing 0 = 1 = 5KHz 2 = 6.25KHz 3 = 10KHz 4 = 12.5KHz

M30 U R S 9 P W 1 A N S P 0 1

1 23 4 5 6 7 8 9 10 11 1213141516

330 to 370MHz

366 to 410MHz

403 to 437MHz

438 to 482MHz

470 to 620MHz

Product Specific UHF Range

806 to 870MHz*

825 to 870MHz

896 to 941MHz

403-470MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

36 to 60 Watts

61 to 110 Watts

Up to 125 Watts

1 to 25 Watts

25 to 40 Watts

25 to 45 Watts

10 to 35 Watts

10 to 50 Watts

25 to 110 Watts

5 = 15KHz 6 = 20/25KHz 7 = 30KHz 8 = 12.5/25KHz 9 = Variable/Programmabl e

Positions 13 - 16 SP Model Suffix

Position 12 -

Unique Model Variations

C = Cenelec N = Standard Package

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 10 - Feature Level

1 = Basic 2 = Limited Package 3 = Limited Plus 4 = Intermediate 5 = Standard Package

Position 9 - Primary System Ty pe

Conventional

Privacy Plus

Clear SMARTNET

Advanced Conventional Stat-Alert

Enhanced Privacy Plus

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet

IDEN Basic

IDEN Advanced Feature

JSMR Digital

LTR Protocol

Single Sideband

Programmable

Secure Conventional

Secure SMARTNET

TETRA

SmartZone

* MPT = Ministry of Posts and Telecommunication s

Position 8 - Primary Operation

Conventional/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Digital Dispatch

Programmable

Digital Interconnect

Digital Multi-Service

9600 Capable

TDMA

* FDMA = Frequency Division Multiple Access

6 = Standard Plus 7 = Expanded Package 8 = Expanded Plus 9 = Full Feature/ Programmable

** TDMA = Time Division Multiple Access

MAEPF-27634-B

6878215A01

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. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication Products listed below (“Product”) against defects in material and workmanship under normal use and service for a period of time from the date of purchase as scheduled below:

ASTRO APX Mobile Radio One (1) Year

Product Accessories One (1) Year

Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period. All replaced parts of Product shall become the property of MOTOROLA.

This express limited warranty is extended by MOTOROLA to the original end user purchaser only and is not assignable or transferable to any other party. This is the complete warranty for the Product manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or modifications to this warranty unless made in writing and signed by an officer of MOTOROLA. Unless made in a separate agreement between MOTOROLA and the original end user purchaser, MOTOROLA does not warrant the installation, maintenance or service of the Product.

MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by MOTOROLA which is attached to or used in connection with the Product, or for operation of the Product with any ancillary equipment, and all such equipment is expressly excluded from this warranty. Because each system which may use the Product is unique, MOTOROLA disclaims liability for range, coverage, or operation of the system as a whole under this warranty.

II. General Provisions

This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product. Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW.

6878215A01

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. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number) in order to receive warranty service and, also, deliver or send the Product item, transportation and insurance prepaid, to an authorized warranty service location. Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary

manner.

B. Defects or damage from misuse, accident, water, or neglect.

C. Defects or damage from improper testing, operation, maintenance, installation, alteration,

modification, or adjustment.

D. Breakage or damage to antennas unless caused directly by defects in material workmanship.

E. A Product subjected to unauthorized Product modifications, disassemblies or repairs

(including, without limitation, the addition to the Product of non-Motorola supplied equipment) which adversely affect performance of the Product or interfere with Motorola's normal warranty inspection and testing of the Product to verify any warranty claim.

F. Product which has had the serial number removed or made illegible.

G. Rechargeable batteries if:

- any of the seals on the battery enclosure of cells are broken or show evidence of tampering.

- the damage or defect is caused by charging or using the battery in equipment or service other than the Product for which it is specified.

H. Freight costs to the repair depot.

I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the

Product, does not function in accordance with MOTOROLA’s published specifications or the FCC certification labeling in effect for the Product at the time the Product was initially distributed from MOTOROLA.

J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of

the Product.

K. Normal and customary wear and tear.

6878215A01

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. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such

claim;

B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its

settlement or compromise; and

C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the

subject of a claim of infringement of a United States patent, that such purchaser will permit MOTOROLA, at its option and expense, either to procure for such purchaser the right to continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept its return. The depreciation will be an equal amount per year over the lifetime of the Product or parts as established by MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent infringement which is based upon the combination of the Product or parts furnished hereunder with software, apparatus or devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary equipment or software not furnished by MOTOROLA which is attached to or used in connection with the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of patents by the Product or any parts thereof.

Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute copies of such Motorola software. MOTOROLA software may be used in only the Product in which the software was originally embodied and such software in such Product may not be replaced, copied, distributed, modified in any way, or used to produce any derivative thereof. No other use including, without limitation, alteration, modification, reproduction, distribution, or reverse engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent rights or copyrights.

VII. Governing Law

This Warranty is governed by the laws of the State of Illinois, USA.

6878215A01

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 Dimensions

Figure 1-1, Figure 1-2, Figure 1-3 and Figure 1-4 show the basic dimensions of the dash mount

transceiver trunnion APX mobile radio. The transceiver portion of a remote mount APX mobile is sized similarly.

When installing the radio, make sure to plan the installation carefully and leave additional room in the rear of the radio for cabling and accessory connections; in the front of the radio for access, controls, and cabling (if remote mount); and to the sides of the radio so that you may access and install the trunnion screws/wing screws.

NOTE: The measurement unit used in Figure 1-1 to Figure 1-22 is millimeter.

206

180

Figure 1-1. Front View of APX 7500

Mid Power Dash Mount Transceiver and Trunnion

Figure 1-2. Side View of APX 7500 Mid Power

Dash Mount Transceiver and Trunnion

256 244

NOTE: The rear accessory connector adds 0.75 in to the overall length. The remote mount length

is 244 mm.

222

224 206

209

Figure 1-3. Front View of APX 2500/4500

Mid Power Dash Mount Transceiver and Trunnion

Figure 1-4. Side View of APX 2500/4500

Mid Power Dash Mount Transceiver and Trunnion

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

Figure 1-5. Front View of APX 7500

High Power (100W) Transceiver and Trunnion

206

293

Figure 1-6. Side View of APX 7500 High Power (100W)

Transceiver and Trunnion

278

269

Figure 1-7. Front View of O2 Control Head

Attached to APX 7500 Mid Power Dash Mount

Transceiver and Trunnion

224

178

Figure 1-9. Front View of O7 Control Head

Attached to APX 2500 Mid Power Dash Mount

Transceiver and Trunnion

Figure 1-8. Side View of O2 Control Head

Attached to APX7500 Mid Power Dash Mount

Transceiver and Trunnion

207

194

Figure 1-10. Side View of O7 Control Head

Attached to APX 2500 Mid Power Dash Mount

Transceiver and Trunnion

6878215A01

Introduction Mobile Radio Description 1-3

153

Figure 1-11. Front View of O3 Control

Head with Coiled Cable

209

Figure 1-12. Side View of O3 Control

Head with Coiled Cable

123

Figure 1-13. Front View of O2 Control Head with

Remote Mount and Trunnion

180

Figure 1-15. Front View of O5 Control Head with

Remote Mount and Trunnion

Figure 1-14. Side View of O2 Control Head with

Remote Mount and Trunnion

Figure 1-16. Side View of O5 Control Head with

Remote Mount and Trunnion

6878215A01

1-4 Introduction Mobile Radio Description

209

178

Figure 1-17. Front View of O7 Control Head with

Remote Mount and Trunnion

190

178

108

Figure 1-18. Side View of O7 Control Head with

Remote Mount and Trunnion

Figure 1-19. Front View of O9 Control Head with

Trunnion

185

210

Figure 1-21. Top View of O9 Universal

Relay Controller with Trunnion

(URC is an orderable accessory.)

Figure 1-20. Side View of O9 Control Head with

Trunnion

61.5

Figure 1-22. Side View of O9 Universal

Relay Controller with Trunnion

(URC is an orderable accessory.)

6878215A01

Introduction Standard Configurations 1-5

1.2 Standard Configurations

1.2.1 Dash Mount Configuration

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.

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 for O2, O5 and O7 and between the connectors on the front of the transceiver and at the back of the TIB for the O3.

ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile

Figure 1-23. Dash Mount Configuration for O2 Control Head

ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile

ASTRO 25 Subscribers APX 2500/APX 4500

ASTRO 25 Subscribers APX 2500

6878215A01

Figure 1-24. Dash Mount Configuration for O3 Control Head

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.

6878215A01

Introduction Standard Configurations 1-7

1.2.2 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. If the transceiver is located in a car trunk, ensure that it is mounted securely and that sufficient cooling is provided. Do not cover the transceiver with baggage, blankets, etc.

NOTE: The keypad mic should only be plugged into the Modified Modular Plug (MMP) connector

located on the control head, in either dash mount or remote mount configuration.

ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile

ASTRO 25 Subscribers APX 2500/APX 4500

MMP

Figure 1-27. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board,

CHIB Rear Assembly and O2 Control Head

ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile

5 m (17 ft) Extension Cable

Figure 1-28. Remote Mount Configuration with Mid Power Transceiver,

Transceiver Interface Board and O3 Control Head

6878215A01

1-8 Introduction Standard Configurations

ASTRO 25 Subscribers APX 5500/ APX 6500/APX 7500/ APX 6500 Li Mobile

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

Figure 1-30. Remote Mount Configuration with Mid Power Transceiver,

Transceiver Interface Board, CHIB Rear Assembly and O7 Control Head

ASTRO 25 Subscribers APX 7500

17 ft Extension Cable

Figure 1-31. Remote Mount Configuration with Mid Power Transceiver,

Transceiver Interface Board and O9 Control Head

6878215A01

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

6878215A01

Figure 1-34. Remote Mount Configuration with High Power (100W)

Radio Transceiver and O5 Control Head

1-10 Introduction Standard Configurations

Figure 1-35. Remote Mount Configuration with High Power (100W)

Radio Transceiver and O7 Control Head

Figure 1-36. Remote Mount Configuration with High Power (100W)

Radio Transceiver and O9 Control Head

6878215A01

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.)

6878215A01

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.

6878215A01

Introduction Standard Configurations 1-13

1.2.3 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.

6878215A01

1-14 Introduction Motorcycle Configurations

1.3 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.

1.4 Base/Control Stations

NOTE: The base/control station option is not applicable for 100W radios and O9 control heads.

If mobile radio equipment is installed at a fixed location and operated as a control station or as a fixed unit, the antenna installation must comply with the following requirements in order to ensure optimal performance and compliance with the RF energy exposure limits in the standards and guidelines listed in the 6881095C99 manual:

• The antenna should be mounted outside the building on the roof or a tower if at all possible.

• As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in accordance with applicable regulatory requirements and may require additional compliance actions such as site survey measurements, signage, and site access restrictions in order to ensure that exposure limits are not exceeded.

1.5 Tools Required for APX Mobile Installations

Tool Par t N umber

10 mm wrench –

5 mm Allen wrench –

Rubber-coated pliers –

Regular slot screwdriver of Phillips #2 –

Pin removal tool 6680163F01

RF antenna tool HLN6695_

Wing screw torque tool HLN6970_

6878215A01

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. Before starting the installation, inspect the vehicle and determine how and where you intend to mount the antenna, radio, and accessories. Plan wire and cable runs to provide maximum protection from inching, crushing, and overheating.

Before installing any electrical equipment, check the vehicle manufacturer’s user manual for warnings or recommendations.

C a u t i o n

The installation of this device should be completed by an authorized servicer or installer. Failure to properly install the device may result in damage to the device, or improper operation.

2-2 Standard Configurations Planning the Installation

2.1.1 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).

Antenna 1/4-Wavelength

911

Speaker

Battery

Radio

Figure 2-1. Dash Mount Radios Can Be Located in the Middle Console, on the

Transmission Hump, or Under the Dash (See Figure 2-2 for 100W Radio Install)

Speaker

Control Head

Battery

Antenna 1/4-Wavelength

911

Radio

Control Head

Figure 2-2. Remote Mount Radio Control Heads Can Be Located in the Middle

Console, on the Transmission Hump, or Under the Dash

Control Head

Speaker

Siren Speaker

Battery

Antenna 1/4-Wavelength

Radio

Siren Box

911

Universal Relay Controller Box

Figure 2-3. Remote Mount of the Radio, O9 Control Head

and Universal Relay Controller (URC is optional.)

NOTE: 100W radio install is typically at the rear vehicle compartment.

6878215A01

2-14 Standard Configurations Planning the Installation

2.1.3 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.e. Ignition as: Required, Blank, Soft Power Off, TX Inhibit, PTT TX Inhibit, Ignition Only Power Up).

Choose a clean ignition point which is not shared in the immediate vicinity by other high current accessories/devices. This will help to reduce the transients on the ignition line. Examples of  high-current accessories/devices are: Air Horn, relays, lightbars and etc. It is recommended to wire to the vehicle’s ACC line, not the START or the solenoid side of the ignition circuit. Refer to chapter 6 for best installation practices. The Ignition sense (ACC) cable uses either a 3-amp fuse (6580283E01) or 4-amp fuse (6580283E02).

2.1.3.1 Dash Mount: Power, Ignition, and Emergency Cable Installation

The standard dash mount rear ignition sense cable HLN6863 contains a “thin red” ignition wire, a jumper wire that shorts emergency to ground, and two gray wires attached to an external speaker plug. The thin RED wire is the ignition sensed wire. Refer to Table 2-1, Table 2-2, or Table 2-3 for its correct wiring configurations.

NOTE: This cable MUST be attached in order for the radio to operate in Dash mount, regardless of

how emergency is programmed in CPS or wired inside the vehicle. Either the emergency jumper wire or an emergency accessory (footswitch or button) must be wired to the rear of the transceiver in Dash mount. Otherwise, upon attachment of the radio’s power cable to the vehicle battery, the radio will incorrectly determine that emergency operation has been activated, such as when an emergency footswitch is de-pressed and the emergency pin is ungrounded.

6878215A01

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. If the HLN6863 is attached at J100 of the O2, O5, O7 or O9 control head, the “thin red” wire will NOT function as an ignition sense wire, since the J100 connector has no ignition sense electrical connection.

NOTE: It is incorrect for installation to attach ignition sense at more than one wire or connector. 

Refer to

The O3 control head receives its power down the CAN cable, and detects the ignition state by the ignition sense pin at either J2 or J600. On mid power radios, the J2 and J600 connectors can also be used for ignition sense. On high power radios, only the J600 connector can be used for ignition sense.

In Multi-Control Head installations, the yellow ignition wire must be connected to the head assigned ID # 1. See Section 2.2.2.5 “Setting the Initial Control Head ID” on page 2-29 for further information.

In remote mount O2, O3, O5, O7 or O9, an Emergency jumper to ground is placed by default on the TIB (JU344) so that there is no need to attach a cable with an emergency accessory at either J2 or at J600. This jumper must be removed if an emergency accessory (footswitch or button to Ground) is installed at either J2 or J600 (or J626 on the accessory cable) locations. If the jumper JU344 is removed but no emergency accessory is installed, the radio will power-up incorrectly into emergency mode all the time. Refer to Figure 4-3 for details.

Table 2-1 or Table 2-2 for its correct wiring configurations.

The design of the control head is different compared to the transceiver, therefore it is also NOT necessary to attach HLN6863 at J100 to prevent accidental emergency operation. The control head uses an edge-detect, not a state-detect like on the transceiver, so mounting of HLN6863 is not mandatory.

6878215A01

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

Connected to ignition switch

Ignition switch controls

Transceiver

Red Power

Wire

HLN6863

Thin Red Wire

XXX X

No ignition switch control. Enables ignition switch functionality

Transceiver

Red Power

Wire

HLN6863

Thin Red Wire

XXX

as programmed in the codeplug.

Transceiver

Red Power

Wire

Illegal wiring configuration. See CAUTION note.

HLN6863

Thin Red Wire

Table 2-2. Remote O2, O5, O7, or O9 Radio Operations Dependent Upon A+ and Ignition Connections

Remote

Mount

Connected to battery

Connected to ignition switch

Ignition switch controls

Control Head

Red Wire

Control Head

Yello w Wire

Control Head

Red Wire

Control Head

Yello w Wire

Control Head

Red Wire

Control Head

Yellow Wire

XXX X

XXX

No ignition switch control. Enables ignition switch functionality

as programmed in the codeplug.

Illegal wiring configuration. See CAUTION note.

Table 2-3. Remote O2, O5, O7 or O9 Radio Operations Dependent Upon A+ and Ignition Connections

Mid Power

Dash/Remote

High Power

Dash/Remote

Connected to battery

Connected to ignition switch

Ignition switch controls

HLN6863

Thin Red Wire

Transceiver

Red Power

Wire

at J2

HLN6863

Transceiver

Red Power

Wire

Thin Red Wire

at J626

XXX

No ignition switch control. Enables ignition switch functionality

as programmed in the codeplug.

HLN6863

Thin Red Wire

at J2

Transceiver

HLN6863

Thin Red Wire

at J2

Red Power

HLN6863

Thin Red Wire

at J626

Wire

HLN6863

Thin Red Wire

at J626

XXX

Illegal wiring configuration. See CAUTION note.

DO NOT connect any wires to the battery terminals until you have finished the entire radio installation (Dash or Remote Mount) configuration to avoid potential equipment

damage.

C a u t i o n

Incorrect wiring of the radio may result in incorrect ignition sense detection, incorrect power-on state, or incorrect power-off state of the radio system.

The Control Head Power cable wire (RED) and Transceiver Power cable wire (RED) are always attached to the battery terminal and NOT to the ignition switch.

6878215A01

Standard Configurations Planning the Installation 2-17

2.1.4 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 Description

Blank • 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.

TX Inhibit • 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.

•If IGNITION is not present all transmissions are inhibited.

• The radio will not affiliate with trunking systems and therefore CANNOT receive any

trunking dispatch communications.

• Emergency Alarm transmissions are NOT possible with the use of the emergency power

up feature.

PTT TX Inhibit • 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.

•If IGNITION is not present all transmissions are inhibited.

• The radio is able to affiliate with trunking systems. The radio can ONLY receive trunking

dispatch communications.

• Emergency Alarm transmissions are possible with the use of the emergency power up feature.

Required • Radio POWERS ON when the Power Button is pressed and Ignition is present.

• Radio POWERS ON when Ignition is cycled and radio was previously ON.

• Radio POWERS OFF when the Power Button is pressed, or when Ignition is lost.

Soft Power Off • Radio POWERS ON when the Power Button is pressed, or when Ignition is detected.

• Radio POWERS OFF when the Power Button is pressed, or when Ignition is lost.

Ignition Only Power Up • Radio POWERS ON when Ignition is present.

• Radio POWERS OFF when Ignition is lost.

• Control head power button is ignored.

NOTE: When either TX Inhibit, PTT TX Inhibit or Required are selected, the Emergency Power Up

feature will not be available to the radio-user.



When any other Ignition Switch setting is made, Emergency Power Up is available to the radio-user, regardless of current ignition state.



Any optional inactivity time-out timer setting in CPS may delay the power off of the radio once Ignition sense is removed.

6878215A01

2-18 Standard Configurations Planning the Installation

2.1.5 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. Using an appropriate pin removal tool, extract pin 35 and move it to one of the following pin locations:

- pin location 36 for 75W operation

- pin location 28 for 65W or 130W operation

3. For 65W or 75W operation, no further changes are required. Reassemble the connector.

4. For 130W operation, you must parallel two 11 speakers, each rated at 65W minimum. Proper phasing of the two speakers is important--when connecting two speakers in parallel, wire similar speaker terminals together to ensure maximum loudness and prevent "deadspots." For example, if the terminals are marked "1" and "2", connect the terminals marked "1" together and connect those wires to one speaker lead. Connect the terminals marked "2" together and connect those wires to the other speaker lead.

Before continuing, remember that under a high-line supply condition

C a u t i o n

5. When the Siren/PA is configured for dual speaker, 130W operation, it is necessary to remove a resistor and move two jumpers to set the correct power level. Remove the Siren/PA cover, and locate resistor R219 (0 ohm). This resistor should be removed for 130W operation. Locate jumpers JU100 and JU101. These jumpers should be installed for 130W operation.

6. Close and reconnect the Siren/PA connector cover.

NOTE: Jumpers JU100 and JU101 do not affect the Siren output level. JU100 and JU101

Pin locations of various power level configurations are listed in

65W 20,28 IN Across pins A and B

75W 20,36 IN Across pins A and B

100W 20,35 IN Across pins A and B

130W 20,28 OUT Across pins B and C

(16.6V), up to 30% more power will go to the speaker(s) after reconfiguring for 130W operation. Do this only when your PA speakers are capable of handling the extra power.

compensate for the lower speaker load and the two speakers in parallel, by decreasing the gain U102-1. JU100 affects the radio PA level and JU101 affects the PA audio level.

Table 2-5

Table 2-5. Power Level Configurations

Pin location of speaker

leads

R219 JU100/JU101

6878215A01

Standard Configurations Radio Mounting 2-19

2.2 Radio Mounting

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.

C a u t i o n

The mounting location must be accessible and visible. Select a location that will permit routing the RF antenna cable as directly as possible.

NOTE: For optimum radio performance, orient the mounting trunnion as shown in

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. If the radio sits in water for a length of time, moisture may seep inside the radio and damage the electronic components.

DO NOT allow water to stand in recessed areas of vertically mounted radios. Remove any moisture immediately to prevent it from seeping down into the radio.

Care must be taken to shield the control head (front and back) from direct exposure to pressurized water. The pressurized water from a hose, in most cases, is more severe than the stated test and conditions in typical environments.

Figure 2-22 or Figure 2-23 for mid power and Figure 2-24 for high power. For new or existing installations of

all but 100W radios, use only the APX mobile trunnion, kit number HLN7002_except for APX 2500 and APX 4500 which shall use the trunnion with kit number HLN6861_. For new or existing installations of 100W radios, use only the APX mobile trunnion, kit numbers HLN7003_.

Figure 2-22. APX 7500/ APX6500/ APX5500/ APX6500Li Mid Power Trunnion Orientation

6878215A01

RADIO FRONT

APPLIES TO RADIOS IN DASH AND REMOTE INSTALLATIONS

(Cannot Be Used for 100W Radios)

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. Trunnion Orientation for 100W Radios

6878215A01

Standard Configurations Radio Mounting 2-21

2.2.1 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. Plan your installation ensuring enough room for the Accessory connector and cable in the back of the radio.

3. Using the trunnion mounting bracket as a template, mark the positions of the holes on the mounting surface. Use the innermost four holes for a curved mounting surface such as the transmission hump, and the four outmost holes for a flat surface such as under the dash.

4. Center punch the spots you have marked and realign the trunnion in position.

5. Secure the trunnion mounting bracket with the four self-drilling screws provided  (see Figure 2-25 and Figure 2-26).

6. Ensure that the plastic guides are aligned (horizontal) to the grooves of the trunnion. Slide the radio into the grooves until it snaps into place (see Figure 2-26).

Table 2-6. Mid Power Trunnion Kit

Item Part Number Description Mid Power Transceiver

0371859H01 Trunnion Mounting Screw APX 5500/APX 6500/APX 6500 Li/APX 7500

0305760W02 Trunnion Mounting Wing Screw APX 2500/APX 4500

APX 5500/APX 6500/APX 6500 Li/APX 7500

2 0312002B14 Self-Drilling Tapping Screw

APX 2500/APX 4500

HLN7002_ Mackinaw Trunnion Hardware Kit APX 5500/APX 6500/APX 6500 Li/APX 7500

HLN6861_ Millenium Trunnion Hardware Kit APX 2500/APX 4500

6878215A01

2-22 Standard Configurations Radio Mounting

Figure 2-25. Transmission Hump Trunnion Mounting

Groove

Threaded Hole for Screw

Tabs

Plastic Guides

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. The tool can also be used to loosen the wing screws. Detailed instructions are included in the tool packaging.

NOTE: This configuration shows the O5 control head. The TIB is used for O3 control head for the

same configuration.

6878215A01

Standard Configurations Radio Mounting 2-23

2.2.2 Remote Mount with Trunnion

Before installing any electrical equipment, check the vehicle manufacturer’s user manual.

C a u t i o n

For a remote mount installation, the transceiver may be mounted anywhere in the vehicle, provided that the installation location is safe, follows the cautions mentioned at the beginning of this section, and is accessible for servicing/maintenance as well as cabling. A typical mounting location recommended by Motorola is in the vehicle’s trunk. The trunnion provided may still be used to mount the transceiver, and the mounting process is the same as for the dash mount installation  (

Section 2.2.1 on page 2-21). However, for 100W radios you must follow the procedure detailed

below in Section 2.2.2.1. See Figure 2-10, Figure 2-11, Figure 2-13, or Figure 2-14 for a remote installation.

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).

6878215A01

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. Center-punch the spots you have marked and realign the trunnion in position.

3. Secure the trunnion mounting bracket with the four self-drilling screws provided  (see

Figure 2-27).

4. After the trunnion has been mounted in the vehicle using the screws provided, install the radio. Place the radio with the lock handle fully opened on the trunnion, oriented at least 10 mm in front of the rear catches. Push the radio towards the rear catches. The radio is lifted up slightly and then drops back down, flushed with the trunnion, and stops against the rear catches. Once this occurs, close the lock handle. Rotate the handle towards the top of the radio until it is locked in place. The key is not needed in the lock to close the handle, but is needed to reopen. The keys can only be removed from the lock when it is in the locked position.

Figure 2-27. 100W Radio Mounting into Quick Release Trunnion

2.2.2.2 Remote Mount Control Head Installation

Choose a mounting location for the radio, considering accessibility, and control and antenna cable lengths.

The recommended mounting surfaces for the control unit are under the mounting surface, on the transmission hump, or on the center console. Figure 2-28 and Figure 2-29 shows how the trunnion, control head, and cables should be installed for the O2, O5, O7 or O9 control head.

NOTE: Connector-protective covers (i.e. Dust Covers) HLN6980_ are provided with the radio.

They should be installed on exposed connectors for added environmental robustness.

6878215A01

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. If that is not possible, use a metal backing plate (not supplied) to strengthen the installation. Install the control follows:

1. Use the control unit 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 control head (adjusting for proper viewing angle) and fasten it to the trunnion with two wing screws. Test the installation to be sure the control head feels securely locked in place while you are pressing its buttons.

4. Finish installation by fully tightening screws.

Metal Backing Plate (Not Supplied)

6878215A01

Figure 2-28. O5 Control Head Installation Exploded View

(Also applicable for O2 and O7 Control Heads)

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

Figure 2-29. O9 Control Head Installation Exploded View

Figure 2-30. O5 Control Head Rear View

(Also applicable for O2 and O7 Control Heads)

DRILL FOUR 5/32'' HOLES IN MOUNTING SURFACE

6878215A01

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. Control heads can also be connected a “daisy chain” configuration from a single transceiver CAN connector. See Figure 2-32 for examples.

NOTE: The transceiver must be configured for Multiple Control Head via CPS programming.

Navigate to the “Control Head” tab in the Radio Wide section of CPS, and select “Help” for further information and tutorials.

J300R

J300L

Control Head 1

J300R

J200

J300L

Control Head 3

FUSE

J300R

Control Head 2

J200

FUSE

J300R

FUSE

Control Head 4

J200

FUSE

RED LEAD

(+)

(-)

BATTERY

6878215A01

2-28 Standard Configurations Radio Mounting

FUSE

J300R

J300L

Control Head 1

J200

J300R

J300L

Control Head 2

J300L

Control Head 3

J200

FUSE

J300R

Control Head 4

J200

FUSE

RED LEAD

(+)

BATTERY

(-)

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 2.2.2.5 “Setting the Initial Control Head

ID” on page 2-29 for further information.

Use the most convenient configuration for your installation, ensuring that the combined cable lengths do not exceed 131 feet (40 meters). See Table 2-7 for a list of available CAN cable lengths. Control head ground, power and ignition sense wires (black, red, and yellow respectively) may need additional length (not supplied) in installations that locate the head more than 10 feet from a power source.

Table 2-7. Available CAN Cables

Part Number Description

HKN6164_ Cable, Remote Mount, 40m (131ft)

HKN6165_ Cable, Remote Mount, 35m (115ft)

HKN6166_ Cable, Remote Mount, 23m (75ft)

HKN6167_ Cable, Remote Mount, 15m (50ft)

HKN6168_ Cable, Remote Mount, 9m (30ft)

HKN6169_ Cable, Remote Mount, 5m (17ft)

HKN6170_ Cable, Remote Mount, 3m (10ft)

PMLN4958_ Cable, O3 Extension, 5m (17ft)

6878215A01

Standard Configurations Radio Mounting 2-29

Table 2-8. Ignition Interface Cables

Part Number Description

HLN6863_ Cable, M.A.P. 26pin with Only Ignition and SPK

PMLN4959_ 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. It is not recommended to route cabling or wiring inside the wheel wells of a vehicle.

2.2.2.5 Setting the Initial Control Head ID

The Front Panel Programming (FPP) mode allows you to define which control head in a Multi Control Head system becomes control head number 1-4.

Set the control head ID number for each attached head the first time Multi Control Head is used.

1. Press the power button to power off the radio.

2. Press and hold left-most menu and the orange button on the control head simultaneously.

Power Button

Left-most Menu Button

Emergency Button

Figure 2-33. APX Mobile O5 Control Head Front View

3. Press the power button to power on the control head. The head will power on into FPP mode and display the current control head ID number:

CH ID#

Figure 2-34. Radio Display with Current Control Head ID

4. Turn the Mode knob to change the control head’s ID number.

6878215A01

2-30 Standard Configurations Radio Mounting

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. The control head extension cable and the accessories cable should be installed and routed properly to avoid complications. Route the cables in the vehicle’s wiring troughs (where available) or route the cables where they are protected from pinching, sharp edges, or crushing. One suggested route is along one side of the driveshaft hump under the carpet. Use grommets in any holes where the cable passes through metal panels.

Top

Front RightLeft Back

Figure 2-36. O3 Control Head

The recommended mounting surface for the control unit is on the center console.

Figure 2-38 shows

how the hang-up clip control head, and cables should be installed for the O3 control head.

NOTE: Connector-protective covers are provided with the radio. They should be used for added

environmental robustness.

6878215A01

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. Drill 7/16” deep holes for upper and lower screws.

3. Use the tapping screw provided to install the mounting clip.

Care must be taken to shield the control head (front and back) from direct exposure to

C a u t i o n

pressurized water. The pressurized water from a hose, in most cases, is more severe than the stated test and conditions in typical environments.

VEHICLE

Vehicle Mounting Surface

DASHBOARD

Item

No.

Part Number Description

1 01-80743T91 Mic Hang-Up Clip

Assembly

2 03-07644M19 Screw, Machine,

8-32 x 7/16

Figure 2-37. O3 Control Head Rear View Figure 2-38. Hang-Up Clip Installation

Exploded View

6878215A01

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.

NOTE: For mobile radios with rated power of 7 watts or less, the only installation restrictions are to

use only Motorola approved antennas and install the antenna externally on metal body vehicles. For mobile radios with tuned power greater than 7 watts, always adhere to all the guidelines and restrictions in

2.4.1 Selecting an Antenna Site/Location on a Metal Body Vehicle

1. External installation – Check the requirements of the antenna supplier and install the

vehicle antenna external to a metal body vehicle in accordance with those requirements.

2. Roof top – For optimum performance and compliance with RF Energy Safety standards,

mount the antenna in the center area of the roof.

3. Trunk lid – On some vehicles with clearly defined, flat trunk lids, the antennas of some radio

models (see restrictions below) can also be mounted on the center area of the trunk lid. For vehicles without clearly defined, flat trunk lids (such as hatchback autos, sports utility vehicles, and pick-up trucks), mount the antenna in the center area of the roof.

Section 2.4.1 below.

Before installing an antenna on the trunk lid,

- Be sure that the distance from the antenna location on the trunk lid will be at least 85 cm (33 inches) from the front surface of the rear seat-back to assure compliance with RF Energy Safety standards.

- Ensure that the trunk lid is grounded by connecting grounding straps between the trunk lid and the vehicle chassis.

C a u t i o n

If these conditions cannot be satisfied, then mount the antenna on the roof top.

4. Mounting restrictions for certain radio models.

For all VHF and UHF 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. Check the antenna location for any electrical interference.

6878215A01

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.

3 ft

3 ft3 ft

911

Figure 2-49. Multiple Antennas Separation

6878215A01

2-40 Standard Configurations Antenna Installation

2.4.2 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 connection of an antenna cable's mini-UHF plug to a radio's mini-UHF jack, their interlocking features must be properly engaged. If they are not properly engaged, the system will loosen. Using a tool (pliers or wrench) will not overcome a poor engagement, and is not recommended.

NOTE: Applying excessive force with a tool can cause damage to the antenna or the connector 

(e.g., stripping threads, deforming the collar or connector, or causing the connector to twist in the housing opening and break).

The mini-UHF connector tool (Motorola part number HLN6695_) is designed to securely tighten the antenna plug–radio jack connection without damaging either the plug or the jack.

Motorola recommends the following sequence to ensure proper attachment of the system  (see Figure 2-50 and Figure 2-51):

Figure 2-50). To ensure a secure

Coax Conductor

Plug (Pin)

Collar Pulled

Back to Flange

Flange

Cable

Mini UHF

Jack

RF Antenna

Connector Label

Figure 2-50. Mini-UHF Connection (As Shown on Mid Power)

Coax Conductor

Plug (Pin)

Collar Pulled

Back to Flange

Flange

Mini UHF

Jack

Cable

Figure 2-51. Mini-UHF Connection (100W Radios Only)

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.

6878215A01

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. Give a final tug, by hand, to the collar, and retighten by hand as firmly as possible.

8. Slip the mini-UHF connector tool over the coaxial cable, using the gap between the tool’s legs (see

Figure 2-52). Then, slide the tool up onto the plug’s knurled collar. Squeeze the two

straight legs of the tool firmly together between your thumb and index finger and turn clockwise (as shown) to tighten the collar. It should take 1/4 turn or less. When you feel the tool slipping on the collar, the connection has been properly tightened. The tool can also be used to loosen a tight collar.

NOTE: DO NOT use pliers or any other device to grip the tightening tool. It has been designed to

allow you to achieve the proper torque on the collar without overtightening. Overtightening the collar can damage the connector and the radio.

HLN6695_

)

(

(1) Squeeze

Firmly Together

Figure 2-52. Mini-UHF Connector Tool (As Shown on Mid Power)

(

)

HLN6695_

(1) Squeeze

Firmly Together

6878215A01

Figure 2-53. Mini-UHF Connector Tool (100W Radios Only)

2-42 Standard Configurations Antenna Installation

2.4.3 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.

2.4.4 GPS Connection

To ensure a secure connection of the GPS antenna cable's SMA plug to a radio's SMA jack, the connector must be fully seated. If the connectors are not fully seated, the system will loosen. This should be done by hand to ensure excess force is not applied. GPS positions as shown in 

Figure 2-54 and Figure 2-55 are located in different positions. The mid power radio has the GPS

antenna connector on the back of the radio while the 100W radio has the antenna connector on the front of the radio.

NOTE: Applying excessive force with a tool can cause damage to the antenna or the connector 

(e.g. stripping threads, deforming the collar or connector, or causing the connector to twist in the housing opening and break).

Figure 2-54. GPS Antenna Connector on the Back of the Mid Power Radio

Figure 2-55. GPS Antenna Connector on the Front of the 100W Radio

6878215A01

Standard Configurations Speaker 2-43

2.5 Speaker

DO NOT ground the radio's speaker leads. This system has a floating speaker output

C a u t i o n

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. The trunnion allows the speaker to tilt for best operation. Mount the speaker out of the way so that it will not be kicked or knocked around by the vehicle occupants. Mount the speaker as follows:

(DC voltage on both leads); damage to the audio circuit will result if either lead is grounded or if they are shorted together.

1. Use the speaker mounting bracket as a template to mark the mounting hole locations.

2. Use the self-drilling screws provided to fasten the trunnion.

3. Attach the speaker and fasten to the trunnion with two wing screws.

4. Route the speaker wires under the carpet or floor covering, or behind the kick panels. Be sure the wires are out of the way and will not be snagged and broken by the occupants of the vehicle.

5. Do not submerse the 2-pin speaker connector in water nor place this connector in an area that could have standing water.

6878215A01

Dashboard

Firewall

Figure 2-56. Speaker Mounting

Trunnion

Bracket

MAEPF-25764-O

2-44 Standard Configurations Speaker

2.5.1 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. Remove the four screws found on the control head with a Torx T-20 bit as shown in

Figure 2-57. Discard the screws.

Figure 2-57. Removing the screws on the Control Head

3. Firmly grasp the front panel of the control head. Carefully remove the front housing assembly from the back housing assembly as shown in Figure 2-58. Note the position of the attached flex and do not pull on it excessively.

Figure 2-58. Removing the Control Head

6878215A01

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. Make sure that the flex is returned to its original position and that the o-ring on the back housing assembly is not pinched.

6878215A01

Figure 2-60. Reattaching the Control Head

7. Secure the front housing assembly back to the back housing assembly with four new screws using the Torx T-20 bit as shown in Figure 2-60. Apply 9 in. lbs. torque for each screw.

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. To avoid interference when removing the microphone, install the flathead screw in the top clip hole.

Some microphone models require the grounding of the microphone clip in order for HUB operation to work correctly. Refer to the documentation that comes with your Motorola microphone model.

NOTE: For multi-control head configuration where only one of the control heads has a microphone,

the control heads without a microphone attached must have their HUB or Monitor pin (J100-22) jumpered by a wire to GND (J100-1 or J100-14) for HUB operation to work.

2.7 RFID (Option)

An APX mobile radio equipped with an RFID tag allows an alternate option for tracking the radio asset. Each RFID equipped radio has an RFID tag preprogrammed with the individual radio’s serial number (also found on the FCC label) as well as band and radio model information (see below for further info).

RFID Tag

Figure 2-61. RFID Location on Mid Power Radio

RFID Tag

Figure 2-62. RFID Location on APX 2500/APX 4500 Mid Power Radio

6878215A01

Standard Configurations RFID (Option) 2-47

RFID Tag

Figure 2-63. RFID Location on High Power Radio

6878215A01

2-48 Standard Configurations RFID (Option)

2.7.1 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. Read distance is independent of Tag Angle, but the reader should be as close to perpendicular to the tag as possible (Read Angle).

As Read Angle increases past 60 degrees, read distance will begin to decrease; tag will become unreadable once Read Angle exceeds 90 degrees (see cannot be read through metal. The orientation of the reader (Reader Orientation) and the tag must be aligned to improve read and writability (see Figure 2-70).

Read Angle

RFID Tag

Figure 2-64 and Figure 2-66). RFID tag

Figure 2-64. Read Angle for Mid Power Radio

Tag Angle

Figure 2-65. Tag Angle for Mid Power Radio

RFID Tag

6878215A01

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.

6878215A01

2-50 Standard Configurations RFID (Option)

Tag Angle

RFID Tag

Figure 2-69. Tag Angle for High Power Radio

Reader

Tag

Figure 2-70. Examples of Reader and Tag Aligned (Reader Orientation)

Reader

Tag

Figure 2-71. Example of Reader and Tag Misaligned (Reader Orientation)

6878215A01

Standard Configurations RFID (Option) 2-51

2.7.2 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. Model Number Chart in 12-Digit ASCII Format

Model Number Radio Tier/Band/Output Level Last Two Digits

M30KSS9PW1AN APX Mobile SB-MP VHF D2

M24KSS9PW1AN

M22KSS9PW1AN

M30KTS9PW1AN APX Mobile SB-HP VHF D3

M30QSS9PW1AN APX Mobile SB-MP UHF1 E2

M30QTS9PW1AN APX Mobile SB-HP UHF1 E3

M30SSS9PW1AN APX Mobile SB-MP UHF2 D2

M20TSS9PW1AN APX Mobile DB-MP 7/800-MP VHF R2

M30TXS9PW1AN APX Mobile DB-MP 7/800-HP VHF R3

M30URS0PW1AN APX Mobile SB-MP 7/800 F2

M22URS9PW1AN

M24URS9PW1AN

APX Low Tier Mobile-MP VHF D8

APX Low Tier Mobile-MP 7/800 F8

Table 2-11. Serial Number with Radio Band/Tier/Power

Characters Radio Band/Tier/Power

F7/800

DVHF

E UHF

R 7/800 and VHF

T VHF and UHF

E UHF1 and UHF2

S 7/800 and UHF

1 APX7000

2 APX7500 Mid Power

3 APX7500 High Power

4 APX6000

5 APX6500 Mid Power

6878215A01

2-52 Standard Configurations Completing the Installation

Table 2-11. Serial Number with Radio Band/Tier/Power

6 APX6500 HighPower

7 APX Low Tier Portable

8 APX Low Tier Mobile MP

9 APX Low Tier Mobile HP

2.8 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.

6878215A01

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. A separate ground for isolation exists between the relay and MCU sections, which is provided by the use of iCoupler from Analog Devices. Each relay is connected to an output with 15 A fuse. The maximum load allowed on each output is 12 A. Two cables, each with the maximum of 60 A, can be used to connect to the input connector at the bus bar. Each cable is connected with a 60 A circuit breaker. One-wire EEPROM is employed to enable GCAI to recognize the URC accessory ID. CPS can be used to program the relay patterns.

When installing URC, make sure to plan the installation carefully and leave additional room in the front and rear of the box for cabling and accessory connections; and also to the sides of the radio so that you may access and install the trunnion screws.

The recommended mounting location for URC is in the car trunk, either next to the transceiver or within the area not further than 4.5 m away from the transceiver. Ensure that sufficient cooling is provided. Do not cover URC with baggage, blankets, etc.

C a u t i o n

Do not backfeed power into URC.

3.1 Universal Relay Controller Mounting

The mounting location must be accessible and visible. Select a location that permits routing the cable as directly as possible.

NOTE: For optimum URC performance, orient the mounting trunnion as shown in

Figure 3-1. Universal Relay Controller Orientation

An adjustable trunnion, which allows a number of mounting positions, is supplied for mounting the URC. The installation must not interfere with the operation of the vehicle or its accessories.

Figure 3-1.

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. Test the installation to ensure that the unit is securely locked in place.

USE FOUR MOUNTING SCREWS ON ALL INSTALLATIONS

ADJUST THE UNIVERSAL RELAY CONTROLLER TO DESIRED  ANGLE AND SECURE WITH WING SCREWS

TRUNNION

MOUNTING SURFACE

IMPORTANT USE A METAL BACKING PLATE (NOT SUPPLIED) IF MOUNTING TRUNNION ON PLASTIC OR UNSTABLE SURFACE

Figure 3-2. Universal Relay Controller Installation Exploded View

DRILL FOUR 5/32'' HOLES IN MOUNTING SURFACE

6878215A01

Universal Relay Controller Installation O7/O9 Universal Relay Controller Cable Assembly 3-3

3.2 O7/O9 Universal Relay Controller Cable Assembly

3.2.1 Power Cable

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. User can decide to install one or two power cables based on the requirements. The power cables (A+) are not supplied.

2. The loose end of the power cable with cable strip length 7.94 mm (5/16”) is then placed on the power lug and secured down by a set screw. The cap nut is then reassembled with tightening torque 18 lb-in.

3. The other end of the power cable should be connected to circuit breaker (Motorola part number 40012006001) end which indicates "AUX" and then, to power supply on the other end which indicates "BAT", instead of connecting to power supply directly.

4. Repeat steps 1 to 3 to install the second power cable, if required.

5. If only one power cable is installed, it is recommended to cover the other side of the power cable gland with power cable gland seal with tightening torque 18 lb-in.

3.2.2 Ground Cable

1. Remove the cap nut of ground cable gland assembly, insert the ground cable through the cap nut and then reassemble the cap nut. Use ground cable with AWG 14 only (recommended OD range of cable is 2 mm to 4 mm) that is able to withstand 5 A. The ground cables (A+) are not supplied.

NOTE: The ground is used to switch the relays, and not act as a ground to the actual device being

controlled.

2. The loose end of the ground cable with cable strip length 7.94 mm (5/16”) is then connected to a two-pin terminal block. Both pins on the terminal block are inter-connected and either pin can be used. The cap nut is then reassembled with tightening torque 7 lb-in.

Power Cable Gland

Ground Cable Gland

Figure 3-3. Power and Ground Cable Glands

6878215A01

3-4 Universal Relay Controller Installation O7/O9 Universal Relay Controller Cable Assembly

3.2.3 Wires

1. Assemble the wires into the lightbar gasket retainer and lightbar gasket. The URC can

2. Each individual loose wire (prior to stripping off the wire jacket) needs to be inserted one at a

3. Thin wires 2.5 mm and below should be dressed into the retention feature using a black stick

4. Cover the lightbar gasket retainer's hole with seal, gasket and ground cable gland, if no wire

Cable Gland Body

Neoprene Seal

Cap Nut

Counter Nut

Gasket, Cable Gland

Figure 3-4. Cable Gland Assembly with Gasket

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.

time through the chassis. Ensure the lightbar wire is straight before inserting the wire into the chassis. Each wire is sealed individually by the radial gasket seal. When a thick wire (i.e. AWG 14 wire or wire OD > 2.90 mm) is inserted through the chassis, there is potential torn at the rubber gasket. Remove the rubber gasket residual and continue to the next step.

(see

Figure 3-5); thick wires above 2.5 mm should be routed above the retention feature.

Strip off the wire until 7.94 mm (5/16”) after the wire is inserted into the URC, and install the wire into respective lightbar terminal block.

is inserted.

LIGHTBAR WIRE WITH DIAMETER ABOVE 2.5 mm

WIRE RETENTION FEATURE

LIGHTBAR WIRE WITH DIAMETER

2.5 mm AND BELOW

Figure 3-5. Wires Installation

6878215A01

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. If the current loading for one wire is higher than 12 A, the wires should be splitted before being assembled to the URC system. Wires kit (PMKN4109_) is provided to ease installation of the URC. Incorrect use of the wires kit, e.g. improper connection at external loose end wires, may impact the robustness of the URC.



Remove the wires and gasket residual inside the URC after the wire installation, before closing the top housing of the URC.

3.2.4 O7/O9 to URC Cable

The O7/O9 to URC cable (Motorola part number 3064153H02) can be assembled either before or after reassembling the top housing. Assemble the RJ45 port of the cable into the RJ45 connector on the URC and turn the locking collar instead of cable, 90 degrees to the right to ensure it is locked properly. After that, test whether the cable is locked properly or not by trying to pull out the cable.

Figure 3-7. O7/O9 to URC Cable Installation

6878215A01

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.

Insert the male terminal into the accessory connector assembly in the appropriate location and connect the accessory connector assembly in the rear accessory port. Do not use other generic terminals in the plug. Generic terminals can cause electrical intermittencies and may cause damage to the plug.

4.1.1 Dash-Mount 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 4-1). Close the connector housing; route the finished cable from the switch location to

the control head location.

NOTE: The emergency footswitch should be attached with A+ unattached. 

A+ should be attached after successfully securing the screws in the connector.

C a u t i o n

SPST NORMALLY CLOSED EMERGENCY SWITCH

NOTE 1: REMOVE BLACK JUMPER WIRE INSIDE ACCESSORY CONNECTOR HOUSING. INSERT WIRES FROM EMERGENCY SWITCH

J2 IN DASH MOUNT

J100 IN REMOTE MOUNT

EMER

GND

NOTE 1

PIN 14

PIN 15

ACCESSORIES

CONNECTOR

Figure 4-1. Emergency Switch Wiring Diagram

The radio is sold with correct accessory cables and jumpers in order to have emergency  de-activated by default, regardless of the setting in CPS. However, if cables are not used, or if jumpers are removed without replacing with an emergency accessory button/switch at one of the accessory ports, the radio will power-up upon the application of A+. The display may not show an indication that the radio is on, and this can result in an incorrect operation of the radio as well as excessive current drain of the vehicle’s battery when the engine is off.

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

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 18 and 24 of the connector.

2. Lights Relay – Connect the relay across the head lamp ON/OFF switch, typically found in

the steering column. Open the accessory cable connector and connect the two control wires (male pins) into locations 19 and 24 of the accessory connector.

Figure 4-2, perform the following procedure:

VIP OUT 2

(LIGHTS)

VIP OUT 1

(HORN)

SWB+

SPST

N.O.

RELAY

12V COIL

SPST

N.O.

RELAY

12V COIL

VIP OUT 1

SWB+

VIP OUT 2

CONNECT

CROSS HORN

RING SWITCH

CONNECT ACROSS HEAD LAMP SWITCH

Figure 4-2. Horn/Light Wiring Diagram

4.2 Remote-Mount Accessory Installation

Perform the following installation procedure:

PIN 1

PIN 24

PIN 19

ACCESSORIE

CONNECTOR

1. Select an appropriate place to mount the option or accessory hardware.

2. Route the accessory-to-control head cables under floor coverings or behind panels so that the vehicle occupants do not snag or break the wires.

3. Attach wires from the accessory to the appropriate wire on the VIP cable (see Table 4-1 and

Table 4-2).

The radio is sold with correct accessory cables and jumpers in order to have emergency de-activated by default, regardless of the setting in CPS. However, if

C a u t i o n

cables are not used, or if jumpers are removed without replacing with an emergency accessory button/switch at one of the accessory ports, the radio will power-up upon the application of A+. The display may not show an indication that the radio is on, and this can result in an incorrect operation of the radio as well as excessive current drain of the vehicle’s battery when the engine is off.

6878215A01

Options and Accessories Installation Remote-Mount Accessory Installation 4-3

4.2.1 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. When the button/switch is pressed, its contact opens, the emergency path is un-ungrounded and pulled-high inside the radio transceiver, and detected by the processor. If an emergency accessory is used at either (or both) J2 connector and J626 connector, all jumper wires, shorting emergency to ground, must be removed so button/switch press can be detected.

In additional to removing the default jumper wires in accessory cables, you must also remove a jumper part on the printed circuit board of the TIB, in order for the button/switch to be detected. On the TIB PCB (both mid power and high power use the same TIB) a zero-ohm jumper is placed by default so that the radio does not go into emergency when no cable is attached at either J2 or J626 in remote mount configuration. This jumper part, JU344, must be removed if either or both J2 and J626 will have any type of emergency cable and button/switch attached. Otherwise, the processor will never see emergency become un-grounded.

Figure 4-3. Emergency Jumper Removal in Remote Mount

1. Turn-off power to the radio system.

2. Detach the TIB from the radio transceiver.

3. Detach the TIB flex.

4. Remove TIB PCB from the plastic housing using TORX T10 screwdriver. Refer to the disassembly procedure in the Basic Service Manual.

5. Located JU344, See diagram

6. Remove JU344 from the TIB PCB using a soldering gun. Clean off excess solder.

7. Reassemble the TIB following the Basic Service Manual procedure. Use 6-8 in-lbs torque on each screw. Remember to include the TIB O-ring gasket.

8. Re-attach the TIB flex.

9. Re-attach the TIB to the radio transceiver.

10. Apply 6-8 in-lbs of torque to each screw to secure the TIB to the radio transceiver.

6878215A01

4-4 Options and Accessories Installation Remote-Mount Accessory Installation

4.2.2 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). Connect the relay contacts across the head lamp ON/OFF switch. Connect the two control wires to a SW B+ pin and a VIP OUT pin on the VIP connector.

4.2.4 Gunlock Installation

The O7 or O9 control head can program up to three gunlocks through the programmable buttons. You can set the time for the momentary trigger using the time-out trigger button. Connect the relay contacts across the gunlock switch to install the gunlock. Connect the two control wires to a SW B+ pin and a VIP OUT pin on the VIP connector.

It is recommended to install a failsafe/redundant bypass switch for the gunlock. It is suggested to use a separate timer switch or a manual push-on button switch to activate the gunlock. Connect the switch from the supply to the gunlock directly, as shown in suitable and reachable location, yet not easily seen.

Figure 4-4. Place the manual button at a

GND

Transceiver

and

control head

VIP Cable

VIP OUT

Redundancy

Wiring

Car Battery

Momentary or

time-out bypass

manual switch

Gunlock

GND

Figure 4-4. Gunlock Switch Redundancy Diagram

6878215A01

Options and Accessories Installation Remote-Mount Accessory Installation 4-5

4.2.5 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. Refer to the siren/PA manual (6881093C18) for more information.

To Control Head VIP

Output Programmed for

Horn-Ring Transfer

To SW B+ at

VIP Connector

To Control Head VIP

Input Programmed

for Horn-Ring

Horn Ring

N.C.

COM.

N.O.

Any SPDT Relay with 12V Coil and Suitable Contact Ratings for Vehicle Installation

Break

Here

+ 12V

Under Hood

Horn Relay

To Control Head VIP

Output Programmed for

Horn-Ring Transfer

VIP Connector

To Control Head VIP

Input Programmed

To SW B+ at

for Horn-Ring

Horn

Horn Ring

+ 12V

To DIG. GND at

VIP Connector

Positive-Contact Horn-Ring

Negative-Contact Horn-Ring

Normally-Open

Momentary

Contact Pushbutton

To VIP Input Programmed for Horn-Ring

To DIG. GND at VIP Connector

Pushbutton Connections

Figure 4-5. Siren/PA Horn-Ring Connections

4.2.6 Record Audio Out Jack of Transmit and Receive Audio

N.C.

COM.

N.O.

Break

Here

NOTE: Locate Pushbutton in a Location Convenient to the Driver

To Horn

The use of Power Cable kit HKN6187_ (see Figure 2-47) provides access to both the transmitted audio speech, as well as the received audio speech. This can be recorded with a standard tape recorder using a 2.5 mm connector.

4.2.7 Earphone Jack

The use of Power Cable kit HKN6187_ (see Figure 2-47) provides the ability to use a standard earphone/headset instead of the external speaker. Once a cable is plugged into this 2.5 mm jack, the external speaker attached at the control head will turn mute.

6878215A01

4-6 Options and Accessories Installation Vehicle Interface Port Overview

4.2.8 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.

The USB 4 meter (15 feet) data cable enable HKN6172_ is recommended for remote mount configurations only (at J100).

If the customer intends to use the HKN6172_ for dash mount configurations (at J2), the cable’s  26-pin connector must be opened and an emergency jumper-wire placed across pins 14 and 15. Refer to

Figure 4-1.

4.2.9 RS232 Cables

The following are RS232 cables. Although not compatible with CPS radio reading or programming, they can be used for interfacing with RS232 accessories or RS232 computer programs. HKN6122_ is an RS232 serial COM port computer interface cable from J600 connector. HKN6160_ is a 6 feet dash RS232 cable from J2 connector. HKN6161_ is a 20 feet dash RS232 cable from J2 connector. HKN6183_ is a 4 meter cable from MMP connector.

4.3 Vehicle Interface Port 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 (remote mount only).

VIP Cable

Radio

(HKN6196_)

Wire Color

Number

J400-1 RED SWB +

J400-2 GREEN GND

J400-3 - NO PIN

J400-4 - "VIP" detect: GPIO=HIGH

J400-5 BLUE VIP_OUT_1

J400-6 YELLOW VIP_OUT_2

J400-7 BLACK VIP_OUT_3

J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)

J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)

J400-10 VIOLET VIP_IN_3

Function

Figure 4-6. Remote Control Head Pinouts

Figure 4-7. HKN6196_ VIP Connector Detail

6878215A01

Options and Accessories Installation Vehicle Interface Port Overview 4-7

4.3.1 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 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. The relay can be normally on or normally off depending on the configuration of the VIP outputs. There are three VIP output connections, as follows:

Figure 2-10, Figure 4-12 and Figure 4-13, respectively. Use these connections to

Table 4-1. VIP Output Connections

J400 J2 J100

VIP OUT #

1 Red 1 5 (Blue) 24 18 24 18

2 Red 1 6 (Yellow) 24 19 24 19

3Red 17 (Black)NANANANA

SW B+ Pin

Number

On/Off

Switched Pin

Number

SW B+ Pin

Number

On/Off

Switched Pin

Number

SW B+ Pin

Number

On/Off

Switched Pin

Number

The function of these VIP outputs can be field programmed in the control head. Typical applications for VIP outputs are external horn/lights alarm and horn ring transfer relay control. For further information on VIP outputs, see the control head programming manual.

VIP OUT 1 and VIP OUT 2 can be accessed from either J100 or J400 connectors. This is to allow a previously wired VIP OUT at J2 to move easily to J100. However, when any cable is inserted into J400, J100 VIP OUTs are disabled.

When installing relays to the VIP OUT lines, a diode is necessary to prevent damage to the transistor or MOSFET, due to “back EMF” when the field collapses on the relay coil. Some vendor relays already come with this diode built-in, and other relays require the customer to install it. Figure 4-8 shows the proper placement of the diode across the relay coil. The transistor or MOSFET is located inside the radio or the D.E.K. box.

SW B+

Protection Diode

VIPout

Relay

N.C.

N.O.

NOTE: See Appendix A: Replacement Parts Ordering to order relay’s for your VIP OUT applications.

6878215A01

Note: To 'activate' a VIPOUT, you have to ground the VIPOUT, such that the current now flows thru the relay coil to GND through a MOSFET inside the radio or control head, which causes the relay wiper to toggle. The MOSFET of a VIPOUT should never be used to directly drive an accessory. The MOSFET should be used to control an external relay.

Figure 4-8. Relay Coil

Example relay hardware: TLN4533_ (relay without internal diode), HLN6969_ (relay with internal back EMF protection diode), and HKN4258_ (relay wiring cable).

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. There are three VIP input connections, as follows:

Table 4-2. VIP Input Connections

J400 J2

VIP IN #

1 2 (green) 8 (white) NA NA

2 2 (green) 9 (orange) NA NA

3 2 (green) 10 (violet) NA NA

NOTE: Remote Mount requires the VIP cable to be attached to J400.



MCH installations require the VIP inputs to be connected to the head assigned ID #1. See

Section 2.2.2.5: “Setting the Initial Control Head ID” on page 2-29 for further information.

APX mobile radios equipped with the following features are capable of transmitting automatically, even if the radio is turned off:

C a u t i o n

All APX mobile have accessory connector pins 14 and 15 connected together to allow the radio to power down. Opening this connection by REMOVING the accessory connector, or otherwise failing to maintain a normally closed path, could, if left unchecked, drain the vehicle battery, and possibly cause transmissions to occur.

Ground Pin

Number

• Automatic Vehicle Location

• Other Special Data Products

On/Off Switched

Pin Number

Ground Pin

Number

On/Off Switched

Pin Number

6878215A01

Options and Accessories Installation Compatibility of Emergency when Attaching a Siren 4-9

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. Remove all four screws from the connector in the siren/PA cable.

3. Open the connector cap and locate pin 8.

4. Using the contact removal tool (6684690C02), remove pin 8 from the connector.

5. Put the connector cap in place and proceed to reinstall the four screws and the knob.

67 8

1415

3334

Pin 8

Figure 4-10. Location for Pin 8

2930

3132

6878215A01

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. All approved accessory wires are securely strain-relieved through the exiting slots at the back of the accessory connector assembly. The terminations that are supplied with all accessories are designed to be fully engaged and locked into the plug connector (6680163F01). They can also be detached for service with the assistance of a terminal removal tool. The accessory connector assembly can be serviced multiple times for future installation upgrades.

The accessory connector assembly, supplied with every APX mobile dash-mounted radio, is equipped with a 26-pin plug assembly, two covers, two jackscrews, two cover screws, one emergency jumper, one ignition sense cable assembly, and one speaker pigtail. The jumper is provided to complete the circuit for emergency mode. If this circuit becomes open, the radio will be set to emergency mode.

39800834F03 is the crimping pin part number for use with any wires used inside the accessory cable connector.

4.5.1 Disassembly and Assembly

4.5.1.1 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.

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. Pull the jackscrews away from the plug and hold them back.

6. Pry apart the accessory connector assembly covers.

7. Attach any new wire to its proper location by pushing in the male terminal. When you hear a pop, the wire is engaged. To verify that the wire is engaged, tug gently on the wire and be sure it does not come out. Do not overload the wire: severe damage will result to the plug.

6878215A01

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. Place the second cover onto the plug. Be sure that the flange is protruding through both covers.

NOTE: See APX Mobile Basic Service Manual (6875964M01) for more detailed descriptions of these

6878215A01

Figure 4-11. Exploded View of Accessory Connector Assembly (HLN6863_)

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. Reattach the accessory connector assembly to the back of the radio and fasten it by  finger-tightening the jackscrews to prevent any loosening.

pins and other connectors located in the APX mobile radio.

4-12 Options and Accessories Installation Memory and Three-Day Secure Key Retention Option

4.5.2 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.

Use the HKN6158_ audio adapter kit cable if your vehicle was formerly wired for an ASTRO Spectra or ASTRO Spectra Plus radio, and used the rear cable pins as shown in

Figure 4-12.

SPKR

LO -

GND SPKR

MIC HI

HI +

768

N.C.

IGNITION

PTT

VIP OUT 2

SWB+

54321

VIP OUT 1

DISC.

AUD

EMER

1011121314

N.C.

Figure 4-12. Rear Accessory Connector Audio Configuration

Use the HKN6159_ data adapter kit cable if your vehicle was formerly wired for an ASTRO Spectra or ASTRO Spectra Plus radio, and used the rear cable pins as shown in Figure 4-13.

EMER

1011121314

BUS-VIP OUT 1

CTS-ASTRO

RTS_DCE

BUSY

SPKR

LO -

DIG

GND

RTS-ASTRO

CTS_DCE

SPKR

HI +

768

BUS+

TX-ASTRO

IGNITION

RX_DCE

VIP OUT 2

SWB+

54321

RX-ASTRO

TX_DCE

Figure 4-13. Rear Accessory Connector Data Configuration

You must attach the correct adapter. Installing the wrong adapter may cause damage to the data communication circuitry inside your radio. If you are unsure of the pinout of your former wiring harness, please consult your ASTRO radio installation technician.

4.6 Memory and Three-Day Secure Key Retention Option

For the installation or removal of the Memory or 3-Day Secure Key Retention Options  (MHLN6999_ and MHLN7000_), see the APX Mobile Basic Service Manual (6875964M01).

NOTE: The Three-Day Secure Key Retention Option is not applicable for APX 2500/APX 4500.

6878215A01

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.

NOTE: The APX Mobile Basic Service Manual (6875964M01) includes complete parts lists and parts

numbers for all parts shown in the exploded views in this chapter.



A small label is included with the motorcycle radio, which can be placed on the radio to identify it as a motorcycle radio. The label should be placed on a flat and protected area to avoid damage during handling.

See Figure 5-1.

Figure 5-1. Identification of a Motorcycle Radio by Using a Label

5.1.1 Transceiver Enclosure

The transceiver is mounted in the weather-resistant enclosure that consists of a bottom housing and a hinged top cover. The top cover has a locking latch that requires a key to open. The enclosure is mounted above the rear motorcycle wheel, oriented so that the lock is forward and the hinged cover opens toward the rear of the motorcycle. The bottom housing has a grommeted hole for cable entry and weep holes to permit water drainage.

The enclosure is mounted on the motorcycle with a universal mounting plate and shock and vibration isolators. A large, braided ground-strap (installed between the mounting plate bolts and the motorcycle frame) grounds the transceiver.

5.1.2 Control/Display Unit

All radio functions, except push-to-talk (PTT), are activated from the control head, which also is weather-resistant. The control head and the external speaker are mounted for easy access near the center of the handlebars. The control head is positioned for unobstructed viewing, and it may be tilted on the horizontal axis for ease of viewing. The microphone cable port on the front of the control head is plugged and is not used.

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. The cable is shielded to reduce the effects of radio frequency interference and ignition sense noise.

5.1.4 Microphone

A weather-resistant, palm microphone and coiled cord plug into a pigtail connector on the control cable. The microphone attaches to a hang-up bracket located within easy reach of the motorcycle rider. The coiled cord is long enough to be operated by someone standing next to the motorcycle, yet short enough to not interfere with the motorcycle’s steering or operation.

5.1.5 Keypad Mic

The Mobile Keypad Microphone (Mic) is a full keypad handheld microphone. The keypad on this microphone is intended to assist in navigating through the menus on its parent device, as well as entering information such as phone numbers and menu picks.

5.1.6 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.

5.1.7 Headset Capability

The motorcycle radio is compatible with headset accessories that would provide hands-free operation of the radio. Motorola does not manufacture headset equipment, but provides the interconnection for headset equipment with the motorcycle radio. Aftermarket headset equipment is available through Motorola (see

To avoid possible injury to hearing, the audio setting in the mobile radio MUST be

C a u t i o n

confirmed, if the Motorola mobile radio is used with any motorcycle helmet headset. See CPS Help for details.

5.1.8 Antenna

The antenna(s) are mounted on top of the transceiver’s weather-resistant enclosure.  The enclosure’s metal lining acts as the antenna’s ground plane.

5.1.9 Ignition Sense (ACC) Wire

The ignition sense wire connects to the motorcycle’s fuse box and is routed along the motorcycle frame to the transceiver’s rear accessory connector.

Appendix A: Replacement Parts Ordering).

The radio is wired so that transmission is inhibited if the motorcycle’s ignition sense switch is off.  If the PTT switch is pressed with the ignition sense off, a low-frequency tone sounds. The receiver is controlled by the control head on/off switch.

6878215A01

Motorcycle Radio Installation Installation Overview 5-3

5.2 Installation Overview

5.2.1 General

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. For tests and alignment procedures, refer to the appropriate service manual (refer to

Generally, the installation of the motorcycle radio takes place in the following parts:

• Mounting the universal mounting plate and related hardware at the rear of the motorcycle;

• Mounting the control head, speaker, microphone, and related hardware forward on the

motorcycle;

• Routing the power cable, control-head cable, speaker cable, and ignition sense cable to the

weather-resistant enclosure;

• Mounting the weather-resistant enclosure and radio chassis, and connecting the cables;

• Mounting the antenna(s) to the weather-resistant enclosure.

A universal mounting plate, supplied by Motorola, is first mounted to either a motorcycle carrier at the rear of the motorcycle or to the rear frame of the motorcycle itself. The mounting procedures for the universal mounting plate vary from motorcycle to motorcycle. Therefore, the procedures given in this manual for installing the mounting plate may not specifically apply, but are provided for guidance.

“Related Publications” on page vi).

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. Because of the large number of motorcycle makes and models in existence, the customer-built brackets are necessary to tailor the mounting of the Motorola equipment to the particular motorcycle being used. Suggestions for customer-built brackets are given in this manual.

The power cable, control-head cable, speaker cable, and ignition sense cable are routed to the weather-resistant enclosure position. The enclosure and the radio chassis are then mounted. Special care is required when connecting cables to the radio equipment within the enclosure.

6878215A01

5-4 Motorcycle Radio Installation Installation Overview

5.2.2 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

• All components must be mounted securely in order to withstand the constant and sometimes severe vibration experienced on a motorcycle.

• No cantilever action, which could cause severe vibration, should be generated in the mounting hardware.

• The control head and microphone must be placed for ease of accessibility by the motorcycle operator.

• Forward components (control head, microphone, and speaker) should not interfere with visual or physical access to controls and instruments.

• Forward components should not interfere with the handling of the motorcycle.

• Cabling between the control head and the radio chassis should be run to minimize interference with operator movements.

• The weather-resistant enclosure should be placed to avoid any interference with the motorcycle operator.

• Electrical continuity must be present through the enclosure shock mounts to the motorcycle frame for proper electrical and RF grounding.

• The antenna(s) are designed for mounting on the top of the weather-resistant enclosure.

• Only the supplied microphone mounting clip should be used to ensure secure mounting of the microphone. This clip has a very strong spring to ensure positive retention of the microphone over rough terrain. Also, there must be electrical continuity from this clip to the motorcycle frame for DC grounding.

• Direct access to the microphone should be provided from both sides of the motorcycle.

• Sufficient slack in the microphone coiled cord should be allowed so as not to impede steering.

• Mounting hardware must be stainless steel to prevent corrosion.

• If an extra length of cable is used to extend the microphone, ensure that the added capacitance does not interfere with the operation of the radio.

Figure 5-16.

6878215A01

Motorcycle Radio Installation Installation Overview 5-5

5.2.3 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). Those parts supplied by Motorola are contained in one of the following kits:

• Motorcycle Weather-Resistant Microphone

• Motorcycle Weather-Resistant Speaker with Mute Switch

• Motorcycle Weather-Resistant Speaker with Keypad Mic

• Motorcycle Hardware Kit SECURENET or Motorcycle Hardware Kit

• Motorcycle Power Cable Kit

• Motorcycle Mounting Kit

• Weather-Resistant Enclosure (Black)

• Antenna

5.2.4 Order of Installation

Before starting the installation, familiarize yourself with the mounting hardware (see Figure 5-2 through Figure 5-17). Perform the installation procedures in the order that follows.

1. Install the universal mounting plate on the motorcycle.

2. Install the control head and speaker.

3. Install the microphone hang-up clip.

4. Install antenna base and cable onto enclosure.

5. Install the cables.

6. Install the weather-resistant enclosure on the universal mounting plate.

7. Route the cables inside the weather-resistant enclosure.

8. Install the transceiver in the weather-resistant enclosure.

9. Install the antenna(s) on the enclosure.

6878215A01

5-6 Motorcycle Radio Installation Installing the Universal Mounting Plate

5.3 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. After the plate has been securely mounted to the motorcycle, mounting the weather-resistant enclosure onto the plate is straightforward.

Figure 5-2 illustrates the universal mounting plate mounted to a motorcycle carrier. Since there are

so many makes and models of motorcycles and motorcycle carriers, it is impossible to give specific step-by-step instructions for mounting the universal mounting plate. However, noting the following considerations will aid in the installation procedure.

• A minimum of holes are predrilled into this plate as supplied. Mounting holes must be drilled as required for the particular motorcycle on which the plate is being mounted.

• The universal mounting plate should be mounted on the motorcycle in such a manner that the later mounting of the weather-resistant enclosure will not interfere with the motorcycle seat back, with any other obstacles, or with the motorcycle operator. The enclosure may be temporarily bolted to the universal mounting plate and the unit positioned on the motorcycle to ensure the above criteria are met.

• To ensure a good grounding path from the universal mounting plate to the motorcycle carrier or frame, stainless steel lock washers must be used with the mounting hardware in two areas to score through the paint on the universal mounting plate and on the carrier or frame, thereby, providing good electrical contact with the underside of the motorcycle carrier or motorcycle frame.

Figure 5-2. Universal Mounting Plate Installation (Part of Radio Enclosure Kit)

Follow the procedures below to mount the universal mounting plate to the motorcycle  (see Figure 5-2).

1. Determine the mounting position for the mounting plate.

2. Determine whether stainless steel spacers are required for clearance in mounting the plate.

3. Drill four 9/32-inch holes in the mounting plate and the corresponding motorcycle carrier or

chassis for mounting the plate.

4. Attach the universal mounting plate to the motorcycle using four machine screws, eight lock

washers, and four nuts. Tighten screws securely. The lock washers must cut through the paint on the plate and motorcycle carrier or frame to ensure a good ground path.

6878215A01

Motorcycle Radio Installation Installing the Speaker and Control Head 5-7

5.4 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. 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. Alternately, the control head may be mounted by itself using a smaller control-head bracket supplied by Motorola. In this case, the speaker is mounted elsewhere. This section outlines installation procedures for each configuration mentioned above. The customer (or installer) is in the best position to determine the most appropriate mounting configuration for the control head and speaker based on the particular motorcycle on which the equipment is to be mounted.

C a u t i o n

When determining its location, position the control head so that it is clearly visible and within easy reach of the motorcycle operator.

Figure 5-3. Motorcycle Control Head Cabling (3075217A01)

6878215A01

5-8 Motorcycle Radio Installation Installing the Speaker and Control Head

5.4.1 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. In this case the  handlebar-mounting bracket is mounted to the motorcycle, and the combination bracket is then mounted to the handlebar-mounting bracket.

Figure 5-4. Handlebar Installation with Speaker and Control Head Mounted Together

6878215A01

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

Hang-Up Clip” on page 5-14 for the hang-up clip procedure. Install the speaker and control head as

described below.

1. Determine the location where the speaker/control head is to be mounted. Consider how the speaker/control-head bracket may be mounted, and whether or not a handlebar-mounting bracket is needed. Take care to select a location that is not only mechanically convenient, but is located for ease of operation.

NOTE: The angle at which the handlebar-mounting bracket or the speaker/control-head bracket is

mounted to the motorcycle determines the firing angle of the speaker.

2. If the handlebar-mounting bracket is needed, install it first.

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, lock washers, and nuts.

4. Mount the 9-pin D-connector end of the motorcycle control-head cable to the speaker/control head bracket, using two machine screws, flat washers, and nuts. (Cable routing directions appear later in this section.)

5. Mount the speaker on the speaker/control-head bracket, using two machine screws and lock washers. Torque these screws to 20 in-lbs.

6. Attach the control-head cable to the control head and tighten the locking screws on the connector. This connection must be made before you mount the control head in the bracket. (Cable routing directions appear later in this section.)

7. Mount the control head to the bracket, using two machine screws, lock washers, and flat washers.

8. Adjust the control head viewing angle by loosening its mounting screws and rotating the control head to the desired angle. Then, retighten screws to 20 in-lbs torque. This concludes the speaker/control-head installation.

Section 5.6: “Installing the Microphone

5.4.2 Fuel Tank Console Installation with Speaker and Control Head Mounted Together

Some motorcycles provide a console for mounting radio equipment. This console is attached to the top of the fuel tank. With the use of a mounting bracket, screws, nuts, and lock washers, the combination speaker/control-head bracket can be mounted to this console. Figure 5-5 illustrates this type of mounting.

The console attachment screws must be removed, and the console must be lifted slightly from the fuel tank to gain access in order to attach mounting hardware, and to route cables later.

In this installation, the microphone (mic), mic hang-up bracket, and mic extension bracket will interfere with handlebar travel.

Installation using this method is the same as in Section 5.4.1: “Handlebar Installation with Speaker

and Control Head Mounted Together” on page 5-8.

6878215A01

5-10 Motorcycle Radio Installation Installing the Speaker and Control Head

Figure 5-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Together

6878215A01

Motorcycle Radio Installation Installing the Speaker and Control Head 5-11

5.4.3 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.

Before installing the control head using the bracket described above, the control-head end of the control-head cable should be temporarily fastened to the control head, and the control head fastened to its bracket. Motorola-supplied spacers and the mic-cable bracket are required to mount the control head to the handlebar. This mic-cable bracket has holes to mount the microphone-cable connector.

Follow these procedures when mounting the smaller control-head bracket:

1. Determine the location at which the control head is to be mounted. Take care to choose a location that is not only mechanically convenient, but is located for ease of operation.

2. Securely mount the Motorola-supplied spacers, mic-cable bracket, and small control-head bracket to the handlebars.

3. Mount the 9-pin D-connector end of the motorcycle control-head cable to the mic-cable bracket, using two machine screws, flat washers, and nuts. (Cable routing directions appear later in this section.)

4. Attach the control-head end of the cable to the control head and tighten the locking screws on the connector.

5. Mount the control head to the small control-head bracket, at the proper viewing angle, using two wing screws. Tighten firmly. This concludes the control-head installation.

6878215A01

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.

6878215A01

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

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.

6878215A01

Section 5.4.2: “Fuel Tank Console Installation with Speaker and

Motorola 92FT3826 Users Manual

Specifications and Main Features

Frequently Asked Questions

User Manual