Motorola 92FT4904 Users Manual

Foreword

This manual covers the O3, O5, and O9 models of the ASTRO® APX™ 7500 digital mobile radios. It includes all the
information necessary to install mid power and high power radios, and configure radio installation inside vehicles.

For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A
list of related publications is provided in the section “Related Publications,” on page vi.

Product Safety and RF Exposure Compliance

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 informa tion on how to obtain replacement parts. For part numbers, refer
to the ASTRO APX 7500 Digital 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.

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, the Stylized M logo, FLASHport, and ASTRO are registered in the US Patent & Trademark Office. All other
product or service names are the property of their respective owners.

© 2009, 2010 by Motorola, Inc.

i

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 cont rol ov er th eir expo sure t o 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 “Antenna Installation,” on page 2-33 of this manual

• 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, the operator must be familiar with the RF energy awareness information and
operating instructions in the Product Safety and RF Exposure booklet enclosed with each radio (Motorola
Publication part number 6881095C99) to ensure compliance with Radio Frequency (RF) energy exposure
limits.

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.motorola.com/governmentandenterprise.

ii

Table of Contents iii

Table of Contents

Foreword..........................................................................................................i

Product Safety and RF Exposure Compliance.............................................................................................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....................................................xi

Commercial Warranty.................................................................................xiii

Limited Warranty ......................................................................................................................................xiii

MOTOROLA COMMUNICATION PRODUCTS... ... .... ... ... ... .... ... ... ... ... ....... ... ... .... ... ... ... ... .... ... ... ... . xiii

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

II. General Provisions............................................................................................................... xiii

III. State Law Rights................... ... ... ....................................... ... ... .... ... ... ... ..............................xiv

IV. How To Get Warranty Service............................................................................................xiv

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

VI. Patent And Software Provisions ..........................................................................................xv

VII. Governing Law....................................................................................................................xv

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

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

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

1.2 Standard Configurations................................................................................................................1-3

1.2.1 Dash Mount Configuration................................................................................................ 1-3

1.2.2 Remote Mount Configuration............................................................................................ 1-5

1.2.3 Multi Control Head............................................................................................................1-7

1.3 Motorcycle Configurations................................ ... ... .... ... ... ....................................... ... ... ... ............. 1-8

1.4 Base/Control Stations....................................................................................................................1-8

1.5 Tools Required for APX 7500 Installations....................................................................................1-8

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

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

2.1.3 Radio Operation Wiring for Dash and Remote Configurations....................................... 2-11

2.1.3.1 Dash Mount: Power, Ignition, and Emergency Cable Installation..........................2-11

2.1.3.2 Remote Mount: Power, Ignition, and Emergency Cable Installation......................2-12

2.1.4 Ignition Sense Switch (Radio Wide Advance) ................................................................2-14

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2.2 Radio Mounting ........................................................................................................................... 2-15

2.2.2 Remote Mount with Trunnion.......................................................................................... 2-17

2.2.2.1 100W Radios Only............... ... ... .... ... ... ... .... ...................................... .... ... ... ... ... .... . 2-18

2.2.2.2 Remote Mount Control Head Installation............................................................... 2-18

2.2.2.3 Multiple Control Head Installation.......................................................................... 2-22

2.2.2.4 Cable Installation................................. ... .... ... ... ... ....................................... ... ... .... . 2-23

2.2.2.5 Setting the Initial Control Head ID......................................................................... 2-24

2.2.2.6 O3 Control Head and Remote Mount Cabling....................................................... 2-25

2.2.3 Locking Kit (Optional) .....................................................................................................2-27

2.2.3.1 All Radios Except 100W................................................ ... ... .... ... ... ....... ... ... ... ... .... . 2-27

2.2.3.2 100W Radios.......................................... ....................................... ... .... ... ... ... ........ 2-27

2.3 Power Cables (Transceiver and Control Head)........................................................................... 2-28

2.3.1 Optional Locking Feature for High Power Chassis Power Cables.................................. 2-28

2.3.2 O5 or O9 Control Head Power Cables ................................... ... ... .... ... ........................... 2-31

2.3.3 Battery Selector Switch................................................................................................... 2-32

2.4 Antenna Installation..................................................................................................................... 2-33

2.4.1 Selecting an Antenna Site/Location on a Metal Body Vehicle........................................ 2-33

2.4.2 Mini-UHF Connection ................................ ... ....................................... ... ... .... ... ... ... ........ 2-35

2.4.3 GPS Antenna Placement................................................................................................ 2-37

2.4.4 GPS Connection.............................................................................................................2-37

2.5 Speaker ....................................................................................................................................... 2-38

2.6 Microphone Hang-Up Clip ...................... ... ... ... ....................................... ... .... ... ... ... .... ................. 2-39

2.6.1 Standard or O3 Control Head Hang-Up Clip .................................................................. 2-39

2.7 RFID (Option) .............................................................................................................................. 2-39

2.7.1 RFID Reading................................................................................................................. 2-40

2.7.2 Programming RFID (If Equipped)................................................................................... 2-42

2.8 Completing the Installation .......................................................................................................... 2-43

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

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

3.2 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 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

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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................................................................................. 5-20

5.11 Transceiver and Cabling Installation............................................................................................5-21

5.11.1 Installing Cabling in the Enclosure.................................................................................. 5-21

5.11.2 Installing the Transceiver................................................................................................5-22

5.12 Installing the Emergency Switch Option ......................................................................................5-24

5.13 Installing the External Alarm Relay Option ..................................................................................5-24

5.14 Installing the Headset Accessory.................................................................................................5-24

5.15 Installing the Control Head Sunshield.......................................................................................... 5-25

5.16 Horn/Lights Wiring....................................................................................................................... 5-27

5.17 Emergency Switch Wiring.................... ... ... ....................................... ... .... ... ... ... ...........................5-27

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

6.1 Cable Connection .......................................................................................................................... 6-1

6.1.1 O9 Control Head . ... .... ... ... ... .... ...................................... .... ... ... ... ... .... ................................ 6-1

6.1.2 O5 Control Head . ... .... ... ... ... .... ...................................... .... ... ... ... ... .... ................................ 6-1

6.1.3 O3 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 I gnition 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

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

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

Related Publications

ASTRO APX 7500 Digital Mobile Radio O3 Control Head User Guide ..................................... 6875946M01

ASTRO APX 7500 Digital Mobile Radio O5 Control Head User Guide ..................................... 6875947M01

ASTRO APX 7500 Digital Mobile Radio O9 Control Head User Guide .................................... 68007024014

ASTRO APX 7500 Digital Mobile Radio Basic Service Manual ................................................. 6875964M01

ASTRO APX 7500 Digital Mobile Radio Detailed Service Manual ............................................ 6875963M01

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List of Figures vii

List of Figures

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

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

Figure 1-3. Front View of High Power (100W) Transceiver and Trunnion.. ... .... ... ... ... ............................. 1-1

Figure 1-4. Side View of High Power (100W) Transceiver and Trunnion................................................1-1

Figure 1-5. Front View of O3 Control Head with Coiled Cable................................................................ 1-2

Figure 1-6. Side View of O3 Control Head with Coiled Cable.................................................................1-2

Figure 1-7. Front View of O5 Control Head with Trunnion ...................................................................... 1-2

Figure 1-8. Side View of O5 Control Head with Trunnion........................................................................ 1-2

Figure 1-9. Front View of O9 Control Head with Trunnion ...................................................................... 1-2

Figure 1-10. Side View of O9 Control Head with Trunnion........................................................................1-2

Figure 1-11. Top View of O9 Universal Relay Controller with Trunnion

(URC is an orderable accessory.)......................................................................................... 1-3

Figure 1-12. Side View of O9 Universal Relay Controller with Trunnion

(URC is an orderable accessory.)......................................................................................... 1-3

Figure 1-13. Dash Mount Configuration with O5 Control Head.... ... .... ... ... ... ....................................... ... ... 1-3

Figure 1-14. Dash Mount Configuration with Transceiver Interface Board and O3 Control Head ............ 1-4

Figure 1-15. Remote Mount Configuration with Mid Power Transceiver and O5 Control Head................1-5

Figure 1-16. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board,

and O3 Control Head............................................................................................................ 1-5

Figure 1-17. Remote Mount Configuration with High Power (100W) Radio Transceiver

and O5 Control Head............................................................................................................ 1-6

Figure 1-18. Remote Mount Configuration with High Power (100W) Radio Transceiver

and O3 Control Head............................................................................................................ 1-6

Figure 1-19. Remote Mount Configuration with Radio Transceiver and O9 Control Head .......................1-6

Figure 1-20. Remote Mount Configuration with Mid Power Radio Transceiver,

Universal Relay Controller and O9 Control Head (URC is optional.).................................... 1-7

Figure 1-21. Remote Mount Configuration with High Power (100W) Radio Transceiver,

Universal Relay Controller and O9 Control Head (URC is optional.).................................... 1-7

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 (O5 Mid Power Dash Mount).................................................................... 2-3

Figure 2-5. Radio Installation (O3 Mid Power Dash Mount).................................................................... 2-4

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

Figure 2-7. Radio Installation (O3 Mid Power Remote Mount)................................................................2-5

Figure 2-8. Radio Installation (O3 High Power Remote Mount)........................................... ... ... .... .........2-5

Figure 2-9. Radio Installation (O5 High Power Remote Mount)........................................... ... ... .... .........2-6

Figure 2-10. Radio Installation of O9 Remote Mount with Transceiver (URC is optional.)........................2-6

Figure 2-11. Radio Installation (O9 Remote Mount with Pinouts) ............................................................. 2-7

Figure 2-12. Remote Control Head Pinouts ..............................................................................................2-7

Figure 2-13. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios)........... 2-8

Figure 2-14. Cabling Interconnect Diagram for Remote Mount................................................................. 2-9

Figure 2-15. Cabling Interconnect Diagram for 09 Remote Mount (URC is optional.) ............................ 2-10

Figure 2-16. Trunnion Orientation (Cannot Be Used for 100W Radios)..................................................2-15

Figure 2-17. Trunnion Orientation for 100W Radios................................................................................2-15

Figure 2-18. Transmission Hump Trunnion Mounting.................. ... .... ... ... ... ... ....................................... . 2-16

Figure 2-19. Below Dash Trunnion Mounting..........................................................................................2-17

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viii List of Figures

Figure 2-20. 100W Radio Mounting into Quick Release Trunnion.......................................................... 2-18

Figure 2-21. O5 Control Head Installation Exploded View.................................... .... ... ... ... .... ................. 2-19

Figure 2-22. O9 Control Head Installation Exploded View.................................... .... ... ... ... .... ................. 2-20

Figure 2-23. O5 Control Head Rear View............................................................................................... 2-20

Figure 2-24. O9 Control Head Rear View............................................................................................... 2-21

Figure 2-25. Multiple Control Heads Example Configurations ................................................................ 2-22

Figure 2-26. APX 7500 Front View .... ... ... ... ....................................... ... .... ... ... ... ... .................................. 2-24

Figure 2-27. Radio Display with Current Control Head ID ...................................................................... 2-24

Figure 2-28. APX 7500 Front View – Mode Knob................................................................................... 2-24

Figure 2-29. O3 Control Head................................................................................................................. 2-25

Figure 2-30. O3 Control Head Rear View............................................................................................... 2-26

Figure 2-31. Hang-Up Clip Installation Exploded View ......................................... .... ...... ... .... ... ... ... ... .... . 2 -26

Figure 2-32. Locking Kit (Optional) (Cannot Be Used for 100W Radios)................................................ 2-27

Figure 2-33. Lock Supplied with 100W Quick Release Trunnion............................................................ 2-27

Figure 2-34. Bracket Installation . ... .... ... ... ....................................... ... ... .... ... ... ... ..................................... 2-28

Figure 2-35. Bracket Installation . ... .... ... ... ....................................... ... ... .... ... ... ... ..................................... 2-29

Figure 2-36. Bracket Installation (Assembled State)............................................................................... 2-29

Figure 2-37. Bracket Uninstallation............. .... ... ... ... ... ....................................... ... .... ... ... ... .... ................. 2-30

Figure 2-38. Bracket Uninstallation............. .... ... ... ... ... ....................................... ... .... ... ... ... .... ................. 2-30

Figure 2-39. HKN6188_ Power Cable with External Speaker Connector............................................... 2-31

Figure 2-40. HKN6187_ Power Cable with External Speaker Connector,

Record Audio Output Jack (2.5 mm) and Earphone Jack (2.5 mm)................................... 2-31

Figure 2-41. Battery Selector Switch.. ... ... ... ............................................................................................ 2-32

Figure 2-42. Multiple Antennas Separation............................................................................... ... ... ........ 2-34

Figure 2-43. Mini-UHF Connection (As Shown on Mid Power)............................................................... 2-35

Figure 2-44. Mini-UHF Connection (100W Radios Only).......................................... ... ... ........................ 2-35

Figure 2-45. Mini-UHF Connector Tool (As Shown on Mid Power)......................................................... 2-36

Figure 2-46. Mini-UHF Connector Tool (100W Radios Only).................................................................. 2-36

Figure 2-47. GPS Antenna Connector on the Back of the Mid Power Radio.......................................... 2-37

Figure 2-48. GPS Antenna Connector on the Front of the 100W Radio................................................. 2-37

Figure 2-49. Speaker Mounting ... ....................................... ... ... .... ... ... ... .................................................. 2-38

Figure 2-50. RFID Location on Mid Power Radio ................................................................................... 2-39

Figure 2-51. RFID Location on High Power Radio.................................................................................. 2-39

Figure 2-52. Read Angle for Mid Power Radio ........ ....................................... ... ... .... ... ... ... ..................... 2-40

Figure 2-53. Tag Angle for Mid Power Radio.......................................................................................... 2-40

Figure 2-54. Read Angle for High Power Radio....... ............................................................................... 2-41

Figure 2-55. Tag Angle for High Power Radio......................................................................................... 2-41

Figure 2-56. Examples of Reader and Tag Aligned (Reader Orientation).............................. ... ... ... ... .... . 2-41

Figure 2-57. Example of Reader and Tag Misaligned (Reader Orientation) ........................................... 2-42

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. 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

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List of Figures ix

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

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. Routing the Coaxial Cable for GPS .................................................................................... 5-16

Figure 5-11. Routing the Coaxial Cable for Band 1.................................................................................5-17

Figure 5-12. Routing the Coaxial Cable for Band 2.................................................................................5-17

Figure 5-13. Cable Routing ... ... .... ... ... ... .... ... ... ........................................................................................5-18

Figure 5-14. Weather-Resistant Enclosure Installation...........................................................................5-20

Figure 5-15. Installing Cables.......... ... ... .... ...... ........................................................................................5-22

Figure 5-16. Installing the Transceiver.................................................................................................... 5-23

Figure 5-17. Motorcycle Wiring Harness Rework....................................................................................5-24

Figure 5-18. Remote Mount Trunnion with Sunshield............................................................................. 5-25

Figure 5-19. Position the Sunshield ........................................................................................................5-25

Figure 5-20. Slide the Control Head onto Trunnion.................................................................................5-26

Figure 5-21. Position Control Head as Desired......... ... ... ... .... ... ... ... ....................................... ... ... .... ....... 5-26

Figure 5-22. Horn/Lights Wiring Diagram................................................................................................5-27

Figure 5-23. Emergency Switch Wiring Diagram .................................................................................... 5-27

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

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x List of Tables

List of Tables

Table 2-1. Dash O5 Radio Operations Dependent Upon A+ and Ignition Connections............ 2-13

Table 2-2. Remote O5 or O9 Radio Operations Dependent Upon A+

and Ignition Connections.......................................................................................... 2-13

Table 2-3. Remote O5 or O9 Radio Operations Dependent Upon A+

and Ignition Connections.......................................................................................... 2-13

Table 2-4. Ignition Sense Switch Settings in CPS..................................................................... 2-14

Table 2-5. Available CAN Cables........ ... .... ... ... ... ... ....... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ....... ... .. 2-23

Table 2-6. Ignition Interface Cables.......................................................................................... 2-23

Table 2-7. Power Cables........................................................................................................... 2-28

Table 2-8. Model Number Chart in 12-Digit ASCII Format........................................................ 2-42

Table 2-9. Serial Number with Radio Band/Tier/Power............................................................. 2-42

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

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

Table 5-1. Transceiver Installation Parts List ............................................................................ 5-23

6878215A01

Mobile Radio Model Numbering Scheme xi

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

Position 4 - Frequency Band

Less than 29.7 MHz

A

=

29.7 to 35.99 MHz

B

=

36 to 41 MHz

C

=

42 to 50 MHz

D

=

300 to 345 MHz

E

=

66 to 80 MHz

F

=

74 to 90 MHz

G

=

Product Specific

H

=

VHF Range
136 to 162 MHz

J

=

146 to 178 MHz

K

=

174 to 210 MHz

L

=

190 to 235 MHz

M

=

330 to 370 MHz

N

=

366 to 410 MHz

P

=

403 to 437 MHz

Q

=

438 to 482 MHz

R

=

470 to 620 MHz

S

=
* For APX 7500 "U" in Position 4 represents
764 to 870 MHz.

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

Position 5 - Power Level

A

=

0 to 0.7 Watts

B

=

0.7 to 0.9 Watts

C

=

1.0 to 3.9 Watts

D

=

4.0 to 5.0 Watts

E

=

5.1 to 6.0 Watts

F

=

6.1 to 10 Watts

G

=

10.1 to 15 Watts

H

=

16 to 25 Watts

J

=

26 to 35 Watts

K

=

36 to 60 Watts

L

=

61 to 110 Watts

M

=

Up to 125 Watts

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

Position 6 - Physical Packages

RF Modem Operation

A

=

Receiver Only

B

=

Standard Control; No Display

C

=

Standard Control; With Display

D

=

Limited Keypad; No Display

E

=

Limited Keypad; With Display

F

=

Full Keypad; No Display

G

=

Full Keypad; With Display

H

=

Limited Controls; No Display

J

=

Limited Controls; Basic Display

K

=

Limited Controls; Limited Display

L

=

Rotary Controls; Standard Display

M

=

Enhanced Controls; Enhanced Display

N

=

Low Profile; No Display

P

=

Low Profile; Basic Display

Q

=

Low Profile; Basic Display, Full Keypad

R

=

S

=

T

=

U

=

VDV Control Head

V

=

Control Head #2

W

=

X

=

Y

=

Z

=

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

M30U RS 9 P W 1 A N S P 0 1

123 4 56 7 8 910111213141516

Product Specific

T

=

UHF Range
806 to 870 MHz

U

=

825 to 870 MHz

V

=

896 to 941 MHz

W

=

403 to 470 MHz

X

=

1.0 to 1.6 GHz

Y

=

1.5 to 2.0 GHz

Z

=

450 to 527 MHz

1

=

136 to 174 MHz

2

=

3

=

4

=

5

=

6

=

7

=

8

=

9

=

=

1 to 25 Watts

N

=

25 to 40 Watts

P

=

25 to 45 Watts

Q

=

10 to 35 Watts

R

=

Programmable

S

=

T

=

V

=

W

=

X

=

Y

=

Z

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

Positions 13 - 16
SP Model Suffix

Position 12 -

Unique Model Variations

A

=

B

=

C

=

Cenelec

D

=

E

=

F

=

G

=

H

=

J

=

K

=

L

=

M

=

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 10 - Feature Level
0 =
1 = Basic
2 = Limited Package
3 = Limited Plus
4 = Intermediate
5 = Standard Package

Position 9 - Primary System Type

A

Conventional

=

B

Privacy Plus

=

C

Clear SMARTNET

=

D

Advanced Conventional Stat-Alert

=

E

Enhanced Privacy Plus

=

F

Nauganet 888 Series

=

G

JSMR* Trunking

=

H

Multi-Channel Access

=

(MCA) Trunking

J

CoveragePLUS

=

K

MPT1327** - Public

=

L

MPT1327** - Private

=

M

Radiocom

=

N

Tone Signalling

=

* JSMR = Japan Specialized Mobile Radio

** MPT = Ministry of Posts and Telecommunications

Position 8 - Primary Operation

=

Conventional/Simplex

A

=

Conventional/Duplex

B

=

Trunked Twin Type

C

=

Dual Mode Trunked

D

=

Dual Mode Trunked/Duplex

E

=

Trunked Type I

F

=

Trunked Type II

G

=

FDMA* Digital Dual Mode

H

=

TDMA** Digital Dual Mode

J

=

Single Sideband

K

=

Global Positioning Satellite Capable

L

=

Amplitude Companded Sideband (ACSB)

M

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

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

Standard Package

N

=

P

=

Q

=

R

=

S

=

T

=

U

=

V

=

W

=

X

=

Y

=

Z

=

P

=

Binary Signalling

Q

=

Phonenet

R

=

IDEN Basic

S

=

IDEN Advanced Feature

T

=

JSMR Digital

U

=

LTR Protocol

V

=

Single Sideband

W

=

Programmable

X

=

Secure Conventional

Y

=

Secure SMARTNET

Z

=

Trans European Trunked
Radio (TETRA)

2

=

SmartZone

=

N

Digital Dispatch

=

P

Programmable

=

Q

Digital Interconnect

=

R

Digital Multi-Service

=

S

=

T

TDMA

=

U

=

V

=

W

=

X

=

Y

=

Z

6878215A01

Chapter 1 Introduction

This manual covers the installation procedures for ASTRO APX 7500 mobile and motorcycle radios
with O3, O5 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 and Figure 1-2 show the basic dimensions of the dash mount transceiver trunnion

APX 7500 radio. The transceiver portion of a remote mount APX 7500 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 rad io so that you may acce ss an d ins tall the
trunnion screws/wing screws.

NOTE: The measurement unit used in Figure 1-1 to Figure 1-12 is millimeter.

206
180

Figure 1-1. Front View of Mid Power

Dash Mount Transceiver and Trunnion

Figure 1-2. Side View of Mid Power

Dash Mount Transceiver and Trunnion

256
244

51

83

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

is 244 mm.

223

293

74

90

Figure 1-3. Front View of High Power

(100W) Transceiver and Trunnion

Figure 1-4. Side View of High Power

(100W) Transceiver and Trunnion

1-2 Introduction: Mobile Radio Description

61

153

Figure 1-5. Front View of O3 Control

Head with Coiled Cable

180

38

Figure 1-6. Side View of O3 Control

Head with Coiled Cable

75

51

Figure 1-7. Front View of O5 Control

Head with Trunnion

190

178

Figure 1-9. Front View of O9 Control

Head with Trunnion

Figure 1-8. Side View of O5 Control

Head with Trunnion

83

Figure 1-10. Side View of O9 Control

Head with Trunnion

6878215A01

Introduction: Mobile Radio Description 1-3

185

61.5

210

Figure 1-11. Top View of O9 Universal

Relay Controller with Trunnion

(URC is an orderable accessory.)

Figure 1-12. Side View of O9 Universal

Relay Controller with Trunnion

(URC is an orderable accessory.)

6878215A01

1-4 Introduction: Standard Configurations

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 7500 dash mount. The first is the O5 control head which is
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 transcei ver and at the back of the control head for the O5
and between the connectors on the front of the transceiver and at the back of the TIB for the O3.

Figure 1-13. Dash Mount Configuration with O5 Control Head

Figure 1-14. Dash Mount Configuration with Transceiver Interface Board and

O3 Control Head

For details on this configuration, see Section 2.2.1 on pag e 2-16.

6878215A01

Introduction: Standard Configurations 1-5

1.2.2 Remote Mount Configuration

In the remote control version, the transceiver and the control head are mounted separately in the
vehicle. The O5 control head is mounted in a remote trunnion n ea r the op era tor, and the O3 and O9
control heads are also mounted near the operator using an extension cable. The transceiver and
control head are mounted by means of a trunnion or other mounting hardware. If the transceiver is
located in a car trunk, be sure that secure mounting and sufficient cooling ar e provided. Do not cover
the transceiver with baggage, blankets, etc.

MMP

MMP

Figure 1-15. Remote Mount Configuration with Mid Power Transceiver and

O5 Control Head

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.

5 m (17 ft) Extension Cable

Figure 1-16. Remote Mount Configuration with Mid Power Transceiver,

Transceiver Interfac e Boa rd , an d O3 Con tr ol Hea d

6878215A01

1-6 Introduction: Standard Configurations

Figure 1-17. Remote Mount Configuration with High Power (100W)

Radio Transceiver and O5 Control Head

5 m (17 ft) Extension Cable

Figure 1-18. Remote Mount Configuration with High Power (100W)

Radio Transceiver and O3 Control Head

17'' Extension Cable

Figure 1-19. Remote Mount Configuration with Radio Transceiver and O9 Control Head

6878215A01

Introduction: Standard Configurations 1-7

17'' Extension Cable

O9 to URC Cable

Figure 1-20. Remote Mount Configuration with Mid Power Radio Transceiver,

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

O9 to URC Cable

Figure 1-21. 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 2-17.

1.2.3 Multi Control Head

The multi control head option allows separate, remotely opera ted control heads to operate and
control the radio. For example, a fire truck could hav e a co ntr o l hea d locate d in the ca b an d on the
rear of the truck so that the radio could be operated from outside the vehicle.

17'' Extension Cable

NOTE: The dual control head can be used together in the future.

6878215A01

1-8 Introduction: Motorcycle Configurations

1.3 Motorcycle Configurations

NOTE: The motorcycle configurations are not applicable for 100W radios and O9 control he ads.

The ASTRO APX 7500 motorcycle radio models provide most of the equipment needed for installing
a standard ASTRO APX 7500 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 regula to ry re qu irem en ts and may req uir e ad dit ion a l
compliance actions such as site survey measurement s, signage, and site a ccess r estrictions in
order to ensure that exposure limits are not exceeded .

1.5 Tools Required for APX 7500 Installations

Tool Part Number

10 mm wrench –
5 mm Allen wrench –
Rubber-coated pliers –
Regular slot screwdriver of Phillips #2 –
Pin removal tool 6680163F01
RF antenna tool HLN6695_

6878215A01

Chapter 2 Standard Configurations

2.1 Planning the Installation

The APX 7500 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 inst a llation, in spect the ve hicle
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

Radio

Speaker

Radio

Battery

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

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.

Siren Box

6878215A01