I
nstallation instructions
for RRP600 intercom and
mobile radios
Step #1: Location for intercom and radio
Find a good location to mount intercom and mobile radio. If possible mount mobile radio
no more than 3 feet from intercom. Standard mobile radio to intercom interface cables are
3 ft. long. Extensions are available when mounting requires more than 3 feet apart. PN#
CS-RADIO-EXT
Note: Be sure to mount away from ignition boxes to avoid RF interference.
Step #2 Mount intercom and radio
Mount intercom with L bracket mounts. Be sure to allow enough room behind the
intercom for the cables to be connected. The unique RRP600 mounting design allows you
to easily slide intercom out of the mounting brackets for plugging in cables and adjusting
radio transmit levels.
Mount mobile radio with the U bracket mounting supplied by manufacturer.
Step #3 Headset to intercom cables
Route the headset cables from the intercom to each seat. Be sure
to run cables in a location where there is not excessive heat or
they may get damaged. Always route cables away from ignition
boxes or coils as RF interference may occur. After routing
cables plug headset cables into the correct position into the
intercom. Be sure the driver cable is plugged into the driver
position on the intercom. If the co-driver and driver are reversed
the co-drivers mic will turn on when the driver pushes their
push to talk for car to car transmitting. Plug cables into back of
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the intercom.
Step #4 Push to talks
If you’re using headset direct cables the push to talk on the headset will be active for car to
car transmitting.
If you’re using the intercom cables with Nexus style blue jack, remote push to talks will need
to be installed.
Hole mount push to talk
Simply drill a ¾” hole and mount the push to talk. Connect the CS-PTT-ADPT adaptor cable
to the PTT and plug into the back of the intercom. Use shrink tube to seal connection of PTT
and adaptor cable. Be sure to plug in the driver PTT into the PTT jack just below the driver
headset jack.
Velcro mount push to talk
Velcro push to talks can be mounted on the steering wheel, grab bar, or shifter. If mounting
on the steering wheel, be sure to coil the cable around the steering wheel column. Turn
steering wheel lock to lock and make sure the cable does not bind. Note: Damage can occur if
the cable binds while turning. Connect the CS-PTT-ADPT adaptor cable to the PTT and plug
into the back of the intercom. Use shrink tube to seal connection of PTT and adaptor cable.
Be sure to plug in the driver PTT into the PTT jack just below the driver headset jack.
Note: Be sure to locate the push to talks and their cable away from pinching or binding areas.
Damage may occur because of improper location.
Step #5 Intercom to Radio cable
Plug in the 5 pin connector (Figure 1) into the pigtail cable coming out of the back of the
intercom. Plug the Serial style connector (Figure 3) into the back of the car to car radio. Plug
the 3.5mm gold plug (Figure 4) into the back of the radio into the external speaker port. Plug
the 2 pin white molex connector (Figure 2) into the power plug coming from the intercom.
The power from the radio will supply power to the intercom.
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Note: Cable may be different per radio brand and model. Not all cables will supply power to
the intercom.
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2
4
1
Step #6 Antenna and coax cable
Find a good location for the antenna. For best performance mount the antenna on a metal or
aluminum roof in the center. The ½ wave NGP antennas do not require a ground plane but it
is always best to have enough metal surface area over 2’x 2’ ft. area.
Mount NMO connector(Gold) to a 3/8” hole in roof or roll bar tap. Be sure to remove any
paint so the NMO mount gets a good ground. Route the coax cable away from ignition boxes
and coils to the car to car radio. IMPORTANT! If there is any extra coax cable DO NOT
COIL CABLE, simply route cable further around car. Coiling this cable will cause transmit
problems, and limit radio range.
Step #7 Connect power
Radio: Route the power cable supplied with the car to car radio directly to the battery. DO
NOT remove the fuses that are in line with the factory cable. This may void the factory
warranty.
Intercom: If you are using the CJ-VX4200 adaptor cable simply plug in the power cable from
the intercom into the 2 pin white molex conector on this adaptor. If a car to car radio is not
used just route the intercom power cable directly to the battery.
Note: Route all power cables directly to the battery. If power is tied to ignition, light, or other
power sources a ground loop problem may occure.
Note: The RRP600 intercom will run on 9-24V DC. This intercom is very efficient and will
run on very low power.
Step #8 Intercom operation
Rotate VOX (Squelch) control on intercom full clockwise. Turn on intercom by rotating
volume control clockwise. Put headset on and move microphone as close to your mouth as
possible. Speak into mic and you should hear your voice in the headset. This is a VOX
intercom with sidetone. Adjust the volume control to the desired level. Rotate the squelch
control counter clockwise one click at a time until the mics turn off. Speak into mic and the
VOX should turn mic on. Set this level higher to cut out wind and engine noise.
Note: Running the mics as close to your mouth as possible will allow a higher squelch setting
to be used. This will block out more background noise while mics are turned off.
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Step #9 Car to car radio operation
Turn on car to car radio and select the channel you wish to transmit on. The incoming
volume of the other cars is controlled by the radio. If the incoming car to car audio is too
loud or too low simply adjust the volume control on the radio. Push the remote push to talk
on the steering wheel or headset when headset direct cables are used. The LED in the
intercom will turn from green to orange. This will show that the intercom is transmitting.
The car to car radio LED will turn red. This will show that the radio is transmitting.
The intercom LED will turn red when car to car radio is transmitting.
Note: Refer to radios owners manual for complete radio operation and functions.
Step #10 Car to car transmit level
The intercom is preset for the proper transmit level but fine tuning may be needed. If your
transmit volume to too low or your transmitting to much background noise simply adjust
the RADIO GAIN control on the back of the intercom. Remove the small round plastic
cover. Insert a small screw driver into the hole. Rotate the control one click at a time.
Counter clockwise will decrease the transmit level and clockwise will increase the transmit
level. Replace plastic cover when finished.
Step #11 Music input
The RRP600 has a 3.5mm plug in the front of the intercom and a rear molex cable for hard
wiring music devices (See Optional Accessories). For 3.5mm front port operation simply
plug in a 3.5mm stereo cable into the intercom and the music device. Turn on music device
and set the volume level. Since the RRP600 is a VOX intercom the music will mute when
talking over intercom or radio transmitting. If music is always muted reset VOX (Squelch)
control on the intercom so the mics turn off.
Note: The volume for the music is only controlled by the music device.
Step #12 Check installation
Check the entire installation. Make sure all cables are tied up and away from heat sources or
places where damage may occur. Check all bolts + mounting hardware to make sure
everything is tight. Once everything is checked you are ready to ride. Enjoy your off-road
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adventure and be safe – communicate!
Optional accessory cable
The RRP600 has the ability to connect cell phones, in car cameras, and stereo systems with
the rear 9 pin detachable Molex plug. When not installing these devices this cable will not
be used. But if you are using these devices simply plug in the accessory cable into the AUX
post on the back of the intercom. Follow the diagram for proper hook up of these devices.
1 4 7
2 5 8
3 6 9
Note: When looking at the Molex connector the aligning bumps are on the left side.
1 Music In R Red
2 Music In L White
3 Ground LG Black
4 Audio Out L Green
5 Audio Out R SM Black
6 Ground LG Black
7 Cell Mic Yellow
8 Cell Speaker Blue
9 Ground LG Black
Cell phone hook up
Follow the wiring diagram for proper connection of speaker and microphone. There is a cell
microphone audio control located behind the back panel of the intercom. This will control
the microphone transmit level of the cell phone. Simply remove the 4 screws on the back
panel of the RRP600 intercom. Located on the bottom of the circuit board is a blue housing
volume pot. While talking over the cell phone rotate the volume pot until the desired
transmit level is reached. Replace the back panel and tighten the 4 screws.
Optional DSP
Rugged now has an optional Digital Speech Processing upgrade. DSP removes 90% of the
background noise for crystal clear communication between driver, co-driver, and
passengers. DSP samples your voice and blocks out the rest. Call today for the easy to
install and unbelievable performing DSP. PN# DSP-B
Conclusion
Thank you for purchasing the Rugged RRP600 intercom system. These intercoms are
highly adjustable and can be configured for any application. If you have any questions or
concerns please feel free to contact our tech line. We appreciate your comments and
suggestions.
Customer Service and Tech Line: 888-541-7223 or 805-541-1696
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