HARRIS TR-0022-E M7100 800 MHz Mobile Radio User Manual MM102343V1RevA

HARRIS CORPORATION M7100 800 MHz Mobile Radio MM102343V1RevA

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Users Manual Motorcycle Revised

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Users Manual Motorcycle Revised

Installation ManualMM102343V1Rev. A, May-04M7100IPMobile Radio & Control Unit Motorcycle Installation

3TABLE OF CONTENTS Page1 SAFETY SYMBOL CONVENTIONS ................................................... 42 RF ENERGY EXPOSURE INFORMATION ....................................... 52.1 RF ENERGY EXPOSURE INFORMATION....................................... 52.1.1 Federal Communications Commission Regulations ................ 62.2 COMPLIANCE WITH RF EXPOSURE STANDARDS...................... 62.2.1 Mobile Antennas...................................................................... 82.2.2 Approved Accessories ............................................................. 82.2.3 Contact Information................................................................. 83 OPERATION SAFETY RECOMMENDATIONS................................ 93.1 TRANSMITTER HAZARDS ............................................................... 93.2 SAFE DRIVING RECOMMENDATIONS ........................................ 104 GENERAL INFORMATION ............................................................... 124.1 RELATED DOCUMENTATION....................................................... 125 OPTIONS AND ACCESSORIES ......................................................... 135.1 VENDOR DROP SHIP OPTIONS ..................................................... 155.1.1 External Headset Options ...................................................... 155.2 HARDWARE KITS ............................................................................ 155.3 USER SUPPLIED EQUIPMENT ....................................................... 195.4 POWER CONSIDERATIONS............................................................ 195.4.1 RF Power Adjustments .......................................................... 196 INSTALLATION ................................................................................... 216.1 TOOLS REQUIRED........................................................................... 216.2 EQUIPMENT INSTALLATION ........................................................ 216.2.1 Weather Resistant Case Assembly and Installation............... 216.2.2 Harley-Davidson Installation................................................. 246.3 RADIO MOUNTING BRACKETS .................................................... 247 CONTROL UNIT MOUNTING........................................................... 267.1.1 Control Unit and Mic Hanger Installation ............................. 277.2 SPEAKER MOUNTING..................................................................... 297.3 CABLE ROUTING............................................................................. 297.3.1 Power and Control Cables ..................................................... 297.3.2 Option Cable.......................................................................... 307.3.3 Typical Harley-Davidson Installation.................................... 307.4 CABLE CONNECTIONS................................................................... 337.4.1 Power Cable........................................................................... 347.4.2 Control Cable......................................................................... 347.4.3 Ignition Switch Option .......................................................... 347.4.4 Accessory Cable .................................................................... 357.5 ANTENNA INSTALLATION............................................................ 357.5.1 General .................................................................................. 357.5.2 Typical Motorcycle Mount Antenna Installation................... 368 FINAL CHECKS AND CONNECTIONS............................................ 378.1 HEADSET INSTALLATION (OPTION)........................................... 378.1.1 Dual Radio Application (Mobile with Portable).................... 388.1.2 Headset Operation ................................................................. 419 WARRANTY.......................................................................................... 56

1 SAFETY SYMBOL CONVENTIONS The following conventions are used throughout this manual to alert the user togeneral safety precautions that must be observed during all phases ofoperation, service, and repair of this product. Failure to comply with theseprecautions or with specific warnings elsewhere in this manual violates safety standards of design, manufacture, and intended use of the product. M/A-COM, Inc. assumes no liability for the customer’s failure to comply withthese standards. WARNINGThe WARNING symbol calls attention to a procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury. Do not proceed beyond a WARNING symbol until the conditions identifiedare fully understood or met.CAUTIONThe CAUTION symbol calls attention to an operatingprocedure, practice, or the like, which, if not performedcorrectly or adhered to, could result in damage to theequipment or severely degrade the equipment performance.NOTEThe NOTE symbol calls attention to supplementalinformation, which may improve system performance orclarify a process or procedure. The ESD symbol calls attention to procedures, practices, or the like, which could expose equipment to the effects ofElectro-Static Discharge. Proper precautions must be taken to prevent ESD when handling circuit modules.4

2 RF ENERGY EXPOSURE INFORMATION2.1 RF ENERGY EXPOSURE AWARENESS, CONTROL INFORMATION, AND OPERATION INSTRUCTIONS FOR FCC OCCUPATIONAL USE REQUIREMENTSBEFORE USING YOUR MOBILE TWO-WAY RADIO, READ THISIMPORTANT RF ENERGY AWARENESS AND CONTROLINFORMATION AND OPERATIONAL INSTRUCTIONS TO ENSURE COMPLIANCE WITH THE FCC’S RF EXPOSUREGUIDELINES.NOTICE: This radio is intended for use in occupational/controlledconditions, 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.CAUTIONChanges or modifications not expressly approved by M/A-COM, Inc. could void the user's authority to operate theequipment.This two-way radio uses electromagnetic energy in the radio frequency (RF)spectrum to provide communications between two or more users over a distance. It uses RF energy or radio waves to send and receive calls. RF energy is one form of electromagnetic energy. Other forms include, but are not limited to, electric power, sunlight, and x-rays. RF energy, however,should not be confused with these other forms of electromagnetic energy,which, when used improperly, can cause biological damage. Very high levelsof x-rays, for example, can damage tissues and genetic material.5

6Experts in science, engineering, medicine, health, and industry work with organizations to develop standards for exposure to RF energy. These standards provide recommended levels of RF exposure for both workers and the general public. These recommended RF exposure levels include substantial margins of protection. All two-way radios marketed in North America are designed, manufactured, and tested to ensure they meet government established RF exposure levels. In addition, manufacturers also recommend specific operating instructions to users of two-way radios. These instructions are important because they inform users about RF energy exposure and provide simple procedures on how to control it. Please refer to the following websites for more information on what RF energy exposure is and how to control your exposure to assure compliance with established RF exposure limits. http://www.fcc.gov/oet/rfsafety/rf-faqs.htmlhttp://www.osha.gov./SLTC/radiofrequencyradiation/index.html2.1.1 Federal Communications Commission RegulationsYour M/A-COM, Inc. M7100IP mobile two-way radio is designed and tested to comply with the FCC RF energy exposure limits for mobile two-way radios before it can be marketed in the United States. When two-way radios are used as a consequence of employment, the FCC requires users to be fully aware of and able to control their exposure to meet occupational requirements. Exposure awareness can be facilitated by the use of a label directing users to specific user awareness information. Your M/A-COM, Inc. M7100IP two-way radio has an RF exposure product label. Also, your M7100IP Installation and Operator’s Manuals include information and operating instructions required to control your RF exposure and to satisfy compliance requirements. 2.2 COMPLIANCE WITH RF EXPOSURE STANDARDSYour M/A-COM, Inc. M7100IP mobile two-way radio is designed and tested to comply with a number of national and international standards and guidelines (listed below) regarding human exposure to RF electromagnetic energy. This radio complies with the IEEE and ICNIRP exposure limits for occupational/controlled RF exposure environment at duty factors of up to 50% talk-50% listen and is authorized by the FCC for occupational use. In terms of measuring RF energy for compliance with the FCC exposure guidelines, your radio antenna radiates measurable RF energy only while it is transmitting (talking), not when it is receiving (listening) or in standby mode.

Your M/A-COM, Inc. M7100IP mobile two-way radio complies with thefollowing RF energy exposure standards and guidelines:x United States Federal Communications Commission (FCC), Code ofFederal Regulations; 47 CFR §§ 2 sub-part J. x American National Standards Institute (ANSI)/Institute of Electrical and Electronic Engineers (IEEE) C95.1-1992. x Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999. CAUTIONTable 2-1 lists the recommended minimum lateral distancefor a controlled environment and for unaware bystanders inan uncontrolled environment, from transmitting types ofantennas (i.e., monopoles over a ground plane, or dipoles)at rated radio power for mobile radios installed on amotorcycle. Transmit only when unaware bystanders are atleast the uncontrolled recommended minimum lateraldistance away from the transmitting antenna.Table 2-1: Rated Power and Recommended Minimum Lateral Distance RECOMMENDED MINIMUM LATERAL DISTANCE FROM TRANSMITTING ANTENNAMOBILERADIOFREQUENCYSPLITRATED POWER OF MOTORCYCLE-INSTALLED MOBILE TWO-WAY RADIO CONTROLLED UNCONTROLLED50 Watts, (378 MHz, AntennaP/N: LE-OM406BKTNC)85.23 cm 190.60 cmUHF–L50 Watts, (378 MHz, AntennaP/N: LE-OM420BKTNC)85.23 cm 190.60 cm50 Watts, (450 MHz, AntennaP/N: LE-OM440BKTNC)68.62 cm 153.43 cm50 Watts, (450 MHz, AntennaP/N: LE-OM450BKTNC)68.62 cm 153.43 cm50 Watts, (450 MHz, AntennaP/N: LE-OM470BKTNC)68.62 cm 153.43 cmUHF-H50 Watts, (450 MHz, AntennaP/N: LE-OM490BKTNC)68.62 cm 153.43 cm800 MHz 35 Watts, (806 MHz, AntennaP/N: LE-OM806DBKTNCDS)47.90 cm 107.20 cm2.2.17

Mobile AntennasNOTEThis device must not be co-located or operating in conjunctionwith any other antenna or transmitter.Install the radio’s antenna (refer to Table 2-1 for frequencies and corresponding part numbers of recommended antennas) on the end of themotorcycle case farthest away from the driver. These mobile antenna installation guidelines are limited to motorcycles fit with the motorcycle radiocase with integral antenna grounding plane. The antenna installation shouldadditionally be in accordance with the following. x The requirements of the antenna manufacturer/supplier included with theantenna.x Instructions in the M7100IP Radio and Control Unit MotorcycleInstallation Manual, including minimum antenna cable lengths.x The installation manual providing specific information of how to installthe antennas to facilitate recommended operating distances to allpotentially exposed persons. Use only the M/A-COM approved/supplied antenna(s) or approvedreplacement antenna(s). Unauthorized antennas, modifications, or attachments could damage the radio and may violate FCC regulations.2.2.2 Approved AccessoriesThis radio has been tested and meets the FCC RF guidelines when used withthe M/A-COM accessories supplied or designated for use with this product. Use of other accessories may not ensure compliance with the FCC’s RF exposure guidelines, and may violate FCC regulations.For a list of M/A-COM approved accessories refer to the product manuals,M/A-COM’s Products and Services Catalog, or contact M/A-COM at 1-800-528-7711.2.2.3 Contact InformationFor additional information on exposure requirements or other information,contact M/A-COM, Inc. at 1-800-528-7711 or at http://www.macom-wireless.com.8

3 OPERATION SAFETY RECOMMENDATIONS3.1 TRANSMITTER HAZARDSWARNINGThe operator of any mobile radio should be aware ofcertain hazards common to the operation of radio transmitters. A list of several possible hazards is given:x Explosive Atmospheres – Just as it is dangerous to fuel a vehicle withthe motor running, similar hazards exist when operating a mobile radio. Be sure to turn the radio off while fueling the motorcycle. Do nottransport containers of fuel.Areas with potentially explosive atmosphere are often, but not always, clearly marked. Turn OFF your radio when in any area with a potentially explosive atmosphere. It is rare, but not impossible that the radio or its accessories could generate sparks. x Interference to Vehicular Electronics Systems – Electronic fuel injection systems, electronic anti-skid braking systems, electronic cruise control systems, etc., are typical electronic systems that may malfunctiondue to the lack of protection from radio frequency energy present whentransmitting. If the vehicle contains such equipment, consult the dealerand enlist their aid in determining the expected performance of electronic circuits when the radio is transmitting.x Electric Blasting Caps – To prevent accidental detonation of electric blasting caps, DO NOT use two-way radios within 1000 feet of blastingoperations. Always obey the “Turn Off Two-Way Radios” signs postedwhere electric blasting caps are being used. (OSHA Standard: 1926-900)x Liquefied Petroleum (LP) Gas Powered Vehicles – Mobile radioinstallations in vehicles powered by liquefied petroleum gas with the LPgas container in the trunk or other sealed-off space within the interior of the vehicle must conform to the National Fire Protection Associationstandard NFPA 58 requiring:¾ The space containing the radio equipment shall be isolated by a seal from the space containing the LP gas container and its fittings. ¾ Outside filling connections shall be used for the LP gas container. ¾ The LP gas container shall be vented to the outside of the vehicle.9

103.2 SAFE DRIVING RECOMMENDATIONS (Recommended by AAA) x Read the literature on the safe operation of the radio. x Use both hands to steer and keep the microphone in its hanger whenever the vehicle is in motion. x Place calls only when the vehicle is stopped. x When talking from a moving vehicle is unavoidable, drive in the slower lane. Keep conversations brief. x If a conversation requires taking notes or complex thought, stop the vehicle in a safe place and continue the call. x Whenever using a mobile radio, exercise caution.

Figure 3-1: Typical M7100IP Motorcycle Installation 11

4 GENERAL INFORMATIONThis manual contains instructions for installing the M7100IP mobile radio,M7100IP control unit, and associated hardware on a motorcycle. Theinstructions in this manual are typical installation instructions, and are notintended to cover all makes and models of motorcycles.Final installation of the radio equipment is left to the discretion of the radioinstaller.To simplify installation and minimize difficulties, it is suggested that the installer read the entire manual prior to installation. Figure 3-1 shows a typical motorcycle installation.NOTEM/A-COM, Inc. does not assume liability for possibledegradation of the radio or motorcycle performance due tomounting procedures. 4.1 RELATED DOCUMENTATIONM7100IP Mobile Radio Operator’s Manual,Scan & System................................................................. MM102341V1M7100IP Mobile Radio Installation Manual,Scan & System................................................................. MM102342V1M7100IP Mobile Radio Motorcycle Installation Manual,(50W TX and Below) ...................................................... MM102343V1M7100IP Mobile Radio Maintenance ManualUHF (378-430 MHz and 450-512 MHz)......................... MM102346V1VHF (136-174 MHz) ....................................................... MM102345V1800 MHz (806-870 MHz)................................................ MM102347V112

155.1 VENDOR DROP SHIP OPTIONS There are external headsets available through M/A-COM vendors (refer to the Options and Accessories list in Table 5-1). 5.1.1 External Headset OptionsThere are two different applications for the Headset. One is for use with just the M7100IP mobile radio and the other is for use with the M7100IP mobile radio and a portable radio. See Section 8.1. In addition, Belt Box Assembly Interfaces are available for use with the dual application that allows the headset to be used with the M7100IP mobile radio and a portable radio. 5.2 HARDWARE KITS The typical motorcycle mount application requirements are shown in Figure 5-1 (radio, control unit, microphone, and antenna are all ordered separately). Hardware Kits 350A1396G1-G4 are shown in Figure 5-2 and Figure 5-3. Hardware kit 350A1396G1 is used to factory-install the radio mounting bracket and alternator whine reject filter to the weather-resistant case. Hardware kits, 350A1396G2-G4, are used by the customer in the field to mount the case and control head to the motorcycle (and may require the optional Harley-Davidson adapter bracket).x MIL-STD weather-resistant locking M7100IP radio case with integral antenna ground plane x Motorcycle Case hardware kit x Motorcycle Radio Mounting bracket and hardware x Case/Antenna bracket x Case/Antenna Mount hardware kit x Control Unit Mount hardware kit x Case Adapter bracket (for Harley-Davidson motorcycles) x Case Adapter Mount hardware kit x RF Interface filter x MIL-STD weatherproof speaker x Radio-to-Control Unit Motorcycle cable x Motorcycle Accessory cable x Power/Control cable

Figure 5-1: Typical Motorcycle Kit 16

Hardware Application Kit 350A1396G1 Case/Antenna Assembly Hardware Kit 350A1396G2 Figure 5-2: Hardware Installation Kits for Harley-Davidson Motorcycles 17

Control Unit/Microphone Hardware Kit 350A1396G3 Motorcycle Adapter Mounting Kit 350A1396G4 Figure 5-3: Hardware Kits for Harley-Davidson Motorcycles 18

5.3 USER SUPPLIED EQUIPMENT x Motorcycle Bracket (Motorcycle’s interface with this Motorcycle Radio Case and associated hardware. Refer to  and  in Figure 6-1 and Figure 6-2.) 5.4 POWER CONSIDERATIONSThe motorcycle may be equipped with additional lights, light flashers, sirens,PA systems, etc. Therefore, consideration must be given to the total systemcurrent drain. It is recommended that the radios be set to not exceed the applicable rated RF power output and current drain shown in Table 5-2 for allM7100IP motorcycle applications.CAUTIONDo NOT use a M7100IP mobile radio with power exceeding the power limits shown in Table 5-2 for motorcycleapplications. To do so will result in damage to themotorcycle alternator, battery, and all circuits. Also, thepossibility of interference is increased if the proper RF power level is not used. As a final note, RF power may notbe set to exceed the maximum regulatory RF power specified by that country’s regulatory agency.5.4.1 RF Power AdjustmentsFor factory installed options, the maximum RF power levels are factory presetand should only require verification in the field. See Table 5-2. For field installed options, the RF power of previously purchased M7100IPmobile radios in the field must be appropriately set via modification of themaximum RF power tracking data fields. The tracking data numbers areadjusted to produce RF power as specified in the “actual” column in Table 5-2.5.4.1.1 Setting RF Power in the Field Perform the following steps to adjust the RF power level tracking data.1. Using ProGrammer, read the personality from the radio. (Refer toProGrammer On-Line Help for detailed instructions.)2. Click on the “Systems” tab, then double click on “System Setup.”3. Select the “General” tab and choose the System Name that needs tobe adjusted. 19

204. Enter the appropriate value corresponding to the rated power in the “Power Level” control box (for example: 8 for low power in the UHF bands; 15 for mid-power in the 800 MHz band). Refer to Table 5-2. Click OK. 5. Write the new personality to radio. Typical RF power tracking data settings are listed in the M7100IP Mobile Radio Maintenance Manuals in the programming sections. Table 5-2: RF Power Versus Current Setting M7100IP MOBILE RF POWER (Standard Application) M7100IP MOBILE RF POWER (Motorcycle Application) RF PWR (Rated)CURRENT(Typical) RF POWER(Rated)RF POWER(Actual) CURRENT(Typical) 378-430 MHz 50W 12A 25W 27 r0.5W8A30W 9A 20W 19.5 r0.5W 7A450-512 MHz 50W 12A 25W 27 r0.5W 8A30W 9A 20W 19.5 r0.5W 7A800 MHz (Repeater Input Band 806-825 MHz) 35W 9A 25W 27 r0.5W 7A12W 5A 12W 13.0 r0.5W 5A800 MHz (Talkaround Band 851-870 MHz) 30W 8A 25W 27 r0.5W 7A12W 5A 12W 13.0 r0.5W 5A

216 INSTALLATION Installation of the M7100IP mobile radio and control unit consists of: x Assembling and installing the weather resistant motorcycle case assembly, including the adapter bracket, case/antenna mounting bracket, and bottom case (previously assembled) to the existing interface bracket (user supplied) on the motorcycle. x Installing the radio in the radio mounting bracket located inside the weather-resistant case. x Installing the control unit, microphone, and speaker. x Installing the antenna. x Routing the power, control, and option cables. x Connecting all cables, including power, control, and option cables. x Installing the Headset Option. x Performing an operational check All mounting hardware consists of stainless steel screws, locknuts, nuts, and lockwashers to resist corrosion. 6.1 TOOLS REQUIRED x Socket wrench set U.S./metric with 3" extender x Open end wrench, adjustable x Wire clippers x TORX® BIT set, small metric 6.2 EQUIPMENT INSTALLATION 6.2.1 Weather Resistant Case Assembly and InstallationThe motorcycle Weather Resistant Case Assembly may be installed on almost any motorcycle. Installation instructions provided here include information for the Harley-Davidson® Dyna® and Road King® models. Figure 6-1 and Figure 6-2 illustrate installation on Harley-Davidson motorcycles. Refer to these diagrams during installation. Installation on other motorcycles is at the discretion of the installer.

Figure 6-1: Radio Installation(188D6803, Sh. 1A, Rev. 4)22

Figure 6-2: Radio Installation(188D6803, Sh. 1B, Rev. 4)23

6.2.2 Harley-Davidson Installation1. Unpack the weather resistant motorcycle case, remove the key taped tothe top cover and open the case. 2. Refer to Figure 6-1 and Figure 6-2 and verify all components shown inthe diagrams are available. 3. Mount the adapter bracket to the existing Dyna or Road King (interface) bracket on the motorcycle (user supplied) using the 1/4-20 x 5/8 screwsprovided.NOTEThe interface radio mounting bracket (user supplied) for the Dyna and Road King models are different and require adifferent mounting hole configuration. See Figure 6-1 andFigure 6-2. 4. Insert the power, control, and antenna cables through the square hole inthe case/antenna mounting bracket and then through the bottom case assembly.5. Mount the case mounting bracket and bottom case assembly onto the 4resilient mounts using the serrated flange nuts and flat washers included inside the case. Refer to Figure 6-3. 6. Refer to Figure 6-4 and connect the power cable to the radio. (Refer toCable Connections.)7. Position the radio, fins up, inside the bracket in the bottom case assemblyand slide onto the arms. Lock in place using the TORX head screws and lock washers (taped to the radio bracket). 8. Refer to Figure 6-4 and connect the antenna and control cables to theradio. (Refer to Antenna Installation.)9. Mount the antenna to the case/antenna mounting bracket using the M3 x 16 mm pan head screws provided. Refer to Figure 6-3. 6.3 RADIO MOUNTING BRACKETS Radio mounting brackets are not available from M/A-COM for all models ofbikes. Should a special application arise for a custom-made radio mountingbracket, it must be made using 0.125" steel (minimum). When designing andmounting the bracket, corners/edges should be rounded to the maximumextent possible.24

Figure 6-3: Case Mounting Bracket and Case AssemblyFigure 6-4: Radio Connections25

7 CONTROL UNIT MOUNTING Mount the control unit within convenient reach of the operator, and where it will not interfere with the safe operation of the motorcycle. Figure 7-1 showsa typical installation of the control unit and microphone. Note also, thelocation of the option switch for the Headset Option.Due to the large number of different makes and models of motorcycles, it isup to the installer to decide how to mount the control unit and optionalequipment. Mounting brackets for all makes and models are not availablefrom the factory, making it necessary to obtain a custom made bracket.When designing and mounting the control unit bracket, the followingguidelines should be considered.x The installation must NOT interfere with steering or operation of themotorcycle.x Mounting locations must NOT interfere with the driver or withinstrument visibility.x The installation should provide easy access to the radio operatingcontrols.x Rounded corners/edges should be employed to the maximum extentpossible.CAUTIONBe careful to avoid damaging some vital part of themotorcycle if it becomes necessary to drill mounting holes. Also, always check to see how far the mounting screws willextend below the mounting surface before installing.Caution must be exercised to not drill through the gasoline tank.26

Figure 7-1: Typical Control Unit Installation7.1.1 Control Unit and Mic Hanger InstallationRefer to Figure 7-2 for a detailed mechanical drawing of the control unit andmicrophone mounting assembly. The mounting bracket shown mates with theHarley-Davidson Road King hardware. For all other models, an additionaladapter bracket is required. 27

Figure 7-2: Control Unit Mounting Assembly(188D6804, Sh. 1, Rev. 2)1. Using the hardware supplied, (part of Hardware Kit 350A1396G3) mountthe control unit bracket to the motorcycle.NOTEA special spacer may be required between the control unit bracket and the motorcycle to raise the level of the control unitbracket. This spacer, if needed, must be constructed locally. 2. Mount the control unit and mic hanger to the mounting bracket.After installing the control unit, do not make any cable connections until all cables have been run and secured. Speaker and option connectors are shownon the Interconnection Diagrams listed in the Table of Contents.28

7.2 SPEAKER MOUNTINGMount the speaker where the operator can hear it, and where it does notinterfere with the safe operation of the motorcycle. On some motorcycles, thespeaker can be attached to the windshield bracket using existing bolts tosecure the speaker mounting bracket (see Figure 7-3). Figure 7-3: Typical Speaker Mounting7.3 CABLE ROUTING7.3.1 Power and Control CablesCable routing consists of planning and routing the cable runs between theradio, control unit, and battery. The cables should be routed away fromexhaust pipes, mufflers, and moving parts, or where mechanical damage mayresult. Secure all cables with black cable ties to provide a clean installation.The power and control cables, red and black, exit the radio case assemblythrough the square hole in the front of the box and are routed to the area beneath the saddle. The fused power cables (19B802622P2 or19B802554P25) from the radio terminate here and are connected to thebattery. The control cable is routed through the triangular frame assembly tothe rear of the control unit.29

7.3.2 Option CableThe option cable is routed from the option connector on the rear of the controlunit CG/PTT disable switch mounted on the left handlebar.7.3.3 Typical Harley-Davidson Installation1. Disconnect gas line from tank and drain gas into an approved container.2. Remove cowling, gas tank, and fairing, if required, to gain access to thetriangular frame assembly, beneath the gas tank, to permit cable routing.3. Push saddle support springs forward to release the saddle and tilt it forward to gain access to the area beneath the saddle. NOTEThe power cable is designed for negative ground systemsonly. The power and control cable consists of three separatecables: RED (positive), BLACK (negative), and a controlcable.4. Pass the power and control cables through the square hole in the bottomof the radio case assembly to the area beneath the saddle. See Figure 6-4 which shows cable routing under the center of the case assembly. Figure7-4 shows the cabling underneath the saddle area. (Note the location ofthe option cable and connector, not being used.) 5. Refer to Figure 7-5 and route the cables through the center of thetriangular frame assembly to the area at the rear of the control unit. Thecable may be routed along side existing cables and secured to them withcable ties. NOTEIt may be necessary to notch a portion of the cowling at thecontrol unit end and at the saddle area to provide entranceand exit holes for the cable. The entrance and exit cutaway holes are required to permit the cowling to be remountedflush to the gas tank.6. Route the control cable to the rear of the control unit and make theconnection to the right rear of the control unit as shown in Figure 7-6. Any excess cable will reside beneath the saddle area. (The option andaccessory cable is shown connected to the left rear of the control unit). 7. Re-examine cable routing and be sure that all cables are neatly routed and secured with cable ties. 8. Install a cable clamp on saddle mounting bracket (left side) and secure the power and control cables from the radio case assembly.30

9. Route speaker leads from the control cable underneath the handlebar tothe rear of the instrument panel assembly in the vicinity of the speaker.Secure to headlight cabling with cable ties. Excess cable should be bundled and secured with cable ties behind the instrument panelassembly.NOTERefer to Section 8.1 for accessory cable routing instructions.10. Connect speaker leads from accessory cable to speaker cable. 11. Connect negative power lead to the battery negative (-) terminal.12. Connect positive power lead to the battery positive (+) terminal.13. Reinstall gas tank, cowling, and secure saddle.14. Verify all electrical connections: radio, control unit, antenna, optionswitch, speaker, and battery.15. Close and lock radio case assembly.Figure 7-4: Option Cable Stored Beneath Saddle Area 31

Figure 7-5: Triangular Frame AssemblyFigure 7-6: Control Unit Connections 32

7.3.3.1 For Motorcycle Models Equipped with Gas Tank Fairing The cable may be routed from the saddle area, under the fairing, around theleft side of the gas tank filler pipe, and up to the area of the control unit. Thefairing may have to be notched to provide entrance and exit space. Run the control cable as directed in Steps 1 through 3. 1. Remove all the screws securing the fairing. Next, unscrew and removethe gas tank cap and lift off the fairing. Replace the gas cap immediately.WARNINGAlways replace the gas cap as soon as the fairing isreplaced/removed. This is necessary to reduce thepossibility of an explosion as well as to prevent drillshavings or other debris from getting into the gas tank.2. Run the cables from the saddle area up the left side of the gas tank to thearea of the control unit. NOTEIt may be necessary to notch a portion of the fairing at thecontrol unit end and at the saddle area to provide entranceand exit holes for the cable. The entrance and exit cutaway holes are required to permit the fairing to be remountedflush to the gas tank.3. Before replacing the fairing, the control cable and any option cables maybe run under the fairing also. Replace the fairing by removing the gas cap, repositioning the fairing, then replacing the gas cap and the screwsthat secure the fairing. 7.3.3.2 For Motorcycles Not Equipped with a Gas Tank Fairing After making power connections, run the control cables up the left side of themotorcycle to the control unit and secure the cables with the cable ties. Note:All cables connect to the back of the control unit.7.4 CABLE CONNECTIONSCable connections consist of connecting the power and control cables(individual red + and black -), the radio control cable, and the antenna cable.Verify that all cables have been connected and are secure. Refer to control cable assembly drawings 19B802554 and InterconnectionDrawings (188D6783) for electrical and mechanical application details.33

7.4.1 Power CableAs shipped from the factory, the power cable (19B802622P2) is equippedwith a 12 amp in-line fuse (installed) and ring terminals. The power cablesupplies power from the battery to the radio. Refer to Figure 6-4. 1. Connect the red lead (+) to the battery terminal on the alternator whinefilter and the black lead (-) to ground on the alternator whine filter. 2. Route the cables to the battery and then connect the black (-) and the redlead (+) to the battery terminals.7.4.2 Control CableThe control cable (remote mount, extended option) is routed between thecontrol unit and the motorcycle radio case. In addition to the main cable, thecable assembly contains a pair of black speaker leads and a single yellow wire for ignition switch standby control. Normally, the ignition switch standby control feature is not used in motorcycle applications and the yellow fuseassembly provided is discarded and the wire terminated. However, at thecustomer’s discretion, the ignition switch standby control feature may be used.The plug connections include the microphone, speaker, option cable, and thecontrol cable. Refer to the interconnection diagram 188D6783 and to diagram19B802554P23 for cable identification.1. Plug the black speaker leads from the control cable into the speaker cable.2. Plug the control cable into the right rear receptacle of the control unit. 7.4.3 Ignition Switch OptionNOTEThe M7100IP radio, as shipped from the factory, has the“ignition sense” feature disabled. As such, the radio ispowered ON or OFF as determined by the front panel ON-OFF/VOLUME control only (assuming A+ and A- are connected). If the “ignition sense” feature is to be enabled, open the top cover of the radio and remove the shield fromthe logic PWB. Slide switch SW601 from position 3-2 to 1-2. Replace shield and top cover. Be sure to apply the correcttorque to the screws holding the top cover in place. Refer to the M7100IP Maintenance Manual for configurationinstructions.34

7.4.4 Accessory Cable The accessory cable (19B802554P24) provides connections for the external headset, DES keyloader, and other options (i.e., data terminal, externalencoder/decoder, etc).7.5 ANTENNA INSTALLATION7.5.1 GeneralThe M/A-COM M7100IP motorcycle options are designed for use with theantennas listed in Table 2-1 and Table 5-1. With these antennas, a ground plane is no longer necessary. These antennas are end-fed high-impedanceantennas that provide the proper VSWR and radiation pattern without the use of a ground plane. Typical antenna gain without a ground plane is 0 dB.The case/antenna mounting plate (188D6437P1) was designed to fit the holemounting pattern for all these antenna mounts.CAUTIONSince the antennas are high impedance, voltage fed antennas, the length of the coaxial cable from the antennasto the M7100IP RF port is critical. It cannot be just anyarbitrary length. To prevent possible extraneous radiation,RFI feedback from the antenna to the radio, high VSWR, orantenna ground currents, select an antenna coaxial cablelength that is close to a multiple of an odd quarter-wavelength.To properly use a thru-line wattmeter, one of the following two conditionsmust be met:x If the wattmeter is installed right at the M7100IP RF port and the odd multiple of a quarter-wavelength of coax to the antenna is used, correctreadings will result. Any other length of coax will result in improperreadings.x If a length of coax equal to a multiple of a half-wave length is installedbetween the M7100IP RF port and the thru-line wattmeter and an oddmultiple of a quarter-wavelength of coax to the antenna is used, correctreadings will also result. Any other length of coax will result in improperreadings.To calculate the proper cable length of the antenna coaxial cable, proceed as follows:1. Determine the center frequency of the majority of programmed transmitchannel frequencies.35

2. Use the formula: ¼Oin = 2805F(MHz)Example 1: Assume the customer has an 800 MHz M7100IP with most of thetransmit frequencies between 816-821 MHz. Therefore, center frequency is818.5 MHz. Applying the above formula results in: ¼Oin = 2805 = 3.43 inches 818.5 ½Owavelength (in inches)= 6.85 inchesThe cable length should be 3.43 + n x 6.85 inches. Since the installer will need a length of the coax from the antenna to the radio to be at least 22 incheslong to physically connect the antenna to the radio, he must calculate a lengthof coax that will meet the odd quarter-wavelength requirement and be greater than 22 inches.Choose n=3. Coaxial cable length is 3.43 + 3 x 6.85= 23.99 inches.Example 2: Assume the center frequency is 155 MHz. Applying the formula:¼O = 18.10 inches; ½ wavelength = 36.19 inches; n=1.Coaxial cable length is 18.10 + 1 x 36.19= 54.29 inches.7.5.2 Typical Motorcycle Mount Antenna InstallationIt is important to refer to the minimum lateral distance recommendationswhen installing your antenna (see Table 2-1). The minimum lateral distancesare calculated using a 50% duty cycle. 1. After the proper length of coax cable has been calculated, cut the coax cable so that when the TNC crimp style connector is installed the overalllength will equal the calculated length.2. Route the assembled proper length coax from the antenna, under theantenna bracket, and into the weather-resistant case. 3. Connect the antenna cable to the RF port on the M7100IP radio.WARNINGSee Section 2, RF ENERGY EXPOSURE INFORMATION, at the beginning of this manual forfurther information regarding Maximum PermissibleExposure (MPE) limits set by the FCC.36

8 FINAL CHECKS AND CONNECTIONS After the weather resistant case is installed, all cables run, and the radio,control unit, speaker, and microphone installed, refer to the interconnectiondiagrams and verify that all connections have been made and the equipment isproperly grounded. Make a final check of all cables to make sure they areproperly connected and dressed away from all moving parts and exhaustpipes, and secured with cable ties. Then recheck all electrical connections andradio mounting hardware. 8.1 HEADSET INSTALLATION (OPTION) NOTETo enable the PTT switch on the handlebar switch for external headset options, the M7100IP mobile radio must be programmed so that INP2 is defined to be “PTT” or“EXTPTT”. Without this software addition, the headset options will not transmit.37

8.1.1 Dual Radio Application (Mobile with Portable)The Headset Option includes the helmet-mounted noise canceling microphonewith single (or dual) speakers, the belt box assembly (with internal amplifier),and the Helmet Kit Interface Cable. Figure 8-1: Headset Option with M7100IP Mobile Radio withPortable Radio (P7100IP shown) 1. Install the noise-canceling microphone and single (or dual) speakers inthe helmet per instructions provided by the vendor. 2. Remove the plug 19B802554P26 from the option connector on the backof the M7100IP radio control unit. Connect the accessory cable19B802554P24 to the option connector.38

393. Install the Helmet Kit Interface Cable (SM-MCH-71GT, etc.) containing the PTT only pushbutton switch or the PTT/CG disable switch to the left handlebar, insuring that freedom of motion is not compromised. Route the eight pin waterproof connector over to and mate it with the eight pin waterproof connector that is part of accessory cable 19B802554P24. 4. Route the long end of the Helmet Kit Interface Cable containing the four position quick disconnect plug along the bike and bring it out near the location of the driver’s hip. 5. The long end of the accessory cable 19B802554P24 which contains the 25 pin D-subminiature receptacle connector is to also be routed along the bike and any excess is to be coiled up and left under the seat. 6. The driver takes the belt boxes (listed in Table 5-1) and attaches it to his belt. The helmet kit quick disconnect plug is mated to the belt box quick disconnect connector. 7. Finally, the other quick disconnect connector of the belt box is mated to the Helmet Kit Interface Cable quick disconnect connector.

8.1.1.1 M7100IP Mobile Radio Only Application This Headset Option includes the helmet-mounted noise cancelingmicrophone with single (or dual) speakers, the extender cable assembly, andthe Helmet Kit Interface Cable. Figure 8-2: Headset Option with Mobile Radio Only Application1. Follow steps 1-5 of the “Dual Radio Application.”2. The helmet kit quick disconnect plug is mated to the extender cableSM-25-0694 (no need for a belt box). 3. Finally, the other quick disconnect connector of the extender cable ismated to the Helmet Kit Interface Cable quick disconnect connector. 40

NOTEThe headset option speakers are a nominal 24 ohms. Use of other impedance value speakers will result in non-optimumsound performance from the speaker(s). The SM-KA-23dual speaker helmet kit has the two speakers wired in parallel. They must be re-wired in series to performproperly.NOTEThe Helmet Kit Interface Cables SM-MCH-71GT and SM-MCK-71GT have a pushbutton switch that only supportsthe PTT function. The Interface Cables SM-MCH-72GT, SM-MCK-72GT, and SM-MCH-73GT have a three-position rocker switch that supports both the PTT and CGDecode Disable functions.8.1.2 Headset Operation1. If the motorcycle is equipped with the SM-MCH-71GT or SM-MCK-71GT Motorcycle Interface cable, simply press and hold the PTT button (and talk into the noise-canceling mic) to transmit. Release the PTTbutton to receive. Adjust the volume switch on the control head for thedesired level.2. If the motorcycle is equipped with the SM-MCH-72GT, SM-MCH-73GT, or SM-MCK-72GT Motorcycle Interface cable, press and hold the three position toggle switch to the momentary (PTT) position (and talk into the noise-canceling mic) to transmit. Release the toggle switch to itscenter position to receive. In this center position, the user is in MONITOR mode because any programmed decoder has beendeactivated. To be in receive mode with any programmed decoders activated, press the toggle switch to the latched position. Adjust the volume control on the control head for the desired level.41

Interconnection Diagram (188D6783, Sh. 1, Rev. 3) 42

Interconnection Diagram (188D6783, Sh. 1, Rev. 3) 43

Remote Mount, Motorcycle Extended (19B802554P23, Sh. 23, Rev. 27) 44

Motorcycle Accessory Cable (19B802554P24, Sh. 24, Rev. 27) 45

Power Control Cable (19B802622P2, Sh. 1, Rev. 6) 46

Power Control Cable (19B802622P2, Sh. 2, Rev. 6) 47

Power Control Cable (19B802622P2, Sh. 3, Rev. 6) 48

Motorcycle Radio Case Assembly (188D6465, Rev.5, Part 1)49

Motorcycle Radio Case Assembly (188D6465, Rev.5, Part 2)50

51PARTS LISTS Option MAHG-CP7W: Scan Control Unit, KRY 101 1632/12 PART NUMBER DESCRIPTIONNP101411V1 NameplateKRY 101 1632/12 M7100IP Control Unit, Scan model Option MAHG-CP7X: System Control Unit, KRY 101 1632/14 PART NUMBER DESCRIPTIONNP101411V1 NameplateKRY 101 1632/14 M7100IP Control Unit, System model Option MAHG-ZN6R: Motorcycle Field Upgrade Kit (M7100IP Radio Conversion) PART NUMBER DESCRIPTION19A703965P2 Alternator Filter 19B802554P23 Control Cable 19B802554P24 Accessory Cable 19B802622P2 Power Cable 188D6464P1 Motorcycle Case (Black) 188D6437P1 Case/Antenna Bracket KT101533V4 Motorcycle Radio Mounting Bracket And Hardware Kit188D6438P1 Adapter Bracket (For Harley-Davidson Motorcycles) 350A1396G1 Hardware Kit For Motorcycle Case 350A1396G2 Hardware Kit For Case/Antenna Bracket 350A1396G3 Hardware Kit For Control Unit Mounting Bracket 350A1396G4 Hardware Kit For Adapter Bracket (For Harley-Davidson Motorcycles)

52Option MAHG-ZN6D: Motorcycle Accessories (Remote Mount) Option MAHG-ZN6E: Motorcycle Accessories (Remote Mount) w/o Motorcycle Accessory Cable PART NUMBER DESCRIPTION19B802671P1 Front Cover, Remote Radio 344A3723P11 Label, Power Set 350A1396G1 Motorcycle Case Hardware Kit 350A1396G2 Case/Antenna Mount Hardware Kit 350A1396G3 Control Unit Mounting Hardware Kit 350A1396G4 Case Adapter Mounting Hardware Kit 188D6437P1 Case/Antenna Bracket 188D6438P1 Case Adapter Bracket 188D6464P1 Radio Mount (Black) Case LS102824V1 Mobile Speaker, MIL STD, 4 ohm 19A703965P2 RF Interface Filter 19B802554P23 Remote Mount Motorcycle Extended Option Cable 19B802554P24 Motorcycle Accessory Cable (not included with Option MAHG-ZN6E)19B802622P2 Motorcycle Power Cable KT101533V14 Motorcycle Radio Mounting Bracket and Hardware Kit 19B235310P6 Nameplate; Blank NP101410V2 Nameplate, M7100IP Mobile

53Motorcycle Radio Mount Case and Hardware PART NO. DESCRIPTIONMotorcycle Radio Case – 188D6464P1188D6215P1 Case Top 188D6221P1 Case Bottom 19B804433P1 Hinge (top & bottom) 350A1341P1 Gasket19B804263P1 Catch Assembly EMKA 1048-U14 Lock Assembly (lock, tumbler, mounting nut, bolt and key) 19B804711P1 Lock Stop EMKA 1109-SU10 Key; unmolded EMKA 1108-U35 or 19B804717P2Key 19B804715P2 Friction Washer 19B804429P2 Hooked Cam SBA 123 030/0060 Cap screw (used to secure hinge) 19A149819P1 Thread Locker (Loctite® 425) 19A115204P1 Cam Lubricant (Lubriplate® 130A) 344A1396G1 Motorcycle Case Hardware Kit L14BP15014 Screw, Hex Head, Mach (Qty. 4) Control Unit/Microphone Mounting Bracket and Hardware Kit PART NO. DESCRIPTION188D6530P1 Control Unit Bracket (Qty. 1) 350A1408P1 Washer, Breakaway (Qty. 2) 19B802554P26 Plug, DB25 (Qty. 1) 19B802871P2 Cover, Microphone, Connector (Qty. 1) 19A115409P4 Washer, Lock (Qty. 2) N24P21010 Screw, Cap Hex head, SS (Qty. 2) N24P23014 Screw, Hex head HD, 5-16x7 - 8 (Qty. 2) Microphone Hanger Kit (188D6556G1) 4031458G2 SpringSBA123040/0080 Screw, Mach., SS 4031457G1 Bracket, Mounting with holes 19B804356P1 Bracket, Microphone Hanger

54Motorcycle Radio Case Adapter Bracket Mounting Kit PART NO. DESCRIPTION188D6438P1 Bracket, Case Adapter Case Adapter Bracket Mounting Hardware Kit 350A1396G4 19A134763P3 Mount, Rubber Motorcycle Case Hardware Kit 350A1396G1 PART NO. DESCRIPTIONN415P25 Washer, Lock (Qty. 4) N400P35 Washer, Flat (Qty. 4) SBA123030/0080 Screw, SS (Qty. 4) SBA123040/0120 Screw, Pan Head, Torx SS (Qty. 4) N415P11 Washer, Metal, Lock (Qty. 4) N415P16 Washer, Lock, SS (Qty. 4) L14BP15014 Screw, Hex Head, Mach (Qty. 4) Option MAHG-ZN6F: Hand Held Controller (without Siren) Option MAHG-ZN6G: Hand Held Controller (without Siren and no accessory cable) Option MAHG-ZN6H: Hand Held Controller (with Siren) Mounting Hardware Kit (Less Bracket) 350A1396G2 & G4 PART NO. DESCRIPTIONN400AP42 Washer, Metal, Lock (Qty. 4) N415P25 Washer, Metal, Lock (Qty. 4) N400P35 Washer, Metal, Lock (Qty. 3) SBA123030/0140 Screw, Mach, Torx, SS (Qty. 3) N279AP23B6 Nut, Serrated, 5/16” (Qty. 8) N400P41 Washer, Flat (Qty. 4) N24P21010 Screw, Cap, Hex Head, SS (Qty. 4) N24P23014 Screw, Hex Head, Mach, SS (Qty. 4) CA101619V1* Hand Held Controller Interface cable (without Siren Interface) CA101619V5** Hand Held Controller Interface cable (with Siren Interface) CU101239V1 Control Unit *Only for Options MAHG-ZN6F and MAHG-ZN6G. **Only for Option MAHG-ZN6H

55Motorcycle Radio Mounting Bracket (KT101533V4) PART NO. DESCRIPTIONPhoto not available. N402P9B17 Washer, Flat, 0.203ID/0.406OD, Black FM102906V1 Bracket, Motorcycle Radio Mount L14P14010B17 Screw, Hex, M5x10, Black L401P25B17 Washer, Lock, Split, M5, Black

569 WARRANTY A. M/A-COM, Inc. (hereinafter "Seller") warrants to the original purchaser for use (hereinafter "Buyer") that Equipment manufactured by or for the Seller shall be free from defects in material and workmanship, and shall conform to its published specifications. With respect to all non-M/A-COM Equipment, Seller gives no warranty, and only the warranty, if any, given by the manufacturer shall apply. Rechargeable batteries are excluded from this warranty but are warranted under a separate Rechargeable Battery Warranty (ECR-7048). B. Seller’s obligations set forth in Paragraph C below shall apply only to failures to meet the above warranties occurring within the following periods of time from date of sale to the Buyer and are conditioned on Buyer’s giving written notice to Seller within thirty (30) days of such occurrence: 1. for fuses and non-rechargeable batteries, operable on arrival only. 2. for parts and accessories (except as noted in B.1) sold by Seller’s Service Parts Operation, ninety (90) days. 3. for PANTHER¥ Series handportable and mobile radios, two (2) years. 4. for all other equipment of Seller’s manufacture, one (1) year. C. If any Equipment fails to meet the foregoing warranties, Seller shall correct the failure at its option (i) by repairing any defective or damaged part or parts thereof, (ii) by making available at Seller’s factory any necessary repaired or replacement parts, or (iii) by replacing the failed Equipment with equivalent new or refurbished Equipment. Any repaired or replacement part furnished hereunder shall be warranted for the remainder of the warranty period of the Equipment in which it is installed. Where such failure cannot be corrected by Seller’s reasonable efforts, the parties will negotiate an equitable adjustment in price. Labor to perform warranty service will be provided at no charge during the warranty period only for the Equipment covered under Paragraph B.3 and B.4. To be eligible for no-charge labor, service must be performed at a M/A-COM factory, by an Authorized Service Center (ASC) or other Servicer approved for these purposes either at its place of business during normal business hours, for mobile or personal equipment, or at the Buyer’s location, for fixed location equipment. Service on fixed location equipment more than thirty (30) miles from the Service Center or other approved Servicer’s place of business will include a charge for transportation.D. Seller’s obligations under Paragraph C shall not apply to any Equipment, or part thereof, which (i) has been modified or otherwise altered other than pursuant to Seller’s written instructions or written approval or, (ii) is normally consumed in operation or, (iii) has a normal life inherently shorter than the warranty periods specified in Paragraph B, or (iv) is not properly stored, installed, used, maintained or repaired, or, (v) has been subjected to any other kind of misuse or detrimental exposure, or has been involved in an accident. E. The preceding paragraphs set forth the exclusive remedies for claims based upon defects in or nonconformity of the Equipment, whether the claim is in contract, warranty, tort (including negligence), strict liability or otherwise, and however instituted. Upon the expiration of the warranty period, all such liability shall terminate. The foregoing warranties are exclusive and in lieu of all other warranties, whether oral, written, expressed, implied or statutory. NO IMPLIED OR STATUTORY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE SHALL APPLY. IN NO EVENT SHALL THE SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, SPECIAL, INDIRECT OR EXEMPLARY DAMAGES.This warranty applies only within the United States. M/A-COM, Inc. M/A-COM, Inc. 1011 Pawtucket Blvd. 221 Jefferson Ridge Parkway Lowell, MA 01853 Lynchburg, VA 24501 1-877-OPENSKY 1-800-528-7711 ECR-7047C

57NOTES

58NOTES

59NOTES

M/A-COM Wireless Systems 221 Jefferson Ridge Parkway Lynchburg, Virginia 24501 (Outside USA, 434-385-2400) Toll Free 800-528-7711 www.macom-wireless.com Printed in U.S.A.

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