Motorola Solutions 92FT4915 Mobile 2-Way Radio User Manual Installation Manual 1 of 2

Motorola Solutions, Inc. Mobile 2-Way Radio Installation Manual 1 of 2

Installation Manual 1 of 2

APX™ TWO-WAY RADIOSAPX MOBILES O2, O3, O5, O7 & O9 CONTROL HEADINSTALLATION MANUAL
iForewordThis manual covers the O2, O3, O5, O7 and O9 models of the ASTRO® APX™ mobile radios. It includes all the information necessary to install mid power and high power radios, and configure radio installation inside vehicles.For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A list of related publications is provided in the section “Related Publications,” on page vi.RF Energy Exposure and Product Safety Guide for Mobile Two-way RadiosSee “Installation Requirements for Compliance with Radio Frequency (RF) Energy Exposure Safety Standards,” on page ii.Manual RevisionsChanges 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 OrderingSee Appendix A: Replacement Parts Ordering for information on how to obtain replacement parts. For part numbers, refer to the ASTRO APX Mobile Radio Basic Service Manual (Motorola publication part number 6875964M01).Computer Software CopyrightsThe 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 CopyrightsNo 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.DisclaimerThe 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.TrademarksMOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective owners.© 2009 – 2012 by Motorola Solutions, Inc.All rights reserved.
iiInstallation Requirements for Compliance withRadio Frequency (RF) Energy Exposure Safety StandardsATTENTION!This radio is intended for use in occupational/controlled conditions, where users have full knowledge of their exposure and can exercise control over their exposure to meet FCC limits. This radio device is NOT authorized for general population, consumer, or any other use.To ensure compliance to RF Energy Safety Standards:• Install only Motorola approved antennas and accessories• Be sure that antenna installation is per “Antenna Installation,” on page 2-38 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, read the guide enclosed with your radio which contains important operating instructions for safe usage and RF energy awareness and control for compliance with applicable standards and regulations.For a list of Motorola-approved antennas and other accessories, visit the following web site which lists approved accessories for your radio model: http://www.motorolasolutions.com.
Table of Contents iii6878215A01Table of ContentsForeword..........................................................................................................iRF Energy Exposure and Product Safety Guide for Mobile Two-way Radios..............................................iManual Revisions .........................................................................................................................................iParts Ordering ..............................................................................................................................................iComputer Software Copyrights ....................................................................................................................iDocument Copyrights ...................................................................................................................................iDisclaimer.....................................................................................................................................................iTrademarks ..................................................................................................................................................iInstallation Requirements for Compliance withRadio Frequency (RF) Energy Exposure Safety Standards.......................iiMobile Radio Model Numbering Scheme..................................................xiiiCommercial Warranty ..................................................................................xvLimited Warranty .......................................................................................................................................xvMOTOROLA COMMUNICATION PRODUCTS...............................................................................xvI. What This Warranty Covers And For How Long ....................................................................xvII. General Provisions ................................................................................................................xvIII. State Law Rights ................................................................................................................. xviIV. How To Get Warranty Service ............................................................................................ xviV. What This Warranty Does Not Cover................................................................................... xviVI. Patent And Software Provisions ........................................................................................ xviiVII. Governing Law.................................................................................................................. xviiChapter 1 Introduction ......................................................................... 1-11.1 Mobile Radio Description............................................................................................................... 1-11.1.1 Dimensions ....................................................................................................................... 1-11.2 Standard Configurations ................................................................................................................ 1-51.2.1 Dash Mount Configuration ................................................................................................ 1-51.2.2 Remote Mount Configuration............................................................................................ 1-71.2.3 Multi Control Head .......................................................................................................... 1-131.3 Motorcycle Configurations ........................................................................................................... 1-141.4 Base/Control Stations .................................................................................................................. 1-141.5 Tools Required for APX Mobile Installations ............................................................................... 1-14Chapter 2 Standard Configurations.................................................... 2-12.1 Planning the Installation................................................................................................................. 2-12.1.3 Radio Operation Wiring for Dash and Remote Configurations ....................................... 2-142.1.3.1 Dash Mount: Power, Ignition, and Emergency Cable Installation.......................... 2-142.1.3.2 Remote Mount: Power, Ignition, and Emergency Cable Installation...................... 2-152.1.4 Ignition Sense Switch (Radio Wide Advance) ................................................................ 2-172.1.5 Siren/PA Configuration/Programming............................................................................. 2-18
iv Table of Contents6878215A012.2 Radio Mounting ........................................................................................................................... 2-192.2.2 Remote Mount with Trunnion.......................................................................................... 2-232.2.2.1 100W Radios Only................................................................................................. 2-242.2.2.2 Remote Mount Control Head Installation............................................................... 2-242.2.2.3 Multiple Control Head Installation.......................................................................... 2-272.2.2.4 Cable Installation ................................................................................................... 2-292.2.2.5 Setting the Initial Control Head ID ......................................................................... 2-292.2.2.6 O3 Control Head and Remote Mount Cabling....................................................... 2-302.2.3 Locking Kit (Optional) .....................................................................................................2-322.2.3.1 All Radios Except 100W ........................................................................................ 2-322.2.3.2 100W Radios ......................................................................................................... 2-322.3 Power Cables (Transceiver and Control Head) ........................................................................... 2-332.3.1 Optional Locking Feature for High Power Chassis Power Cables.................................. 2-332.3.2 O2, O5, O7 or O9 Control Head Power Cables.............................................................. 2-362.3.3 Battery Selector Switch................................................................................................... 2-372.4 Antenna Installation ..................................................................................................................... 2-382.4.1 Selecting an Antenna Site/Location on a Metal Body Vehicle ........................................ 2-382.4.2 Mini-UHF Connection ..................................................................................................... 2-402.4.3 GPS Antenna Placement................................................................................................ 2-422.4.4 GPS Connection .............................................................................................................2-422.5 Speaker ....................................................................................................................................... 2-432.5.1 Internal Speaker Disassembly ........................................................................................ 2-442.6 Microphone Hang-Up Clip ........................................................................................................... 2-462.6.1 Standard or O3 Control Head Hang-Up Clip .................................................................. 2-462.7 RFID (Option) .............................................................................................................................. 2-462.7.1 RFID Reading ................................................................................................................. 2-482.7.2 Programming RFID (If Equipped) ................................................................................... 2-512.8 Completing the Installation .......................................................................................................... 2-52Chapter 3 Universal Relay Controller Installation ............................. 3-13.1 Universal Relay Controller Mounting ............................................................................................. 3-13.2 O7/O9 Universal Relay Controller Cable Assembly ...................................................................... 3-33.2.1 Power Cable ..................................................................................................................... 3-33.2.2 Ground Cable ................................................................................................................... 3-33.2.3 Wires ................................................................................................................................ 3-43.2.4 O7/O9 to URC Cable........................................................................................................ 3-5Chapter 4 Options and Accessories Installation ............................... 4-14.1 Dash-Mount Accessory Installation ............................................................................................... 4-14.1.1 Dash-Mount Emergency Pushbutton or Footswitch Installation ....................................... 4-14.1.2 Dash-Mount Horn and Lights (External Alarms) Relays ................................................... 4-24.2 Remote-Mount Accessory Installation ........................................................................................... 4-24.2.1 Emergency Pushbutton or Footswitch Installation............................................................ 4-34.2.2 Horn (External Alarm) Relay Installation........................................................................... 4-44.2.3 Lights (External Alarm) Relay Installation......................................................................... 4-44.2.4 Gunlock Installation .......................................................................................................... 4-44.2.5 Horn-Ring Transfer ........................................................................................................... 4-54.2.6 Record Audio Out Jack of Transmit and Receive Audio................................................... 4-54.2.7 Earphone Jack.................................................................................................................. 4-54.2.8 USB Data Cables.............................................................................................................. 4-64.2.9 RS232 Cables .................................................................................................................. 4-6
Table of Contents v6878215A014.3 Vehicle Interface Port Overview .................................................................................................... 4-64.3.1 VIP Output Connections ................................................................................................... 4-74.3.2 VIP Input Connections ......................................................................................................4-84.4 Compatibility of Emergency when Attaching a Siren ..................................................................... 4-94.5 Accessory Connector Assembly Details (P2) (All Models Except 100W).................................... 4-104.5.1 Disassembly and Assembly ............................................................................................ 4-104.5.1.1 Disassembly .......................................................................................................... 4-104.5.1.2 Assembly ............................................................................................................... 4-114.5.2 Adapter Cable................................................................................................................. 4-124.6 Memory and Three-Day Secure Key Retention Option ............................................................... 4-12Chapter 5 Motorcycle Radio Installation ............................................ 5-15.1 Motorcycle Radio Description ........................................................................................................ 5-15.1.1 Transceiver Enclosure ......................................................................................................5-15.1.2 Control/Display Unit .......................................................................................................... 5-15.1.3 Control Head Cable .......................................................................................................... 5-25.1.4 Microphone ....................................................................................................................... 5-25.1.5 Keypad Mic ....................................................................................................................... 5-25.1.6 External Speaker .............................................................................................................. 5-25.1.7 Headset Capability............................................................................................................ 5-25.1.8 Antenna ............................................................................................................................ 5-25.1.9 Ignition Sense (ACC) Wire................................................................................................ 5-25.2 Installation Overview...................................................................................................................... 5-35.2.1 General ............................................................................................................................. 5-35.2.2 Important Installation Hints ...............................................................................................5-45.2.3 Parts Identification ............................................................................................................ 5-55.2.4 Order of Installation .......................................................................................................... 5-55.3 Installing the Universal Mounting Plate.......................................................................................... 5-65.4 Installing the Speaker and Control Head ....................................................................................... 5-75.4.1 Handlebar Installation with Speaker and Control Head Mounted Together...................... 5-85.4.2 Fuel Tank Console Installation with Speaker and Control Head Mounted Together ........ 5-95.4.3 Handlebar Installation with Speaker and Control Head Mounted Separately ................. 5-115.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted Separately ... 5-125.5 Installing the Speaker .................................................................................................................. 5-145.6 Installing the Microphone Hang-Up Clip ...................................................................................... 5-145.6.1 Extension Bracket Mounting ........................................................................................... 5-145.6.2 Speaker/Control Head Bracket Side Mounting ............................................................... 5-145.6.3 Other Hang-Up Clip Mounting ........................................................................................ 5-155.7 Installing Antenna Base and Cables............................................................................................ 5-155.8 Installing the Antenna .................................................................................................................. 5-185.9 Cable Routing .............................................................................................................................. 5-185.10 Installing the Weather-Resistant Enclosure................................................................................. 5-215.11 Transceiver and Cabling Installation............................................................................................ 5-225.11.1 Installing Cabling in the Enclosure.................................................................................. 5-225.11.2 Installing the Transceiver................................................................................................5-235.12 Installing the Emergency Switch Option ......................................................................................5-255.13 Installing the External Alarm Relay Option ..................................................................................5-255.14 Installing the Headset Accessory................................................................................................. 5-255.15 Installing the O5 Control Head Sunshield....................................................................................5-265.16 Horn/Lights Wiring ....................................................................................................................... 5-285.17 Emergency Switch Wiring............................................................................................................ 5-28
vi Table of Contents6878215A01Chapter 6 Finishing the Installation.................................................... 6-16.1 Cable Connection .......................................................................................................................... 6-16.1.1 O2 Control Head............................................................................................................... 6-16.1.2 O3 Control Head............................................................................................................... 6-16.1.3 O5 Control Head............................................................................................................... 6-16.1.4 O7 Control Head............................................................................................................... 6-26.1.5 O9 Control Head............................................................................................................... 6-26.2 Dust Cover Installation .................................................................................................................. 6-36.3 Miscellaneous Information ............................................................................................................. 6-4Chapter 7 Best Practices: Installation & Troubleshooting ............... 7-17.1 Check Wiring of Ignition and Radio Ignition Sensing..................................................................... 7-17.2 Check Physical Installation of Radio Ground and Radio Accessory Wiring .................................. 7-27.3 Improve the Electrical Quality of the Power and Ignition Lines ..................................................... 7-27.4 Minimize the Effect of Poorly Grounded Antennas........................................................................ 7-37.5 Jump-Start the Vehicle .................................................................................................................. 7-37.6 Eliminate Noise/Howling from PA Speaker ................................................................................... 7-3Appendix A Replacement Parts Ordering..............................................A-1A.1 Basic Ordering Information............................................................................................................ A-1A.2 Motorola Online ............................................................................................................................. A-1A.3 Mail Orders .................................................................................................................................... A-1A.5 Fax Orders..................................................................................................................................... A-2A.6 Parts Identification ......................................................................................................................... A-2A.7 Product Customer Service............................................................................................................. A-2A.8 Asia Pacific Service Centers ......................................................................................................... A-2Index.....................................................................................................Index-1Glossary.........................................................................................Glossary-1Related PublicationsASTRO APX Mobile Radio O2 Control Head User Guide..........................................................68012006035ASTRO APX Mobile Radio O3 Control Head User Guide ..........................................................6875946M01ASTRO APX Mobile Radio O5 Control Head User Guide ..........................................................6875947M01ASTRO APX Mobile Radio O7 Control Head User Guide..........................................................68012006034ASTRO APX Mobile Radio O9 Control Head User Guide .........................................................68007024014ASTRO APX Mobile Radio Basic Service Manual .....................................................................6875964M01ASTRO APX Mobile Radio Detailed Service Manual .................................................................6875963M01
List of Figures vii6878215A01List of FiguresFigure 1-1. Front View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion ....................... 1-1Figure 1-2. Side View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion......................... 1-1Figure 1-3. Front View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion .............. 1-1Figure 1-4. Side View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion................ 1-1Figure 1-5. Front View of APX 7500 High Power (100W) Transceiver and Trunnion ............................. 1-2Figure 1-6. Side View of APX 7500 High Power (100W) Transceiver and Trunnion............................... 1-2Figure 1-7. Front View of O2 Control Head Attached to APX 7500 Mid Power Dash Mount Transceiver and Trunnion ..................................................................................................... 1-2Figure 1-8. Side View of O2 Control Head Attached to APX7500 Mid Power Dash Mount Transceiver and Trunnion ......................................................................................................................... 1-2Figure 1-9. Front View of O7 Control Head Attached to APX 2500 Mid Power Dash Mount Transceiver and Trunnion ..................................................................................................... 1-2Figure 1-10. Side View of O7 Control Head Attached to APX 2500 Mid Power Dash Mount Transceiver and Trunnion ......................................................................................................................... 1-2Figure 1-11. Front View of O3 Control Head with Coiled Cable................................................................ 1-3Figure 1-12. Side View of O3 Control Head with Coiled Cable ................................................................. 1-3Figure 1-13. Front View of O2 Control Head with Remote Mount and Trunnion....................................... 1-3Figure 1-14. Side View of O2 Control Head with Remote Mount and Trunnion........................................ 1-3Figure 1-15. Front View of O5 Control Head with Remote Mount and Trunnion....................................... 1-3Figure 1-16. Side View of O5 Control Head with Remote Mount and Trunnion........................................ 1-3Figure 1-17. Front View of O7 Control Head with Remote Mount and Trunnion....................................... 1-4Figure 1-18. Side View of O7 Control Head with Remote Mount and Trunnion........................................ 1-4Figure 1-19. Front View of O9 Control Head with Trunnion ...................................................................... 1-4Figure 1-20. Side View of O9 Control Head with Trunnion........................................................................ 1-4Figure 1-21. Top View of O9 Universal Relay Controller with Trunnion(URC is an orderable accessory.) ......................................................................................... 1-4Figure 1-22. Side View of O9 Universal Relay Controller with Trunnion(URC is an orderable accessory.) ......................................................................................... 1-4Figure 1-23. Dash Mount Configuration for O2 Control Head ................................................................... 1-5Figure 1-24. Dash Mount Configuration for O3 Control Head ................................................................... 1-5Figure 1-25. Dash Mount Configuration for O5 Control Head (Only Applicable for ASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li Mobile) ................... 1-6Figure 1-26. Dash Mount Configuration for O7 Control Head ................................................................... 1-6Figure 1-27. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O2 Control Head......................................................................... 1-7Figure 1-28. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board and O3 Control Head ............................................................................................................ 1-7Figure 1-29. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O5 Control Head......................................................................... 1-8Figure 1-30. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O7 Control Head......................................................................... 1-8Figure 1-31. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board and O9 Control Head ............................................................................................................ 1-8Figure 1-32. Remote Mount Configuration with High Power (100W) Radio Transceiver and O2 Control Head ................................................................................................................... 1-9Figure 1-33. Remote Mount Configuration with High Power (100W) Radio Transceiver and O3 Control Head ................................................................................................................... 1-9Figure 1-34. Remote Mount Configuration with High Power (100W) Radio Transceiver and O5 Control Head ................................................................................................................... 1-9
viii List of Figures6878215A01Figure 1-35. Remote Mount Configuration with High Power (100W) Radio Transceiver and O7 Control Head.................................................................................................................1-10Figure 1-36. Remote Mount Configuration with High Power (100W) Radio Transceiver and O9 Control Head.................................................................................................................1-10Figure 1-37. Remote Mount Configuration with Mid Power Radio Transceiver, Universal Relay Controller and O7 Control Head (URC is optional.)...................................1-11Figure 1-38. Remote Mount Configuration with Mid Power Radio Transceiver, Universal Relay Controller and O9 Control Head (URC is optional.)...................................1-11Figure 1-39. Remote Mount Configuration with High Power (100W) Radio Transceiver,Universal Relay Controller and O7 Control Head (URC is optional.).................................. 1-12Figure 1-40. Remote Mount Configuration with High Power (100W) Radio Transceiver,Universal Relay Controller and O9 Control Head (URC is optional.).................................. 1-12Figure 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) ............... 2-2Figure 2-2. Remote Mount Radio Control Heads Can Be Located in the MiddleConsole, on the Transmission Hump, or Under the Dash .................................................... 2-2Figure 2-3. Remote Mount of the Radio, O9 Control Headand Universal Relay Controller (URC is optional.)................................................................ 2-2Figure 2-4. Radio Installation (O2 Mid Power Dash Mount).................................................................... 2-3Figure 2-5. Radio Installation (O3 Mid Power Dash Mount).................................................................... 2-3Figure 2-6. Radio Installation (O5 Mid Power Dash Mount).................................................................... 2-4Figure 2-7. Radio Installation (O7 Mid Power Dash Mount).................................................................... 2-4Figure 2-8. Radio Installation (O2 Mid Power Remote Mount) ............................................................... 2-5Figure 2-9. Radio Installation (O3 Mid Power Remote Mount) ............................................................... 2-6Figure 2-10. Radio Installation (O5 Mid Power Remote Mount) ............................................................... 2-6Figure 2-11. Radio Installation (O7 Mid Power Remote Mount) ............................................................... 2-7Figure 2-12. Radio Installation (O2 High Power Remote Mount).............................................................. 2-7Figure 2-13. Radio Installation (O3 High Power Remote Mount).............................................................. 2-8Figure 2-14. Radio Installation (O5 High Power Remote Mount).............................................................. 2-8Figure 2-15. Radio Installation (O7 High Power Remote Mount).............................................................. 2-9Figure 2-16. Radio Installation of O9 Remote Mount with Transceiver (URC is optional.) ....................... 2-9Figure 2-17. Radio Installation (O9 Remote Mount with Pinouts) ........................................................... 2-10Figure 2-18. Remote Control Head Pinouts ............................................................................................ 2-10Figure 2-19. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios) ..........2-11Figure 2-20. Cabling Interconnect Diagram for Remote Mount .............................................................. 2-12Figure 2-21. Cabling Interconnect Diagram for 09 Remote Mount (URC is optional.) ............................ 2-13Figure 2-22. APX 7500/ APX6500/ APX5500/ APX6500Li Mid Power Trunnion Orientation (Cannot Be Used for 100W Radios) ................................................................................... 2-19Figure 2-23. APX 2500/APX4500 Mid Power Trunnion Orientation (Cannot Be Used for 100W Radios)................................................................. 2-20Figure 2-24. Trunnion Orientation for 100W Radios ............................................................................... 2-20Figure 2-25. Transmission Hump Trunnion Mounting ............................................................................. 2-22Figure 2-26. Below Dash Trunnion Mounting.......................................................................................... 2-22Figure 2-27. 100W Radio Mounting into Quick Release Trunnion .......................................................... 2-24Figure 2-28. O5 Control Head Installation Exploded View (Also applicable for O2 and O7 Control Heads) ................................................................. 2-25Figure 2-29. O9 Control Head Installation Exploded View...................................................................... 2-26Figure 2-30. O5 Control Head Rear View (Also applicable for O2 and O7 Control Heads).................... 2-26Figure 2-31. O9 Control Head Rear View ............................................................................................... 2-27Figure 2-32. Multiple Control Heads Example Configurations ................................................................ 2-28Figure 2-33. APX Mobile O5 Control Head Front View........................................................................... 2-29Figure 2-34. Radio Display with Current Control Head ID ...................................................................... 2-29Figure 2-35. APX Mobile O5 Control Head Front View – Mode Knob .................................................... 2-30Figure 2-36. O3 Control Head................................................................................................................. 2-30
List of Figures ix6878215A01Figure 2-37. O3 Control Head Rear View ............................................................................................... 2-31Figure 2-38. Hang-Up Clip Installation Exploded View ........................................................................... 2-31Figure 2-39. Locking Kit (Optional) (Cannot Be Used for 100W Radios) ................................................ 2-32Figure 2-40. Lock Supplied with 100W Quick Release Trunnion ............................................................ 2-32Figure 2-41. Bracket Installation.............................................................................................................. 2-33Figure 2-42. Bracket Installation.............................................................................................................. 2-34Figure 2-43. Bracket Installation (Assembled State) ............................................................................... 2-34Figure 2-44. Bracket Uninstallation ......................................................................................................... 2-35Figure 2-45. Bracket Uninstallation ......................................................................................................... 2-35Figure 2-46. HKN6188_ Power Cable with External Speaker Connector ............................................... 2-36Figure 2-47. HKN6187_ Power Cable with External Speaker Connector, Record Audio Output Jack (2.5 mm) and Earphone Jack (2.5 mm) .............................................................................. 2-36Figure 2-48. Battery Selector Switch....................................................................................................... 2-37Figure 2-49. Multiple Antennas Separation ............................................................................................. 2-39Figure 2-50. Mini-UHF Connection (As Shown on Mid Power) ............................................................... 2-40Figure 2-51. Mini-UHF Connection (100W Radios Only) ........................................................................ 2-40Figure 2-52. Mini-UHF Connector Tool (As Shown on Mid Power) ......................................................... 2-41Figure 2-53. Mini-UHF Connector Tool (100W Radios Only) .................................................................. 2-41Figure 2-54. GPS Antenna Connector on the Back of the Mid Power Radio.......................................... 2-42Figure 2-55. GPS Antenna Connector on the Front of the 100W Radio ................................................. 2-42Figure 2-56. Speaker Mounting ............................................................................................................... 2-43Figure 2-57. Removing the screws on the Control Head ........................................................................ 2-44Figure 2-58. Removing the Control Head................................................................................................ 2-44Figure 2-59. Disconnecting the Speaker Connector ............................................................................... 2-45Figure 2-60. Reattaching the Control Head............................................................................................. 2-45Figure 2-61. RFID Location on Mid Power Radio....................................................................................2-46Figure 2-62. RFID Location on APX 2500/APX 4500 Mid Power Radio ................................................. 2-46Figure 2-63. RFID Location on High Power Radio .................................................................................. 2-47Figure 2-64. Read Angle for Mid Power Radio........................................................................................ 2-48Figure 2-65. Tag Angle for Mid Power Radio .......................................................................................... 2-48Figure 2-66. Read Angle for APX 2500/APX 4500 Mid Power Radio ..................................................... 2-49Figure 2-67. Tag Angle for APX 2500/APX 4500 Mid Power Radio ........................................................ 2-49Figure 2-68. Read Angle for High Power Radio...................................................................................... 2-49Figure 2-69. Tag Angle for High Power Radio......................................................................................... 2-50Figure 2-70. Examples of Reader and Tag Aligned (Reader Orientation)............................................... 2-50Figure 2-71. Example of Reader and Tag Misaligned (Reader Orientation) ........................................... 2-50Figure 3-1. Universal Relay Controller Orientation.................................................................................. 3-1Figure 3-2. Universal Relay Controller Installation Exploded View ......................................................... 3-2Figure 3-3. Power and Ground Cable Glands ......................................................................................... 3-3Figure 3-4. Cable Gland Assembly with Gasket...................................................................................... 3-4Figure 3-5. Wires Installation................................................................................................................... 3-4Figure 3-6. Wire Installation with Black Stick........................................................................................... 3-5Figure 3-7. O7/O9 to URC Cable Installation .......................................................................................... 3-5Figure 4-1. Emergency Switch Wiring Diagram ......................................................................................4-1Figure 4-2. Horn/Light Wiring Diagram.................................................................................................... 4-2Figure 4-3. Emergency Jumper Removal in Remote Mount ................................................................... 4-3Figure 4-4. Gunlock Switch Redundancy Diagram ................................................................................. 4-4Figure 4-5. Siren/PA Horn-Ring Connections.......................................................................................... 4-5Figure 4-6. Remote Control Head Pinouts .............................................................................................. 4-6Figure 4-7. HKN6196_ VIP Connector Detail.......................................................................................... 4-6Figure 4-8. Relay Coil.............................................................................................................................. 4-7Figure 4-9. Field adjustment for Emergency Operation with Siren Accessory ........................................ 4-9Figure 4-10. Location for Pin 8 .................................................................................................................. 4-9Figure 4-11. Exploded View of Accessory Connector Assembly (HLN6863_)........................................ 4-11
xList of Figures6878215A01Figure 4-12. Rear Accessory Connector Audio Configuration ................................................................ 4-12Figure 4-13. Rear Accessory Connector Data Configuration.................................................................. 4-12Figure 5-1. Identification of a Motorcycle Radio by Using a Label .......................................................... 5-1Figure 5-2. Universal Mounting Plate Installation (Part of Radio Enclosure Kit) ..................................... 5-6Figure 5-3. Motorcycle Control Head Cabling (3075217A01) ................................................................. 5-7Figure 5-4. Handlebar Installation with Speaker and Control Head Mounted Together .......................... 5-8Figure 5-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Together ........... 5-10Figure 5-6. Handlebar Installation with Speaker and Control Head Mounted Separately ..................... 5-12Figure 5-7. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately........ 5-13Figure 5-8. Location of Band 1 or Band 2 (Depending on the Antenna Port They Align to) ................. 5-15Figure 5-9. Antenna Band Identification................................................................................................ 5-16Figure 5-10. APX 2500/APX 4500 Antenna Band Identification ............................................................. 5-16Figure 5-11. Routing the Coaxial Cable for GPS .................................................................................... 5-17Figure 5-12. Routing the Coaxial Cable for Band 1 ................................................................................5-17Figure 5-13. Routing the Coaxial Cable for Band 2 ................................................................................5-18Figure 5-14. Cable Routing ..................................................................................................................... 5-19Figure 5-15. Weather-Resistant Enclosure Installation........................................................................... 5-21Figure 5-16. Installing Cables ................................................................................................................. 5-23Figure 5-17. Installing the Transceiver.................................................................................................... 5-24Figure 5-18. Motorcycle Wiring Harness Rework....................................................................................5-25Figure 5-19. Remote Mount Trunnion with Sunshield............................................................................. 5-26Figure 5-20. Position the Sunshield ........................................................................................................ 5-26Figure 5-21. Slide the Control Head onto Trunnion ................................................................................5-27Figure 5-22. Position Control Head as Desired....................................................................................... 5-27Figure 5-23. Horn/Lights Wiring Diagram................................................................................................ 5-28Figure 5-24. Emergency Switch Wiring Diagram .................................................................................... 5-28Figure 6-1. Dust Cover Installation Locations ......................................................................................... 6-3
List of Tables xi6878215A01List of TablesTable 2-1. Dash O2, O5 or O7 Radio Operations Dependent Upon A+ and Ignition Connections. 2-16Table 2-2. Remote O2, O5, O7, or O9 Radio Operations Dependent Upon A+ and Ignition Connections ...................................................................................................... 2-16Table 2-3. Remote O2, O5, O7 or O9 Radio Operations Dependent Upon A+ and Ignition Connections ...................................................................................................... 2-16Table 2-4. Ignition Sense Switch Settings in CPS .......................................................................... 2-17Table 2-5. Power Level Configurations........................................................................................... 2-18Table 2-6. Mid Power Trunnion Kit.................................................................................................. 2-21Table 2-7. Available CAN Cables.................................................................................................... 2-28Table 2-8. Ignition Interface Cables ................................................................................................ 2-29Table 2-9. Power Cables................................................................................................................. 2-33Table 2-10. Model Number Chart in 12-Digit ASCII Format.............................................................. 2-51Table 2-11. Serial Number with Radio Band/Tier/Power .................................................................. 2-51Table 4-1. VIP Output Connections .................................................................................................. 4-7Table 4-2. VIP Input Connections ..................................................................................................... 4-8Table 5-1. Transceiver Installation Parts List .................................................................................. 5-24
xii List of Tables6878215A01Notes
6878215A01Mobile Radio Model Numbering Scheme xiiiMobile Radio Model Numbering SchemePosition 1 - Type of UnitM = Mobile L = Table Top StationPositions 2 & 3 - Model SeriesPosition 4 - Frequency BandLess than 29.7MHz29.7 to 35.99MHz36 to 41MHz42 to 50MHz300 to 345MHz66 to 80MHz74 to 90MHzProduct Specific VHF Range136 to 162MHz146 to 178MHz174 to 210MHz190 to 235MHz330 to 370MHz366 to 410MHz403 to 437MHz438 to 482MHz470 to 620MHzProduct Specific UHF Range806 to 870MHz*825 to 870MHz896 to 941MHz403-470MHz1.0 to 1.6GHz1.5 to 2.0GHzPosition 5 - Power Level0 to 0.7 Watts0.7 to 0.9 Watts1.0 to 3.9 Watts4.0 to 5.0 Watts5.1 to 6.0 Watts6.1 to 10 Watts10.1 to 15 Watts16 to 25 Watts26 to 35 WattsPosition 6 - Physical PackagesRF Modem OperationReceiver OnlyStandard Control; No DisplayStandard Control; With DisplayLimited Keypad; No DisplayLimited Keypad; With DisplayFull Keypad; No DisplayFull Keypad; With DisplayLimited Controls; No DisplayLimited Controls; Basic DisplayLimited Controls; Limited DisplayRotary Controls; Standard DisplayEnhanced Controls; Enhanced DisplayLow Profile; No DisplayLow Profile; Basic DisplayLow Profile; Basic Display, Full KeypadTranceiver with Selectable Control HeadVDV Control HeadControl Head #2Position 7 - Channel Spacing0 =1 = 5KHz2 = 6.25KHz3 = 10KHz4 = 12.5KHz5 = 15KHz6 = 20/25KHz7 = 30KHz8 = 12.5/25KHz9 = Variable/ProgrammableTypical Model Number:Position:Position 8 - Primary OperationConventional/SimplexConventional/DuplexTrunked Twin TypeDual Mode TrunkedDual Mode Trunked/DuplexTrunked Type ITrunked Type IIFDMA* Digital Dual ModeTDMA** Digital Dual ModeSingle SidebandGlobal Positioning Satellite CapableAmplitude Companded Sideband (ACSB)Digital DispatchProgrammableDigital InterconnectDigital Multi-Service9600 CapableTDMA* FDMA = Frequency Division Multiple Access** TDMA = Time Division Multiple AccessPosition 9 - Primary System TypeConventionalPrivacy PlusClear SMARTNETAdvanced Conventional Stat-AlertEnhanced Privacy PlusNauganet 888 SeriesJapan Specialized Mobile Radio (JSMR)Multi-Channel Access (MCA)CoveragePLUSMPT1327* - PublicMPT1327* - PrivateRadiocomTone SignallingBinary SignallingPhonenetIDEN BasicIDEN Advanced FeatureJSMR DigitalLTR ProtocolSingle SidebandProgrammableSecure ConventionalSecure SMARTNETTETRASmartZone* MPT = Ministry of Posts and TelecommunicationsPosition 10 - Feature Level1 = Basic2 = Limited Package3 = Limited Plus4 = Intermediate5 = Standard Package6 = Standard Plus7 = Expanded Package8 = Expanded Plus9 = Full Feature/ ProgrammablePosition 11 - VersionVersion Letter (Alpha) - Major ChangePosition 12 - Unique Model VariationsC = CenelecN = Standard PackagePositions 13 - 16SP Model Suffix1 23 4 5 6 7 8 9 10 11 1213 141516M30 U R S 9 P W 1 A N S P 0 130 = APX 7500 24 = APX 250025 = APX 6500 22 = APX 4500ABCDEFGHJKLM============NPQRSTUVWXYZ============A BCDEFGHJ=========36 to 60 Watts61 to 110 WattsUp to 125 Watts1 to 25 Watts25 to 40 Watts25 to 45 Watts10 to 35 Watts10 to 50 Watts25 to 110 WattsK LMNPQRST=========A BCDEFGHJKLMNPQRSTUVW=====================A BCDEFGHJKLMNPQRST==================A BCDEFGHJKLMNPQRSTUVWXYZ2=========================MAEPF-27634-B* For APX 7500 "K" in Position 4 represents 136-174MHz.* For APX 7500 "Q" in Position 4 represents 380-470MHz.* For APX 7500 "S" in Position 4 represent 470-520MHz.* For APX 7500 "U" in Position 4 represent 762-870MHz.Note: Values represented are not absolute, and are given to indicate range only.Note: Values represented are not absolute, and are given to indicate range only.
6878215A01Notesxiv Mobile Radio Model Numbering Scheme
6878215A01Commercial Warranty xvCommercial WarrantyLimited WarrantyMOTOROLA COMMUNICATION PRODUCTSI. What This Warranty Covers And For How LongMOTOROLA SOLUTIONS INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication Products listed below (“Product”) against defects in material and workmanship under normal use and service for a period of time from the date of purchase as scheduled below:Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period. All replaced parts of Product shall become the property of MOTOROLA.This express limited warranty is extended by MOTOROLA to the original end user purchaser only and is not assignable or transferable to any other party. This is the complete warranty for the Product manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or modifications to this warranty unless made in writing and signed by an officer of MOTOROLA. Unless made in a separate agreement between MOTOROLA and the original end user purchaser, MOTOROLA does not warrant the installation, maintenance or service of the Product.MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by MOTOROLA which is attached to or used in connection with the Product, or for operation of the Product with any ancillary equipment, and all such equipment is expressly excluded from this warranty. Because each system which may use the Product is unique, MOTOROLA disclaims liability for range, coverage, or operation of the system as a whole under this warranty.II. General ProvisionsThis warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product. Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW.ASTRO APX Mobile Radio One (1) YearProduct Accessories One (1) Year
6878215A01xvi Commercial Warranty III. State Law RightsSOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.This warranty gives specific legal rights, and there may be other rights which may vary from state to state.IV. How To Get Warranty ServiceYou must provide proof of purchase (bearing the date of purchase and Product item serial number) in order to receive warranty service and, also, deliver or send the Product item, transportation and insurance prepaid, to an authorized warranty service location. Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.V. What This Warranty Does Not CoverA. Defects or damage resulting from use of the Product in other than its normal and customary manner.B. Defects or damage from misuse, accident, water, or neglect.C. Defects or damage from improper testing, operation, maintenance, installation, alteration, modification, or adjustment.D. Breakage or damage to antennas unless caused directly by defects in material workmanship.E. A Product subjected to unauthorized Product modifications, disassemblies or repairs (including, without limitation, the addition to the Product of non-Motorola supplied equipment) which adversely affect performance of the Product or interfere with Motorola's normal warranty inspection and testing of the Product to verify any warranty claim.F. Product which has had the serial number removed or made illegible.G. Rechargeable batteries if:- any of the seals on the battery enclosure of cells are broken or show evidence of tampering.- the damage or defect is caused by charging or using the battery in equipment or service other than the Product for which it is specified.H. Freight costs to the repair depot.I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the Product, does not function in accordance with MOTOROLA’s published specifications or the FCC certification labeling in effect for the Product at the time the Product was initially distributed from MOTOROLA.J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of the Product.K. Normal and customary wear and tear.
6878215A01Commercial Warranty xviiVI. Patent And Software ProvisionsMOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the extent that it is based on a claim that the Product or parts infringe a United States patent, and MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following:A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim;B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; andC. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the subject of a claim of infringement of a United States patent, that such purchaser will permit MOTOROLA, at its option and expense, either to procure for such purchaser the right to continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept its return. The depreciation will be an equal amount per year over the lifetime of the Product or parts as established by MOTOROLA.MOTOROLA will have no liability with respect to any claim of patent infringement which is based upon the combination of the Product or parts furnished hereunder with software, apparatus or devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary equipment or software not furnished by MOTOROLA which is attached to or used in connection with the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of patents by the Product or any parts thereof.Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute copies of such Motorola software. MOTOROLA software may be used in only the Product in which the software was originally embodied and such software in such Product may not be replaced, copied, distributed, modified in any way, or used to produce any derivative thereof. No other use including, without limitation, alteration, modification, reproduction, distribution, or reverse engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent rights or copyrights.VII. Governing LawThis Warranty is governed by the laws of the State of Illinois, USA.
6878215A01Notesxviii Commercial Warranty
Chapter 1 IntroductionThis manual covers the installation procedures for ASTRO APX mobile and motorcycle radios with O2, O3, O5, O7 and O9 control heads, and accessories required to complete the radio system. The radio system consists of a control head, radio, antenna, microphone, speaker, cabling, Universal Relay Controller (URC), and accessories.1.1 Mobile Radio Description1.1.1 DimensionsFigure 1-1, Figure 1-2, Figure 1-3 and Figure 1-4 show the basic dimensions of the dash mount transceiver trunnion APX mobile radio. The transceiver portion of a remote mount APX mobile is sized similarly. When installing the radio, make sure to plan the installation carefully and leave additional room in the rear of the radio for cabling and accessory connections; in the front of the radio for access, controls, and cabling (if remote mount); and to the sides of the radio so that you may access and install the trunnion screws/wing screws.NOTE: The measurement unit used in Figure 1-1 to Figure 1-22 is millimeter.NOTE: The rear accessory connector adds 0.75 in to the overall length. The remote mount lengthis 244 mm.Figure 1-1. Front View of APX 7500 Mid Power Dash Mount Transceiver and Trunnion Figure 1-2. Side View of APX 7500 Mid PowerDash Mount Transceiver and TrunnionFigure 1-3. Front View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion Figure 1-4. Side View of APX 2500/4500 Mid Power Dash Mount Transceiver and Trunnion20618025624451832242066989222209
6878215A011-2 Introduction Mobile Radio DescriptionNOTE: The rear accessory connector adds 0.75 in to the overall length. The remote mount lengthis 194mm.Figure 1-5. Front View of APX 7500 High Power (100W) Transceiver and Trunnion Figure 1-6. Side View of APX 7500 High Power (100W) Transceiver and TrunnionFigure 1-7. Front View of O2 Control Head Attached to APX 7500 Mid Power Dash Mount Transceiver and TrunnionFigure 1-8. Side View of O2 Control Head Attached to APX7500 Mid Power Dash Mount Transceiver and TrunnionFigure 1-9. Front View of O7 Control Head Attached to APX 2500 Mid Power Dash Mount Transceiver and TrunnionFigure 1-10. Side View of O7 Control Head Attached to APX 2500 Mid Power Dash Mount Transceiver and Trunnion22374902932069269278269207194518017851224
6878215A01Introduction Mobile Radio Description 1-3Figure 1-11. Front View of O3 ControlHead with Coiled Cable Figure 1-12. Side View of O3 ControlHead with Coiled CableFigure 1-13. Front View of O2 Control Head with Remote Mount and Trunnion Figure 1-14. Side View of O2 Control Head with Remote Mount and TrunnionFigure 1-15. Front View of O5 Control Head with Remote Mount and Trunnion Figure 1-16. Side View of O5 Control Head with Remote Mount and Trunnion6115338209991239751180 75
6878215A011-4 Introduction Mobile Radio DescriptionFigure 1-17. Front View of O7 Control Head with Remote Mount and Trunnion Figure 1-18. Side View of O7 Control Head with Remote Mount and TrunnionFigure 1-19. Front View of O9 Control Head with Trunnion Figure 1-20. Side View of O9 Control Head with TrunnionFigure 1-21. Top View of O9 UniversalRelay Controller with Trunnion(URC is an orderable accessory.)Figure 1-22. Side View of O9 UniversalRelay Controller with Trunnion(URC is an orderable accessory.)2091789110882178190 8318521061.5
6878215A01Introduction Standard Configurations 1-51.2 Standard Configurations1.2.1 Dash Mount ConfigurationNOTE: The dash mount configuration is not applicable for 100W radios and O9 control heads.There are two versions of the APX mobile dash mount. The first are the O2, O5 and O7 control heads which are mounted on the front of the transceiver housing. The second is the O3 control head which is connected to the transceiver via a coiled cable, which is plugged into the CAN connector on the transceiver.Electrical connection between the two takes place within the radio via a flexible circuit board between the connectors on the front of the transceiver and at the back of the control head for O2, O5 and O7 and between the connectors on the front of the transceiver and at the back of the TIB for the O3.Figure 1-23. Dash Mount Configuration for O2 Control HeadFigure 1-24. Dash Mount Configuration for O3 Control HeadASTRO 25 Subscribers APX 2500ASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li MobileASTRO 25 Subscribers APX 2500/APX 4500ASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li Mobile
6878215A011-6 Introduction Standard ConfigurationsFor details on this configuration, see Section 2.2.1 on page 2-21.Figure 1-25. Dash Mount Configuration for O5 Control Head (Only Applicable for ASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li Mobile)Figure 1-26. Dash Mount Configuration for O7 Control HeadASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li MobileASTRO 25 Subscribers APX 2500ASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li Mobile
6878215A01Introduction Standard Configurations 1-71.2.2 Remote Mount ConfigurationIn the remote control version, the transceiver and the control head are mounted separately in the vehicle. The O2, O5 and O7 control heads are mounted in remote trunnions near the operator.The O3 and O9 control heads are also mounted near the operator using extension cables. The transceiver and control head are mounted using a trunnion or other mounting hardware. If the transceiver is located in a car trunk, ensure that it is mounted securely and that sufficient cooling is provided. Do not cover the transceiver with baggage, blankets, etc.NOTE: The keypad mic should only be plugged into the Modified Modular Plug (MMP) connector located on the control head, in either dash mount or remote mount configuration.Figure 1-27. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O2 Control HeadFigure 1-28. Remote Mount Configuration with Mid Power Transceiver,Transceiver Interface Board and O3 Control HeadMMPMMPASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li MobileASTRO 25 Subscribers APX 2500/APX 4500MMPMMP5 m (17 ft) Extension CableASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li Mobile
6878215A011-8 Introduction Standard ConfigurationsFigure 1-29. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O5 Control HeadFigure 1-30. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board, CHIB Rear Assembly and O7 Control HeadFigure 1-31. Remote Mount Configuration with Mid Power Transceiver, Transceiver Interface Board and O9 Control HeadMMPMMPASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li MobileMMPMMPASTRO 25 Subscribers APX 5500/APX 6500/APX 7500/APX 6500 Li MobileASTRO 25 Subscribers APX 250017 ft Extension CableASTRO 25 Subscribers APX 7500
6878215A01Introduction Standard Configurations 1-9Figure 1-32. Remote Mount Configuration with High Power (100W)Radio Transceiver and O2 Control HeadFigure 1-33. Remote Mount Configuration with High Power (100W)Radio Transceiver and O3 Control HeadFigure 1-34. Remote Mount Configuration with High Power (100W)Radio Transceiver and O5 Control Head5 m (17 ft) Extension Cable
6878215A011-10 Introduction Standard ConfigurationsFigure 1-35. Remote Mount Configuration with High Power (100W)Radio Transceiver and O7 Control HeadFigure 1-36. Remote Mount Configuration with High Power (100W)Radio Transceiver and O9 Control Head
6878215A01Introduction Standard Configurations 1-11Figure 1-37. Remote Mount Configuration with Mid Power Radio Transceiver,Universal Relay Controller and O7 Control Head (URC is optional.)Figure 1-38. Remote Mount Configuration with Mid Power Radio Transceiver,Universal Relay Controller and O9 Control Head (URC is optional.)17 ft Extension CableO7 to URC CableO9 to URC Cable17 ft Extension Cable
6878215A011-12 Introduction Standard ConfigurationsFigure 1-39. Remote Mount Configuration with High Power (100W) Radio Transceiver,Universal Relay Controller and O7 Control Head (URC is optional.)Figure 1-40. Remote Mount Configuration with High Power (100W) Radio Transceiver,Universal Relay Controller and O9 Control Head (URC is optional.)For details on these configurations, see Section 2.2.2 on page 2-23.O7 to URC Cable17 ft Extension CableO9 to URC Cable17 ft Extension Cable
6878215A01Introduction Standard Configurations 1-131.2.3 Multi Control HeadThe multi control head option allows separate, remotely operated control heads to operate and control the radio. For example, a fire truck could have a control head located in the cab and on the rear of the truck so that the radio could be operated from outside the vehicle.NOTE: The dual control head can be used together in the future.
6878215A011-14 Introduction Motorcycle Configurations1.3 Motorcycle ConfigurationsNOTE: The motorcycle configurations are not applicable for 100W radios and O9 control heads.The ASTRO APX mobile motorcycle radio models provide most of the equipment needed for installing a standard ASTRO APX mobile radio on a motorcycle. Most of this radio system is standard equipment. See Chapter 5: Motorcycle Radio Installation for further information.1.4 Base/Control StationsNOTE: The base/control station option is not applicable for 100W radios and O9 control heads.If mobile radio equipment is installed at a fixed location and operated as a control station or as a fixed unit, the antenna installation must comply with the following requirements in order to ensure optimal performance and compliance with the RF energy exposure limits in the standards and guidelines listed in the 6881095C99 manual:• The antenna should be mounted outside the building on the roof or a tower if at all possible.• As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in accordance with applicable regulatory requirements and may require additional compliance actions such as site survey measurements, signage, and site access restrictions in order to ensure that exposure limits are not exceeded.1.5 Tools Required for APX Mobile InstallationsTool Part Number10 mm wrench –5 mm Allen wrench –Rubber-coated pliers –Regular slot screwdriver of Phillips #2 –Pin removal tool 6680163F01RF antenna tool HLN6695_Wing screw torque tool HLN6970_
Chapter 2 Standard Configurations2.1 Planning the InstallationThe APX mobile radio operates only in negative ground electrical systems with a valid operating range of 10.8VDC to 16.3VDC. Before starting the radio installation, make sure that the ground polarity of the vehicle is correct. Accidentally reversing the polarity will not damage the radio, but will cause the cable fuses to blow.Planning is the key to fast, easy radio installation. Before starting the installation, inspect the vehicle and determine how and where you intend to mount the antenna, radio, and accessories. Plan wire and cable runs to provide maximum protection from inching, crushing, and overheating.Before installing any electrical equipment, check the vehicle manufacturer’s user manual for warnings or recommendations.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.!C a u t i o n
6878215A012-2 Standard Configurations Planning the Installation2.1.1 Installation ExamplesThe 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).Figure 2-1. Dash Mount Radios Can Be Located in the Middle Console, on theTransmission Hump, or Under the Dash (See Figure 2-2 for 100W Radio Install)Figure 2-2. Remote Mount Radio Control Heads Can Be Located in the MiddleConsole, on the Transmission Hump, or Under the DashFigure 2-3. Remote Mount of the Radio, O9 Control Headand Universal Relay Controller (URC is optional.)NOTE: 100W radio install is typically at the rear vehicle compartment.911Antenna1/4-WavelengthRadioSpeakerBattery Radio911Antenna1/4-WavelengthControlHeadSpeakerBattery ControlHeadRadio911Antenna1/4-WavelengthControl HeadSpeakerBatteryUniversal Relay Controller BoxRadioSiren Speaker Siren Box
6878215A01Standard Configurations Planning the Installation 2-32.1.2 Wiring DiagramsFigure 2-6 through Figure 2-17 show the wiring diagrams for all the possible configurations. The title under each figure identifies the O2, O3, O5, O7 or O9 control head configurations. Identify which of these figures shows the configuration that you are installing, and use the diagram when planning the installation.Figure 2-4. Radio Installation (O2 Mid Power Dash Mount)Figure 2-5. Radio Installation (O3 Mid Power Dash Mount)BATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHFUSEFUSEBLOCK(+)(-)RED LEADFUSEFIREWALLHOLEMOUNTINGSCREWDASH MOUNT RADIOANTENNA CONNECTION ANTENNA 13 ftIGN SENSE (ACC)P2(SEE J2PINOUT)DCPOWER CABLETRUNNION J2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)ANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)3 ftBATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHFUSEFUSEBLOCK(+)(-)RED LEADFUSEFIREWALLHOLEMOUNTINGSCREWRADIOANTENNA CONNECTION ANTENNA 1IGN SENSE (ACC)P2(SEE J2PINOUT)DCPOWER CABLETRUNNIONJ2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)ANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)3 ft 3 ft
6878215A012-4 Standard Configurations Planning the InstallationFigure 2-6. Radio Installation (O5 Mid Power Dash Mount)Figure 2-7. Radio Installation (O7 Mid Power Dash Mount)BATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHFUSEFUSEBLOCK(+)(-)RED LEADFUSEFIREWALLHOLEMOUNTINGSCREWDASH MOUNT RADIOANTENNA CONNECTION ANTENNA 13 ftIGN SENSE (ACC)P2(SEE J2PINOUT)DCPOWER CABLETRUNNION J2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)ANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)3 ftBATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHFUSEFUSEBLOCK(+)(-)RED LEADFUSEFIREWALLHOLEMOUNTINGSCREWDASH MOUNT RADIOANTENNA CONNECTION ANTENNA 13 ftIGN SENSE (ACC)P2(SEE J2PINOUT)DCPOWER CABLETRUNNION J2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)ANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)3 ft
6878215A01Standard Configurations Planning the Installation 2-5NOTE: In dash mount configuration, it is mandatory that a rear accessory cable be attached at the back of a mid power transceiver, in order to ground the Emergency pin to GND. Or, an emergency footswitch or pushbutton switch must be attached at the back of a mid power. If the emergency pin is not grounded, upon the attachment of the A+ cable at the DC connector, the radio will detect a HIGH for the emergency pin state, and assume that emergency has been activated. This will attempt to power on the radio, and will result in excessive current draw and incorrect radio operation. Refer to Section 2.1.3.1 for further details and recommended wiring of emergency in dash mount.Figure 2-8. Radio Installation (O2 Mid Power Remote Mount)BATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHRED LEADFUSEBLOCKYELLOWLEADBLACKLEAD(+)(-)FUSEFUSECONTROL HEAD FIREWALLHOLEANTENNA CONNECTION ANTENNA 1DC POWER CABLERADIOFUSEANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)PWRSPKJ400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 CAN CAN DEKVIPJ400ACC USBPORTS ON REAR OF REMOTE CONTROL HEADVIP CONNECTOR PIN-OUTJ4006910742581RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunction3 ft 3 ft
6878215A012-6 Standard Configurations Planning the InstallationFigure 2-9. Radio Installation (O3 Mid Power Remote Mount)Figure 2-10. Radio Installation (O5 Mid Power Remote Mount)BATTERYHORN RELAYLIGHT RELAYCHhangupboxSPEAKERO3CH5m (17ft) CABLE (PMLN4958)EMERGENCYSWITCHFUSEFUSEBLOCK(+)(-)RED LEADFUSEFIREWALLHOLEMOUNTINGSCREWIGN SENSE (ACC)P2(SEE J626PINOUT)CABLE HLN 6863DCPOWER CABLETRUNNIONconnect to P2FRONT ACCESSORY CABLE (PMLN4959)ANTENNA CONNECTION ANTENNA 1J2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)ANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)3 ft 3 ftBATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHRED LEADFUSEBLOCKYELLOWLEADBLACKLEAD(+)(-)FUSEFUSECONTROL HEAD FIREWALLHOLEANTENNA CONNECTION ANTENNA 1DC POWER CABLERADIOFUSEANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)PWRSPKJ400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 CAN CAN DEKVIPJ400ACC USBPORTS ON REAR OF REMOTE CONTROL HEADVIP CONNECTOR PIN-OUTJ4006910742581RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunction3 ft 3 ft
6878215A01Standard Configurations Planning the Installation 2-7Figure 2-11. Radio Installation (O7 Mid Power Remote Mount)Refer to Section 2.1.3.2 and Section 4.2.1 for further details and recommended wiring of emergency in remote mount.Figure 2-12. Radio Installation (O2 High Power Remote Mount)BATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICEMERGENCYSWITCHRED LEADFUSEBLOCKYELLOWLEADBLACKLEAD(+)(-)FUSEFUSECONTROL HEAD FIREWALLHOLEANTENNA CONNECTION ANTENNA 1DC POWER CABLERADIOFUSEANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)PWRSPKJ400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 CAN CAN DEKVIPJ400ACC USBPORTS ON REAR OF REMOTE CONTROL HEADVIP CONNECTOR PIN-OUTJ4006910742581RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunction3 ft 3 ftEMERGENCYSWITCHFIREWALLHOLEANTENNA CONNECTION GPSANTENNA CONNECTORDC POWER CABLEANTENNA CONNECTION RADIOCONTROL HEADBATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICRED LEADFUSEBLOCKYELLOWLEAD(+)(-)FUSEFUSE REMOTE MOUNT CONTROL CABLEANTENNA 1ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)FUSEPWRSPKCAN CAN DEKVIPJ400ACC USBPORTS ON REAR OF REMOTE CONTROL HEADVIP CONNECTOR PIN-OUTJ4006910742581J400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunction3 ft 3 ft
6878215A012-8 Standard Configurations Planning the InstallationFigure 2-13. Radio Installation (O3 High Power Remote Mount)Figure 2-14. Radio Installation (O5 High Power Remote Mount)BATTERYHORN RELAYLIGHT RELAYCHhangupboxSPEAKEREMERGENCYSWITCHFUSEFUSEBLOCK(+)(-)RED LEADFUSEFIREWALLHOLEIGN SENSE (ACC)P2(SEE J626PINOUT)CABLE HLN6863J626Front Accessory Cable(PMLN4959)DCPOWER CABLEO3CH5m (17ft) CABLE (PMLN4958)ANTENNA CONNECTION ANTENNA 1J2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)ANTENNA CONNECTION ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)3 ft 3 ftEMERGENCYSWITCHFIREWALLHOLEANTENNA CONNECTION GPSANTENNA CONNECTORDC POWER CABLEANTENNA CONNECTION RADIOCONTROL HEADBATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICRED LEADFUSEBLOCKYELLOWLEAD(+)(-)FUSEFUSE REMOTE MOUNT CONTROL CABLEANTENNA 1ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)FUSEPWRSPKCAN CAN DEKVIPJ400ACC USBPORTS ON REAR OF REMOTE CONTROL HEADVIP CONNECTOR PIN-OUTJ4006910742581J400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunction3 ft 3 ft
6878215A01Standard Configurations Planning the Installation 2-9Figure 2-15. Radio Installation (O7 High Power Remote Mount)Figure 2-16. Radio Installation of O9 Remote Mount with Transceiver (URC is optional.)EMERGENCYSWITCHFIREWALLHOLEANTENNA CONNECTION GPSANTENNA CONNECTORDC POWER CABLEANTENNA CONNECTION RADIOCONTROL HEADBATTERYHORN RELAYLIGHT RELAYMICCLIPSPEAKERMICRED LEADFUSEBLOCKYELLOWLEAD(+)(-)FUSEFUSE REMOTE MOUNT CONTROL CABLEANTENNA 1ANTENNA 2(FOR DUAL BAND RADIOS)ANTENNA CONNECTION ANTENNA 3GPS (OPTIONAL)FUSEPWRSPKCAN CAN DEKVIPJ400ACC USBPORTS ON REAR OF REMOTE CONTROL HEADVIP CONNECTOR PIN-OUTJ4006910742581J400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunction3 ft 3 ftMICMICCLIPEMERGENCYSWITCH(SEE J2PINOUT)GUN LOCKEARJACKControl HeadSpeakerSiren SpeakerSiren BoxRED LEADHORNRELAYANTENNA 1ANTENNACONNECTIONFIREWALLHOLEDC POWERCABLEURC Controller BoxBLACKLEADLIGHTBARO9 TO URC CableRADIOCAN CableANTENNACONNECTIONANTENNA 2(+)(-)RED LEADRED LEADRED LEADYELLOW LEADCONTROL HEADFUSEFUSEFUSEFUSEBLOCKBATTERYFUSECIRCUIT BREAKER
6878215A012-10 Standard Configurations Planning the InstallationFigure 2-17. Radio Installation (O9 Remote Mount with Pinouts)Refer to Section 2.1.3.2 and Section 4.2.1 for further details and recommended wiring of emergency in remote mount.Figure 2-18. Remote Control Head PinoutsVIP CONNECTOR PIN-OUTJ4006910742581J400-1 RED SWB +J400-2 GREEN GNDJ400-3 - NO PINJ400-4 - "VIP" detect: GPIO=HIGHJ400-5 BLUE VIP_OUT_1 J400-6 YELLOW VIP_OUT_2J400-7 BLACK VIP_OUT_3J400-8 WHITE VIP_IN_1 (VIP_IN GPIO)J400-9 ORANGE VIP_IN_2 (VIP_IN GPIO)J400-10 VIOLET VIP_IN_3 RadioPinNumberVIP Cable(HKN6196_)Wire ColorFunctionJ2REAR ACCESSORY CONNECTOR1781413202126SPKR-SPKR+VIPOUT 212V(RELAY)VIPOUT 112V(RELAY)GROUNDEMERGENCYIGN SENSE(ACC)GCAIJ400DEK/VIP(YELLOW)J300RCAN(BLUE)J500USBJ100M.A.P.J200PWR/SPKR(RED) J300LCAN(BLUE)M.A.P. PWRSPK (RED)CAN(BLUE)CAN(BLUE)DEKVIP(YELLOW)USBJ100J200 J300L J300R J400 J500
6878215A01Standard Configurations Planning the Installation 2-11RADIO COMPARTMENT = OPERATOR COMPARTMENT VEHICLE BATTERY COMPARTMENTCONTROL HEADIGN SENSE (thin RED)ACC lineFigure 2-19. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios)
6878215A012-12 Standard Configurations Planning the Installation IGN SENSE (YELLOW)ACC lineVEHICLEIGNITION SWITCHGROMMETVEHICLEBATTERYCHASSIS GNDMICROPHONECONTROL HEAD (REAR VIEW)DIGITAL CONTROL CABLEREMOTE MOUNT OPERATIONRADIO COMPARTMENT VEHICLE BATTERYCOMPARTMENTOPERATOR COMPARTMENTTRANSCEIVERCHASSIS GNDREARCONNECTORTIBGROMMETSPEAKER A+ (RED)SEE NOTEFUSEFUSEFigure 2-20. Cabling Interconnect Diagram for Remote Mount
6878215A01Standard Configurations Planning the Installation 2-13RADIO COMPARTMENT OPERATOR COMPARTMENT VEHICLE BATTERYCOMPARTMENTSiren BoxCAUTION(BLK)A+(Red)A+(Red)15A FuseMICROPHONEVEHICLEIGNITION SWITCHVEHICLEBATTERYPART OFVEHICLEWIRINGSiren SpeakerON/ACC3A OR 4A FUSE SEE NOTESPEAKERRADIO POWER CABLE(RED/BATTERY HOT)15A, 20A OR30A FUSE16A Circuit BreakerGROMMETGROMMETGROMMETREARCONNECTORURC ControllerBoxChassis GNDGCAI to RJ45CableRADIOTIBChassis GNDCAN extension cableA+(Red)IGN Sense(yellow)(BLK)Control Head (Rear View)Chassis GND(+) (-)Figure 2-21. Cabling Interconnect Diagram for 09 Remote Mount (URC is optional.)NOTE:For remote mount configurations, do not supply IGNITION at the radio's rear accessory connector. IGNITION should be supplied according to TABLE 2-2. See TABLE 2-2 for combinations of wiring theRED and YELLOW cables.The RED and YELLOW power cables connect to either the vehicle battery or the ignition switch. Connect the RED cable directly to the battery. The receiver operates when the control head is on. Connecthe YELLOW cable to the ignition switch. The transmitter operates only when the ignition switch is on.Alternate connections: Connecting both RED and YELLOW cables to the battery allows the control head to turn the receiver and transmitter on or off. Connecting both RED and YELLOW cables to theignition switch allows the ignition switch to turn the receiver and transmitter on or off. Alternator whine and other noise problems may occur. Isolate the RED cable with a Motorola relay (5900813674).
6878215A012-14 Standard Configurations Planning the Installation2.1.3 Radio Operation Wiring for Dash and Remote ConfigurationsDetermine from Table 2-1, Table 2-2, or Table 2-3 the radio functionality you wish to achieve, which is controlled by the vehicle’s ignition switch state, the physical wiring of the radio’s ignition sense (ACC) wire, and by the programmed CPS setting. For additional radio functionality as determined by the programming of the ignition switch in CPS, refer to the HELP menu in your CPS (i.e. Ignition as: Required, Blank, Soft Power Off, TX Inhibit, PTT TX Inhibit, Ignition Only Power Up).Choose a clean ignition point which is not shared in the immediate vicinity by other high current accessories/devices. This will help to reduce the transients on the ignition line. Examples of high-current accessories/devices are: Air Horn, relays, lightbars and etc. It is recommended to wire to the vehicle’s ACC line, not the START or the solenoid side of the ignition circuit. Refer to chapter 6 for best installation practices. The Ignition sense (ACC) cable uses either a 3-amp fuse (6580283E01) or 4-amp fuse (6580283E02).2.1.3.1 Dash Mount: Power, Ignition, and Emergency Cable InstallationThe standard dash mount rear ignition sense cable HLN6863 contains a “thin red” ignition wire, a jumper wire that shorts emergency to ground, and two gray wires attached to an external speaker plug. The thin RED wire is the ignition sensed wire. Refer to Table 2-1, Table 2-2, or Table 2-3 for its correct wiring configurations.NOTE: This cable MUST be attached in order for the radio to operate in Dash mount, regardless of how emergency is programmed in CPS or wired inside the vehicle. Either the emergency jumper wire or an emergency accessory (footswitch or button) must be wired to the rear of the transceiver in Dash mount. Otherwise, upon attachment of the radio’s power cable to the vehicle battery, the radio will incorrectly determine that emergency operation has been activated, such as when an emergency footswitch is de-pressed and the emergency pin is ungrounded.
6878215A01Standard Configurations Planning the Installation 2-152.1.3.2 Remote Mount: Power, Ignition, and Emergency Cable InstallationThe single control head O2, O5, O7 or O9 remote mount configurations receive power from the J200 connector’s red and black wires. The yellow wire at J200 is one ignition sense wire. On mid power radios, the J2 and J600 connectors can also be used for ignition sense. On high power radios, the J200 yellow wire or the J600 connector can be used for ignition sense. If the HLN6863 is attached at J100 of the O2, O5, O7 or O9 control head, the “thin red” wire will NOT function as an ignition sense wire, since the J100 connector has no ignition sense electrical connection.NOTE: It is incorrect for installation to attach ignition sense at more than one wire or connector. Refer to Table 2-1 or Table 2-2 for its correct wiring configurations.The O3 control head receives its power down the CAN cable, and detects the ignition state by the ignition sense pin at either J2 or J600. On mid power radios, the J2 and J600 connectors can also be used for ignition sense. On high power radios, only the J600 connector can be used for ignition sense.In Multi-Control Head installations, the yellow ignition wire must be connected to the head assigned ID # 1. See Section 2.2.2.5 “Setting the Initial Control Head ID” on page 2-29 for further information.In remote mount O2, O3, O5, O7 or O9, an Emergency jumper to ground is placed by default on the TIB (JU344) so that there is no need to attach a cable with an emergency accessory at either J2 or at J600. This jumper must be removed if an emergency accessory (footswitch or button to Ground) is installed at either J2 or J600 (or J626 on the accessory cable) locations. If the jumper JU344 is removed but no emergency accessory is installed, the radio will power-up incorrectly into emergency mode all the time. Refer to Figure 4-3 for details.The design of the control head is different compared to the transceiver, therefore it is also NOT necessary to attach HLN6863 at J100 to prevent accidental emergency operation. The control head uses an edge-detect, not a state-detect like on the transceiver, so mounting of HLN6863 is not mandatory.
6878215A012-16 Standard Configurations Planning the InstallationTable 2-1. Dash O2, O5 or O7 Radio Operations Dependent Upon A+ and Ignition ConnectionsDash Mount Transceiver Red Power WireHLN6863Thin Red WireTransceiver Red Power WireHLN6863Thin Red WireTransceiver Red Power WireHLN6863Thin Red WireConnected to batteryXXX XConnected to ignition switchXXXIgnition switch controlsNo ignition switch control. Enables ignition switch functionality as programmed in the codeplug.Illegal wiring configuration. See CAUTION note.Table 2-2. Remote O2, O5, O7, or O9 Radio Operations Dependent Upon A+ and Ignition ConnectionsRemote Mount Control Head Red Wire Control Head Yellow Wire Control Head Red Wire Control Head Yellow Wire Control Head Red Wire Control Head Yellow WireConnected to batteryXXX XConnected to ignition switchXXXIgnition switch controlsNo ignition switch control. Enables ignition switch functionality as programmed in the codeplug.Illegal wiring configuration. See CAUTION note.Table 2-3. Remote O2, O5, O7 or O9 Radio Operations Dependent Upon A+ and Ignition ConnectionsMid Power Dash/Remote Transceiver Red Power WireHLN6863Thin Red Wire at J2 Transceiver Red Power WireHLN6863Thin Red Wire at J2 Transceiver Red Power WireHLN6863Thin Red Wire at J2High Power Dash/RemoteHLN6863Thin Red Wire at J626HLN6863Thin Red Wire at J626HLN6863Thin Red Wire at J626Connected to batteryXXXConnected to ignition switchXXXIgnition switch controlsNo ignition switch control. Enables ignition switch functionality as programmed in the codeplug.Illegal wiring configuration. See CAUTION note.DO NOT connect any wires to the battery terminals until you have finished the entire radio installation (Dash or Remote Mount) configuration to avoid potential equipment damage.Incorrect wiring of the radio may result in incorrect ignition sense detection, incorrect power-on state, or incorrect power-off state of the radio system.The Control Head Power cable wire (RED) and Transceiver Power cable wire (RED) are always attached to the battery terminal and NOT to the ignition switch.!C a u t i o n
6878215A01Standard Configurations Planning the Installation 2-172.1.4 Ignition Sense Switch (Radio Wide Advance)CPS selectable settings to control the radio’s functionality based on the state of the vehicle’s Ignition status.NOTE: When either TX Inhibit, PTT TX Inhibit or Required are selected, the Emergency Power Up feature will not be available to the radio-user.When any other Ignition Switch setting is made, Emergency Power Up is available to the radio-user, regardless of current ignition state.Any optional inactivity time-out timer setting in CPS may delay the power off of the radio once Ignition sense is removed.Table 2-4. Ignition Sense Switch Settings in CPSFeature DescriptionBlank • Radio POWERS ON when the Power Button is pressed or with the emergency power up feature.• Radio POWERS OFF when the Power Button is pressed.TX Inhibit • Radio POWERS ON when the Power Button is pressed or with the emergency power up feature.• Radio POWERS OFF when the Power Button is pressed.•If IGNITION is not present all transmissions are inhibited.• The radio will not affiliate with trunking systems and therefore CANNOT receive any trunking dispatch communications.• Emergency Alarm transmissions are NOT possible with the use of the emergency power up feature.PTT TX Inhibit • Radio POWERS ON when the Power Button is pressed or with the emergency power up feature.• Radio POWERS OFF when the Power Button is pressed.•If IGNITION is not present all transmissions are inhibited.• The radio is able to affiliate with trunking systems. The radio can ONLY receive trunking dispatch communications.• Emergency Alarm transmissions are possible with the use of the emergency power up feature.Required • Radio POWERS ON when the Power Button is pressed and Ignition is present.• Radio POWERS ON when Ignition is cycled and radio was previously ON.• Radio POWERS OFF when the Power Button is pressed, or when Ignition is lost.Soft Power Off • Radio POWERS ON when the Power Button is pressed, or when Ignition is detected.• Radio POWERS OFF when the Power Button is pressed, or when Ignition is lost.Ignition Only Power Up • Radio POWERS ON when Ignition is present.• Radio POWERS OFF when Ignition is lost.• Control head power button is ignored.
6878215A012-18 Standard Configurations Planning the Installation2.1.5 Siren/PA Configuration/ProgrammingThe Siren/PA is shipped pre-wired for 100W operation. It can be rewired for 65W, 75W, or 130W power levels.To change to another power level, perform the following:1. Open the Siren/PA connector cover to gain access to the two-connector speaker leads. Do not change the speaker common lead (pin 20). The other lead is connected to pin 35 (for 100W operation).2. Using an appropriate pin removal tool, extract pin 35 and move it to one of the following pin locations:- pin location 36 for 75W operation- pin location 28 for 65W or 130W operation3. For 65W or 75W operation, no further changes are required. Reassemble the connector. 4. For 130W operation, you must parallel two 11ȍ speakers, each rated at 65W minimum. Proper phasing of the two speakers is important--when connecting two speakers in parallel, wire similar speaker terminals together to ensure maximum loudness and prevent "deadspots." For example, if the terminals are marked "1" and "2", connect the terminals marked "1" together and connect those wires to one speaker lead. Connect the terminals marked "2" together and connect those wires to the other speaker lead.5. When the Siren/PA is configured for dual speaker, 130W operation, it is necessary to remove a resistor and move two jumpers to set the correct power level. Remove the Siren/PA cover, and locate resistor R219 (0 ohm). This resistor should be removed for 130W operation. Locate jumpers JU100 and JU101. These jumpers should be installed for 130W operation.6. Close and reconnect the Siren/PA connector cover.NOTE:Jumpers JU100 and JU101 do not affect the Siren output level. JU100 and JU101 compensate for the lower speaker load and the two speakers in parallel, by decreasing the gain U102-1. JU100 affects the radio PA level and JU101 affects the PA audio level.Pin locations of various power level configurations are listed in Table 2-5Before continuing, remember that under a high-line supply condition (16.6V), up to 30% more power will go to the speaker(s) after reconfiguring for 130W operation. Do this only when your PA speakers are capable of handling the extra power.Table 2-5. Power Level ConfigurationsPin location of speaker leads R219 JU100/JU10165W 20,28 IN Across pins A and B75W 20,36 IN Across pins A and B100W 20,35 IN Across pins A and B130W 20,28 OUT Across pins B and C!C a u t i o n
6878215A01Standard Configurations Radio Mounting 2-192.2 Radio MountingThe mounting location must be accessible and visible. Select a location that will permit routing the RF antenna cable as directly as possible.NOTE: For optimum radio performance, orient the mounting trunnion as shown in Figure 2-22 or Figure 2-23 for mid power and Figure 2-24 for high power. For new or existing installations of all but 100W radios, use only the APX mobile trunnion, kit number HLN7002_except for APX 2500 and APX 4500 which shall use the trunnion with kit number HLN6861_. For new or existing installations of 100W radios, use only the APX mobile trunnion, kit numbers HLN7003_.Figure 2-22. APX 7500/ APX6500/ APX5500/ APX6500Li Mid Power Trunnion Orientation (Cannot Be Used for 100W Radios)DO NOT mount the radio on a plastic mounting surface without first reinforcing the mounting surface; the weight of the radio may crack or break the mounting surface.DO NOT mount the radio on a flat or concave surface where the radio could be partially submersed in water. This is especially important if the cab area of the vehicle is cleaned by spraying with water. If the radio sits in water for a length of time, moisture may seep inside the radio and damage the electronic components.DO NOT allow water to stand in recessed areas of vertically mounted radios. Remove any moisture immediately to prevent it from seeping down into the radio.Care must be taken to shield the control head (front and back) from direct exposure to pressurized water. The pressurized water from a hose, in most cases, is more severe than the stated test and conditions in typical environments.!C a u t i o nRADIO FRONTAPPLIES TO RADIOS IN DASH AND REMOTE INSTALLATIONS
6878215A012-20 Standard Configurations Radio MountingFigure 2-24. Trunnion Orientation for 100W RadiosFigure 2-23. APX 2500/APX4500 Mid Power Trunnion Orientation (Cannot Be Used for 100W Radios)RADIO FRONT
6878215A01Standard Configurations Radio Mounting 2-212.2.1 Dash Mount with TrunnionNOTE: This configuration is not applicable for 100W radios.1. Referring to Figure 2-6, select the suitable trunnion kit per the type of mid power transceiver.2. Select the location to mount your radio on the transmission hump (see Figure 2-25) or under the dash (see Figure 2-26).NOTE: When mounting the trunnion on the transmission hump take care the transmission housing is not affected. Plan your installation ensuring enough room for the Accessory connector and cable in the back of the radio.3. Using the trunnion mounting bracket as a template, mark the positions of the holes on the mounting surface. Use the innermost four holes for a curved mounting surface such as the transmission hump, and the four outmost holes for a flat surface such as under the dash.4. Center punch the spots you have marked and realign the trunnion in position.5. Secure the trunnion mounting bracket with the four self-drilling screws provided (see Figure 2-25 and Figure 2-26).6. Ensure that the plastic guides are aligned (horizontal) to the grooves of the trunnion. Slide the radio into the grooves until it snaps into place (see Figure 2-26).Table 2-6. Mid Power Trunnion KitItem Part Number Description Mid Power Transceiver10371859H01 Trunnion Mounting Screw APX 5500/APX 6500/APX 6500 Li/APX 75000305760W02 Trunnion Mounting Wing Screw APX 2500/APX 45002 0312002B14 Self-Drilling Tapping ScrewAPX 5500/APX 6500/APX 6500 Li/APX 7500APX 2500/APX 45003HLN7002_ Mackinaw Trunnion Hardware Kit APX 5500/APX 6500/APX 6500 Li/APX 7500HLN6861_ Millenium Trunnion Hardware Kit APX 2500/APX 4500
6878215A012-22 Standard Configurations Radio MountingFigure 2-25. Transmission Hump Trunnion MountingFigure 2-26. Below Dash Trunnion Mounting7. Secure the radio with two screws provided (Item 1 in Table 2-6). The torque down force for 0371859H01 should be between 50in-lbf to 52in-lbf.8. For screw 0305760W02, the wing screw torque tool (HLN6970_) is designed to securely tighten the trunnion wing screws while installing the radio. The tool can also be used to loosen the wing screws. Detailed instructions are included in the tool packaging.NOTE: This configuration shows the O5 control head. The TIB is used for O3 control head for the same configuration.TabsThreaded Hole for ScrewGroovePlastic Guides1321113
6878215A01Standard Configurations Radio Mounting 2-232.2.2 Remote Mount with TrunnionFor a remote mount installation, the transceiver may be mounted anywhere in the vehicle, provided that the installation location is safe, follows the cautions mentioned at the beginning of this section, and is accessible for servicing/maintenance as well as cabling. A typical mounting location recommended by Motorola is in the vehicle’s trunk. The trunnion provided may still be used to mount the transceiver, and the mounting process is the same as for the dash mount installation (Section 2.2.1 on page 2-21). However, for 100W radios you must follow the procedure detailed below in Section 2.2.2.1. See Figure 2-10, Figure 2-11, Figure 2-13, or Figure 2-14 for a remote installation.Before installing any electrical equipment, check the vehicle manufacturer’s user manual.The installation of this device should be completed by an authorized servicer or installer.Before making any holes in the trunk for radio mounting, check the vehicle manufacturer's user manual for restrictions (e.g. due to the gas tank location).!C a u t i o n
6878215A012-24 Standard Configurations Radio Mounting2.2.2.1 100W Radios OnlyNOTE: Cabling to the front of the radio (TIB) should not be completed with the handle opened as it is needed to be removed to close the handle. It is suggested that the cabling is to be attached to the front of the radio after the radio is assembled into the trunnion.1. After selecting the mounting location, use the trunnion mounting bracket as a template and mark the positions of the holes on the mounting surface.2. Center-punch the spots you have marked and realign the trunnion in position.3. Secure the trunnion mounting bracket with the four self-drilling screws provided (see Figure 2-27).4. After the trunnion has been mounted in the vehicle using the screws provided, install the radio. Place the radio with the lock handle fully opened on the trunnion, oriented at least10 mm in front of the rear catches. Push the radio towards the rear catches. The radio is lifted up slightly and then drops back down, flushed with the trunnion, and stops against the rear catches. Once this occurs, close the lock handle. Rotate the handle towards the top of the radio until it is locked in place. The key is not needed in the lock to close the handle, but is needed to reopen. The keys can only be removed from the lock when it is in the locked position.Figure 2-27. 100W Radio Mounting into Quick Release Trunnion2.2.2.2 Remote Mount Control Head InstallationChoose a mounting location for the radio, considering accessibility, and control and antenna cable lengths.The recommended mounting surfaces for the control unit are under the mounting surface, on the transmission hump, or on the center console. Figure 2-28 and Figure 2-29 shows how the trunnion, control head, and cables should be installed for the O2, O5, O7 or O9 control head.NOTE: Connector-protective covers (i.e. Dust Covers) HLN6980_ are provided with the radio.They should be installed on exposed connectors for added environmental robustness.
6878215A01Standard Configurations Radio Mounting 2-25An adjustable trunnion, which allows a number of mounting positions, is supplied for mounting the control unit. The installation must not interfere with the operation of the vehicle or its accessories, nor disturb passenger seating or leg room. The control head must be within convenient reach and viewing of the user.If the trunnion is mounted on a plastic mounting surface, all four mounting screws should penetrate the mounting surface’s supporting metal frame. If that is not possible, use a metal backing plate (not supplied) to strengthen the installation. Install the control follows:1. Use the control unit trunnion as a template to mark the mounting holes; drill 5/32" holes. If mounting on a plastic surface, use a metal backing plate.2. Attach the trunnion bracket using all four 10-16" x 5/8" self-tapping screws provided.3. Temporarily install the control head (adjusting for proper viewing angle) and fasten it to the trunnion with two wing screws. Test the installation to be sure the control head feels securely locked in place while you are pressing its buttons.4. Finish installation by fully tightening screws.Figure 2-28. O5 Control Head Installation Exploded View (Also applicable for O2 and O7 Control Heads)Metal Backing Plate (Not Supplied)
6878215A012-26 Standard Configurations Radio MountingFigure 2-29. O9 Control Head Installation Exploded ViewFigure 2-30. O5 Control Head Rear View(Also applicable for O2 and O7 Control Heads)ADJUST THE CONTROL HEAD TO DESIRED ANGLE AND SECURE WITH WING SCREWSUSE FOUR MOUNTING SCREWS ON ALL INSTALLATIONSTRUNNIONDRILL FOUR 5/32'' HOLES IN MOUNTING SURFACEMOUNTING SURFACEIMPORTANTUSE A METAL BACKING PLATE (NOT SUPPLIED) IF MOUNTING TRUNNION ON PLASTIC OR UNSTABLE SURFACE
6878215A01Standard Configurations Radio Mounting 2-27Figure 2-31. O9 Control Head Rear View2.2.2.3 Multiple Control Head InstallationControl heads in a multiple control head configuration should be installed per the steps detailed in Section 2.2.2.2: “Remote Mount Control Head Installation” on page 2-24. Two heads can be connected to each of the two CAN connectors on the transceiver, with the remaining heads connected to one or both of the first two. Control heads can also be connected a “daisy chain” configuration from a single transceiver CAN connector. See Figure 2-32 for examples.NOTE: The transceiver must be configured for Multiple Control Head via CPS programming. Navigate to the “Control Head” tab in the Radio Wide section of CPS, and select “Help” for further information and tutorials.Control Head 1 Control Head 2J300R J300RJ200 J200J300L(-)RED LEAD(+)BATTERYFUSEFUSEFUSEFUSEControl Head 3 Control Head 4J300RJ200 J200J300LJ300R
6878215A012-28 Standard Configurations Radio MountingFigure 2-32. Multiple Control Heads Example ConfigurationsNOTE: In Multiple Control Head (MCH) installations, the yellow ignition sense wire must be connected to the head assigned ID # 1. See Section 2.2.2.5 “Setting the Initial Control Head ID” on page 2-29 for further information.Use the most convenient configuration for your installation, ensuring that the combined cable lengths do not exceed 131 feet (40 meters). See Table 2-7 for a list of available CAN cable lengths. Control head ground, power and ignition sense wires (black, red, and yellow respectively) may need additional length (not supplied) in installations that locate the head more than 10 feet from a power source.Table 2-7. Available CAN CablesPart Number DescriptionHKN6164_ Cable, Remote Mount, 40m (131ft)HKN6165_ Cable, Remote Mount, 35m (115ft)HKN6166_ Cable, Remote Mount, 23m (75ft)HKN6167_ Cable, Remote Mount, 15m (50ft)HKN6168_ Cable, Remote Mount, 9m (30ft)HKN6169_ Cable, Remote Mount, 5m (17ft)HKN6170_ Cable, Remote Mount, 3m (10ft)PMLN4958_ Cable, O3 Extension, 5m (17ft)Control Head 1 Control Head 2J300R J300RJ200 J200J300L J300L(-)RED LEAD(+)BATTERYFUSEFUSEFUSEFUSEControl Head 3 Control Head 4J300RJ200 J200J300LJ300R
6878215A01Standard Configurations Radio Mounting 2-292.2.2.4 Cable InstallationRoute the cables where they are protected from pinching, sharp edges or crushing. Use grommets in any holes where the cable passes through metal panels. Figure 2-19 shows how the cables and components are connected. It is not recommended to route cabling or wiring inside the wheel wells of a vehicle.2.2.2.5 Setting the Initial Control Head IDThe Front Panel Programming (FPP) mode allows you to define which control head in a Multi Control Head system becomes control head number 1-4.Set the control head ID number for each attached head the first time Multi Control Head is used.1. Press the power button to power off the radio.2. Press and hold left-most menu and the orange button on the control head simultaneously.Figure 2-33. APX Mobile O5 Control Head Front View3. Press the power button to power on the control head. The head will power on into FPP mode and display the current control head ID number:Figure 2-34. Radio Display with Current Control Head ID4. Turn the Mode knob to change the control head’s ID number.Table 2-8. Ignition Interface CablesPart Number DescriptionHLN6863_ Cable, M.A.P. 26pin with Only Ignition and SPKPMLN4959_ Cable, Y-Splitter with DB-25 and M.A.P. InterfaceO5Left-most Menu ButtonPower ButtonEmergency ButtonCH ID#1
6878215A012-30 Standard Configurations Radio MountingFigure 2-35. APX Mobile O5 Control Head Front View – Mode Knob5. Repeat steps 1 to 4 above to set the ID of the remaining control heads.NOTE: In Multiple Control Head (MCH) installations, the yellow ignition sense wire must be connected to the head assigned ID # 1.2.2.2.6 O3 Control Head and Remote Mount CablingChoose a mounting location for the radio, considering accessibility, and control and antenna cable lengths. The control head extension cable and the accessories cable should be installed and routed properly to avoid complications. Route the cables in the vehicle’s wiring troughs (where available) or route the cables where they are protected from pinching, sharp edges, or crushing. One suggested route is along one side of the driveshaft hump under the carpet. Use grommets in any holes where the cable passes through metal panels.Figure 2-36. O3 Control HeadThe recommended mounting surface for the control unit is on the center console. Figure 2-38 shows how the hang-up clip control head, and cables should be installed for the O3 control head.NOTE: Connector-protective covers are provided with the radio. They should be used for added environmental robustness.O5Mode KnobTopFront RightLeft Back
6878215A01Standard Configurations Radio Mounting 2-31A mounting clip, which allows the control head to be mounted, is supplied together with the control head. The installation must not interfere with the operation of the vehicle or its accessories, nor disturb the passenger seating. The control head must be within convenient reach and viewing of the user.Install the mounting clip as follows:1. Use the provided mounting clip to determine the location of the two screw holes.2. Drill 7/16” deep holes for upper and lower screws.3. Use the tapping screw provided to install the mounting clip.Care must be taken to shield the control head (front and back) from direct exposure to pressurized water. The pressurized water from a hose, in most cases, is more severe than the stated test and conditions in typical environments.Figure 2-37. O3 Control Head Rear View Figure 2-38. Hang-Up Clip InstallationExploded View!C a u t i o nVEHICLEDASHBOARD221221Vehicle Mounting SurfaceItem No. Part Number Description1 01-80743T91 Mic Hang-Up Clip Assembly2 03-07644M19 Screw, Machine,8-32 x 7/16
6878215A012-32 Standard Configurations Radio Mounting2.2.3 Locking Kit (Optional)2.2.3.1 All Radios Except 100WIf an optional locking kit (HLN6372_) is used (shown in Figure 2-39), position the lock housing on the trunnion after installing the radio mounting screws. Then rotate the lock with the key in it and remove the key to lock the radio. You can install the lock on either side of the radio, and in dash and remote mount installations.Figure 2-39. Locking Kit (Optional) (Cannot Be Used for 100W Radios)2.2.3.2 100W RadiosAn integral lock is included with all 100W radios. The use of a key is only required to unlock the radio (see Figure 2-40).Figure 2-40. Lock Supplied with 100W Quick Release TrunnionLockLockHousingExistingMountingScrew
6878215A01Standard Configurations Power Cables (Transceiver and Control Head) 2-332.3 Power Cables (Transceiver and Control Head)Route the RED power cable from both the radio and the control head to the vehicle’s battery compartment, using accepted industry methods and standards. Be sure to grommet the firewall hole to protect the cable. Remove the 15-amp (part number 6580283E06), 20-amp (part number 6580283E07) or 30-amp (part number 6580283E09) fuse from the fuseholder and connect the red lead of the radio power cable to the positive battery terminal using the hardware provided as shown in Figure 2-46 and Figure 2-47. Connect the black lead to a convenient solid chassis ground point. DO NOT connect the black lead directly to the battery’s negative terminal.NOTE: Remote Control Head power cable uses a 5A Fuse (part number 6580283E03).2.3.1 Optional Locking Feature for High Power Chassis Power CablesAn optional clip (HLN7017_) can be used to increase DC cable retention in the high power radios. Directions for assembly and disassembly are:1. Install the DC cable to the radio by aligning the male and female portions of the battery side with the mating components on the radio side.Figure 2-41. Bracket InstallationTable 2-9. Power CablesDescription Part NumberMid Power Dash Mount HKN4191_Mid Power Remote Mount HKN4192_High Power Remote Mount HKN6110_O5, O7, and O9 Remote Control Head Power CableHKN6188_(1)
6878215A012-34 Standard Configurations Power Cables (Transceiver and Control Head)2. Insert the locking bracket (HLN7017_) onto the DC cable.3. Slide the bracket toward the radio until the bracket clips snap onto the radio features.Figure 2-42. Bracket InstallationFigure 2-43. Bracket Installation (Assembled State)(3)(2)
6878215A01Standard Configurations Power Cables (Transceiver and Control Head) 2-354. To disassemble the power cable, squeeze the locking bracket clips inward and while squeezing the clips, pull the locking clip and power cable to remove the power cable.Figure 2-44. Bracket UninstallationFigure 2-45. Bracket Uninstallation(4)(5)
6878215A012-36 Standard Configurations Power Cables (Transceiver and Control Head)2.3.2 O2, O5, O7 or O9 Control Head Power CablesFigure 2-46. HKN6188_ Power Cable with External Speaker ConnectorFigure 2-47. HKN6187_ Power Cable with External Speaker Connector, RecordAudio Output Jack (2.5 mm) and Earphone Jack (2.5 mm)NOTE: Audio Out – Does not require CPS programming. Attaching a headset will mute the external speakers of the radio which are attached at the SPK jack of the control head.Record Out – Requires CPS programming. In CPS, navigate to Radio Wide/Advanced/Record Audio and select TX + RX Audio.
6878215A01Standard Configurations Power Cables (Transceiver and Control Head) 2-372.3.3 Battery Selector SwitchIn vehicles which have installed a Battery Selector Switch, the ignition sense (yellow) wire should be the only wire connected to the battery selector switch (see Figure 2-48). Radio transceiver and control head power wires (red) must be connected directly to the vehicle battery. If the control head power wire and the control head ignition sense wire are both connected to a battery selector switch, but the radio transceiver power lead is not, improper power-cycling and off-state battery drainage may occur. If the desired state of the radio is a total battery drain elimination, then all power and ignition sense wires must be routed through the battery selector switch, so that the control head and radio transceiver both see the loss of battery power at the same time.Figure 2-48. Battery Selector Switch
6878215A012-38 Standard Configurations Antenna Installation2.4 Antenna InstallationIMPORTANT: To assure optimum performance and compliance with RF Energy Safety standards, these antenna installation guidelines and instructions are limited to metal-body vehicles with appropriate ground planes and take into account the potential exposure of back seat passengers and bystanders outside the vehicle. NOTE: For mobile radios with rated power of 7 watts or less, the only installation restrictions are to use only Motorola approved antennas and install the antenna externally on metal body vehicles. For mobile radios with tuned power greater than 7 watts, always adhere to all the guidelines and restrictions in Section 2.4.1 below. 2.4.1 Selecting an Antenna Site/Location on a Metal Body Vehicle1. External installation – Check the requirements of the antenna supplier and install the vehicle antenna external to a metal body vehicle in accordance with those requirements.2. Roof top – For optimum performance and compliance with RF Energy Safety standards, mount the antenna in the center area of the roof. 3. Trunk lid – On some vehicles with clearly defined, flat trunk lids, the antennas of some radio models (see restrictions below) can also be mounted on the center area of the trunk lid. For vehicles without clearly defined, flat trunk lids (such as hatchback autos, sports utility vehicles, and pick-up trucks), mount the antenna in the center area of the roof. Before installing an antenna on the trunk lid, - Be sure that the distance from the antenna location on the trunk lid will be at least 85 cm (33 inches) from the front surface of the rear seat-back to assure compliance with RF Energy Safety standards.- Ensure that the trunk lid is grounded by connecting grounding straps between the trunk lid and the vehicle chassis.4. Mounting restrictions for certain radio models.For all VHF and UHF models, the 1/4 wave antenna should be mounted only in the center area of the roof, not on the trunk lid, to assure compliance with RF Energy Safety standards.5. Ensure that the antenna cable can be easily routed to the radio. Route the antenna cable as far away as possible from any vehicle electronic control units and associated wiring.6. Check the antenna location for any electrical interference.If these conditions cannot be satisfied, then mount the antenna on the roof top.!C a u t i o n
6878215A01Standard Configurations Antenna Installation 2-397. Ensure that any transmitting radio antennas on this vehicle are separated from each other by at least 3 feet (0.9 meter). See Figure 2-49.8. The minimum distance between the antenna and the radio/accessories should be at least 3 feet (91.44 cm).NOTE: Any two metal pieces rubbing against each other (such as seat springs, shift levers, trunk and hood lids, exhaust pipes, etc.) in close proximity to the antenna can cause severe receiver interference.Figure 2-49. Multiple Antennas Separation9113 ft3 ft3 ft
6878215A012-40 Standard Configurations Antenna Installation2.4.2 Mini-UHF ConnectionTo help aid in the installation of the radio antenna(s), there are labels indicating the frequency. The first is on the FCC label at the top of the radio which calls out the frequency and by using arrow points, which side the RF connector of the frequency is located at the back of the radio. The second is located at the back of the radio, next to the RF connector(s) (see Figure 2-50). To ensure a secure connection of an antenna cable's mini-UHF plug to a radio's mini-UHF jack, their interlocking features must be properly engaged. If they are not properly engaged, the system will loosen. Using a tool (pliers or wrench) will not overcome a poor engagement, and is not recommended. NOTE: Applying excessive force with a tool can cause damage to the antenna or the connector (e.g., stripping threads, deforming the collar or connector, or causing the connector to twist in the housing opening and break).The mini-UHF connector tool (Motorola part number HLN6695_) is designed to securely tighten the antenna plug–radio jack connection without damaging either the plug or the jack.Motorola recommends the following sequence to ensure proper attachment of the system (see Figure 2-50 and Figure 2-51):Figure 2-50. Mini-UHF Connection (As Shown on Mid Power)Figure 2-51. Mini-UHF Connection (100W Radios Only)1. Make sure that there is sufficient slack in the antenna cable.2. Make sure that the collar of the antenna cable plug is loose and does not bind.3. Make sure that the mini-UHF jack is tight in the radio housing.Coax ConductorPlug (Pin)FlangeCableCollar PulledBack to FlangeMini UHFJack RF Antenna Connector Label Coax ConductorPlug (Pin)FlangeCableCollar PulledBack to FlangeMini UHFJack
6878215A01Standard Configurations Antenna Installation 2-414. Slide the collar back against the flange. Insert the antenna cable plug’s pin fully into the radio jack, but do not engage the threads.5. Ensure that the plug’s and jack’s interlocking features are fully seated. Check this by grasping the crimp on the cable jack, rotating the cable, and noting any movement. If the features are seated correctly, there should be NO movement.6. Finger-tighten the antenna cable plug’s collar onto the radio’s jack.7. Give a final tug, by hand, to the collar, and retighten by hand as firmly as possible.8. Slip the mini-UHF connector tool over the coaxial cable, using the gap between the tool’s legs (see Figure 2-52). Then, slide the tool up onto the plug’s knurled collar. Squeeze the two straight legs of the tool firmly together between your thumb and index finger and turn clockwise (as shown) to tighten the collar. It should take 1/4 turn or less. When you feel the tool slipping on the collar, the connection has been properly tightened. The tool can also be used to loosen a tight collar.NOTE: DO NOT use pliers or any other device to grip the tightening tool. It has been designed to allow you to achieve the proper torque on the collar without overtightening. Overtightening the collar can damage the connector and the radio.Figure 2-52. Mini-UHF Connector Tool (As Shown on Mid Power)Figure 2-53. Mini-UHF Connector Tool (100W Radios Only)(1) SqueezeFirmly TogetherHLN6695_ (2) Tighten(1) SqueezeFirmly TogetherHLN6695_ (2) Tighten
6878215A012-42 Standard Configurations Antenna Installation2.4.3 GPS Antenna PlacementThe GPS antenna (excluding the Motorcycle GPS antenna) must be placed at least, 3 feet (0.9 meters) away from any transmitting antenna, and the antenna must have a clear, unobstructed view of the sky for best performance. The length of the cabling must be taken into consideration before the installation is started.2.4.4 GPS ConnectionTo ensure a secure connection of the GPS antenna cable's SMA plug to a radio's SMA jack, the connector must be fully seated. If the connectors are not fully seated, the system will loosen. This should be done by hand to ensure excess force is not applied. GPS positions as shown in Figure 2-54 and Figure 2-55 are located in different positions. The mid power radio has the GPS antenna connector on the back of the radio while the 100W radio has the antenna connector on the front of the radio.NOTE: Applying excessive force with a tool can cause damage to the antenna or the connector (e.g. stripping threads, deforming the collar or connector, or causing the connector to twist in the housing opening and break).Figure 2-54. GPS Antenna Connector on the Back of the Mid Power RadioFigure 2-55. GPS Antenna Connector on the Front of the 100W Radio
6878215A01Standard Configurations Speaker 2-432.5 SpeakerThe speaker kit includes a trunnion bracket that allows the speaker to be mounted in a variety of ways. With the trunnion bracket, the speaker can mount permanently on the mounting surface or in accessible firewall areas. The trunnion allows the speaker to tilt for best operation. Mount the speaker out of the way so that it will not be kicked or knocked around by the vehicle occupants. Mount the speaker as follows:1. Use the speaker mounting bracket as a template to mark the mounting hole locations.2. Use the self-drilling screws provided to fasten the trunnion.3. Attach the speaker and fasten to the trunnion with two wing screws.4. Route the speaker wires under the carpet or floor covering, or behind the kick panels. Be sure the wires are out of the way and will not be snagged and broken by the occupants of the vehicle.5. Do not submerse the 2-pin speaker connector in water nor place this connector in an area that could have standing water.Figure 2-56. Speaker MountingDO NOT ground the radio's speaker leads. This system has a floating speaker output (DC voltage on both leads); damage to the audio circuit will result if either lead is grounded or if they are shorted together.!C a u t i o nDashboardFirewallTrunnionBracketORMAEPF-25764-O

Navigation menu