Motorola Solutions 92FT4870 Astro Digital Mobile Radio XTL5000 User Manual 96C72 B

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zTitle Page ® XTL™ 5000

Digital Mobile Radio

Installation Manual

(Mid-Power and 100W Radios)

Motorola, Inc.

8000 West Sunrise Boulevard

Fort Lauderdale, Florida 33322 6881098C38-O

Foreword

This manual covers all models of the ASTRO® XTL™ 5000 digital mobile radios (models W3, W4, W5, W7, and W9),

unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum

working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level

and is typical of some local service centers, self-maintained customers, and distributors.

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 vii.

Product Safety and RF Exposure Compliance

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

Manual Revisions

Changes which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs provide

complete replacement pages for all added, changed, and deleted items.

To obtain FMRs, go to https://businessonline.motorola.com.

Parts Ordering

See Appendix A: Replacement Parts Ordering for information on how to obtain replacement parts. For part numbers, refer

to the ASTRO XTL 5000 Digital Mobile Radio Basic Service Manual (Motorola publication part number 6881096C73).

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in

semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain

exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in

any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the

Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in

any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not

be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or

patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the

sale of a product.

Document Copyrights

No duplication or distribution of this document or any portion thereof shall take place without the express written permission

of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic

or mechanical, for any purpose without the express written permission of Motorola.

Disclaimer

The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is

assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve

readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product

or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.

Trademarks

MOTOROLA, the Stylized M logo, FLASHport, and ASTRO are registered in the US Patent & Trademark Office. All other

product or service names are the property of their respective owners.

iii

Installation Requirements for Compliance with

Radio Frequency (RF) Energy Exposure Safety

Standards

ATTENTION!

This radio is intended for use in occupational/controlled conditions, where users have full knowledge

of their exposure and can exercise control over their exposure to meet FCC limits. This radio device is

NOT authorized for general population, consumer, or any other use.

To ensure compliance to RF Energy Safety Standards:

• Install only Motorola approved antennas and accessories

• Be sure that antenna installation is per “Antenna Installation,” on page 2-21 of this manual

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

upon completion of the installation of this radio

Before using this product, the operator must be familiar with the RF energy awareness information and

operating instructions in the Product Safety and RF Exposure booklet enclosed with each radio (Motorola

Publication part number 68P81095C99) to ensure compliance with Radio Frequency (RF) energy exposure

limits.

For a list of Motorola-approved antennas and other accessories, visit the following web site which lists

approved accessories for your radio model: http://www.motorola.com/cgiss/index.shtml.

This Page Intentionally Left Blank

Table of Contents v

6881098C38-O September 17, 2004

Table of Contents

Foreword.........................................................................................................ii

Product Safety and RF Exposure Compliance ............................................................................................ii

Manual Revisions ........................................................................................................................................ii

Parts Ordering .............................................................................................................................................ii

Computer Software Copyrights ...................................................................................................................ii

Document Copyrights ..................................................................................................................................ii

Disclaimer....................................................................................................................................................ii

Trademarks .................................................................................................................................................ii

Installation Requirements for Compliance with

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

Mobile Radio Model Numbering Scheme....................................................xi

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

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

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

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

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

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

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

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

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

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

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

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

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

1.2.1 Dash Mount Configuration ................................................................................................ 1-2

1.2.2 Remote Mount Configuration............................................................................................ 1-2

1.2.3 Dual Control Configuration ............................................................................................... 1-3

1.3 Motorcycle Configurations ............................................................................................................. 1-3

1.4 Base/Control Stations .................................................................................................................... 1-3

1.5 Tools Required for XTL 5000 Installations..................................................................................... 1-4

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

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

2.2 Radio Mounting.............................................................................................................................. 2-7

2.2.2 Remote Mount with Trunnion.......................................................................................... 2-10

2.2.2.1 Transceiver ............................................................................................................ 2-10

2.2.2.2 Control Head and Remote Mount Cabling............................................................. 2-12

2.2.3 Locking Kit (Optional) .....................................................................................................2-18

2.2.3.1 All Radios Except 100W ........................................................................................ 2-18

vi Table of Contents

September 17, 2004 6881098C38-O

2.2.3.2 100W Radios ......................................................................................................... 2-18

2.3 Power Cable ................................................................................................................................ 2-18

2.4 Ignition Sense Cable ................................................................................................................... 2-21

2.5 Antenna Installation ..................................................................................................................... 2-21

2.5.1 Selecting an Antenna Site/Location on a Metal Body Vehicle ........................................ 2-21

2.5.2 Mini-UHF Connection ..................................................................................................... 2-22

2.6 Speaker ...................................................................................................................................... 2-24

2.7 Microphone Hang-Up Clip ........................................................................................................... 2-24

2.7.1 Standard Hang-Up Clip................................................................................................... 2-24

2.7.2 Handheld Hang-Up Box (W3 Model) .............................................................................. 2-25

2.8 Completing the Installation .......................................................................................................... 2-25

Chapter 3 Options and Accessories Installation ............................... 3-1

3.1 VIP Overview ................................................................................................................................. 3-1

3.1.1 VIP Output Connections ................................................................................................... 3-1

3.1.2 VIP Input Connections......................................................................................................3-2

3.2 Remote-Mount Accessory Installations for W4/5/7/9 Models ........................................................ 3-2

3.2.1 Emergency Pushbutton, Footswitch, Horn Relay, and Light Relay Installation ............... 3-3

3.2.1.1 Emergency Pushbutton or Footswitch Installation................................................... 3-3

3.2.1.2 Horn (External Alarm) Relay Installation ................................................................. 3-4

3.2.1.3 Lights (External Alarm) Relay Installation................................................................ 3-4

3.3 Dash-Mount Accessory Installations for W4/5/7/9 Models ............................................................ 3-4

3.3.1 MDC Emergency Pushbutton or Footswitch Installation................................................... 3-5

3.3.2 Horn and Lights (External Alarms) Relays........................................................................ 3-5

3.4 Remote-Mount Accessory Installations for W3 Model................................................................... 3-6

3.4.1 MDC Emergency Pushbutton or Footswitch Installation for W3 with

Remote Cable Assembly .................................................................................................. 3-6

3.4.2 Horn and Lights (External Alarms) Relays Installation for W3 with

Remote Cable Assembly .................................................................................................. 3-6

3.5 Accessory Connector Assembly Details (P2) ................................................................................ 3-7

3.5.1 Installation into the Vehicle ............................................................................................... 3-7

3.5.2 Installation onto the Radio ................................................................................................3-8

3.5.3 Disassembly and Assembly.............................................................................................. 3-9

3.5.3.1 Disassembly ............................................................................................................ 3-9

3.5.3.2 Assembly .................................................................................................................3-9

3.5.4 Adapter Cable................................................................................................................. 3-10

3.5.5 Rear Accessory Jack Connection................................................................................... 3-11

Chapter 4 Motorcycle Radio Installation ............................................ 4-1

4.1 Motorcycle Radio Description ........................................................................................................ 4-1

4.1.1 Transceiver Enclosure ......................................................................................................4-1

4.1.2 Control/Display Unit .......................................................................................................... 4-1

4.1.3 Control Head Cable .......................................................................................................... 4-1

4.1.4 Microphone ....................................................................................................................... 4-1

4.1.5 External Speaker .............................................................................................................. 4-2

4.1.6 Headset Capability............................................................................................................ 4-2

4.1.7 Antenna ............................................................................................................................ 4-2

4.1.8 Ignition Wire...................................................................................................................... 4-2

4.2 Installation Overview ..................................................................................................................... 4-2

4.2.1 General............................................................................................................................. 4-2

4.2.2 Important Installation Hints ...............................................................................................4-3

Table of Contents vii

6881098C38-O September 17, 2004

4.2.3 Parts Identification ............................................................................................................ 4-3

4.2.4 Order of Installation .......................................................................................................... 4-4

4.3 Installing the Universal Mounting Plate.......................................................................................... 4-4

4.4 Installing the Speaker and Control Head ....................................................................................... 4-5

4.4.1 Handlebar Installation with Speaker and Control Head Mounted Together...................... 4-6

4.4.2 Fuel Tank Console Installation with Speaker and Control Head Mounted Together ........ 4-7

4.4.3 Handlebar Installation with Speaker and Control Head Mounted Separately ................... 4-9

4.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted Separately ... 4-10

4.5 Installing the Speaker .................................................................................................................. 4-10

4.6 Installing the Microphone Hang-Up Clip ...................................................................................... 4-11

4.6.1 Extension Bracket Mounting ........................................................................................... 4-11

4.6.2 Speaker/Control Head Bracket Side Mounting ............................................................... 4-11

4.6.3 Other Hang-Up Clip Mounting ........................................................................................ 4-11

4.7 Installing Cables .......................................................................................................................... 4-12

4.8 Installing the Weather-Resistant Enclosure................................................................................. 4-13

4.9 Transceiver and Cabling Installation............................................................................................ 4-14

4.9.1 Installing Cabling in the Enclosure.................................................................................. 4-14

4.9.2 Installing the Transceiver................................................................................................ 4-15

4.10 Installing the Antenna .................................................................................................................. 4-18

4.11 Installing the Emergency Switch Option ......................................................................................4-18

4.12 Installing the External Alarm Relay Option ..................................................................................4-18

4.13 Installing the Headset Accessory................................................................................................. 4-18

4.14 Horn/Lights Wiring ....................................................................................................................... 4-18

4.15 Emergency Switch Wiring............................................................................................................ 4-19

Chapter 5 Finishing the Installation: Cable Connection ................... 5-1

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

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

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

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

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

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

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

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

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

Related Publications

ASTRO XTL 5000 Digital Mobile Radio Model W3 User’s Guide ................................................6881096C67

ASTRO XTL 5000 Digital Mobile Radio Models W4, W5, W7, and W9 User’s Guide ................6881096C68

ASTRO XTL 5000 Digital Mobile Radio Basic Service Manual ...................................................6881096C73

CPS Programming Installation Guide ..........................................................................................6881095C44

ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual.........6881091C78

Spectra Control Station Installation Manual ................................................................................6880101W87

viii List of Figures

September 17, 2004 6881098C38-O

List of Figures

Figure 1-1. Front View of Dash Mount Radio (All but 100W Radios)...................................................... 1-1

Figure 1-2. Side View of Dash Mount Radio (All but 100W Radios) ....................................................... 1-1

Figure 1-3. Front View of 100W Radio.................................................................................................... 1-1

Figure 1-4. Side View of 100W Radio ..................................................................................................... 1-1

Figure 1-5. Dash Mount Configuration (All but 100W Radios) ................................................................ 1-2

Figure 1-6. Remote Mount Configuration (Cannot Be Used for 100W Radios) ...................................... 1-2

Figure 1-7. Remote Mount Configuration (100W Only)........................................................................... 1-3

Figure 2-1. Mounting Flexibility in Middle Console (Cannot Be Used for 100W Radios) ........................ 2-2

Figure 2-2. On Top or Under Dash Mounting (Cannot Be Used for 100W Radios) ................................ 2-2

Figure 2-3. Remote Mount–Control Head in Console ............................................................................. 2-2

Figure 2-4. In Dash Mounting (Cannot Be Used for 100W Radios) ........................................................ 2-2

Figure 2-5. Remote Mount–Control Head in Dash.................................................................................. 2-2

Figure 2-6. Remote Mount–Control Head on Top or Under Dash........................................................... 2-2

Figure 2-7. Radio Installation (Dash Mount) Using W4, W5, or W7 Control Heads

(Cannot Be Used for 100W Radios).......................................................................................................... 2-3

Figure 2-8. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads ............................... 2-4

Figure 2-9. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads (100W Only) .......... 2-4

Figure 2-10. Radio Installation (Dash Mount) Using W3 Control Heads

(Cannot Be Used for 100W Radios).......................................................................................................... 2-5

Figure 2-11. Radio Installation (Remote) Using W3 Control Heads.......................................................... 2-6

Figure 2-12. Radio Installation (Remote) Using W3 Control Heads (100W Only) .................................... 2-6

Figure 2-13. Trunnion Orientation (Cannot Be Used for 100W Radios).................................................... 2-7

Figure 2-14. Trunnion Orientation for 100W Radios (Quick Release Trunnion)........................................ 2-8

Figure 2-15. Trunnion Orientation for 100W Radios (Screw-Mounted Trunnion)...................................... 2-8

Figure 2-16. Transmission Hump Trunnion Mounting ............................................................................... 2-9

Figure 2-17. Below Dash Trunnion Mounting.......................................................................................... 2-10

Figure 2-18. 100W Radio Mounting into Quick Release Trunnion ...........................................................2-11

Figure 2-19. 100W Radio Mounting into Screw-Mounted Trunnion .........................................................2-11

Figure 2-20. W4, W5, W7, and W9 Control Heads ................................................................................. 2-12

Figure 2-21. W4, W5, and W7 Control Head Installation Exploded View ............................................... 2-13

Figure 2-22. W9 Control Head Installation Exploded View ..................................................................... 2-14

Figure 2-23. W4, W5, and W7 Control Head Rear View......................................................................... 2-14

Figure 2-24. W3 Control Head ................................................................................................................ 2-15

Figure 2-25. Fuseholder Assembly for Orange and Green Control Cables ............................................ 2-16

Figure 2-26. Locking Kit (Optional) (Cannot Be Used for 100W Radios)................................................ 2-18

Figure 2-27. Lock Supplied with 100W Quick Release Trunnion............................................................ 2-18

Figure 2-28. Cabling Interconnect Diagram for Remote Mount .............................................................. 2-19

Figure 2-29. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios) ......... 2-20

Figure 2-30. Mini-UHF Connection (Cannot Be Used for 100W Radios)................................................ 2-22

Figure 2-31. Mini-UHF Connection (100W Radios Only) ........................................................................ 2-22

Figure 2-32. Mini-UHF Connector Tool (Cannot Be Used for 100W Radios).......................................... 2-23

Figure 2-33. Mini-UHF Connector Tool (100W Radios Only) .................................................................. 2-23

Figure 2-34. Speaker Mounting............................................................................................................... 2-24

Figure 3-1. VIP Connector Detail ............................................................................................................ 3-3

Figure 3-2. Emergency Switch Wiring Diagram for W4/5/7/9.................................................................. 3-5

Figure 3-3. Horn/Light Wiring Diagram for W4/5/7/9...............................................................................3-6

Figure 3-4. Emergency Switch Wiring Diagram for W3........................................................................... 3-6

Figure 3-5. Horn/Light Wiring Diagram for W3........................................................................................ 3-7

Figure 3-6. Exploded View of Accessory Connector Assembly (P2) ...................................................... 3-9

Figure 3-7. Rear Accessory Connector Audio Configuration ................................................................ 3-10

List of Figures ix

6881098C38-O September 17, 2004

Figure 3-8. Rear Accessory Connector Data Configuration .................................................................. 3-10

Figure 3-9. Rear Accessory Jack Pin Configuration (J2) (Radio Side) ................................................. 3-11

Figure 4-1. Universal Mounting Plate Installation (Part of Radio Enclosure Kit) ..................................... 4-5

Figure 4-2. Handlebar Installation with Speaker and Control Head Mounted Together .......................... 4-6

Figure 4-3. Fuel Tank Console Installation with Speaker and Control Head Mounted Together ............. 4-8

Figure 4-4. Handlebar Installation with Speaker and Control Head Mounted Separately ....................... 4-9

Figure 4-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately ........ 4-10

Figure 4-6. Cable Routing ..................................................................................................................... 4-12

Figure 4-7. Weather-Resistant Enclosure Installation ........................................................................... 4-13

Figure 4-8. Installing Cables.................................................................................................................. 4-15

Figure 4-9. Installing the Transceiver .................................................................................................... 4-17

Figure 4-10. Horn/Lights Wiring Diagram................................................................................................ 4-18

Figure 4-11. Emergency Switch Wiring Diagram .................................................................................... 4-19

September 17, 2004 6881098C38-O

List of Tables

Table 2-1. Radio Functions Connections .................................................................................. 2-16

Table 2-2. Fuse Assembly for Orange and Green Leads Parts List.......................................... 2-17

Table 3-1. VIP Output Connections ............................................................................................ 3-1

Table 3-2. VIP Input Connections ............................................................................................... 3-2

Table 3-3. Rear Accessory Jack Pin Functions......................................................................... 3-12

Table 3-4. Rear Connector and Front Connector Naming Schemes ........................................ 3-13

Table 3-5. How to Connect to a Computer1 (DTE Device)........................................................ 3-13

Table 4-1. Transceiver Installation Parts List ............................................................................ 4-16

6881098C38-O September 17, 2004

Mobile Radio Model Numbering Scheme xi

Mobile Radio Model Numbering Scheme

Position 1 - Type of Unit

M = Mobile

L = Table Top Station

Positions 2 & 3 - Model Series

Position 4 - Frequency Band

Less than 29.7MHz

29.7 to 35.99MHz

36 to 41MHz

42 to 50MHz

300 to 345MHz

66 to 80MHz

74 to 90MHz

Product Specific

VHF Range

136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

330 to 370MHz

366 to 410MHz

403 to 437MHz

438 to 482MHz

470 to 620MHz

Product Specific

UHF Range

806 to 870MHz*

825 to 870MHz

896 to 941MHz

403-470MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

10.1 to 15 Watts

16 to 25 Watts

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Tranceiver with Selectable Control Head

VDV Control Head

Control Head #2

Position 7 - Channel Spacing

0 =

1 = 5KHz

2 = 6.25KHz

3 = 10KHz

4 = 12.5KHz

5 = 15KHz

6 = 20/25KHz

7 = 30KHz

8 = 12.5/25KHz

9 = Variable/Programmable

Typical Model Number:

Position:

Position 8 - Primary Operation

Conventional/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Digital Dispatch

Programmable

Digital Interconnect

Digital Multi-Service

9600 Capable

TDMA

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

Position 9 - Primary System Type

Conventional

Privacy Plus

Clear SMARTNET

Advanced Conventional Stat-Alert

Enhanced Privacy Plus

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet

IDEN Basic

IDEN Advanced Feature

JSMR Digital

LTR Protocol

Single Sideband

Programmable

Secure Conventional

Secure SMARTNET

TETRA

SmartZone

* MPT = Ministry of Posts and Telecommunications

Position 10 - Feature Level

1 = Basic

2 = Limited Package

3 = Limited Plus

4 = Intermediate

5 = Standard Package

6 = Standard Plus

7 = Expanded Package

8 = Expanded Plus

9 = Full Feature/

Programmable

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 12 -

Unique Model Variations

C = Cenelec

N = Standard Package

Positions 13 - 16

SP Model Suffix

1 23 4 5 6 7 8 9 10 11 1213141516

M20 U RS 9 P W 1 A N S P 0 1

20 = XTL 5000

26 to 35 Watts

36 to 60 Watts

61 to 110 Watts

Up to 125 Watts

1-25 Watts

25-40 Watt

25-45 Watt

10-35 Watt

MAEPF-27634-O

* For XTL 5000 "U" in Position 4 represents

764-870MHz.

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.

September 17, 2004 6881098C38-O

xii Mobile Radio Model Numbering Scheme

Notes

6881098C38-O September 17, 2004

Commercial Warranty xiii

Commercial Warranty

Limited Warranty

MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

MOTOROLA 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 Provisions

This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product.

Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive

remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED

WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE

DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR

DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF

USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS

OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE

USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE

DISCLAIMED BY LAW.

ASTRO XTL 5000 Digital Mobile Radio One (1) Year

Product Accessories One (1) Year

September 17, 2004 6881098C38-O

xiv Commercial Warranty

III. State Law Rights

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR

CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY

LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.

This warranty gives specific legal rights, and there may be other rights which may vary from state to

state.

IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number)

in order to receive warranty service and, also, deliver or send the Product item, transportation and

insurance prepaid, to an authorized warranty service location. Warranty service will be provided by

Motorola through one of its authorized warranty service locations. If you first contact the company

which sold you the Product, it can facilitate your obtaining warranty service. You can also call

Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty Does Not Cover

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

manner.

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

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

modification, or adjustment.

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

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

ing, 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 tamper-

ing.

- 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 Prod-

uct, does not function in accordance with MOTOROLA’s published specifications or the FCC

type acceptance labeling in effect for the Product at the time the Product was initially distrib-

uted 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.

6881098C38-O September 17, 2004

Commercial Warranty xv

VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the

extent that it is based on a claim that the Product or parts infringe a United States patent, and

MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in

any such suit which are attributable to any such claim, but such defense and payments are

conditioned on the following:

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

claim;

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

settlement or compromise; and

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

subject of a claim of infringement of a United States patent, that such purchaser will permit

MOTOROLA, at its option and expense, either to procure for such purchaser the right to con-

tinue using the Product or parts or to replace or modify the same so that it becomes nonin-

fringing or to grant such purchaser a credit for the Product or parts as depreciated and accept

its return. The depreciation will be an equal amount per year over the lifetime of the Product

or parts as established by MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent infringement which is based

upon the combination of the Product or parts furnished hereunder with software, apparatus or

devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary

equipment or software not furnished by MOTOROLA which is attached to or used in connection with

the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of

patents by the Product or any parts thereof.

Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for

copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute

copies of such Motorola software. MOTOROLA software may be used in only the Product in which

the software was originally embodied and such software in such Product may not be replaced,

copied, distributed, modified in any way, or used to produce any derivative thereof. No other use

including, without limitation, alteration, modification, reproduction, distribution, or reverse

engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is

permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent

rights or copyrights.

VII. Governing Law

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

September 17, 2004 6881098C38-O

xvi Commercial Warranty

Notes

Chapter 1 Introduction

This manual covers the installation procedures for ASTRO XTL 5000 mobile and motorcycle radios

and accessories required to complete the radio system. The radio system consists of a control head,

radio, antenna, microphone, speaker, cabling, and accessories.

1.1 Mobile Radio Description

1.1.1 Dimensions

Figure 1-1 and Figure 1-2 show the basic dimensions of the dash mount (mid-power) XTL 5000

radio, and Figure 1-3 and Figure 1-4 show the basic dimensions of the 100W (high-power) XTL 5000

radio. The transceiver portion of a remote mount XTL 5000 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 wing screws.

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

Figure 1-1. Front View of Dash Mount Radio

(All but 100W Radios)

Figure 1-2. Side View of Dash Mount Radio

(All but 100W Radios)

Figure 1-3. Front View of 100W Radio Figure 1-4. Side View of 100W Radio

8.5"

7.1"

9.1"

3.5"

7.00"

8.78"

12.25"

3.25"

2.38"

September 17, 2004 6881098C38-O

1-2 Introduction: Standard Configurations

1.2 Standard Configurations

1.2.1 Dash Mount Configuration

NOTE: The dash mount configuration is not applicable for 100W radios.

In the dash mounting version of the XTL 5000, the control head is mounted on the front of the

transceiver housing. 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.

Figure 1-5. Dash Mount Configuration (All but 100W Radios)

For details on this configuration, see Section 2.2.1 on page 2-9.

1.2.2 Remote Mount Configuration

In the remote control version, the transceiver and the control head are mounted separately in the

vehicle. The control head is mounted in a remote trunnion near the operator. The transceiver is

mounted by means of a trunnion or other mounting hardware. If the transceiver is located in a car

trunk, be sure that secure mounting and sufficient cooling are provided. Do not cover the transceiver

with baggage, blankets, etc.

Figure 1-6. Remote Mount Configuration (Cannot Be Used for 100W Radios)

MAEPF-27638-O

PWR

Mode Scan

Phon Sel

Call

Vol

DIM

HOME

XMIT

BUSY

123

456

789

Sts Msg

H/L Mon Dir

RclDel

6881098C38-O September 17, 2004

Introduction: Motorcycle Configurations 1-3

Figure 1-7. Remote Mount Configuration (100W Only)

For details on these configurations, see Section 2.2.2 on page 2-10.

1.2.3 Dual Control Configuration

The dual control head option allows two, 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.

For details on this configuration, see the ASTRO Digital Spectra Mobile Radios Dual Control Head

Radio System Service Manual (Motorola publication part number 6881091C78).

1.3 Motorcycle Configurations

NOTE: The motorcycle configurations are not applicable for 100W radios.

The ASTRO XTL 5000 motorcycle radio models provide most of the equipment needed for installing

a standard ASTRO XTL 5000 radio on a motorcycle. Most of this radio system is standard

equipment. See Chapter 4: Motorcycle Radio Installation for further information.

1.4 Base/Control Stations

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

The base/control station option provides the radio with a desk microphone and power supply for use

at a fixed location. All operations are the same as the mobile, except for the desk microphone.

Choose a location for your base/control station as close as possible to where the antenna cable

enters the building. Be sure an electric outlet is available. Make sure sufficient air can flow around

the radio to permit adequate cooling.

The antenna should be installed outside of the building, but never within two feet (for radios with less

than 50 watts power output) or within three feet (for radios with 50 watts or higher power output) of

station operators or bystanders.

For more information, refer to the Spectra Control Station Installation Manual (Motorola publication

part number 6880101W87).

PWR

Mode Scan

Phon Sel

Call

Vol

DIM

HOME

XMIT

BUSY

123

456

789

Sts Msg

H/L Mon Dir

Rcl Del

MAEPF-28156-O

September 17, 2004 6881098C38-O

1-4 Introduction

1.5 Tools Required for XTL 5000 Installations

Tool Part Number

11/32 hex driver —

RF cable tool HLN6695_

Regular slot screwdriver of

Phillips #2

—

Pin removal tool 6680163F01

1/4 hex driver —

Chapter 2 Standard Configurations

2.1 Planning the Installation

The XTL 5000 radio operates only in negative ground electrical systems. 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.

CAUTION 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.

September 17, 2004 6881098C38-O

2-2 Standard Configurations: Planning the Installation

2.1.1 Installation Examples

Your mobile two-way radio offers various methods of installation, including dash or remote mount.

Except for 100W radios, all versions of the XTL 5000 can be either dash or remote mounted (see

Figure 2-1 through Figure 2-6).100W radios can only be mounted remotely (see Figure 2-3,

Figure 2-5, and Figure 2-6).

Figure 2-1. Mounting Flexibility in Middle Console

(Cannot Be Used for 100W Radios)

Figure 2-2. On Top or Under Dash Mounting

(Cannot Be Used for 100W Radios)

Figure 2-3. Remote Mount–Control Head in Console Figure 2-4. In Dash Mounting

(Cannot Be Used for 100W Radios)

Figure 2-5. Remote Mount–Control Head in Dash Figure 2-6. Remote Mount–Control Head on Top or

Under Dash

Radio

Antenna

1/4-Wavelength

Battery

Speaker

Radio

Antenna

1/4-Wavelength

Battery

Speaker

Radio

Battery

Speaker

Control Head

Antenna

1/4-Wavelength

Radio

Antenna

1/4-Wavelength

Battery

Speaker

Radio

Battery

Speaker

Control Head

Antenna

1/4-Wavelength

Radio

Battery

Speaker

Control Head

Control Head Antenna

1/4-Wavelength

6881098C38-O September 17, 2004

Standard Configurations: Planning the Installation 2-3

2.1.2 Wiring Diagrams

Figure 2-7 through Figure 2-11 show the wiring diagrams for all the possible configurations. The title

under each figure identifies which model control head is being shown. Identify which of these figures

shows the configuration that you are installing, and use the diagram when planning the installation.

Figure 2-7. Radio Installation (Dash Mount) Using W4, W5, or W7 Control Heads

(Cannot Be Used for 100W Radios)

(For complete pin configuration, see Figure 3-9.)

PWR

Mode Scan

Phon Sel

Call

Vol

DIM

HOME

XMIT

BUSY

123

78 9

Sts Msg

H/L Mon Dir

Rcl Del

MIC

BATTERY

HORN

RELAY

LIGHT

RELAY

MIC

CLIP

SPEAKER

MIC

EMERGENCY

SWITCH

FUSE

BLOCK

(+)

(-)

REDLEAD

FUSE

FIREWALL

HOLE

MOUNTING

SCREW

CONTROLHEAD*

*MODELW7SHOWN

ANTENNA

CONNECTION

ANTENNA

MAEPF-27612-O

IGNITIONCABLE

(SEEJ2

PINOUT)

POWER

CABLE

TRUNNION

REARACCESSORYCONNECTOR

SPKR-

SPKR+

VIPOUT2

12V

(RELAY)

VIPOUT1

12V

(RELAY)

GROUND

EMERGENCY

IGNITION

September 17, 2004 6881098C38-O

2-4 Standard Configurations: Planning the Installation

Figure 2-8. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads

Figure 2-9. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads (100W Only)

PWR

Mode Scan

Phon Sel

Call

Vol

DIM

HOME

XMIT

BUSY

123

78 9

Sts Msg

H/L Mon Dir

Rcl Del

MIC

BATTERY

HORN

RELAY

LIGHT

RELAY

MIC

CLIP

SPEAKER

MIC

EMERGENCY

SWITCH

GRN LEAD

FUSE

BLOCK

ORG LEAD

(+)

(-)

FUSE

REMOTE

MOUNT

CONTROL

CABLE

CONTROL HEAD*

* MODEL W7 SHOWN

MAEPF-27613-O

12345 781011

12 13 14 15 16 17

1918 20 21 23 24 26 27 28 29 30 31 32 33

34 35 36 37 38 40 41 43 44 45 46 47 48 49 50

VIP MIC RADIO

VIP SECTION PIN OUT

1 VIP OUT - 2

2 VIP OUT - 1

3 VIP IN - 2 *

4 VIP IN - 1

5 DEK DATA OUT

* EMERGENCY WITH JUMPER CHANGES TO CONTROL HEADS

18 SWB +

19 SWB +

20 GROUND

21 GROUND

34 VIP OUT - 3 / DEK STROBE

35 SWB +

36 GROUND

37 VIP IN - 3 / DEK DATA IN

38 DEK CLOCK

J0103

PORT ON BACK OF CONTROL HEAD

FIREWALL

HOLE

ANTENNA

CONNECTION

ANTENNA

DC POWER

CABLE

RADIO

P506 J6

FUSE

PWR Mode Scan

Phon Sel

Call

Vol

DIM

HOME

XMIT

BUSY

123

78 9

Sts Msg

H/L Mon Dir

Rcl Del

MIC

BATTERY

HORN

RELAY

LIGHT

RELAY

MIC

CLIP

SPEAKER

MIC

GRN LEAD

FUSE

BLOCK

ORG LEAD

(+)

(-)

FUSE

REMOTE

MOUNT

CONTROL

CABLE

12345 781011

12 13 14 15 16 17

1918 20 21 23 24 26 27 28 29 30 31 32 33

34 35 36 37 38 40 41 43 44 45 46 47 48 49 50

VIP MIC RADIO

VIP SECTION PIN OUT

1 VIP OUT - 2

2 VIP OUT - 1

3 VIP IN - 2 *

4 VIP IN - 1

5 DEK DATA OUT

* EMERGENCY WITH JUMPER CHANGES TO CONTROL HEADS

18 SWB +

19 SWB +

20 GROUND

21 GROUND

34 VIP OUT - 3 / DEK STROBE

35 SWB +

36 GROUND

37 VIP IN - 3 / DEK DATA IN

38 DEK CLOCK

J0103

PORT ON BACK OF CONTROL HEAD

ANTENNA

FUSE

EMERGENCY

SWITCH

CONTROL HEAD*

* MODEL W7 SHOWN

FIREWALL

HOLE

ANTENNA

CONNECTION DC POWER

CABLE

RADIO

MAEPF-28157-O

6881098C38-O September 17, 2004

Standard Configurations: Planning the Installation 2-5

Figure 2-10. Radio Installation (Dash Mount) Using W3 Control Heads

(Cannot Be Used for 100W Radios)

(For complete pin configuration, see Figure 3-9.)

BATTERY

LIGHTOR

HORN

RELAY

SPEAKER

EMERGENCY

SWITCH

FUSE

BLOCK

(+)

(-)

FUSE

FIREWALL

HOLE

MOUNTING

SCREW

CONTROLHEAD

ANTENNA

CONNECTION

IGNITIONCABLE

POWER

CABLE

TRUNNION

HANG-UP

BOX

HANDHELD

CONTROL

HEAD

FUSE

ANTENNA

MAEPF-27614-O

REARACCESSORYCONNECTOR

(SEEJ2

PINOUT)

SPKR-

SPKR+

VIPOUT2

12V

(RELAY)

VIPOUT1

12V

(RELAY)

GROUND

EMERGENCY

IGNITION

P506 J6

September 17, 2004 6881098C38-O

2-6 Standard Configurations: Planning the Installation

Figure 2-11. Radio Installation (Remote) Using W3 Control Heads

Figure 2-12. Radio Installation (Remote) Using W3 Control Heads (100W Only)

BATTERY

LIGHT OR

HORN

RELAY

PEAKER

EMERGENCY

SWITCH

FUSE

BLOCK

(+)

(-)

REMOTE

MOUNT CONTROL

CABLE

MAEPF-27615-O

FIREWALL

HOLE

ANTENNA

CONNECTION

DC POWER

CABLE

RADIO

REMOTE MOUNT

ACCESSORY CONNECTOR

DIG

GND

SPKR

LO SPKR

IGNITION

SWB+

VIP

OUT 2

EMER

NOTE 1

BUS+

NC NOTE 2 BUSY

VIP OUT 1 BUS-

NOTES:

1. TX AUDIO IN SP CUSTOMER APPLICATIONS.

2. DET AUDIO IN SP CUSTOMER APPLICATIONS.

12345

15 14 13 12 11 10 9

HANDHELD

CONTROL

HEAD

HANG-UP

BOX

IGNITION CABLE

PINOUT

FUSE

P506 J6

BATTERY

LIGHT OR

HORN

RELAY

SPEAKER

EMERGENCY

SWITCH

FUSE

BLOCK

(+)

(-)

REMOTE MOUNT

ACCESSORY CONNECTOR

DIG

GND

SPKR

LO SPKR

IGNITION

SWB+

VIP

OUT 2

EMER

NOTE 1

BUS+

NC NOTE 2 BUSY

VIP OUT 1 BUS-

NOTES:

1. TX AUDIO IN SP CUSTOMER APPLICATIONS.

2. DET AUDIO IN SP CUSTOMER APPLICATIONS.

12345

15 14 13 12 11 10 9

HANDHELD

CONTROL

HEAD

HANG-UP

BOX

IGNITION CABLE

PINOUT

FUSE

ANTENNA

CONNECTION

RADIO

REMOTE

MOUNT CONTROL

CABLE

FIREWALL

HOLE

DC POWER

CABLE

MAEPF-28158-O

6881098C38-O September 17, 2004

Standard Configurations: Radio Mounting 2-7

2.2 Radio Mounting

The mounting location must be accessible and visible. Select a location that will permit routing the

RF antenna cable as directly as possible.

NOTE: For optimum radio performance, orient the mounting trunnion as shown in Figure 2-11 or

Figure 2-12. For new or existing installations of all but 100W radios, use only the XTL 5000

trunnion, kit number HLN6861_. For new or existing installations of 100W radios, use only the

XTL 5000 trunnion, kit numbers HLN6909_ or HLN6910_.

Figure 2-13. Trunnion Orientation (Cannot Be Used for 100W Radios)

CAUTION: DO NOT mount the radio on a plastic dashboard

without first reinforcing the dashboard; the weight of the radio may

crack or break the dashboard.

CAUTION: 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.

CAUTION: 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.

C a u t i o n

RADIO

FRONT

APPLIESTORADIOSWITHINTEGRAL

ORREMOTEMOUNTCONTROLUNITS

September 17, 2004 6881098C38-O

2-8 Standard Configurations: Radio Mounting

Figure 2-14. Trunnion Orientation for 100W Radios

(Quick Release Trunnion)

Figure 2-15. Trunnion Orientation for 100W Radios

(Screw-Mounted Trunnion)

TOP

BOTTOM

TOP

BOTTOM

6881098C38-O September 17, 2004

Standard Configurations: Radio Mounting 2-9

2.2.1 Dash Mount with Trunnion

NOTE: This configuration is not applicable for 100W radios.

1. Select the location to mount your radio on the transmission hump (see Figure 2-16) or under

the dash (see Figure 2-17). When mounting the trunnion on the transmission hump take care

the transmission housing is not affected.

2. 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.

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

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

Figure 2-16 and Figure 2-17).

5. 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 2-16). Secure the radio with the two

wing screws provided.

Figure 2-16. Transmission Hump Trunnion Mounting

Tabs

Trunnion

Groove

WingScrew

WingScrew PlasticGuides

ThreadedHole

forWingScrew

September 17, 2004 6881098C38-O

2-10 Standard Configurations: Radio Mounting

Figure 2-17. Below Dash Trunnion Mounting

2.2.2 Remote Mount with Trunnion

2.2.2.1 Transceiver

For a remote mount installation, the transceiver may be mounted anywhere in the vehicle, provided

that the installation location is safe, follows the cautions mentioned at the beginning of this section,

and is accessible for servicing/maintenance as well as cabling. A typical mounting location

recommended by Motorola is in the vehicle’s trunk. The trunnion provided may still be used to mount

the transceiver, and the mounting process is the same as for the dash mount installation (Section

2.2.1 on page 2-9). However, for 100W radios you must follow the procedure detailed below in

Section 2.2.2.1.1. See Figure 2-8 or Figure 2-9 for a remote W4, W5, W7, and W9 installation, and

Figure 2-11 or Figure 2-12 for a remote W3 installation.

2.2.2.1.1 100W Radios Only

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 five self-drilling screws provided (see Figure 2-

14 and Figure 2-15).

4. A. Quick release trunnion (HLN6909_): See Figure 2-18. After the trunnion has been

mounted in the vehicle using the screws provided, insert the rear of the radio into the rear

catches of the trunnion and rotate the radio down into place. Then push the handle towards

the back of the radio to secure it. Using the keys provided, lock the handle in place and

remove the keys.

CAUTION 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.

Trunnion

WingScrew

Holesfor

Microphone

S-Hook

6881098C38-O September 17, 2004

Standard Configurations: Radio Mounting 2-11

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

B. Screw-mounted trunnion (HLN6910_): See Figure 2-19. After mounting the trunnion to the

vehicle using the screws provided, insert the rear of the radio into the rear catches of the

trunnion and rotate the radio down into place. Secure the radio by installing the four wing

screws provided.

Figure 2-19. 100W Radio Mounting into Screw-Mounted Trunnion

September 17, 2004 6881098C38-O

2-12 Standard Configurations: Radio Mounting

2.2.2.2 Control Head and Remote Mount Cabling

For radios equipped with optional remote mount control heads, see Figure 2-8 or Figure 2-9. For

radios equipped with remote handheld control heads, see Figure 2-11 or Figure 2-12. Choose a

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

2.2.2.2.1 Remote W4, W5, W7, and W9 Model Control Head Installation

Figure 2-20 shows each of the control head models.

If you are required to insert any of the replaceable buttons available with these radios, refer to the

XTL 5000 Basic Service Manual (Motorola publication part number 6881096C73) for further

information.

Figure 2-20. W4, W5, W7, and W9 Control Heads

The recommended mounting surfaces for the control unit are under the dashboard, on the

transmission hump, or on the center console. Figure 2-21 shows how the trunnion, control head, and

cables should be installed for the W4, W5, and W7 control heads. Figure 2-22 shows the installation

for the W9 model control head.

NOTE: For control head models W4, W5, and W7 only: To seal the control head and meet

U. S. MIL-STD-810D environmental specifications, covers are supplied for protection of the

control head’s rear connector pins. These covers are in the bag that is fastened to the remote

control head’s mounting trunnion.

If the VIP connector is not being used to connect options, the VIP protective cover should be

installed as shown in Figure 2-23. If the microphone is connected to the front of the control

head, the MIC protective cover should be installed as shown in Figure 2-23. Alternately, the

microphone can be connected to the rear connector in place of the cover, and the control head

will still be environmentally sealed.

An adjustable trunnion, which allows a number of mounting positions, is supplied for mounting the

control unit. The installation must not interfere with the operation of the vehicle or its accessories, nor

disturb passenger seating or leg room. The control head must be within convenient reach and

viewing of the user.

If the trunnion is mounted on a plastic dashboard, all four mounting screws should penetrate the

dashboard’s supporting metal frame. If that is not possible, use a metal backing plate (not supplied)

to strengthen the installation. Install the control unit as 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.

6881098C38-O September 17, 2004

Standard Configurations: Radio Mounting 2-13

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 unit does not wobble or feel

“spongy” when you press the buttons.

NOTE: Use all four mounting screws and be sure they are tightly screwed into metal — either a

dashboard support bracket or a backing plate.

Figure 2-21. W4, W5, and W7 Control Head Installation Exploded View

CAUTION: 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 n

IMPORTANT

USE A METAL BACKING PLATE

(NOT SUPPLIED) IF MOUNTING

TRUNNION ON A PLASTIC DASHBOARD

DRILL FOUR 5/32"

HOLES IN DASHBOARD

DASHBOARD

TRUNNION

03-00136756

USE FOUR MOUNTING SCREWS

ON ALL INSTALLATIONS

ADJUST THE CONTROL HEAD

TO DESIRED ANGLE AND

SECURE WITH WING SCREWS

VIP CONNECTOR

MICROPHONE

SPEAKER

RADIO

ORANGE AND

GREEN LEADS

MAEPF-21453-O

September 17, 2004 6881098C38-O

2-14 Standard Configurations: Radio Mounting

Figure 2-22. W9 Control Head Installation Exploded View

Figure 2-23. W4, W5, and W7 Control Head Rear View

IMPORTANT

USE A METAL BACKING PLATE

(NOT SUPPLIED) IF MOUNTING

TRUNNION ON A PLASTIC DASHBOARD

DRILL FOUR 5/32"

HOLES IN DASHBOARD

DASHBOARD

TRUNNION

03-00136756

USE FOUR MOUNTING SCREWS

ON ALL INSTALLATIONS

ADJUST THE CONTROL HEAD

TO DESIRED ANGLE AND

SECURE WITH WING SCREWS

VIP CONNECTOR

MICROPHONE

SPEAKER

RADIO

ORANGE AND

GREEN LEADS

DESCRIPTION

TECHNICAL PUBLICATIONS DEPT.

DWG. NO.

MAEPF 21373

MAEPF-21373-0

VIP CONNECTOR

PROTECTIVE COVER

CONTROL CABLE

CONNECTOR

MIC CONNECTOR

PROTECTIVE COVER

6881098C38-O September 17, 2004

Standard Configurations: Radio Mounting 2-15

2.2.2.2.2 Remote W3 Model Control Head Installation

Figure 2-24 shows the W3 control head model.

Figure 2-24. W3 Control Head

For the remote handheld control unit, mount the control cable with the screws provided. Connect the

control cable as shown in Figure 2-11 or Figure 2-12. Connect the speaker to the accessory cable

harness.

2.2.2.2.3 Remote Radio Control Cable Installation

The radio control cable should go from the rear of the control head to the radio. 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 2-28 shows how the cables and components are connected.

2.2.2.2.4 Transmit/Receive Control Cable Installation (W4, W5, W7, W9 Remote Control Heads)

The radio system includes two separate wires, one orange (66") and one green (106"). The

HLN4952_ Fuse Kit contains crimp-on ring tongue lugs and crimp-on spade lugs. The spade lugs

allow connection to hot leads at the fuse block of the vehicle, and the ring tongue lugs permit

attachment to screw terminals. Determine from Table 2-1 which radio functions are to be switched

through the vehicle ignition switch.

A typical system allows the receiver to operate with the radio switched on while the ignition switch is

in the off position, but the transmitter will not operate unless the ignition switch is in the on position.

In this case, connect the orange wire to the accessory terminal of the ignition switch and the green

wire to the ungrounded terminal of the battery or starter solenoid.

CAUTION: To ensure a proper water seal, the jackscrews on the

radio cable connector must be tight. If the accessory port on a

remote mounted radio is not used, the cover gasket assembly

(HLN6233_) must be installed and torqued to 6 to 8 inch-pounds.

C a u t i o n

September 17, 2004 6881098C38-O

2-16 Standard Configurations: Radio Mounting

If either wire is to be connected in the vehicle’s battery compartment, pass the end of the wire

through the same firewall hole that the red radio power cable uses. At this point, install a fuseholder

assembly in both wires (see Figure 2-25); the following procedures apply to both green and orange

wires:

Figure 2-25. Fuseholder Assembly for Orange and Green Control Cables

• A fuse will need to be placed in-line for both the orange and green wires; consideration should

be taken when deciding where to place the fuses so that they are easy to inspect. However,

they should also be placed as close as possible to the battery or the vehicle’s ignition switch

terminal.

• After choosing the fuse locations, the fuse receptacles need to be installed. This is done by cut-

ting the wire at the chosen location and stripping 1/8-inch of insulation on all loose ends. Make

sure the wire will reach its intended destination.

CAUTION: DO NOT connect either lead to the ungrounded

terminal of the battery until you have finalized the installation and

have been instructed to do so.

Table 2-1. Radio Functions Connections

Conductor Green Orange Green Orange Green Orange

Connected to battery X X X

Connected to ignition

switch

XXX

Ignition switch controls No ignition switch control Transmitter ignition switch

controlled

Complete radio ignition

switch controlled

In any application, trim and strip wires. Crimp on ring lug for battery connections. For ignition switch connections, crimp

on ring or spade lug (whichever is required).

C a u t i o n

SPADE OR RING

TONGUE LUG

(RING TONGUE

LUG SHOWN)

PLASTIC INSULATOR

FUSE HOLDER CAP

METAL FUSE

CLIPS CRIMP

AND SOLDER

TO WIRE

TO CONTROL

HEAD

SPRING

FUSE

PLASTIC INSULATOR

FUSE HOLDER

MAEPF-21361-O

6881098C38-O September 17, 2004

Standard Configurations: Radio Mounting 2-17

• Slide the plastic insulator fuseholder over the end of the wire that is connected to the cable kit.

Insert the stripped end of that wire into one of the metal fuse clips, and crimp it closed onto the

exposed wire. Solder it for a better electrical contact.

• On the end of the loose wire, repeat the above crimping and soldering process with the remain-

ing metal fuse clip.

• Temporarily, install the fuse into the fuse clips onto both sides of the fuse. Slide the spring over

the remaining loose end of the wire. The spring should be followed by the plastic insulator fuse-

holder oriented as shown in Figure 2-25. Slide the plastic insulator fuse holder together, by first

making sure the spring slips inside the plastic insulator fuseholder cap. Now, twist the fusehold-

ers until they lock together. After assembly proves successful, remove the fuses until instructed

to install them later.

With the spring and plastic insulator fuseholder cap still in place on the loose portion of the wires

(orange and green), insert the stripped end of the wire into the spade or ring tongue lug. Crimp and

solder the lug as was done on the metal fuse clips above.

2.2.2.2.4.1 Transmitter Control Power Lead (Orange)

Connect the orange lead to the ignition switch (recommended) or directly to the battery hot supply

(see Figure 2-28).

2.2.2.2.4.2 Receiver Control Power Lead (Green)

Connect the green lead to the positive battery terminal (recommended) or the ignition switch (see

Figure 2-28).

Table 2-2. Fuse Assembly for Orange and Green Leads Parts List

Motorola Part Number Description

1482882A01 Insulator, Fuseholder Body

1482883A01 Insulator, Fuseholder Cap

2900136968 Lug

2900824456 Lug, Ring Tongue

2900865065 Lug, Ring Tongue

4182885A01 Spring, Compression; Fuse

4282884Q01 Clip, Fuse

6500020404 Fuse, 3-Amp 250V (Qty. 2)

September 17, 2004 6881098C38-O

2-18 Standard Configurations

2.2.3 Locking Kit (Optional)

2.2.3.1 All Radios Except 100W

If an optional locking kit is used (shown in Figure 2-26), position the lock bottom housing on the

trunnion before installing the radio mounting screws. Then slip the top lock housing on and remove

the key. You can install the lock on either side of the radio, and by rotating it 180°, you can also install

it on dash installations.

Figure 2-26. Locking Kit (Optional) (Cannot Be Used for 100W Radios)

2.2.3.2 100W Radios

An integral lock is included in the quick release trunnion (HLN6909_). The use of this lock is required

for proper operation (see Figure 2-27).

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

2.3 Power Cable

Route the red radio power cable from the radio 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 (P/N 6580283E06) or 20-amp (P/N 6580283E07) 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 2-28 and Figure 2-29. Connect the black lead to a convenient solid chassis ground

point. DO NOT connect the black lead directly to the battery’s negative terminal.

Existing

Mounting

Screw

Lock

Housing

HLN6372_ Locking Kit

6881098C38-O September 17, 2004

Standard Configurations: Power Cable 2-19

RADIOCOMPARTMENT OPERATORCOMPARTMENT VEHICLEBATTERY

COMPARTMENT

goodchassisconnectionviatheblackprimary

powercableisessentialforradiooperationand

topreventdamagetotheradioandcablekit.

Connectiontothevehicleframeisdesirable.

VEHICLE

BATTERY

15AOR20A

FUSE

PARTOF

VEHICLE

WIRING

VEHICLE

IGNITIONSWITCH

ON/ACC

GROMMET

GROMMET SEENOTE

RADIOPOWERCABLE

(RED/BATTERYHOT)

RECEIVER

CONTROL

CABLE(GRN)

RADIOCONTROL

CABLE(BLK/MULTI-

CONDUCTOR)

SPEAKER

TRANSMITTER

CONTROL

CABLE(ORG)

3AOR4AFUSE

MICROPHONE

VIP

MIC

RADIO (ORG)

(GRN)

RADIOPOWERCABLE(BLK/GROUND)

RADIO

(-)

(+)

CAUTION

NOTE:

Forremotemountconfigurations,donotsupplyIGNITIONattheradio'srearaccessoryconnector.IGNITIONshouldbesuppliedaccordingtoTable2-1.



(SeeTable2-1forcombinationsofwiringtheGreenandOrangeCables)

Theorangeandgreenpowercablesconnecttoeitherthevehiclebatteryortheignitionswitch.Connectthegreencabledirectlytothebattery.Thereceiveroperates

whenthecontrolheadison.Connecttheorangecabletotheignitionswitch.Thetransmitteroperatesonlywhentheignitionswitchison.



Alternateconnections:

Connectingbothgreenandorangecablestothebatteryallowsthecontrolheadtoturnthereceiverandtransmitteronoroff.Connectingbothgreenandorangecables

totheignitionswitchallowstheignitionswitchtoturnthereceiverandtransmitteronoroff.(Alternatorwhineandothernoiseproblemsmayoccur.Isolatethegreen

cablewithaMotorolarelay,part#59-00813674.)

MAEPF-27616-O

REAR

CONNECTOR

I.B.

Figure 2-28. Cabling Interconnect Diagram for Remote Mount

September 17, 2004 6881098C38-O

2-20 Standard Configurations: Power Cable

RADIOCOMPARTMENT=OPERATORCOMPARTMENT VEHICLEBATTERY

COMPARTMENT

Agoodchassisconnectionviatheblackprimary

powercableisessentialforradiooperationand

topreventdamagetotheradioandcablekit.

Connectiontothevehicleframeisdesirable.

VEHICLE

BATTERY

15AOR20A

FUSE

PARTOF

VEHICLE

WIRING

VEHICLE

IGNITIONSWITCH

ON/ACC

GROMMET

RADIOPOWERCABLE

(RED/BATTERYHOT)

RADIOIGNITION

CABLE(thinRED)

SPEAKER

3AOR4AFUSE

MICROPHONE

RADIOPOWERCABLE(BLK/GROUND)

RADIO

(-)

(+)

CAUTION

MAEPF-27646-O

Rearconnector

CH SEENOTE

NOTE:

Caution:ifyouchoosetoconnecttheradio'sIGNITIONlinedirectlytothecar'sbattery,excessuseoftheradiowhenthecar'signitionisnotrunning(i.e.alternatorrunning)

couldresultinaslowdischargeofthecar'sbattery.Thisconfigurationallowstheradiotooperatewiththecar'signitionswitchONorOFF.

Iftheradio'sIGNITIONlineiswiredtothecar'signitionswitch,theradiowillonlyfunctionwhenthecar'signitionswitchisturnedON.

Figure 2-29. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios)

6881098C38-O September 17, 2004

Standard Configurations: Ignition Sense Cable 2-21

2.4 Ignition Sense Cable

Motorola supplies an ignition sense cable and recommends that it be used with every mobile

installation. The ignition sense cable allows the radio to be turned on and off with the vehicle ignition

switch, and allows the radio to “remember” the state of the radio on/off switch, even if it is changed

while the vehicle is off.

• For radio ON/OFF control independent of the ignition switch, connect the red ignition cable

(orange for remote) (pin 25 of accessory connector) to “battery hot” at the vehicle fuse block

(dash mount only).

• For radio ON/OFF control via the ignition switch, connect the red ignition cable (orange for

remote) to “ignition” at the fuse block.

Note that for remote mount installations, the green and orange leads are connected, not the red lead

from the rear of the radio. See Table 2-1.

The ignition sense cable uses either a 3-amp (P/N 6580283E01) or 4-amp (P/N 6580283E02) fuse.

For other considerations when connecting the ignition cable, see the XTL 5000 Basic Service

Manual (Motorola publication part number 6881096C73).

2.5 Antenna Installation

IMPORTANT NOTE: 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 rated power greater than 7 Watts, always adhere to all the

guidelines and restrictions in section 2.5.1 below.

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

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

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

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

mount the antenna in the center area of the roof.

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

models (see restrictions below) can also be mounted on the center area of the trunk lid. For

vehicles without clearly defined, flat trunk lids (such as hatchback autos, sport uitility 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.

IF THESE CONDITIONS CANNOT BE SATISFIED, THEN MOUNT THE ANTENNA ON

THE ROOF TOP!

September 17, 2004 6881098C38-O

2-22 Standard Configurations: Antenna Installation

4. Mounting restrictions for certain radio models

For 40 Watt UHF models and all 100W 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.

7. Ensure that any other mobile radio antenna on this vehicle is at least one foot (30.48 cm)

away from this antenna.

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.

2.5.2 Mini-UHF Connection

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 2-30 and Figure 2-31):

Figure 2-30. Mini-UHF Connection (Cannot Be Used for 100W Radios)

Figure 2-31. Mini-UHF Connection (100W Radios Only)

CoaxConductor

Plug(Pin)

Flange

Cable

CollarPulled

BacktoFlange

MiniUHF

Jack

6881098C38-O September 17, 2004

Standard Configurations: Antenna Installation 2-23

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.

4. Slide the collar back against the flange. Insert the antenna cable plug’s pin fully into the radio

jack, but do not engage the threads.

5. Ensure that the plug’s and jack’s interlocking features are fully seated. Check this by grasping

the crimp on the cable jack, rotating the cable, and noting any movement. If the features are

seated correctly, there should be NO movement.

6. Finger-tighten the antenna cable plug’s collar onto the radio’s jack.

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

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

(see Figure 2-32). 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 2-32. Mini-UHF Connector Tool (Cannot Be Used for 100W Radios)

Figure 2-33. Mini-UHF Connector Tool (100W Radios Only)

(1)Squeeze

FirmlyTogether

HLN6695_

(

)

(1)Squeeze

FirmlyTogether

HLN6695_

(

)

MAEPF-28159-O

September 17, 2004 6881098C38-O

2-24 Standard Configurations: Speaker

2.6 Speaker

The speaker kit includes a trunnion bracket that allows the speaker to be mounted in a variety of

ways. With the trunnion bracket, the speaker can mount permanently on the dashboard 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.

Figure 2-34. Speaker Mounting

2.7 Microphone Hang-Up Clip

2.7.1 Standard Hang-Up Clip

The hang-up clip must be within reach of the operator(s). Measure this distance before actually

mounting the bracket. Since the bracket has a positive-detent action, the microphone can be

mounted in any position. The microphone hang-up clip must be grounded.

CAUTION: DO 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 n

Dashboard

Firewall

Trunnion

Bracket

MAEPF-25764-O

6881098C38-O September 17, 2004

Standard Configurations: Completing the Installation 2-25

Use the hang-up clip as a template to locate the mounting holes. To avoid interference when

removing the microphone, install the flathead screw in the top clip hole.

2.7.2 Handheld Hang-Up Box (W3 Model)

Use the hang-up box (HUB) as a template to locate the mounting holes. Be sure the HUB will be

within easy reach of the operator. Route the control wire with the male pin to the accessory cable

connector at the rear of the radio or cable harness as shown in Figure 2-10, Figure 2-11, and

Figure 2-12. Open the accessory cable connector and connect the HUB control wire to location 3 of

the accessory connector. Connect the other control wire from the HUB to a convenient solid chassis

ground point.

2.8 Completing the Installation

Complete the installation by mounting the radio in its trunnion, connecting the speaker and power

wires, and plugging in the microphone cable/handheld control unit. Be sure to connect the

microphone S-hook to the holes in the trunnion provided (see Figure 2-17) for strain relief.

September 17, 2004 6881098C38-O

2-26 Standard Configurations: Completing the Installation

Notes

Chapter 3 Options and Accessories Installation

3.1 VIP Overview

The vehicle interface port (VIP) allows the control head to operate outside circuits and to receive

inputs from outside the control head. There are three VIP outputs which are used for relay control.

There are also three VIP inputs which accept inputs from switches.

3.1.1 VIP Output Connections

The VIP output pins are on the back of the control head (J0103), or the rear accessory panel (J2).

The pin information is shown in Figure 2-8 and Figure 3-9, respectively. Use these connections to

wire control relays. One end of the relay should connect to switched B+ voltage, while the other side

connects to a software controlled ON/OFF switch inside the control head. The relay can be normally

on or normally off depending on the configuration of the VIP outputs. There are three VIP output

connections, as follows:

The function of these VIP outputs can be field programmed in the control head. Typical applications

for VIP outputs are external horn/lights alarm and horn ring transfer relay control. For further

information on VIP outputs, see the control head programming manual.

Table 3-1. VIP Output Connections

J0103 J2 J3

VIP Number SW B+ Pin

Number

On/Off

Switched

Pin Number

SW B+ Pin

Number

On/Off

Switched

Pin Number

SW B+ Pin

Number

On/Off

Switched

Pin Number

11922418412

218124194 3

3 35 34 NANANANA

September 17, 2004 6881098C38-O

3-2 Options and Accessories Installation: Remote-Mount Accessory Installations for W4/5/7/9 Models

3.1.2 VIP Input Connections

The VIP input pins are only available on the back of the control head. These connections control

inputs from switches. One side of the switch connects to ground while the other side connects to a

buffered input on the control head. The switch can be normally closed (NC) or normally open (NO)

depending on the configuration of the VIP inputs. There are three VIP input connections, as follows:

3.2 Remote-Mount Accessory Installations for W4/5/7/9 Models

NOTE: Remove JU629 (J5 emergency to ground) and JU618 (emergency to pin 13 of J6) from the

radio interconnect board. Do not remove JU628 (pin 13 of J6 to ground). Other options (such

as siren/PA) may require this.

Remote-mount configurations offer more flexibility with accessories connections. There are two

methods of terminations that can be combined in parallel:

1. The first and most convenient method is to connect to the rear of the control head using the

J1003 connector. This connector, unlike the accessory connector assembly, has female

terminals. These terminals are supplied crimped to wires in all Motorola-approved

accessories.

a. Insert the female terminal into the J1003 connector housing in the appropriate location

and connect the J1003 connector into the rear of the control head (see Figure 3-1). A

removal tool is available through Motorola. (See Appendix A: Replacement Parts Order-

ing.)

Table 3-2. VIP Input Connections

J0103 J2 J3

VIP Number SW B+ Pin

Number

On/Off

Switched

Pin Number

SW B+ Pin

Number

On/Off

Switched

Pin Number

SW B+ Pin

Number

On/Off

Switched

Pin Number

1 21 4 NA NA NA NA

2 20 3 NA NA NA NA

33637NANANANA

CAUTION: XTL 5000 radios equipped with the following features

are capable of transmitting automatically, even if the radio is turned

off:

• MDC Status/Message

• MDC Emergency

• Trunking Products

• Automatic Vehicle Location

• Other Special Data Products

All XTL 5000 have accessory connector pins 14 and 15 connected

together to allow the radio to power down. Opening this connection

by REMOVING the accessory connector, or otherwise failing to

maintain a normally closed path, could, if left unchecked, drain the

vehicle battery, and possibly cause transmissions to occur.

C a u t i o n

6881098C38-O September 17, 2004

Options and Accessories Installation: Remote-Mount Accessory Installations for W4/5/7/9 Models 3-3

b. Secure all wires using tie straps or appropriate electrical tape to insure the wire’s safety.

Any wires passing through the vehicle’s metal panels must be protected with grommets.

This will prevent the shaving of the wire’s protective jacket, which will result in a short.

2. The second method is to use the accessory connector assembly (not supplied with the

remote mount configuration). The process is similar to the dash mount process (see Section

3.3 on page 3-4). DO NOT connect two of the same accessories simultaneously at the rear of

the control head and the accessory connector assembly (e.g., two emergency switches

would both need to be engaged in order to operate).

3.2.1 Emergency Pushbutton, Footswitch, Horn Relay, and Light Relay Installation

Perform the following installation procedure:

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

2. Connect the male-pin control leads (wires) to the VIP connector in the appropriate location

(see Table 3-1 and Table 3-2). Figure 3-1 shows how wires are plugged into the connector

and how to use an extraction tool to remove wires.

3. Route the accessory-to-control head cables under floor coverings or behind panels so that

the vehicle occupants do not snag or break the wires.

Figure 3-1. VIP Connector Detail

3.2.1.1 Emergency Pushbutton or Footswitch Installation

Mount the switch using the hardware that comes with the kit. Connect the emergency switch wires to

a ground pin and a VIP IN pin on the VIP connector.

3.2.1.1.1 W9 Control Head

1. Remove JU23 (emergency to ground) from the W9 control head.

2. Connect a jumper wire between pin 27 (emergency) and pin 3 (VIP IN 2) of P103 inside the

W9 control head.

3. Remove R84 (if installed) from the W9 control head.

4. Install the emergency switch between pins 3 (VIP IN 2) and 20 (ground) of the control head

back connector.

CAUTION: When connecting the various microphones available,

make sure to attach the S-hook provided on the microphone cable

(see Figure 2-17 in Chapter 2) to the dash or remote mount

trunnion to avoid damage to the microphone control head

interconnect.

C a u t i o n

VIP

GASKET EXTRACTION

TOOL

WIRE

VIP

CONNECTOR

CRIMPED

RECEPTACLE

MAEPF-21424-O

September 17, 2004 6881098C38-O

3-4 Options and Accessories Installation: Dash-Mount Accessory Installations for W4/5/7/9 Models

3.2.1.1.2 W4/5/7 Control Head

1. Remove JU1008 (emergency to ground) from the control head remote back housing

(HLN6432_).

2. Place JU1007 (emergency to VIP IN 2) on the control head remote back housing

(HLN6432_).

3. Remove R84 (if installed) from the W4/5/7 control head.

4. Install the emergency switch between pins 3 (VIP IN 2) and 20 (ground) of the control head

back connector.

3.2.1.2 Horn (External Alarm) Relay Installation

Mount the horn relay in a suitable location (normally under the dash). Connect the relay contacts

across the horn ring switch, typically found in the steering column. Connect the two control wires to a

SW B+ pin and a VIP OUT pin on the VIP connector.

3.2.1.3 Lights (External Alarm) Relay Installation

Mount the light relay in a suitable location (normally under the dash). Connect the relay contacts

across the headlamp ON/OFF switch. Connect the two control wires to a SW B+ pin and a VIP OUT

pin on the VIP connector.

3.3 Dash-Mount Accessory Installations for W4/5/7/9 Models

NOTE: This configuration is not applicable for 100W radios.

For dash-mounted configurations, the accessories must be installed through the accessory

connector assembly that is located on the rear of the radio, adjacent to the power connector.

Motorola-approved accessories are supplied with male terminals crimped to a 20-gauge wire

specifically designed to fit the plug of the accessory connector assembly.

Insert the male terminal into the accessory connector assembly in the appropriate location and

connect the accessory connector assembly in the rear accessory port (see Figure 3-9). Do not use

other generic terminals in the plug. Generic terminals can cause electrical intermittencies and may

cause damage to the plug.

6881098C38-O September 22, 2004

Options and Accessories Installation: Dash-Mount Accessory Installations for W4/5/7/9 Models 3-5

3.3.1 MDC Emergency Pushbutton or Footswitch Installation

Mount the footswitch using the hardware that comes with the kit. Open the accessory cable

connector housing; remove the jumper wire. Connect the emergency switch wires to pins 14 and 15

(see Figure 3-2). Close the connector housing; route the finished cable from the switch location to

the control head location.

Figure 3-2. Emergency Switch Wiring Diagram for W4/5/7/9

3.3.2 Horn and Lights (External Alarms) Relays

For installations that use the horn/lights option, select a suitable location for mounting (normally

under the dash) and, referring to Figure 3-3, perform the following procedure:

NOTE: The handheld control head can have a horn or light option, but not both. Control wires for

either option should be connected to pins 18 and 24 of the accessory connector.

1. Horn Relay—Connect the relay contacts across the horn ring switch, typically found in the

steering column. Open the accessory cable connector and connect the two control wires

(male pins) into locations 18 and 24 of the connector.

2. Lights Relay—Connect the relay across the headlamp ON/OFF switch, typically found in the

steering column. Open the accessory cable connector and connect the two control wires

(male pins) into locations 19 and 24 of the accessory connector.

Figure 3-3. Horn/Light Wiring Diagram for W4/5/7/9

ACCESSORIES

CONNECTOR

PIN 14

PIN 15

NOTE 1

SPST NORMALLY CLOSED

EMERGENCY SWITCH

NOTE 1: REMOVE BLACK JUMPER WIRE INSIDE

ACCESSORY CONNECTOR HOUSING.

INSERT WIRES FROM EMERGENCY SWITCH

GND

EMER

MAEPF-27617-O

CONNECT

CROSS HORN

RING SWITCH

CONNECT

ACROSS HEAD

LAMP SWITCH

SPST

N.O.

RELAY

12V COIL

VIP OUT 1

SWB+

VIP OUT 2

SPST

N.O.

RELAY

ACCESSORIE

CONNECTOR

PIN 1

PIN 24

PIN 19

MAEPF-27618-O

SWB+

VIP OUT 2

(LIGHTS)

VIP OUT 1

(HORN)

September 22, 2004 6881098C38-O

3-6 Options and Accessories Installation: Remote-Mount Accessory Installations for W3 Model

3.4 Remote-Mount Accessory Installations for W3 Model

Accessories for the W3 remote mount handheld control head are connected through the J3

connector located in the remote cable assembly. It requires a different P3 connector (supplied). This

P3 connector is a 15 pin D-sub (see Figure 2-11 in Chapter 2), unlike the 26-pin accessory connector

assembly (see Figure 3-9). The terminals that are required are the same for both. Therefore all

accessories will be compatible with all XTL 5000 radios.

1. Remove P3 connector from remote harness by pulling it out.

2. Remove the two screws holding the 15-pin D-sub.

3. Loosen the strain-relief screw located adjacent to the wire-exiting hole in the back of the

connector cover.

4. Extract the D-sub by pushing the wires into the cover.

5. Route the accessory wires through the hole and insert the male pin into the appropriate

location. A tool is available to remove the male terminals if service is required. (See Appendix

A: Replacement Parts Ordering.)

6. While holding the cover, pull each wire to achieve a uniform slack, then pull all wires until the

D-sub is seated against the cover.

7. Reattach the two screws to secure the D-sub, and tighten them appropriately.

8. Tighten the strain-relief screw adjacent to the wire outlet hole appropriately.

9. Reconnect the P3 connector onto the remote cable assembly.

10. Secure all wires using tie straps or electrical tape to prevent damage or shorting.

3.4.1 MDC Emergency Pushbutton or Footswitch Installation for W3 with Remote

Cable Assembly

Mount the footswitch using the hardware that comes with the kit. Open the accessory cable

connector housing; remove the jumper wire. Connect the emergency switch wires to pins 2 and 8

(see Figure 3-4). Close the connector housing; route the finished cable from the switch location to

the J3 connector location.

Figure 3-4. Emergency Switch Wiring Diagram for W3

3.4.2 Horn and Lights (External Alarms) Relays Installation for W3 with Remote

Cable Assembly

For installations that use the horn/lights option, select a suitable location for mounting (normally

under the dash) and, referring to Figure 3-5, perform the following procedure:

NOTE: The handheld control head can have a horn or light option, but not both. Control wires for

either option should be connected to pins 12 and 4 of the accessory connector.

ACCESSORIES

CONNECTOR

PIN 2

PIN 8

123

811

1314 10 915

NOTE 1

SPST NORMALLY CLOSED

EMERGENCY SWITCH

NOTE 1: REMOVE BLACK JUMPER WIRE INSIDE

ACCESSORY CONNECTOR HOUSING.

INSERT WIRES FROM EMERGENCY SWITCH

DIG GND EMER

6881098C38-O September 17, 2004

Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-7

1. Horn Relay—Connect the relay contacts across the horn ring switch, typically found in the

steering column. Open the accessory cable connector and connect the two control wires

(male pins) into locations 12 and 4 of the connector.

2. Lights Relay—Connect the relay across the headlamp ON/OFF switch, typically found in the

steering column. Open the accessory cable connector and connect the two control wires

(male pins) into locations 3 and 4 of the accessory connector.

Figure 3-5. Horn/Light Wiring Diagram for W3

3.5 Accessory Connector Assembly Details (P2)

NOTE: This assembly is not applicable for 100W radios.

The XTL 5000 accessory connector assembly is mounted on the right rear of the radio, opposite the

antenna and adjacent to the power connector. It is fastened to the radio via jackscrews and held

together by the two cover screws. It is a multi-functional connector that allows for many different

types of adaptations. All approved accessory wires are securely strain-relieved through the exiting

slots at the back of the accessory connector assembly. The terminations that are supplied with all

accessories are designed to be fully engaged and locked into the plug connector (P/N 6680163F01).

They can also be detached for service with the assistance of a terminal removal tool. The accessory

connector assembly can be serviced multiple times for future installation upgrades.

The accessory connector assembly, supplied with every XTL 5000 dash-mounted radio, is equipped

with a 26-pin plug assembly, two covers, two jackscrews, two cover screws, one emergency jumper,

one ignition sense cable assembly, and one speaker pigtail. The jumper is provided to complete the

circuit for emergency mode. If this circuit becomes open, the radio will be set to emergency mode.

3.5.1 Installation into the Vehicle

1. Disconnect the negative terminal from the vehicle’s battery. Make sure that the battery cable

is secured such that it will not power the vehicle’s electrical system.

2. Place the accessory connector assembly in the approximate location for the permanent

installation of the radio. Allocate a sufficient service loop for ease of removing and servicing

the radio.

CAUTION 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.

123

811

1314 10 915

SWB+ VIP OUT 2 (LIGHTS)

VIP OUT 1 (HORN)

CONNECT

ACROSS HORN

RING SWITCH

CONNECT

ACROSS HEAD

LAMP SWITCH

SPST

N.O.

RELAY

12V COIL

VIP OUT 1

SWB+

VIP OUT 2

SPST

N.O.

RELAY

ACCESSORIES

CONNECTOR

PIN 12

PIN 4

PIN 3

September 17, 2004 6881098C38-O

3-8 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

3. Route the ignition wire to either an ignition switch circuit or a power source that is always hot

(see Section 2.4 on page 2-21). In either case, verify that the source will be capable of

withstanding a load of 4 amps (see the wiring diagrams in the vehicle manufacturer’s service

manual). Always use the supplied fuse holder to prevent damage to the radio.

4. Secure wires with tie straps or electrical tape to prevent damage to or entanglement of the

wire. If wires are passed through drilled holes through firewalls or through any other metal

panels within the vehicle, the holes must be fitted with a rubber grommet (not supplied) to

prevent shaving of the wire’s protective jacket, which could cause electrical shorting.

NOTE: The speaker pigtail is connected to the speaker assembly. Be sure not to route the speaker

pigtail or wires through any areas that could cause potential damage to them. The audio

system is a floating ground; therefore, any speaker lines that come into contact with the

ground can cause damage to the radio. Check all wires for electrical shorts; properly repair

any electrical shorting issues immediately.

5. If there are no issues, reconnect the battery. Follow the vehicle manufacturer’s instructions

for the proper procedure.

3.5.2 Installation onto the Radio

The accessory connector assembly is fastened to the back of the radio by jackscrews. The radio

should be fully mounted and secured in its trunnion prior to connecting the accessory connector

assembly to the radio. Be sure when connecting the accessory connector assembly to the radio that

there are no foreign materials in the mating surfaces. Do not force the connector on. It should slide

on with very little resistance. Be sure that both jackscrews are engaged in their threaded holes

before tightening them. Finger tighten the jackscrews securely to prevent loosening.

6881098C38-O September 17, 2004

Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-9

3.5.3 Disassembly and Assembly

3.5.3.1 Disassembly

1. Disconnect the negative terminal from the vehicle’s battery. Make sure that the battery cable

is secured such that it will not power the vehicle’s electrical system. See Figure 3-6.

2. Unscrew both jackscrews completely.

3. Pull the accessory connector assembly out from the radio.

4. Loosen both cover screws, but do not remove them completely.

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

6. Pry apart the accessory connector assembly covers.

7. Attach any new wire to its proper location by pushing in the male terminal. When you hear a

pop, the wire is engaged. To verify that the wire is engaged, tug gently on the wire and be

sure it does not come out. Do not overload the wire: severe damage will result to the plug.

3.5.3.2 Assembly

1. Place the plug in one cover. Be sure that the flange of the plug is in the slot of the cover. See

Figure 3-6.

2. Push the jackscrew through the plug to hold it in.

3. Position each wire across the strain-relief features in the cover. Avoid damaging loads on the

plug by allowing some slack in each wire in the accessory connector assembly’s wire

chamber.

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

covers.

Figure 3-6. Exploded View of Accessory Connector Assembly (P2)

September 17, 2004 6881098C38-O

3-10 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

5. Squeeze the covers together bending the wires in the strain-relief features. You may need a

pair of pliers to seat the assembly covers.

6. Once the covers are fully seated, fasten them with the cover screws. Tighten the screws

firmly but do not over-tighten them. Be sure none of the wires are pinched.

7. Reattach the accessory connector assembly to the back of the radio and fasten it by finger-

tightening the jackscrews to prevent any loosening.

3.5.4 Adapter Cable

If you are planning on installing an XTL 5000 radio as a replacement for an ASTRO Spectra radio,

the following adapter cables are available:

Use the HKN6158_ audio adapter kit cable if your vehicle was formerly wired for an ASTRO Spectra

or ASTRO Spectra Plus radio, and used the rear cable pins as shown in Figure 3-7:

Figure 3-7. Rear Accessory Connector Audio Configuration

Use the HKN6159_ data adapter kit cable if your vehicle was formerly wired for an ASTRO Spectra

or ASTRO Spectra Plus radio, and used the rear cable pins as shown in Figure 3-8:

Figure 3-8. Rear Accessory Connector Data Configuration

It is highly recommended that you attach the correct adapter. Installing the wrong adapter may cause

damage to the data communication circuitry inside your radio. If you are unsure of the pinout of your

former wiring harness, please consult your ASTRO radio installation technician.

HKN6158_ Cable, Audio Adapter Kit

HKN6159_ Cable, Data Adapter Kit

VIPOUT2

IGNITION

SPKR

LO-N.C.

GND SPKR

HI+

SWB+ EMER

N.C.

VIPOUT1

MICHI N.C.

PTT DISC.

AUD

N.C.

54321

1011121314

768

VIPOUT2

IGNITION

SPKR

LO-

CTS-ASTRO

RTS_DCE

DIG

GND

SPKR

HI+

SWB+ EMER

BUS-

VIPOUT1

RTS-ASTRO

CTS_DCE

BUSY

TX-ASTRO

RX_DCE

RX-ASTRO

TX_DCE

BUS+

54321

1011121314

768

6881098C38-O September 17, 2004

Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-11

3.5.5 Rear Accessory Jack Connection

Figure 3-9 shows the complete pin configuration for the J2 rear accessory jack, and Table 3-3

explains the functions of each of the pins.

Figure 3-9. Rear Accessory Jack Pin Configuration (J2) (Radio Side)

AUX

MIC

PTT

USB+

CTS

RTS

USB-

TXD

BUS-

BUS+

RXD

MAEPF-27619-O

EMERGENCY

GROUND GROUND

RXFILT

AUDIO

MONITOR

RESET

SPKR-

SWB+

SPKR+

VIP

OUT1

VIP

OUT2

ONE

WIRE

IGNITION

BUSY

USB

PWR

CHAN

ACT

September 17, 2004 6881098C38-O

3-12 Options and Accessories Installation

1This pin must be connected to ground by jumper on accessory cable if emergency is disabled, even if disabled by

CPS. If enabled, this line must be grounded via a switch, which is normally closed. The emergency debounce time

is programmable via CPS.

2Pulling this line to ground will activate PTT function, activating the AUX_MIC input.

3Fixed level (independent of volume level) received audio signal, including alert tones. Flat or de-emphasis are pro-

grammed by CPS. Output voltage is approximately 100 mVrms per 1kHz of deviation. The DC offset is 1.4V.

4This output is used to detect when a rear microphone accessory is taken off-hook, to override PL to alert the user

to busy traffic prior to transmitting.

5This microphone signal is independent of the microphone signal on the front microphone connector. The nominal

input level is 80mVrms for 60% deviation when used for motorcycle, but can also support 300 mVrms for future

APCO accessories. The DC impedance is 660 ohms and the AC impedance is 560 ohms.

6See Table 2-1 in Chapter 2 for wiring options.

Note: Please see the XTL 5000 Basic Service manual (Motorola publication part number 6881096C73) for more

detailed descriptions of these pins.

Table 3-3. Rear Accessory Jack Pin Functions

No. Pin Name Pin Function Pin

No. Pin Name Pin Function

1GND Ground 14 GND Ground

2BUS+ SB9600 BUS+ Data 15 EMERGENCY Emergency1

3BUS- SB9600 BUS- Data 16 PTT* P u s h To Ta l k2

4TXD RS232 Transmit Data 17 ONE WIRE One-Wire Data

5RXD RS232 Receive Data 18 VIP OUT 1 Vehicular Interface Output

6USB- USB - (Data) 19 VIP OUT 2 Vehicular Interface Output

7USB+ USB + (Data) 20 SPKR+ Speaker + (3.2 ohm

minimum impedance)

8RESET SB9600 RESET 21 RX FILT AUDIO Receive Filtered Audio Out3

9BUSY SB9600 BUSY 22 MONITOR Monitor Overrides PL4

10 CTS RS232 Clear-To-Send 23 AUX MIC Rear Microphone Input5

11 RTS RS232 Request-To-Send 24 SW B+ Switched Battery Voltage

12 USB PWR USB Power (5V from USB

accessory/cable)

25 Ignition Ignition Sense6

13 CHAN ACT Channel Activity (qualified

received signal)

26 SPKR- Speaker - (3.2 ohm minimum

impedance)

6881098C38-O September 17, 2004

Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-13

1As indicated for front and rear connectors

2Pin function as a true “DCE” device according to EIA standard

1EIA standard

2The DB9 (female) serial port cable can be added to the P2 rear accessory cable (Figure 3-6).

Note: TX to RX and RTS to CTS, not “same to same” (e.g., not TX to TX).

Table 3-4. Rear Connector and Front Connector Naming Schemes

J2 Pin Number J2 Pin Name1Pin Alternate Name EIA Compatible Name at

Rear Connector J22

J2-4 UARTA_TX No change TX_DCE

J2-5 UARTA_RX No change RX_DCE

J2-10 UARTA_CTS Becomes RTS RTS_DCE

J2-11 UARTA_RTS Becomes CTS CTS_DCE

Table 3-5. How to Connect to a Computer1 (DTE Device)

Radio Pin Direction

DB9 (Female) Serial Port

Connector2 = DCE

Interface

DB9 (Male) Serial Port

Connector = DTE

Interface

Data Device Pin

Direction

Output TX_DCE = pin 2 pin 2 = RX_DTE Input

Input RX_DCE = pin 3 pin 3 = TX_DTE Output

Output RTS_DCE = pin 8 pin 8 = CTS_DTE Input

Input CTS_DCE = pin 7 pin 7 = RTS_DTE Output

September 17, 2004 6881098C38-O

3-14 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

Notes

Chapter 4 Motorcycle Radio Installation

NOTE: This installation is not applicable for 100W radios.

4.1 Motorcycle Radio Description

The motorcycle model includes all the same components in the standard radio, with the exceptions

listed in the model charts in the XTL 5000 Basic Service Manual (Motorola publication part number

6881096C73). The following paragraphs describe the unique items provided with the motorcycle

models.

NOTE: The XTL 5000 Basic Service Manual includes complete parts lists and parts numbers for all

parts shown in the exploded views in this chapter.

4.1.1 Transceiver Enclosure

The transceiver is mounted in the weather-resistant enclosure that consists of a bottom housing and

a hinged top cover. The top cover has a locking latch that requires a key to open. The enclosure is

mounted above the rear motorcycle wheel, oriented so that the lock is forward and the hinged cover

opens toward the rear of the motorcycle. The bottom housing has a grommeted hole for cable entry

and weep holes to permit water drainage.

The enclosure is mounted on the motorcycle with a universal mounting plate and shock and vibration

isolators. A large, braided ground-strap (installed between the mounting plate bolts and the

motorcycle frame) grounds the transceiver.

4.1.2 Control/Display Unit

All radio functions, except push-to-talk (PTT), are activated from the control head, which also is

weather-resistant. The control head and the external speaker are mounted for easy access near the

center of the handlebars. The control head is positioned for unobstructed viewing, and it may be

tilted on the horizontal axis for ease of viewing. The microphone cable port on the front of the control

head is plugged and is not used.

4.1.3 Control Head Cable

The control-head cable connects the control head to the transceiver. This 2.8-meter cable is routed

along the motorcycle’s frame and has weather-resistant connections at both ends. Excess cable is

coiled under the transceiver inside the weather-resistant enclosure.

Each end of the cable is strain-relieved with jackscrews at the control head and the transceiver. The

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

4.1.4 Microphone

A weather-resistant, palm microphone and coiled cord plug into a pigtail connector on the control

cable. The microphone attaches to a hang-up bracket located within easy reach of the motorcycle

rider. The coiled cord is long enough to be operated by someone standing next to the motorcycle, yet

short enough to not interfere with the motorcycle’s steering or operation.

September 17, 2004 6881098C38-O

4-2 Motorcycle Radio Installation: Installation Overview

4.1.5 External Speaker

A 3.2-ohm, 10-watt-rated-audio-power, external speaker is mounted on the front of the motorcycle.

The speaker cable is routed along the motorcycle frame to the transceiver’s rear accessory

connector. A sealed, weather-resistant, speaker-muting (toggle) switch is mounted on top of the

speaker.

The external speaker connects to the rear accessory connector of the transceiver.

4.1.6 Headset Capability

The motorcycle radio is compatible with headset accessories that would provide hands-free

operation of the radio. Motorola does not manufacture headset equipment, but provides the

interconnection for headset equipment with the motorcycle radio. Aftermarket headset equipment is

available through Motorola (see Appendix A: Replacement Parts Ordering).

4.1.7 Antenna

The antenna is mounted on top of the transceiver’s weather-resistant enclosure. The enclosure’s

metal lining acts as the antenna’s ground plane.

4.1.8 Ignition Wire

The ignition wire connects to the motorcycle’s fuse box and is routed along the motorcycle frame to

the transceiver’s rear accessory connector.

The radio is wired so that transmission is inhibited if the motorcycle’s ignition switch is off. If the PTT

switch is pressed with the ignition off, a low-frequency tone sounds. The receiver is controlled by the

control head on/off switch.

4.2 Installation Overview

4.2.1 General

All XTL 5000 radios are tested and inspected before shipment. It is, however, suggested that the

transmitter frequency, deviation, and power output be checked at the time of installation. It is the

license holder’s responsibility to ensure that the operating parameters of his station comply with

applicable laws governing radio communications equipment. For tests and alignment procedures,

refer to the appropriate service manual (refer to “Related Publications” on page v).

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

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

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

motorcycle;

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

resistant enclosure;

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

• Mounting the antenna to the weather-resistant enclosure.

A universal mounting plate, supplied by Motorola, is first mounted to either a motorcycle carrier at the

rear of the motorcycle or to the rear frame of the motorcycle itself. The mounting procedures for the

universal mounting plate vary from motorcycle to motorcycle. Therefore, the procedures given in this

manual for installing the mounting plate may not specifically apply, but are provided for guidance.

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Installation Overview 4-3

The control head, speaker, and microphone are mounted forward on the motorcycle, on or near the

steering column. There are several possible mounting configurations which use a combination of

Motorola and customer-built brackets. These configurations are outlined in this manual. Because of

the large number of motorcycle makes and models in existence, the customer-built brackets are

necessary to tailor the mounting of the Motorola equipment to the particular motorcycle being used.

Suggestions for customer-built brackets are given in this manual.

The power cable, control-head cable, speaker cable, and ignition cable are routed to the weather-

resistant enclosure position. The enclosure and the radio chassis are then mounted. Special care is

required when connecting cables to the radio equipment within the enclosure.

4.2.2 Important Installation Hints

Consider the following when mounting the radio components:

• Excess lengths of control-head, power, ignition, and speaker cables must be routed in the

enclosure as shown in Figure 4-8.

• All components must be mounted securely in order to withstand the constant and sometimes

severe vibration experienced on a motorcycle.

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

hardware.

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

operator.

• Forward components (control head, microphone, and speaker) should not interfere with visual

or physical access to controls and instruments.

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

• Cabling between the control head and the radio chassis should be run to minimize interference

with operator movements.

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

operator.

• Electrical continuity must be present through the enclosure shock mounts to the motorcycle

frame for proper electrical and RF grounding.

• The antenna is designed for mounting on the top of the weather-resistant enclosure.

• Only the supplied microphone mounting clip should be used to ensure secure mounting of the

microphone. This clip has a very strong spring to ensure positive retention of the microphone

over rough terrain. Also, there must be electrical continuity from this clip to the motorcycle

frame for dc grounding.

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

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

• Mounting hardware must be stainless steel to prevent corrosion.

4.2.3 Parts Identification

The following installation procedures refer to Figure 4-1 through Figure 4-9. Detailed descriptions of

the mounting hardware used in each procedure are provided in parts lists located in the exploded

views located in the XTL 5000 Basic Service Manual (Motorola publication part number

6881096C73). Those parts supplied by Motorola are contained in one of the following kits:

• Motorcycle Weather-Resistant Microphone

• Motorcycle Weather-Resistant Speaker with Mute Switch

• Motorcycle Hardware Kit SECURENET or Motorcycle Hardware Kit

September 17, 2004 6881098C38-O

4-4 Motorcycle Radio Installation: Installing the Universal Mounting Plate

• Motorcycle Power Cable Kit

• Motorcycle Mounting Kit

• Weather-Resistant Enclosure (White)

• Weather-Resistant Enclosure (Black)

4.2.4 Order of Installation

Before starting the installation, familiarize yourself with the mounting hardware (see Figure 4-1

through Figure 4-9). Perform the installation procedures in the order that follows.

1. Install the universal mounting plate on the motorcycle.

2. Install the control head and speaker.

3. Install the microphone hang-up clip.

4. Install the cables.

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

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

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

8. Install the antenna on the enclosure.

4.3 Installing the Universal Mounting Plate

The universal mounting plate, supplied with the motorcycle radio, must be mounted on the

motorcycle first. It provides the base on which the weather-resistant enclosure is to be mounted. The

method used for mounting the plate depends on the make and model of the motorcycle and whether

the plate is mounted to a carrier or to the motorcycle chassis. After the plate has been securely

mounted to the motorcycle, mounting the weather-resistant enclosure onto the plate is

straightforward.

Figure 4-1 illustrates the universal mounting plate mounted to a motorcycle carrier. Since there are

so many makes and models of motorcycles and motorcycle carriers, it is impossible to give specific

step-by-step instructions for mounting the universal mounting plate. However, noting the following

considerations will aid in the installation procedure.

• A minimum of holes are predrilled into this plate as supplied. Mounting holes must be drilled as

required for the particular motorcycle on which the plate is being mounted.

• The universal mounting plate should be mounted on the motorcycle in such a manner that the

later mounting of the weather-resistant enclosure will not interfere with the motorcycle seat

back, with any other obstacles, or with the motorcycle operator. The enclosure may be tempo-

rarily bolted to the universal mounting plate and the unit positioned on the motorcycle to ensure

the above criteria are met.

• To ensure a good grounding path from the universal mounting plate to the motorcycle carrier or

frame, stainless steel lockwashers must be used with the mounting hardware in two areas to

score through the paint on the universal mounting plate and on the carrier or frame, thereby,

providing good electrical contact with the underside of the motorcycle carrier or motorcycle

frame.

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Installing the Speaker and Control Head 4-5

Figure 4-1. Universal Mounting Plate Installation (Part of Radio Enclosure Kit)

Follow the procedures below to mount the universal mounting plate to the motorcycle (see

Figure 4-1).

1. Determine the mounting position for the mounting plate.

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

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

chassis for mounting the plate.

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

lockwashers, and four nuts. Tighten screws securely. The lockwashers must cut through the

paint on the plate and motorcycle carrier or frame to ensure a good ground path.

4.4 Installing the Speaker and Control Head

The control head mounting location and configuration is determined largely by the make and model

of motorcycle. Two different mounting configurations are described below. One involves mounting

the speaker and control head together as a unit using the combination speaker/control-head bracket

(shown in Figure 4-2) supplied by Motorola. Alternately, the control head may be mounted by itself

using a smaller control-head bracket supplied by Motorola. In this case, the speaker is mounted

elsewhere. This section outlines installation procedures for each configuration mentioned above.

The customer (or installer) is in the best position to determine the most appropriate mounting

configuration for the control head and speaker based on the particular motorcycle on which the

equipment is to be mounted.

When determining its location, position the control head so

that it is clearly visible and within easy reach of the motorcycle

operator.

C a u t i o n

September 17, 2004 6881098C38-O

4-6 Motorcycle Radio Installation: Installing the Speaker and Control Head

4.4.1 Handlebar Installation with Speaker and Control Head Mounted Together

Figure 4-2 illustrates the combination speaker/control head bracket. This combination bracket is

used only when the control head and speaker are to be mounted as a unit. Also illustrated in

Figure 4-2 is a handlebar-mounting bracket which may be required if the combination speaker/

control-head bracket cannot be easily mounted to the motorcycle. In this case the handlebar-

mounting bracket is mounted to the motorcycle, and the combination bracket is then mounted to the

handlebar-mounting bracket.

Figure 4-2. Handlebar Installation with Speaker and Control Head Mounted Together

Provision has been made on the combination speaker/control-head bracket for mounting the

microphone hang-up clip. If that mounting is desired, the hang-up clip must be attached to the

bracket before installing the control head and speaker. See Section 4.6: “Installing the Microphone

Hang-Up Clip” on page 4-11 for the hang-up clip procedure. Install the speaker and control head as

described below.

1. Determine the location where the speaker/control head is to be mounted. Consider how the

speaker/control-head bracket may be mounted, and whether or not a handlebar-mounting

bracket is needed. Take care to select a location that is not only mechanically convenient, but

is located for ease of operation.

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

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

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

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Installing the Speaker and Control Head 4-7

3. Mount the speaker/control-head bracket, either directly to the motorcycle, or, if used, to the

handlebar-mounting bracket, using four stainless-steel machine screws, lockwashers, and

nuts.

4. Mount the 9-pin D-connector end of the motorcycle control-head cable to the speaker/control-

head bracket, using two machine screws, flat washers, and nuts. (Cable routing directions

appear later in this section.)

5. Mount the speaker on the speaker/control-head bracket, using two machine screws and

lockwashers. Torque these screws to 20 in.-lbs.

6. Attach the control-head cable to the control head and tighten the locking screws on the

connector. This connection must be made before you mount the control head in the bracket.

(Cable routing directions appear later in this section.)

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

washers.

8. Adjust the control head viewing angle by loosening its mounting screws and rotating the

control head to the desired angle. Then, retighten screws to 20 in.-lbs torque. This concludes

the speaker/control-head installation.

4.4.2 Fuel Tank Console Installation with Speaker and Control Head Mounted

Together

Some motorcycles provide a console for mounting radio equipment. This console is attached to the

top of the fuel tank. With the use of a mounting bracket, screws, nuts, and lockwashers, the

combination speaker/control-head bracket can be mounted to this console. Figure 4-3 illustrates this

type of mounting.

The console attachment screws must be removed, and the console must be lifted slightly from the

fuel tank to gain access in order to attach mounting hardware, and to route cables later.

In this installation, the microphone (mic), mic hang-up bracket, and mic extension bracket will

interfere with handlebar travel.

Installation using this method is the same as in Section 4.4.1: “Handlebar Installation with Speaker

and Control Head Mounted Together” on page 4-6.

September 17, 2004 6881098C38-O

4-8 Motorcycle Radio Installation: Installing the Speaker and Control Head

Figure 4-3. Fuel Tank Console Installation with Speaker and Control Head Mounted Together

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Installing the Speaker and Control Head 4-9

4.4.3 Handlebar Installation with Speaker and Control Head Mounted Separately

It may be necessary to use the smaller control head bracket (part no. 07-80127N02) and mount the

speaker and microphone hang-up clip in another location on the motorcycle.

Before installing the control head using the bracket described above, the control-head end of the

control-head cable should be temporarily fastened to the control head, and the control head fastened

to its bracket. Motorola-supplied spacers and the mic-cable bracket are required to mount the control

head to the handlebar. This mic-cable bracket has holes to mount the microphone-cable connector.

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

1. Determine the location at which the control head is to be mounted. Take care to choose a

location that is not only mechanically convenient, but is located for ease of operation.

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

bracket to the handlebars.

3. Mount the 9-pin D-connector end of the motorcycle control-head cable to the mic-cable

bracket, using two machine screws, flat washers, and nuts. (Cable routing directions appear

later in this section.)

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

the connector.

5. Mount the control head to the small control-head bracket, at the proper viewing angle, using

two wing screws. Tighten firmly. This concludes the control-head installation.

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

September 17, 2004 6881098C38-O

4-10 Motorcycle Radio Installation: Installing the Speaker

4.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted

Separately

The control head may be mounted to the fuel tank console using the smaller control-head bracket

and spacers/hardware. In this configuration, the microphone cable connector may be attached

directly to the console, eliminating the need for a custom bracket.

Figure 4-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately

Installation is the same as detailed in Section 4.4.2: “Fuel Tank Console Installation with Speaker and

Control Head Mounted Together” on page 4-7 and Section 4.4.3: “Handlebar Installation with

Speaker and Control Head Mounted Separately” on page 4-9.

4.5 Installing the Speaker

Use the following procedure when the speaker is mounted separate from the control head. The

speaker bracket supplied with the speaker may be used alone if a suitable location can be found, or

if necessary, a customer-supplied bracket may be fabricated for mounting the speaker.

1. Determine the location in which the speaker is to be mounted and whether there is a

requirement for a customer-supplied bracket.

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Installing the Microphone Hang-Up Clip 4-11

2. Fabricate a bracket if required. Use the Motorola-supplied speaker bracket as a template for

drilling mounting holes. Also drill holes in the fabricated bracket for mounting to the

motorcycle.

3. Mount the fabricated bracket to the motorcycle chassis.

4. Mount the Motorola-supplied bracket to the fabricated bracket using two machine screws, flat

washers, lockwashers, and nuts.

5. Mount the speaker to the speaker bracket using two wing screws. Directions for speaker

cable routing appear later in this section. Speaker mounting is now complete.

4.6 Installing the Microphone Hang-Up Clip

Install the hang-up clip either on the supplied microphone extension bracket or on the side of the

speaker/control head bracket. Both methods are shown in Figure 4-2. Determine the mounting

location and install as described in the following paragraphs.

NOTE: Wherever the hang-up clip is mounted, it must be DC grounded for proper operation. After

mounting the clip, be sure there is electrical continuity between the clip and the motorcycle

chassis.

4.6.1 Extension Bracket Mounting

Using this method, you can mount the clip so that it faces the operator.

1. Attach the bracket to the speaker/control-head bracket using two machine screws, four

lockwashers, and two nuts as shown in Figure 4-2, Detail A.

2. Torque nuts to 20 in.-lbs torque.

3. Fasten the hang-up clip to the extension bracket using two machine screws, lockwashers,

and nuts as shown in Figure 4-2, Detail A.

4. Torque nuts to 20 in.-lbs torque.

4.6.2 Speaker/Control Head Bracket Side Mounting

Attach the hang-up clip to the left side of the speaker/control-head bracket using two machine

screws, lockwashers, and nuts as shown in Figure 4-2. Torque nuts to 20 in.-lbs. torque.

4.6.3 Other Hang-Up Clip Mounting

To mount the microphone hang-up clip in another location, a customer-supplied bracket may be

used. Suggested locations include the handlebars, fuel-tank console, or any location which provides

easy access to the microphone without blocking controls and indicators and without interfering with

motorcycle handling. See Figure 4-3, Figure 4-4, and Figure 4-5 for alternative microphone hang-up

clip mounting methods.

1. Fabricate a bracket, then secure it to the motorcycle.

2. Use two machine screws, lockwashers, and nuts to secure the hang-up clip to the customer-

supplied bracket. Ensure that the microphone clip is DC grounded to the motorcycle chassis

(a grounding lug and strap are provided in the hang-up clip kit for this purpose) – this is

essential for proper radio operation.

September 17, 2004 6881098C38-O

4-12 Motorcycle Radio Installation: Installing Cables

4.7 Installing Cables

Five cables must be installed to interconnect the components of the radio system as shown in

Figure 4-6. The antenna cable is routed away from the other cables inside the enclosure’s hinged

cover. (See the antenna installation instructions shipped with the antenna option for more antenna-

routing information.) The four remaining cables, routed along the motorcycle frame, are described in

the following paragraphs.

NOTE: Removal of the fuel tank and seat from the motorcycle will facilitate routing the cables along

the frame. Motorcycles with consoles attached to fuel tanks require routing cables between

console and fuel tank. In this case the tank is not removed.

Figure 4-6. Cable Routing

1. Speaker Cable — runs from the speaker to the accessory-cable connector inside the

weather-resistant enclosure.

2. Control Cable — runs from the rear of the control head to the front of the transceiver inside

the enclosure.

3. Ignition (Red) Wire Portion of Accessory Cable — runs from the ignition fuse terminal of the

fuse box to the rear area inside the enclosure. The lug for attaching the ignition wire is

contained on the accessory cable.

4. Power Cable — The red, unterminated end runs from the positive terminal of the battery to

the power connector that plugs in the rear of the transceiver. Lugs for attaching the red and

black leads are contained in the motorcycle power-cable kit. The black, unterminated end

runs from a suitable motorcycle chassis ground to the power connector. DO NOT connect the

black lead directly to the negative battery post.

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Installing the Weather-Resistant Enclosure 4-13

You may route the cables in any order. As you route each cable, temporarily fasten it at both ends.

When all cables have been run, permanently fasten the cables with appropriate cable tie wraps.

Observe the following during routing and hook-up:

1. Route the cables so that none interfere with motorcycle operation.

2. Fasten the cables with supplied nylon tie wraps. The wraps should be firmly installed at

frequent intervals along the cable length in such a manner that motorcycle vibration will not

cause metal fatigue and subsequent breakage of the cable wires.

3. Take care to position cables away from parts of the motorcycle that get hot.

Bundle excess cable length inside the weather-resistant enclosure as discussed later in Section 4.9:

“Transceiver and Cabling Installation” on page 4-14.

The fifth cable is the microphone with coiled cord. Plug the 9-pin D-connector end of the coiled cord

into its mating connector, which was attached near the control head discussed in an earlier

paragraph. Tighten the coiled-cord-retention screws. Insert the S-hook strain relief (terminated to the

coiled cord) into the hole in the mounting bracket. Slide the microphone into the microphone hang-up

bracket.

4.8 Installing the Weather-Resistant Enclosure

Figure 4-7. Weather-Resistant Enclosure Installation

1. Remove the radio-mounting plate by removing four screws, lock washers, and flat washers.

2. The weather-resistant enclosure is mounted to the universal mounting plate using shock

mounts. Assemble the shock-mount components exactly as shown in Figure 4-7. Be sure to

install ground straps between the shock-mount and the transceiver trunnion mount, and

install one 7-1/2-inch ground strap between the right rear mount and the enclosure lid’s

antenna ground plane 0 (shown in Figure 4-7 and in Figure 4-9).

3. The order of assembly is important to ensure proper shock mount operation. All components

are supplied with the mounting kit. The 4-1/2-inch ground straps are used on the front shock

mounts. The three 7- 1/2-inch straps are used on the rear shock mounts—two from shock

mount to trunnion, and one from the shock mount to the lid’s antenna ground plane.

September 17, 2004 6881098C38-O

4-14 Motorcycle Radio Installation: Transceiver and Cabling Installation

NOTE: Grounding through the power-supply cable is NOT sufficient. Whether the radio transceiver

is mounted to a carrier or the chassis itself, the transceiver MUST be properly grounded to

the motorcycle chassis. The ground strap supplied with the installation kit may have to be

used to ensure a good RF ground path from the radio transceiver to the motorcycle chassis.

4. Install the 3-foot ground strap on one of the front shock mounts. Route it through the cable-

routing hole and connect the other end to the motorcycle frame (see Figure 4-7).

5. The diagram of the shock mount is shown loosely assembled. After the hex screws are

tightened, the rubber washers are compressed to fasten the weather- resistant enclosure

securely to the universal mounting plate.

6. Figure 4-9 is an exploded view of the enclosure; it shows details that will help to understand

how the enclosure is mounted. After the enclosure is completely mounted, check for proper

ground connection–continuity between the antenna ground plane and the motorcycle frame.

4.9 Transceiver and Cabling Installation

After the weather-resistant enclosure has been installed, the radio chassis (transceiver) is installed in

the enclosure and then appropriate cables are connected. However, before the transceiver can be

installed, the cabling must be properly positioned in the enclosure.

4.9.1 Installing Cabling in the Enclosure

Position the cabling in the weather-resistant enclosure as follows:

1. Run the speaker, power, control-head, and ignition cables into the enclosure.

2. Lay the excess cable length between the radio mounting bosses in an S configuration as

shown in Figure 4-8. Do not coil any excess cable. Use the supplied tie wraps to bundle cable

as shown.

NOTE: If the extra cable length is not sufficient to match the illustrated cable routing, then match the

illustration as closely as possible.

3. Connect the speaker cable to the accessory cable connector.

NOTE: The accessory-cable emergency connector is shipped with a shorting plug installed. The

headset connector is also shipped with a shorting plug installed. The plugs must remain in if

an emergency switch and/or headset is not used. If an emergency switch and/or headset is

used, remove the shorting plug(s) and discard.

4. Install the mounting plate in position on top of the cables installed above. Take care not to

damage or pinch the cables when securing the mounting plate in position.

NOTE: At this point, the control-head cable plug should be located at the forward end of the

enclosure, and the power-cable, speaker-cable, and accessory-cable plugs should be located

at the rear of the enclosure.

DO NOT connect the ground strap directly to the negative

battery post.

W A R N I N G

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Transceiver and Cabling Installation 4-15

Figure 4-8. Installing Cables

4.9.2 Installing the Transceiver

Install the transceiver in the weather-resistant enclosure as follows (see Figure 4-9).

NOTE: For new or existing installations, use only the XTL 5000 trunnion (kit number: HLN6861_).

1. Install the mounting trunnion and loose ends of the four ground straps to the radio-mounting

plate, using four screws, flat washers, and external-tooth lockwashers (see Figure 4-9). The

ground straps must be sandwiched between the flat washers and lockwashers. The lock

washer must be against the trunnion. The flat washer must be under the screw head.

2. Attach the transceiver to the mounting trunnion and secure with two wing screws.

3. Connect the control cable to the front of the transceiver. Ensure the control-cable connector

screws are tightened.

4. Attach the accessory connector to the transceiver. Plug in the power connector.

5. Install the grommet around the cables and push the grommet into the cable-routing hole of

the weather-resistant enclosure.

September 17, 2004 6881098C38-O

4-16 Motorcycle Radio Installation: Transceiver and Cabling Installation

Table 4-1. Transceiver Installation Parts List

1 Lockwasher

2 Flat washer (8 used)

3Screw

4Screw

5Grommet

6Screw

7 Lock catch

8 Radio mounting plate

9 Bottom housing

10 Ground shield plane

11 Top cover

12 Gasket

13 Hinge

14 Enclosure mounts

15 Transceiver

16 Wing screw

17 Trunnion

18 External tooth lockwasher (8 used)

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Transceiver and Cabling Installation 4-17

Figure 4-9. Installing the Transceiver

September 17, 2004 6881098C38-O

4-18 Motorcycle Radio Installation: Installing the Antenna

4.10 Installing the Antenna

Refer to the antenna installation instructions in the antenna option package.

4.11 Installing the Emergency Switch Option

Use the two-conductor, green/black cable which has as one end terminated with two contacts (part

no. 3080221P02) and which is supplied with this W688 Motorcycle Emergency Push Button.

Disconnect the emergency switch shorting plug from the accessory cable. Replace the shorting wire

of the shorting plug with the terminated end of the green/black emergency cable. Reconnect the plug

to the accessory cable.

4.12 Installing the External Alarm Relay Option

The motorcycle radio is offered with only one optional relay connection. If both horn and lights are

required, wire a second relay coil parallel to the first relay. Use the two-conductor green/black cable

which has one end terminated with two contacts (part no. 3080221P02) and which is supplied with

this W116 Motorcycle Alarm Relay Option. Insert the contacts into positions 3 and 4 of the

emergency shorting plug of the accessory cable. Refer to Figure 4-10.

4.13 Installing the Headset Accessory

A six-position connector on the accessory cable has been made available for connecting a headset

accessory. Headset manufacturers should be consulted for compatibility with the motorcycle radio

prior to purchase and installation of the headset. To install, disconnect the headset shorting plug.

Remove the headset shorting wire from the headset shorting plug. Terminate the contacts provided

to the applicable wires of the headset cable. Insert the terminated wires into the headset shorting

plug per the contact positions illustrated in the typical headset schematic found in this manual.

Reconnect the terminated headset shorting plug to the accessory cable.

4.14 Horn/Lights Wiring

Figure 4-10. Horn/Lights Wiring Diagram

6881098C38-O September 17, 2004

Motorcycle Radio Installation: Emergency Switch Wiring 4-19

4.15 Emergency Switch Wiring

Figure 4-11. Emergency Switch Wiring Diagram

Motorcycle products must have pins 1 and 2 connected

together to allow the radio to power down. Opening this

connection by REMOVING the emergency shorting plug,

or pressing the emergency switch, will turn on the radio.

Failure to maintain a normally-closed path could drain

the vehicle battery if left unchecked.

EMERGENCY-equipped radios are capable of

TRANSMITTING without warning.

W A R N I N G

September 17, 2004 6881098C38-O

4-20 Motorcycle Radio Installation

Notes

Chapter 5 Finishing the Installation: Cable Connection

Perform the following if it has not been previously done:

1. For all models except W3, remove the control head from its mounting trunnion. Plug the

radio’s control cable into the proper location on the back of the control head (see Figure 2-21

and Figure 2-22 in Chapter 2). The connectors “click” when snapped into place. W4, W5, and

W7 control head models can have the microphone plugged into either the lower left corner of

the control head front panel or in the middle section of the connector on the rear of the control

head. W9 control head models have only the rear connection on the control head available.

Connect the microphone cable S-hook (see Figure 2-17 in Chapter 2) into the hole in the

cable strain relief bracket on the back of the control head (W9 model) or on the mounting

trunnion (W4, W5, and W7 models).

2. Connect the plug from the speaker lead to the mating connector coming out of the control

cable connector or accessory cable harness (W3 model).

3. Plug the VIP connector into the remaining location on the back of the control head.

4. Connect the control cable to the radio and tighten the connector by tightening the jack

screws.

5. Be sure the control head and microphone PTT switches are OFF. Install the 15- or 20-amp

fuse in the radio power cable fuseholder and the 3- or 4-amp fuse(s) in the ignition cable

fuseholder(s).

6. Turn the radio ON at the control head and verify proper operation of all controls and

indicators. Radio operation in some installations require turning on the ignition. Perform a

complete operational check of the radio.

7. Dress the control and power cables out of the way to prevent damage (pull any excess cable

into the trunk area) securing with clamps and tie wraps where necessary.

CAUTION: For all except 100W radios: To ensure a proper water

seal, the jackscrews on the radio cable connector must be tight. If

the accessory port on a remote-mounted radio is not used, the

cover gasket assembly (HLN6233_) must be installed and torqued

to 6 to 8 inch-pounds.

C a u t i o n

September 17, 2004 6881098C38-O

5-2 Finishing the Installation: Cable Connection

Notes

Appendix A Replacement Parts Ordering

A.1 Basic Ordering Information

When ordering replacement parts or equipment information, the complete identification number

should be included. This applies to all components, kits, and chassis. If the component part number

is not known, the order should include the number of the chassis or kit of which it is a part, and

sufficient description of the desired component to identify it.

Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model

number in which the part is used.

The ASTRO XTL 5000 Digital Mobile Radio Basic Service Manual (Motorola publication part number

6881096C73) includes complete parts lists and parts numbers.

A.2 Motorola Online

Motorola Online users can access our online catalog at

https://www.motorola.com/businessonline

To register for online access:

• Domestic customers: please call 800-814-0601 (U.S. and Canada).

• International customers: please go to https://www.motorola.com/businessonline and click on

“Sign Up Now.”

A.3 Mail Orders

Send written orders to the following addresses:

Replacement Parts/

Test Equipment/Manuals/

Crystal Service Items:

Motorola Inc.

Radio Products and Services

Division*

Attention: Order Processing

2200 Galvin Drive

Elgin, IL 60123

U.S.A.

Federal Government Orders:

Motorola Inc.

U.S. Federal Government

Markets Division

Attention: Order Processing

7230 Parkway Drive

Landover, MD 21076

U.S.A.

International Orders:

Motorola Inc.

Radio Products and Services

Division*

Attention: Order Processing

2200 Galvin Drive

Elgin, IL 60123

U.S.A.

September 17, 2004 6881098C38-O

A-2 Replacement Parts Ordering: Telephone Orders

A.4 Telephone Orders

Radio Products and Services Division*

(United States and Canada)

7:00 AM to 7:00 PM (Central Standard Time)

Monday through Friday (Chicago, U.S.A.)

1-800-422-4210

1-847-538-8023 (International Orders)

U.S. Federal Government Markets Division (USFGMD)

1-800-826-1913 Federal Government Parts - Credit Cards Only

8:30 AM to 5:00 PM (Eastern Standard Time)

A.5 Fax Orders

Radio Products and Services Division*

(United States and Canada)

1-800-622-6210

1-847-576-3023 (International)

USFGMD

(Federal Government Orders)

1-800-526-8641 (For Parts and Equipment Purchase Orders)

A.6 Parts Identification

Radio Products and Services Division*

(United States and Canada)

1-800-422-4210, menu 3

A.7 Product Customer Service

Customer Response Center

(Non-technical Issues)

1-800-247-2346

FAX:1-800-247-2347

*The Radio Products and Services Division (RPSD) was formerly known as the Customer Care and Services

Division (CCSD) and/or the Accessories and Aftermarket Division (AAD).

Glossary Glossary

This glossary contains an alphabetical listing of terms and their definitions that are applicable to

ASTRO portable and mobile subscriber radio products.

Term Definition

A/D See analog-to-digital conversion.

Abacus IC A custom integrated circuit providing a digital receiver intermediate

frequency (IF) backend.

ADC See analog-to-digital converter.

ADDAG See Analog-to-Digital, Digital-to-Analog and Glue.

ALC See automatic level control.

analog Refers to a continuously variable signal or a circuit or device designed

to handle such signals. See also digital.

Analog-to-Digital,

Digital-to-Analog

and Glue

An integrated circuit designed to be an interface between the radio’s

DSP, which is digital, and the analog transmitter and receiver ICs.

analog-to-digital

conversion

Conversion of an instantaneous dc voltage level to a corresponding

digital value. See also D/A.

analog-to-digital

converter

A device that converts analog signals into digital data. See also DAC.

APCO 25 A standard of digital two-way radio communications, developed by the

Association of Public-Safety Communications Officials, providing

maximum radio spectrum efficiency; competition in system life cycle

procurements; effective, efficient and reliable intra-agency and inter-

agency communications; and “user friendly” equipment. See also

Association of Public-Safety Communications Officials.

Association of

Public-Safety

Communications

Officials

An association dedicated to an industry-wide effort (known as APCO 25

or Project 25) to set the recommended voluntary standards of uniform

digital two-way radio technology for public safety organizations. This

allows radio interoperability with multiple vendor products which are all

APCO 25 compatible. See also APCO 25.

automatic level

control

A circuit in the transmit RF path that controls RF power amplifier output,

provides leveling over frequency and voltage, and protects against high

VSWR.

band Frequencies allowed for a specific purpose.

September 17, 2004 6881098C38-O

Glossary-2

BBP See baseband interface port.

baseband interface

port

Synchronous serial interface to the transceiver board used to transfer

transmit and receive audio data.

BGA See ball grid array.

ball grid array A type of IC package characterized by solder balls arranged in a grid

that are located on the underside of the package.

CODEC See coder/decoder.

coder/decoder A device that encodes or decodes a signal.

CPS See Customer Programming Software.

Customer

Programming

Software

Software with a graphical user interface containing the feature set of an

ASTRO radio.

D/A See digital-to-analog conversion.

DAC See digital-to-analog converter.

DCE Data communication equipment: The EIA definition for device (i.e.,

radio) data communications using the RS232 protocol. The correct data

communication wiring requires the device’s TX pins (output) to connect

to the RX pins (input) and the RTS pins (output) to connect to the CTS

pins (input). It is incorrect to attach the “same name” to “same name”.

default A pre-defined set of parameters.

digital Refers to data that is stored or transmitted as a sequence of discrete

symbols from a finite set; most commonly this means binary data

represented using electronic or electromagnetic signals. See also

analog.

digital-to-analog

conversion

Conversion of a digital signal to a voltage that is proportional to the input

value. See also A/D.

digital-to-analog

converter

A device that converts digital data into analog signals. See also ADC.

Digital Private-Line A type of digital communications that utilizes privacy call, as well as

memory channel and busy channel lock out to enhance communication

efficiency.

digital signal

processor

A microcontroller specifically designed for performing the mathematics

involved in manipulating analog information, such as sound, that has

been converted into a digital form. DSP also implies the use of a data

compression technique.

Term Definition

6881098C38-O September 17, 2004

Glossary-3

digital signal

processor code

Object code executed by the Digital Signal Processor in an ASTRO

subscriber radio. The DSP is responsible for computation-intensive

tasks, such as decoding ASTRO signaling.

DPL See Digital Private-Line. See also PL.

DSP See digital signal processor.

DSP code See digital signal processor code.

DTE Data terminal equipment: i.e., a computer.

DTMF See dual tone multi-frequency.

dual tone multi-

frequency

The system used by touch-tone telephones. DTMF assigns a specific

frequency, or tone, to each key so that it can easily be identified by a

microprocessor.

EEPOT Electrically Programmable Digital Potentiometer.

EEPROM See Electrically Erasable Programmable Read-Only Memory.

Electrically Erasable

Programmable

Read-Only Memory

A special type of PROM that can be erased by exposing it to an

electrical charge. An EEPROM retains its contents even when the

power is turned off.

FCC Federal Communications Commission.

firmware Code executed by an embedded processor such as the Host or DSP in

a subscriber radio. This type of code is typically resident in non-volatile

memory and as such is more difficult to change than code executed

from RAM.

FGU See frequency generation unit.

flash A non-volatile memory device similar to an EEPROM. Flash memory

can be erased and reprogrammed in blocks instead of one byte at a

time.

FLASHcode A 13-digit code which uniquely identifies the System Software Package

and Software Revenue Options that are enabled in a particular

subscriber radio. FLASHcodes are only applicable for radios which are

upgradeable through the FLASHport process.

FLASHport A Motorola term that describes the ability of a radio to change memory.

Every FLASHport radio contains a FLASHport EEPROM memory chip

that can be software written and rewritten to, again and again.

FMR See Florida Manual Revision.

Florida Manual

Revision

A publication that provides supplemental information for its parent

publication before it is revised and reissued.

Term Definition

September 17, 2004 6881098C38-O

Glossary-4

frequency Number of times a complete electromagnetic-wave cycle occurs in a

fixed unit of time (usually one second).

frequency

generation unit

This unit generates ultra-stable, low-phase noise master clock and other

derived synchronization clocks that are distributed throughout the

communication network.

General-Purpose

Input/Output

Pins whose function is programmable.

GPIO See General-Purpose Input/Output.

host code Object code executed by the host processor in an ASTRO subscriber

radio. The host is responsible for control-oriented tasks such as

decoding and responding to user inputs.

IC See integrated circuit.

IF Intermediate Frequency.

IMBE A sub-band, voice-encoding algorithm used in ASTRO digital voice.

inbound signaling

word

Data transmitted on the control channel from a subscriber unit to the

central control unit.

integrated circuit An assembly of interconnected components on a small semiconductor

chip, usually made of silicon. One chip can contain millions of

microscopic components and perform many functions.

ISW See inbound signaling word.

key-variable loader A device used to load encryption keys into a radio.

kHz See kilohertz.

kilohertz One thousand cycles per second. Used especially as a radio-frequency

unit.

KVL See key-variable loader.

LCD See liquid-crystal display.

LED See light emitting diode.

light emitting diode An electronic device that lights up when electricity is passed through it.

liquid-crystal display An LCD uses two sheets of polarizing material with a liquid-crystal

solution between them. An electric current passed through the liquid

causes the crystals to align so that light cannot pass through them.

LO Local oscillator.

low-speed

handshake

150-baud digital data sent to the radio during trunked operation while

receiving audio.

Term Definition

6881098C38-O September 17, 2004

Glossary-5

LSH See low-speed handshake.

Master In Slave Out SPI data line from a peripheral to the MCU.

Master Out Slave In SPI data line from the MCU to a peripheral.

MCU See microcontroller unit.

MDC Motorola Digital Communications.

MDI MCU/DSP Interface internal to the Patriot IC.

MHz See Megahertz.

Megahertz One million cycles per second. Used especially as a radio-frequency

unit.

microcontroller unit Also written as µC. A microprocessor that contains RAM and ROM

components, as well as communications and programming components

and peripherals.

MISO See Master In Slave Out.

MOSI See Master Out Slave In.

multiplexer An electronic device that combines several signals for transmission on

some shared medium (e.g., a telephone wire).

MUX See multiplexer.

NiCd Nickel-cadmium.

NiMH Nickel-metal-hydride.

OMPAC See over-molded pad-array carrier.

open architecture A controller configuration that utilizes a microprocessor with extended

ROM, RAM, and EEPROM.

oscillator An electronic device that produces alternating electric current and

commonly employs tuned circuits and amplifying components.

OSW See outbound signaling word.

OTAR See over-the-air rekeying.

outbound signaling

word

Data transmitted on the control channel from the central controller to the

subscriber unit.

over-molded pad-

array carrier

A Motorola custom IC package, distinguished by the presence of solder

balls on the bottom pads.

over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the

radio.

PA Power amplifier.

Term Definition

September 17, 2004 6881098C38-O

Glossary-6

paging One-way communication that alerts the receiver to retrieve a message.

Patriot IC A dual-core processor that contains an MCU and a DSP in one IC

package.

PC Board Printed Circuit Board. Also referred to as a PCB.

phase-locked loop A circuit in which an oscillator is kept in phase with a reference, usually

after passing through a frequency divider.

PL See private-line tone squelch.

PLL See phase-locked loop.

private-line tone

squelch

A continuous sub-audible tone that is transmitted along with the carrier.

Motorola Solutions 92FT4870 Astro Digital Mobile Radio XTL5000 User Manual 96C72 B

Motorola Solutions, Inc. Astro Digital Mobile Radio XTL5000 96C72 B

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