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

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Date Submitted	2004-11-05 00:00:00
Date Available	2005-04-02 00:00:00
Creation Date	2004-09-17 12:39:28
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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.
© Motorola, Inc. 2004.
ii
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.
iii
This Page Intentionally Left Blank
iv
Table of Contents
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
1.1
1.3
1.4
1.5
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
Motorcycle Configurations ............................................................................................................. 1-3
Base/Control Stations .................................................................................................................... 1-3
Tools Required for XTL 5000 Installations..................................................................................... 1-4
Chapter 2
2.1
2.2
Introduction ......................................................................... 1-1
Standard Configurations .................................................... 2-1
Planning the Installation................................................................................................................. 2-1
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
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September 17, 2004
vi
Table of Contents
2.3
2.4
2.5
2.6
2.7
2.8
2.2.3.2 100W Radios ......................................................................................................... 2-18
Power Cable ................................................................................................................................ 2-18
Ignition Sense Cable ................................................................................................................... 2-21
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
Speaker ...................................................................................................................................... 2-24
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
Completing the Installation .......................................................................................................... 2-25
Chapter 3
3.1
3.2
3.3
3.4
3.5
VIP Overview ................................................................................................................................. 3-1
3.1.1 VIP Output Connections ................................................................................................... 3-1
3.1.2 VIP Input Connections ...................................................................................................... 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
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
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
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
4.1
4.2
Options and Accessories Installation ............................... 3-1
Motorcycle Radio Installation ............................................ 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
Installation Overview ..................................................................................................................... 4-2
4.2.1 General ............................................................................................................................. 4-2
4.2.2 Important Installation Hints ............................................................................................... 4-3
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6881098C38-O
Table of Contents
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
vii
4.2.3 Parts Identification ............................................................................................................ 4-3
4.2.4 Order of Installation .......................................................................................................... 4-4
Installing the Universal Mounting Plate.......................................................................................... 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
Installing the Speaker .................................................................................................................. 4-10
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
Installing Cables .......................................................................................................................... 4-12
Installing the Weather-Resistant Enclosure................................................................................. 4-13
Transceiver and Cabling Installation............................................................................................ 4-14
4.9.1 Installing Cabling in the Enclosure.................................................................................. 4-14
4.9.2 Installing the Transceiver ................................................................................................ 4-15
Installing the Antenna .................................................................................................................. 4-18
Installing the Emergency Switch Option ...................................................................................... 4-18
Installing the External Alarm Relay Option .................................................................................. 4-18
Installing the Headset Accessory................................................................................................. 4-18
Horn/Lights Wiring ....................................................................................................................... 4-18
Emergency Switch Wiring............................................................................................................ 4-19
Chapter 5
Finishing the Installation: Cable Connection ................... 5-1
Appendix A Replacement Parts Ordering..............................................A-1
A.1
A.2
A.3
A.5
A.6
A.7
Basic Ordering Information ............................................................................................................A-1
Motorola Online .............................................................................................................................A-1
Mail Orders ....................................................................................................................................A-1
Fax Orders.....................................................................................................................................A-2
Parts Identification .........................................................................................................................A-2
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
6881098C38-O
September 17, 2004
viii
List of Figures
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
September 17, 2004
6881098C38-O
List of Figures
ix
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
6881098C38-O
September 17, 2004
x
List of Tables
Table 2-1.
Table 2-2.
Table 3-1.
Table 3-2.
Table 3-3.
Table 3-4.
Table 3-5.
Table 4-1.
Radio Functions Connections .................................................................................. 2-16
Fuse Assembly for Orange and Green Leads Parts List.......................................... 2-17
VIP Output Connections ............................................................................................ 3-1
VIP Input Connections ............................................................................................... 3-2
Rear Accessory Jack Pin Functions......................................................................... 3-12
Rear Connector and Front Connector Naming Schemes ........................................ 3-13
How to Connect to a Computer1 (DTE Device)........................................................ 3-13
Transceiver Installation Parts List ............................................................................ 4-16
September 17, 2004
6881098C38-O
Mobile Radio Model Numbering Scheme
xi
Mobile Radio Model Numbering Scheme
Typical Model Number: M
Position: 1
Position 1 - Type of Unit
M = Mobile
L = Table Top Station
10
11
12
13
14
15
16
Positions 13 - 16
SP Model Suffix
Position 12 Unique Model Variations
C = Cenelec
N = Standard Package
Positions 2 & 3 - Model Series
20 = XTL 5000
Position 4 - Frequency Band
A = Less than 29.7MHz
N=
B = 29.7 to 35.99MHz
P =
C = 36 to 41MHz
Q=
D = 42 to 50MHz
R=
E = 300 to 345MHz
S =
F = 66 to 80MHz
T =
G = 74 to 90MHz
H = Product Specific
U=
VHF Range
V =
J = 136 to 162MHz
W=
K = 146 to 178MHz
X =
L = 174 to 210MHz
Y =
M = 190 to 235MHz
Z =
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
* For XTL 5000 "U" in Position 4 represents
764-870MHz.
Note: Values represented are not absolute,
and are given to indicate range only.
Position 5 - Power Level
A = 0 to 0.7 Watts
J = 26 to 35 Watts
B = 0.7 to 0.9 Watts K = 36 to 60 Watts
C = 1.0 to 3.9 Watts L = 61 to 110 Watts
D = 4.0 to 5.0 Watts M = Up to 125 Watts
E = 5.1 to 6.0 Watts N = 1-25 Watts
F = 6.1 to 10 Watts P = 25-40 Watt
G = 10.1 to 15 Watts Q = 25-45 Watt
H = 16 to 25 Watts
R = 10-35 Watt
Note: Values represented are not absolute,
and are given to indicate range only.
Position 6 - Physical Packages
A = RF Modem Operation
B = Receiver Only
C = Standard Control; No Display
D = Standard Control; With Display
E = Limited Keypad; No Display
F = Limited Keypad; With Display
G = Full Keypad; No Display
H = Full Keypad; With Display
J = Limited Controls; No Display
K = Limited Controls; Basic Display
L = Limited Controls; Limited Display
M = Rotary Controls; Standard Display
N = Enhanced Controls; Enhanced Display
P = Low Profile; No Display
Q = Low Profile; Basic Display
R = Low Profile; Basic Display, Full Keypad
S = Tranceiver with Selectable Control Head
T =
U=
V = VDV Control Head
W = Control Head #2
Position 7 - Channel Spacing
0=
5 = 15KHz
1 = 5KHz
6 = 20/25KHz
2 = 6.25KHz 7 = 30KHz
3 = 10KHz
8 = 12.5/25KHz
4 = 12.5KHz 9 = Variable/Programmable
Position 11 - Version
Version Letter (Alpha) - Major Change
Position 10 - Feature Level
1 = Basic
6 = Standard Plus
2 = Limited Package 7 = Expanded Package
3 = Limited Plus
8 = Expanded Plus
4 = Intermediate
9 = Full Feature/
5 = Standard Package
Programmable
Position 9 - Primary System Type
A = Conventional
B = Privacy Plus
C = Clear SMARTNET
D = Advanced Conventional Stat-Alert
E = Enhanced Privacy Plus
F = Nauganet 888 Series
G = Japan Specialized Mobile Radio (JSMR)
H = Multi-Channel Access (MCA)
J = CoveragePLUS
K = MPT1327* - Public
L = MPT1327* - Private
M = Radiocom
N = Tone Signalling
P = Binary Signalling
Q = Phonenet
R = IDEN Basic
S = IDEN Advanced Feature
T = JSMR Digital
U = LTR Protocol
V = Single Sideband
W = Programmable
X = Secure Conventional
Y = Secure SMARTNET
Z = TETRA
2 = SmartZone
* MPT = Ministry of Posts and Telecommunications
Position 8 - Primary Operation
A = Conventional/Simplex
B = Conventional/Duplex
C = Trunked Twin Type
D = Dual Mode Trunked
E = Dual Mode Trunked/Duplex
F = Trunked Type I
G = Trunked Type II
H = FDMA* Digital Dual Mode
J = TDMA** Digital Dual Mode
K = Single Sideband
L = Global Positioning Satellite Capable
M = Amplitude Companded Sideband (ACSB)
N = Digital Dispatch
P = Programmable
Q = Digital Interconnect
R = Digital Multi-Service
S = 9600 Capable
T = TDMA
* FDMA = Frequency Division Multiple Access
** TDMA = Time Division Multiple Access
MAEPF-27634-O
6881098C38-O
September 17, 2004
xii
Mobile Radio Model Numbering Scheme
Notes
September 17, 2004
6881098C38-O
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:
ASTRO XTL 5000 Digital Mobile Radio
One (1) Year
Product Accessories
One (1) Year
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.
6881098C38-O
September 17, 2004
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 (including, without limitation, the addition to the Product of non-Motorola supplied equipment) which
adversely affect performance of the Product or interfere with Motorola's normal warranty
inspection and testing of the Product to verify any warranty claim.
F.
Product which has had the serial number removed or made illegible.
G. Rechargeable batteries if:
- any of the seals on the battery enclosure of cells are broken or show evidence of tampering.
- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.
H. Freight costs to the repair depot.
I.
A Product which, due to illegal or unauthorized alteration of the software/firmware in the Product, does not function in accordance with MOTOROLA’s published specifications or the FCC
type acceptance labeling in effect for the Product at the time the Product was initially distributed from MOTOROLA.
J.
Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
K. Normal and customary wear and tear.
September 17, 2004
6881098C38-O
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 continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept
its return. The depreciation will be an equal amount per year over the lifetime of the Product
or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.
VII. Governing Law
This Warranty is governed by the laws of the State of Illinois, USA.
6881098C38-O
September 17, 2004
xvi
Commercial Warranty
Notes
September 17, 2004
6881098C38-O
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.
8.5"
9.1"
7.1"
2"
3.5"
Figure 1-1. Front View of Dash Mount Radio
(All but 100W Radios)
8.78"
Figure 1-2. Side View of Dash Mount Radio
(All but 100W Radios)
12.25"
7.00"
2.38"
3.25"
Figure 1-3. Front View of 100W Radio
Figure 1-4. Side View of 100W Radio
NOTE: The rear accessory connector adds 0.75 in. to the overall length.
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.
PWR
Mode
Vol
DIM
Phon
Scan
Call
Sel
HOME
XMIT
BUSY
4 Sts
7H/L
Rcl
8 Mon
6 Msg
9 Dir
Del
MAEPF-27638-O
Figure 1-6. Remote Mount Configuration (Cannot Be Used for 100W Radios)
September 17, 2004
6881098C38-O
Introduction: Motorcycle Configurations
1-3
PWR
Mode
Vol
Phon
DIM
Scan
Call
Sel
HOME
XMIT
BUSY
4 Sts
7H/L
Rcl
8 Mon
6 Msg
9 Dir
Del
MAEPF-28156-O
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).
6881098C38-O
September 17, 2004
1-4
1.5
Introduction
Tools Required for XTL 5000 Installations
Tool
September 17, 2004
Part Number
11/32 hex driver
—
RF cable tool
HLN6695_
Regular slot screwdriver of
Phillips #2
—
Pin removal tool
6680163F01
1/4 hex driver
—
6881098C38-O
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.
2-2
2.1.1
Standard Configurations: Planning the Installation
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).
Speaker
Radio
Antenna
1/4-Wavelength
Speaker
Radio
Battery
Radio
Battery
Figure 2-1. Mounting Flexibility in Middle Console
(Cannot Be Used for 100W Radios)
Speaker
Antenna
1/4-Wavelength
Control Head
Battery
Radio
Antenna
1/4-Wavelength
Antenna
1/4-Wavelength
Radio
Battery
Figure 2-4. In Dash Mounting
(Cannot Be Used for 100W Radios)
Control Head
Speaker
Antenna
1/4-Wavelength
Speaker
Radio
Figure 2-5. Remote Mount–Control Head in Dash
September 17, 2004
Figure 2-2. On Top or Under Dash Mounting
(Cannot Be Used for 100W Radios)
Speaker
Figure 2-3. Remote Mount–Control Head in Console
Control Head
Battery
Antenna
1/4-Wavelength
Control Head
Battery
Radio
Figure 2-6. Remote Mount–Control Head on Top or
Under Dash
6881098C38-O
Standard Configurations: Planning the Installation
2.1.2
2-3
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.
FUSE
BATTERY
(+)
RED LEAD
ANTENNA
(-)
FUSE
BLOCK
FIREWALL
HOLE
J2
REAR ACCESSORY CONNECTOR
IGNITION CABLE
20
FUSE
HORN
RELAY
P2
(SEE J2
PINOUT)
LIGHT
RELAY
DC
POWER
CABLE
ANTENNA
CONNECTION
TRUNNION
MIC
CLIP
PWR
Mode
Phon
Scan
Call
Vol
SPEAKER
4 Sts
6 Msg
XMIT
DIM
MIC
Sel
BUSY
HOME
7H/L 8 Mon
Rcl
9 Dir
Del
26
SPKR+
SPKR-
VIPOUT 2
12V
(RELAY)
13
IGNITION VIPOUT 1
12V
(RELAY)
MOUNTING
SCREW
CONTROL HEAD*
MIC
EMERGENCY
21
GROUND
14
EMERGENCY
SWITCH
* MODEL W7 SHOWN
MAEPF-27612-O
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.)
6881098C38-O
September 17, 2004
2-4
Standard Configurations: Planning the Installation
FUSE
BATTERY
(+)
J0103
PORT ON BACK OF CONTROL HEAD
GRN LEAD FUSE
(-)
VIP
FUSE
BLOCK
MIC
ORG LEAD
18 19 20 21
FUSE
34 35 36 37 38
REMOTE
MOUNT
CONTROL
CABLE
HORN
RELAY
LIGHT
RELAY
PWR
Mode
MIC
CLIP
Phon
Scan
Call
Vol
4 Sts
6 Msg
BUSY
DIM
7H/L
8 Mon
9 Dir
Rcl
HOME
CONTROL HEAD*
MIC
RADIO
10 11 12 13 14 15 16 17
23 24
26 27 28 29 30 31 32 33
43 44 45 46 47 48 49 50
40 41
ANTENNA
VIP SECTION PIN OUT
XMIT
MIC
SPEAKER
Sel
1 VIP OUT - 2
18 SWB +
34 VIP OUT - 3 / DEK STROBE
2 VIP OUT - 1
19 SWB +
35 SWB +
3 VIP IN - 2 *
20 GROUND
36 GROUND
4 VIP IN - 1
21 GROUND
37 VIP IN - 3 / DEK DATA IN
5 DEK DATA OUT
Del
38 DEK CLOCK
* EMERGENCY WITH JUMPER CHANGES TO CONTROL HEADS
FIREWALL
HOLE
DC POWER
CABLE
ANTENNA
CONNECTION
RADIO
P506
J6
J5
EMERGENCY
SWITCH
* MODEL W7 SHOWN
MAEPF-27613-O
Figure 2-8. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads
FUSE
BATTERY
(+)
J0103
PORT ON BACK OF CONTROL HEAD
GRN LEAD FUSE
(-)
ANTENNA
FUSE
BLOCK
VIP
3 4
MIC
ORG LEAD
18 19 20 21
FUSE
34 35 36 37 38
REMOTE
MOUNT
CONTROL
CABLE
HORN
RELAY
LIGHT
RELAY
PWR
MIC
CLIP
Phon
Vol
Scan
Call
Sel
4 Sts
6 Msg
7H/L
8 Mon
9 Dir
XMIT
DIM
MIC
SPEAKER
Mode
BUSY
Rcl
HOME
Del
RADIO
10 11 12 13 14 15 16 17
23 24
26 27 28 29 30 31 32 33
40 41
43 44 45 46 47 48 49 50
VIP SECTION PIN OUT
1 VIP OUT - 2
18 SWB +
34 VIP OUT - 3 / DEK STROBE
2 VIP OUT - 1
19 SWB +
35 SWB +
3 VIP IN - 2 *
20 GROUND
36 GROUND
4 VIP IN - 1
21 GROUND
37 VIP IN - 3 / DEK DATA IN
5 DEK DATA OUT
38 DEK CLOCK
* EMERGENCY WITH JUMPER CHANGES TO CONTROL HEADS
CONTROL HEAD*
FIREWALL
HOLE
ANTENNA
CONNECTION
MIC
DC POWER
CABLE
EMERGENCY
SWITCH
* MODEL W7 SHOWN
RADIO
MAEPF-28157-O
Figure 2-9. Radio Installation (Remote) Using W4, W5, W7, or W9 Control Heads (100W Only)
September 17, 2004
6881098C38-O
Standard Configurations: Planning the Installation
BATTERY
(+)
2-5
FUSE
ANTENNA
(-)
FUSE
BLOCK
FIREWALL
HOLE
J2
REAR ACCESSORY CONNECTOR
20
IGNITION CABLE
LIGHT OR
HORN
RELAY
FUSE
HANG-UP
BOX
DC
POWER
CABLE
P2
(SEE J2
PINOUT)
ANTENNA
CONNECTION
TRUNNION
P506
SPEAKER
26
J6
J5
SPKR+
13
SPKR- VIPOUT 2
12V
(RELAY)
IGNITION VIPOUT 1
12V
(RELAY)
MOUNTING
SCREW
CONTROL HEAD
HANDHELD
CONTROL
HEAD
EMERGENCY
21
GROUND
14
EMERGENCY
SWITCH
MAEPF-27614-O
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.)
6881098C38-O
September 17, 2004
2-6
Standard Configurations: Planning the Installation
BATTERY
(+)
J3
REMOTE MOUNT
ACCESSORY CONNECTOR
FUSE
VIP
SPKR
NOTE 1
IGNITION OUT 2
LO
DIG
SPKR
GND
SWB+
EMER
HI
(-)
FUSE
BLOCK
IGNITION CABLE
LIGHT OR
HORN
RELAY
FUSE
15
J3
PINOUT
REMOTE
MOUNT CONTROL
CABLE
HANG-UP
BOX
14
12
13
NC
NC
BUS+
11
10
BUSY
NOTE 2
VIP OUT 1
BUS-
NOTES:
1. TX AUDIO IN SP CUSTOMER APPLICATIONS.
2. DET AUDIO IN SP CUSTOMER APPLICATIONS.
SPEAKER
FIREWALL
HOLE
DC POWER
CABLE
HANDHELD
CONTROL
HEAD
ANTENNA
CONNECTION
RADIO
P506
J6
J5
EMERGENCY
SWITCH
MAEPF-27615-O
Figure 2-11. Radio Installation (Remote) Using W3 Control Heads
BATTERY
(+)
J3
REMOTE MOUNT
ACCESSORY CONNECTOR
FUSE
(-)
VIP
SPKR
NOTE 1
IGNITION OUT 2
LO
DIG
SPKR
GND
SWB+
EMER
HI
ANTENNA
FUSE
BLOCK
IGNITION CABLE
LIGHT OR
HORN
RELAY
FUSE
15
14
13
12
11
10
J3
PINOUT
HANG-UP
BOX
NC
NC
REMOTE
MOUNT CONTROL
CABLE
BUS+
NOTE 2
VIP OUT 1
BUSY
BUS-
NOTES:
1. TX AUDIO IN SP CUSTOMER APPLICATIONS.
2. DET AUDIO IN SP CUSTOMER APPLICATIONS.
SPEAKER
FIREWALL
HOLE
HANDHELD
CONTROL
HEAD
ANTENNA
CONNECTION
DC POWER
CABLE
EMERGENCY
SWITCH
RADIO
MAEPF-28158-O
Figure 2-12. Radio Installation (Remote) Using W3 Control Heads (100W Only)
September 17, 2004
6881098C38-O
Standard Configurations: Radio Mounting
2.2
2-7
Radio Mounting
Caution
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.
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_.
RADIO
FRONT
APPLIES TO RADIOS WITH INTEGRAL
OR REMOTE MOUNT CONTROL UNITS
Figure 2-13. Trunnion Orientation (Cannot Be Used for 100W Radios)
6881098C38-O
September 17, 2004
2-8
Standard Configurations: Radio Mounting
TOP
BOTTOM
Figure 2-14. Trunnion Orientation for 100W Radios
(Quick Release Trunnion)
TOP
BOTTOM
Figure 2-15. Trunnion Orientation for 100W Radios
(Screw-Mounted Trunnion)
September 17, 2004
6881098C38-O
Standard Configurations: Radio Mounting
2.2.1
2-9
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.
Wing Screw
Plastic Guides
Trunnion
Tabs
Wing Screw
Groove
Threaded Hole
for Wing Screw
Figure 2-16. Transmission Hump Trunnion Mounting
6881098C38-O
September 17, 2004
2-10
Standard Configurations: Radio Mounting
Trunnion
Wing Screw
Holes for
Microphone
S-Hook
Wing Screw
Figure 2-17. Below Dash Trunnion Mounting
2.2.2
Remote Mount with Trunnion
2.2.2.1 Transceiver
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.
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 214 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.
September 17, 2004
6881098C38-O
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
6881098C38-O
September 17, 2004
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.
W4
W5
W5
W9
W9
W7
W7
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.
September 17, 2004
6881098C38-O
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.
Caution
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.
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
TO
RADIO
TO
MICROPHONE
ORANGE AND
GREEN LEADS
TO
SPEAKER
MAEPF-21453-O
Figure 2-21. W4, W5, and W7 Control Head Installation Exploded View
6881098C38-O
September 17, 2004
2-14
Standard Configurations: Radio Mounting
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
TO
RADIO
ORANGE AND
GREEN LEADS
TO
SPEAKER
MAEPF-21373-0
TO
MICROPHONE
TECHNICAL PUBLICATIONS DEPT.
DESCRIPTION
DWG. NO.
MAEPF 21373
Figure 2-22. W9 Control Head Installation Exploded View
VIP CONNECTOR
PROTECTIVE COVER
MIC CONNECTOR
PROTECTIVE COVER
CONTROL CABLE
CONNECTOR
DE
IL
Figure 2-23. W4, W5, and W7 Control Head Rear View
September 17, 2004
6881098C38-O
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.
Caution
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.
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.
6881098C38-O
September 17, 2004
2-16
Standard Configurations: Radio Mounting
Caution
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
Connected to battery
Green
Orange
Green
Orange
Green
Orange
Connected to ignition
switch
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).
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:
SPADE OR RING
TONGUE LUG
(RING TONGUE
LUG SHOWN)
PLASTIC INSULATOR
FUSE HOLDER CAP
METAL FUSE
CLIPS CRIMP
AND SOLDER
TO WIRE
SPRING
FUSE
TO CONTROL
HEAD
PLASTIC INSULATOR
FUSE HOLDER
MAEPF-21361-O
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 cutting 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.
September 17, 2004
6881098C38-O
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 remaining 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 fuseholder 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 fuseholders 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.
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)
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).
6881098C38-O
September 17, 2004
2-18
2.2.3
Standard Configurations
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.
Existing
Mounting
Screw
Lock
Housing
Lock
HLN6372_ Locking Kit
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.
September 17, 2004
6881098C38-O
6881098C38-O
I.B.
GROMMET
VIP
RADIO CONTROL
CABLE (BLK/MULTICONDUCTOR)
SPEAKER
RADIO (ORG)
(GRN)
MIC
MICROPHONE
RECEIVER
CONTROL
CABLE (GRN)
RADIO POWER CABLE
(RED/BATTERY HOT)
SEE NOTE
ON/ACC
3A OR 4A FUSE
TRANSMITTER
CONTROL
CABLE (ORG)
VEHICLE
IGNITION SWITCH
OPERATOR COMPARTMENT
15A OR 20A
FUSE
GROMMET
(-)
Figure 2-28. Cabling Interconnect Diagram for Remote Mount
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
(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.
VEHICLE
BATTERY
(+)
PART OF
VEHICLE
WIRING
VEHICLE BATTERY
COMPARTMENT
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.
REAR
CONNECTOR
RADIO
RADIO POWER CABLE (BLK/GROUND)
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.
CAUTION
RADIO COMPARTMENT
Standard Configurations: Power Cable
2-19
September 17, 2004
September 17, 2004
CH
SPEAKER
MICROPHONE
SEE NOTE
ON/ACC
3A OR 4A FUSE
RADIO POWER CABLE
(RED/BATTERY HOT)
RADIO IGNITION
CABLE (thin RED)
VEHICLE
IGNITION SWITCH
15A OR 20A
FUSE
GROMMET
(-)
VEHICLE
BATTERY
(+)
PART OF
VEHICLE
WIRING
VEHICLE BATTERY
COMPARTMENT
Figure 2-29. Cabling Interconnect Diagram for Dash Mount (Cannot Be Used for 100W Radios)
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.
MAEPF-27646-O
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.
NOTE:
Rear connector
RADIO
RADIO POWER CABLE (BLK/GROUND)
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.
CAUTION
RADIO COMPARTMENT = OPERATOR COMPARTMENT
2-20
Standard Configurations: Power Cable
6881098C38-O
Standard Configurations: Ignition Sense Cable
2.4
2-21
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!
6881098C38-O
September 17, 2004
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):
Coax Conductor
Plug (Pin)
Collar Pulled
Back to Flange
Flange
Mini UHF
Jack
Cable
Figure 2-30. Mini-UHF Connection (Cannot Be Used for 100W Radios)
Figure 2-31. Mini-UHF Connection (100W Radios Only)
September 17, 2004
6881098C38-O
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.
HLN6695_
(2) T
ig
en
ht
(1) Squeeze
Firmly Together
Figure 2-32. Mini-UHF Connector Tool (Cannot Be Used for 100W Radios)
(2) T
ig
en
ht
HLN6695_
(1) Squeeze
Firmly Together
MAEPF-28159-O
Figure 2-33. Mini-UHF Connector Tool (100W Radios Only)
6881098C38-O
September 17, 2004
2-24
2.6
Standard Configurations: Speaker
Speaker
Caution
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.
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.
Trunnion
Bracket
Dashboard
Firewall
OR
MAEPF-25764-O
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.
September 17, 2004
6881098C38-O
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.
6881098C38-O
September 17, 2004
2-26
Standard Configurations: Completing the Installation
Notes
September 17, 2004
6881098C38-O
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:
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
19
24
18
12
18
24
19
35
34
NA
NA
NA
NA
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.
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:
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
21
NA
NA
NA
NA
20
NA
NA
NA
NA
36
37
NA
NA
NA
NA
Caution
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.
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 Ordering.)
September 17, 2004
6881098C38-O
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
Caution
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.
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.
VIP
GASKET
EXTRACTION
TOOL
WIRE
CRIMPED
RECEPTACLE
VIP
CONNECTOR
MAEPF-21424-O
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.
6881098C38-O
September 17, 2004
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.
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Options and Accessories Installation: Dash-Mount Accessory Installations for W4/5/7/9 Models
3.3.1
3-5
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.
NOTE 1
SPST NORMALLY CLOSED
EMERGENCY SWITCH
PIN 14
PIN 15
NOTE 1: REMOVE BLACK JUMPER WIRE INSIDE
ACCESSORY CONNECTOR HOUSING.
INSERT WIRES FROM EMERGENCY SWITCH
ACCESSORIES
CONNECTOR
20
13
26
EMER
21
GND
14
MAEPF-27617-O
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.
CONNECT
ACROSS HORN
RING SWITCH
SPST
N.O.
RELAY
VIP OUT 1
PIN 18
12V COIL
SWB+
CONNECT
ACROSS HEAD
LAMP SWITCH
SPST
N.O.
RELAY
PIN 24
VIP OUT 2
PIN 19
ACCESSORIES
CONNECTOR
12V COIL
20
13
26
VIP OUT 2
(LIGHTS)
VIP OUT 1
(HORN)
SWB+
21
14
MAEPF-27618-O
Figure 3-3. Horn/Light Wiring Diagram for W4/5/7/9
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3-6
3.4
Options and Accessories Installation: Remote-Mount Accessory Installations for W3 Model
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.
NOTE 1
SPST NORMALLY CLOSED
EMERGENCY SWITCH
PIN 2
PIN 8
NOTE 1: REMOVE BLACK JUMPER WIRE INSIDE
ACCESSORY CONNECTOR HOUSING.
INSERT WIRES FROM EMERGENCY SWITCH
ACCESSORIES
CONNECTOR
EMER
DIG GND
15
14
13
12
11
10
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.
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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.
SPST
N.O.
RELAY
CONNECT
ACROSS HORN
RING SWITCH
VIP OUT 1
PIN 12
12V COIL
SWB+
SPST
N.O.
RELAY
CONNECT
ACROSS HEAD
LAMP SWITCH
PIN 4
VIP OUT 2
PIN 3
ACCESSORIES
CONNECTOR
12V COIL
SWB+
15
14
VIP OUT 2 (LIGHTS)
13
12
11
10
VIP OUT 1 (HORN)
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
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.
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.
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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.
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Options and Accessories Installation: Accessory Connector Assembly Details (P2)
3.5.3
3-9
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)
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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 fingertightening 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:
HKN6158_
Cable, Audio Adapter Kit
HKN6159_
Cable, Data Adapter Kit
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:
SPKR
LO GND
IGNITION
SPKR
HI +
15
14
13
EMER
12
11
PTT
10
VIP OUT 1
N.C.
MIC HI
N.C.
VIP OUT 2
SWB+
N.C.
N.C.
DISC.
AUD
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:
SPKR
LO DIG
GND
SPKR
HI +
15
CTS-ASTRO
VIP OUT 2 RTS_DCE
IGNITION
SWB+
14
BUS+
13
12
EMER
11
VIP OUT 1
10
BUS-
RTS-ASTRO TX-ASTRO RX-ASTRO BUSY
CTS_DCE
RX_DCE
TX_DCE
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.
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Options and Accessories Installation: Accessory Connector Assembly Details (P2)
3.5.5
3-11
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.
20
26
SPKR+
13
CHAN
ACT
SPKRVIP
OUT 2
USBUSB
PWR
IGNITION
VIP
OUT 1
SWB+
RXD
RTS
ONE
WIRE
AUX
MIC
TXD
CTS
PTT
MONITOR
BUSBUSY
EMERGENCY
RX FILT
AUDIO
21
USB+
BUS+
RESET
GROUND
14
GROUND
MAEPF-27619-O
Figure 3-9. Rear Accessory Jack Pin Configuration (J2) (Radio Side)
6881098C38-O
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3-12
Options and Accessories Installation
Table 3-3. Rear Accessory Jack Pin Functions
Pin
No.
Pin Name
Pin Function
Pin
No.
Pin Name
Pin Function
GND
Ground
14
GND
Ground
BUS+
SB9600 BUS+ Data
15
EMERGENCY
Emergency1
BUS-
SB9600 BUS- Data
16
PTT*
Push To Talk2
TXD
RS232 Transmit Data
17
ONE WIRE
One-Wire Data
RXD
RS232 Receive Data
18
VIP OUT 1
Vehicular Interface Output
USB-
USB - (Data)
19
VIP OUT 2
Vehicular Interface Output
USB+
USB + (Data)
20
SPKR+
Speaker + (3.2 ohm
minimum impedance)
RESET
SB9600 RESET
21
RX FILT AUDIO Receive Filtered Audio Out3
BUSY
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)
This 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.
Pulling this line to ground will activate PTT function, activating the AUX_MIC input.
Fixed level (independent of volume level) received audio signal, including alert tones. Flat or de-emphasis are programmed by CPS. Output voltage is approximately 100 mVrms per 1kHz of deviation. The DC offset is 1.4V.
This 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.
This 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.
See 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.
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Options and Accessories Installation: Accessory Connector Assembly Details (P2)
3-13
Table 3-4. Rear Connector and Front Connector Naming Schemes
J2 Pin Name1
J2 Pin Number
Pin 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
As indicated for front and rear connectors
Pin function as a true “DCE” device according to EIA standard
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
EIA standard
The 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).
6881098C38-O
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3-14
Options and Accessories Installation: Accessory Connector Assembly Details (P2)
Notes
September 17, 2004
6881098C38-O
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.
4-2
4.1.5
Motorcycle Radio Installation: Installation Overview
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 weatherresistant 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.
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6881098C38-O
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 weatherresistant 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
6881098C38-O
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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 temporarily 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.
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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.
Caution
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September 17, 2004
4-6
4.4.1
Motorcycle Radio Installation: Installing the Speaker and Control Head
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 handlebarmounting 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.
September 17, 2004
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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/controlhead 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.
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September 17, 2004
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
September 17, 2004
6881098C38-O
Motorcycle Radio Installation: Installing the Speaker and Control Head
4.4.3
4-9
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.
6.
Figure 4-4. Handlebar Installation with Speaker and Control Head Mounted Separately
6881098C38-O
September 17, 2004
4-10
4.4.4
Motorcycle Radio Installation: Installing the Speaker
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.
September 17, 2004
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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 customersupplied 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.
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September 17, 2004
4-12
4.7
Motorcycle Radio Installation: Installing Cables
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 antennarouting 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.
September 17, 2004
6881098C38-O
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.
6881098C38-O
September 17, 2004
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 cablerouting hole and connect the other end to the motorcycle frame (see Figure 4-7).
WARNING
DO NOT connect the ground strap directly to the negative
battery post.
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.
September 17, 2004
6881098C38-O
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.
6881098C38-O
September 17, 2004
4-16
Motorcycle Radio Installation: Transceiver and Cabling Installation
Table 4-1. Transceiver Installation Parts List
September 17, 2004
Lockwasher
Flat washer (8 used)
Screw
Screw
Grommet
Screw
Lock catch
Radio mounting plate
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
Motorcycle Radio Installation: Transceiver and Cabling Installation
4-17
Figure 4-9. Installing the Transceiver
6881098C38-O
September 17, 2004
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
September 17, 2004
6881098C38-O
Motorcycle Radio Installation: Emergency Switch Wiring
4-19
4.15 Emergency Switch Wiring
Figure 4-11. Emergency Switch Wiring Diagram
WARNING
WARNING
6881098C38-O
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.
September 17, 2004
4-20
Motorcycle Radio Installation
Notes
September 17, 2004
6881098C38-O
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.
Caution
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.
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.
5-2
Finishing the Installation: Cable Connection
Notes
September 17, 2004
6881098C38-O
Appendix A
A.1
Replacement Parts Ordering
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:
Federal Government Orders:
International Orders:
Motorola Inc.
Radio Products and Services
Division*
Attention: Order Processing
2200 Galvin Drive
Elgin, IL 60123
U.S.A.
Motorola Inc.
U.S. Federal Government
Markets Division
Attention: Order Processing
7230 Parkway Drive
Landover, MD 21076
U.S.A.
Motorola Inc.
Radio Products and Services
Division*
Attention: Order Processing
2200 Galvin Drive
Elgin, IL 60123
U.S.A.
A-2
A.4
Replacement Parts Ordering: Telephone Orders
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).
September 17, 2004
6881098C38-O
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 interagency 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.
Glossary-2
Term
Definition
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.
September 17, 2004
6881098C38-O
Glossary-3
Term
Definition
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 multifrequency
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.
6881098C38-O
September 17, 2004
Glossary-4
Term
Definition
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.
September 17, 2004
6881098C38-O
Glossary-5
Term
Definition
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 padarray 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.
6881098C38-O
September 17, 2004
Glossary-6
Term
Definition
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.
See also DPL.
Programmable
Read-Only Memory
A memory chip on which data can be written only once. Once data has
been written onto a PROM, it remains there forever.
programming cable
A cable that allows the CPS to communicate directly with the radio
using RS232.
Project 25
See APCO 25.
PROM
See Programmable Read-Only Memory.
PTT
See Push-to-Talk.
Push-to-Talk
The switch or button usually located on the left side of the radio which,
when pressed, causes the radio to transmit. When the PTT is released,
the unit returns to receive operation.
radio frequency
The portion of the electromagnetic spectrum between audio sound and
infrared light (approximately 10 kHz to 10 GHz).
radio frequency
power amplifier
Amplifier having one or more active devices to amplify radio signals.
Radio Interface Box
Not used with XTL 5000. The radio communicates directly to the
computer via a single programming cable. See programming cable.
Radio Service
Software
Not used with XTL 5000. See Customer Programming Software.
RAM
See random access memory.
random access
memory
A type of computer memory that can be accessed randomly; that is, any
byte of memory can be accessed without touching the preceding bytes.
read-only memory
A type of computer memory on which data has been prerecorded. Once
data has been written onto a ROM chip, it cannot be removed and can
only be read.
September 17, 2004
6881098C38-O
Glossary-7
Term
Definition
real-time clock
A module that keeps track of elapsed time even when a computer is
turned off.
receiver
Electronic device that amplifies RF signals. A receiver separates the
audio signal from the RF carrier, amplifies it, and converts it back to the
original sound waves.
registers
Short-term data-storage circuits within the microcontroller unit or
programmable logic IC.
repeater
Remote transmit/receive facility that re-transmits received signals in
order to improve communications range and coverage (conventional
operation).
repeater/talkaround
A conventional radio feature that permits communication through a
receive/transmit facility, which re-transmits received signals in order to
improve communication range and coverage.
RESET
Reset line: an input to the microcontroller that restarts execution.
RF
See radio frequency.
RF PA
See radio frequency power amplifier.
RIB
See Radio Interface Box.
ROM
See read-only memory.
RPCIC
Regulator/power control IC.
RPT/TA
See repeater/talkaround.
RS232
A common interface standard for data communications equipment.
RSS
See Radio Service Software.
RTC
See real-time clock.
RX
Receive.
RX DATA
Recovered digital data line.
SAP
See Serial Audio CODEC Port.
SCI IN
Serial Communications Interface Input line.
Serial Audio CODEC
Port
SSI to and from the GCAP II IC CODEC used to transfer transmit and
receive audio data.
Serial
Communication
Interface Input Line
A full-duplex (receiver/transmitter) asynchronous serial interface.
SCI IN
See Serial Communication Interface Input Line.
6881098C38-O
September 17, 2004
Glossary-8
Term
Definition
Serial Peripheral
Interface
How the microcontroller communicates to modules and ICs through the
CLOCK and DATA lines.
signal
An electrically transmitted electromagnetic wave.
Signal Qualifier
mode
An operating mode in which the radio is muted, but still continues to
analyze receive data to determine RX signal type.
softpot
See software potentiometer.
software
Computer programs, procedures, rules, documentation, and data
pertaining to the operation of a system.
software
potentiometer
A computer-adjustable electronic attenuator.
spectrum
Frequency range within which radiation has specific characteristics.
SPI
See Serial Peripheral Interface.
squelch
Muting of audio circuits when received signal levels fall below a predetermined value. With carrier squelch, all channel activity that exceeds
the radio’s preset squelch level can be heard.
SRAM
See static RAM.
SRIB
Smart Radio Interface Box. See RIB.
SSI
See Synchronous Serial Interface.
Standby mode
An operating mode in which the radio is muted but still continues to
monitor data.
static RAM
A type of memory used for volatile, program/data memory that does not
need to be refreshed.
Synchronous Serial
Interface
DSP interface to peripherals that consists of a clock signal line, a frame
synchronization signal line, and a data line.
system central
controllers
Main control unit of the trunked dispatch system; handles ISW and
OSW messages to and from subscriber units (See ISW and OSW).
system select
The act of selecting the desired operating system with the system-select
switch (also, the name given to this switch).
thin small-outline
package
A type of dynamic random-access memory (DRAM) package that is
commonly used in memory applications.
time-out timer
A timer that limits the length of a transmission.
TOT
See time-out timer.
transceiver
Transmitter-receiver. A device that both transmits and receives analog
or digital signals. Also abbreviated as XCVR.
September 17, 2004
6881098C38-O
Glossary-9
Term
Definition
transmitter
Electronic equipment that generates and amplifies an RF carrier signal,
modulates the signal, and then radiates it into space.
TSOP
See thin small-outline package.
TX
Transmit.
UART
See also Universal Asynchronous Receiver Transmitter.
UHF
Ultra-High Frequency.
Universal
Asynchronous
Receiver Transmitter
A microchip with programming that controls a computer's interface to its
attached serial devices.
Universal Serial Bus
An external bus standard that supports data transfer rates of 12 Mbps.
USB
See Universal Serial Bus.
VCO
See voltage-controlled oscillator.
vector sum excited
linear predictive
coding
Not used with XTL 5000. Replaced with the APCO 25 standard. See
APCO 25.
VHF
Very-High Frequency.
VIP
Vehicle Interface Port.
VOCON
See vocoder/controller.
vocoder
An electronic device for synthesizing speech by implementing a
compression algorithm particular to voice. See also voice encoder.
vocoder/controller
A PC board that contains an ASTRO radio’s microcontroller, DSP,
memory, audio and power functions, and interface support circuitry.
voice encoder
The DSP-based system for digitally processing analog signals, and
includes the capabilities of performing voice compression algorithms or
voice encoding. See also vocoder.
voltage-controlled
oscillator
An oscillator in which the frequency of oscillation can be varied by
changing a control voltage.
VSELP
See vector sum excited linear predictive coding.
6881098C38-O
September 17, 2004
Glossary-10
Notes
September 17, 2004
6881098C38-O
Index
Index
Numerics
100W radios
antenna connection .............................................2-22
configurations ........................................................1-3
dimensions .............................................................1-1
installation ............................................. 2-4, 2-6, 2-10
lock ......................................................................2-18
trunnions ................................................................2-8
accessories
connector assembly ......................... 3-2, 3-3, 3-4, 3-7
assembly ............................................................3-9
disassembly .......................................................3-9
exploded view ....................................................3-9
installing .............................................................3-7
connector pins .......................................................3-2
headset .........................................................4-2, 4-18
installing
dash mount ........................................................3-4
emergency pushbutton .......................................3-3
footswitch ...........................................................3-3
horn relay ...........................................................3-4
light relay ............................................................3-4
remote mount ..............................................3-2, 3-6
port .......................................................................2-15
rear jack connection ............................................. 3-11
antenna .....................................................................4-4
base/control stations ..............................................1-3
cable, see Cables, antenna
connection ...........................................................2-22
diagrams .....................................................2-22, 2-23
installing ......................................................2-21, 4-18
motorcycle .............................................................4-2
mounting ..............................................................2-21
site .......................................................................2-21
base stations .............................................................1-3
black lead ............................................. 2-18, 4-12, 4-18
cables ................................................ 4-2, 4-3, 4-4, 4-14
accessory .... 2-25, 3-3, 3-5, 3-6, 3-7, 3-13, 4-12, 4-18
adapter .................................................................3-10
antenna .........................................................2-7, 2-23
battery .............................................................3-7, 3-9
connection .............................................................5-1
diagrams 2-3, 2-4, 2-5, 2-6, 2-13, 2-16, 2-19, 2-20, 222, 4-12, 4-15
emergency ...........................................................4-18
excess ................................................................. 4-14
ignition ..........................................................2-21, 3-7
ignition sense ...................................................... 2-21
microphone ............................................3-3, 4-1, 4-10
motorcycle control head ................ 4-1, 4-7, 4-9, 4-12
motorcycle control head, installing ...................... 4-12
motorcycle transceiver ......................................... 4-14
power ..........................................................2-18, 4-12
programming .........................................................A-6
remote control ..................................................... 2-15
remote control, installing ...................................... 2-15
remote mount ...............................................2-12, 3-6
routing ................................................................. 4-13
serial port ............................................................. 3-13
speaker ................................................4-2, 4-11, 4-12
tools ....................................................................... 1-4
transmit/receive control, installing ....................... 2-15
configurations
100W radios .......................................................... 1-3
dash mount ............................................................ 1-2
dual control ............................................................ 1-3
motorcycle ............................................................. 1-3
remote mount ........................................................ 1-2
control head ..............................................2-12, 3-1, 3-2
cabling ................................................................. 2-12
dash mount ............................................................ 1-2
diagrams .....................................................2-13, 2-14
dual ........................................................................ 1-3
handheld .........................................................3-5, 3-6
installation examples ............................................. 2-2
models, photos of .......................................2-12, 2-15
remote mount ........................................................ 1-2
see also specific model names
wiring diagrams ..................................................... 2-3
control stations .......................................................... 1-3
dash mount
accessories installations ........................................ 3-4
configuration .......................................................... 1-2
installation .......................................................2-3, 2-5
installation examples ............................................. 2-2
radio dimensions ................................................... 1-1
trunnion ........................................................2-9, 2-10
dual control
configuration .......................................................... 1-3
emergency footswitch .................................3-3, 3-5, 3-6
emergency pushbutton ...............................3-3, 3-5, 3-6
emergency switch
installing ............................................................... 4-18
wiring ................................................................... 4-19
external alarm
installing ............................................................... 4-18
see also Horn relay or Light relay
Index-2
footswitch, emergency ................................3-3, 3-5, 3-6
green lead .......................... 2-15, 2-16, 2-17, 2-21, 4-18
high power, see 100W radios ................................... 1-1
horn relay ............................ 3-3, 3-4, 3-5, 3-6, 3-7, 4-18
ignition
cable ............................................................. 2-21, 3-7
switch ................................................2-15, 2-16, 2-17
wire ...................................................................... 4-12
wire, for motorcycle ............................................... 4-2
installation
examples ............................................................... 2-2
important hints ....................................................... 4-3
order of .................................................................. 4-4
J0103
pin configuration .................................................... 2-4
J2 ..............................................................3-1, 3-2, 3-13
pin configuration .................................... 2-3, 2-5, 3-11
J3
pin configuration .................................................... 2-6
ignition wire ........................................................... 4-2
installation ............................................................. 4-2
antenna ........................................................... 4-18
cables .............................................................. 4-12
cabling ............................................................. 4-14
control head ....................................................... 4-5
emergency switch ................................... 4-18, 4-19
external alarm .................................................. 4-18
fuel tank console ............................... 4-7, 4-8, 4-10
handlebar ................................................... 4-6, 4-9
headset ............................................................ 4-18
horn/lights wiring ............................................. 4-18
microphone hang-up clip ..................................4-11
speaker ..................................................... 4-5, 4-10
transceiver .............................................. 4-14, 4-17
universal mounting plate ................................... 4-4
weather-resistant enclosure ............................ 4-13
microphone ........................................................... 4-1
transceiver ............................................................ 4-1
mounting configurations ........................................... 2-7
dash ............................................................... 1-2, 2-9
dual control ........................................................... 1-3
motorcycle ............................................................. 1-3
remote .......................................................... 1-2, 2-10
mounting plate, universal ............................ 4-1, 4-2, 4-4
installing ................................................................ 4-4
mounting, antenna
restrictions ........................................................... 2-22
roof top ................................................................ 2-21
trunk lid ............................................................... 2-21
orange lead ..................................2-15, 2-16, 2-17, 2-21
ordering replacement parts ....................................... A-1
leads
black ..................................................2-18, 4-12, 4-18
green .............................. 2-15, 2-16, 2-17, 2-21, 4-18
orange ......................................2-15, 2-16, 2-17, 2-21
light relay ............................ 3-3, 3-4, 3-5, 3-6, 3-7, 4-18
locking kit, installing ................................................ 2-18
parts, ordering replacement ...................................... A-1
pin
emergency ............................................................ 3-3
functions .............................................................. 3-12
ground ................................................................... 3-3
naming schemes ................................................. 3-13
removal tool .......................................................... 1-4
SW B+ ..................................................... 3-1, 3-2, 3-4
VIP in .................................................................... 3-2
VIP out ........................................................... 3-1, 3-4
pin configurations
J0103 .................................................................... 2-4
J2 .......................................................... 2-3, 2-5, 3-11
J3 .......................................................................... 2-6
pushbutton, emergency .............................. 3-3, 3-5, 3-6
microphone ...............................................2-12, 4-1, 4-3
cable, see Cables, microphone
desk ....................................................................... 1-3
hang-up box ........................................................ 2-25
hang-up clip, installing ......................................... 4-11
hang-up clip, standard ....................2-24, 4-4, 4-6, 4-9
mounting ............................................................... 4-3
S-hook .................................................2-10, 2-25, 5-1
motorcycle
antenna ................................................................. 4-2
configuration .......................................................... 1-3
control head cable ................................................. 4-1
display unit ............................................................ 4-1
external speaker .................................................... 4-2
headset ................................................................. 4-2
September 17, 2004
rear accessory jack, see J2
relays
horn ................................. 3-3, 3-4, 3-5, 3-6, 3-7, 4-18
light ................................. 3-3, 3-4, 3-5, 3-6, 3-7, 4-18
remote mount
accessory installations ................................... 3-2, 3-6
cable assembly ..................................................... 3-6
6881098C38-O
Index-3
cabling ................................................................. 2-12
configuration .......................................................... 1-2
control cable installation ...................................... 2-15
control head installation .............................. 2-12, 2-15
installation ...................................................... 2-4, 2-6
installation examples ............................................. 2-2
transmit/receive control cable installation ............ 2-15
trunnion ............................................................... 2-10
replacement parts, ordering ......................................A-1
orientation ...................................................... 2-7, 2-8
remote mount ............................................... 1-2, 2-10
transmission hump mounting ................................ 2-9
universal mounting plate ............................. 4-1, 4-2, 4-4
installing ................................................................ 4-4
speaker ..................................................................... 4-4
cable, see Cables, speaker
connecting .................................................. 2-15, 2-25
external ................................................................. 4-2
fuel tank console installation .................4-7, 4-8, 4-10
handlebar installation ..................................... 4-6, 4-9
installing ................................................4-5, 4-6, 4-10
mounting ............................................................. 2-24
pigtail ..................................................................... 3-8
VIP
connector ................................................ 3-3, 3-4, 5-1
connector cover .................................................. 2-12
input connections .................................................. 3-2
output connections ................................................ 3-1
tools, required ........................................................... 1-4
trunnion ................................................................... 2-12
100W radios .......................................................... 2-8
below dash mounting .......................................... 2-10
bracket for speaker ............................................. 2-24
dash mount ........................................................... 2-9
diagrams ............................................................. 2-13
locking kit ............................................................ 2-18
motorcycle installation ......................................... 4-15
mounting bracket ................................................... 2-9
6881098C38-O
W3 control head ..............................2-5, 2-6, 2-15, 2-25
accessories ........................................................... 3-6
cabling ................................................................... 5-1
wiring ..................................................................... 3-7
W4 control head 2-3, 2-4, 2-12, 2-13, 2-14, 2-15, 3-2, 34, 3-5, 3-6, 5-1
W5 control head 2-3, 2-4, 2-12, 2-13, 2-14, 2-15, 3-2, 34, 3-5, 3-6, 5-1
W7 control head 2-3, 2-4, 2-12, 2-13, 2-14, 2-15, 3-2, 34, 3-5, 3-6, 5-1
W9 control head 2-4, 2-12, 2-14, 2-15, 3-2, 3-3, 3-4, 3-5,
3-6, 5-1
wiring diagrams ........................................................ 2-3
September 17, 2004
Index-4
Notes
September 17, 2004
6881098C38-O

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