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Motorola APX 7500 05 Installation Manual
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Motorola APX 7500 05 Installation Manual

Two-way radios
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APX™ Two-Way Radios
APX 7500 O3, O5 & O9
Installation Manual

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Summary of Contents for Motorola APX 7500 05

  • Page 1 APX™ Two-Way Radios APX 7500 O3, O5 & O9 Installation Manual...

  • Page 3: Foreword

    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.

  • Page 4: Installation Requirements For Compliance With Radio Frequency (Rf) Energy Exposure Safety Standards

    Product Safety and RF Exposure booklet enclosed with each radio (Motorola Publication part number 6881095C99) 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/governmentandenterprise.

  • Page 5: Table Of Contents

    Radio Frequency (RF) Energy Exposure Safety Standards .......ii 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.
  • Page 6 Table of Contents Radio Mounting ........................... 2-15 2.2.2 Remote Mount with Trunnion..................2-17 2.2.2.1 100W Radios Only....................2-18 2.2.2.2 Remote Mount Control Head Installation............... 2-18 2.2.2.3 Multiple Control Head Installation................2-22 2.2.2.4 Cable Installation ....................2-23 2.2.2.5 Setting the Initial Control Head ID ................. 2-24 2.2.2.6 O3 Control Head and Remote Mount Cabling ............
  • Page 7 Table of Contents Vehicle Interface Port Overview ....................4-6 4.3.1 VIP Output Connections ....................4-7 4.3.2 VIP Input Connections ...................... 4-8 Compatibility of Emergency when Attaching a Siren ..............4-9 Accessory Connector Assembly Details (P2) (All Models Except 100W) ........4-10 4.5.1 Disassembly and Assembly ....................
  • Page 8 Jump-Start the Vehicle ........................7-3 Eliminate Noise/Howling from PA Speaker ................... 7-3 Appendix A Replacement Parts Ordering..........A-1 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 Index .....................Index-1...
  • Page 9 List of Figures List of Figures Figure 1-1. Front View of Mid Power Dash Mount Transceiver and Trunnion......... 1-1 Figure 1-2. Side View of Mid Power Dash Mount Transceiver and Trunnion .......... 1-1 Figure 1-3. Front View of High Power (100W) Transceiver and Trunnion..........1-1 Figure 1-4.
  • Page 10 viii List of Figures Figure 2-20. 100W Radio Mounting into Quick Release Trunnion ............2-18 Figure 2-21. O5 Control Head Installation Exploded View ..............2-19 Figure 2-22. O9 Control Head Installation Exploded View ..............2-20 Figure 2-23. O5 Control Head Rear View ....................2-20 Figure 2-24.
  • Page 11 List of Figures Figure 4-9. Field adjustment for Emergency Operation with Siren Accessory ........4-9 Figure 4-10. Location for Pin 8 ........................4-9 Figure 4-11. Exploded View of Accessory Connector Assembly (HLN6863_)........4-11 Figure 4-12. Rear Accessory Connector Audio Configuration ..............4-12 Figure 4-13.
  • Page 12 List of Tables List of Tables Table 2-1. Dash O5 Radio Operations Dependent Upon A+ and Ignition Connections.... 2-13 Table 2-2. Remote O5 or O9 Radio Operations Dependent Upon A+ and Ignition Connections..................2-13 Table 2-3. Remote O5 or O9 Radio Operations Dependent Upon A+ and Ignition Connections..................

  • Page 13: Mobile Radio Model Numbering Scheme

    Mobile Radio Model Numbering Scheme Mobile Radio Model Numbering Scheme Typical Model Number: Position: 12 13 Position 1 - Type of Unit Positions 13 - 16 M = Mobile SP Model Suffix L = Table Top Station Positions 2 & 3 - Model Series Position 12 - Unique Model Variations 30 = APX 7500...
  • Page 14 Mobile Radio Model Numbering Scheme Notes 6878215A01...

  • Page 15: Commercial Warranty

    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.

  • Page 16: Iii. State Law Rights

    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.

  • Page 17: Vi. Patent And Software Provisions

    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.
  • Page 18 Commercial Warranty Notes 6878215A01...

  • Page 19: Chapter 1 Introduction

    Chapter 1 Introduction This manual covers the installation procedures for ASTRO APX 7500 mobile and motorcycle radios with O3, O5 and O9 control heads, and accessories required to complete the radio system. The radio system consists of a control head, radio, antenna, microphone, speaker, cabling, Universal Relay Controller (URC), and accessories.

  • Page 20: Figure 1-5. Front View Of O3 Control Head With Coiled Cable

    Introduction: Mobile Radio Description Figure 1-5. Front View of O3 Control Figure 1-6. Side View of O3 Control Head with Coiled Cable Head with Coiled Cable Figure 1-7. Front View of O5 Control Figure 1-8. Side View of O5 Control Head with Trunnion Head with Trunnion Figure 1-9.

  • Page 21: Figure 1-11. Top View Of O9 Universal Relay Controller With Trunnion

    Introduction: Mobile Radio Description 61.5 Figure 1-11. Top View of O9 Universal Figure 1-12. Side View of O9 Universal Relay Controller with Trunnion Relay Controller with Trunnion (URC is an orderable accessory.) (URC is an orderable accessory.) 6878215A01...

  • Page 22: Standard Configurations

    Introduction: Standard Configurations Standard Configurations 1.2.1 Dash Mount Configuration NOTE: The dash mount configuration is not applicable for 100W radios and O9 control heads. There are two versions of the APX 7500 dash mount. The first is the O5 control head which is mounted on the front of the transceiver housing.

  • Page 23: Remote Mount Configuration

    Introduction: Standard Configurations 1.2.2 Remote Mount Configuration In the remote control version, the transceiver and the control head are mounted separately in the vehicle. The O5 control head is mounted in a remote trunnion near the operator, and the O3 and O9 control heads are also mounted near the operator using an extension cable.

  • Page 24: Figure 1-17. Remote Mount Configuration With High Power (100W) Radio Transceiver

    Introduction: Standard Configurations Figure 1-17. Remote Mount Configuration with High Power (100W) Radio Transceiver and O5 Control Head 5 m (17 ft) Extension Cable Figure 1-18. Remote Mount Configuration with High Power (100W) Radio Transceiver and O3 Control Head 17'' Extension Cable Figure 1-19.

  • Page 25: Multi Control Head

    Introduction: Standard Configurations 17'' Extension Cable O9 to URC Cable Figure 1-20. Remote Mount Configuration with Mid Power Radio Transceiver, Universal Relay Controller and O9 Control Head (URC is optional.) O9 to URC Cable 17'' Extension Cable Figure 1-21. Remote Mount Configuration with High Power (100W) Radio Transceiver, Universal Relay Controller and O9 Control Head (URC is optional.) For details on these configurations, see Section 2.2.2 on page...

  • Page 26: Motorcycle Configurations

    Introduction: Motorcycle Configurations Motorcycle Configurations NOTE: The motorcycle configurations are not applicable for 100W radios and O9 control heads. The ASTRO APX 7500 motorcycle radio models provide most of the equipment needed for installing a standard ASTRO APX 7500 radio on a motorcycle. Most of this radio system is standard equipment.

  • Page 27: Chapter 2 Standard Configurations

    Chapter 2 Standard Configurations Planning the Installation The APX 7500 radio operates only in negative ground electrical systems with a valid operating range of 10.8VDC to 16.3VDC. Before starting the radio installation, make sure that the ground polarity of the vehicle is correct. Accidentally reversing the polarity will not damage the radio, but will cause the cable fuses to blow.

  • Page 28: Figure 2-1. Dash Mount Radios Can Be Located In The Middle Console, On The Transmission Hump, Or Under The Dash

    Standard Configurations: Planning the Installation 2.1.1 Installation Examples The mobile two-way radio offers various methods of installation, with accessories placed to the vehicle as desired. The radio can be a dash or remote mount except for the 100W radio or with 09 control head, which can only be mounted remotely.

  • Page 29: Figure 2-4. Radio Installation (O5 Mid Power Dash Mount)

    Standard Configurations: Planning the Installation 2.1.2 Wiring Diagrams Figure 2-4 through Figure 2-11 show the wiring diagrams for all the possible configurations. The title under each figure identifies the O3, O5 or O9 control head configurations. Identify which of these figures shows the configuration that you are installing, and use the diagram when planning the installation.

  • Page 30: Figure 2-5. Radio Installation (O3 Mid Power Dash Mount)

    Standard Configurations: Planning the Installation FUSE BATTERY ANTENNA 2 RED LEAD ANTENNA 3 (FOR DUAL ANTENNA 1 BAND RADIOS) GPS (OPTIONAL) 3 ft 3 ft FUSE FIREWALL BLOCK HOLE IGN SENSE (ACC) FUSE HORN ANTENNA ANTENNA ANTENNA RELAY (SEE J2 POWER CONNECTION CONNECTION...

  • Page 31: Figure 2-7. Radio Installation (O3 Mid Power Remote Mount)

    Standard Configurations: Planning the Installation FUSE BATTERY ANTENNA 2 RED LEAD ANTENNA 3 (FOR DUAL ANTENNA 1 BAND RADIOS) GPS (OPTIONAL) 3 ft 3 ft FUSE FIREWALL BLOCK HOLE IGN SENSE (ACC) FUSE HORN ANTENNA ANTENNA ANTENNA RELAY POWER (SEE J626 CONNECTION CONNECTION CONNECTION...

  • Page 32: Figure 2-10. Radio Installation Of O9 Remote Mount With Transceiver (Urc Is Optional.)

    Standard Configurations: Planning the Installation PORTS ON REAR OF REMOTE CONTROL HEAD FUSE BATTERY FUSE ANTENNA 2 ANTENNA 3 RED LEAD (FOR DUAL ANTENNA 1 BAND RADIOS) (OPTIONAL) FUSE J400 BLOCK YELLOW 3 ft 3 ft VIP CONNECTOR PIN-OUT LEAD FUSE REMOTE HORN...

  • Page 33: Figure 2-11. Radio Installation (O9 Remote Mount With Pinouts)

    Standard Configurations: Planning the Installation REAR ACCESSORY CONNECTOR SPKR+ VIPOUT 2 SPKR- (RELAY) IGN SENSE (ACC) VIPOUT 1 (RELAY) EMERGENCY J500 GROUND VIP CONNECTOR PIN-OUT J100 M.A.P. J400 J200 PWR/SPKR VIP Cable Radio (RED) (HKN6196_) Function J300L Wire Color Number J400-1 SWB + J300R...
  • Page 34 Standard Configurations: Planning the Installation 6878215A01...
  • Page 35 Standard Configurations: Planning the Installation 6878215A01...
  • Page 36 2-10 Standard Configurations: Planning the Installation 6878215A01...

  • Page 37: Radio Operation Wiring For Dash And Remote Configurations

    Standard Configurations: Planning the Installation 2-11 2.1.3 Radio Operation Wiring for Dash and Remote Configurations Determine from Table 2-1, Table 2-2, or Table 2-3 the radio functionality you wish to achieve, which is controlled by the vehicle’s ignition switch state, the physical wiring of the radio’s ignition sense (ACC) wire, and by the programmed CPS setting.

  • Page 38: 2.1.3.2 Remote Mount: Power, Ignition, And Emergency Cable Installation

    2-12 Standard Configurations: Planning the Installation 2.1.3.2 Remote Mount: Power, Ignition, and Emergency Cable Installation The single control head O5 or O9 remote mount configurations receive power from the J200 connector’s red and black wires. The yellow wire at J200 is one ignition sense wire. On mid power radios, the J2 and J600 connectors can also be used for ignition sense.

  • Page 39: Table 2-1. Dash O5 Radio Operations Dependent Upon A+ And Ignition Connections

    Standard Configurations: Planning the Installation 2-13 Table 2-1. Dash O5 Radio Operations Dependent Upon A+ and Ignition Connections Transceiver Transceiver Transceiver HLN6863 HLN6863 HLN6863 Dash Mount Red Power Red Power Red Power Thin Red Wire Thin Red Wire Thin Red Wire Wire Wire Wire...

  • Page 40: Ignition Sense Switch (Radio Wide Advance)

    2-14 Standard Configurations: Planning the Installation 2.1.4 Ignition Sense Switch (Radio Wide Advance) CPS selectable settings to control the radio’s functionality based on the state of the vehicle’s Ignition status. Table 2-4. Ignition Sense Switch Settings in CPS Feature Description Blank •...

  • Page 41: Radio Mounting

    Standard Configurations: Radio Mounting 2-15 Radio Mounting DO NOT mount the radio on a plastic mounting surface without first reinforcing the mounting surface; the weight of the radio may crack or break the mounting surface. DO NOT mount the radio on a flat or concave surface where the radio could be C a u t i o n partially submersed in water.

  • Page 42: Figure 2-18. Transmission Hump Trunnion Mounting

    2-16 Standard Configurations: Radio Mounting 2.2.1 Dash Mount with Trunnion NOTE: This configuration is not applicable for 100W radios. 1. Select the location to mount your radio on the transmission hump (see Figure 2-18) or under the dash (see Figure 2-19).

  • Page 43: Remote Mount With Trunnion

    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...

  • Page 44: 2.2.2.1 100W Radios Only

    2-18 Standard Configurations: Radio Mounting 2.2.2.1 100W Radios Only NOTE: Cabling to the front of the radio (TIB) should not be completed with the handle opened as it is needed to be removed to close the handle. It is suggested that the cabling is to be attached to the front of the radio after the radio is assembled into the trunnion.

  • Page 45: Figure 2-21. O5 Control Head Installation Exploded View

    Standard Configurations: Radio Mounting 2-19 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.

  • Page 46: Figure 2-22. O9 Control Head Installation Exploded View

    2-20 Standard Configurations: Radio Mounting ADJUST THE CONTROL HEAD TO DESIRED ANGLE AND SECURE WITH WING SCREWS USE FOUR MOUNTING SCREWS ON ALL INSTALLATIONS TRUNNION MOUNTING SURFACE DRILL FOUR 5/32'' HOLES IMPORTANT IN MOUNTING SURFACE USE A METAL BACKING PLATE (NOT SUPPLIED) IF MOUNTING TRUNNION ON PLASTIC OR UNSTABLE SURFACE...

  • Page 47: Figure 2-24. O9 Control Head Rear View

    Standard Configurations: Radio Mounting 2-21 Figure 2-24. O9 Control Head Rear View 6878215A01...

  • Page 48: 2.2.2.3 Multiple Control Head Installation

    2-22 Standard Configurations: Radio Mounting 2.2.2.3 Multiple Control Head Installation Control heads in a multiple control head configuration should be installed per the steps detailed in Section 2.2.2.2: “Remote Mount Control Head Installation” on page 2-18. Two heads can be connected to each of the two CAN connectors on the transceiver, with the remaining heads connected to one or both of the first two.

  • Page 49: 2.2.2.4 Cable Installation

    Standard Configurations: Radio Mounting 2-23 NOTE: In Multiple Control Head (MCH) installations, the yellow ignition sense wire must be connected to the head assigned ID # 1. See Section 2.2.2.5 “Setting the Initial Control Head ID” on page 2-24 for further information. Use the most convenient configuration for your installation, ensuring that the combined cable lengths do not exceed 131 feet (40 meters).

  • Page 50: 2.2.2.5 Setting The Initial Control Head Id

    2-24 Standard Configurations: Radio Mounting 2.2.2.5 Setting the Initial Control Head ID The Front Panel Programming (FPP) mode allows you to define which control head in a Multi Control Head system becomes control head number 1-4. Set the control head ID number for each attached head the first time Multi Control Head is used. 1.

  • Page 51: 2.2.2.6 O3 Control Head And Remote Mount Cabling

    Standard Configurations: Radio Mounting 2-25 2.2.2.6 O3 Control Head and Remote Mount Cabling Choose a mounting location for the radio, considering accessibility, and control and antenna cable lengths. The control head extension cable and the accessories cable should be installed and routed properly to avoid complications.

  • Page 52: Figure 2-30. O3 Control Head Rear View

    2-26 Standard Configurations: Radio Mounting Vehicle Mounting Surface VEHICLE DASHBOARD Item Part Number Description 01-80743T91 Mic Hang-Up Clip Assembly 03-07644M19 Screw, Machine, 8-32 x 7/16 Figure 2-30. O3 Control Head Rear View Figure 2-31. Hang-Up Clip Installation Exploded View 6878215A01...

  • Page 53: Locking Kit (Optional)

    Standard Configurations: Radio Mounting 2-27 2.2.3 Locking Kit (Optional) 2.2.3.1 All Radios Except 100W If an optional locking kit (HLN6372_) is used (shown in Figure 2-32), position the lock housing on the trunnion after installing the radio mounting screws. Then rotate the lock with the key in it and remove the key to lock the radio.

  • Page 54: Power Cables (Transceiver And Control Head)

    2-28 Standard Configurations: Power Cables (Transceiver and Control Head) Power Cables (Transceiver and Control Head) Route the RED power cable from both the radio and the control head to the vehicle’s battery compartment, using accepted industry methods and standards. Be sure to grommet the firewall hole to protect the cable.

  • Page 55: Figure 2-35. Bracket Installation

    Standard Configurations: Power Cables (Transceiver and Control Head) 2-29 2. Insert the locking bracket (HLN7017_) onto the DC cable. 3. Slide the bracket toward the radio until the bracket clips snap onto the radio features. Figure 2-35. Bracket Installation Figure 2-36. Bracket Installation (Assembled State) 6878215A01...

  • Page 56: Figure 2-37. Bracket Uninstallation

    2-30 Standard Configurations: Power Cables (Transceiver and Control Head) 4. To disassemble the power cable, squeeze the locking bracket clips inward and while squeezing the clips, pull the locking clip and power cable to remove the power cable. Figure 2-37. Bracket Uninstallation Figure 2-38.

  • Page 57: O5 Or O9 Control Head Power Cables

    Standard Configurations: Power Cables (Transceiver and Control Head) 2-31 2.3.2 O5 or O9 Control Head Power Cables Figure 2-39. HKN6188_ Power Cable with External Speaker Connector Figure 2-40. HKN6187_ Power Cable with External Speaker Connector, Record Audio Output Jack (2.5 mm) and Earphone Jack (2.5 mm) NOTE: Audio Out –...

  • Page 58: Battery Selector Switch

    2-32 Standard Configurations: Power Cables (Transceiver and Control Head) 2.3.3 Battery Selector Switch In vehicles which have installed a Battery Selector Switch, the ignition sense (yellow) wire should be the only wire connected to the battery selector switch (see Figure 2-41).

  • Page 59: Antenna Installation

    NOTE: For mobile radios with rated power of 7 watts or less, the only installation restrictions are to use only Motorola approved antennas and install the antenna externally on metal body vehicles. For mobile radios with tuned power greater than 7 watts, always adhere to all the guidelines and restrictions in Section 2.4.1...

  • Page 60: Figure 2-42. Multiple Antennas Separation

    2-34 Standard Configurations: Antenna Installation 7. Ensure that any transmitting radio antennas on this vehicle are separated from each other by at least 3 feet (0.9 meter). See Figure 2-42. 8. The minimum distance between the antenna and the radio/accessories should be at least 3 feet (91.44 cm).

  • Page 61: Mini-Uhf Connection

    (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.

  • Page 62: Figure 2-45. Mini-Uhf Connector Tool (As Shown On Mid Power)

    2-36 Standard Configurations: Antenna Installation 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.

  • Page 63: Gps Antenna Placement

    Standard Configurations: Antenna Installation 2-37 2.4.3 GPS Antenna Placement The GPS antenna (excluding the Motorcycle GPS antenna) must be placed at least, 3 feet (0.9 meters) away from any transmitting antenna, and the antenna must have a clear, unobstructed view of the sky for best performance. The length of the cabling must be taken into consideration before the installation is started.

  • Page 64: Speaker

    2-38 Standard Configurations: Speaker Speaker DO NOT ground the radio's speaker leads. This system has a floating speaker output (DC voltage on both leads); damage to the audio circuit will result if either lead is grounded or if they are shorted together. C a u t i o n The speaker kit includes a trunnion bracket that allows the speaker to be mounted in a variety of ways.

  • Page 65: Microphone Hang-Up Clip

    Some microphone models require the grounding of the microphone clip in order for HUB operation to work correctly. Refer to the documentation that comes with your Motorola microphone model. NOTE: For multi-control head configuration where only one of the control heads has a microphone, the control heads without a microphone attached must have their HUB or Monitor pin (J100-22) jumpered by a wire to GND (J100-1 or J100-14) for HUB operation to work.

  • Page 66: Rfid Reading

    2.7.1 RFID Reading To read an RFID tag using a UHF Gen 2 RFID reader (e.g. Motorola’s MC9090-G), open an appropriate RFID read application, point the RFID reader at the tag and activate the reader's RFID antenna (e.g. pull Motorola’s MC9090-G scanning trigger). RFID reader must be within 1 foot from tag in order to read.

  • Page 67: Figure 2-54. Read Angle For High Power Radio

    Standard Configurations: RFID (Option) 2-41 Read Angle RFID Tag Figure 2-54. Read Angle for High Power Radio NOTE: APX 7500 high power mobile radio is shown without handle to allow visibility of RFID tag. Tag Angle RFID Tag Figure 2-55. Tag Angle for High Power Radio Figure 2-56.

  • Page 68: Programming Rfid (If Equipped)

    2.7.2 Programming RFID (If Equipped) The user can reprogram the tag (up to 12 ASCII characters when encoded to hexadecimal format) using any UHF Gen 2 capable RFID writer (e.g. Motorola’s MC9090-G). NOTE: Follow read direction in Section 2.7.1 to optimized reprogramming.

  • Page 69: Completing The Installation

    Standard Configurations: Completing the Installation 2-43 Completing the Installation Complete the installation by connecting the speaker to the accessory cable; verify the ignition sense wire is attached according to planned ignition sense; attach the accessory cable into J600; verify the control head is attached to either the TIB or the CAN extension cable;...
  • Page 70 2-44 Standard Configurations Notes 6878215A01...

  • Page 71: Chapter 3 Universal Relay Controller Installation

    Chapter 3 Universal Relay Controller Installation The Universal Relay Controller (URC) is an extension of and an orderable accessory for O9 control head. URC is used to control high power switching peripherals, e.g. lightbar. URC works on all lightbars which can be controlled by power application. URC is connected to the transceiver's GCAI port.

  • Page 72: Figure 3-2. Universal Relay Controller Installation Exploded View

    Universal Relay Controller Installation: Universal Relay Controller Mounting Install the URC as follows: 1. Use the URC trunnion as a template to mark the mounting holes; drill 5/32" holes. If mounting on a plastic surface, use a metal backing plate. 2.

  • Page 73: O9 Universal Relay Controller Cable Assembly

    The cap nut is then reassembled with tightening torque 18 lb-in. 3. The other end of the power cable should be connected to circuit breaker (Motorola part number 40012006001) end which indicates "AUX" and then, to power supply on the other end which indicates "BAT", instead of connecting to power supply directly.

  • Page 74: Wires

    Universal Relay Controller Installation: O9 Universal Relay Controller Cable Assembly Counter Nut Cable Gland Body Gasket, Cable Gland Neoprene Seal Cap Nut Figure 3-4. Cable Gland Assembly with Gasket 3.2.3 Wires 1. Assemble the wires into the lightbar gasket retainer and lightbar gasket. The URC can support lightbars through control wires with outer diameter ranging from 1.52 mm to 3.77 mm (0.06”...

  • Page 75: O9 To Urc Cable

    3.2.4 O9 to URC Cable The O9 to URC cable (Motorola part number 3064153H02) can be assembled either before or after reassembling the top housing. Assemble the RJ45 port of the cable into the RJ45 connector on the URC and turn the locking collar instead of cable, 90 degrees to the right to ensure it is locked properly.
  • Page 76 Universal Relay Controller Installation Notes 6878215A01...

  • Page 77: Chapter 4 Options And Accessories Installation

    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.

  • Page 78: Dash-Mount Horn And Lights (External Alarms) Relays

    Options and Accessories Installation: Remote-Mount Accessory Installation 4.1.2 Dash-Mount Horn and Lights (External Alarms) Relays NOTE: For installations that use the horn/lights option, select a suitable location for mounting (normally under the dash) and, referring to Figure 4-2, perform the following procedure: 1.

  • Page 79: Emergency Pushbutton Or Footswitch Installation

    Options and Accessories Installation: Remote-Mount Accessory Installation 4.2.1 Emergency Pushbutton or Footswitch Installation Mount the switch using the hardware that comes with the kit. Connect the button/switch wires to a ground pin and the emergency pin, removing the default jumper wire in the rear accessory cable. The button/switch will short the pins when in-active.

  • Page 80: Horn (External Alarm) Relay Installation

    Options and Accessories Installation: Remote-Mount Accessory Installation 4.2.2 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.

  • Page 81: Horn-Ring Transfer

    Options and Accessories Installation: Remote-Mount Accessory Installation 4.2.5 Horn-Ring Transfer Configure the Horn Relay for either Negative Contact or Positive Contact as shown in section 6.3 of the siren/PA manual (6881093C18). Program the designated VIP-OUT line for “Horn-Ring Transfer” and program the designated VIP-IN line for “Horn-Ring”. Figure 4-5 shows wiring diagrams for connecting the Horn-Ring via a transfer relay for both negative and positive ground systems.

  • Page 82: Usb Data Cables

    Options and Accessories Installation: Vehicle Interface Port Overview 4.2.8 USB Data Cables It is recommended that the USB 1.5 meter data cable HKN6163_ is used for both dash mount configurations (at J2 connector) and for remote mount configurations (at J100 connector). This is because the HKN6163_ has the emergency jumper present, which is necessary for correct dash mount configurations.

  • Page 83: Vip Output Connections

    Options and Accessories Installation: Vehicle Interface Port Overview 4.3.1 VIP Output Connections The VIP output pins are on the back of the control head (J100 and J400), or the rear accessory port (J2), as shown in Figure 2-6, Figure 4-12 Figure 4-13, respectively.

  • Page 84: Vip Input Connections

    Options and Accessories Installation: Vehicle Interface Port Overview 4.3.2 VIP Input Connections The VIP input pins are only available on the back of the control head (remote mount). 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.

  • Page 85: Compatibility Of Emergency When Attaching A Siren

    Options and Accessories Installation: Compatibility of Emergency when Attaching a Siren Compatibility of Emergency when Attaching a Siren When using emergency footswitch or pushbutton with siren/PA configuration, REMOVE pin 8 (emergency) from the siren connector of the HKN4363_ siren cable as follows: Siren Cable Figure 4-9.

  • Page 86: Accessory Connector Assembly Details (P2) (All Models Except 100W)

    4-10 Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 100W) Accessory Connector Assembly Details (P2) (All Models Except 100W) The APX 7500 accessory connector assembly is mounted on the right rear of the radio, opposite the antenna and adjacent to the power connector.

  • Page 87: 4.5.1.2 Assembly

    Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 100W) 4-11 4.5.1.2 Assembly 1. Place the plug in one cover. Be sure that the flange of the plug is in the slot of the cover. Figure 4-11. 2.

  • Page 88: Adapter Cable

    4-12 Options and Accessories Installation: Memory and Three-Day Secure Key Retention Option 4.5.2 Adapter Cable If you are planning on installing an APX 7500 radio as a replacement for an ASTRO Spectra radio, the following adapter cables are available: Part Number Description HKN6158_ Cable, Audio Adapter Kit...

  • Page 89: Chapter 5 Motorcycle Radio Installation

    Chapter 5 Motorcycle Radio Installation NOTE: The motorcycle radio installation is not applicable for 100W radios and O9 control heads. 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 APX 7500 Basic Service Manual (6875964M01). The following paragraphs describe the unique items provided with the motorcycle models.

  • Page 90: Control Head Cable

    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).

  • Page 91: Installation Overview

    • Mounting the antenna(s) 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.

  • Page 92: Important Installation Hints

    Motorcycle Radio Installation: Installation Overview 5.2.2 Important Installation Hints Consider the following when mounting the radio components: • Excess lengths of control-head, power, ignition sense, and speaker cables must be routed in the enclosure as shown in Figure 5-15. • All components must be mounted securely in order to withstand the constant and sometimes severe vibration experienced on a motorcycle.

  • Page 93: Parts Identification

    APX 7500 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 •...

  • Page 94: Installing The Universal Mounting Plate

    Motorcycle Radio Installation: Installing the Universal Mounting Plate 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.

  • Page 95: Installing The Speaker And Control Head

    Figure 5-4) 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.

  • Page 96: Handlebar Installation With Speaker And Control Head Mounted Together

    Motorcycle Radio Installation: Installing the Speaker and Control Head 5.4.1 Handlebar Installation with Speaker and Control Head Mounted Together Figure 5-4 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 5-4 is a handlebar-mounting bracket which may be required if the combination speaker/ control-head bracket cannot be easily mounted to the motorcycle.

  • Page 97: Fuel Tank Console Installation With Speaker And Control Head Mounted Together

    Motorcycle Radio Installation: Installing the Speaker and Control Head 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 5.6: “Installing the Microphone Hang-Up Clip”...

  • Page 98: Figure 5-5. Fuel Tank Console Installation With Speaker And Control Head Mounted Together

    5-10 Motorcycle Radio Installation: Installing the Speaker and Control Head Figure 5-5. Fuel Tank Console Installation with Speaker and Control Head Mounted Together 6878215A01...

  • Page 99: Handlebar Installation With Speaker And Control Head Mounted Separately

    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.

  • Page 100: Fuel Tank Console Installation With Speaker And Control Head Mounted Separately

    5-12 Motorcycle Radio Installation: Installing the Speaker and Control Head Figure 5-6. Handlebar Installation with Speaker and Control Head Mounted Separately 5.4.4 Fuel Tank Console Installation with Speaker and Control Head Mounted Separately The control head may be mounted to the fuel tank console using the smaller control-head bracket and spacers/hardware.

  • Page 101: Figure 5-7. Fuel Tank Console Installation With Speaker And Control Head Mounted Separately

    Motorcycle Radio Installation: Installing the Speaker and Control Head 5-13 Figure 5-7. Fuel Tank Console Installation with Speaker and Control Head Mounted Separately Installation is the same as detailed in Section 5.4.2: “Fuel Tank Console Installation with Speaker and Control Head Mounted Together” on page 5-9 Section 5.4.3: “Handlebar Installation with Speaker and Control Head Mounted Separately”...

  • Page 102: Installing 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. 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.

  • Page 103: Other Hang-Up Clip Mounting

    Motorcycle Radio Installation: Installing Antenna Base and Cables 5-15 5.6.3 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.

  • Page 104: Figure 5-9. Antenna Band Identification

    7. Remove the metal liner from the top cover. 8. For Band 1 and Band 2 positions, use the Motorola RPX-4378A Hole-Cutting Saw or equivalent, and carefully drill a 3/4-inch hole at the marked location from the inside of the cover until the saw bottoms out.

  • Page 105: Figure 5-11. Routing The Coaxial Cable For Band 1

    Motorcycle Radio Installation: Installing Antenna Base and Cables 5-17 12. Attach the 7/800, VHF or UHF antenna base per Antenna Installation Manual. IMPORTANT: Antenna Placement and Cable Routing in the Antenna Installation Manual is not applicable for the APX series. 13.

  • Page 106: Installing The Antenna

    5-18 Motorcycle Radio Installation: Installing the Antenna Installing the Antenna IMPORTANT: Antenna Placement and Cable Routing as described inside the Antenna Installation Manual is not applicable for the APX radio series. Refer to information listed below. • Connect the appropriate antenna connectors to the antenna receptacles on the radio. Tighten the coupling until fully engaged.
  • Page 107 Motorcycle Radio Installation: Cable Routing 5-19 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.

  • Page 108: 5.10 Installing The Weather-Resistant Enclosure

    5-20 Motorcycle Radio Installation: Installing the Weather-Resistant Enclosure 5.10 Installing the Weather-Resistant Enclosure TO MOTORCYCLE CHASSIS GROUND Item No. Description Item No. Description Universal Mounting Plate Flat Rubber Washer Machine Screw Shouldered Rubber Washer Lockwasher 7-1/2-inch Ground Strap Flat Washer Ground Strap Figure 5-14.

  • Page 109: 5.11 Transceiver And Cabling Installation

    Motorcycle Radio Installation: Transceiver and Cabling Installation 5-21 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. Figure 5-16 is an exploded view of the enclosure;...

  • Page 110: 5.11.2 Installing The Transceiver

    5-22 Motorcycle Radio Installation: Transceiver and Cabling Installation ACCESSORY CABLE ACCESSORY EMERGENCY AND CABLE HEADSET EXTERNAL ALARM CONNECTOR CONNETOR TRANSCEIVER HEADSET POWER CABLE SPORTING PLUG EMERGENCY CABLE SHORTING PLUG ACCESSORY CABLE IGNITION SENSE (ACC) CONTROL CABLE CONTROL HEAD (CAN) GROUND (BLACK) CONTROL HEAD CONTROL HEAD POWER (RED)

  • Page 111: Figure 5-16. Installing The Transceiver

    Motorcycle Radio Installation: Transceiver and Cabling Installation 5-23 Figure 5-16. Installing the Transceiver Table 5-1. Transceiver Installation Parts List Item No. Description Item No. Description Lock washer Ground shield plane Flat washer (8 used) Top cover Screw Gasket Screw Hinge Grommet Enclosure mounts Screw...

  • Page 112: 5.12 Installing The Emergency Switch Option

    5-24 Motorcycle Radio Installation: Installing the Emergency Switch Option 5.12 Installing the Emergency Switch Option Use the two-conductor, green/black cable which has as one end terminated with two contacts (part number 3080221P02) and which is supplied with this W688 Motorcycle Emergency Push Button. Disconnect the emergency switch shorting plug from the accessory cable.

  • Page 113: 5.15 Installing The Control Head Sunshield

    Motorcycle Radio Installation: Installing the Control Head Sunshield 5-25 5.15 Installing the Control Head Sunshield Install the sunshield (part number NNTN7279_) to the control head as follows. 1. Assemble the sunshield to the remote mount trunnion as shown in Figure 5-18.

  • Page 114: Figure 5-20. Slide The Control Head Onto Trunnion

    5-26 Motorcycle Radio Installation: Installing the Control Head Sunshield 3. Slide the control head onto the trunnion while aligning the edge of the control head with the edge of the sunshield as shown in Figure 5-20. Make sure the Velcro properly adheres to the control head.

  • Page 115: 5.16 Horn/Lights Wiring

    Motorcycle Radio Installation: Horn/Lights Wiring 5-27 5.16 Horn/Lights Wiring Figure 5-22. Horn/Lights Wiring Diagram 5.17 Emergency Switch Wiring Figure 5-23. Emergency Switch Wiring Diagram Motorcycle products must have pins 1 and 2 connected together to allow the radio to power down. Opening this connection by REMOVING the emergency shorting plug, or pressing the emergency switch, will turn on the radio.
  • Page 116 5-28 Motorcycle Radio Installation Notes 6878215A01...

  • Page 117: Chapter 6 Finishing The Installation

    Chapter 6 Finishing the Installation Cable Connection 6.1.1 O9 Control Head Perform the following if it has not been previously done: 1. Remove the control head from its mounting trunnion. Plug the radio's CAN cable into the proper location on the back of the control head (see Figure 2-22 Figure 2-24 Chapter 2).

  • Page 118: O3 Control Head

    Finishing the Installation: Cable Connection 6.1.3 O3 Control Head Perform the following if it has not been previously done: 1. Unplug the CAN coiled cable connector on the Transceiver Interface. Plug in the connector again. A “click” sound should be heard. Ensure location of CAN connector is correct (i.e.

  • Page 119: Dust Cover Installation

    Finishing the Installation: Dust Cover Installation Dust Cover Installation To help protect and ensure debris does not effect or damage your unused connectors, please use the provided dust covers. Refer to Figure 6-1 to determine which cover is for which connector. A: 1515047C01 B: 1515048C01 C: 1515049C01...

  • Page 120: Miscellaneous Information

    Finishing the Installation: Miscellaneous Information Miscellaneous Information On the mid power and 100W radios, there are rubber port plug which seals an opening which is used for a future antenna connection. On the mid power, the port plug is located at the bottom of the radio behind the control head or TIB.

  • Page 121: Chapter 7 Best Practices: Installation & Troubleshooting

    Chapter 7 Best Practices: Installation & Troubleshooting In this section are Motorola recommended vehicle installation practices that can address or prevent many issues, including: • Radio circuit damage due to over voltage condition • Radio/Accessories "lock up" • Radio/Accessories change state/lock-up when radio PTT is depressed •...

  • Page 122: Check Physical Installation Of Radio Ground And Radio Accessory Wiring

    Best Practices: Installation & Troubleshooting: Check Physical Installation of Radio Ground and Radio Accessory Wiring Check Physical Installation of Radio Ground and Radio Accessory Wiring • Take care to scrape away paint on the chassis at the place where the ground connection is to be made, and try to keep the ground lead as short as possible.

  • Page 123: Minimize The Effect Of Poorly Grounded Antennas

    The state of your radio prior to needing a jump-start may be unknown, and the radio may attempt to return to its last state (radio ON), when doing a jump-start. Therefore, Motorola recommends the following steps be taken before jump-starting any vehicle containing a radio.
  • Page 124 Best Practices: Installation & Troubleshooting Notes 6878215A01...

  • Page 125: Appendix A Replacement Parts Ordering

    The ASTRO APX 7500 Digital Mobile Radio Basic Service Manual (Motorola publication part number 6875964M01) includes complete parts lists and part numbers.

  • Page 126: Fax Orders

    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) Fax Orders Radio Products and Services Division*...

  • Page 127: Index

    Index Index configurations 100W radios ............1-6 dash mount ............1-3 motorcycle ............. 1-8 multi control ............1-7 Numerics remote mount ............1-5 control head ..........2-24, 4-6, 4-8 100W radios cabling ..............2-18 antenna connection ..........2-35 diagrams ........... 2-19, 2-20, 2-21 configurations ............
  • Page 128 Index-2 J2 ............... 4-7, 4-8 ordering replacement parts ........A-1 leads parts, ordering replacement ........A-1 black ..........2-28, 5-19, 5-24 green ..............5-24 ground ..............4-3 light relay ......... 4-2, 4-3, 4-4, 5-24, 5-27 SW B+ ............. 4-4, 4-7, 4-8 locking kit, installing ..........
  • Page 129 Index-3 wiring diagrams ............2-3 connector ............4-2, 6-1 input connections ..........4-8 output connections ..........4-7 6878215A01...
  • Page 130 Index-4 Notes 6878215A01...

  • Page 131: Glossary

    Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to the ASTRO radio. Term Definition See analog-to-digital conversion. Abacus IC A custom integrated circuit providing a digital receiver intermediate frequency (IF) backend. See analog-to-digital converter. See automatic level control.
  • Page 132 Glossary-2 Term Definition 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. Controller Area Network protocol. The CAN cable is the remote communications cable which provides audio, data, and power signaling information between the Control head and the Transceiver.
  • Page 133 Glossary-3 Term Definition 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 A microcontroller specifically designed for performing the mathematics processor involved in manipulating analog information, such as sound, that has been converted into a digital form.
  • Page 134 Glossary-4 Term Definition FLASHport A Motorola term that describes the ability of a radio to change the contents of its memory. Every FLASHport radio contains FLASH that can be software written and rewritten to, again and again. frequency Number of times a complete electromagnetic-wave cycle occurs in a fixed unit of time (usually one second).
  • Page 135 Data transmitted on the control channel from the central controller to the word subscriber unit. over-molded pad- A Motorola custom IC package, distinguished by the presence of solder array carrier balls on the bottom pads. over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the radio.
  • Page 136 Glossary-6 Term Definition Power amplifier. paging One-way communication that alerts the receiver to retrieve a message. 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.
  • Page 137 Glossary-7 Term Definition 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. real-time clock A module that keeps track of elapsed time even when a computer is turned off.
  • Page 138 Glossary-8 Term Definition software Computer programs, procedures, rules, documentation, and data pertaining to the operation of a system. software A computer-adjustable electronic attenuator. potentiometer spectrum Frequency range within which radiation has specific characteristics. See Serial Peripheral Interface. squelch Muting of audio circuits when received signal levels fall below a pre- determined value.
  • Page 139 Glossary-9 Term Definition Ultra-High Frequency. Universal A microchip with programming that controls a computer's interface to its Asynchronous attached serial devices. Receiver Transmitter Universal Serial Bus An external bus standard that supports data transfer rates of 12 Mbps. See Universal Serial Bus. See voltage-controlled oscillator.
  • Page 140 Glossary-10 Notes 6878215A01...
  • Page 142 Motorola, Inc. 1301, E. Algonquin Rd. Schaumburg, IL 60196-1078, U.S.A. MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. © 2009, 2010 by Motorola, Inc.

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