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INSTALLATION GUIDELINE
Suited to vehicle; Toyota Land Cruiser, Hard Top, HZJ78L-RJMRSV, 11 seats, LHD, 4WD, 2 door
Toyota Land Cruiser, Hard Top, HZJ78L-RJMRS, 6 seats, LHD, 4WD, 2 door
INTRODUCTION
Purpose
The objective is the documentation for the standardized installation of Non-Factory-Fit-Accessories with
the description of the technical installation process. Produce guidelines with best illustration of steps for
defined standard installation of land mobile high frequency (HF) two-way radio system. Scope, to UNHCR
light vehicles as specified in the standard GFM Model Line-up 2014.
Further goals; to ease the installation of HF radios at the global hubs in standardized manner and to assure
reliability of installation by mandated professionals and trained personnel. Use the present production of
description as reference for the quality control. Furthermore, aim for cost reduction.
Reference
The manufacturer’s recommendations prevails as the relevant instruction guideline in regards to the
CODAN, NGT SRx Transceiver HF radio and must be consulted prior installation. The CODAN references
remain the lead standard. Every HF radio kit is provided with written instructions.
• CODAN, NGT SRx Transceiver; Reference Manual
• CODAN, NGT transceiver vehicle-mount cradle; Fitting Instruction
• CODAN, 3040 Automatic Whip Antenna; Installation Handbook
• CODAN, 9350 Automatic Whip Antenna; Installation Handbook
• Radio Installation Kit Code 112; General Instruction
• Handset cradle assembly; Fitting Instruction
•
It is recommended to consult chapter 4 “Installation”, in the CODAN Reference Manual; Pay attention to
headings as; Mobile station, whip antenna, transceiver positioning and grounding, power supply (battery
and other factors), cables, connections and protection.
The present works of UNHCR installation guide line focus on standard HF radio installation for the specific
vehicle only, to be used by trained UNHCR personnel and contractors. The information has been prepared
in accordance with current engineering principles and generally accepted practices, using the information
available at the time of publication.
The present works cannot and does not repeat the manufacturer’s description of installations. Therefore,
refer to CODAN manual, fitting instruction and installation handbook. In particular pay attention to safety
precautions further, indicated warnings, cautions and notes. Read the relevant instructions carefully and
completely prior installation.
All necessary material needed to install and operate the HF radio CODAN NGT SRx is fully supplied; with
transceiver kit inclusive cradle, mounts, fasteners, hand-set, straps and cables and the whip antenna with
all needed sets of documentations.
The recipient body – UNHCR admin at the hub and/or the installer – must cross-check the supplied
hardware against the inventory list at time breaking the boxes before installation.
Installation
Reference made to the installation description further down the page; INSTALLATION PROCESS BY
ILLUSTRATION AND DESCRIPTION – CODAN NGT SRx Transceiver. As a summary, the principle steps to
consider as follows;
Ensure that the power supply to operate the mobile station is 12 V DC!
Read and follow installation guidelines, manuals and instructions first before start to action.
Test
After final installation, perform operation tests; short wave ratio (SWR) and on-air testing, power supply
and transceiver operation. All described in the CODAN, NGT SRx Transceiver Reference Manual. (Do brake
control before extensive driving).
ANNEX
Pinpoints of importance to pay attention too.
Although it may appear everything is known, always something remains unknown. It is recommended to
work through the reference documentation.
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Installation Guideline, HF Radio, Toyota LC78L, GFM Project, February 2014, 15-2-2014 Page 3 of 31
Principal lay-out of the HF radio accessories and cables installation in the specific vehicle models;
a a a a
Toyota Land
Cruiser HT, 78L
(11 seats)
The documented assembling steps and display of additional items are supplementary to the only relevant
CODAN Instruction. Reference made to follow basic documentations;
CODAN “Reference Manual” NGT SRx Transceiver (supplied with each kit)
CODAN Automatic Tuning Whip Antenna 9350 (Installation Handbook, with each kit)
CODAN Automatic Tuning Whip Antenna 3040 (Installation Handbook, with each kit)
Contact www(dot); www.codan.com.au/hfradio
Display of main components;
Transceiver
Handset / microphone
Loudspeaker
Display in principal;
Overview;
New generation antenna kit, Automatic Tuning
Whip Antenna 3040;
• Antenna 3040 with ground braid strap
• with spring attached
• Control cable
• RF( Radio Frequency) coaxial cable
• With connectors / adapters
• Special CODAN contact grease
• Amalgamating tape (self-polymerizing)
• Manual; Installation Handbook with
features for reference
Overview;
CODAN NGT SRx Transceiver Radio kit;
• Transceiver set (with serial number)
• Cradle with twin core cable (power/
ground) and fastener
• Loud speaker set (in box)
• Braid strap
• Manual Installation
instruction/features
• Connector cable handset & loud
speaker
• Kit cable ties, screws, lugs, tapes
assorted
CODAN NGT SRx - Picture 6 CODAN•NGT Hanger/cradle
SRx – Text 6 for
handset/microphone
• Handset / microphone
Installation Guideline, HF Radio, Toyota LC78L, GFM Project, February 2014, 15-2-2014 Page 6 of 31
Kit of;
• Assorted cable ties of different size
• Crimp lugs for electric cables
• Assorted screws of different size
• 2 straps of amalgamating tape (self-
polymerizing)
Cradle
Ground cables
Suited to vehicle; Toyota Land Cruiser, Hard Top, HZJ78L-RJMRSV, 11 seats, LHD, 4WD, 2 door
Toyota Land Cruiser, Hard Top, HZJ78L-RJMRS, 6 seats, LHD, 4WD, 2 door
Remark; disassembling – system installation – assembling often goes together, and therefore this operation
is not mentioned separately in the following process description.
System feed.
Power/positive pick-up connection directly at
the battery terminal.
System feed.
Power/positive pick-up connection directly at
the battery terminal.
Optional/New Version;
Automatic Tuning Whip Antenna 3040;
Cradle
Grommet in bulkhead
HF – Land Cruiser, 78L – Text Transceiver 1 HF – Land Cruiser, 78L – Text Transceiver 2
Cradle in place.
Centre trim panel in place.
Rear trim panel cut to appropriate size and
fit in place. Prior installation, drill two (2)
holes diameter 10mm in alignment with
the holes in bracket.
2 Jack tools in place.
Cables and split loom tube ready connect
to transceiver.
In order to conclude with the HF radio installation, the following operations remain;
Check all cables whether fit properly and put firmly in place.
All mountings fitted back in their former places, sockets and connections.
Check on bolts, screws and nuts whether properly fit and tight.
Check whether fuses installed in place.
Connect the positive/power terminal.
Connect the negative/ground terminal.
Ensure quality control with CHECK-LIST and perform the final tests.
Installation Guideline, HF Radio, Toyota LC78L, GFM Project, February 2014, 15-2-2014 Page 24 of 31
HF – Land Cruiser, 78L – Text Transceiver 3 HF – Land Cruiser, 78L – Text Transceiver 4
Material requirement;
Aluminum plate, designed by UNHCR to
serve requirement.
Set of fastener fittings.
In order to conclude with the HF radio installation, the following operations remain;
Check all cables whether fit properly and put firmly in place.
All mountings fitted back in their former places, sockets and connections.
Check on bolts, screws and nuts whether properly fit and tight.
Check whether fuses installed in place.
Connect the positive/power terminal.
Connect the negative/ground terminal.
Ensure quality control with CHECK-LIST and perform the final tests.
Installation Guideline, HF Radio, Toyota LC78L, GFM Project, February 2014, 15-2-2014 Page 29 of 31
ANNEX
Foreword. The UNHCR installation guideline remain supplementary to the CODAN HF radio
manufacturer. The UNHCR installation guideline focus on the radio system installation only fit to the
specific vehicle. The actual works do not repeat the installation guideline in the manufacturer’s
reference manual.
The Reference Manual supplied by the CODAN manufacturer/dealer is predominant. Pay attention to
the CODAN, NGT SRx Transceiver Reference Manual; The CODAN manufacturer’s recommendation
prevails in regards to his HF radio system and is the lead standard manual to be consulted prior
installation. In particular pay attention to transceiver installation, positioning and grounding transceiver,
control device, antenna, connections and power supply, cables, protection.
Summary; The following must be observed for the proper installation of communication equipment;
The positive power connection to be connected directly from the battery terminal.
Install the fuse as close to the battery as practicable.
The negative power connection to be made to body sheet metal, must be clean of paint.
Antennas for two-way (transmitter / receiver) radios in front or rear of vehicle.
Magnets may affect the accuracy or operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring.
Use only fully shielded coaxial cable.
Match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mob radio equipment with output power greater than normal require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems.
The owner’s first line of contact regarding vehicle problems is the dealer.
Caution; Do not operate the VHF radio, without the engine run, because battery discharge!
Caution; Ensure operational status of battery. Maintenance is paramount!
Reference also made to Owner’s Manual supplied with each vehicle.
is secured and concealed as much as possible; cables under the floor mats and padding
ensures the control cables are separated from the DC power cable by at least 200 mm (8 in),
except over short distances where they may pass through the same hole in a bulkhead
Arrange and keep cables in the engine compartment away from; heat, AC system, water pipes, fan,
throttle linkages and corrosive liquids, e.g. engine oil, battery and brake fluid.
As longer the cable the bigger the cross-section need.
Where wiring passes through bulkhead provide grommet to prevent insulation being cut.
Protect all cable, with isolation tape, split loom tube, grommets and cable ties.
Hint; A bend radius of six times the harness diameter is recommended.
Grounding is the most important to tuner and transceiver to avoid poor radio performance.
Disconnect always the battery NEGATIVE first before beginning work. Note that some components
may lose short-term memory (e.g.: radio presets, or VTS)
To add power pick-up from existing power plus cable, no splicing or use of jumper terminal at the
socket tolerated.
For higher power transmitters, connect the power cable (battery +) at the battery terminal.
For high power installations, connect the battery ground cable/braid additionally to body.
The engine hood must be bonded to body. Connection with braid straps.
If the power connection is underhood, use a weatherproof holder, install cartridge fuse.
DO NOT FUSE THE GROUND LEAD.
Use plated ground screws, then proper size of ring terminal with lockwasher serrations.
If the appropriate terminal is exposed to weather apply a commercial protectant, use
sylicon/dielectric grease or pole protection spray “presto” (Trademark), corrosion retarder.
If the power cable must pass through the bulkhead, search for unused holes in grommet.
If no passage is available; drill/enlarge a hole in upper side footwell, smooth the edges.
Fit a standard grommet to run the cable(s), ensure the additional holes are well sealed.
Hint; To create a hole in the bulkhead, drill diam. 12 or 5mm for pilot hole and open further by a
tapered awl/reamer tool.
Ensure that all connectors are fully mated and that latches are locked
Caution; Disconnect NEGATIVE and POSITIVE terminal prior any type of welding!
TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control
and power cables.
Route flat along body, avoid sharp edges and pinches.
Cross over wiring at right angles. In some cases, additional shielding may be helpful.
It is recommendable to maintain the maximum spacing from the vehicle harnesses
Mechanical pressure on the cable can cause degradation or even short circuits.
ANTENNA. The antennas should be mounted to body e.g. front bumper or bull bar.
Most inportant is earthing, ensure conductive braid strap is well connected to ground.
The heavy anodization on the bull bar for corrosion protection is a very hard. Break the Aluminum
layer by grinding the surface in order to ensure good ground connectivity.
Some antennas reflect transmission power back to the feedpoint. Much of this will be radiated
from the feedline inside the passenger compartment with negative impact.
Intermediate, agreed checks should be performed during installation and recorded. At the
end the none-visible is the most essential, hidden errors can’t be corrected easily.
o Recommended 3-step quality check; electrical connections, installation of VTS
components, assembling completion. Final check/commissioning is the 4th step.
Final, certified approval of the installation works shall be done by the installer itself or/and
by third parties as by a consultant.