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CODAN NGT Mobile Transceiver Installation Guideline

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    #21
    Transceiver installation to LC78L;

    Rear option (rear right side panel)

    Toyota LC, 11 seats,

    Pre-fabricated Aluminum base plate is essential.
    The Alu plate will serve as firm anchor and base plate for the location of transceiver cradle.

    In order to install the Aluminum plate, the center trim board at the rear right side must be removed. At the end of installation, the trim board will be cut to the appropriate size.

    Caution; Do not install, the cradle directly on the weak cardboard of side trim. If installed in such way, the heavy transceiver unit will not be stable.
    HF Land Cruiser 78L Picture 58



    Material requirement;
    • Aluminum plate, designed to serve requirement.
    • Set of fastener fittings.

    The Aluminum plate must be processed by milling/cutting, to meet the required standard.
    Fabricated by engineering shop.

    Note; Proper design/drawing is pre-condition, for production in engineering shop.


    HF Land Cruiser 78L Picture 59


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      #22
      The Alu plate will be installed with rivets;

      • Needed to enlarge slightly the existing holes (red ring).
      • Hole diameter according the nut-rivet for
      the installation of bolt M6.

      The raised edge of the rivet is advantage to make a even level between rivet edge and the panel. The Alu plate will lay flat on the panel to ensure tight fit (red arrow).

      Pre-fabrication Alu plate in place. (machining/ milling done at the engineering shop as per design).

      Next step, riveting of Alu plate to the side panel, process shown on the picture;

      7 holes of diameter 8mm for the Alu plate installation to the rear sided panel.

      4 holes of diam. 6.5mm for the installation of the transceiver cradle/base plate.


      Milling two (2) of different diameter for cabling
      • Upper hole, diameter 40mm
      • Bottom hole, diam. 30mm
      4 holes for transceiver cradle (red rings)
      • 2 upper holes, drill diam. 6.5mm, bolt M6.
      • 2 bottom holes, drill diam. 4.5mm to fit self-tapping screws diameter 6mm.

      7 holes for Alu plate installation (yellow rings), drill diam. 8mm, because of alignment, bolt M6

      9 – 12 slits for vent holes, see pic no. 63
      Last edited by Polandr76; 07-27-2017, 06:21 AM.

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        #23
        HF Land Cruiser 78L Picture 63







        Connection of earth/ground cable;

        Bolt the cable with lug properly to the inside of the side panel, scratch the paint off before (blue ring/arrow).

        Click image for larger version

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        Final check at the end of installation;
        • Measure resistance with Ohm-meter, should not exceed Ohm 0.1.




        Click image for larger version

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        Arrange all cables properly in the side compartment.

        Coil the surplus cables, use sufficient cable ties, and then tie the cables to the inside panel firmly.

        Note; Ensure the cables do not chafe because loose and of the vehicle shaking.














        The installation of the cradle must be done prior installation of the Alu plate.

        Watch out; The bottom hole at the center for the Alu plate installation is the focus.

        Align the fifth (5th) hole on the cradle, counted from the lock side, with the bottom hole of the Alu plate (yellow ring).

        Drill through the holes at the furthermost ends of the cradle.
        Attached Files
        Last edited by Polandr76; 07-27-2017, 06:24 AM.

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          #24
          Click image for larger version  Name:	image_2855.jpg Views:	1 Size:	84.6 KB ID:	6379




          Situation shows the rear side of the Alu plate.

          The two lower self-tapping screws of the cradle
          are bolted with the Alu plate but not with the side panel (red rings).

          However, the bottom bolt M6 in the centre runs through the Alu plate and is bolted with the side panel (yellow ring).

          Caution; Ensure the lower bolt is properly tight, for stability of the Alu plate and transceiver.


          Click image for larger version  Name:	image_2856.jpg Views:	1 Size:	67.6 KB ID:	6380
          HF Land Cruiser 78L Picture 65









          Transceiver mounted on cradle ready for operation.

          Essential cables connected to the transceiver.

          Cables are protected with split loom tubes and with isolation tape wrapped around.















          Seat bench in non-service position with back rest folded.
          Last edited by Polandr76; 07-27-2017, 06:28 AM.

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            #25
            HF Land Cruiser 78L Picture 69






            Seat bench in service position with seat bench down.

            Side trim board in the centre has yet to be installed.















            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.


            ANNEX

            Foreword. The installation guideline remain supplementary to the CODAN HF radio manufacturer. The 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.



            QUOTE; excerpt from CODAN Reference Manual;
            CABLING

            WARNING Do not cut the control, coaxial or speaker cable. If the cables are too long, gather the excess neatly and secure it out of the way.
            CAUTION Large magnetic fields can be generated along the power cable during transmission and these fields may be coupled into the control cabling. Failure to keep these cables separated causes distortion of the transmitted signal.
            NOTE 32 A cartridge fuse (CODAN part number 15-00711) is recommended.
            UNQUOTE

            Additional Radio Com Equipment Installation Recommendations.
            The following is excerpted from several vehicle manufacturer’s. These are supplementary to the CODAN reference manual. Mobile two-way radio and telephone equipment must be installed by properly trained personnel.

            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.

            CABLING, WIRING must be in a position that;
            • is away from operator’s feet. Arrange cable not being exposed to foot trafficking.
            • 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.

            CONTROLS. Mount the transceiver to a solid surface (Aluminum panel)
            • Preliminary; Try out intended installation before drilling of any hole.
            • Screws through the floor pan, must be sealed over the underbody projections (moisture).
            • Watch out for wire harnesses routed under carpet and behind instrument panel.
            • If you mount the radio under the instrument panel; Mount the control head or front panel (especially the microphone cable) clear of the steering wheel, column controls and passenger airbag. Stabilize heavy units.
            • If ignition switch control is desired, use a power relay to reduce load on the i-switch

            REMOTE TRANSCEIVER. For trunk/boot mount installations in passenger car.
            • Fit along the inner side panel of body but don’t mount on floor anywhere!
            • Fabricate Aluminum plate to replace weak side trim cardboard to locate the transceiver
            • Locate away from any vehicle electronic modules located in the rear of the vehicle.
            • Assure, check for good air circulation. Do not pile things on top of the unit.


            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.

            WIRE HARNESS AND ROUTING
            • Harness and in-line connectors shall be anchored to prevent free movement.
            • An anchor point shall be no further than 8cm from a connector.
            • The length of an unanchored section of harness should be no more than 30 cm.
            • Use tie wraps on harness covering only, not individual wires.
            • Do not anchor harness with tie wraps in contact with wire insulation.
            • Tie wraps shall not pull on the harness so that connector cable seals are distorted.
            • Allow cable to exit connector body without pulling on the connector.
            • Harness routing shall not interfere with oil fill plugs, sensor locations.
            • To prevent cross threading start all cap screws and nuts by hand then use driver/spanner. Footnote;
            • Design CHECK-LIST in order to perform quality control on the entire installation.
            • Use installation guideline to draft check-list.
            • 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.
            • Recommended 3-step quality check; electrical connections, installation of VTS components, assembling completion. Final check/commissioning is the 4th step.
            • Perform functional test of the CODAN radio.
            • Final, certified approval of the installation works shall be done by the installer itself or/and by third parties as by a consultant.

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