T5 - Example of The Surelinx Installation Manual PDF

Installation Guideline, HF Radio, Toyota LC78L, GFM Project, February 2014, 15-2-2014 Page 1 of 31
INSTALLATION GUIDELINE
HF Radio; CODAN NGT SRx Mobile Transceiver

Subject; Description of HF Radio Installation Procedure to specific vehicle models.
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
Reference; UNHCR item ID number: 00006796

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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.
However, pin-points of importance are summarized in the ANNEX of this production.

Material requirements, tools
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;
• Before start of installation, consult the relevant manufacturer’s documentations.

• Pay attention to safety precautions, warnings, notes and material handling.
• Follow the present installation guideline for the specified vehicle.
• Prepare the vehicle, e.g. assure fully charged battery, and arrange for work area.
• Pre-position, arrange for additional installation material, e.g. Aluminum plates.
• Provision for the necessary tools, special tools and hardware by the responsible installer.
• Disassemble components; in engine compartment, in vehicle interior on passenger side and in
boot compartment.
• Perform installation of HF radio system to the specific vehicle.
• Assembling; in opposite order as disassembling process.
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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Principal lay-out of the HF radio accessories and cables installation in the specific vehicle models;
Toyota Land 12 V Battery Transceiver with

Cruiser HT, 78L (cable with fuse) connection to ground
(6 seats)
a a
Antenna w/ 2nd 12 Volt Handset / Loud

support battery microphone speaker
a a a a
Toyota Land
Cruiser HT, 78L
(11 seats)
Grey Cable. Control, from antenna to transceiver.

Black Cable. Radio Frequency (RF), coaxiale cable, run from antenna to transceiver
Red/Black Cable (2 cables). Positiv and negative from battery run to transceiver
Grey cable. From the transceiver run to the handheld set
All devices installed must be properly and firmly grounded (not shown in design in order
not to obstruct the view on the essential)
Instruction/guideline of HF radio installation in specific vehicle models

HF Radio; CODAN NGT SRx
Subject; Description of HF Radio Installation Procedure to specific vehicle models.
Reference; UNHCR item ID number: 00006796
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;
CODAN NGT SRx Transceiver Radio
 Transceiver
 Handset / microphone
 Loudspeaker
CODAN NGT SRx - Picture 1 CODAN NGT SRx – Text 1
Display in principal;
Display; View the principal of the CODAN

installation with all components.
In addition; 12Volt battery.
(Display with; Automatic Tuning Whip Antenna

9350, older version)
3040 Automatic Tuning Whip Antenna

Display; New generation antenna
Basic feature; 70% reduced high, tuning twice

as fast as the 9350 type antenna. Refer to the
antenna instruction handbook.

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; Antenna kit, Automatic Tuning

Whip Antenna 9350;
• Antenna with ground braid strap
• Spring (detached)
• Control cable
• RF (Radio Frequency) coaxial cable
• With connectors / adapters
• Special CODAN contact grease
• Amalgamating tape (self-polymerizing)
• Manual; Installation handbook with
features to be referred too
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
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)
Instruction sheet refer to the installation.

Some redundancy of items is taken into
account, depending on vehicle/models the
installation is going to be made.
Loudspeaker with cable, cradle and screws
Assorted bolts and screws of different size
Cradle
Ground cables
32 Amps cartridge fuse (CODAN 15-00711)
Power and ground cable/twin core cable

(battery to transceiver)
INSTALLATION PROCESS BY ILLUSTRATION AND DESCRIPTION – CODAN NGT SRx Transceiver
Remark; disassembling – system installation – assembling often goes together, and therefore this operation
is not mentioned separately in the following process description.
Land Cruiser 78L (6 seats)

[With 2nos. of 12Volt factory-fit batteries]
System feed.
Power/positive pick-up connection directly at
the battery terminal.
Ground/negative terminal connection made

directly at the battery. In addition, connect
battery negative terminal with the body metal
sheet. Use appropriate cable and lugs.
HF – Land Cruiser, 78L - Picture 9 HF – Land Cruiser, 78L – Text 9

[With 1no. of 12Volt factory-fit battery]
System feed.
Power/positive pick-up connection directly at
the battery terminal.
Ground/negative terminal connection made

directly at the battery. In addition, connect
battery negative terminal with the body metal
sheet. Use appropriate cable and lugs.

[With 1nos. of 12Volt factory-fit batteries]
No battery close to bulkhead

Space available to work through the grommet
to run cables.
Original, factory-fit rubber boot on bulkhead,

to be seen (yellow ring).
Never connect system to 24 V battery!

Cut opening into rubber boot as shown.
Cut scarcely – approx. 30mm – minimum

length of cut only to push cable heads through
the opening.
Push cables from foot rest side at passenger’s

compartment through rubber grommet.
Fit split loom tubes to protect the cables.

Wrap isolation tape around.
4 cables, HF radio related, run through the

rubber boot in bulkhead;
 RF coax cable (Radio Frequency), black
color
 Control cable, white colour
 Twin core cable (power/ground cable)
Avoid to route power cable and control cable
run together unless limited space at bulkhead.
Improved option; Drill add hole with crown

drill to fit diameter 30 mm rubber grommet.
Locate as high as practicable (red ring dots).
Rubber boot with cable harness;
Finally apply silicon sealant in order to close

and seal the cuts and holes. Seal properly.
Improved option; Drill additional hole with

crown drill to fit diameter 30 mm rubber
grommet. Locate as high as practicable (red
ring dots). – Check inside passenger
compartment for free space, ensure no cables
and pipes block the way!

Pack the cable into appropriate sized flexible

split loom tube for entire protection of cables.
In order to keep the split loom tube firmly

together wrap isolation tape around as show in
the picture.
Only the absolutely necessary cable length

should remain in the engine room, surplus
length stow in passenger compartment.
Run split loom tube behind air filter housing

and attach it with sufficient numbers of cable
ties.
Cut the split loom tube to length at the level of

the cable connector box nut.
Hint; Alternative/option, to run cables through

bulkhead; use the rubber boot on bulkhead on
the driver side.
Antenna installation; Automatic Tuning Whip

Antenna 9350, older version.
Check completeness of antenna components.
Place the antenna on the bull bar.
Antenna mounting; support at the level of

engine bonnet, not higher.
Install the supplied hardware.

Optional/New Version;
Automatic Tuning Whip Antenna 3040;
Consult/refer to the installation manual which

is supplied with installation kit.
New; 3 point installation of support base.
Antenna base, set in level to engine bonnet.
Antenna mounting on the factory-weld bracket

on bull bar.
Grind off the paint with emery/sand paper to

assure proper contact between bull bar
(chassis) and antenna base.
Apply the CODAN Special Conductive grease

for the maximum connectivity.
Connect the black RF coaxial cable (Radio

Frequency) at lower connector of antenna.
Wrap the amalgamated tape around the RF

cable for proper sealing.
Avoid tight cable bends, in particular after any

coupling, e.g. after box nut.
HF – Land Cruiser, 78L – Picture 20 HF – Land Cruiser, 78L – Text 20

Wrap and stretch the amalgamated tape

tightly around the cable in order to assure the
self-polymerization.
Ensure overlapping of about 3cm down the

cable and make sure tight seal.
Wrap and stretch amalgamated tape tightly

around the white control cable on the upper
connector of antenna base.
Stretch the tape and ensure seal and tight fit

about 3cm down the cable.
Sealing must be weatherproof.
Unfold the braid strap, and connect the

antenna to the body metal sheet for proper
grounding.
Remove the paint on body at the contact

surface to ensure proper grounding.
Apply the CODAN conductive special grease.
Bolt down the braid cable on the body, and fix

cable ties as appropriate.
Finally coat all with a film of CODAN grease.
If no lug fit on braid strap, add washer of

diameter same width as braid strap.

Finally, wrap the remaining amalgamated tape

around the cables and split loom tube, ensure
seal fit.
Fit sufficient numbers of cable ties to assure

the braid ground strap and split loom tube
remain properly in place. Consider driving
vibration, attach all cables securely to body
parts of vehicle, do not spare in using cable
ties!
Cut off surplus cable ties to appropriate length.
Bolt the braid strap to body and engine bonnet

for proper ground.
Apply CODAN conductive special grease.
Fit cable lugs in correct position.
Install the handset / microphone
Install the support for cradle with 2 screws

diameter 4 mm. Place the cradle. Install as
shown in picture, on the left side of yellow dot-
line. The lower screw in horizontal line (red
dot-line) with the hand grip.
Try out and pre-install assembly, support,

cradle and handset, before any screw is fitted.
Cradle

Screw down the support, with diameter 4 mm

self-tape screws.
• To prevent cradle support is slipping

over the head of screw, fit
recommended diameter
• Replace the factory-delivered screws

with diam. 3.5 mm (yellow ring)
Final position of handset installed.
Assure enough space available between

handset right side and left side of handle grip.
Swing the lid of glove compartment and assure

the handset is not touched.
Installation of loud speaker;
Location; underneath of instrument center

lower cluster. Fitment of cradle;
• In horizontal length, align the long side of

bracket along the edge below the ash tray
and center lower cluster.
• In horizontal length, align the long side of

bracket along the edge below the ash tray
and center lower cluster.
HF – Land Cruiser, 78L – Picture 29 HF •– Land Cruiser,

Fix with
78L –2Text
nos.29self-tape screws.
Installed loudspeaker, in obstacle free position

and adjustment up/down radio box possible.
Between loudspeaker and bottle, still enough

free space left.
Junction box or cable connector, installation

under dashboard and bolted at the foot rest of
front passenger seat;
Two (2) incoming cables of handset /

microphone and loudspeaker at junction box.
One (1) only outgoing cable to the transceiver.
Surplus cables arrange in loops and place it

under the floor carpet at the foot rest on the
front passenger side.
Picture shows recommended option to arrange

cables with cable ties.
Avoid sharp bends of cables. Bend radius of six

time the harness diameter is recommended.

The CODAN Cable harness is run through the

bulkhead to the front passenger side.
• Coax cable (Radio Frequency)
• Control cable
• Power/ground twin core cable
Grommet in bulkhead
Removed side board for accessibility.
Split loom tube with cables from bulkhead to

doorsill.
The grey cables is connect to the junction box,

further to loudspeaker and handset.
Cable harness packed in split loom tube.
Run the split tube below the side trim (red

doted triangle) and lead to the doorsill.
Install the scuff plate on doorsill back in his

place (yellow dotted line) later.
Cables run under and along doorsill. Separate

the power cables from RF coaxial cable.
Assure cables protected against chaffing on
sharp edges.

Cable harness packed in split loom tube.
The cable run below the cowl (red doted

triangle) leads to the doorsill.
Install the scuff plate to the doorsill at the end

of installation (yellow dotted line).
The split loom tube runs along doorsill.

Separate the power cables from RF coaxial
cable whenever possible.

Ensure cables protected against chaffing on
sharp edges.of cables and routing;
Installation
(At this point different from LC76L)
Seen at rear seat, arrival of cables from the

doorsill.
Pack the cables in split loom tube.
Drill a hole in side panel to run the split loom

tube into the side compartment.
Drill a hole of diam. 24mm with a crown drill

into side panel (picture with arrow)
 Smooth the edges.
 Install a grommet for the cable protection
Run the split loom tube just before the hole

and cut, because of diameter size. At the end
of the flex tube, wrap with isolation tape.

Remove the factory-fit, plastic tie nut;

• Cut the plastic strap (picture).
• Remove the factory-fit cable harness.
• Loosen the plastic clamp and remove
entirely.
The two (2) stud bolts remain in place as
anchor points.
Run the smaller cable harness outside along

the stud bolts, because of smaller diameter.
Modify the plastic tie nut;

• Open the slot at the tie nut by appropriate
screw driver.
• Then run the black cable tie through the
slot opening.
Push the tie nut with the cable tie together

over the stud bolt by finger pressure.
Put the split tube at the panel side (fuel funnel

side) in location.
The split loom tube for the HF radio runs panel

side (fuel funnel) along the stud bolts, because
bigger in diameter. – The split tube is anchored
by cable ties to the two (2) plastic tie nuts.
The small cable harness is firmly tied on to the

split tube and therefore well anchored. Use
sufficient cable ties.
Note; The installation example to serve as

specification for quality standard.

The carpet can be placed as flat as practicable,

because of above performed cable installation.
The cable run under the carpet are firmly

placed, and well protected from passenger
feet.
Run the cables through the panel into the side

compartment.
Ensure the cables are well packed with

isolation tape wrapped around, especially at
the location of the hole.
Grommet must be in place.
Use cable ties to bunch the cables together.
Coil the surplus length of cables behind the

safety belt pretensioner.
Use sufficient cable ties.

Transceiver installation to LC78L; In order to install the Aluminum plate, the

center trim board at the rear right side must be
Center option (rear right side panel) removed. At the end of installation, the trim
board will be cut to the appropriate size.
Toyota LC, HZJ78L-RJMRS, 6 seats,
Caution; Do not install, the cradle directly on
Pre-fabricated Aluminum base plate is essential. the weak cardboard of side trim. If installed in
The Alu plate will serve as firm anchor and base such way, the heavy transceiver unit will not be
plate for the location of transceiver cradle.
stable.
HF – Land Cruiser, 78L – Text Transceiver 1 HF – Land Cruiser, 78L – Text Transceiver 2
The Aluminum plate, designed by UNHCR shall

serve purpose and requirement.
Standard size cut to size by metal engineering

shop. Two (2) milled slots for cabling, 4 holes
for cradle mount (red rings), 3 square holes to
install the plate on the side panel (blue rings).
Riveted bracket mounts, support area for the
edge of trim board. Two (2) holes to fasten the
trim board. M6 holes will be drilled later in the
course of installation (yellow rings).
Fastening kit for the installation of the

Aluminum plate;
 Spacer washers (only 1 will be used!)
Inside diam. 11mm, outside 16mm,
strength 3mm
 Pan head bolts M8x30 with square
(prevent rotating) seen with spacer washer
and knurled nut.
 Hexagonal bolts M6, knurled type.
 Knurled nuts M8 (grip/self-lock surface).
HF – Land Cruiser, 78L – Picture 46 HFNote;

– LandBolt and78L
Cruiser, nuts for46cradle not on the
– Text
picture
Cradle bolted with Aluminium plate by 4 M6

bolts (supplied with kit).
Installation of Alu plate onto side panel;
 3 pan head, square bolts M8x30 (blue
rings)
 3 nos. hexagonal bolts M8 (yellow rings)
Caution; Double blue ring; The single one bolt

with strength 3mm spacer washer behind Alu
plate. Washer inside diameter 11mm, outside
diam. 16mm.
The protruding square (red indicated) would

punch and distort a hole in the side panel. To
avoid this happen, the protrusion must be
equalized with spacer washer.
Push the spacer washers over the four edges to

equalize the protrusion. Apply bit of grease to
keep stuck the washer to the Alu plate. Then
all complete; the bolts with plate and spacer
washers inserted through the side panel and
the knurled nuts installed.
Installation of Aluminum plate;
Push the squared pan head bolt M8x30 in the

square hole of the Alu plate.
Then apply a coat of sticky grease on the

spacer contact face, place it over the
protruding edges of the pan head bolt.
The spacer will remain stuck on the Alu plate.

Prevent shifting in the course of installation.

Installation of Alu plate with cradle.
Bolts described; refer to above in picture/text.

 3 Square, pan head bolts, M8 (blue rings),
at back side of plate put spacer washer.
 3 Hex bolts M6 (yellow rings)
 4 Hex bolts M6, cradle mounting (red
rings)
Caution; Double blue ring; The only bolt with

spacer washer at back side of Alu plate.
HF – Land Cruiser, 78L – Picture 50

the Alu plate.
HF – Land Cruiser, 78L – Text 50
Connection of earth/ground cable.

 One end of cable lug to be bolted to panel/
body, behind Alu plate, scratch off the
paint at the place of contacts (blue arrow).
 Lug bolt to transceiver (blue ring).
Bracket for trim panel, riveted 3x to plate at

time of machining/milling (yellow arrows).
2 Holes, diameter 10mmm drilled in bracket

for the installation of pins (yellow rings).
Final appearance of installation;
 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.

Course of final installation;
 Transceiver installed in place

 Cable harness protected with split loom
tubes and isolation tape
 Surplus cables arranged in loops and
lashed in place
Final installation view from the boot side.
Rear trim panel with all plastic pins refit in

place.
• Side trim board cut to required size and
installed to the side panel.
• Additionally two (2) holes drilled through
the trim board then plastic pins installed
(yellow rings)
Power pick-up directly after battery positive

terminal then lead to fuse cartridge.
Installation of 35 Amps cartridge fuse nearest

as practicable to the battery positive terminal.
Bolt cartridge to the fender splash wall.

Installed cartridge fuse (red ring).
Measure resistance with Ohm-meter, should

not exceed Ohm 0.1.
Ensure best grounding. Measure resistance,

should not exceed 0.1 Ohm (yellow rings)
Add additional braid strap for grounding at

battery minus terminal. Connect all terminals
and tight clamps and bolts.
Situation with seat bench in service position.
Side trim board in the centre yet to be fit.
Summary of possible installations;
HF radio, CODAN NGT SRx (yellow oval)
VHF radio, ICOM dPMR Transceiver (blue oval)
VTS tracking system, SureLinx 8100c (red oval)
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.
Transceiver installation to LC78L; In order to install the Aluminum plate, the

center trim board at the rear right side must be
Rear option (rear right side panel) removed. At the end of installation, the trim
board will be cut to the appropriate size.
Toyota LC, HZJ78L-RJMRSV, 11 seats,
Caution; Do not install, the cradle directly on
Pre-fabricated Aluminum base plate is essential. the weak cardboard of side trim. If installed in
The Alu plate will serve as firm anchor and base such way, the heavy transceiver unit will not be
plate for the location of transceiver cradle.
stable.
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.
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.
Needed fasteners in order to install the

Aluminum plate;
• 7 nos. pan head bolts M6, with nut type
rivet and flat washer.
Base plate/cradle installation;
 2 nos. M6 bolts, with washers and spring
washers, on upper side (supplied in kit)
option; fit knurled nut without washers.
 2 nos. screws diam. 6mm, bottom side
(supplied in kit)

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

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).
Final check at the end of installation;

 Measure resistance with Ohm-meter,
should not exceed Ohm 0.1.
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.

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.
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.

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 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.
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.
o 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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Installation Guideline, HF Radio, Toyota LC78L, GFM Project, February 2014, 15-2-2014 Page 1 of 31

HF Radio; CODAN NGT SRx Mobile Transceiver

Reference; UNHCR item ID number: 00006796

However, pin-points of importance are summarized in the ANNEX of this production.

Material requirements, tools

• Before start of installation, consult the relevant manufacturer’s documentations.

Toyota Land 12 V Battery Transceiver with

Antenna w/ 2nd 12 Volt Handset / Loud

Grey Cable. Control, from antenna to transceiver.

Instruction/guideline of HF radio installation in specific vehicle models

CODAN NGT SRx Transceiver Radio

CODAN NGT SRx - Picture 1 CODAN NGT SRx – Text 1

CODAN NGT SRx Transceiver Radio

Display; View the principal of the CODAN

In addition; 12Volt battery.

(Display with; Automatic Tuning Whip Antenna

CODAN NGT SRx - Picture 2 CODAN NGT SRx – Text 2

3040 Automatic Tuning Whip Antenna

Basic feature; 70% reduced high, tuning twice

CODAN NGT SRx - Picture 3 CODAN NGT SRx – Text 3

CODAN NGT SRx - Picture 4 CODAN NGT SRx – Text 4

Overview; Antenna kit, Automatic Tuning

CODAN NGT SRx - Picture 5 CODAN NGT SRx – Text 5

Instruction sheet refer to the installation.

CODAN NGT SRx - Picture 7 CODAN NGT SRx – Text 7

Loudspeaker with cable, cradle and screws

Assorted bolts and screws of different size

32 Amps cartridge fuse (CODAN 15-00711)

Power and ground cable/twin core cable

INSTALLATION PROCESS BY ILLUSTRATION AND DESCRIPTION – CODAN NGT SRx Transceiver

Land Cruiser 78L (6 seats)

Ground/negative terminal connection made

HF – Land Cruiser, 78L - Picture 9 HF – Land Cruiser, 78L – Text 9

Land Cruiser 78L (11 seats)

Ground/negative terminal connection made

HF – Land Cruiser, 78L - Picture 10 HF – Land Cruiser, 78L – Text 10

Land Cruiser 78L (11 seats)

No battery close to bulkhead

Original, factory-fit rubber boot on bulkhead,

Never connect system to 24 V battery!

HF – Land Cruiser, 78L - Picture 11 HF – Land Cruiser, 78L – Text 11

Cut opening into rubber boot as shown.

Cut scarcely – approx. 30mm – minimum

Push cables from foot rest side at passenger’s

Fit split loom tubes to protect the cables.

HF – Land Cruiser, 78L - Picture 12 HF – Land Cruiser, 78L – Text 12

4 cables, HF radio related, run through the

Improved option; Drill add hole with crown

HF – Land Cruiser, 78L - Picture 13 HF – Land Cruiser, 78L – Text 13

Rubber boot with cable harness;

Finally apply silicon sealant in order to close

Improved option; Drill additional hole with

HF – Land Cruiser, 78L - Picture 14 HF – Land Cruiser, 78L – Text 14

Pack the cable into appropriate sized flexible

In order to keep the split loom tube firmly

Only the absolutely necessary cable length

HF – Land Cruiser, 78L - Picture 15 HF – Land Cruiser, 78L – Text 15

Run split loom tube behind air filter housing

Cut the split loom tube to length at the level of

Hint; Alternative/option, to run cables through

HF – Land Cruiser, 78L - Picture 16 HF – Land Cruiser, 78L – Text 16

Antenna installation; Automatic Tuning Whip

Check completeness of antenna components.