RUGGED RADIOS MASTER COMMUNICATION KIT

Parts List

• ✔️ (1) MOBILE RADIO
• ✔️ (1) INTERCOM
• ✔️ (1) ANTENNA
• ✔️ (2) PUSH-TO-TALK BUTTONS
• ✔️ (1) 15' ANTENNA COAX CABLE
• ✔️ (2) 12' INTERCOM CABLES
• ✔️ (2) R-WRAPS CABLE TIES
• ✔️ (1) ACTIVE FILTER

Equipment Needed

• 7MM SOCKET WRENCH
• 10MM SOCKET WRENCH
• SMALL CRESCENT WRENCH
• PHILLIPS SCREWDRIVER
• ELECTRIC DRILL
• 3/8" DRILL BIT

* Some vehicles may require additional tools

Vehicle-Specific Installation Videos

Scan the QR code to see vehicle-specific and detailed installation videos.

Visit RuggedRadios.com for more information.

Installation Overview

Mounting Location

• Choose a Protected Spot: Select a location for the radio and intercom that is easy to reach and protected from the elements, such as under the dashboard, in, or beside the center console.
• Attach the Mount: Use the universal mounting hardware included in the kit, or, if you have a Rugged Radios mount, vehicle-specific mounting instructions are available separately.
• Plan Cable Routing: Consider cable routing at this stage to ensure easy access and protection.

Basic Connections

Before you begin, it may help to have an overview visual of your complete radio and intercom assembly. Installation can be completed in a few hours.

Diagram Description: The basic connections diagram illustrates the layout of the system. It shows the Antenna connecting to the Mobile Radio. Driver and Co-Driver headset cables plug into the Mobile Radio or an Intercom Back Panel. An Accessory Hub and Active Filter are shown, with the Active Filter connecting to the 12V Battery. PTT (Push-To-Talk) buttons are also indicated.

Install the Antenna Mount

• Select the Best Location: Mount the antenna as high as possible on your vehicle and away from obstructions to maximize signal quality.
• Secure the Antenna Mount: Attach the antenna mount securely, but avoid over tightening the nut.
• Connect the Antenna Cable to the Radio: After mounting, connect the antenna cable to the radio. Make sure it's snug but not overly tightened.

Note: Never transmit on the radio without the antenna connected, as this can damage the radio.

Connect the Power and Ground Cables

• Direct Connection to Battery: Route the power and ground cables from the radio and intercom directly to the vehicle's battery for optimal performance.
• Secure the Cables: Avoid using zip-ties on communication cables; instead, use the provided Rugged R-WRAPS to secure the cabling.

Warning: Ensure correct polarity when connecting the power and ground cables, as reversing polarity will damage the radio and void the warranty.

Connect the Intercom Cables

• Attach the Driver's and Passenger's Cables: Plug the helmet or headset cables into the intercom, with the driver's side on the left and passenger's side on the right.
• Test Cable Routing: Ensure all cables are routed to avoid pinching, smashing, or cutting. Proper cable routing is essential to avoid interference and protect the cables from damage.
• Separate Communication and Power Cables: When routing, keep communication cables separated from power cables as shown in the diagram to reduce electrical interference.

Your exact configuration may vary.

Diagram Description: The connection diagram shows the RADIO/INTERCOM unit, PTT buttons, ANTENNA, and COAX CABLE. It illustrates the connection to the DRIVER HELMET/HEADSET and CO-DRIVER HELMET/HEADSET, as well as the connection to the BATTERY via positive (+) and negative (-) terminals. The diagram emphasizes separating communication and power cables.

Note: Any physical damage can cause your system to malfunction.

WARNING: Polarity reversal will damage your radio and void warranty.

Never coil or bundle excess coax (antenna) cabling. Route along the vehicle to use excess cable.

Cable Type Guide:

• Use with all STEREO INTERCOMS AND CABLES.
• Use with all MONO INTERCOMS AND CABLES.

Power On and Test the 2-Way Radio and Intercom

• Turn On the System: Power on the radio and intercom by pressing the power buttons.
• Select and Set Up a Channel: Set the radio to a specific channel for testing and adjust the volume to a midpoint.
• Test Transmission with Another Radio:
  • Ensure another radio is set to the same channel.
  • On the driver's side, press and hold the PTT (Push-To-Talk) button for a second, then speak. Release the button when finished.
  • Confirm that the receiving radio picked up the transmission. Then, have the other radio return the call to ensure you can receive transmissions as well.
• Repeat for the Passenger Side: Follow the same steps to verify proper functioning for the passenger side.

Hand Mic Setup and Tips

• Mount or Store the Hand Mic: Choose a convenient place for the hand mic where both the driver and passenger can access it. You can use a magnetic mount or store it in the glove box for emergencies.
• Keep the Hand Mic Unplugged During Intercom Use: To avoid unnecessary ambient noise when transmitting, unplug the hand mic when using the intercom.
• Test the Hand Mic (Optional): If you plan to use the hand mic, test it.

Installation Complete

If you have any questions, please contact Rugged Radios at (888) 541-7223. Thank you!

Designed in Arroyo Grande, CA by enthusiasts for enthusiasts. This product is backed by 30 years of experience with one goal, connecting people.

Important Warnings

CALIFORNIA PROP 65 WARNING: Cancer and Reproductive Harm. Visit www.p65warnings.ca.gov for more information.