MFJ MFJ-4402 User manual

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
ii
DISCLAIMER
Information in this manual is designed for user purposes only and is not intended
to supersede information contained in customer regulations, technical
manuals/documents, positional handbooks, or other official publications. The
copy of this manual provided to the customer will not be updated to reflect
current data.
Customers using this manual should report errors or omissions,
recommendations for improvements, or other comments to:
M J Enterprises,
300 Industrial Park Road,
Starkville, MS 39759.
Phone: [phone]
AX: [phone].
Business hours:
M- 8:00 AM-4:30 PM CST.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
iii
Table of Contents
The M J-4402 Mobile Transceiver Protector .................................................... 1
Specifications .................................................................................................... 2
Installation ......................................................................................................... 2
Radio is Already Installed .............................................................................. 3
Radio and Power Lines Not Installed Yet ...................................................... 4
Ignition Sense Line Installation.......................................................................... 5
Checkout and Operation................................................................................ 6
Adjustments................................................................................................... 6
Timer Adjustment ...................................................................................... 6
Undervoltage Cutout.................................................................................. 6
use Replacement .................................................................................... 6
Powerpole® Connector Assembly................................................................. 7
Additional Materials That May Be Needed ........................................................ 8
Schematic.......................................................................................................... 9
Troubleshooting................................................................................................. 9
NOTES ............................................................................................................ 11
ULL 12-MONTH WARRANTY....................................................................... 12

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
1
THE MFJ-4402 MOBILE TRANSCEIVER ROTECTOR
This little box helps protect your mobile radio from a number of power related
problems found in vehicles these days
There are times when during starting of the vehicle the battery voltage will sag to
levels that will cause your radio’s controller to act up or corrupt the internal
memory. Some of these symptoms include the radio not powering up correctly,
memory channels lost, and service and setup memory (hidden menus) being
corrupted. Even with the power switch off some of the circuits still have power on
them. The M J-4402 has a delay timer circuit controlled from the ignition sense
line insuring your radio does not turn on till your vehicle has started and the
voltage has reached normal levels. This is done by disconnecting the power till
the time out period is completed.
Another issue is operating the radio while the engine is off. At some point the
battery voltage will drop to the point that the radio may not operate correctly such
as distorted audio, frequency shifting with modulation, or even the voltage
dropping to the point that the vehicle will not start. The M J-4402 has a circuit to
cut the radio off before the voltage gets down too low for proper operation.
A third issue that occasionally happens is leakage currents in the portions of the
radio that do not get disconnected when the power is turned off rise to levels that
can discharge batteries, especially batteries that are near the end of their life.
The M J-4402 disconnects the power to the radio completely from the positive
line to the battery insuring that a radio with high current leakage will not be the
cause of a dead battery.
A fourth issue is a problem with electrical surges. The regulator in the alternator
can go bad causing excessive voltages, sudden changes in loads causing
momentary overshoots of the alternator voltage and jumping off other cars
causing voltage spikes, or even worse a truck with a 24V electrical system trying
to jump off your car. The internal Transient Surge Protector and the fuse make a
protective circuit to catch momentary spikes and blowing the fuse on extended
voltage spikes. The protector will also blow the fuse of the voltage is reversed on
the battery power leads.
Connections between the M J-4402 and the vehicle and the radio are made
through Anderson Powerpole® connectors for the high current lines and a quick
disconnect connector for the ignition sense line. A 30A (max) fuse is used to
protect for over current and reverse voltages.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
2
S ECIFICATIONS
Time Delay 2 to 6.5 sec
set to 4 sec
Low Voltage Dropout 10.25 to 12.4 volts set to 10.8V
Pickup at 10.3 to 12.42 volts
Surge Clamping Voltage 21.2V
Max Radio Current 30A
Ignition Sense Current 120mA
INSTALLATION
Plan the installation out before actually cutting wire or drilling holes. Make sure
you have the tools needed to complete the job and the additional hardware to
properly wire to the car before starting the job. A little planning will save hours
running down to the auto parts or electronics store for forgotten connectors or
parts.
Install the M J-4402 in a convenient out of the way place that is not exposed to
outside conditions. The M J-4402 is not waterproof or made for exterior use.
Do not use on positive ground vehicles. The M J-4402 is designed for negative
ground 12V electrical systems only.
WHEN WORKING AROUND THE BATTERY IT IS RECOMMENDED TO
DISCONNECT THE BATTERY TERMINALS TO REDUCE THE
CHANCE OF A SHORT CIRCUIT. A SHORT CIRCUIT CAN CAUSE
THE BATTERY TO EXPLODE.
Note: The wirin requires connections to the battery and an accessory
connection in the fuse box. If you are not comfortable in makin these
connections take your vehicle to a qualified auto electric technician or
someone experienced in mobile equipment installation.
The RED terminals and wires are always connected to the POSITIVE
connections and the BLACK terminals and connections are always connected to
the NEGATIVE or GROUND connections.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
3
FUSE
PANEL
RED
BLACK
+
-
RED
BLACK
Radio is Already Installed
If the radio has already been installed and there is enough slack to connect the
M J-4402 then the job of installation is simplified. The assumption in this section
is the original installation does not use Anderson Powerpoles® to connect the
radio to the power lines. If it does then you can skip the Powerpole® installation
and go to step 4.
When wiring make sure that the RED terminals go on the positive wires which
should be red and the BLACK terminals go on the negative wires which should
be black.
1. Remove the fuses in the line to the battery.
2. Cut the cable where the M J-4402 is to be installed.
3. Install Powerpoles® on each end of the cut cable.
4. Make sure the Powerpole® connectors are put together to match the
connectors on the M J-4402. Red to RED and BLACK to BLACK.
5. Connect the line from the battery to the terminals marked BATTERY.
6. Connect the line from the radio to the terminals marked RADIO.
7. Reinstall the fuses in the line to the battery.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
4
Radio and Power Lines Not Installed Yet
Because each vehicle installation is different, complete exact instructions would
be impractical. It would be wise to study mobile installation techniques in the
various amateur radio books and magazines before proceeding. Also check with
the manufacturer or dealer to see if they have any information on two way radio,
CB radio, or Aftermarket Audio System installation in your vehicle. If you are not
comfortable with the installation find experienced assistance or professional help.
If you have to drill holes or drive screws make sure you do not screw into or drill
into vehicular wiring or equipment. In running the wires do not route them in
areas that can interfere with the foot pedals, mechanical assemblies, exhaust
lines, fuel lines, or other moving parts under the hood or in the vehicle cabin. Use
wire ties to tie down the cables so they can not shift and cause a hazard. Do not
install the fuses till the wiring is complete.
Connections to the battery should be done properly using connectors designed
for the job. Loosening the bolt and stuffing the wire behind the bolt is not
recommended. Corrosion and reliability issues will show up in the future. Good
quality, properly sized solder lugs, special terminals, or special side mount bolts
that have screw terminals to replace the existing side mount bolts are strongly
recommended. These should be available at well stocked auto parts stores.
1. Connect a power line set to the battery with fuses at the battery to
protect the cables in case of short. Route the power line set through the
firewall into the cabin of the vehicle being very careful to not damage
the vehicle or interfere with the vehicle operation. Also route the lines so
the insulation will not chafe and short to the chassis.
2. Run the power lines to where the M J-4402 will be placed allowing
some extra slack if needed.
3. Install Powerpoles® on the lines to the battery. Make sure the
Powerpole® connectors are put together to match the connectors on the
M J-4402. RED to RED and BLACK to BLACK.
4. Run the power lines from the radio to the location of the M J-4402.
5. Put Powerpole® connectors on the lines from the radio to the M J-4402.
Make sure the Powerpole® connectors are put together to match the
connectors on the M J-4402. RED to RED and BLACK to BLACK.
Use the shortest practical wire lengths to reduce the voltage drop in the wiring.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
5
IGNITION SENSE LINE INSTALLATION
Installation of the IGNITION SENSE line into the fuse box will take some care to
insure that the fuse holders are not damaged or the fuse box is not shorted out.
Study the vehicle owner’s manual to insure you do not connect to a fuse that
could cause the car to malfunction.
If you are not comfortable with the installation find experienced assistance
or professional help.
Connectors may be needed to safely connect to the fuse box. Once you identify
what these connectors are, they can be obtained from auto parts stores or
electronics supply stores. The object is to find a connection that is switched by
the ignition switch preferably the accessory circuit. Check with the dealer to find
out if there are connections that can be used for this purpose. The best
connection would be a bayonet lug connection supplying switched accessory
power. The next choice is one of the fuses that are on the accessory circuit. This
would be a fuse to the switched line on the radio or other similar circuit. Use a
voltmeter and identify the fuse that is switched on with the accessory position
and the on position of the key switch.
DO NOT USE A FUSE CONNECTION THAT POWERS HEADLIGHTS,
BRAKES, AIRBAGS, IGNITION SYSTEMS, COMPUTER SYSTEMS, OR ANY
SAFETY DEVICE ON THE CAR. INTERRUPTING THESE SYSTEMS CAN
CAUSE THE CAR TO MALFUNCTION.
If tapping a fuse connection, use adapters that are designed for this job. Just
pushing a bare wire in between the fuse lug and the socket is not safe. Stray wire
strands can short out the block. ollow the instructions with the adapters to
insure they are installed correctly. Put the connector on the fused side of the fuse
to protect the connection and wire in case of a short circuit.
Do not cut and tap a wire in any wiring harness to obtain the switched
power. Cutting and splicing wires can cause electrical problems in the car and
even if covered with electrical tape the tape can come off over time causing a
chance of a short in the wiring. Tapping the wrong wire can cause sever
problems in the vehicle.
Once the Acc. power source has been identified run a wire between the M J-
4402 and the fuse box. Use the proper connector at the fuse box side and a
standard insulated female quick disconnect connector (supplied) at the M J-
4402. In running the wires do not route them in areas that can interfere with the
foot pedals, mechanical assemblies, or other moving parts under the dash or in
the vehicle cabin. Use wire ties to tie down the cables so they can not shift and
cause a hazard.
Carefully crimp on the connectors following the instructions with the connectors if
any. Use the proper crimp tools when available. It is suggested to solder the
connectors on where possible to insure both a mechanical and electrical
connection that will not pull apart later. or the supplied connector remember to
put the plastic boot on first before putting on the connector then slide it over the
connector to insulate it.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
6
heckout and Operation
1. Install the fuses at the battery.
2. Plug in the battery line to the BATTERY connector and the radio line to
the RADIO connector if not already done so.
3. Plug in IGNITION SENSE line if not already done so.
4. Turn the ignition switch to Acc.
5. The relay and the radio should energize after 4 to 6 seconds.
Normal operation, when you turn on the car the relay will be delayed long enough
to allow the car to start and then turn on the radio. The time delay can be
adjusted to lengthen or shorten the delay as needed.
It is possible to connect more than 1 radio to the M J-4402 as long as the total
current does not exceed 30 amps or the maximum fuse size you are currently
using. Use pigtail set to connect both radios, or a box such as the M J-1106 and
a short jumper cable.
Adjustments
Timer Adj stment
1. Using a small tuning tool or jeweler’s screwdriver turn the DELAY SET
control (R5) for the desired delay after turn on. Range is approximately
2 seconds to 8 seconds. Mid range is approximately 4 seconds
Undervoltage C to t
1. Adjustment range is approximately 10 to 12.5V. Mid range is
approximately 10.8V.
2. This adjustment requires an adjustable power supply to properly set the
level.
3. Remove the M J-4402 from the vehicle.
4. Connect an adjustable power supply to the M J-4402 with the negative
connection to either of the BLACK Powerpole® connections and the
positive to the IGNITION SENSE line input.
5. Adjust the power supply to the desired low voltage cutout level. This is
usually the minimum level the radio manufacturer specifies or a little
higher than the minimum that the vehicle will start at.
6. Adjust the LV SET pot using a small tuning tool or jeweler’s screwdriver
and adjust the level to where the relay drops out then turn to where the
relay just energizes.
7. Turn the voltage on the power supply up and down around the set point
to verify that the relay drops out and energizes at the desired point.
8. Reinstall the M J-4402 in the vehicle.
F se Replacement
If for some reason the fuse blows identify the cause for the failure and repair the
problem. Replace the fuse with one of the same type and of the value the radio
manufacturer recommends for the radio. Do not install a fuse above 30 amps.
Smaller value fuses are fine as long as the radio will work without blowing them.

MFJ-4402 Mobile Transceiver Protector Instruction Manual
© 2012 MFJ Enterprises, Inc.
7
Powerpole® onnector Assembly
irst, slide two connector housings together to match the configuration of the
corresponding connectors on your M J-4402. It’s easier to do this now rather
than after the wired terminals have been inserted in the housings.
You can install the Powerpole® connectors on your wires by either soldering or
crimping, as long as you make sure you have good, solid connections. Wires
smaller than #12 gauge will not allow for crimping, and must be soldered to the
terminals.
To crimp, first strip the wire, making sure not to damage the wire strands. Insert
the wire into the terminal and crimp. Be careful not to deform or squash the
terminal body. If you do, crimp again to return it to its original shape. Otherwise,
the terminal may not fit inside the housing. Be sure that you have a good firm
connection to reduce resistance.
If you solder wires to the terminals, tin them lightly first. When soldering, flow
solder only into the hole in which the wire is inserted. Be careful not to get any
solder around the outer body of the terminal.
Then insert the flanged end of
the terminal into the contact housing through
the open, square end of the housing ( igs.
3, 4 and 5). The terminal will snap into place when correctly oriented.
Internal view of two
Powerpoles®
connected.
(Anderson Power drawings; www.andersonpower.com)
Fig 3
: Correct orientation of
terminal and housing.
Fig 4: Using an insertion tool
to snap terminal in place. A
very small, flat-blade
screwdriver will work.
Fig 5: Assembled terminal
and housing.