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Installation Guide
Copyright 2002, Cummins Inc. All rights reserved. Cummins Inc. shall not be liable for technical or editorial omissions herein; nor for incidental or consequential damages from the furnishing, performance, or use of this material. For technical assistance with installation or the use of the RoadRelay, call: 1-800-433-9341 in The USA 0800-286646 in the United Kingdom +1-812-3778136 for international calls To make your call go as smoothly as possible, please make sure you have the following information handy when you call: Make and model of the vehicle in which the RoadRelay is installed Engine type (for example, 98 Cummins N14) Version number of your RoadRelay unit (for example, RoadRelay 4) Transmission type Any electronic systems on the vehicle (for example, ABS)
Contents
Overview........................................................................................... 5
Mounting Choices .........................................................................................................5
In-Dash Installation......................................................................... 12
Tools Needed..............................................................................................................12 Identify Components ...................................................................................................13 Starting In-Dash Installation ........................................................................................14 Preparing Location......................................................................................................14 Cutting the Hole ..........................................................................................................15
Standard Installation....................................................................... 24
Checking Voltage........................................................................................................25 Locate Fuse Panel......................................................................................................25 Locate Battery or Unswitched Voltage........................................................................26 Locate Switched or Ignition Voltage............................................................................27 Locate Lights-on Power ..............................................................................................28
Overview
The RoadRelay 4 is a vehicle monitoring system that works with all electronic engines. The unit collects, analyzes, and saves vehicle data in memory.
Mounting Choices
Installation of the RoadRelay may be on-dash, in-dash, or under-dash. This manual covers the installation for all three locations.
On-Dash Installation
Tools Needed
These tools are needed for the standard on-dash installation: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 3/8-inch electric drill 1/4-inch bit 1-1/8-inch bit (or hole saw) Medium screwdriver Small screwdriver Large pliers Adjustable wrench Set of nut drivers Wire cutter Multimeter or other DC voltage meter
On-Dash Installation
IMPORTANT: Before making any electrical connections to vehicle power, disconnect the positive and negative cables from the battery. Check the vehicle electrical system to make sure the power is off before proceeding.
Choosing a Location
This chapter covers units mounted on the vehicle dash or roof. (For indash or under-dash mounting, see later sections of this guide.) Choose a location that is both visible and accessible for operation. For best viewing, the unit should be facing the driver and within easy reach. IMPORTANT: For safety purposes, do not mount the unit in any location that will obstruct the drivers vision.
If possible, route the cable to the underside of the dash without drilling a hole. If a hole is necessary, drill a 1-1/8-inch hole. CAUTION: Carefully drill the hole in the dash. Do not allow the drill to protrude into the dash area when the bit breaks through the surface, as serious damage could result.
Remove the bracket from the unit. Position the bracket on the dash according to your marks. Now mark the holes in the bracket.
On-Dash Installation
Drill two 1.4-inch mounting holes (drill 1/2-inch holes if the jack nuts are used). Install the bracket with the fasteners supplied in the installation kit. CAUTION: Carefully drill the holes in the dash. Do not allow the drill to protrude into the dash area when the bit breaks through the surface, as serious damage could result.
Continue with "Standard Installation" and "Connecting the Electrical Wiring" sections.
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In-Dash Installation
Tools Needed
These tools are needed for the standard in-dash installation: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 3/8-inch electric drill 1/4-inch bit 1-1/8-inch bit (or hole saw) Medium screwdriver Small screwdriver Large pliers Adjustable wrench Set of nut drivers Wire cutter Multimeter or other DC voltage meter Torx driver
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IMPORTANT: Before making any electrical connections to vehicle power, disconnect the positive and negative cables from the battery. Check the vehicle electrical system to make sure the power is off before proceeding.
Preparing Location
This chapter covers units mounted in the vehicle dash. (For on-dash or under-dash mounting, see other sections of this guide.) Choose a location that is both visible and accessible for operation. For best viewing, the unit should be facing the driver and within easy reach.
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Route the cables through the rectangular hole in the dash at the chosen location. (Wiring the electrical connections is described in the Connecting the Electrical Wiring section.)
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In-Dash Installation
Adjust the side latches on each side of the unit to correspond to the thickness of the dash. The latches are ruled in 1-mm granulations. After the latches have been adjusted to the appropriate measurement, tighten the screws to a torque value of 0.588 Nm [0.434 ft-lb]. Slide the RoadRelay unit into the dash opening.
Continue with "Standard Installation" and "Connecting the Electrical Wiring" sections.
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Under-Dash Installation
Tools Needed
These tools are needed for the standard under-dash installation: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 3/8-inch electric drill 1/4-inch bit 1-1/8-inch bit (or hole saw) Medium screwdriver Small screwdriver Large pliers Adjustable wrench Set of nut drivers Wire cutter Multimeter or other DC checker
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IMPORTANT: Before making any electrical connections to vehicle power, disconnect the positive and negative cables from the battery. Check the vehicle electrical system to make sure the power is off before proceeding.
Choosing a Location
This chapter covers the flat face paneled data logger units mounted under the vehicle dash. (For in-dash or on-dash mounting, see earlier sections of this guide.) The data logger RoadRelay 4 unit differs from the on-dash and in-dash installed units in that there is no driver interface with the unit. It may even be preferable for the unit to be oriented so as to be undetectable by the driver. In this installation, choose a location that is far enough underneath the dash that it will not be visible or noticeable to the driver.
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Remove the bracket from the unit. Position the bracket under the dash according to your marks. Now mark the holes in the bracket.
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Under-Dash Installation
Drill two 1.4-inch mounting holes (drill 1/2-inch holes if the jack nuts are used). Install the bracket with the fasteners supplied in the installation kit. CAUTION: Carefully drill the holes in the dash. Do not allow the drill to protrude into the dash area when the bit breaks through the surface, as serious damage could result.
Continue with "Standard Installation" and "Connecting the Electrical Wiring" sections.
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Standard Installation
The following procedures will help you identify battery voltage, switched voltage, lights-on power, and chassis ground at the fuse panel or ignition switch. The vehicle electrical system must have battery power for you to make the following checks. If you disconnected the battery, reconnect the cables.
Reconnect the positive battery cable first; negative last. Check the vehicle electrical system to make sure it is receiving power.
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Checking Voltage
For the following procedures, you will need a multimeter. Set the meter to read DC voltage. If a meter is not available, a 12-volt tester can be used. It is also possible to make a tester using a 12-volt lamp socket and lamp. The lamp socket must have two wire leads.
NOTE: The RoadRelay connections should always be made to the bus side of the fuse or circuit breaker. If the fuse panel is a circuit breaker type of panel or does not have available terminals, test the vehicle wiring just alongside the panel until suitable connection points can be found. These wires should be the wires supplying the bus, not the wires supplying vehicle equipment.
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Standard Installation
NOTE: Most panels will have a battery hot (continuous 12 VDC) connection on them. This connection should be used, if available. Some panels will also have an ignition ON +12 VDC connection. If present, this connection should also be used.
CAUTION: The system will only operate correctly when the switched power is supplied in the ignition ON position. No voltage is present in the ACCESSORY position.
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When you find a terminal that powers up with the ignition in the ON position, check it by turning the switch ON and OFF several times. Check the terminal with the ignition in the ACCESSORY position. The terminal must not have power in this position. If this source is continuous while the switch is in the ON position, it can be used for switched or ignition voltage. Identify the terminal location with a piece of tape.
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When you find a terminal that shows 12 VDC with the ignition OFF and the lights ON, turn the lights OFF. The meter should show NO voltage with the lights turned OFF. Identify the terminal location with a piece of tape.
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Connect the vehicle cable 6-pin connector (Packard Part No. 12064762) to the mating vehicle cable connector (Packard Part No. 12064763) from the RoadRelay unit. For installations using a bracket, position the RoadRelay in the bracket, and install the thumb retainer screws.
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NOTE: It is not necessary to connect the green wire for the under-dash installation of the data logger RoadRelay unit.
Twisted pair: BLACK = DL Data line RED = DLI Data line NOTE: Cut off the bare wire that is with the twisted pair.
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NOTE: Fuses must be used in the switched and unswitched power lines. Locate one of the wire splices. Insert the ends of the cable assembly wire and the fuse assembly wire into the splice. Using a large pair of pliers, compress the splice button until it is flush. Pull firmly on each wire with your fingers to make sure the wires are seated in the splice.
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Locate the WHITE wire in the cable assembly. Pull the wire to the area of the fuse wire. Cut off any unnecessary length of cable wire.
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NOTE: The lights-on discrete will dim the display brightness when the vehicles lights are ON. Discrete input shall be considered on when voltage is greater than 3.0 (+/- 0.5) VDC. Locate the GREEN wire in the cable assembly. Pull the wire to the area of the fuse wire. Cut off any unnecessary length of cable wire.
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Locate one of the wire splices. Insert the ends of the cable assembly wire and the BLACK ground wire into the splice. Using a large pair of pliers, compress the splice button until it is flush. Pull firmly on each wire with your fingers to make sure the wires are seated in the splice.
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NOTE: See the section Connector Pin Assignments for data link connectors, line identification, and vehicle data link location. IMPORTANT: If you are unsure about the data line identity, STOP! Contact a local Cummins Dealer for help.
The data link connector may be covered with a flexible split conduit. Open the conduit and pull the connector and wires several inches out. NOTE: If there are more than two wires leading into the connector, the data line will be a twisted pair of wires.
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Locate the two self-stripping wire splices in the kit. Note that the splices have a slit in one side to fit over an existing wire and a hole in the other side to accept the end of a wire. Position the splices over the data link wires so the hole in the splice is away from the data link connector.
Connect Data Link Wires Insert the BLACK DL (+) cable assembly wire into the splice on the (+) data line of the twisted pair from the vehicle. Insert the RED DLI (-) cable assembly wire into the other splice. IMPORTANT: With the data link connector configured as described above (shown below), RECHECK the wire placement: BLACK DL to data link (+) line (pin A of the 2-pin connector). RED DLI to data link (-) line (pin B of the 2-pin connector).
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IMPORTANT: There are several more installation steps that must be completed. However, before finishing the installation:
Check the RoadRelay display for correct operation. Check the terminals to make sure they are tight. Check the ground connection. Check the area to verify that no wires touch. Make sure the keyswitch is in the OFF position.
Turn the keyswitch to the ON position. The display should come on and show the introduction screen.
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After pressing the Up arrow key several times, the RoadRelay display should come on; if it did not, check the unswitched (battery voltage) connection and the ground connection.
Check for correct switched and unswitched connections. Turn the ignition to OFF. If the RoadRelay shuts off immediately, the switched and unswitched connections are reversed. The RoadRelay should shut off only after a 30-second delay, which indicates the correct switched and unswitched connections.
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NOTE: In situations where primary power (vehicle battery) will be disconnected from the RoadRelay 4, the backup battery should also be disconnected. This can be done by removing the loop-back connector from the RoadRelay 4. Failure to remove the connector may result in a dead backup battery. Some data will be lost when the connector is removed.
Loop-Back Connector
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RoadRelay Options
GPS
RoadRelay 4 supports optional Global Positioning System (GPS) circuitry. If the GPS option is purchased, install the GPS antenna by screwing onto the connector provided at the rear of the RoadRelay 4. Make sure it has unobscured visibility to the sky through the windshield or mount outside of the vehicle. The cable should be secured under the dash where it will not interfere with the normal operation of the vehicle.
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Troubleshooting
Introduction
This is a basic guide to troubleshooting common problems with the RoadRelay unit.
Tools Needed
Use a digital multimeter to measure voltages and resistances. Reading No. 1 is the only resistance reading listed. The rest of the readings are for DC voltages. Readings No. 4 and No. 5 are data link measurements that fluctuate with the data that is moving across the connection, but the readings should be close to those listed below. The following table lists the readings that should be taken when troubleshooting RoadRelay wiring problems:
Ground
Between Position A & Truck, Ground Between Position A & B, Constant +12 VDC
White
Red
Keyswitch On Between Position A & C, Ign On, +12 VDC +12 VDC DatalinkBetween Position A & D, 0 to 1 VDC Between Position A & E, 4.5 VDC Between Position A & F, Lights-on, +12 VDC
Orange
Green
Datalink+
Blue
Lights-on
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Procedure
Check Reading No. 1 Check Reading No. 2 Check Reading No. 3
Fault
Open to tractor ground No +12 VDC present No +12 VDC with ignition switch in the ON position
2.
RoadRelay illuminates only after the ignition switch is turned on several times.
Procedure
Check Reading No. 2 Check Reading No. 3
Fault
No +12 VDC with ignition switch ON only +12 VDC present at all times OR only when the ignition switch is turned on
3.
RoadRelay goes blank right after the ignition switch is turned off.
Procedure
Check Reading No. 2 Check Reading No. 3
Fault
+12 VDC with ignition switch ON only +12 VDC present at all times
4.
Procedure
Check Reading No. 2 Check Reading No. 3 5.
Fault
+12 VDC present at all times (normal) +12 VDC present at all times (incorrect)
Procedure
Check Reading No. 4 Check Reading No. 5
Fault
Make sure the voltages are within the specified ranges Make sure the voltages are within the specified ranges
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Troubleshooting
6. After initial hook-up, the RoadRelay displays Improper data link connection.
Procedure
Switching Data Link Wires
Fault
The data link wires have been wired backwards
7.
After initial hookup, the RoadRelay displays No power from back-up battery.
Procedure
Finish Installation
Fault
The loop-back connector has not been installed to its mating 10-pin connector from the RoadRelay unit
On most new tractors, the data link connector is located in the dash, facing down toward the floor. The data lines from the RoadRelay are connected to one of two connectors running to the engine data link connector on the dash. Make sure the RoadRelay data lines are connected to this data line connection. See sections "Locating the J1587 Data Link" and "Connect Data Link Wires".
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10-Pin Vehicle Connector with Mating Loop-back 10-Pin Connector 10-Pin Vehicle Connector with Mating Loop-back 10-Pinview of loop-back Side Connector
10-pin co
A= B= C= D= E= F=
Battery (-) Battery (+) Switch Power J1587 (-) J1587 (+) Lights-On Discrete
A= B= C= D= E= F= G= H= J= K=
Battery (-) Pull-up wake-up #1 (CTS) Pull-up wake-up #2 RS-232 RXD Port 2 RS-232 RXD Port 1 RS-232 TXD Port 1 Output Pulldown wake-up Back-up Battery(-) RS-232 TXD Port 2
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Technical Support 1-800-433-9341 2002 Cummins , Inc. Bulletin No. 3401767, Rev. B