Road Relay 4 1s62q
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RoadRelay™ 4
Installation Guide
RoadRelay™ 4 Installation Guide Bulletin No. 3401767 Revision B
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)
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Contents Overview........................................................................................... 5 Mounting Choices .........................................................................................................5
On-Dash Installation ......................................................................... 6 Tools Needed................................................................................................................6 Identify Components .....................................................................................................7 Starting On-Dash Installation ........................................................................................8 Choosing a Location.....................................................................................................8
In-Dash Installation......................................................................... 12 Tools Needed..............................................................................................................12 Identify Components ...................................................................................................13 Starting In-Dash Installation ........................................................................................14 Preparing Location......................................................................................................14 Cutting the Hole ..........................................................................................................15
Under-Dash Installation .................................................................. 18 Tools Needed..............................................................................................................18 Identify Components ...................................................................................................19 Starting Under-Dash Installation .................................................................................20 Choosing a Location...................................................................................................20
Standard Installation....................................................................... 24 Checking Voltage........................................................................................................25 Locate Fuse ......................................................................................................25 Locate Battery or Unswitched Voltage........................................................................26 Locate Switched or Ignition Voltage............................................................................27 Locate Lights-on Power ..............................................................................................28
Connecting the Electrical Wiring ................................................... 30 Connect to Battery Voltage.........................................................................................31 Connect Switched Power............................................................................................33 Connect Lights-on Power ...........................................................................................35 Connect the Ground ...................................................................................................37 Locate the J1587 Data Link ........................................................................................38 Connect Data Link Wires ............................................................................................39 Switching Data Link Wires ..........................................................................................42 Finish Installation ........................................................................................................43 Installing the Loop-back Connector ............................................................................43
RoadRelay Options......................................................................... 46 Troubleshooting.............................................................................. 48 Connector Pin Assignments........................................................... 52
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4
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.
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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.
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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
RoadRelay™ 4 Installation Guide Identify Components Before starting, lay out all of the items in the on-dash kit and for each. If you are missing any of the following, check with the dealer who sold you the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
RoadRelay 4 unit Bracket Thumb screws (2) Power and data link cable assembly Fuse assembly (red) Fuse assembly (white) Fuse assembly (green) Wire with terminal (black) Wire connectors (2) Wire splices (4) Wire ties 2-inch x 2-inch wire seal patches (2) Mounting hardware Jack nut wrench
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On-Dash Installation
Starting On-Dash Installation If all of the components are ed for, and you have the necessary tools, you are ready to begin. WARNING: Remove rings, bracelets, watches or other conductive items before working on the system.
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 driver’s vision.
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RoadRelay™ 4 Installation Guide Temporarily install the mounting bracket. Position the unit in the desired mounting location. Leave sufficient room for the cable. While holding the unit in position, mark the location of the mounting bracket with a pencil or tape. Also, mark the hole for the cable (if necessary).
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.
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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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RoadRelay™ 4 Installation Guide Identify Components Before starting, lay out all of the items in the in-dash kit and for each. If you are missing any of the following, check with the dealer who sold you the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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RoadRelay 4 unit Nuts (2) Power and data link cable assembly Fuse assembly (red) Fuse assembly (white) Fuse assembly (green) Wire with terminal (black) Wire connectors (2) Wire splices (4) Wire ties 2-inch x 2-inch wire seal patches (2)
In-Dash Installation Starting In-Dash Installation If all of the components are ed for, and you have the necessary tools, you are ready to begin. WARNING: Remove rings, bracelets, watches or other conductive items before working on the system.
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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RoadRelay™ 4 Installation Guide Cutting the Hole NOTE: Before cutting the hole, make sure there are no obstructions under that area of the dash, such as cables or brackets, which might interfere with mounting the RoadRelay unit. Cut a 7.17-inch wide by 2.08-inch high rectangular hole in the dash at the chosen location. CAUTION: Carefully cut 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.
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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RoadRelay™ 4 Installation Guide
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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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RoadRelay™ 4 Installation Guide Identify Components Before starting, lay out all of the items in the under-dash kit and for each. If you are missing any of the following, check with the dealer who sold you the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
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RoadRelay 4 “data logger” unit Bracket Thumb screws (2) Power and data link cable assembly Fuse assembly (red) Fuse assembly (white) Fuse assembly (green) Wire with terminal (black) Wire connectors (2) Wire splices (4) Wire ties 2-inch x 2-inch wire seal patches (2) Mounting hardware Jack nut wrench
Under-Dash Installation Starting Under-Dash Installation If all of the components are ed for, and you have the necessary tools, you are ready to begin. WARNING: Remove rings, bracelets, watches or other conductive items before working on the system.
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 ed “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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RoadRelay™ 4 Installation Guide Temporarily install the mounting bracket under the dash in the chosen location. Make sure that the unit, when installed into the bracket, will be out of the driver’s line of sight. But do not install the unit so far under the dash that the electrical hookups cannot be easily accomplished, or the cabling is crowded. While another person holds the unit in position, mark the location of the mounting bracket with a pencil or tape.
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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RoadRelay™ 4 Installation Guide
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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 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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RoadRelay™ 4 Installation Guide
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.
Locate Fuse In most vehicles, the fuse will be located somewhere in the cab. Also, most fuse s will have a terminal area where the wires are connected.
NOTE: The RoadRelay connections should always be made to the bus side of the fuse or circuit breaker. If the fuse is a circuit breaker type of or does not have available terminals, test the vehicle wiring just alongside the 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 s will have a “battery hot” (continuous 12 VDC) connection on them. This connection should be used, if available. Some s 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.
Locate Battery or Unswitched Voltage Using the multimeter or test lamp, check the terminals of the selected switch or electrical accessory for a 12-volt source. When you find a 12-volt source, turn the ignition switch ON and OFF several times. If this power source is continuous, it can be used for battery or unswitched power. Identify the terminal location with a piece of tape.
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RoadRelay™ 4 Installation Guide Locate Switched or Ignition Voltage Start this check with the ignition switch in the OFF position. Again, using the multimeter or test lamp, check for the terminals of the selected switch or electrical accessory for NO VOLTAGE. When you locate a terminal that shows NO voltage, turn the ignition to the ON position.
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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Standard Installation Locate Lights-on Power Turn the ignition switch to the OFF position. Turn the vehicle lights ON. Using the multimeter or test lamp, check for the terminals of the selected switch or electrical accessory for a 12-volt source.
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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RoadRelay™ 4 Installation Guide If you have not already done so, route the cable assembly from the display unit to the underside of the dash in the area of the fuse . You should route through an existing opening, if one is available, or through the 1-1/8-inch hole drilled previously under "Choosing a Location". NOTE: Avoid routing the cable near any radio antenna cable.
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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Connecting the Electrical Wiring The cable assembly has six wires: Single wires: RED = WHITE = GREEN = BLACK =
Battery voltage Switched voltage (ignition) Lights-on switch Ground
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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RoadRelay™ 4 Installation Guide Connect to Battery Voltage NOTE: Battery voltage is continuous, unswitched power. Locate the fuse with the RED wires in the kit. Remove the fuse from the holder. Remove the nut from the fuse battery connection, which was determined earlier. Place the fuse ring terminal on the terminal, and replace the terminal nut.
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Connecting the Electrical Wiring Locate the RED wire in the cable assembly. Pull the wire to the area of the fuse wire. Cut off any unnecessary length of cable wire.
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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RoadRelay™ 4 Installation Guide Connect Switched Power NOTE: The system will only operate correctly when the switched power is on (the ignition switch is in the ON position). No voltage is present when the ignition switch is in the ACCESSORY position. Locate the fuse with the WHITE wires. Remove the fuse from the holder. Remove the nut from the terminal for switched power on the fuse , which was determined earlier. Place the fuse ring terminal on the terminal, and replace the terminal nut.
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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Connecting the Electrical Wiring 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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RoadRelay™ 4 Installation Guide Connect Lights-on Power NOTE: For the under-dash installation, this connection is not necessary since that unit does not have a display. The source for this signal is the lights control. Power is applied when the vehicle lights are ON. Locate the fuse with the GREEN wires in the kit. Remove the fuse from the holder. Remove the nut from the fuse lights control connection, which was determined earlier. Place the fuse ring terminal on the terminal, and replace the terminal nut.
NOTE: The lights-on discrete will dim the display brightness when the vehicle’s 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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Connecting the Electrical Wiring 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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RoadRelay™ 4 Installation Guide Connect the Ground IMPORTANT: Do not use a ground connection that is shared by another electrical component. Choose an existing screw or bolt on the metal area in the vehicle cab, or on the chassis, for the ground connection. If a suitable fastener can not be found, drill a small hole, and install a sheet metal screw. Locate the BLACK wire with ring terminal. Attach the wire terminal to the selected vehicle ground screw or stud. Tighten the ground retainer securely. NOTE: Use a star washer under the ring terminal on all ground locations to ensure a good ground connection.
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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Connecting the Electrical Wiring Locate the J1587 Data Link Locate the J1587 public data link connection in the vehicle:
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! 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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RoadRelay™ 4 Installation Guide Locate the BLACK and RED (twisted pair) wires in the cable assembly. Route the cable assembly wire pair to the area of the data link connector. Cut off any unnecessary length of wire. NOTE: The data line wires connected to the data link connector may not always be black and red. They may be any color or number.
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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Connecting the Electrical Wiring Using a large pair of pliers, as shown, compress the splice blade into position. Close the locking tab.
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 that no wires touch. Make sure the keyswitch is in the OFF position.
Insert the fuses into the three fuse holders.
Turn the keyswitch to the ON position. The display should come on and show the introduction screen.
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RoadRelay™ 4 Installation Guide If there is no display, press the “Up” arrow key several times to brighten the display. Or, if the display is too bright, press the “Down” arrow key to dim it. The display should now come on; check the switched connection for power.
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.
With the display on, start the engine.
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Connecting the Electrical Wiring If the RoadRelay unit displays “Improper Data Link Connection,” the data link is wired incorrectly (backwards).
Switching Data Link Wires Shut OFF the engine. Using the pliers, carefully pull the metal blade up in both wire splices. Exchange the data link wires. Using the pliers, seat the metal blade in both splices.
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RoadRelay™ 4 Installation Guide Finish Installation Start the engine and check for proper operation of the display. If the display responds to the running engine by displaying engine data, finish the installation. If the display still does not work correctly, that the RoadRelay is properly connected to the data link lines. The data link splices must be sealed to prevent corrosion. Locate the two 2x2-inch black sealant patches in the kit. Peel the white sheet off the sealant patch, and place the patch around the wire splice and wires, as shown. Squeeze the two halves of the patch together to seal the splice t. Seal both splices.
Installing the Loop-back Connector Connect the loop-back 10-pin connector (Packard Part No. 12064770) to the mating 10-pin vehicle connector (Packard Part No. 12064769) from the RoadRelay unit.
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Connecting the Electrical Wiring NOTE: The RoadRelay may display “No power from back-up battery” if the loop-back 10-pin connector has not been installed to its mating connector from the RoadRelay unit.
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™ 4 Installation Guide
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RoadRelay Options GPS RoadRelay 4 s 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.
Option For Printer Hookup A printer kit is also available and can be ordered from your nearest Cummins Distributor. The Part No. for the printer kit is 4005923. Note: This cable contains the loop-back connection normally provided by the loop-back connector.
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RoadRelay™ 4 Installation Guide
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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:
Troubleshooting Wiring Problems Reading No.
RR Pigtail Wire Color
Connctr. Cavity Position
Signal
1
Black
A
Ground
2
White
B
Battery + +12 VDC
3
Red
C
4
Orange
D
Datalink-
Between Position A & D, 0 to 1 VDC
5
Green
E
Datalink+
Between Position A & E, 4.5 VDC
6
Blue
F
Lights-on
Between Position A & F, Lights-on, +12 VDC
DVM Reading
Between Position A & Truck, Ground Between Position A & B, Constant +12 VDC
Keyswitch On Between Position A & C, Ign On, +12 VDC +12 VDC
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RoadRelay™ 4 Installation Guide General Troubleshooting Procedures Check the readings listed in the Troubleshooting Wiring Problems table (see previous page) when you encounter one of the RoadRelay problems listed below: 1.
RoadRelay does not illuminate when the ignition is switched on.
Procedure Check Reading No. 1 Check Reading No. 2 Check Reading No. 3
2.
RoadRelay illuminates only after the ignition switch is turned on several times.
Procedure Check Reading No. 2 Check Reading No. 3
3.
Procedure
Fault +12 VDC with ignition switch ON only +12 VDC present at all times
RoadRelay illuminates even when the ignition switch is turned off.
Procedure Check Reading No. 2 Check Reading No. 3 5.
Fault No +12 VDC with ignition switch ON only +12 VDC present at all times OR only when the ignition switch is turned on
RoadRelay goes blank right after the ignition switch is turned off. Check Reading No. 2 Check Reading No. 3
4.
Fault Open to tractor ground No +12 VDC present No +12 VDC with ignition switch in the ON position
Fault +12 VDC present at all times (normal) +12 VDC present at all times (incorrect)
RoadRelay displays “Data Link Timeout.”
Procedure Check Reading No. 4 Check Reading No. 5
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Fault Make sure the voltages are within the specified ranges Make sure the voltages are within the specified ranges
Troubleshooting 6.
After initial hook-up, the RoadRelay displays “Improper data link connection.”
Procedure Switching Data Link Wires
7.
Fault The data link wires have been wired backwards
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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RoadRelay™ 4 Installation Guide
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Connector Pin Assignments RoadRelay Cables and Connectors: Pin Assignments:
6-Pin Vehicle Connector
A= B= C= D= E= F=
Battery (-) Battery (+) Switch Power J1587 (-) J1587 (+) Lights-On Discrete
3-Pin J1939 Connector
10-Pin Vehicle Connector with Mating Loop-back 10-Pin 10-Pin Connector Vehicle Connector with Mating Loop-back 10-Pin Connector Side view of loop-back
Side view of loop-back 10-pin connected to vehicle 10-pin
A= B= C= D= E= F=
A = J1939 (+) B = J1939 (-) C = J1939 Common
10-pin co
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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RoadRelay™ 4 Installation Guide Note: Because the J1939 data link option is not currently ed with a connector in the kit, the RoadRelay unit’s third cable assembly connector (3-pin) is not used.
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Technical 1-800-433-9341 © 2002 Cummins , Inc. Bulletin No. 3401767, Rev. B
Installation Guide
RoadRelay™ 4 Installation Guide Bulletin No. 3401767 Revision B
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)
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Contents Overview........................................................................................... 5 Mounting Choices .........................................................................................................5
On-Dash Installation ......................................................................... 6 Tools Needed................................................................................................................6 Identify Components .....................................................................................................7 Starting On-Dash Installation ........................................................................................8 Choosing a Location.....................................................................................................8
In-Dash Installation......................................................................... 12 Tools Needed..............................................................................................................12 Identify Components ...................................................................................................13 Starting In-Dash Installation ........................................................................................14 Preparing Location......................................................................................................14 Cutting the Hole ..........................................................................................................15
Under-Dash Installation .................................................................. 18 Tools Needed..............................................................................................................18 Identify Components ...................................................................................................19 Starting Under-Dash Installation .................................................................................20 Choosing a Location...................................................................................................20
Standard Installation....................................................................... 24 Checking Voltage........................................................................................................25 Locate Fuse ......................................................................................................25 Locate Battery or Unswitched Voltage........................................................................26 Locate Switched or Ignition Voltage............................................................................27 Locate Lights-on Power ..............................................................................................28
Connecting the Electrical Wiring ................................................... 30 Connect to Battery Voltage.........................................................................................31 Connect Switched Power............................................................................................33 Connect Lights-on Power ...........................................................................................35 Connect the Ground ...................................................................................................37 Locate the J1587 Data Link ........................................................................................38 Connect Data Link Wires ............................................................................................39 Switching Data Link Wires ..........................................................................................42 Finish Installation ........................................................................................................43 Installing the Loop-back Connector ............................................................................43
RoadRelay Options......................................................................... 46 Troubleshooting.............................................................................. 48 Connector Pin Assignments........................................................... 52
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4
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.
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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.
6
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
RoadRelay™ 4 Installation Guide Identify Components Before starting, lay out all of the items in the on-dash kit and for each. If you are missing any of the following, check with the dealer who sold you the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
RoadRelay 4 unit Bracket Thumb screws (2) Power and data link cable assembly Fuse assembly (red) Fuse assembly (white) Fuse assembly (green) Wire with terminal (black) Wire connectors (2) Wire splices (4) Wire ties 2-inch x 2-inch wire seal patches (2) Mounting hardware Jack nut wrench
7
On-Dash Installation
Starting On-Dash Installation If all of the components are ed for, and you have the necessary tools, you are ready to begin. WARNING: Remove rings, bracelets, watches or other conductive items before working on the system.
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 driver’s vision.
8
RoadRelay™ 4 Installation Guide Temporarily install the mounting bracket. Position the unit in the desired mounting location. Leave sufficient room for the cable. While holding the unit in position, mark the location of the mounting bracket with a pencil or tape. Also, mark the hole for the cable (if necessary).
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.
9
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.
10
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
11
RoadRelay™ 4 Installation Guide Identify Components Before starting, lay out all of the items in the in-dash kit and for each. If you are missing any of the following, check with the dealer who sold you the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12
RoadRelay 4 unit Nuts (2) Power and data link cable assembly Fuse assembly (red) Fuse assembly (white) Fuse assembly (green) Wire with terminal (black) Wire connectors (2) Wire splices (4) Wire ties 2-inch x 2-inch wire seal patches (2)
In-Dash Installation Starting In-Dash Installation If all of the components are ed for, and you have the necessary tools, you are ready to begin. WARNING: Remove rings, bracelets, watches or other conductive items before working on the system.
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.
13
RoadRelay™ 4 Installation Guide Cutting the Hole NOTE: Before cutting the hole, make sure there are no obstructions under that area of the dash, such as cables or brackets, which might interfere with mounting the RoadRelay unit. Cut a 7.17-inch wide by 2.08-inch high rectangular hole in the dash at the chosen location. CAUTION: Carefully cut 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.
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.)
14
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.
15
RoadRelay™ 4 Installation Guide
16
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
17
RoadRelay™ 4 Installation Guide Identify Components Before starting, lay out all of the items in the under-dash kit and for each. If you are missing any of the following, check with the dealer who sold you the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
18
RoadRelay 4 “data logger” unit Bracket Thumb screws (2) Power and data link cable assembly Fuse assembly (red) Fuse assembly (white) Fuse assembly (green) Wire with terminal (black) Wire connectors (2) Wire splices (4) Wire ties 2-inch x 2-inch wire seal patches (2) Mounting hardware Jack nut wrench
Under-Dash Installation Starting Under-Dash Installation If all of the components are ed for, and you have the necessary tools, you are ready to begin. WARNING: Remove rings, bracelets, watches or other conductive items before working on the system.
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 ed “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.
19
RoadRelay™ 4 Installation Guide Temporarily install the mounting bracket under the dash in the chosen location. Make sure that the unit, when installed into the bracket, will be out of the driver’s line of sight. But do not install the unit so far under the dash that the electrical hookups cannot be easily accomplished, or the cabling is crowded. While another person holds the unit in position, mark the location of the mounting bracket with a pencil or tape.
Remove the bracket from the unit. Position the bracket under the dash according to your marks. Now mark the holes in the bracket.
20
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.
21
RoadRelay™ 4 Installation Guide
22
Standard Installation The following procedures will help you identify battery voltage, switched voltage, lights-on power, and chassis ground at the fuse 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.
23
RoadRelay™ 4 Installation Guide
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.
Locate Fuse In most vehicles, the fuse will be located somewhere in the cab. Also, most fuse s will have a terminal area where the wires are connected.
NOTE: The RoadRelay connections should always be made to the bus side of the fuse or circuit breaker. If the fuse is a circuit breaker type of or does not have available terminals, test the vehicle wiring just alongside the until suitable connection points can be found. These wires should be the wires supplying the bus, not the wires supplying vehicle equipment.
24
Standard Installation NOTE: Most s will have a “battery hot” (continuous 12 VDC) connection on them. This connection should be used, if available. Some s 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.
Locate Battery or Unswitched Voltage Using the multimeter or test lamp, check the terminals of the selected switch or electrical accessory for a 12-volt source. When you find a 12-volt source, turn the ignition switch ON and OFF several times. If this power source is continuous, it can be used for battery or unswitched power. Identify the terminal location with a piece of tape.
25
RoadRelay™ 4 Installation Guide Locate Switched or Ignition Voltage Start this check with the ignition switch in the OFF position. Again, using the multimeter or test lamp, check for the terminals of the selected switch or electrical accessory for NO VOLTAGE. When you locate a terminal that shows NO voltage, turn the ignition to the ON position.
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.
26
Standard Installation Locate Lights-on Power Turn the ignition switch to the OFF position. Turn the vehicle lights ON. Using the multimeter or test lamp, check for the terminals of the selected switch or electrical accessory for a 12-volt source.
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.
27
RoadRelay™ 4 Installation Guide If you have not already done so, route the cable assembly from the display unit to the underside of the dash in the area of the fuse . You should route through an existing opening, if one is available, or through the 1-1/8-inch hole drilled previously under "Choosing a Location". NOTE: Avoid routing the cable near any radio antenna cable.
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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Connecting the Electrical Wiring The cable assembly has six wires: Single wires: RED = WHITE = GREEN = BLACK =
Battery voltage Switched voltage (ignition) Lights-on switch Ground
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.
29
RoadRelay™ 4 Installation Guide Connect to Battery Voltage NOTE: Battery voltage is continuous, unswitched power. Locate the fuse with the RED wires in the kit. Remove the fuse from the holder. Remove the nut from the fuse battery connection, which was determined earlier. Place the fuse ring terminal on the terminal, and replace the terminal nut.
30
Connecting the Electrical Wiring Locate the RED wire in the cable assembly. Pull the wire to the area of the fuse wire. Cut off any unnecessary length of cable wire.
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.
31
RoadRelay™ 4 Installation Guide Connect Switched Power NOTE: The system will only operate correctly when the switched power is on (the ignition switch is in the ON position). No voltage is present when the ignition switch is in the ACCESSORY position. Locate the fuse with the WHITE wires. Remove the fuse from the holder. Remove the nut from the terminal for switched power on the fuse , which was determined earlier. Place the fuse ring terminal on the terminal, and replace the terminal nut.
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.
32
Connecting the Electrical Wiring 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.
33
RoadRelay™ 4 Installation Guide Connect Lights-on Power NOTE: For the under-dash installation, this connection is not necessary since that unit does not have a display. The source for this signal is the lights control. Power is applied when the vehicle lights are ON. Locate the fuse with the GREEN wires in the kit. Remove the fuse from the holder. Remove the nut from the fuse lights control connection, which was determined earlier. Place the fuse ring terminal on the terminal, and replace the terminal nut.
NOTE: The lights-on discrete will dim the display brightness when the vehicle’s 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.
34
Connecting the Electrical Wiring 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.
35
RoadRelay™ 4 Installation Guide Connect the Ground IMPORTANT: Do not use a ground connection that is shared by another electrical component. Choose an existing screw or bolt on the metal area in the vehicle cab, or on the chassis, for the ground connection. If a suitable fastener can not be found, drill a small hole, and install a sheet metal screw. Locate the BLACK wire with ring terminal. Attach the wire terminal to the selected vehicle ground screw or stud. Tighten the ground retainer securely. NOTE: Use a star washer under the ring terminal on all ground locations to ensure a good ground connection.
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.
36
Connecting the Electrical Wiring Locate the J1587 Data Link Locate the J1587 public data link connection in the vehicle:
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! 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.
37
RoadRelay™ 4 Installation Guide Locate the BLACK and RED (twisted pair) wires in the cable assembly. Route the cable assembly wire pair to the area of the data link connector. Cut off any unnecessary length of wire. NOTE: The data line wires connected to the data link connector may not always be black and red. They may be any color or number.
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).
38
Connecting the Electrical Wiring Using a large pair of pliers, as shown, compress the splice blade into position. Close the locking tab.
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 that no wires touch. Make sure the keyswitch is in the OFF position.
Insert the fuses into the three fuse holders.
Turn the keyswitch to the ON position. The display should come on and show the introduction screen.
39
RoadRelay™ 4 Installation Guide If there is no display, press the “Up” arrow key several times to brighten the display. Or, if the display is too bright, press the “Down” arrow key to dim it. The display should now come on; check the switched connection for power.
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.
With the display on, start the engine.
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Connecting the Electrical Wiring If the RoadRelay unit displays “Improper Data Link Connection,” the data link is wired incorrectly (backwards).
Switching Data Link Wires Shut OFF the engine. Using the pliers, carefully pull the metal blade up in both wire splices. Exchange the data link wires. Using the pliers, seat the metal blade in both splices.
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RoadRelay™ 4 Installation Guide Finish Installation Start the engine and check for proper operation of the display. If the display responds to the running engine by displaying engine data, finish the installation. If the display still does not work correctly, that the RoadRelay is properly connected to the data link lines. The data link splices must be sealed to prevent corrosion. Locate the two 2x2-inch black sealant patches in the kit. Peel the white sheet off the sealant patch, and place the patch around the wire splice and wires, as shown. Squeeze the two halves of the patch together to seal the splice t. Seal both splices.
Installing the Loop-back Connector Connect the loop-back 10-pin connector (Packard Part No. 12064770) to the mating 10-pin vehicle connector (Packard Part No. 12064769) from the RoadRelay unit.
42
Connecting the Electrical Wiring NOTE: The RoadRelay may display “No power from back-up battery” if the loop-back 10-pin connector has not been installed to its mating connector from the RoadRelay unit.
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
43
RoadRelay™ 4 Installation Guide
44
RoadRelay Options GPS RoadRelay 4 s 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.
Option For Printer Hookup A printer kit is also available and can be ordered from your nearest Cummins Distributor. The Part No. for the printer kit is 4005923. Note: This cable contains the loop-back connection normally provided by the loop-back connector.
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RoadRelay™ 4 Installation Guide
46
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:
Troubleshooting Wiring Problems Reading No.
RR Pigtail Wire Color
Connctr. Cavity Position
Signal
1
Black
A
Ground
2
White
B
Battery + +12 VDC
3
Red
C
4
Orange
D
Datalink-
Between Position A & D, 0 to 1 VDC
5
Green
E
Datalink+
Between Position A & E, 4.5 VDC
6
Blue
F
Lights-on
Between Position A & F, Lights-on, +12 VDC
DVM Reading
Between Position A & Truck, Ground Between Position A & B, Constant +12 VDC
Keyswitch On Between Position A & C, Ign On, +12 VDC +12 VDC
47
RoadRelay™ 4 Installation Guide General Troubleshooting Procedures Check the readings listed in the Troubleshooting Wiring Problems table (see previous page) when you encounter one of the RoadRelay problems listed below: 1.
RoadRelay does not illuminate when the ignition is switched on.
Procedure Check Reading No. 1 Check Reading No. 2 Check Reading No. 3
2.
RoadRelay illuminates only after the ignition switch is turned on several times.
Procedure Check Reading No. 2 Check Reading No. 3
3.
Procedure
Fault +12 VDC with ignition switch ON only +12 VDC present at all times
RoadRelay illuminates even when the ignition switch is turned off.
Procedure Check Reading No. 2 Check Reading No. 3 5.
Fault No +12 VDC with ignition switch ON only +12 VDC present at all times OR only when the ignition switch is turned on
RoadRelay goes blank right after the ignition switch is turned off. Check Reading No. 2 Check Reading No. 3
4.
Fault Open to tractor ground No +12 VDC present No +12 VDC with ignition switch in the ON position
Fault +12 VDC present at all times (normal) +12 VDC present at all times (incorrect)
RoadRelay displays “Data Link Timeout.”
Procedure Check Reading No. 4 Check Reading No. 5
48
Fault Make sure the voltages are within the specified ranges Make sure the voltages are within the specified ranges
Troubleshooting 6.
After initial hook-up, the RoadRelay displays “Improper data link connection.”
Procedure Switching Data Link Wires
7.
Fault The data link wires have been wired backwards
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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RoadRelay™ 4 Installation Guide
50
Connector Pin Assignments RoadRelay Cables and Connectors: Pin Assignments:
6-Pin Vehicle Connector
A= B= C= D= E= F=
Battery (-) Battery (+) Switch Power J1587 (-) J1587 (+) Lights-On Discrete
3-Pin J1939 Connector
10-Pin Vehicle Connector with Mating Loop-back 10-Pin 10-Pin Connector Vehicle Connector with Mating Loop-back 10-Pin Connector Side view of loop-back
Side view of loop-back 10-pin connected to vehicle 10-pin
A= B= C= D= E= F=
A = J1939 (+) B = J1939 (-) C = J1939 Common
10-pin co
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
51
RoadRelay™ 4 Installation Guide Note: Because the J1939 data link option is not currently ed with a connector in the kit, the RoadRelay unit’s third cable assembly connector (3-pin) is not used.
52
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Technical 1-800-433-9341 © 2002 Cummins , Inc. Bulletin No. 3401767, Rev. B
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