AWARE VEHICLE INTELLIGENCE TM INSTALLATION MANUAL FOR STERLING MODELS 2001 ACTERRA AND NEWER MODULES ARE NOT ACTIVATED WHEN SHIPPED. PLEASE SEE THE ACTIVATION GUIDE. 1 March 6 th, 2008
TABLE OF CONTENTS 1. AWARE TM Vehicle Models...4 1.1. Before Installing...4 1.2. FCC RF Exposure Information...4 2. How the system works...4 3. Kit Installation Components...5 3.1. Generic Kit Components...5 3.2. Driver Alert Kit Components (Optional)...5 3.3. Components Provided by Installer...5 4. AWARE Module Installation...7 4.1. Location of Module...7 5. AWARE Main Harness Installation...8 5.1. Battery, Ignition & Ground...9 5.2. J1939 Terminating Resistor...11 5.3. Diagnostic Connector...11 Route the J1708/J1587 twisted pair of wires (blue and gray) from the AWARE main harness under the driver side instrument panel to the diagnostic connector...11 Splice and heat shrink with a wire crimp, the J1708+ (blue) and J1708 (gray) wires of the AWARE main harness to the J1708+ (green) and J1708 (orange) terminals of the cab harness behind the 9- pin diagnostic connector....11 5.3.1. 6-Pin Gray Connector...13 5.3.2. 9-Pin Black Connector...14 5.4. Accessory Equipment Monitoring Connection...15 5.4.1. Service Brake...15 6. Antenna Installation...15 7. Driver Alert Switch Installation (Optional)...17 8. Software Upgrade...18 9. Configuration...20 9.1. Download Templates...20 9.1.1. Dealers...20 9.1.2. Customers...20 9.2. Import Templates into Diamond Logic Builder...20 9.3. Apply Templates to module...21 9.4. Program Templates to module...21 10. Activation...22 11. Final Assembly Steps...22 Service Brake (If service brake wiring has been performed, perform the next step)...24 1. Select Parameter: Analog 3 Mode...24 Enter Value: Analog Battery/Ignition biased...24 2. Select Parameter: Analog 3 X Values...24 Enter Values: 30, 30, 50, 70, 70...24 3. Select Parameter: Analog 3 Y Values...24 Enter Values: 1, 2, 2, 2, 0...24 4. Select Parameter: Service Brake Switch Status Source...24 A B APPENDIX Program Parameters Manually...23 Aware TM Telematics Module LED Troubleshooting Table...25 2 March 6 th, 2008
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1. AWARE TM Vehicle Models This installation procedure is for the Sterling Acterra model year 2003 and newer. 1.1. Before Installing Please read this entire document prior to installing the AWARE module. Pay attention to all Cautions and Warnings. CAUTION: Unauthorized antennas, modifications, or attachments could impair call quality, damage the module, or result in violation of FCC regulations. Do not use the module with a damaged antenna. Please contact your local authorized International dealer for antenna replacement. WARNING: To avoid property damage, personal injury, or death, park the vehicle on a flat level surface, set the parking brake, turn the engine off, and chock the wheels. 1.2. FCC RF Exposure Information In August 1996 the Federal Communications Commission (FCC) of the United States with its action in Report and Order FCC 96-326 adopted an updated safety standard for human exposure to radio frequency electromagnetic energy emitted by FCC regulated transmitters. Those guidelines are consistent with the safety standard previously set by both U.S. and international standards bodies. The design of this cellular module complies with the FCC guidelines and these international standards. WARNING: While the system is in operation, a separation distance of at least 20 centimeters (approximately 8 inches) must be maintained between the cellular antenna and the body of all persons in order to meet the FCC RF exposure guidelines. 2. How the system works The AWARE module is a data collection and communication system mounted on a vehicle. It consists of a GPS and cellular antenna and a data communicator module. The data communicator module collects the vehicle s location and system information and sends it to the network control center through wireless technology. 4 March 6 th, 2008
3. Kit Installation Components 3.1. Generic Kit Components Kit Part Number: 2592405C91 3620482C91 AWARE module 3594959C91 AWARE main harness 2588456C91 Harness, ABS Flat 3-pin 2590243C91 Harness, J1939 adaptor, Flat 3-pin 2588150C91 Combined GPS & Cellular Antenna 3561047C1 Bolt, M6 x 1.0 x 30mm long, class 10 3535410C1 Nut, M6 x 1.0 w/ washer, class 10 1331637 Screw, #14 x 1.5 inch, self drilling 1659750C1 Terminals, Deutsch Diagnostic Connector 1661208C1 Terminals, Packard 18 AWG 1661209C1 Terminals, Packard 14-16 AWG 1326518 Grommet, Tyco CES1 2027572C1 Crimp, Duraseal 14-16 AWG 3519178C91 J1939 Terminating Resistor, 3-pin Weather Pack 365679C2 Terminal, Eyelet 1661707C1 Terminal, In-line Fuse 1667639C1 Fuse, In-line body 1687784C1 Fuse, In-line cap 509080C1 Fuse, 15A 131220C1 Fuse, 5A 2591447C91 Harness, Fuel Tax Adaptor 2018946C1 Terminal, 630 Metri-pack Activation Guide 1336182 Tubing, Corrugated 3/8 diameter, 10ft 1336193 Cable Tie, Black 7.4 1336205 Tie Down, Black 1 x 1 3.2. Driver Alert Kit Components (Optional) Kit Part Number: 2589356C91 3593875C2 Driver Alert Switch 3594960C91 Driver Alert Switch Harness 3.3. Components Provided by Installer Assorted tie-wraps Splice kit crimp tool Industrial Strength Velcro 2 wide 5 March 6 th, 2008
Diamond Logic Builder Service tool for programming / provisioning module EZ-Tech COM cable (IC3 or IC4) 6 March 6 th, 2008
4. AWARE Module Installation GPS Antenna Cellular Antenna Figure 1 - Module antenna plugs J1 Connector (Color: Black) J2 Connector (Color: Gray) Figure 2 - Module connector locations 4.1. Location of Module The AWARE module should be mounted inside the cab of the truck. Currently, the best mounting location is on the floor behind the driver s seat. This location is not in an area that will interfere with driver operations and is serviceable for the technician in the event that troubleshooting is required. Selftapping screws have been supplied in the kit for mounting of the module. Optionally, industrial strength velco may be used to affix the module to the floor of the cab. Test fit the location to make sure that the harness and antennas can be connected once module is mounted. The module should be mounted with the J1 and J2 connectors facing the driver door as illustrated in Figure 3.. 7 March 6 th, 2008
5. AWARE Main Harness Installation 1. Remove driver side door scuff plate - (4) #2 Phillips screws. 2. Remove driver side kick panel cover Button plug and (1) #2 Phillips screw 3. Remove lower steering column cover (5) T-20 bolts Figure 3 Steering Cover 4. Remove dash cover around instrument panel (7) T-20 bolts Dash Cover Figure 4 Dash cover 5. Remove instrument panel (6) T-20 bolts 6. Remove top dash cover (4) T-20 bolts Top Dash Cover Figure 5 Top dash cover 7. Remove Fuse panel cover (4) ½ turn #2 Phillips 8 March 6 th, 2008
Figure 6 Fuse Panel Cover 8. Remove clear fuse panel cover (3) # 2 Phillips Figure 7 Clear Fuse Panel Cover 9. Route the J1 and J2 mating connectors on the AWARE harness from the instrument panel cavity in the dash down through the kick panel and in the wire trough below the driver side door scuff plate. 10. Route the J-1708 blue and gray twisted pair wires from the instrument panel cavity in the dash down to the kick panel area on the driver s side. 11. Route the battery, ignition & ground blunt cut wires through the dash over to the fuse panel on the passenger side. 5.1. Battery, Ignition & Ground 1. Locate the BATTERY (red) wire from the AWARE harness. 2. Assemble the in-line fuse: a. Cut the BATTERY wire 8 inches from the end. b. Feed the wires through the in-line body housing. In-line body housing Figure 8 Inline fuse 9 March 6 th, 2008
c. Strip the wires and crimp in-line fuse terminals onto each of these wires. In-line body housing Terminals Figure 10 Inline fuse d. Pull back on the wires to lock the terminals into the in-line fuse body housing. e. Insert the 15A fuse into the body housing. f. Attach the fuse cap over the fuse. AWARE Harness Fuse Cap 8 wire segment (Attach to battery feed) Figure 11 In-line fuse Fuse 3. Locate the 12V battery feed terminal source on the fuse panel designated terminal A and connect the 8 BATTERY wire.. NOTE: An I-terminal (eyelet terminal) is provided in the kit, which can be attached to the 8 wire for battery studs. 4. Locate the IGNITION (pink) wire from the AWARE harness. 5. Assemble the in-line fuse: a. Use the 5amp fuse for ignition. b. Follow the same assembly instructions as listed above for battery. 6. Locate the ignition feed terminal on the fuse panel designated terminal B and connect the 8 pink wire. NOTE: An I-terminal (eyelet terminal) is provided in the kit, which can be attached to the 8 wire for ignition studs. 7. Locate the GROUND (white) wire in the AWARE harness. 8. Locate the ground terminal source on the fuse panel designated terminal C and connect the GROUND (white) wire in the AWAREharness to it. 10 March 6 th, 2008
NOTE: An I-terminal (eyelet terminal) is provided in the kit, which can be attached to the white wire for ground studs. 5.2. J1939 Terminating Resistor 1. Locate the J1939 Terminating Resistor contained within the kit. 2. Locate the J1939 Terminating Resistor 3-pin connector near the two AWARE module connectors. 3. Attached the Terminating Resistor to the connector. J1939 Terminating Resistor Figure 3 - J1939 Terminating Resistor 5.3. Diagnostic Connector Route the J1708/J1587 twisted pair of wires (blue and gray) from the AWARE main harness under the driver side instrument panel to the diagnostic connector. Splice and heat shrink with a wire crimp, the J1708+ (blue) and J1708 (gray) wires of the AWARE main harness to the J1708+ (green) and J1708 (orange) terminals of the cab harness behind the 9-pin diagnostic connector. PIN Description Color A Ground White B Battery Violet C D E - - F J1708+ Green G J1708- Orange H - - J - - Figure 13-9 Pin Diagnostic Connector Pinout 11 March 6 th, 2008
1. Locate the Diagnostic Connector in the vehicle. It s located under the driver s side dash. There are two different installation methods depending if the Diagostic Connector is a 6-pin gray connector or a 9-pin black connector: a. 6-pin gray connector See Section 5.3.1 b. 9-pin black connector See Section 5.3.2 9-pin Diagnostic Connector Figure 14 9-pin Diagnostic Connector 12 March 6 th, 2008
5.3.1. 6-Pin Gray Connector In this method, a dedicated J1939 network will be created for the AWARE module. -&RQQHFWLRQZLWK$ZDUH+DUQHVV $%6+DUQHVV - &RQQHFWRU -$%6+DUQHVV - &RQQHFWRU - &RQQHFWRU 3LQ 'LDJQRVWLF &RQQHFWRU $ZDUH7HOHPDWLFV+DUQHVV 7HUPLQDWLQJ 5HVLVWRU - &RQQHFWRU $ZDUH 7HOHPDWLFV 0RGXOH Figure 15 6-Pin Diagnostic Connector, Configuration with J1939 ABS Harness 4. Attach the male J1939 connector on the ABS Harness to the female J1939 connector on the AWARE main harness. 5. Tie the female J1939 connector on the ABS Harness to the main cab harness. This connector is not used in this application. 6. Remove the 6-pin diagnostic connector. 7. Cut off all four wires close to the connector back shell. 8. Route the J1708/J1587 twisted pair of wires (blue and gray) from the AWARE telematics main harness to the diagnostic connector. 9. Splice and heat shrink with a wire crimp, the J1708+ (blue) and J1708 (gray) wires of the AWARE main harness to the J1708+ (green) and J1708 (orange) terminals of the cab harness behind the 9-pin diagnostic connector. 10. Re-terminate the four wires with the Deutsch terminals provided in the kit. 11. Insert the four wires in the 9-pin diagnostic connector that is part of the J1939 ABS harness. See the attached pin out chart for the 9-pin diagnostic connector as a guide. 13 March 6 th, 2008
12. Attach the 9-pin diagnostic connector to the instrument panel base rail in the same location that was taken up by the 6-pin diagnostic connector. PIN Description Color A J1708+ Green B J1708- Orange C Battery Violet D - - E Ground White F - - Figure 16-6-Pin Diagnostic Connector PIN Description Color A Ground White B Battery Violet C J1939+ Yellow D J1939- Green E - - F J1708+ Green G J1708- Orange H - - J - - Figure 17-9-Pin Diagnostic Connector 5.3.2. 9-Pin Black Connector 1. Route the J1708/J1587 twisted pair of wires (blue and gray) from the AWARE telematics main harness to the diagnostic connector. 2. Splice and heat shrink with a wire crimp, the J1708+ (blue) and J1708 (gray) wires of the AWARE main harness to the J1708+ (green) and J1708 (orange) 3. There is no J1939 datalink on the Acterra model. On vehicles equipped with 9-pin diagnostic connectors, use one of the following options. a. De-pin the J1939+ (Yellow) and J1939- wires from the 9-pin connector on the ABS Harness supplied in the AWARE kit and insert them into the appropriate cavities on the vehicle diagnostic connector as illustrated in Figure 17. b. Replace the 9-pin diagnostic connector attached to the vehicle with the ABS Harness supplied in the AWARE kit by either de-pinning the vehicle diagnostic connector or cutting the wires and re-terminating them with the supplied 14 March 6 th, 2008
diagnostic connector pins. Insert the terminals into the 9-pin diagnostic connector on the ABS harness as illustrated in Figure 17. 5.4. Accessory Equipment Monitoring Connection 5.4.1. Service Brake 1. Locate the wire labeled AD3 (gray) of the AWARE main harness. 2. Route AD3 wire to bulkhead connector BHB on cab harness. 3. Locate circuit number 36B (red with white stripe) in cavity 44 of the bulkhead connector. 4. Splice and heatshrink circuit AD3 to the service brake circuit 36B. Remember to configure with Diamond Logic Builder. 6. Antenna Installation 1. Locate flat surface under top dash cover that allows clearance of antenna fin and cover. 2. Clean area with a mild detergent and wipe dry. 3. Remove the backing from bottom of the antenna to reveal the adhesive surface. 4. Mount the antenna to the previously cleaned surface and press down to ensure good adhesion. Figure 19 Antenna mounting 5. Route antenna wires across dash and down through gauge cluster cavity to driver s side kick panel and in wire trough under door scuff plate. 6. Route GPS and Cell antenna wires to the module and wire tie any excess. GPS Antenna 15 March 6 th, 2008
Cellular Antenna Figure 20 Antenna routing CAUTION The routing of the AWARE antenna cable is extremely important. There must not be any kinks in the cable, and it must not be routed in such a manner as to make it susceptible to cuts in the outer insulator. Cuts and/or kinks in the cable will adversely affect AWARE signal reception and may permanently damage the AWARE module. 16 March 6 th, 2008
7. Driver Alert Switch Installation (Optional) 1. The recommended location for the Driver Alert Switch is an available switch opening to the right side of the instrument cluster. (If the recommended location is not available, select a location that is accessible to the driver but away from normal vehicle operation equipment.) Recommended Location Figure 4 - Switch location 2. Insert the Driver Alert Switch from the front side of the panel until it snaps securely in place. NOTE: If the driver alert switch does not fit into an open switch blank, look for another location to mount the switch. The recommended method to create a rectangular switch slot is to use a Green Lee Punch (P/N ZTSE4426 from SPX). 3. Connect the Driver Alert Switch connector to the switch mounted in the instrument panel. 4. Connect the small black 8-pin connector on Driver Alert Switch harness to the Aware TM telamatics main harness. 5. Locate the wire in the vehicle that feeds panel dim for the cluster or switches. 6. Locate the panel dimmer feed (blue wire) from the Driver Alert Switch harness. 7. Splice and heat shrink with a wire crimp, the blue panel dimmer wire from step 6 to accessory feed wire found in the vehicle in step 5. Remember to configure with Diamond Logic Builder 17 March 6 th, 2008
8. Software Upgrade Verify the module contains the latest version of software by using Diamond Logic Builder. Launch Diamond Logic Builder while connected to the Internet to ensure the latest version of Diamond Logic Builder software is downloaded onto the computer: 1. Connect your International EZ-Tech or other laptop with Diamond Logic Builder to the Internet 2. Launch Diamond Logic Builder. Once Diamond Logic Builder opens, the computer may be disconnected from the internet. 3. Turn ignition Key ON. 4. Attach the computer to the diagnostic connector in the vehicle using an EZ-Tech COM cable. 5. Allow Diamond Logic Builder to detect the vehicle and module. 6. On the Select Tab, highlight the VIN/Name 7. Under Module, highlight International Telematics 8. Select Tools, Get Data, Get Module Data 18 March 6 th, 2008
9. Select Edit, Update Software, Update Module a. If the screen displays a message Already at latest version, click the OK button and proceed to the next section. (The module already has the latest version of software). b. If the Status field next to VIN/Name updates to Unsaved Changes, perform the following steps. (The module needs upgraded to the newer version of Software as displayed in the selected module column): 1. Select File, Save 2. Select Tools, Program, Program Module 19 March 6 th, 2008
9. Configuration The follow section details how to configure the parameters by using templates. To configure the parameters manually, see Appendix A. 9.1. Download Templates 9.1.1. Dealers Templates can be downloaded from the ISIS web page http://service.navistar.com/ Select menu item: Technical Publications Select menu item: Aware Technical Publication Scroll down on the screen to view the list of templates. 9.1.2. Customers Templates can be downloaded from http://awaretechpubs.internationaldelivers.com/ Scroll down on the screen to view the list of templates. 9.2. Import Templates into Diamond Logic Builder 1. Click on the hyperlink for the applicable template. 2. After the File Download screen appears, select Save 3. After the Save As screen appears, select a folder you will remember. 4. At the bottom of the Save As screen, for Save as type select All Files 5. Select Save 6. Once the template file finishes downloading, go back to Diamond Logic Builder, and select File, Import 20 March 6 th, 2008
7. When the Open window appears, select the template file that was downloaded to the laptop and click Open. 8. The template will now appear at the bottom of the VIN/Name list 9.3. Apply Templates to module 9. Highlight VIN/Name 10. Under Module, highlight International Telematics 11. Select Edit, Apply Templates 12. Select the desired template 13. Checkbox only Parameters 14. Select Apply Selected Templates 15. Next to the VIN/Name, Status will change to Unsaved Changes 16. Select File, Save 9.4. Program Templates to module 17. Select Tools, Program, Program Module 21 March 6 th, 2008
10. Activation The module MUST be activated to communicate to the website. 1. Select Tools, Activate 2. Follow Diamond Logic Builder prompts. 3. On the bottom right side of the screen, State will update to: AWARE attempting to connect 4. Allow 10 minutes for the module to activate. 5. Upon activation of the module, the State will update to: AWARE activated 11. Final Assembly Steps 1. Locate all remaining blunt cut wires of the AWARE main harness. Wrap the wire ends in electrical tape to ensure no short circuits. Do not cut or remove the wires. 2. Reassemble any part of the truck that was taken apart to install the AWARE system. 22 March 6 th, 2008
A Program Parameters Manually Parameters can be programmed manually (instead of using templates) in Diamond Logic Builder through the following steps: Engine Operating Hours 1. Select Parameter: Engine Operating Hours Source Enter Value: J1587 Engine Retarder Status Source 1. Select Parameter: Engine Retarder Status Source Enter Value: J1587 Most Engines Engine Speed Source 1. Select Parameter: Engine Speed Source Enter Value: J1587 Fuel Level Source 1. Select Parameter: Fuel Level Source Enter Value: None J1939 Drivetrain Datalink 1. Select Parameter: J1939 Drivetrain Datalink Installed Enter Value: Uncheck checkbox Transmission Retarder Status 1. Select Parameter: Transmission Retarder Status Source Enter Value: J1587 Truck ABS Status 1. Select Parameter: Truck ABS Status Source Enter Value: J1587 Vehicle Distance Source 1. Select Parameter: Vehicle Distance Source Enter Value: J1587 Vehicle Speed Source 1. Select Parameter: Vehicle Speed Source Enter Value: J1939 Park Brake Source 1. Select Parameter: Park Brake Switch Status Source Enter Value: J1587 23 March 6 th, 2008
Driver Alert Switch (If the Driver Alert Switch has been installed, perform the next step.) 1. Select Parameter: Driver Alert Switch Installed Enter Value: Enable Service Brake (If service brake wiring has been performed, perform the next step) 1. Select Parameter: Analog 3 Mode Enter Value: Analog Battery/Ignition biased 2. Select Parameter: Analog 3 X Values Enter Values: 30, 30, 50, 70, 70 3. Select Parameter: Analog 3 Y Values Enter Values: 1, 2, 2, 2, 0 4. Select Parameter: Service Brake Switch Status Source Enter Value: General Purpose Input 3 5. Select File, Save 6. Select Tools, Program, Program Module 24 March 6 th, 2008
B AWARE Module LED Troubleshooting Table Indicated Items LED s A B C D Comments Power disconnected OFF OFF OFF OFF Sleep mode active Awake mode active Ignition is ON Internal Fault Detected Heartbeat Slow Flash Steady ON Fast Flash OFF OFF OFF - - - - - - - - - Highest priority for LED A. Indicates in Awake and Ignition modes also. GPS OFF - OFF - - GPS active - Slow - - Flash GPS acquired - Steady ON - - Cellular Modem OFF - - OFF - Cellular Modem signal - - Slow - strength (Low & no service) Flash Cellular Modem signal - - Steady - strength (High) ON Cellular modem transmitting data - - Fast Flash - Highest priority for LED C. Shall indicate for a minimum of 3 seconds. Communication on J1939 data link Cellular modem receiving data - - - Slow Flash - - - Fast Flash Highest priority for LED D. Shall indicate for a minimum of 3 seconds. Flash Rate Definition Heartbeat = 1 flash every minute Slow Flash = 1 flash every second Fast Flash = 4 flashes every second 25 March 6 th, 2008