AWARE TM VEHICLE INTELLIGENCE INSTALLATION MANUAL FOR INTERNATIONAL TRUCKS CXT, RXT, MXT, 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500 and 8600 For Models Built After 2007 MODULES ARE NOT ACTIVATED WHEN SHIPPED. PLEASE SEE THE ACTIVATION GUIDE. 1 March 6 th, 2008
TABLE OF CONTENTS 1. AWARE TM Vehicle Models... 3 1.1. Before Installing. 3 1.2. FCC RF Exposure Information.. 3 2. How the system works... 3 3. Kit Installation Components...4 3.1. HPV Kit Components.4 3.2. Driver Alert Kit Components (Optional)... 4 3.3. Fuel Tax Indicator Light Components (Optional). 4 3.4. Components Provided by Installer. 5 4. AWARE Module Installation. 5 5. AWARE Main Harness Installation... 8 5.1. Battery, Ignition & Ground 9 5.2. J1939 Connection. 10 5.2.1. J1939 Connection with Terminating Resistor.. 11 5.2.2. J1939 Connection with NO Terminating Resistor... 12 5.3. J1708/J1587 Connection.. 13 6. Antenna Installation. 14 7. Driver Alert Switch Installation (Optional)..16 8. Fuel Tax Reporting Indicator Light (Optional) 18 9. Software Upgrade 23 10. Configuration 25 10.1. Download Templates 25 10.1.1. Dealers. 25 10.1.2. Customers. 25 10.2. Import Templates into Diamond Logic Builder 25 10.3. Apply Templates to module. 26 10.4. Program Templates to module. 26 11. Activation. 27 12. Final Assembly Steps... 28 APPENDIX A Program Parameters Manually... 29 B Aware TM Telematics Module LED Troubleshooting Table... 30 2 March 6 th, 2008
1. AWARE TM Vehicle Models This installation procedure is for International XT and High Performance Vehicles built after 2007. Applicable models include International CXT, RXT, MXT, 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500 and 8600. Other vehicles may not be similar. 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. 3 March 6 th, 2008
3. Kit Installation Components 3.1. HPV Kit Components Kit Part Number: 2596821C91 3620482C91 AWARE module 366533291 AWARE main harness 3626207C1 Combined GPS & Cellular Antenna 380517091 Bracket, IP Module 3626208C2 Bracket, Antenna 31052R1 Bolt, M6 x 70mm, hex flange head 31081R1 Nut, M6, hex flange, PHC finish 31048R1 Bolt, M6 x 30mm, hex flange head 3544343C1 Nut, speed, M6 x 1, U-nut, short, locking 2027572C1 Wire crimps, Duraseal D-406-002 2590862R1 Activation Guide 0441-310-1605 Deutcsh Terminal Remover 3.2. Driver Alert Kit Components (Optional) Kit Part Number: 2589356C91 3593875C2 Driver Alert Switch 3594960C91 Driver Alert Switch Harness 3.3. Fuel Tax Indicator Light Components (Optional) Kit Part Number: 2592410C91 3803693C1 Light, Data Not Logged 3607384C1 Relay, Fuel Tax 3.4. Fuel Tax Indicator Light Components (Optional Datalink) Kit Part Number: 3672230P91 Part Number Part Description Quantity 3533928C1 Backlight LED, Amber 1 3587033C1 Amber Warning Light Assembly 1 3587034C1 Light, Amber LED, 3 Candlepower 1 3672232C1 Product Graphic, No Data Logged 1 NOTE: Either fuel tax kit may be used. The optional datalink kit is easier to install but requires 1 switch location in a datalinked switchpack to be available 4 March 6 th, 2008
3.5. Components Provided by Installer Assorted tie-wraps Splice kit crimp tool 3M double sided tape, 1/16 inch or thinner Green Lee Punch for standard rectangular Eaton/Cutler Hammer Switch (part number ZTSE4426 from SPX). Diamond Logic Builder Service tool for programming / provisioning module EZ-Tech COM cable (IC3 or IC4) 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 5 March 6 th, 2008
1. Remove the instrument cluster. Reference the Cab Master Service Manual for more information. The manual can be found on ISIS at evalue.internationaldelivers.com. 2. Cut the cable tie strap holding the vehicle s main cab harness to the IP Bar. The cable tie strap is fastened to the IP Bar through a mounting hole. Remove cable tie strap fully leaving the hole open. Remove cable tie strap IP Bar Figure 3 - Instrument Cluster Removed 3. Place U-nuts over the four end holes on the IP Bracket. 4. Insert IP Bracket over IP Bar. 5. Align IP Bracket hole with the IP Bar hole on the backside of IP Bar. (Hole is facing the front cab/engine wall.) Not Visible: IP Bar hole on back side of bar IP Bracket Figure 4 - IP Bracket on IP Bar 6 March 6 th, 2008
6. With the backside IP Bar hole aligned with the IP Bracket hole, drill a hole in the front of the IP Bar. Drill hole on front side of IP Bar Figure 5 - Drill hole in IP Bar 7. Insert bolt and finger tighten nut. TOP VIEW: Bolt & nut fastening the IP Bracket to the IP Bar Figure 6 - IP Bracket fastened to IP Bar 7 March 6 th, 2008
8. Connect the AWARE harness to the AWARE module with the two Deutsch connectors. The two connectors are keyed and should be aligned before inserting. 9. Align the module holes with the module upside down (LEDs facing down) and antenna connectors facing the driver s seat. 10. Secure module with fastening bolts through the module and U-nuts on the IP Bracket. 11. Tighten bolt and nut in the IP Bar until the bracket cannot move. Module mounted to IP Bracket Antenna connections facing the driver s seat Figure 7 - Module fastened to IP Bracket 5. AWARE Main Harness Installation 1. Remove the Center Panel Trim piece by pulling straight back to unfasten the mounting clips. 2. Remove the Storage Box by unfastening the clips on both sides. Center Panel Trim Storage Box Figure 8 - Center Panels to Remove 8 March 6 th, 2008
3. Remove the passenger side Fuse & Relay Close Out Cover by pulling the topside away from the instrument panel. Figure 9 - Exposed Fuse / Relay Close Out Cover 5.1. Battery, Ignition & Ground 1. Route the GROUND (white) wire into the center dash area. 2. Insert the GROUND wire into the GROUND (1003) Splice Pack located behind the Storage Box. NOTE: Verify the GROUND wire is connected to the GROUND Splice Pack, not the PANEL DIMMER Splice Pack that is located in the same area. Ground Splice Pack Figure 10 - Ground Splice Pack 3. If the GROUND splice pack is not available, locate the white ground circuit umber A11 in a switch pack pigtail harness. Cut and splice circuit using a wire crimp. 4. Route the BATTERY (red) and IGNITION (pink) wires through the dash panel into the Fuse & Relay area. 9 March 6 th, 2008
5. Find the spare BATTERY and IGNITION wires on the vehicle s cab harness, located on the left side of the Fuse & Relay area. The wires may be taped and strapped into place with wire ties. Remove the wire ties and tape from the blunt cut wires. Cab Harness Battery & Ignition Feed Cab Harness Figure 11 - Battery & Ignition Feeds Route Telematics Harness Battery & Ignition 6. Splice and heat shrink with a wire crimp, the Aware TM telematics main harness to the cab harness. Ignition Feed Battery Feed Figure 12 - Completed Battery & Ignition Splice 5.2. J1939 Connection (for vehicle using Air Brakes) 1. Route the 2-pin J1939 connector on the AWARE harness through the dash panel into the Driver kick panel area. 2. Locate the 2-pin J1939 Connector in the cab harness that is positioned near the rear of the cab ECU. (It will contain a YELLOW and GREEN wire twisted pair.) a. J1939 connector with terminating resistor See Section 5.2.1 (located here for vehicles with Air Brakes) 10 March 6 th, 2008
Cab Harness Figure 13 - J1939 Terminating Resistor Location on Cab Harness 5.2.1. J1939 Connection with Terminating Resistor 1. Disconnect the J1939 Terminating Resistor assembly from the cab harness connector. 2. Connect the J1939 Terminating Resistor to the 2-pin connector on the AWARE harness located near the AWARE module, next to the two module connectors. Figure 14 - J1939 Terminating Resistor on the Telematics Harness 3. Connect the J1939 connector on the AWARE harness to the J1939 connector on the vehicle s main cab harness. J1939 Connection J1939 Terminating Resistor Figure 15 - J1939 Connection between Cab & Telematics Harness 11 March 6 th, 2008
4. Proceed to Section 5.3 J1708/J1587 Connection 5.2.2. J1939 Connection (for vehicles using Hydralic Brakes) 1. Route the 2-pin J1939 connector on the AWARE harness through the dash panel into the driver kick panel area. 2. Locate the black 72 way pass-thru connector located in the engine compartment to the lower left of the steering shaft. Remove the dust cover and then unbolt the retaining bolt that holds the connector halves together. 72 way pass-thru connector 3. Once the connector is released, proceed to the inside half of the connector. Depin the green and yellow twisted pair J1939 wires from cavities 61 and 62 by removing the red terminal lock from the inside of the connector and then releasing the wires. Replace the wires with the J1939 wires in the Aware harness. Ensure that the green wire goes in cavity 61 and the yellow wire goes in cavity 62. 4. The wires that were removed from the 72 way pass-thru should now be placed in the adapter connector on the Aware harness. Remove the red connector lock and place the wires in the corresponding cavity so the green and yellow wires match when the connectors ends are assembled. 12 March 6 th, 2008
J1939 Connection on Vehicle Main Cab Harness J1939 Connector J1939 Connector Main Cab Harness J1939 Connection with Aware Harness & Extender Harness Main Cab Harness J1939 Connector J1939 Connector J1939 Extender Harness J1939 Connector J1939 Connector Main Cab Harness Aware Telematics Harness J1939 Connector J1939 Connector Aware Telematics Module 1. Proceed to Section 5.3 J1708/J1587 Connection 5.3. J1708/J1587 Connection 1. Route the J1708/J1587 twisted pair of wires (blue and gray) from the AWARE harness under the driver side instrument panel. 2. Locate the 9-pin diagnostic connector in the vehicle under the driver side instrument panel. 3. Remove pins F (Blue J1708+), and the G (Gray J1708-) from the back of the 9-pin diagnostic connector. Place removed pins into the 2-way connector provided on the Aware harness 4. Replace them with J1708 pins from the Aware harness. J1708 replacement pins 2-Way connector 13 March 6 th, 2008
PIN Description Color A Ground White B Battery Violet C J1939+ Yellow D J1939- Green E - - F J1708+ Blue G J1708- Gray H - - J - - 6. Antenna Installation 1. Remove outer trim ring from center panel. 2. Remove rectangular storage pocket. Remove outer trim Remove storage pocket Figure 16 - Antenna Location Overview 3. Place the bracket in the antenna pocket with the short bracket side facing up. Antenna Antenna Bracket Figure 17 - Antenna Bracket Placement 14 March 6 th, 2008
4. First mount the antenna to the bracket with the 3 screws provided in the kit. 5. Mount the antenna by screwing it to the bracket as shown in behind the secondary instrument cluster in the center console using the screw provided in the kit. Cables away from pocket Figure 18 - Antenna on Bracket 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. 6. Route the antenna cables in the cab along the AWARE main harness to the AWARE module. 7. Connect the antenna cables finger tight only. 8. Coil and tie wrap excess antenna cable lengths to the cab harness. Do not kink, pinch or tightly coil while securing excess antenna cable. 15 March 6 th, 2008
7. Driver Alert Switch Installation (Optional) 1. The recommended location for the Driver Alert Switch is the lower right section of the central instrument panel. (If the recommended location is not available, select a location that is accessible to the driver but away from normal vehicle operation equipment.) Center Panel Trim Storage Box Recommended Location Plastic Plate Figure 19 Driver Alert Switch Location 2. Remove the Center Panel Trim piece. 3. Remove the Storage Box. 4. Reach through the Storage Box location and outline the metal dash panel onto the back of the Plastic Plate to ensure the switch will mount without interference. 5. Remove the Plastic Plate. 6. The recommended method to create a rectangular switch slot is to use a Green Lee Punch (P/N ZTSE4426 from SPX). 7. Insert the Driver Alert Switch Connector from the backside of the Plastic Plate until it snaps securely in place. 8. Connect the small black 8-pin connector on Driver Alert Switch harness to the AWARE main harness. 9. Connect the panel dimmer feed (blue wire) from the Driver Alert Switch harness in the vehicle panel dimmer circuit splice pack. The vehicle panel dimmer circuit splice pack is located on the main cab harness in the Storage Box location. 10. If the vehicle panel dimmer circuit splice pack is not available, locate the blue dimmer feed circuit number A62 in a switch pack pigtail harness. Cut and splice circuit using a wire crimp. 16 March 6 th, 2008
Dimmer Splice Pack Figure 20 - Panel dimmer splice pack 11. Connect the Driver Alert Switch to switch connector mounted in the Plastic Plate. 12. Reinstall the Plastic Plate to the metal dash panel. Driver Alert Switch Figure 21 - Completed Driver Alert Switch Remember to configure with Diamond Logic Builder as defined in Section 10 Configuration. 17 March 6 th, 2008
8. Fuel Tax Reporting Indicator Light (Optional) 1. The recommended location for the fuel tax No Data Logged indicator light is the lower right section of the central instrument panel. (If the recommended location is not available, select a location that is accessible to the driver but away from normal vehicle operation equipment.) Center Panel Trim Storage Box Recommended Location Plastic Plate Figure 27 Fuel Tax light location 2. Remove the Center Panel Trim piece. 3. Remove the Storage Box. 4. Reach through the Storage Box location and outline the metal dash panel onto the back of the Plastic Plate to ensure the switch will mount without interference. 5. Remove the Plastic Plate. 6. The recommended method to create a rectangular switch slot is to use a Green Lee Punch (P/N ZTSE4426 from SPX). 8.1. Fuel Tax Indicator Light Components (Optional Datalink) If there are switch locations in an existing switchpack (as shown in figure 27) the Fuel Tax light can easily be added without adding any additional wiring in the truck. 1. Remove the switchpack where the light will be inserted using a DIN removal tool. 2. Remove the rear circuit board protector by using a regular screw driver and prying at the points indicated in figure 28. Start on one side of the switchpach and work your way to the other side gently prying the protector away from the switchpack housing. 18 March 6 th, 2008
Switchpack rear protector 3. Remove the switch blank by squeezing the two black tabs indicated on figure 29, (one on top and one on bottom) and pushing out Switchpack rear 4. Insert the No Data Logged indicator into the open switch location. Ensure that the switch pack is in the proper orientation. The top portion of the switchpack can be identified by looking on the back of the switchpack and noting where the white wire is coming out of the circuit board. Figure 29 shows a switchpack in the upright orientation. The white wire is on top of the circuit board. Also not the orientation of the LEDs; the LED s with the white base are the on indicators where the LED s with the black base are the backlight indicators that light the switch and indicator words. 5. Insert the backlight LED (black base) in the lower LED socket and the yellow (white base) in the upper socket. Note that the LED has an orientation that must be followed when inserting it in the socket. The slots on either side of the LED socket are different sizes. The orientation of the LED is important. If the LED is inserted improperly, it will not light up. Figure 30 and 31 show the LED s and the LED socket up close. The LED s only require a ¼ turn with a screwdriver to seat properly. 6. Once the LED s and the indicator light is installed and the rear circuit board protector has been reinstalled, snap the switch pack back into the dash panel. 19 March 6 th, 2008
7. Insert the No Data Logged light into the Plastic Plate until it snaps securely in place. Figure 22 No Data Logged light 8. Attach the No Data Logged connector from the fuel tax adaptor harness to the No Data Logged indicator light. Figure 23 No Data Logged connector 20 March 6 th, 2008
9. Crimp a splice pack terminal onto the white ground wire CHASGND1 of the fuel tax adaptor harness. 10. Insert the CHASGND1 wire into the GROUND (1003) Splice Pack located behind the Storage Box. NOTE: Verify the GROUND wire is connected to the GROUND Splice Pack, not the PANEL DIMMER Splice Pack that is located in the same area. a. If the GROUND splice pack is not available, locate the white ground circuit number A11 in a switch pack pigtail harness. Cut and splice circuit using a wire crimp. Ground Splice Pack Figure 24 - Ground Splice Pack 11. Splice the pink IGN circuit (ignition) from the fuel tax adaptor harness together with the pink IGN circuit (ignition) of the Aware main harness. 12. Crimp a splice pack terminal onto the blue PNL1+ circuit (panel dimmer feed) of the fuel tax adaptor harness. 13. Connect the blue PNL1+ circuit (panel dimmer feed) from the fuel tax adaptor harness to the vehicle panel dimmer circuit splice pack. The vehicle panel dimmer circuit splice pack is located on the main cab harness in the Storage Box location. a. If the vehicle panel dimmer circuit splice pack is not available, locate the blue dimmer feed circuit number A62 in a switch pack pigtail harness. Cut and splice circuit using a wire crimp. 14. Locate the grey PWMOUT2 circuit in the Aware main harness and crimp a relay connector terminal onto it. 15. Route the grey PWMOUT2 circuit to the relay connector on the fuel tax adaptor harness. NOTE: Depending on location of the fuel tax harness you may need to add additional wire to the PWMOUT2 wire to reach the relay in the fuel tax harness. 21 March 6 th, 2008
16. Insert the PWMOUT2 circuit into cavity 5 of the relay connector (Relay pin 85) of the fuel tax adaptor harness. Insert PWMOUT2 circuit Figure 25 Relay Connector 17. Ensure the relay is firmly connected after the terminal has been connected. Figure 26 Relay Connector with Relay 18. Secure the harness with cable ties. 22 March 6 th, 2008
9. 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 of the vehicle being programmed 7. Under Module, highlight International Telematics 8. Select Tools, Get Data, Get Module Data 23 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 24 March 6 th, 2008
10. Configuration The follow section details how to configure the parameters by using templates. To configure the parameters manually, see Appendix A. 10.1. Download Templates 10.1.1. 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. 10.1.2. Customers Templates can be downloaded from http://awaretechpubs.internationaldelivers.com/ Scroll down on the screen to view the list of templates. 10.2. 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 25 March 6 th, 2008
6. Once the template file finishes downloading, go back to Diamond Logic Builder, and select File, Import 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 10.3. Apply Templates to module 9. Highlight VIN/Name of the vehicle being programmed 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 10.4. Program Templates to module 17. Select Tools, Program, Program Module 26 March 6 th, 2008
11. 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 27 March 6 th, 2008
12. Final Assembly Steps 1. Coil and tie wrap the bundle of wires to the cab harness. 2. Reinstall the Storage Box. 3. Reinstall the Central Trim Panel. 4. Reinstall Fuse & Relay cover. Figure 27 - All Trim Panels Reinstalled 28 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: 1. Highlight VIN/Name of the vehicle being programmed 2. Under Module, highlight International Telematics 3. Select tab Features. 4. Select sub-tab AWARE. Driver Alert Switch (If the Driver Alert Switch has been installed, perform the next step.) 5. Select Parameter: Driver Alert Switch Installed Enter Value: Enable 6. Select File, Save 7. Select Tools, Program, Program Module to program the module 29 March 6 th, 2008
B AWARE Module LED Troubleshooting Table Indicated Items LED s Comments A B C D 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 30 March 6 th, 2008
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