road relay 4

RoadRelay™ 4

InstallationGuide

RoadRelay™ 4Installation Guide

Bulletin No. 3401767Revision B

Copyright© 2002, Cummins Inc. All rights reserved.

Cummins Inc. shall not be liable for technical or editorial omissionsherein; nor for incidental or consequential damages from the furnishing,performance, or use of this material.

For technical assistance with installation or the use of theRoadRelay™, call:

1-800-433-9341 in The USA0800-286646 in the United Kingdom+1-812-3778136 for international calls

To make your call go as smoothly as possible, please make sure you havethe 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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ContentsOverview...........................................................................................5

Mounting Choices .........................................................................................................5

On-Dash Installation .........................................................................6Tools Needed................................................................................................................6Identify Components .....................................................................................................7Starting On-Dash Installation ........................................................................................8Choosing a Location.....................................................................................................8

In-Dash Installation......................................................................... 12Tools Needed..............................................................................................................12Identify Components ...................................................................................................13Starting In-Dash Installation ........................................................................................14Preparing Location......................................................................................................14Cutting the Hole ..........................................................................................................15

Under-Dash Installation .................................................................. 18Tools Needed..............................................................................................................18Identify Components ...................................................................................................19Starting Under-Dash Installation .................................................................................20Choosing a Location...................................................................................................20

Standard Installation....................................................................... 24Checking Voltage........................................................................................................25Locate Fuse Panel......................................................................................................25Locate Battery or Unswitched Voltage........................................................................26Locate Switched or Ignition Voltage............................................................................27Locate Lights-on Power ..............................................................................................28

Connecting the Electrical Wiring ................................................... 30Connect to Battery Voltage.........................................................................................31Connect Switched Power............................................................................................33Connect Lights-on Power ...........................................................................................35Connect the Ground ...................................................................................................37Locate the J1587 Data Link ........................................................................................38Connect Data Link Wires ............................................................................................39Switching Data Link Wires ..........................................................................................42Finish Installation ........................................................................................................43Installing the Loop-back Connector ............................................................................43

RoadRelay Options......................................................................... 46

Troubleshooting.............................................................................. 48

Connector Pin Assignments........................................................... 52

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Overview

The RoadRelay™ 4 is a vehicle monitoring system that works with allelectronic engines. The unit collects, analyzes, and saves vehicle data inmemory.

Mounting ChoicesInstallation 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-DashInstallation

Tools NeededThese tools are needed for the standard on-dash installation:

1. 3/8-inch electric drill2. 1/4-inch bit3. 1-1/8-inch bit (or hole saw)4. Medium screwdriver5. Small screwdriver6. Large pliers7. Adjustable wrench8. Set of nut drivers9. Wire cutter10. Multimeter or other DC voltage meter

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RoadRelay™ 4 Installation Guide

Identify ComponentsBefore starting, lay out all of the items in the on-dash kit and account foreach. If you are missing any of the following, check with the dealer whosold you the unit.

1. RoadRelay 4 unit2. Bracket3. Thumb screws (2)4. Power and data link cable assembly5. Fuse assembly (red)6. Fuse assembly (white)7. Fuse assembly (green)8. Wire with terminal (black)9. Wire connectors (2)10. Wire splices (4)11. Wire ties12. 2-inch x 2-inch wire seal patches (2)13. Mounting hardware14. Jack nut wrench

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On-Dash Installation

Starting On-Dash InstallationIf all of the components are accounted for, and you have the necessarytools, you are ready to begin.

WARNING: Remove rings, bracelets, watches or other conductiveitems before working on the system.

IMPORTANT: Before making any electrical connections to vehiclepower, disconnect the positive and negative cables from the battery.Check the vehicle electrical system to make sure the power is off beforeproceeding.

Choosing a LocationThis chapter covers units mounted on the vehicle dash or roof. (For in-dash or under-dash mounting, see later sections of this guide.) Choose alocation that is both visible and accessible for operation. For bestviewing, the unit should be facing the driver and within easy reach.

IMPORTANT: For safety purposes, do not mount the unit in anylocation that will obstruct the driver’s vision.

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Temporarily install the mounting bracket. Position the unit in the desiredmounting location. Leave sufficient room for the cable. While holdingthe unit in position, mark the location of the mounting bracket with apencil or tape. Also, mark the hole for the cable (if necessary).

If possible, route the cable to the underside of the dash without drilling ahole. 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 toprotrude into the dash area when the bit breaks through the surface, asserious damage could result.

Remove the bracket from the unit. Position the bracket on the dashaccording 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 nutsare used). Install the bracket with the fasteners supplied in the installationkit.

CAUTION: Carefully drill the holes in the dash. Do not allow the drillto protrude into the dash area when the bit breaks through the surface, asserious damage could result.

Continue with "Standard Installation" and "Connecting the ElectricalWiring" sections.

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In-DashInstallation

Tools NeededThese tools are needed for the standard in-dash installation:

1. 3/8-inch electric drill2. 1/4-inch bit3. 1-1/8-inch bit (or hole saw)4. Medium screwdriver5. Small screwdriver6. Large pliers7. Adjustable wrench8. Set of nut drivers9. Wire cutter10. Multimeter or other DC voltage meter11. Torx driver

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Identify ComponentsBefore starting, lay out all of the items in the in-dash kit and account foreach. If you are missing any of the following, check with the dealer whosold you the unit.

1. RoadRelay 4 unit2. Nuts (2)3. Power and data link cable assembly4. Fuse assembly (red)5. Fuse assembly (white)6. Fuse assembly (green)7. Wire with terminal (black)8. Wire connectors (2)9. Wire splices (4)10. Wire ties11. 2-inch x 2-inch wire seal patches (2)

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In-Dash Installation

Starting In-Dash InstallationIf all of the components are accounted for, and you have the necessarytools, you are ready to begin.



Preparing LocationThis chapter covers units mounted in the vehicle dash. (For on-dash orunder-dash mounting, see other sections of this guide.) Choose alocation that is both visible and accessible for operation. For bestviewing, the unit should be facing the driver and within easy reach.

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Cutting the Hole

NOTE: Before cutting the hole, make sure there are no obstructionsunder that area of the dash, such as cables or brackets, which mightinterfere with mounting the RoadRelay unit.

Cut a 7.17-inch wide by 2.08-inch high rectangular hole in the dash atthe chosen location.

CAUTION: Carefully cut the hole in the dash. Do not allow the drill toprotrude into the dash area when the bit breaks through the surface, asserious damage could result.

Route the cables through the rectangular hole in the dash at the chosenlocation. (Wiring the electrical connections is described in theConnecting the Electrical Wiring section.)

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In-Dash Installation

Adjust the side latches on each side of the unit to correspond to thethickness 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.


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16

Under-DashInstallation

Tools NeededThese tools are needed for the standard under-dash installation:

1. 3/8-inch electric drill2. 1/4-inch bit3. 1-1/8-inch bit (or hole saw)4. Medium screwdriver5. Small screwdriver6. Large pliers7. Adjustable wrench8. Set of nut drivers9. Wire cutter10. Multimeter or other DC checker

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Identify ComponentsBefore starting, lay out all of the items in the under-dash kit and accountfor each. If you are missing any of the following, check with the dealerwho sold you the unit.

1. RoadRelay 4 “data logger” unit2. Bracket3. Thumb screws (2)4. Power and data link cable assembly5. Fuse assembly (red)6. Fuse assembly (white)7. Fuse assembly (green)8. Wire with terminal (black)9. Wire connectors (2)10. Wire splices (4)11. Wire ties12. 2-inch x 2-inch wire seal patches (2)13. Mounting hardware14. Jack nut wrench

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Under-Dash Installation

Starting Under-Dash InstallationIf all of the components are accounted for, and you have the necessarytools, you are ready to begin.



Choosing a LocationThis chapter covers the flat face paneled “data logger” units mountedunder the vehicle dash. (For in-dash or on-dash mounting, see earliersections of this guide.) The “data logger” RoadRelay 4 unit differs fromthe on-dash and in-dash installed units in that there is no driver interfacewith the unit. It may even be preferable for the unit to be oriented so asto be undetectable by the driver.

In this installation, choose a location that is far enough underneath thedash that it will not be visible or noticeable to the driver.

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Temporarily install the mounting bracket under the dash in the chosenlocation. Make sure that the unit, when installed into the bracket, will beout of the driver’s line of sight. But do not install the unit so far underthe dash that the electrical hookups cannot be easily accomplished, or thecabling is crowded.

While another person holds the unit in position, mark the location of themounting bracket with a pencil or tape.

Remove the bracket from the unit. Position the bracket under the dashaccording 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 nutsare used). Install the bracket with the fasteners supplied in theinstallation kit.

CAUTION: Carefully drill the holes in the dash. Do not allow the drillto protrude into the dash area when the bit breaks through the surface, asserious damage could result.


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StandardInstallation

The following procedures will help you identify battery voltage,switched voltage, lights-on power, and chassis ground at the fuse panelor ignition switch.

The vehicle electrical system must have battery power for you to makethe following checks. If you disconnected the battery, reconnect thecables.

Reconnect the positive battery cable first; negative last. Check thevehicle electrical system to make sure it is receiving power.

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Checking VoltageFor the following procedures, you will need a multimeter. Set the meterto read DC voltage. If a meter is not available, a 12-volt tester can beused. It is also possible to make a tester using a 12-volt lamp socket andlamp. The lamp socket must have two wire leads.

Locate Fuse PanelIn most vehicles, the fuse panel will be located somewhere in the cab.Also, most fuse panels will have a terminal area where the wires areconnected.

NOTE: The RoadRelay connections should always be made to the busside of the fuse or circuit breaker.

If the fuse panel is a circuit breaker type of panel or does not haveavailable terminals, test the vehicle wiring just alongside the panel untilsuitable connection points can be found. These wires should be the wiressupplying the bus, not the wires supplying vehicle equipment.

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Standard Installation

NOTE: Most panels will have a “battery hot” (continuous 12 VDC)connection on them. This connection should be used, if available. Somepanels 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 switchedpower is supplied in the “ignition ON” position. No voltage is present inthe ACCESSORY position.

Locate Battery or Unswitched VoltageUsing the multimeter or test lamp, check the terminals of the selectedswitch or electrical accessory for a 12-volt source. When you find a12-volt source, turn the ignition switch ON and OFF several times. If thispower source is continuous, it can be used for battery or unswitchedpower. Identify the terminal location with a piece of tape.

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Locate Switched or Ignition VoltageStart this check with the ignition switch in the OFF position. Again,using the multimeter or test lamp, check for the terminals of the selectedswitch or electrical accessory for NO VOLTAGE. When you locate aterminal that shows NO voltage, turn the ignition to the ON position.

When you find a terminal that powers up with the ignition in the ONposition, check it by turning the switch ON and OFF several times.Check the terminal with the ignition in the ACCESSORY position. Theterminal must not have power in this position. If this source iscontinuous while the switch is in the ON position, it can be used forswitched or ignition voltage. Identify the terminal location with a pieceof tape.

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Standard Installation

Locate Lights-on PowerTurn the ignition switch to the OFF position. Turn the vehicle lights ON.Using the multimeter or test lamp, check for the terminals of the selectedswitch or electrical accessory for a 12-volt source.

When you find a terminal that shows 12 VDC with the ignition OFF andthe lights ON, turn the lights OFF. The meter should show NO voltagewith the lights turned OFF. Identify the terminal location with a piece oftape.

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If you have not already done so, route the cable assembly from thedisplay unit to the underside of the dash in the area of the fuse panel.You should route through an existing opening, if one is available, orthrough the 1-1/8-inch hole drilled previously under "Choosing aLocation".

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) fromthe RoadRelay unit.

For installations using a bracket, position the RoadRelay in the bracket,and install the thumb retainer screws.

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Connecting theElectrical Wiring

The cable assembly has six wires:Single wires:

RED = Battery voltageWHITE = Switched voltage (ignition)GREEN = Lights-on switchBLACK = Ground

NOTE: It is not necessary to connect the green wire for the under-dashinstallation of the “data logger” RoadRelay unit.

Twisted pair:

BLACK = DL Data lineRED = DLI Data line

NOTE: Cut off the bare wire that is with the twisted pair.

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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 theholder. Remove the nut from the fuse panel battery connection, whichwas determined earlier. Place the fuse ring terminal on the terminal, andreplace 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 ofthe fuse wire. Cut off any unnecessary length of cable wire.

NOTE: Fuses must be used in the switched and unswitched powerlines.

Locate one of the wire splices. Insert the ends of the cable assembly wireand 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 areseated in the splice.

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Connect Switched Power

NOTE: The system will only operate correctly when the switched poweris on (the ignition switch is in the ON position). No voltage is presentwhen the ignition switch is in the ACCESSORY position.

Locate the fuse with the WHITE wires. Remove the fuse from theholder. Remove the nut from the terminal for switched power on thefuse panel, which was determined earlier. Place the fuse ring terminal onthe terminal, and replace the terminal nut.

Locate the WHITE wire in the cable assembly. Pull the wire to the areaof the fuse wire. Cut off any unnecessary length of cable wire.

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Connect Lights-on Power

NOTE: For the under-dash installation, this connection is not necessarysince that unit does not have a display.

The source for this signal is the lights control. Power is applied when thevehicle lights are ON.

Locate the fuse with the GREEN wires in the kit. Remove the fuse fromthe holder. Remove the nut from the fuse panel lights controlconnection, which was determined earlier. Place the fuse ring terminalon the terminal, and replace the terminal nut.

NOTE: The lights-on discrete will dim the display brightness when thevehicle’s lights are ON. Discrete input shall be considered “on” whenvoltage is greater than 3.0 (+/- 0.5) VDC.

Locate the GREEN wire in the cable assembly. Pull the wire to the areaof the fuse wire. Cut off any unnecessary length of cable wire.

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Connect the Ground

IMPORTANT: Do not use a ground connection that is shared byanother electrical component. Choose an existing screw or bolt on themetal area in the vehicle cab, or on the chassis, for the groundconnection. If a suitable fastener can not be found, drill a small hole, andinstall a sheet metal screw.

Locate the BLACK wire with ring terminal. Attach the wire terminal tothe selected vehicle ground screw or stud. Tighten the ground retainersecurely.

NOTE: Use a star washer under the ring terminal on all groundlocations to ensure a good ground connection.

Locate one of the wire splices. Insert the ends of the cable assembly wireand the BLACK ground wire into the splice. Using a large pair of pliers,compress the splice button until it is flush.


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Locate the J1587 Data Link

Locate the J1587 public data link connection in the vehicle:

NOTE: See the section Connector Pin Assignments for data linkconnectors, line identification, and vehicle data link location.

IMPORTANT: If you are unsure about the data line identity, STOP!Contact a local Cummins Dealer for help.

The data link connector may be covered with a flexible split conduit.Open the conduit and pull the connector and wires several inches out.

NOTE: If there are more than two wires leading into the connector, thedata line will be a twisted pair of wires.

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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 maynot 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 spliceshave a slit in one side to fit over an existing wire and a hole in the otherside to accept the end of a wire. Position the splices over the data linkwires 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 describedabove (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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Using a large pair of pliers, as shown, compress the splice blade intoposition. Close the locking tab.

IMPORTANT: There are several more installation steps that must becompleted. However, before finishing the installation:

• Check the RoadRelay display for correct operation.• Check the terminals to make sure they are tight.• Check the ground connection.• Check the area to verify that no wires touch.• Make sure the keyswitch is in the OFF position.

Insert the fuses into the three fuse holders.

Turn the keyswitch to the ON position. The display should come on andshow the introduction screen.

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If there is no display, press the “Up” arrow key several times to brightenthe display. Or, if the display is too bright, press the “Down” arrow keyto dim it. The display should now come on; check the switchedconnection for power.

After pressing the “Up” arrow key several times, the RoadRelay displayshould come on; if it did not, check the unswitched (battery voltage)connection and the ground connection.

Check for correct switched and unswitched connections. Turn theignition to OFF. If the RoadRelay shuts off immediately, the switchedand unswitched connections are reversed. The RoadRelay should shutoff only after a 30-second delay, which indicates the correct switchedand unswitched connections.

With the display on, start the engine.

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If the RoadRelay unit displays “Improper Data Link Connection,” thedata link is wired incorrectly (backwards).

Switching Data Link Wires

Shut OFF the engine. Using the pliers, carefully pull the metal blade upin both wire splices. Exchange the data link wires. Using the pliers, seatthe metal blade in both splices.

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Finish InstallationStart the engine and check for proper operation of the display. If thedisplay responds to the running engine by displaying engine data, finishthe installation. If the display still does not work correctly, verify thatthe RoadRelay is properly connected to the data link lines.

The data link splices must be sealed to prevent corrosion. Locate the two2x2-inch black sealant patches in the kit. Peel the white sheet off thesealant patch, and place the patch around the wire splice and wires, asshown. Squeeze the two halves of the patch together to seal the splicejoint. Seal both splices.

Installing the Loop-back ConnectorConnect the loop-back 10-pin connector (Packard Part No. 12064770) tothe mating 10-pin vehicle connector (Packard Part No. 12064769) fromthe RoadRelay unit.

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NOTE: The RoadRelay may display “No power from back-up battery”if the loop-back 10-pin connector has not been installed to its matingconnector from the RoadRelay unit.

NOTE: In situations where primary power (vehicle battery) will bedisconnected from the RoadRelay 4, the backup battery should also bedisconnected. This can be done by removing the loop-back connectorfrom the RoadRelay 4. Failure to remove the connector may result in adead backup battery. Some data will be lost when the connector isremoved.

Loop-Back Connector

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RoadRelay Options

GPSRoadRelay 4 supports optional Global Positioning System (GPS)circuitry. If the GPS option is purchased, install the GPS antenna byscrewing onto the connector provided at the rear of the RoadRelay 4.Make sure it has unobscured visibility to the sky through the windshieldor mount outside of the vehicle. The cable should be secured under thedash where it will not interfere with the normal operation of the vehicle.

Option For Printer HookupA printer kit is also available and can be ordered from your nearestCummins Distributor. The Part No. for the printer kit is 4005923.Note: This cable contains the loop-back connection normally providedby the loop-back connector.

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TroubleshootingIntroductionThis is a basic guide to troubleshooting common problems with theRoadRelay unit.

Tools NeededUse a digital multimeter to measure voltages and resistances.

Reading No. 1 is the only resistance reading listed. The rest of thereadings are for DC voltages. Readings No. 4 and No. 5 are data linkmeasurements that fluctuate with the data that is moving across theconnection, but the readings should be close to those listed below.

The following table lists the readings that should be taken whentroubleshooting RoadRelay wiring problems:

Troubleshooting Wiring Problems

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ReadingNo.

RRPigtailWireColor

Connctr.Cavity

PositionSignal DVM Reading

1 Black A GroundBetween Position A & Truck,Ground

2 White B Battery ++12 VDC

Between Position A & B,Constant +12 VDC

3 Red CKeyswitch On

+12 VDCBetween Position A & C, Ign On,+12 VDC

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


General Troubleshooting Procedures

Check the readings listed in the Troubleshooting Wiring Problems table(see previous page) when you encounter one of the RoadRelay problemslisted below:

1. RoadRelay does not illuminate when the ignition is switched on.Procedure Fault

Check Reading No. 1 Open to tractor groundCheck Reading No. 2 No +12 VDC presentCheck Reading No. 3 No +12 VDC with ignition switch

in the ON position

2. RoadRelay illuminates only after the ignition switch is turnedon several times.

Procedure FaultCheck Reading No. 2 No +12 VDC with ignition switch ON onlyCheck Reading No. 3 +12 VDC present at all times OR only

when the ignition switch is turned on

3. RoadRelay goes blank right after the ignition switch is turned off.Procedure Fault

Check Reading No. 2 +12 VDC with ignition switch ON onlyCheck Reading No. 3 +12 VDC present at all times

4. RoadRelay illuminates even when the ignition switch is turned off.Procedure Fault

Check Reading No. 2 +12 VDC present at all times (normal)Check Reading No. 3 +12 VDC present at all times (incorrect)

5. RoadRelay displays “Data Link Timeout.”Procedure Fault

Check Reading No. 4 Make sure the voltages are within thespecified ranges

Check Reading No. 5 Make sure the voltages are within thespecified ranges

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Troubleshooting

6. After initial hook-up, the RoadRelay displays “Improper data linkconnection.”

Procedure FaultSwitching Data Link Wires The data link wires have been wired backwards

7. After initial hookup, the RoadRelay displays “No power fromback-up battery.”

Procedure FaultFinish Installation The loop-back connector has not been installed

to its mating 10-pin connector from theRoadRelay 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 areconnected to one of two connectors running to the engine data linkconnector on the dash. Make sure the RoadRelay data lines areconnected to this data line connection. See sections "Locating the J1587Data Link" and "Connect Data Link Wires".

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50

ConnectorPin AssignmentsRoadRelay Cablesand Connectors:

Pin Assignments: 10-Pin Vehicle Connectorwith Mating Loop-back10-Pin Connector

6-Pin Vehicle Connector Side view of loop-back 10-pin connected to vehicle 10-pin

A = Battery (-)B = Battery (+)C = Switch PowerD = J1587 (-)E = J1587 (+)F = Lights-On Discrete

3-Pin J1939 Connector

A = J1939 (+)B = J1939 (-)C = J1939

Common

10-Pin Vehicle Connectorwith Mating Loop-back10-Pin Connector

Side view of loop-back 10-pinconnected to vehicle 10-pin

A = Battery (-)B = Pull-up wake-up #1

(CTS)C = Pull-up wake-up #2D = RS-232 RXD

Port 2E = RS-232 RXD

Port 1F = RS-232 TXD

Port 1G = OutputH = Pulldown wake-upJ = Back-up Battery(-)K = RS-232 TXD

Port 2

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Note: Because the J1939 data link option is not currently supportedwith a connector in the kit, the RoadRelay unit’s third cable assemblyconnector (3-pin) is not used.

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