re-work gps-comm snow & ice manual - rexroth final 440rc controllers snow & ice installation...

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Installation\REXROTH - 2 - MARCH 2008

AWARETM VEHICLE INTELLIGENCE With

BOSCH/REXROTH 440RC CONTROLLERS

SNOW & ICE

INSTALLATION & CONFIGURATION MANUAL


Table of Contents

Procedure ..................................................................................................................................4 1.0 AwareTM Telematics Vehicles ..........................................................................................5 2.0 How the system works........................................................................................................5 3.0 Components .......................................................................................................................6 4.0 RS232 Cable Installation ....................................................................................................7

4.1 Aware Module Location (HPV Chassis).......................................................................7 4.2 Aware Module Connectors ..........................................................................................8 4.3.0 Rexroth "GPS" Cable to Aware RS232 Harness Connection………………………9 4.3.1 Rexroth "Comm" Cable to Aware RS232 Harness Connection………………….11 4.4 RS232 Cable Routing....................................................................................................13 4.4.1 Bosch/Rexroth Cable Installation………………………………………………….15

4.4.2 Bosch/Rexroth Cable & Aware RS232 Connection…………………………….17 5.0 Software Requirements ...................................................................................................17 5.1 Aware Module ..............................................................................................................17 5.2 Software Upgrade........................................................................................................18 6.0 Aware Module Configuration ........................................................................................20 7.0 Aware Module Configuration Installation ....................................................................21

7.1. Download Templates ..................................................................................................21 7.1.1. Dealers ....................................................................................................................21 7.1.2. Customers...............................................................................................................21

7.2. Import Templates into Diamond Logic® Builder .....................................................21 7.3. Apply Templates to module.......................................................................................22 7.4. Program Templates to module..................................................................................22

7.5. Activation .........................................................................................................................23 8.0 Bosch/Rexroth 440RC Controller Requirements...........................................................24 9.0 Bosch/Rexroth 44RC Controller - GPS Requirements ..................................................24 10.0 Road Temperature System Setup………………………………………………………...24 Appendix A - Aware Manual Parameter Programming ..................................................25 Appendix B - Aware Check List………………………………………………..…………….....26 Appendix C - Bosch/Rexroth Installation Check List…………...…………………………..27 Appendix D - Bosch/Rexroth Detailed Check List…..……………………………………....29


Procedure Aware System The following procedure will be used to install and upgrade the Aware System and Snow Plow equipped chassis:

• Install an Aware Kit (if required - Reference vehicle installations manuals)

• Upgrade the Aware Module Hardware (if required)

• Install the RS232 Jumper Harness

• Upgrade Aware Module Software (if required)

• Configure the Aware reporting parameters

• Activate the Aware Module

• Configure the Application Parameters

• Verify communication at the Aware Website

• Perform Aware Check List - Appendix B

Bosch/Rexroth 440RC Controller - Interface System

• Upgrade the software

• Configure Spreader Controller

• Install the Temperature Sensing Module

• Install Either the Rexroth "GPS" or "Comm" Interface Cable

• Perform Bosch/Rexroth Installation Check List - Appendix C

• Install the RS232 Jumper Harness


1.0 AwareTM Telematics Vehicles This installation procedure is for AwareTM Telematics, and the integration of the Bosch/Rexroth 440RC Controller. This installation procedure is for all vehicles equipped with an AwareTM Telematics Module, and a Bosch/Rexroth 440RC Controller.

2.0 How the system works The AwareTM Telematics module is a data collection, and communication system, which is mounted on a vehicle. It consists of a GPS, cellular antenna, and a data communicator module. The data communicator module collects the vehicle’s location, system information, and sends it to the network control center through wireless technology.

The Bosch/Rexroth 440RC Controller provides the operation for the Snow Plow Spreader functions. These functions may include, but are not limited to, the amount of granular material and pre-wet material that has been discharged.

An RS232 cable will be installed between the AwareTM Telematics module and the Bosch/Rexroth 440RC Controller on the vehicle. The AwareTM Telematics module communicates with the Bosch/Rexroth 440RC Controller via the RS232 cable. The data, which is collected by the AwareTM Telematics module, is then sent to the AwareTM Telematics website.


3.0 Components Recommended Parts

Navistar Interface Cable

Bosch/Rexroth Interface Cables

“GPS Cable” “Comm Cable” • P/N 238422 • P/N 1777252

OR

• 2027572C1 Wire Crimp – Duraseal • See Local Dealer Nylon Ties • See Local Electronics Store A DB9 Adapter is needed with use of the

Comm Cable

Note: It is preferred that the “GPS Cable” be used. This cable does not require a DB9 adapter, as with the “Comm Cable”

“Aware RS232 Interface Cable” • P/N 36643551C91


4.0 RS232 Cable Installation

4.1 Aware Module Location (HPV Chassis)

1) Locate the Aware module under the gauge cluster to the right hand side of the steering column. See Figure 1.

Figure 1


4.2 Aware Module Connectors

1) Once the Aware Module has been located, remove the black (J1) and grey (J2) connectors from the module. See Figure 2.

Figure 2


2) Remove the three white plugs in pin locations 7, 8, &11 of the black (J1) connector. See Figure 3. Then remove the orange lock from the connector. See Figure 4.

Figure 3

Figure 4

Pin 7

Pin 8

Pin 11

Remove Orange

Lock


4.3.0 Wire Installation – with Bosch/Rexroth “GPS Cable”

1) Install the red wire, from the RS-232 harness, into pin location 7 of the black (J1) connector. See Figure 5.

2) Install the green wire, from the RS-232 harness, into pin location 8 of the black (J1) connector. See Fig 5.

3) Install the black wire, from the RS-232 harness, into pin location 11 of the black (J1) connector. See Fig 5.

Figure 5

Bocsh/Rexroth “GPS Cable” to Aware “RS232 Harness”

NOTE: Not all of the RS232 wire harness colors are the same. Please refer to the above wiring diagram for correct pin out locations.

Circuit Color (RS-232 Cable)

Aware Module (J1 Connector)

RS-232 Serial Connector

RED 7 3 GREEN 8 2 BLACK 11 5

23

5

Rexroth 440RCController

P5 8-way23

5

Aware Harness

AwareTCU

78

11

23

5

23

5

Rexroth “GPS Cable”


4.3.1 Wire Installation – with Bosch/Rexroth “Comm” Cable

1) Install the red wire, from the RS-232 harness, into pin location 7 of the black (J1) connector. See Figure 6.

2) Install the green wire, from the RS-232 harness, into pin location 8 of the black (J1) connector. See Fig 6.

3) Install the black wire, from the RS-232 harness, into pin location 11 of the black (J1) connector. See fig 6.

Figure 6

Circuit Color (RS-232 Cable)

Aware Module (J1 Connector)

RS-232 Serial Connector

RED 8 3 GREEN 7 2 BLACK 11 5

Bosch/Rexroth “COMM Cable” to “Aware Harness”

23

5

Rexroth 440RCController

P5 (8-way)23

5

Aware Harness(NOTE Must swap wires to TCU)

AwareTCU

78

11

23

5

23

5

Rexroth “Comm Cable”

2

3

5

2

3

“DB9” Adapter

5

NOTE: If the “Comm” cable is used, a “DB9” adapter must be used to connect the two cables, which can be purchased at your local electronics store. Not all of the RS232 wire harness colors are the same. Please refer to the above wiring diagram for correct pin-outs.


4) NOTE: If a grey wire, HF9V (18GY), is in pin location 11, create a splice between wire HF9V (18GY) and the wire from pin #5 of the Aware RS-232 wire harness as in Figure 6.

Figure 6

5) Use a Duraseal crimp connector to create the splice as require. Check the crimp, by slightly pulling on the crimped wires. If any wires pull out of the crimp, perform the crimp again with a new crimp connector. Then use a heat gun to shrink the Duraseal around the crimp.


4.4 RS232 Cable Routing

0) Install the RS232 harness from the Aware Module along the instrument panel (IP) harness towards the passenger side of the cab and thru the fuse panel. Figure 7

Figure 7

1) Run the RS232 harness from the fuse panel down through the passenger side kick panel Figure 8. If needed, remove the right

side kick panel to install the wire harness.

Figure 8

Remove RH Kick Panel If

Needed


2) Remove the passenger side scuff plate. See Figure 9.

Figure 9

3) Install the RS232 harness under the scuff plate towards the rear of the

cab interior. See Figure 10.

Figure 10


4.4.1 Bosch/Rexroth Cable Installation

1) Locate the back side of the Bosch/Rexroth 440RC and the P5

P5 GPS/DIG Connector/Terminal port. See figure 11

Figure 11

2) Install the Bosch/Rexroth “GPS” or “Comm” cable to the P5 GPS/DIG Connector/Terminal port. See figure 12

Figure 12

3) Install the Bosch/Rexroth “GPS” or “Comm” Cable from the back side to the 440 Controller with the existing snow plow wire harnesses.

“GPS” or “Comm” Connector

P5 GPS/DIG Connector


4) Locate the Bosch/Rexroth 440RC RS232 connector in the wire harness. Note: This connector can be located anywhere in the Bocsh/Rexroth wire harness. See Figure 11.

Figure 11

Bosch/Rexroth 440RC RS232 Connector

Figure 12


4.4.2 RS232 & Aware Module Connection

5) Connect the RS232 connector from the Aware module, and from the Bosch/Rexroth 440RC Controller wire harnesses. Fig 13. Install the connectors together, start one of the retaining screws by a couple of threads, then start the second retaining screw. Once the screws have been started, continue to tighten the screws. CAUTION: DO NOT over tighten the two retaining screws as they can be damaged easily.

Figure13

RS232 Connector End Bosch/Rexroth RS232 From Aware Module Connector End 5.0 Software Requirements 5.1 Aware Module The software for the Aware Module must be loaded with version 97 or higher. Note: The Aware Module software must be installed on a 512k module with S/N 53958xxxx or higher.


5.2 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 (IC4) 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


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


6.0 Aware Module Configuration The Aware Module must be configured with the following parameter values:

Parameter Description Parameter Default

Parameter Value

Snow Plow Error Message Repeat Interval

First Occurrence Interval


Snow Plow Disabled Enabled Snow Plow Periodic Report Interval 1 1

Snow Plow Rexroth Lane Compensation

0, 100, 100, 100, 100, 100, 100, 100, 100, 100

0, 100, 100, 100, 100, 100, 100, 100, 100, 100

Spreader Controller Selection None Rexroth 440RC

Please refer to Appendix A for manual programming instructions.

Dealers

This manual is in ISIS, http://service.internationaldelivers.com/, under Technical Publications. Select Aware Technical Publications. In the Manual and guides, find the Aware Parameter & Configuration Manual guide.

Customers

This manual can be found from the Aware Vehicle Intelligence Customer Website, http://AwareTechPubs.internationaldelivers.com/. In the Manual and Guides, find the Aware Parameter & Configuration Manual guide.


7.0 Configuration Installation The follow section details how to configure the parameters by using templates.

7.1. Download Templates

7.1.1. Dealers Templates can be downloaded from the ISIS web page http://service.internationaldelivers.com/ Select menu item: Technical Publications Select menu item: Aware Technical Publication Scroll down on the screen to view the list of templates.

7.1.2. Customers Templates can be downloaded from http://AwareTechPubs.internationaldelivers.com/ Scroll down on the screen to view the list of templates.

7.2. 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…

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

7.3. 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

7.4. Program Templates to module 17. Select Tools, Program, Program Module


7.5. 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:

AwareTM telematics attempting to connect 4. Back the vehicle outside and allow 10 minutes for the module to activate. Note: Keep clear of any obstructions that will interfere with the GPS/Cellular antenna. 5. Upon activation of the module, the State will update to:

AwareTM telematics activated


8.0 Bosch/Rexroth 440RC Controller Requirements

The Bosch/Rexroth 440RC Controller is located on the vehicle and must be loaded with the following software version or higher.

Description Software Revision Bosch/Rexroth Firmware xxxxxG

Note: The Snow Plow ECU can be at a different software revision than the controller software. No software revision is required for the Snow Plow ECU.

9.0 Bosch/Rexroth 440RC Controller - GPS Requirements The Bosch/Rexroth 440RC controller GPS requirement will need to be configured. Set the 440RC controller with the below settings:

10.0 Road Temperature System Setup The Road Temperature Module from Bosch/Rexroth must be installed on the vehicle for this function to work. Set the 440RC Controller with the below settings:

Description Default Value: Normal Operation

Temperature System Setup: 1) Turn programming side key ON 2) Select: Sensors & Values 3) Select: Temp Sensor 4) Set Sensor value to desired

00

01 (Roadwatch)

02 (Controls)

Description Default Value: Normal Operation

GPS Configuration: 1) Turn programming side key ON 2) Select: System Setup 3) Select: Control Mode 4) Set GPS value to 01 5) Press enter to save 6) Turn programming side key OFF

No

YES


Appendix A

A. Manual Parameter Programming Parameters can be programmed manually, instead of using templates, in Diamond Logic Builder through the following steps:

1. Highlight the VIN/Name of the vehicle to be programmed. 2. Under module, highlight the International Telematics. 3. Select the Features tab. 4. Select the Aware sub-tab

Snow Plow Features: Note: This section is for the specific accessories or unique aspects of a Bosch/Rexroth Snow Plow installation. 5. Select the parameter: Snow Plow Error Message Repeat Interval Enter Value: First Occurrence Interval 6. Select the parameter: Snow Plow Feature Enable Enter Value: Enable 7. Select the parameter: Snow Plow Periodic Report Interval Enter Value: 1 8. Select the parameter: Snow Plow Rexroth Lane Compensation Enter Value: Line 1) 0 2) 100 3) 100 4) 100 5) 100 6) 100 7) 100 8) 100 9) 100 10) 100 9. Select the parameter: System Selection Enter Value: 3 (Rexroth 440RC) 10. Select File, and then Save. 11. Select Tools, Program, to program the Aware Module.


Appendix B

Aware Installation Procedure Checklist The following quality control checklist should be completed for every Aware installation and/or upgrade. The steps are arranged so that they can be checked off as you proceed through a typical Aware installation.

Installation Step Complete

1) Install an Aware Kit (if required – Reference vehicle installations manuals)

2) Upgrade the Aware Module Hardware (if required)

3) Install RS232 Jumper Harness

4) Upgrade Aware Module Software (if required)

5) Place key in ignition and check each Aware LED as follows:

Verify LED A is on solid Verify LED B is either slowly flashing or on solid Verify LED C is not on Verify LED D is slowly flashing

6) Configure the Aware reporting Parameters

7) Configure the Application Parameters

8) Verify Parameter changes in Diamond Logic Builder 9) Confirm Aware Module activation in Diamond Logic

Builder under “Tools-Activate” => the “State” will read “Aware Telematics Activated” (lower left of screen)

10) Place key in ignition and check each Aware LED as follows:

Verify LED A is on solid Verify LED B is on solid Verify LED C is on solid Verify LED D is slowly flashing

11) Login to Aware Customer account or contact Aware Customer Support (1-888-883-5362, option #4) to verify each of the following:

Verify communication by polling vehicle details – check that the data is post-installation

Verify parameter settings match those installed Verify software version on all vehicles


Appendix C

Bosch/Rexroth Snow Plow Installation Checklist This section is for the specific accessories or unique aspects of a Bosch/Rexroth Snow Plow installation.

Aware TCU The Aware TCU software must be configured with the following parameter values:

Parameter Description Value: Normal

Operation

Complete

1) Snow Plow Error Message Repeat Interval


2) Snow Plow Enable/Disable Enabled

3) Snow Plow Periodic Report Interval

1

4) Snow Plow Rexroth Lane Compensation

0, 100, 100, 100, 100, 100, 100, 100, 100, 100

5) Spreader Controller Selection

Rexroth 440RC

Bosch/Rexroth 440RC Controller - Interface System Use the following MASTER CHECKLIST in conjunction with the DETAILED CHECKLISTS that follow as noted.

Master Checklist

Installation Step Complete

1) Upgrade the Bosch/Rexroth 440RC Controller Software – xxxxxG or Higher

2) Install the Temperature Sensing Module – complete Detailed Checklist 1


Bosch/Rexroth 440RC Controller GPS Requirements The Bosch/Rexroth 440RC Controller GPS must be configured.

Road Temperature System Setup The Bosch/Rexroth Road Temperature System must be configured.

Description Value: Normal Operation

Completed

Temperature System Setup: 1) Turn programming side key ON 2) Select: Sensors & Values 3) Select: Temp Sensor 4) Set Sensor value to desired

01 (Roadwatch)

02 (Controls)

Description Value: Normal Operation Completed

GPS Configuration: 1) Turn programming side key ON 2) Select: System Setup 3) Select: Control Mode 4) Set GPS value to 01 5) Press enter to save 6) Turn programming side key OFF

Yes


Appendix D

Bosch/Rexroth Detailed Checklist Bosch/Rexroth 440RC Controller Software

Note: The snow plow ECU can be at a different software revision than the controller software.

Bosch/Rexroth 440RC Controller GPS Requirements The Bosch/Rexroth 440RC Controller GPS must be configured.

Road Temperature System Setup The Bosch/Rexroth Road Temperature System must be configured.

Description Completed Temperature System Setup: 1) Turn programming side key ON 2) Select: Sensors & Values 3) Select: Temp Sensor 4) Set Sensor value to desired

Description Software Revision Complete Bosch/Rexroth Firmware xxxxxG or Higher

Description Completed GPS Configuration: 1) Turn programming side key ON 2) Select: System Setup 3) Select: Control Mode 4) Set GPS value to 01 5) Press enter to save 6) Turn programming side key OFF

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