Eaton Vorad RV Install Guide

Eaton Vorad RV Install Guide
Eaton® VORAD® AlwaysAlert®
Eaton® VORAD® SmartCruise®
Eaton® VORAD® BlindSpotter®
Installation Guide VOIG-0035 March 2004
Copyright Eaton Corporation, 2004.
EATON CORPORATION hereby grants its
customers, vendors, or distributors
permission to freely copy, reproduce and/or
distribute this document in printed format.
THIS INFORMATION IS NOT INTENDED
FOR SALE OR RE-SALE, AND THIS
NOTICE MUST REMAIN ON ALL COPIES.
Eaton VORAD Technologies, L.L.C.
13100 E. Michigan Avenue
Galesburg, MI 49053
U.S.A.
www.roadranger.com/VORAD
© 2004 Eaton VORAD Technologies, L.L.C.
All rights reserved.
Printed in USA
VOIG-0035
Visit our website www.roadranger.com/VORAD for additional information.
Or call 866-RV-VORAD (866-788-6723)
Table of Contents
General Information
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Antenna Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Sensor Display (optional system component) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Sensor (optional system component) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Central Processing Unit (CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Harness (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
3
3
3
3
Component Installation
Antenna Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Surface - License plate mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Surface - Front facia mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recessed - Mounted to bumper/facia from behind through cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selecting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Antenna Assembly Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Vertical Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horizontal Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CPU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Central Processing Unit (CPU) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Driver Display Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Driver Display Unit Installation Procedure - on dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Driver Display Unit Installation Procedure - in dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Side Sensor Display Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Side Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Side Sensor Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring Harness Connection to Vehicle Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Vehicle Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diagnostics
Road Test Check-Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Appendix
VORAD Harness Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Wiring Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cable Termination Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eaton VORAD System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Fault Codes - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
24
25
26
28
General Information
Forward/Reference Data
Forward
This reference guide explains installation of the Eaton® VORAD® System.
Reference Data
The Eaton VORAD family of products:
•
AlwaysAlert - front collision warning system
•
SmartCruise - adaptive cruise control
•
BlindSpotter - side radar lane change assistant
•
EVIMS - Eaton VORAD information management/accident reconstruction data recorder
Special Tools
To perform installation, you will need:
•
PC with the Eaton Service Ranger Diagnostic Software
•
PC with the VORAD Align Installation Software
•
Eaton vehicle link adapter VL-KIT-01
•
Digital level
•
Electrical connection crimping tool
Additional VORAD Literature
Visit the website http://www.roadranger.com or call 1-800-826-HELP.
•
EVT-300 Troubleshooting - VOTS-0030
•
EVT-300 Driver Reference Manual - VODR-0035
•
EVT-300 Illustrated Parts List - VOIP-0030
IMPORTANT NOTICE
This symbol is used throughout this manual to call attention to procedures where carelessness
or failure to follow specific instructions may result in personal injury and/or component damage.
1
General Information
General Information
The VORAD System can be installed on a variety of vehicles. Typical applications include heavy class 8 trucks, medium
duty trucks, transit and shuttle buses, RV motor homes, SUVs and passenger cars.
The VORAD System components and locations are shown below:
3
2
1
5
4
1 - Antenna assembly
2 - Side sensor display
3 - Side sensor
4 - Central Processing Unit
5 - Driver display unit
Antenna Assembly
The antenna assembly on the front of the vehicle transmits and receives low-power, high-frequency radar signals. The
transmitted radar signals are reflected by objects in front of the vehicle and received at the antenna assembly. The
antenna assembly compares the transmitted and received signals, converts this information into a digital format, and
transmits it to the Central Processing Unit for additional processing.
Side Sensor Display (optional system component)
The side sensor display contains red and yellow indicator lights. The yellow indicator light is on when there is no object
within the side sensor detection zone. When the side sensor detects an object, the red indicator light illuminates and the
yellow indicator light goes off. The side sensor display is usually mounted on the inside of the vehicle, in easy view by
the driver, and usually along the same line of sight as the mirror.
2
General Information
Side Sensor (optional system component)
A side sensor is a radar device that senses objects from 2 to 10 feet from the side of the vehicle. Side sensors are generally mounted at or near a blind spot.
Central Processing Unit (CPU)
The Central Processing Unit processes information from the antenna assembly, engine-control unit, speedometer,
optional side sensors, brake and turn signal circuits to produce audible and visual warnings.
Driver Display Unit
General Information
The driver display unit shows power-up conformation, speaker volume, range for vehicle warnings, and following distance for SmartCruise®.
Wiring Harness (not shown)
The main wiring harness connects all of the external inputs and the EVT-300 system components. A secondary wire
harness is supplied with the optional side sensors, to facilitate connection to the main system.
3
Component Installation
Antenna Assembly Installation
There are three antenna assembly mounting options to choose from (two surface and one recessed). To determine
which will work best, review the options and note that there are seven installation holes and one cable pass-through
hole required. These locations are easily established using the license plate mounting plate as a template.
The antenna assembly must be mounted on the centerline of the vehicle between fifteen (15) and forty-five (45) inches
from the ground.
Note: To locate the centerline, measure the distance between two reference points (e.g. headlights), and mark the center
on the surface with a vertical line.
4
Component Installation
Surface - License plate mount
1.
Attach mounting plate to license plate location.
CAUTION: Before drilling, check for any wiring, hoses and components that may be damaged by drilling and/or
mounting hardware.
2.
Drill needed holes though template.
3.
Attach antenna assembly to mounting plate.
4.
Attach fairing over antenna assembly.
Antenna Assembly
Installation
1
2
3
4
1 - Mounting plate
2 - Antenna assembly
3 - Fairing
4 - Adjustment screw accessed from the front
5
Component Installation
Surface - Front facia mount
1.
Locate mounting plate (template) at centerline above license plate and mark hole locations through template.
CAUTION: Before drilling, check for any wiring, hoses and components that may be damaged by drilling and/or
mounting hardware.
2.
Drill needed holes.
3.
Attach antenna assembly directly to bumper/front facia.
4.
Attach fairing over antenna assembly.
1
2
3
4
1 - Mounting plate used as template
2 - Antenna assembly
6
3 - Fairing
4 - Adjustment screw accessed from the front
Component Installation
Recessed - Mounted to bumper/facia from behind through cutout
CAUTION: Before drilling, check for any wiring, hoses and components that may be damaged by drilling and/or
mounting hardware.
1.
Measure antenna assembly at centerline of bumper and cut out shape in bumper.
2.
Determine which bracket configuration will work best and secure antenna assembly to bracket.
3.
Install brackets to RV such that antenna assembly fits through cutout.
1
2
Antenna Assembly
Installation
4
3
1 - Support rails not supplied (fabricated by installer)
2 - Adjustment screw accessed from the rear
3 - Antenna assembly
4 - Cutout hole
Selecting Hardware
When selecting the antenna assembly hardware, consider how the antenna wire harness is to be routed from the Central
Processing Unit to the antenna assembly. There must be room behind the antenna assembly for the antenna connector
to be attached to the rear of the antenna assembly. Care must be taken with the wiring harness, so it does not contact
sharp edges, moving or excessively hot parts.
After installation, align the antenna assembly (see Antenna Assembly Alignment on page 8).
7
Component Installation
Antenna Assembly Alignment
Note: Park the vehicle on a level surface. Make leveling compensations if necessary to ensure proper alignment.
Vertical Alignment
Adjust the antenna assembly to face down 0.50° from vertical.
Use a digital level held against the face of the antenna assembly.
1.
Using a 5/32 Allen wrench, slightly loosen the four screws that attach the antenna assembly to its mounting
brackets.
2.
Hold the antenna alignment tool or digital level against face of the antenna assembly.
3.
Adjust the two alignment screws on the right hand side of the antenna until the digital level indicates -0.50°
(down).
4.
Secure the antenna assembly by tightening the four locking screws with a 5/32 Allen wrench.
2
3
1
2
1 - Digital level
2 - 4 Allen screws that attach antenna assembly to mounting brackets
3 - Vertical alignment screws - up and down
8
Component Installation
Horizontal Alignment
1.
Select two vehicle reference points on the vehicle centerline that are identical and symmetrical. Ensure that the
reference points are equally aligned. Items such as fenders and headlights should not be damaged or distorted; otherwise, the alignment will be off.
2.
Place a long straight edge across the antenna assembly face. Center the straight edge horizontally.
3.
Measure the distance between the reference points and the face of the straight edge.
4.
Adjust the horizontal alignment screw until the two measurement points are equal.
5.
A more precise final alignment will be obtained by using the alignment software supplied with the VORAD system and allowing the software to calculate the required alignment adjustment while the vehicle is following
another vehicle on a straight section of highway. This can be done during the road test. See Road Test CheckOut Procedure on page 20.
1
1 - Horizontal alignment screw - side to side
9
Antenna Assembly
Installation
The antenna assembly must face straight ahead (azimuth) to detect objects out to maximum range traveling in the same
lane as the VORAD-equipped vehicle.
Component Installation
CPU Installation
Central Processing Unit (CPU) Installation
The CPU may be mounted in a variety of locations, such as under the dashboard, seat, or in the storage compartment,
depending on owner preference. The location must be away from elements; such as water. Pick a location that will facilitate easy routing of the main wiring harness to the other components.
+3˚
-3˚
+3˚
4
3
-3˚
1
2
1 - Storage Compartment
2 - Central Processing Unit
3 - Yellow orientation label
4 - Digital level
The CPU must be installed with the yellow label on the CPU pointing up. The mounting location should:
•
Allow for grounding the CPU to the chassis
•
Be out of the way of the driver and/or passenger
•
Allow for stowing any slack in the wiring harness.
1.
Locate the CPU on a stable, vibration-free surface, where the top of the CPU is within 3 degrees of level.
2.
Position the CPU as a guide for drilling the mounting holes.
CAUTION: Before drilling, check for any wiring, hoses or components that may be damaged by drilling and/or
mounting hardware.
10
3.
Install the CPU on the mounting surface, using four #10 star washers and four #10 x 3/4" self-tapping screws.
Alternative: Install the CPU using four customer-furnished, screws, washers and nuts.
4.
Attach the free end of the ground cable to chassis ground, either by using an existing screw or by using the
appropriate size self-tapping screw. Ensure that the ground cable is secured on an unpainted and rust-free
location out of the way of any obstructions.
Component Installation
Driver Display Unit Installation
Install the driver display unit where the driver can easily view and adjust the controls. Usually it will be on top of the
dashboard, flush with the front edge. For a more finished look, the display can be mounted in the dash, using the dash
bezel.
Consider the method chosen for routing the wiring harness to the driver display unit when determining the optimal location, but ease of operation and visibility of the driver display unit front panel are the primary considerations.
Driver Display Unit Installation Procedure - on dash
The following illustration shows a typical installation.
1.
Attach the driver display unit to the mounting bracket with the four supplied #6 x 5/16" self-threading screws.
2.
Use an alcohol-based cleaner on the surface where the driver display unit bracket will be installed.
3.
Attach the driver display unit mounting bracket to the desired spot on the dashboard.
4.
Secure the driver display unit bracket with screws if necessary. Four #6 x 5/16" screws are provided.
Driver Display Unit
Installation
1
2
3
4
5
1 - Driver display unit
2 - DDU mounting bracket
3 - Screws (qty. = 4- #6 x 5/16")
4 - Double-sided tape (part of DDU mounting bracket)
5 - Dashboard
11
Component Installation
Driver Display Unit Installation Procedure - in dash
1.
Use bezel as a template tracing the outer and inner side of the bezel face on the area of dash to be cut.
2.
Cut the dash between the two lines.
3.
Attach bezel to display and snap into cutout.
2
1
4
3
1 - Dashboard
2 - Cutout hole
12
3 - Driver display unit
4 - Screws (qty. = 2- #6 x 5/16")
Component Installation
Side Sensor Display Installation
8
7
9
10
1
2
1
1 - Side sensor display
2 - Self-tapping screw (optional)
3 - Bracket
4 - Lock washer
5 - Flat washer
4 5 6
3
3
4 5 6
6 - Acorn nut
7 - Adjustment angle
8 - Optional mounting (top view)
9 - Windshield
10 - Interior trim
CAUTION: Before drilling, check for any wiring, hoses, or components that may be damaged by drilling and/or
mounting hardware.
1.
The perspective from the driver's seat should determine the proper position of the bracket. If necessary, adjust
the bracket angle by bending the bracket to the desired angle.
2.
Install the side sensor display on the mounting studs, using the two #4 flat washers, two #4 lock washers, and
two #4-40 acorn nuts.
Note: Optional installation - bracket can be flipped over to allow insertion of the bracket between the windshield and the
interior trim.
13
Side Sensor Display
Installation
Install the side sensor display where the driver can easily see it. Usually, this will be on the windshield pillar of the vehicle, generally in the same line of sight as the side mirror, so that the driver can monitor both at the same time. If possible, use existing hardware on the windshield pillar to secure the side sensor display bracket. If existing hardware cannot
be used, drill a mounting hole. The following illustration shows a typical installation.
Component Installation
Side Sensor Installation
Install the side sensor where it provides maximum coverage of the driver's most vulnerable blind spot. The blind spot
should be determined manually. Have an assistant walk from the front to the rear of the vehicle and mark on the ground
where the driver loses sight of the assistant and then regains sight of the assistant as he or she continues to the rear of
the vehicle. When the front and rear limits of the blind spot have been established, place the side sensor on the vehicle
in the approximate middle of the front and rear limits.
For most vehicles, the primary blind spot is on the right side, behind the passenger door. A secondary side sensor can
be located on the right or on the left side of the vehicle. See the following illustration for suggested placement.
CAUTION: Other blind spot may exist; these are ONLY suggested locations for your side sensor.
CAUTION: If the sensor is mounted in a high splash/debris area such as a wheel well, a shield should be place
over the sensor for protection.
14"
28"
22"
15"
48"
Primary side sensor
OPTIMAL:
22" - 36" above ground
39" - 45" behind mirror
Secondary side sensor
OPTIMAL:
22" - 36" above ground
At least 48" away from
primary side sensor
Antenna assembly
OPTIMAL:
15" - 43" above ground
on vehicle centerline (required)
The side sensor should be mounted on the most outer section of the vehicle body, side fairing or step. In certain applications, the customer may have to fabricate a side sensor mounting bracket.
14
Component Installation
Side Sensor Installation Procedure
Drill four mounting holes in the side of the vehicle or bracket.
1.
Use the mounting bracket to trace the cutout for the sensor and mounting holes.
2.
Bolt the spacer to the sensor.
3.
Bring the sensor in from the rear and attach using four stainless steel Phillips screws supplied.
4.
Option - glue or rivet the sensor to the vehicle.
Side Sensor Installation
1
2
3
4
1 - Side sensor
2 - Spacer
3 - Side of coach
4 - Cutout hole
15
Component Installation
Wiring Harness Installation
Installation of the wiring harness should start from the CPU and then extend outward to the other components.
CAUTION: Avoid routing the wiring harness near sharp edges or extreme heat, which could damage wire insulation.
Route the wires along existing wires, up through existing pass-through holes or spaces in the floor or dashboard to the
installed components. Coil up the slack in the wire harness and store it neatly behind the dashboard or kick panels,
depending upon the location of the CPU. The following illustration shows a typical installation of the wiring harness.
1
2
3
4
5
1 - Driver display unit
2 - Side sensor display
3 - To side sensor and antenna assembly
4 - Central Processing Unit
5 - Ground strap
Note: Use the protective loom where necessary. Tie-wrap the harness for a secure/neat installation.
16
Component Installation
Wiring Harness Connection to Vehicle Wiring
Use the Butt connectors provided in this kit to connect the system wires to the existing vehicle wires (see VORAD Harness Schematics).
Parts:
Terminal, P/N 2B-14, Thomas & Betts®
Solder sleeve, P/N CWT-3805, Raychem®
Shrink tubing 5/16
1.
Cut the vehicle wire and slide a solder sleeve over the wire that will remain single. Install the solder sleeve so
the blue band is nearest the end just cut.
2.
Strip 3/8" of insulation from the end of the wires just cut and the wire to be added.
3.
Insert the single wire into one side of the terminal until the wire can be seen at the middle of the terminal.
Crimp the wire in place.
4.
Slide a 4" piece of heat-shrink tubing over the two other wires.
5.
Insert the two stripped wires into the other end of the terminal. Crimp the wires in place.
6.
Slide the solder sleeve over the crimped terminal until the solder ring is centered over the middle of the terminal. Use a heat gun to melt and shrink the solder sleeve over the terminal.
7.
Slide and center the shrink tubing over the solder sleeve. Use the heat gun to shrink the tubing.
Wiring Harness
Installation
2
1
3
1 - Shrink tubing
2 - Heat gun
3 - Wires
4
5
4
3
4 - Solder sleeve
5 - Solder ring
17
Component Installation
Vehicle Wiring Connections
Brake
Required ONLY if the vehicle does not have an SAE J1587 or J1939 data link connection: Connect the wire marked
“BRAKE” to the vehicle harness. Tap into the brake circuit so that current is sensed only when the vehicle service brakes
are applied.
Power
Connect the wire marked “IGNITION,” with the fuse holder, to an ignition switched power source so that the VORAD will
only power up, when the ignition switch is turned to the run position.
Turn Signals
The wires marked “RTURN” and “LTURN” are used only if mounting side sensors on the vehicle. In this case tap into the
turn-signal indicator circuits.
Note: Once the electrical connections are completed, excess slack in the wiring harness should be tie-wrapped and
stowed neatly behind the dash.
Ground
Connect the wire marked “PWR GND” to a battery negative location.
Diagnostic J1587 and J1939
On vehicles with an existing SAE J1587 diagnostic port: Connect the wire marked “1587POS” and the wire marked
“1587NEG” to the vehicle J1587 data bus. Splice into the positive and negative data lines behind the vehicle diagnostic
port. See the illustration on page 18 for location.
Note: On installations where a J1587 or J 1939 data bus is not on the vehicle, you will need to provide a vehicle speed
signal to the VORAD system. In this case the “SPEEDP” must be connected to an electronic speed pickup usually
located on the transmission or engine controller. See your vehicle OEM service dealer for assistance in identifying
an appropriate speed sensor signal. The wire marked “SPEEDN” is not used.
18
Component Installation
Backside of truck
J1939 Diagnostic Connector
J1587 Diagnostic Connector
F
B
A
E
E
F
C
A - J1587 Positive
B - J1587 Negative
C - Battery (+12)
D - Not used
E - Battery ground
F - Not used
C
B
A
G
D
D
J
H
F - J1587 Positive
G - J1587 Negative
H - Not used
J - Not used
A - Ground
B - Battery Positive
C - J1939 Positive
D - J1939 Negative
E - J1939 Shield
SmartCruise requires connecting the VORAD CPU to the SAE J1939 Data Link for control of the engine speed and Jake
Brake. See Appendix for Termination Procedure.
Wiring Harness
Installation
Central
Processing Unit
Engine ECM
UP
EATONVORAD
T E C H N O I O G I E S
EVT-300 COLLISION WARNING RADAR SYSTEM
EATONVORAD
T E C H N O I O G I E S
Eaton VORAD Collision Warning System
WARNING: READ DRIVER REFERENCE MANUAL PRIOR TO USE.
Model EVT-300, Forward Sensor Ferq. 24725 MHz
US Pantent Numbers 4,916,450; 5,181,038; 5,189,426; 5,280,288
Canadian Patent Numbers 1, 293,791 and other patents pending
1997 Eaton VORAD Technologies all rights reserved.
FCC ID: I3LEVT300
"CANADA" 2035102915
This device is sold under waiver of Canada and FCC Industry rules.
Any interference that may be caused should be reported to
your local FCC Feild Office or to the Federal Communications
Commission; Field Operations Bureau; 1919 W. St. NW;
Room 734, Mail Stop 1500; Washington, D.C. 20554-0001.
Manufactured by EATON VOARD Technologies, San Diego, California
Made in U.S.A.
Terminating
resistor
J-1939/11 data link
(OEM supplied)
Shield
termination
+
_
Terminating
resistor
19
Diagnostics
Road Test Check-Out Procedure
After completing the installation of the VORAD components, perform a test drive. It will be necessary to perform a final
alignment of the antenna. If vehicle speed is being obtained through the discrete speed input connected to a speed sensor on the vehicle (common configuration on automotive retrofit installations), it will also be necessary to calibrate the
speed signal. This can be done using a laptop PC and the align software provided with the system.
Insert the ignition key and turn it to the run position, the VORAD system will power-up and go into a self-test mode.
During this test mode the lights on the driver display will be on. After successful completion of the test the green power
light should remain on. If the systems fail to power up correctly the red fail light will be illuminated and diagnostics
must be performed to identify and correct the problem before proceeding. See the Trouble shooting section.
1.
If the VORAD system has the SmartCruise feature the green s/c light will remain on after power-up until the
brake peddle is depressed once.
2.
Depress range knob for two seconds; then release. Confirm demo tones and lights are output on the driver display.
3.
Side sensor test (if equipped with side sensors). Drive the vehicle and confirm that the side sensors are functioning as described:
The yellow light should be on when the ignition is on. When an object is within 2–10 feet of the sensor zone,
the red light should be illuminated. Note: Relative motion is required. The sensor will not issue audible tones if
the host vehicle is also stationary.
Calibrating the Discrete Speed Source
Note: Calibration is not required when using J1587 or J1939 as the speed source.
a.
Use the calibration function on the Alignment Program supplied by Eaton.
b.
Press Speedcal and follow procedure.
This tool checks the alignment of the VORAD antenna.
Alignment should be made to within 0.5 degrees.
A straight road is required.
1. Speed - recommend highway speed 50-65 MPH
2. Distance - follow at 200-300 feet
3. Data amount - recommend 2-5 miles or until the angle calcuation is stable
4. Pause in curves or traffic cut in/out
5. Try to match the lane position of target vehicle
Best vehicle to follow is a semi van trailer because of radar reflective
properties of the flat rear square surface.
OK
Realtime Angle (degrees)
0.12
Following distance (200-300 feet)
245
Turn rate (-0.3 left to 0.3 right)
0.0
Vehicle speed (50-65 MPH)
61
Calculated Average Angle
0.15
Adjust Alignment Screw
3/4 turn clockwise
CPU Serial Number
Start/Stop
20
Clear
Speedcal
Diagnostics
Dynamic Antenna Alignment Procedure
a.
Use Alignment Program supplied by Eaton.
b.
Press Start and follow procedure.
This tool checks the alignment of the VORAD antenna.
Alignment should be made to within 0.5 degrees.
A straight road is required.
1. Speed - recommend highway speed 50-65 MPH
2. Distance - follow at 200-300 feet
3. Data amount - recommend 2-5 miles or until the angle calcuation is stable
4. Pause in curves or traffic cut in/out
5. Try to match the lane position of target vehicle
OK
Realtime Angle (degrees)
Road Test Check Out
Best vehicle to follow is a semi van trailer because of radar reflective
properties of the flat rear square surface.
0.12
Following distance (200-300 feet)
245
Turn rate (-0.3 left to 0.3 right)
0.0
Vehicle speed (50-65 MPH)
61
Calculated Average Angle
0.15
Adjust Alignment Screw
3/4 turn clockwise
CPU Serial Number
Start/Stop
Clear
Speedcal
4.
Activate SmartCruise and confirm operation S/C light should come on when host is within 2 seconds of
another vehicle.
5.
Confirm that the Jake brake activates to maintain the appropriate following distance.
6.
Confirm audible alerts and that the audible alerts are canceled when the brakes are applied.
CAUTION: An operator must be driving the vehicle while an assistant performs the tests.
21
Appendix
VORAD Harness Schematics
Optional
Side Sensor
Antenna Assembly
(Left/Rear)
Side Sensor
Display Assembly
(Left/Rear)
Side Sensor
Antenna Assembly
(Right/Front)
Side Sensor
Display Assembly
(Right/Front)
1
Not
Populated
432
1
Not
Populated
ACB
432
ACB
Red
White
Black
Dk Green
Red
White
Black
Dk Green
White
Black
Violet
Grey
Brown/White
Black/White
Dk Grn/Yellow
Grey/Black
Yellow
Green
Black
4 3 21
DCBA
TOP
ABC
Terminating
resistor
Antenna Transmitter/Receiver
Assembly. Forward looking
22
Driver Display Unit
Appendix
Appendix
Central Processing Unit
For VORAD
diagnostics
9-way
Ground Harness
+12
Connect to Chassis volts
Ground
battery
Red
White
Black
Dk Green
Red
White
Black
Dk Green
White
Black
Violet
Grey
Brown/White
Black/White
Dk Grn/Yellow
Grey/Black
Yellow
Green
Black
C13
C12
C14
C16
D13
D12
D14
D16
C3
C4
C5
C6
D3
D4
D5
D6
D7
D8
D9
C7
C8
Yellow
Blue
Black
4 AMP fuse
(OEM: 5 AMP)
C1
Red
Ignition power (switched power)
run to main power lead that
feeds the ignition bus
C2
Black
Ground Run to Cab Ground Stud
C9
Orange
Brake Input (Optional)
Connect to Service Brakes
C15 Grey
Right Turn Signal Input
D15 Brown
Left Turn Signal Input
(Optional)
J-1939/11 data link
(OEM supplied)
Terminating
resistor
Battery
Ground
Red
6-way
Engine ECM
Shield
termination
J-1587 data link
Connect to
Engine ECM
J1587 Data Link
All OEM responsible wiring shown is "typical".
+12 volt non-switched from battery
+7.3 volt switched from Central Processing Unit
+12 volt switched from Ignition Switch
Signals into the CPU
Communication from and to the CPU
Signal returns, Grounds, and general OEM wiring
23
Appendix
Connector Wiring Quick Reference
GRAY (D)
BLUE (C)
1
D
C
Driver Display Unit
2
Antenna Transmitter/Receiver
VBUS Positive (D05)
Violet
VBUS Negative (D05)
Grey
Black/White
Negative (C04)
Dk Grn/Yellow
VBUS Positive (C05)
6
Black
Power (C03)
5
Negative (D04)
Brown/White
4
White
3
Power (D03)
Gray/Black
VBUS Negative (C05)
8
9
10
White
Power (D13)
Power (D13)
Red
Ground (D14)
Ground (D14)
Black
Side Sensor
Antenna Assembly
White
Red
Power (C13)
Power (C13)
14
Signal (D12)
Side Sensor
Display Assembly
13
Side Sensor
Antenna Assembly
11 12
Side Sensor
Display Assembly
Black
Ground (C14)
Ground (C14)
Dk. Green
Signal (C16)
Signal (C12)
15
RIGHT SENSOR
24
Dk. Green
16
Signal (D16)
LEFT SENSOR (Optional)
Appendix
Recommended Cable Termination Procedure
Remove cable outer jacket approximately 25 mm.
2.
Remove foil shield from exposed wires to within 2 mm of cable jacket.
3.
Strip insulation from data wires 7 ±0.8 mm.
4.
Attach adhesive filled solder sleeve and wire to drain wire per manufacturers recommendation OR attach
extended wire barrel socket contact to the drain wire.
5.
For the solder sleeve option, cut wire on solder sleeve to a length of 25 mm and strip the insulation on that
wire 7 ±0.8 mm.
6.
Crimp the appropriate terminal on each data wire and the solder sleeve wire OR extended socket per manufacturers recommendation.
7.
Slide adhesive filled shrink tube over cable end.
8.
Install terminals into connector body per manufacturers instructions.
9.
Install wedge in front of connector body per manufacturers instructions.
Appendix
1.
10. Apply shrink tube to end of connector body per manufacturers recommendation.
5
1
2
9
3
OR
4
6
7
8
Finished Assembly
9
1 - Shrink tube
2 - Drain wire
3 - Solder sleeve with wire
4 - Terminals
5 - Extended socket
1
6
6 - Plug
7 - Wedge
8 - Data wires
9 - Cable
25
Appendix
Eaton VORAD System Specifications
DESCRIPTION
VALUE
Vehicle Closing Rate
0.25-100 m.p.h., 0.4-160 km/hr.
Operating Range
3-350 feet, 0.9-110 meters (typical)
Host Vehicle Speed
0.5-120 m.p.h., 0.8-190 km/hr.
Power Requirements
12 to 24 Vdc, 20 watts (nominal)
Operating Frequency
Antenna Assembly
24.725 Ghz
Side Sensor
24.725 Ghz
Transmitted PF Power
3.0 milliwatts (typical)
Temperature Range
-40° to +188° F, -40° to +85° C
Vibration Range
7 G’s (10 to 2000 Hz, 5 grms)
Boresight Correction
±3°
System Accuracy
Range
5% ±3 feet
Velocity
1% ±0.2mp
Azimuth
±0.2°
ANTENNA ASSEMBLY
Height
6.45 in., 16.4 cm
Width
8.1 in., 20.6 cm
Depth
2.4 in., 6.09 cm
Weight
5.0 lbs., 2.25 kg
CENTRAL PROCESSING UNIT
Height
2.05 in., 5.2 cm
Width
7.5 in., 18.98 cm
Depth
7.18 in., 18.17 cm
Weight
2.0 lbs., 0.9 kg
DRIVER DISPLAY UNIT
Height
1.7 in., 4.3 cm
Width
3.65 in., 9.3 cm
Depth
4.125 in., 10.5 cm
Weight
0.33 lbs., 0.15 kg
26
Appendix
DESCRIPTION
VALUE
SIDE SENSOR
Height
1.7 in., 12.6 cm
Width
5.87 in., 14.86 cm
Depth
2.0 in., 5.06 cm
Weight
1.25 lbs., 0.57 kg
SIDE SENSOR DISPLAY
Height
1.45 in., 3.7 cm
Width
0.65 in., 1.65 cm
Depth
1.7 in., 4.3 cm
Weight
0.09 lbs., 0.04 kg
MISC. HARDWARE
Weight
1.0 lbs., 0.45 kg (approx.)
TOTAL SYSTEM
Weight
11.22 lbs., 5.05 kg (approx.)
Appendix
27
Appendix
Reading Fault Codes - Troubleshooting
Faults are logged in the system memory as fault codes. A complete listing of these fault codes is provided in the Fault
Code Table.
If the fail light is on when the VORAD system is powered up:
1.
Set the range knob to the minimum level.
Note: Inactive fault codes are displayed if the range knob is turned between ½ and full range position.
2.
Depress the volume dial and hold for six seconds.
3.
In a few seconds the error codes will begin to flash on the Driver Display via the fail light. The format of these
codes is two digits, with a two second pause between digits and a longer six second pause between fault
codes. Record these codes and repeat the process to ensure that the codes have been properly identified.
Diagnostic Codes
Code
Description
11
CPU Internal Failure
12
Memory Card or Card Reader
13
Wiring or Driver Display
14
Wiring or Antenna Assembly
15
Wiring or Right Side Sensor
16
Wiring or Left Side Sensor
21
No Right Turn Signal Input
22
No Left Turn Signal Input
23
No Brake Signal Input
24
No / Bad Speed Signal
26
Unrecognized Engine
27
Engine not Programmed for S/C
28
Less than Desired Retarder Output
31
J1587 Link Failure
32
J1939 Link Failure
33
Internal VBUS Failure
34
No Communication to Display
35
No Communication to Antenna
41
Last Fault Code / No Codes
28
Eaton® VORAD® AlwaysAlert®
Eaton® VORAD® SmartCruise®
Eaton® VORAD® BlindSpotter®
Installation Guide VOIG-0035 March 2004
Copyright Eaton Corporation, 2004.
EATON CORPORATION hereby grants its
customers, vendors, or distributors
permission to freely copy, reproduce and/or
distribute this document in printed format.
THIS INFORMATION IS NOT INTENDED
FOR SALE OR RE-SALE, AND THIS
NOTICE MUST REMAIN ON ALL COPIES.
Eaton VORAD Technologies, L.L.C.
13100 E. Michigan Avenue
Galesburg, MI 49053
U.S.A.
www.roadranger.com/VORAD
© 2004 Eaton VORAD Technologies, L.L.C.
All rights reserved.
Printed in USA
VOIG-0035
Visit our website www.roadranger.com/VORAD for additional information.
Or call 866-RV-VORAD (866-788-6723)
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