X5 Service & Troubleshooting Guide - btcgps.com · such as metal farings. The X5 Dome may be...

X5 Service & Troubleshooting Guide HARDWARE/SOFTWARE

09.28.2011

2 © XATA Corporation

This document is for informational purposes only, and does not constitute a warranty or representation of any kind. Each customer is responsible for selecting what reporting is required by their business and assuring that such reports are accurate and complete. XATA Corporation reserves the right to make changes to this manual and the information contained herein without prior notice to the customer.

No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose without the express written permission of XATA Corporation.

In no event will XATA Corporation be liable for direct, indirect, or consequential damages resulting from the use of this document or any defect in the hardware or software described herein, even if it has been advised of the possibility of such damages. In some states, the laws do not allow the exclusion or limitation of implied warranties or liabilities for incidental or consequential damages, so the above limitation or exclusion may not apply. Copyright, XATA Corporation, 2011. All rights reserved. XATA is a registered trademark of XATA Corporation.

XATA Corporation

965 Prairie Center Drive

Eden Prairie, MN 55344

(952) 894-3680

Document Number: XA-6070, Rev. F

© XATA Corporation 3

Federal Communications Commission Regulations

Warning:

Changes or modifications to equipment not expressly approved by the party responsible for compliance could void the user’s authority to operate this equipment.

RF Exposure Warning:

When installed as directed, the equipment complies with radiation exposure limits for general population/uncontrolled exposure. To ensure user’s safety and to satisfy RF exposure requirements for mobile transmitting devices, this unit must be installed so that a minimum separation distance of 33 cm (13 inches) is always secured between the transmitting structure and the body of the user or nearby persons.

NOTE:

This equipment has been tested and found to comply with the limits for Class B digital devices, pursuant to Part 15 – Radio Frequency Devices - of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced Radio/TV technician for help.


Table of Contents

Introduction .......................................................................................................................... 8

X5 Hardware Components ..................................................................................................... 9

Locating the Hardware Part and Serial Numbers ........................................................................ 13

Maintaining Your X5 Mobile Unit ......................................................................................... 14

Hardware Locations and Wiring ................................................................................................ 15

Calibration ................................................................................................................................ 16

Step 1: Prepare for Calibration ...................................................................................................... 16

Step 2: Calibrate a Vehicle ............................................................................................................ 18

Step 3: Calibration Transmission Status ........................................................................................ 21

Troubleshooting the Mobile Unit ......................................................................................... 24

Before You Call Support ............................................................................................................ 24

Driver Display Troubleshooting & Reboot Processes .................................................................. 24

Access Diagnostic Screens & X5 Troubleshooting ....................................................................... 26

Breakout Box Troubleshooting .................................................................................................. 27

Power Issues Troubleshooting ................................................................................................... 28

X5 Slim Case Lights ......................................................................................................................... 29

Interpret Mobile Unit System Messages .................................................................................... 30

Reboot Messages ........................................................................................................................... 30

Communication Messages ............................................................................................................. 31

GPS Messages ................................................................................................................................ 31

Other Messages ............................................................................................................................. 32

Table of Contents


Interpret Diagnostic Information ............................................................................................... 33

OBD II Troubleshooting ............................................................................................................. 37

Hino Converter Troubleshooting ............................................................................................... 37

Hardwired PTO Troubleshooting ............................................................................................... 38

Wiring Configurations and Diagrams ............................................................................................. 39

Direct Air Switch Wiring Diagram .................................................................................................. 39

Electric Over Air Diagram – Integrated Indicator Light .................................................................. 41

Electric Over Air Diagram– Separate Indicator Light ..................................................................... 42

Air Switch Connections – No Indicator Light ................................................................................. 43

Test Message Waiting Light (if installed) .................................................................................... 44

Replacing Mobile Unit Hardware – RMA Process .................................................................. 45

Removing/Replacing Hardware ........................................................................................... 46

Replace a Driver Display ............................................................................................................ 46

Step 1: Remove the Driver Display ............................................................................................... 46

Step 2: Replace the Driver Display ................................................................................................ 48

Remove and Replace a Breakout Box......................................................................................... 50

Step 1: Remove the Breakout Box ................................................................................................ 50

Step 2: Replace the Breakout Box ................................................................................................. 52

Mount the Breakout Box ............................................................................................................... 54

Remove and Replace a Vehicle Power Wiring Harness ............................................................... 55

Step 1: Remove the Vehicle Power Wiring Harness ..................................................................... 55

Step 2: Replace the Vehicle Power Wiring Harness ...................................................................... 56

Replace a Driver Display Cable .................................................................................................. 59

Step 1: Remove a Driver Display Cable ......................................................................................... 59

Step 2: Replace a Driver Display Cable ......................................................................................... 60

Replace a Drop Cable ................................................................................................................ 62

Step 1: Remove a Drop Cable ....................................................................................................... 62

Table of Contents


Step 2: Replace the Drop Cable .................................................................................................... 64

Replace an X5 ........................................................................................................................... 67

Step 1: Retrieve Vehicle Data from the Existing X5 ...................................................................... 68

Step 2: Remove X5 Hardware from Vehicle .................................................................................. 69

Step 3: Install the Replacement X5 ............................................................................................... 71

Step 4: Remove the old X5 from XATANET ................................................................................... 73

Step 5: Add the Replacement X5 to XATANET .............................................................................. 75

Step 6: Check Vehicle Setup Status ................................................................................................ 77

Step 7: Complete a Test Trip ......................................................................................................... 79

Step 8: Add the X5 to Exec (for Forms Messaging only) ............................................................... 80

Exec for Windows .......................................................................................................................... 80

Remove and Replace the Message Waiting Light ....................................................................... 84

Step 1: Remove the Message Waiting Light Assembly ................................................................. 84

Step 2: Replace the Message Waiting Light Assembly .................................................................. 84

Remove and Replace the Message Light Harness ....................................................................... 86

Step 1 Remove the Message Light Harness ................................................................................... 86

Step 2: Replace the Message Light Harness ................................................................................. 87

Decommissioning a Vehicle ....................................................................................................... 88

Redeploy on a New Vehicle ....................................................................................................... 90

Troubleshooting Forms Messaging ....................................................................................... 91

Forms Messaging Data Issues .................................................................................................... 91

Technical Support ................................................................................................................ 94

XATA Solution Support.............................................................................................................. 94

General Information ................................................................................................................. 94

Escalating an Issue .................................................................................................................... 94

Appendix A: Setup on Exec for AS/400 or Exec for Web ........................................................ 95

Create a Unit Profile on Exec for Web ........................................................................................... 95

Table of Contents


Create a Unit Profile on Exec for AS/400 ....................................................................................... 96

Appendix B: Forms Messaging Maintenance Menu ........................................................... 100

Motion Interlock ..................................................................................................................... 101

PLN Point Display .................................................................................................................... 102

Discretes Port ......................................................................................................................... 103

Vehicle Bus Status .................................................................................................................. 104

Current Position ..................................................................................................................... 105

ADV Config ............................................................................................................................. 106

AVL Rate ................................................................................................................................. 107

Appendix C Test Message Waiting Light ............................................................................ 108

Appendix D Micronet CE Wiring Overview ......................................................................... 109

X5 Mobile Unit Troubleshooting Form ............................................................................... 110


Introduction

The XATANET Service & Troubleshooting Guide provides information on the components of the X5 XATANET system and how they work together, as well as how to maintain and troubleshoot the system.

This guide explains:

• X5 mobile hardware components, including where they are installed and what they do.

• Various system messages that may display on the Driver Display and why.

• Solutions to the most common problems with the X5 mobile unit.

• How to remove and replace X5 hardware.

• How to return X5 hardware.

If you are unable to solve your issue, technical support information is listed at the back of this manual.

The X5 system consists of mobile hardware and software that is connected through cellular or WiFi to the XATANET web application. Information is sent back and forth between the X5 mobile units and the XATANET web application.

The XATANET web application is available through Internet browser on a PC. It is used to view and analyze data from the X5 mobile units. It also sends routes, messages and other information to the Mobile Units. This application also is often called a “Host” because it hosts all the customer data.

The XATANET web application also is used to create reports and manage driver, vehicle, and route information.


X5 Hardware Components

XATANET Mobile Unit refers to the system installed on a vehicle. Mobile Units collect data entered by the driver, sent from the engine, and from its own GPS radio, and transmits it to XATANET. It also receives data from XATANET, such as routes, driver logs, and messages.

The table below provides an overview of each component of the X5 Mobile Unit.

Item Function Location Image

X5 Onboard Computer –

Dome

(dual mode)

Contains radios, software, and data storage.

Works with satellite, cellular, and Wi-Fi communications

Depends on the vehicle type and if there are obstacles to transmission, such as metal farings. The X5 Dome may be mounted to the top, back, or catwalk. On a straight truck, it may be mounted on the front of the cargo box towards the top.

X5 Onboard Computer –

Slim Case

(single mode)

Contains radios, software, and data storage.

Works with cellular and Wi-Fi communications

The X5 Slim Case is mounted inside the cab and uses a wireless antenna mounted externally for communications.

External antenna

(X5 Slim Case only)

Usually mounted on top of the cab.

X5 Service & Troubleshooting Guide



Mounting Brackets

Used to mount the X5 Dome on the vehicle.

Under the X5 Dome.

Back Mounts are installed on the back of tractor, typically on a sleeper, extended cab, or when something inhibits a roof mount.

Generally, on the back of the cab.

A roof mount is most common for day cab installation.

The Mounting Platform Bracket is used with Roof Brackets when a reefer is directly over the cab.

Centered on top of the roof oriented so to allow access to the underside from both sides of the bracket.

A catwalk adapter is used with a roof-mount bracket on straight trucks that include a refrigeration unit and a maintenance catwalk.

Mounted as an extension of the catwalk. This allows the X5 to be out from under the reefer unit to obtain the best signal.

X5 Slim Case back mount

X5 Slim Case roof

mount

Locating the Hardware Part and Serial Numbers



Breakout Box

This is the interface between the vehicle’s power supply and ECM, and the system.

Generally, the Breakout Box is installed inside the cab of the truck. This part should NEVER be installed in the engine compartment. The easiest way to locate this part is to trace either the drop cable or the Driver Display cable.

Driver Display

The driver’s computer used to login in/out, record trip status and delivery information. Shows system diagnostic information. Not included at the Basic/Bronze level.

NOTE: The Driver Display software also can run on handheld devices. XATA has certified select devices to operate with the XATANET Onboard System.

It is typically mounted on the dashboard.

For handhelds, the cradle is typically mounted on the dashboard.

TREQ®-L

TREQ®-M4

CE-507

CE-504

Drop Cable Connects the X5 to the Breakout Box

Down from the X5, along the back of the cab.




Display Cable

Connects the Breakout Box to the Driver Display.

Connects to the Driver Display, and generally runs through the dash to the Breakout Box.

TREQ-M4 Display cable

Vehicle Power Wiring Harness

Connects the X5 System to the power supply and ECM.

Connects to the Breakout Box and runs to the Deutsch Plug.

Ethernet Cable

Optional: Used to connect the Breakout Box to an Ethernet capable display

Connects to the Breakout Box and runs to the display.

Discrete I/O Wiring Harness

Optional: Used to connect the Breakout Box to the Message Waiting Light

The Message Waiting Light only applies to XATANET Forms Messaging customers.

Connects to the Breakout Box and runs to the Message Waiting Light.

Message Waiting Light

Optional: For XATANET with Forms Messaging, this lights when a message is received

The Message Waiting Light only applies to XATANET Forms Messaging customers.

Connects to the i/o Discretes Wiring Harness. In the cab, it is mounted so that the driver will notice the light.



Locating the Hardware Part and Serial Numbers X5 - The part number and serial number are located on a sticker on the side of the X5 near the Drop Cable connector. The part number is marked with P/N. The serial number is marked with S/N. If the sticker has worn off, the X5 serial number appears on the Diagnostic Screens through the Driver Display. If you need the ASN number, you’ll find it on a sticker on the bottom of the X5. See the Driver Display Diagnostic Screens section on page 31 for more information.

Driver Display - The part and serial numbers are in the middle of the back of the Driver Display. If the Driver Display is mounted, this will be covered. If the Driver Display has an attached back plate, the serial and part numbers will be duplicated on the bracket.

Breakout Box -The part and serial numbers are on the side of the Breakout Box. The part number starts with SA. Serial number is below the bar code.

Cables - Cables do not have serial numbers. Cables have a sticker listing the part number near one of the ends.


Maintaining Your X5 Mobile Unit

Perform the following checks when the vehicle is in for maintenance. Verify that Mobile Unit hardware and cables are not damaged or worn to the point where they are unable to send data or power to hardware components.

X5 (Dome or Slim Case) Inspect to make certain it is in good condition (not cracked or broken).

Mounting bracket Inspect the silicon seal between the bracket and the truck for degradation. Replace as needed.

Cables and Wires Check for breaks or cracks. Tighten all connections.

Driver Display These instructions apply to the TREQ-L, the TREQ-M4, and XATA certified handhelds only. For a list of XATA-certified handheld models, contact your Client Manager. Verify that the Driver Display and mount connections are secure. The Driver Display is water resistant, but not waterproof. If the Driver Display screen is dirty, spray alcohol-based window cleaner on a cloth (not directly on the screen) and wipe the screen. Repeat as necessary. If the screen requires only light cleaning, use a dry, lint-free cloth to wipe off fingerprints.

Breakout Box Make sure that all connections to the Breakout Box are secure and that the Breakout Box is secure.



Hardware Locations and Wiring

Vehicle Power Wiring Harness 9-pin plug 6-pin plug

Red wire to + (power connection) Connect the Breakout Box to a vehicle power source capable of supplying 2.5 Amps of current at 12+ volts regardless of the state of the vehicle ignition switch.

B = both J1708 and J1939

C = J1708 only

Black wire to – (ground connection) Connect the Breakout Box to a suitable vehicle ground or tie it onto the vehicle chassis.

A = both J1708 and J1939

E= J1708 only

ATA+ Green wire (J1708 trucks) F = J1708 A= J1708 only

ATA- Orange wire (J1708 trucks) G = J1708 B= J1708 only

CAN High White wire (J1939 trucks) C = J1939

CAN Low Blue wire (J1939 trucks) D = J1939

Ignition (yellow wire) Connects to ignition wire coming off the key. On International trucks, use the pink wire that does not go to the center of the back of the ignition.



Calibration The vehicle should be calibrated if:

• There is a discrepancy between the miles in reports and the vehicle’s odometer.

• There is a discrepancy the vehicle’s odometer and the Driver Display odometer.

• The system has been powered off and the vehicle has been moved, such as when the vehicle is in the shop.

If the vehicle is mechanical, you should routinely calibrate to ensure the information reporting though the X5 is accurate.

Step 1: Prepare for Calibration

Before calibrating the odometer:

1. Verify that the vehicle is not in a trip.

End all trips before performing maintenance procedures. Failure to do so may result in the loss of data.

2. Verify that the vehicle is parked and will not be moved during the calibration process.

3. Verify that you have the vehicle’s current odometer/hubometer reading.

4. Retrieve vehicle data to ensure that the Host has current information. To Retrieve Vehicle Data:

NOTE: Outdated information on the Host will cause an error and the calibration will fail.

a. From any XATANET page, mouse over the Communications menu. b. Click Retrieve Vehicle Data.

Calibration


c. Search for a Vehicle ID or select from the list. Click the radio button in the left column to select a vehicle.

d. Click Send to request vehicle data. The Status of Retrieve Vehicle Data screen appears.

e. Click Refresh to update the status. The Status will change to Success when information is received.

5. You can also click the truck icon to check the status.



Step 2: Calibrate a Vehicle

To calibrate the vehicle:

1. From any XATANET page, mouse over the Fleet Management menu.

2. Click Vehicles.

3. Click the Edit icon (pencil) to the right of the vehicle you want to calibrate to advance to the Vehicle Management page.

Calibration


4. Click Meter Settings to proceed to the Vehicle Management page.

6. Verify the Time Stamp and Odometer under Last Known Value. If the time stamp and odometer do not match the current values, click Retrieve Vehicle Data (see Step 1: Prepare for Calibration). and wait until the Last Known Value is up to date.

7. Click in the New Value field under Odometer and enter the new odometer value.

NOTE: Regarding the Factor Value

Mechanical Engines:

It is common for the factor value to change. However, a change of more than 5% from the original value may signal missing data. The maximum change will be 10% from the original value. For example, if the original value is 99.95% the lowest minimum value would be 89.95 and the highest maximum value would be 109.95.

Electronic engines:

Once the vehicle is setup with the odometer set within one mile of the actual value, auto-calibration will take over. The Factor will remain at 100%.

RMA X5s:

If you replace an X5, check the Override box first and verify the factor is 100%. Then enter current odometer and hubometer reading. This will ensure proper recording of miles in the system.



8. Click Update to return to the Vehicle Management page.

9. Click Send to send the information to the vehicle.

Calibration


Step 3: Calibration Transmission Status

Once the calibration information is sent, you can check on the status of the transmission.

1. From any XATANET page, mouse over the Communications menu.

2. Click Vehicle Setup Status.

3. Specify a date range.

4. Select the vehicles by clicking in the checkbox in the left column.

5. Click Submit to go to the Vehicle Setup Status screen.



In the Response Date column, click Date and Time to find the details of the status. The following table explains the Setup Status Messages:

Pending, In Transit, or Delivered

No action is required. Wait for the transmission to complete.

Success

The setup was successful. If there is a display, it should have the menu system on the screen.

Failed (Timed Out)

The radio was contacted, but was not in coverage long enough to complete the transmission. Check all connections and the Diagnostics screens to verify good coverage.

Calibration


Failed (Undeliverable)

The radio may not be provisioned with the provider. You will get this status almost immediately. There is a Device ID in the Onboard Platform screen. Make a note of this and call XATA Solutions Support. The radio may also be faulty.

Failed (Vehicle Problem)

The Details section of the page will display why the setup was not successful. Correct the issue or contact Support for assistance.


Troubleshooting the Mobile Unit

Before You Call Support Note: At the back of this document is a page for recording diagnostics and other troubleshooting

information.

Inspect each part for damage. Damaged parts need to be replaced. Record the serial number and call Support.

1. Verify that the vehicle is running or will start. The Mobile Unit will not run if the vehicle batteries are dead.

2. Troubleshoot the system using one of the following checklists. Troubleshooting resolves some issues and helps to identify the causes of other issues. If you are not comfortable troubleshooting without help, Support will guide you through the process.

Driver Display Troubleshooting & Reboot Processes Use this checklist if it appears that the Driver Display is not working:

Does the Driver Display show an error message? If so, write down the error and go to Interpret Mobile Unit System Messages to identify the issue.

Is the Driver Display blank?

If so, verify that it has power. For TREQ units, if the buttons light up, the unit has power. If it has power, go to the next step. If it does not have power, go to Troubleshoot Power Issues.

Driver Display Troubleshooting & Reboot Processes


Reboot the Driver Display. To reboot:

• CE-507 – Press the Up arrow button and the 2 top left device buttons at the same time and hold for 5 seconds to reboot. Buttons are shaded.

If the buttons are held for more than 5 seconds, the device will shut off. To turn it back on, press the center Circle button.

• CE-504 – Press the Up arrow button and the 2 left device buttons at the same time and hold for 5 seconds to reboot. Buttons are shaded.

If the buttons are held for more than 5 seconds, the device will shut off. To turn it back on, press the center Circle button.

• TREQ-L - Press the F2 and F4 buttons at the same time. To cancel this soft reboot, press any button. The display restarts automatically.

• TREQ-M4 - Hold down the ◄4 button until the screen goes blank. Press ◄4 again to restart.

After a few seconds, the XATA screen should appear briefly. Then, while the Driver Display re-establishes communication with the X5, the screen will show System Unavailable.

Write down the MD V and EE V numbers that appear at the bottom of the System Unavailable screen.

It may take a couple minutes for the Driver Display to connect to the X5. Then, it will show the MAIN Menu.

NOTE: No information is lost when you reboot a Driver Display.

Contact Support. If display does not work after a reboot, tell Support which steps you tried.

Press Circle button to restart device

Press Circle button to restart device



Access Diagnostic Screens & X5 Troubleshooting Use this checklist when it appears there is an issue with the X5, when GPS is not available, or when the truck is not communicating.

If the vehicle is in a trip, end it at the truck through the Driver Display.

Ping the vehicle through XATANET’s Asset Tracking > Vehicle Locations page and

wait 10 minutes.

Check Vehicle Messages for the Asset Track status. Write down the status.

Does the Driver Display show an error message? If so, write down the error and go to Interpret Mobile Unit System Messages on page 30 to identify the issue.

Collect and write down diagnostic information. To access Diagnostics screens:

Driver Display: Access Diagnostic screens by:

CE-507 Open the fly-out menu. (Press the top right device button.) Touch Diagnostics.

CE-504 Open the fly-up menu. (Press the bottom left device button.) Touch Diagnostics.

TREQ-L (without EMG key) Press the F1 button and then press the F7 button or touch Diagnostics.

TREQ-L (with EMG key) Press the EMG button and then press the F6 button or touch Diagnostics.

TREQ-M4 Press the ◄1 button on the right and touch Diagnostics.

• Use the up and down arrows to scroll through the Diagnostic screens.

• If diagnostic information is not available, make a note of it and go to the next step.

Reboot the X5. Rebooting the X5 is often all you need to do to resolve an issue. To reboot:

a. Go to the first Diagnostic Screen (shown below).

Breakout Box Troubleshooting


b. Touch to go to the reboot screen.

c. Tap YES, and then tap GO.

d. The reboot will take between 5 - 15 minutes. The screen will show please wait while the reboot begins. It will then go through the normal start up screens.

Note: If you are unable to reboot through the Driver Display, contact Support to request an X5 Remote Reboot.

Contact Support or do advanced troubleshooting: • If the X5 does not work after a reboot, collect and record diagnostic information

again. Then:

• Use the diagnostics information to do advanced troubleshooting. Go to Interpret Diagnostics for advanced troubleshooting.

• Tell Support what steps you’ve tried and provide diagnostic information.

Breakout Box Troubleshooting If the vehicle has a TREQ-L and has been converted to the X5 from either the XAM or MDT, the Breakbox Box must be set to the following:

• XAM conversion: Slide the switch to 1 for use with a RS-232 Display Cable. Use 1 for vehicles running XATANET. This is the default position.

• MDT conversion: Slide the switch to 2 for use with a RS-422 Display Cable. Use 2 for vehicles running XATANET with Forms Messaging.



Power Issues Troubleshooting Use this checklist to troubleshoot if all or part of the system will not power up or loses power intermittently. This checklist requires access to the Breakout Box, which is installed behind the instrument panel. You may need to ask your shop or mechanic to perform these steps.

Explanation of the X5 lights are described on page 29.

Lightning strikes will damage a vehicle's electrical systems, including the XATANET system. If lightning struck the vehicle, replace the entire system.

If the system does not power up or loses power intermittently: • Verify that wiring connections and cabling to the Breakout Box are secure.

• Tighten any loose connections. If you cannot secure the Drop Cable or a wiring harnesses because a connector is damaged or stripped, it will need to be replaced.

• If you have an X5 Slim Case, more information about the meaning of the Slim Case lights are listed on page 29.

Verify that a constant 12 volts of power is available to the Vehicle Power Wiring Harness for the Breakout Box.

• If it is not getting enough power, the vehicle batteries may need to be replaced.

• If it is getting enough power and

- Both the Display and X5 do not have power, check the Vehicle Power Wiring Harness for damaged wires or bad connections.

- If the Vehicle Power Wiring Harness is damaged, replace it.

- If the wires are intact and connections secure, replace the Breakout Box.

- The X5 is communicating, but the Driver Display does not have power, check the Driver Display and the Display Cable. If you have a spare working Driver Display, connect it to the Display Cable.

- If the spare Driver Display works, replace the Driver Display.

- If the spare Driver Display does not work, replace the Display Cable.

- If Driver Display has power, check the Drop Cable and X5. Go to Troubleshoot the X5.

Contact Support. • Tell Support what steps you tried and if you have identified a part that needs to be

replaced.

Power Issues Troubleshooting


X5 Slim Case Lights

Light Color & Pattern Description

Power Blue Powered on.

Not lit No power.

Status

Amber Blinks during product initialization, using the sequence of light patterns below.

Solid amber X5 is initializing.

1-1-1 blinking amber (blinks 3 times, pauses)

Firmware is initializing. This may occur during an X5 upgrade.

1-5-1 blinking green (blinks 1 time, quickly 5 times, 1 time, pauses)

Device configuration has been restored to its factory defaults.

Other blinking amber patterns Contact XATA Technical Support

Solid amber Device is powered on and ready for operation.

Cellular Link / Act Solid green A cellular connection has been established.

Blinking green Traffic is on the cellular link.

Cellular Signal Strength

Green Relative signal strength indicator (RSSI), shown by the number of lights. 0 lights = Signal strength unknown or

unacceptable. 1 light = Signal strength low/weak 3 lights = Signal strength high/excellent

GPS

Off No satellites are visible.

Blinking green Satellites are visible, but a satellite connection has not yet been established. The rate of blinking increases as the number of visible satellites increases.

If the antenna is not connected to the X5, the GPS device can indicate “phantom” satellites. This will cause the device to behave as if many satellites are visible to it, although it will not establish a satellite lock. In this case, the X5 will display continuous, fast blinking.

Solid green A satellite connection has been acquired.

Xbee Solid green The XBee network link is up.

Blinking green Activity is on the XBee network link.



Light Color & Pattern Description

Ethernet Solid green An Ethernet connection has been established.

Blinking green Traffic is on the Ethernet link.

WIFI Solid green A WIFI connection has been established.

Blinking green Traffic is on the WIFI link.

Interpret Mobile Unit System Messages The table below shows messages that may appear on screen. Some of these screens appear as part of normal operations.

Reboot Messages

These screens appear when the system powers up or during a reboot.

Screen Cause Resolution

Appears when the X5 powers up and when the Driver Display can't communicate with the X5.

If the system is booting up, give it time to finish the process.

If the message does not clear after a few minutes, Troubleshoot the X5.

Keep paper logs until the Main Menu reappears.

Appears when the system powers up.

Give the system time to finish rebooting.

If the message does not clear after a few minutes, Troubleshoot the X5.

Keep paper logs until the Main Menu reappears.

Reboot screen selected when vehicle is moving.

Press BACK to return to back out of the screen.

Reboot when the truck is parked.

Appears when the system begins to reboot.

Give the system 5 - 15 minutes to shut down and then power up.

NOTE: While the system is powering up, it will show System Unavailable. This is normal.

Interpret Mobile Unit System Messages


Communication Messages


“Connection Lost” appears when the Display cannot communicate with X5.

This screen changes to System Unavailable after a few seconds while the Driver Display reconnects to the X5.

Cellular communication is available.

No action required.

Cellular communication is not available.

Verify the display has been powered up for at least 10 minutes. If it has been powered up for 10 minutes, then reboot the display.

Be sure to give the display another 10 minutes so it has enough time to communicate with the X5.

Satellite communication is available.

No action required.

Satellite communication is not available.

The vehicle must be outside, away from buildings or other obstructions, with a clear view of open sky to acquire Satellite signals.

GPS Messages


Appears when GPS is blocked.

GPS may be temporarily blocked if the vehicle is near a government facility or is inside. In this case, the Automatic Records are Being Recorded screen will appear when GPS has reconnected.




Appears when GPS has reconnected.

If you have no recent location data, Troubleshoot the X5.

GPS is available. No action required.

GPS is not available. GPS may be blocked temporarily if the

vehicle is near a government facility or is inside.

If you have no recent location data, Troubleshoot the X5.

Other Messages


The vehicle has not been setup or has lost setup.

Send vehicle setup.

If the X5 repeatedly loses setup, contact XATA Support.

The vehicle has been setup No action required.

Interpret Diagnostic Information


Interpret Diagnostic Information At the back of this document is a page you can use to record diagnostics.

Diagnostic Screen Description What to Look for What it means What to do

RPS and GPS Screen

X5 Model # X5 Serial Number X5 Software Version Driver Display Software Version Driver Display Forms Version Package: Bronze, Silver, Gold, or Platinum

Engine Speed Odometer Value PTO Status GPS Status State and GPS position

RPM = 0 while the truck is running

Truck is not collecting ATA data.

1. Is the truck setup as mechanical? ATA data is not available if electronic data is not available.

2. Troubleshoot Power Issues. 3. Check the vehicle’s ECM.

GPS = OUT GPS is not available. Maybe temporary if the vehicle is near a government facility or does not have a clear view of the sky.

1. If temporary, the GPS will reconnect when it is available.

2. If the vehicle is in the open and the GPS=OUT after a reboot, request an RMA for the X5.

List of Reboot Reasons with UTC date and time each occurred.




(Optional) If an OBD II device is detected, the following displays:

Serial Number Host processor version OBD II firmware version EEPROM database version Date and time the information was collected

Host: Indicates whether the device is connected to the XATANET Host system TX Msg OK: Number of messages sent TX Msg Failed: Number of failed messages TX Queued: Number of messages queued TX Attempts: Number of attempts to send a message TX Failed: Number of failed attempts RX Msgs: Number of messages received

Host = Unavailable X5 can’t communicate with Host

1. Check the cellular diagnostics data.

TX Msgs OK = 0 No messages have been successfully sent since the last reboot.

1. Ping the vehicle. After the ping: • TX Msgs OK and RX Msgs

should increase.

• TX Msgs Queued should start to drop.

2. Check the Last Communicated date screen.

3. Run the Vehicle Status Report. 4. Reboot the X5, if you have not

done so already. If the X5 does not communicate after the reboot, check the diagnostic data.

TX Msgs Queued = >0

The number of messages currently queued. A high number may mean the system is not communicating with the Host.

RX Msgs = 0 No messages have been successfully sent since the last reboot.

Interpret Diagnostic Information



List of last sent messages: Date and Time and the Communication Network used Date and Time the message was sent

A date in the format of MM-DD Time in 24 hour clock format. Network used for last communication: WIFI, ORBCOMM, CELLULAR

Date and UTC time that the last message was sent to the Host. Communication Network is the network type used to send the last message

If X5 has not communicated for several days: • Reboot the X5, if you have not

done so already. • If X5 does not communicate after

the reboot, check diagnostics screen.

The Communication diagnostic screen will display for the type of network you are using: WIFI, ORBCOMM, or CELLULAR

WIFI Radio status WIFI State WIFI Channel SSID WLAN Signal level IP address

State = Searching for network Authenticated

SSID (Service Set Identifier) = Customer-defined name for the network

Low signal strength Signal strength = % of communication connection 100% = best

Check the communications strength to see if you need to move to a better location.

IP = 0.0.0.0 WIFI is not connected

May need to move to a better location to avoid roaming.

IP = xxx.xx.xx.xx (address will vary by customer)

WiFI is connected





Radio Manufacturer Radio Model Radio Serial Number Software Version Signal Strength Status IP address of radio

No radio serial number

Not seeing the cellular and may indicate a hardware issue

This screen’s data populates in order. The first field displays data first, then the second field, etc. If no data displays on this screen, contact Solution Support to identify a possible hardware issue.

Low signal strength Signal strength = % of communication connection 100 = best signal 0 = worst signal

If low, try moving to a better location.

Stat = Not registered

If not registered, then device is roaming.

May need to move to a better location to avoid roaming.

No IP address May indicate that the device has not been provisioned

Contact Solution Support to verify the provisioning of the device.


Radio Serial Number Hardware Version Software Version Satellite identifier

Satellite identifier = blank

Orbcomm is not connected

May need to move to a better location to ensure you have good visible line of sight to the sky.

Satellite identifier = a number between 5 - 39

Orbcomm is connected

Press Back to exit Diagnostics or press arrows to scroll through pages again.

OBD II Troubleshooting


OBD II Troubleshooting If you are having problems with an OBD II converter, check the following items before calling Support.

1. Is the vehicle model year is 1996 or newer? Older vehicles are not OBD II compatible.

2. Is the Power light on the Streamer lit (red) and not blinking?

• If it is blinking, there is a fault. To correct it, turn the converter off and then turn it back on. If that does not correct the blinking, contact Solution Support.

3. Is the Y-cable connector is securely attached to the vehicle port? • If not tighten the connection.

• If the connection is secure, contact Solution Support.

Hino Converter Troubleshooting If you are having problems with the Hino Converter, check the following items before calling Support.

1. Make sure the vehicle model year is 2008, 2009, or 2010.

2. Make sure that the converter is wired correctly, using the following information.

a. Connection to Vehicle Bus (J1939): 32” 22AWG twisted pair • Yellow: J1939 + (CAN High)

• Green: J1939 – (CAN Low)

A B

C D



b. Connection to J1587: 24” 32AWG twisted pair • Brown: J1708 + (J1708 High) “A”

• Blue: J1708 – (J1708 Low) “B”

c. Ground: 23AWG 32” Black wire

d. Power Input: 16AWG 32” Red wire fused @ 3A – Must be connected to ignition switched power • Input voltage: 10 to 40 VDC

• Input current @12 VDC: 30mA typical, 500mA max at 7.25 volt

Hardwired PTO Troubleshooting If you are having problems with the vehicle’s Hardwired PTO, check the following items before calling Support.

1. Does the vehicle have an electrical engine or a mechanical engine? Hardwired PTO only should be installed on vehicles with electrical engines. It does not apply to vehicles with mechanical engines.

2. Do you have the Discrete I/O Wiring Harness (CB-0133-01)? It is required for this feature.

3. Is the PTO Indicator Light burned out? Lamps must be maintained at all times. If they are burned out, they could cause false PTO readings. It will display as ON.

4. Has a Wired Input setting change been made for this vehicle? Was the change sent to the vehicle through vehicle setup? If a change was made to the setting on the XATANET web application (Fleet Management > Vehicles > Power Take Off Settings > Wired Input), this change must be sent to the vehicle for it to take effect.

See the following diagrams for more specific information on the different types of PTO wiring configurations.

Hardwired PTO Troubleshooting


Wiring Configurations and Diagrams

There are two types of PTO wiring configurations:

• Direct Air Switch Probably the most common after-market PTO installation.

• Electric Over Air This type can either have an integrated indicator light or a separate indicator light. Different wiring configurations are required for each variation.

Use the diagrams on the following pages to show you wiring tap location for the XATA discrete input wire.

The Blue will indicate the tap location for the XATA discrete input wire. In these locations “PTO On” will be detected as a Low state or 0 volts.

For some of the configurations, it is possible to detect PTO as a high state or at vehicle battery voltage. For these tap locations a shows the alternate tap location.

• • •

Direct Air Switch Wiring Diagram

The main difference in Direct Air Switch installations is the connection to vehicle power. The diagram below indicates connection to the battery directly. Some installations will be connected to accessory or ignition-switched power.

The indicator lamp is switched to ground at the PTO gearbox once the PTO gear is engaged. This indication method is common in many configurations.

Note : To validate the PTO status, the X5 only will report PTO as “On” when the Indicator light is On and the engine RPM is greater than 0 RPM. This also prevents false reporting of PTO activation when the Indicator Light is switched with the ignition.

Indicator Light

PTO Air Switch Valve Control



PTO Status Table: Indicator Lights must be intact and lit for correct reporting.

Lamps must be maintained at all times. If they are burned out, they could cause false PTO readings. It will display as ON.

PTO Air Valve Vehicle Indicator Light Set the XN Power Take Off Mode field to:

Reported PTO Status

On Running On Low = PTO On On

Off Running Off Low = PTO On Off

Switched to Vehicle Ground – on PTO gear box

Tap here = PTO Low

Note: This may be connected to ignition-switched vehicle power instead of connected directly to the battery

A burned out Indicator Light will create a false PTO indication

12 volt indicator light

Battery 9 amp fuse holder



Electric Over Air Diagram – Integrated Indicator Light

This type of control uses an electric solenoid air valve to engage the PTO. In this case, the dash control is an electric switch with an integrated indicator light. This light is switched both to the battery at the dash switch and then to ground once the PTO gear is engaged.

PTO Status Table: Indicator Lights must be intact and lighted for correct reporting.

Note : This type of installation has a switch with an internal indicator light. If that light is an LED, the detection of the PTO status may be affected as the transition voltage will not be the same as with the incandescent light.


PTO Air Switch Vehicle Indicator Light Set the XN Power Take Off Mode field to:

Reported PTO Status

On Running On Low = PTO On On

Off Running Off Low = PTO On Off

Ground

Switch with self-contained indicator lamp

Battery

Tap here = PTO Low

9 amp fuse holder




Electric Over Air Diagram– Separate Indicator Light

This type of control uses an electric solenoid air valve to engage the PTO. In this case, the dash control is an electric switch with a separate indicator light. This light is switched both to the battery at the dash switch and then to ground once the PTO gear is engaged.

PTO Status Table: Indicator Lights must be intact and lighted for correct reporting.

Note : The Red tap in this case eliminates a false indication of PTO On when the Indicator Light is burned out.


Tap PTO Dash Switch Vehicle Indicator Light Set the XN Power Take Off Mode field to:

Reported PTO Status

Blue On Running On Low = PTO On On

Blue Off Running Off Low = PTO On Off

Red On Running On High = PTO On On

Red Off Running Off High = PTO On Off

Dash switch

Fuse

Ground Battery

Air Valve on PTO

Goes to transmission

Tap here = PTO Low

Alternate tap = PTO High

Indicator Lamp

Note: This may be connected to ignition switched vehicle power




Air Switch Connections – No Indicator Light

There may be cases where there is no indicator light, or the wiring of the indicator lamp and PTO controls do not conform to the configurations noted in the previous sections.

There may also be conditions where the indicator lamp connection may not provide a detectable voltage transition.

In these cases, the customer needs to have an air switch installed by a certified mechanic to indicate the air supply pressure applied to engage the PTO gear. The X5 i/o wire would then be connected to this air switch.

The air switch is installed to sense pressure activation of the PTO air line that engages the PTO drive gear. The switches are available in normally open and normally closed configurations. The most common application for these switches is brake light control in a vehicle equipped with air brakes.

• Battery Connection : Note for all battery connections, a fuse rated for the wire gauge provided is

required.

Connection to the switch would be from vehicle battery on one terminal and then to the X5 i/o connection on the other terminal. With a normally open air switch, the voltage transition would be from low to high when the PTO was engaged.

• Ground Connection : Fuse not required

Connection to the switch would be from vehicle ground on one terminal and then to the X5 i/o connection on the other terminal. With a normally open air switch, the voltage transition would be from high to low when the PTO was engaged.

Battery

X5

Fuse



Test Message Waiting Light (if installed)

1. Tap Messaging at the bottom of the screen.

2. Tap Utilities.

3. Tap Test Discretes and then tap Enter.

4. When the Test Discretes screen displays, select 1. Remote Msg Light and then tap Enter.

The test begins automatically. The light will blink for five seconds if operating properly. When finished, tap Main.

The message light’s default sends a position once per hour.


Replacing Mobile Unit Hardware – RMA Process

When the system is not working as expected, troubleshoot the system or ask Support to help you troubleshoot. In many cases, troubleshooting will resolve the issue.

If troubleshooting does not resolve the issue, a part may require repair or replacement. The Support Representative will determine if your hardware is under warranty.

For hardware that is no longer under warranty, you can purchase a replacement or request a repair.

• Cables and Breakout Boxes generally require replacements.

• Displays and X5s may be repairable. The Support Representative can create a repair evaluation case for you. You will need to include this case number when you send a part in for a repair evaluation.

For repairs over $350, XATA will give you a repair quote before making repairs.

For hardware that is under warranty:

• Support will issue a Return Material Authorization (RMA).

• XATA will ship you a replacement part. Save the package to return the old part.

• Swap the old part with the replacement.

• Return the old part with the RMA label that was included in the box. Include your RMA reference number in the package.

- If you do not have a return label, contact Support.

- If you do not return a warranty item to XATA within 30 calendar days, you will be charged for that item. Once XATA receives the item, you will be credited.

Once you receive your replacement hardware, remove and replace the old part:

• Remove Driver Display on page 46

• Remove Breakout Box on page 50

• Remove Vehicle Power Wiring Harness on page 55

• Remove Display Cable on page 59

• Remove Drop Cable on page 62

• Remove Message Light Harness on page 86

• Remove Message Waiting Light on page 84

• Remove X5 Hardware on page 69


Removing/Replacing Hardware

Note: If you need to order new hardware, contact your XATA Client Manager.

Replace a Driver Display You will need the following equipment:

• 11/32” wrench or nut driver

• 2 mm Allen Wrench (for CE devices only)

• Tape (or something that will keep the cable from slipping behind the dash while you are working on it)

• Replacement Driver Display

Step 1: Remove the Driver Display

1. For TREQ devices: Unplug the Display Cable at the connector plug in the following pictures. The plug is approximately 12” down the cable from the Driver Display, and may be behind a grommet. (Figure 6-2). This grommet must be removed first to access the white connector plug.

When you unplug the Driver Display cable at the white connector plug, tape or fasten the Display Cable to the dash so that it does not slip behind the dash. If it slips behind the dash, you may need to remove the dash to retrieve it.

Display Cable connection

Display Cable connection (XATANET for Forms Messaging)

Display Cable disconnected from the

Driver Display

Display Cable disconnected from the Driver Display (XATANET for Forms Messaging)

TREQ-M4 cable connection

Replace a Driver Display


For Micronet CE devices: Disconnect the Con 1 and Con 2 connections at the base of the device with a 2 mm Allen Wrench. See the following pictures.

CE Device Con 1 and 2 connections.

Note: For more detail about the Micronet CE’s wiring configuration, see Appendix D on page 109.

2. Use an 11/32” wrench or nut driver to remove the four nuts (2 for the TREQ-M4 and CE devices) from the back of the swivel bracket.

TREQ-L (4 nuts) TREQ-M4 (2 nuts)

3. Remove the old Driver Display from the universal swivel bracket.

Remove the old Driver Display from the swivel bracket.



Step 2: Replace the Driver Display

1. Thread the screws at the back of the Driver Display through the matching holes on the swivel bracket and use the nuts provided to hold in place.

Thread Driver Display screws through the holes on the swivel bracket.

Use hand tools only. Do not over tighten the nuts.

2. For TREQ devices: Connect the Display cable at the white connector plug making certain the connection is secure.

Connect the Display Cable connection to the Driver Display.

Replace a Driver Display


For Micronet CE devices: Connect the Con 1 and Con 2 connections at the base of the device with a 2 mm Allen Wrench. See the following pictures.

CE Device Con 1 and 2 connections.

a. Connect the Con 1 and Con 2 Wiring Harnesses to the Con 1 and Con 2 ports on the underside of the device.

b. Carefully attach one screw on the underside of each wiring harness and another on the backside of each wiring harness using a 2 mm Allen Wrench.

Connections are labeled on the device. The Allen Wrench is not provided.

Make sure the screws are not attached crooked and that they are not over-tightened, which can lead to system failures.


3. Calibrate the touch screen. To do this:

a. Touch the Settings tab.

b. Touch Calibrate Touch. The Touch Screen Calibration screen appears.

Calibration the Touch Screen.

c. Using a stylus or fingernail, tap firmly on the center of the target (crosshair) and release. Repeat as the target moves around the screen. You must complete all the steps to exit the screen.



Remove and Replace a Breakout Box You will need the following equipment:

Replacement Breakout Box.

The Red wire is electrically HOT. Handle it with care.


Step 1: Remove the Breakout Box

1. Remove any cable ties that may be securing the Breakout Box to the vehicle.

2. Unscrew the Drop Cable to disconnect it.

Disconnect the Drop Cable

3. TREQ-Ls: Unplug the Display Cable from the serial port. -or-

TREQ-M4s and CE devices: Unplug the Ethernet Display Cable from the Ethernet port.

For TREQ-Ls, disconnect the Display Cable from the serial port.

For TREQ-M4s and CE devices, disconnect the Display Cable from the Ethernet port.

Remove and Replace a Breakout Box


4. Disconnect the Vehicle Power Wiring Harness from the Breakout Box by pressing on the outer end of the white clip and pulling backward on the Vehicle Power Wiring Harness.

Disconnect the Vehicle Power Wiring Harness.

5. Optional: Disconnect the Message Waiting Light Harness, if there is one.

Optional: Disconnect the Message Waiting Light Harness.

6. Note whether the switch on the back of the Breakout Box is set to either 1 or 2. You will need this information when you install the replacement Breakout Box.



Step 2: Replace the Breakout Box

Generally, you will install a replacement Breakout Box in the same location as the original Breakout Box. This should be a dry location that does not interfere with driver operations. If the old Breakout Box had water damage, do not install it in the same location. If you are not sure where to install the replacement, contact Support.

Keep the Breakout Box enclosed! Do not install the Breakout Box under the floor mat. Water and electronics do not mix!

1. Slide the switch on the back of the Breakout Box to either 1 or 2, depending on the setting used on the old Breakout Box.

2. Attach the Drop Cable to the Breakout Box.

Thread the Drop Cable on straight and not at an angle. The connector could be damaged if you try to thread it at angle.

Attach the Drop Cable to the Breakout Box.


Remove and Replace a Breakout Box


3. Attach the Vehicle Power Wiring Harness (8-pin) to the Breakout Box.

Attach the Vehicle Power Wiring Harness to the Breakout Box.

4. Connect the Display Cable to the Breakout Box, using the Ethernet port.

Attach the Display Cable.

5. If not already done: Tap the Display Cable’s ground, ignition and power supply wires to the same wires in the Vehicle Power Wiring Harness.

Tap Display Cable Wires.... To Vehicle Power Wiring Harness.....

Red wire = Red wire

Black wire = Black wire

Tap Display Cable wires to Vehicle Power Wiring Harness.

Display Cable wires

Vehicle Power Wiring harness wires



Optional: If the truck has a Remote Message Waiting Light, attach the 4-pin connector for the Message Waiting Light wiring harness to the Breakout Box.

Optional: Attach the Message Waiting Light wiring harness.

Mount the Breakout Box

1. Thread cable ties through the slots on the back of the Breakout Box.

2. Secure the ties so that the Breakout Box does not interfere with the normal operation of the vehicle.

Remove and Replace a Vehicle Power Wiring Harness


Remove and Replace a Vehicle Power Wiring Harness You will need the following equipment:

Replacement Vehicle Power Wiring Harness.

The Red wire is electrically HOT. Handle it with care.


Step 1: Remove the Vehicle Power Wiring Harness

1. Disconnect the Vehicle Power Wiring Harness connections from the Deutsch plug.

2. Disconnect the Vehicle Power Wiring Harness from the Breakout Box by pressing on the outer end of the white clip and pulling backward on the Vehicle Power Wiring Harness.

Disconnect the Vehicle Power Wiring Harness from the Breakout Box.

3. Remove the Vehicle Power Wiring Harness from the vehicle.



Step 2: Replace the Vehicle Power Wiring Harness

1. Attach the Vehicle Power Wiring Harness (8-pin) to the Breakout Box. This connects the Breakout Box to the power supply, ignition, ground, and ECM.

Attach the Vehicle Power Wiring Harness to the Breakout Box.

2. Tap the Display Cable’s ground, ignition and power supply wires to the same wires in the Vehicle Power Wiring Harness.

Tap Display Cable Wires.... To Vehicle Power Wiring Harness.....

Red wire = Red wire

Black wire = Black wire

Tap Display Cable wires to Vehicle Power Wiring Harness.


Display Cable wires

Vehicle Power Wiring Harness wires

Remove and Replace a Vehicle Power Wiring Harness


3. Connect the wires from the Vehicle Power Wiring Harness to the vehicle’s Deutsch plug as described in the table below. For more detail about the Micronet CE’s wiring configuration, see Appendix D on page 109.

9-pin Deutsch plug 6-pin Deutsch plug

NOTE: Due to the inconsistent use of J1939 (CAN) standards among truck manufacturers, the supported parameters may be limited based on vehicle configuration. See below for wiring specifics.

Connection J1708 vehicles J1939 vehicles (CAN) 9-pin plug 6-pin plug

Power (battery)

Red wire to + (power connection)

Connect the Breakout Box to a vehicle power source capable of supplying 2.5 Amps of current at 12+ volts regardless of the state of the vehicle ignition switch.

Red wire to + (power connection)

Connect the Breakout Box to a vehicle power source capable of supplying 2.5 Amps of current at 12+ volts regardless of the state of the vehicle ignition switch.

B = both J1708 and J1939

C = J1708 only

Ground Black wire to – (ground connection)

Connect the Breakout Box to a suitable vehicle ground, or tie it onto the vehicle chassis.

Black wire to – (ground connection)

Connect the Breakout Box to a suitable vehicle ground, or tie it onto the vehicle chassis.

A = both J1708 and J1939

E= J1708 only

+ (plus) ATA+ (green) wire to A (J1708+)

CAN High (white) wire to CH (J1939+)

F = J1708 C = J1939

A= J1708 only

- (negative) ATA- (orange) wire to B (J1708-)

CAN Low (blue) wire to CL (J1939-)

G = J1708 D = J1939

B= J1708 only

Ignition Ignition (yellow) to ignition wire coming off the key. On international trucks, the pink wire does not go to the center of the back of the ignition.

The ATA or CAN wires can usually be identified by the heavy twisting of the two pairs of wires. Always minimize the amount of wire and distance running from the Breakout Box to the ATA or CAN connection. CAN wires can only extend 1 meter (3.2 feet) from the connection to the original vehicle wiring harness.



A suitable installation point, in addition to access to suitable power, ground, and ATA or CAN, is typically near the 9-pin Deutsch plug or the 6-pin Deutsch plug of the vehicle. The 6-pin Deutsch plug only supports 1708 vehicles. The 9-Pin Deutsch plug supports both 1939 and 1708 vehicles.

Install the Breakout Box behind the instrument cluster. DO NOT attach the Breakout Box where the Driver can easily access it or where it will become entangled in foot pedal operations.

Keep the Breakout Box enclosed! The number one reason for install failures is an exposed Breakout Box. Do not install Breakout Box under the floor mat. Water and electronics do not mix!

Cables running to the Breakout Box must be covered or wire tied away to avoid interference with Driver operations. Do not run any cable through the clutch or brake pedal hole in the instrument cluster base. Wire tie cables away from steering linkage, fan housings, or any other moving part that can chafe the cable. Verify that the cables do not interfere with the normal operation of the vehicle.

If the Drop Cable has extra slack, wrap the slack into a tight coil and tied the coil as far away from high current sources as possible. High current sources induce “noise” on the data lines running inside the Drop Cable.

NOTES:

• Use a voltmeter to ensure that all connections are correct. The voltage between the Black wire ground terminal (-) and a known chassis ground must be zero VDC in all ignition key positions. There must be continuity between those two ground points since they are both chassis ground.

• The voltage between the Red wire power terminal (+) and the Black wire ground terminal (-) must be a minimum of +12 VDC in all ignition key positions.

• After the wires are connected, tug them firmly to ensure they are not loose.

• Splices are prone to failure if an inappropriate crimping tool is used. Crimping with too small a crimp aperture can cut the wires underneath the crimp, weakening the connection. Crimping with too large a crimp aperture will not tightly bond the wire to the connector. A crimp on a 16-gauge wire should be able to withstand a pull of 20 lbs.

Replace a Driver Display Cable


Replace a Driver Display Cable You will need the following equipment:

Replacement Driver Display Cable.

Cables should be hand tightened only.


Step 1: Remove a Driver Display Cable

1. For TREQ devices: Unplug the Driver Display cable from the Driver Display at the connector plug shown below. The plug is approximately 12” down the cable from the Driver Display. The Driver Display cable for the TREQ-M4 cable has a black connector.



Display Cable disconnected from the

Driver Display

Display Cable disconnected from the Driver Display (XATANET for Forms Messaging)


For CE devices: Unplug the Power Display Cable from the DC-DC converter port.



2. Disconnect the Display Cable from the Breakout Box.

Disconnect the Display Cable from the Breakout Box.

3. Pull the Display Cable from underneath interior panels.

Step 2: Replace a Driver Display Cable

1. Connect the new Display Cable to the Breakout Box. TREQ-L uses the serial port on the Breakout Box. TREQ-M4 and CE devices use the Ethernet port.

Attach the Driver Display Cable to the Breakout Box.

2. Run the Driver Display Cable underneath interior panels and inside the instrument cluster to the area where the Driver Display is mounted.

• Most vehicles have several access holes for wires and cables.

• Make certain the Cable does not interfere with normal operation of the vehicle.

• Ensure that this Cable has enough slack to pull back through the grommet hole in the dashboard.

DO NOT run the Driver Display Cable through a pedal hole.

Replace a Driver Display Cable


3. For TREQ devices: Connect the Driver Display cable at the white connector plug making certain the connection is secure.




For CE devices: Attach the 4-pin Power Display cable from the Breakout Box to the DC-DC converter port. For more detail about the Micronet CE’s wiring configuration, see Appendix D on page 109.

4. Tie the cable away from steering and pedal linkage.



Replace a Drop Cable You will need the following equipment:

• Wire ties

• Replacement Drop Cable

• 100% Silicone Sealant

Cables should be hand tightened only.


Step 1: Remove a Drop Cable

1. Disconnect the Drop Cable from the X5. To do this:

a. Pull the lanyard back and down from the cable connection to release the clip.

Pull the lanyard and Drop Cable to release

Drop Cable on the X5 Slim Case

Always use the attached lanyard to release the clip that holds the Drop Cable in place, if you need to disconnect the Drop Cable from the X5. Forcing the clip without releasing it will break it.

Replace a Drop Cable


b. Pull the Drop Cable away from the X5.

Pull the Drop Cable away from the X5

2. Unscrew the Drop Cable from the Breakout Box.

Disconnect the Drop Cable from the Breakout Box

3. Note how the original Drop Cable was routed. Thread the Drop Cable out through the grommet hole and from the adhesive ties along the back of the vehicle.



Step 2: Replace the Drop Cable

1. Attach the Drop Cable to the X5. The plug will snap into place. Tug on the cable to verify that it is secure.

The plug will snap into place.

2. Run the Drop Cable in neat, taut lines on the same side of the vehicle as the Breakout Box. Generally, this will be the same location as the old Drop Cable.

• Route the Drop Cable so that it is unlikely to be damaged by drivers, mechanics, and washmen, and so it does not interfere with normal vehicle operations.

• Avoid running the Drop Cable close to heat sources, such as the exhaust pipe, or to high current sources, such as the battery or starter cables.

3. Do not pull the cable too tightly, but the cable must be taut enough that it does not bang on the vehicle when it is in motion.

• Secure the Drop Cable along the way with the included cable tie bases and cable ties. Use one wire tie and clamp every 18”-24”.

• Use the supplied adhesive zip ties.

Dome: Route the Drop Cable down the back of Slim Case: Route the Drop Cable down on the floor the truck and secure it with cable ties. of the cab to the Breakout Box.

Replace a Drop Cable


4. Route the Drop Cable into the Driver Compartment where the Breakout Box is located. Use the existing hole.

Routing the Drop Cable under the Truck and into the Engine Compartment

• If there is a deep door channel, you may be able to route the cable through the cab.

Drop Cable over the fender and routed through door channel

• You may need route the cable through the firewall.

Drop Cable routed through firewall.

5. Seal the hole with a heavy layer of 100% silicone sealant, after the cable is in place.

Apply the sealant on both sides of the hole. Provide strain relief for the cable on both sides of the hole.



4. Wire tie excess cabling to prevent the cable from straying in front of a screw hole, or from interfering with factory wiring or diagnostics that a mechanic may need to check in the future. ALL wiring coming from the Breakout Box should be wire tied together to relieve stress on the wiring.

5. Attach the Drop Cable to the Breakout Box.

Attach the Drop Cable to the Breakout Box.

Replace an X5


Replace an X5 You will need the following equipment:

• Replacement X5

• A 7/16” ratcheting wrench

This process requires users to perform some steps at the vehicle and some steps at a computer running XATANET. If you do not have access to XATANET, ask a XATANET user in your organization to complete those steps.

When replacing an X5, there are seven main steps that must be completed.

There is an additional step if you use XATANET with Forms Messaging.

1. Ensure that you are not logged into a Trip, and complete a Retrieve Vehicle Data process to obtain the data from the existing X5.

2. Remove the X5 from the vehicle.

3. Replace the X5 on the vehicle.

4. Remove the old X5 from the vehicle in XATANET.

5. Setup the replacement X5 for the vehicle in XATANET.

6. Confirm setup.

7. Send a test trip.

8. Add the X5 to Exec (XATANET with Forms Messaging only) •



Step 1: Retrieve Vehicle Data from the Existing X5

Ensure that you are not logged into a Trip before you start.

In XATANET: If the existing X5 is partially functional, a XATANET user should attempt to retrieve vehicle data before removing the existing X5 from the vehicle.

If the X5 is not functional, skip this step and go to “Step 2: Remove the XAM from XATANET.”

At a PC:

1. Open a browser window and login to XATANET.

2. Mouse over the Communications menu.

3. Click Retrieve Vehicle Data.

4. Search for a Vehicle ID or select from the list. Click the radio button in the left column to select a vehicle.

5. Click Send to request vehicle data. The Status of Retrieve Vehicle Data screen appears.

Replace an X5


6. Click Refresh to update the status. The Status will change to Success when information is received.

You can also click on the Truck icon, , to check the status.

Step 2: Remove X5 Hardware from Vehicle

At the Vehicle:

1. Disconnect the Drop Cable from the X5. To do this:

a. Pull the lanyard back and down from the cable connection to release the clip.

Use the lanyard to release the Drop Cable Clip.



Always use the attached lanyard to release the clip that holds the Drop Cable in place, if you need to disconnect the Drop Cable from the X5. Forcing the clip without releasing it will break it.

Pull the lanyard and Drop Cable to release Drop Cable on the X5 Slim Case

b. Pull the Drop Cable away from the X5.

Pull the Drop Cable away from the X5

2. Dome: Loosen the four 7/16 bolts from the bottom of the X5. Turn the X5 to unlock it (see locking bolt slots) and lift it from the Mounting Bracket.

Loosen the bolts. Locking bolt slots

Slim Case: Loosen the self-drilling screws of the strain relief bracket/Slim Case structure to remove the entire structure.

Replace an X5


Step 3: Install the Replacement X5

Be sure to note the vehicle’s current odometer reading to the tenth of a mile (if possible). You will need this information to complete setup.

Dome Replacement:

1. Record the Serial Number and ASN number for the new X5. ASN is required for XATANET for Forms Messaging. The ASN number is only available through the sticker on the bottom of the X5.

2. Partially unscrew the four bolts from the bottom of the X5.

3. If the X5 does not have bolts, put four bolts in the bottom of the X5. Do not tighten completely.

4. Set the X5 on the Mounting Bracket so that you can easily access the Drop Cable connector.

5. Tighten the bolts using a 7/16” ratchet wrench.

DO NOT use a power tool to attach the X5 to the bracket. Tighten X5 mounting bolts moderately, so that the X5 can be removed when necessary. Use hand tools only.

Secure the X5 by tightening the bolts with a ratchet wrench.

6. Attach the Drop Cable to the X5. The plug will snap into place. Tug on the cable to verify that it is secure.

The plug will snap into place.



Slim Case Replacement:

1. Record the Serial Number and ASN number for the new X5. ASN is required for XATANET for Forms Messaging. The ASN number is only available through the sticker on the bottom of the X5.

2. Fasten the cap on the Zigbee (XBEE) connector on the X5 Slim Case.

3. Mount the X5 Slim Case on the bracket using 1/4-20 locking nuts.

4. Attach the bracket / Slim Case to the structure location (e.g., seat or bunk), using self-drilling screws. See examples on the following page. Note that the self-drilling screws are not provided.

Do not mount the X5 on the floor or dash.

X5 Slim Case Mounted under the Seat

Same Under the-Seat Mount as above

Replace an X5


X5 Slim Case Mounted to the Side of the Cab

Step 4: Remove the old X5 from XATANET

DO NOT delete the vehicle from XATANET. Deleting a vehicle deletes the vehicle logs and data associated with that vehicle. DOT regulations require that logs be maintained for 6 months. To ensure DOT compliance, make the vehicle inactive for at least 6 months before removing it from XATANET.

At a PC:

1. Open a browser window and log into XATANET.

2. Mouse over the Fleet Management menu.

3. Click Vehicles.

4. Click the Edit icon (pencil) for the vehicle with the X5 that you are going to remove.



5. Click Onboard Platform.

The Vehicle Management page appears.

6. Click the Remove button.

7. Answer the question “Are you sure you want to remove this onboard platform?” by clicking Yes.

Replace an X5


Step 5: Add the Replacement X5 to XATANET

At a PC:

1. If you are not still at the Install a Platform page do the following:

a. Open a browser window and log into XATANET.

b. Mouse over the Fleet Management menu.

c. Click Vehicles.

d. Click the E

Date post:	17-Oct-2020
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X5 Service & Troubleshooting Guide - btcgps.com · such as metal farings. The X5 Dome may be...

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