Wabtec PROD0842 Installation Manual Download

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CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL

DOCU0085 Revision Q

Consult with the client to confirm all equipment

mounting locations and power connections!

Do not weld on ROPs!

Do not drill through ROPs!

Note:

It is solely the responsibility of the Installer to ensure the installation is
compliant with the vehicle manufacturer’s instructions, national/local statutory
and site regulations.

Warning

Summary of Contents for PROD0842

Page 1: ...any action in reliance upon this information by persons or entities other than the intended recipient is prohibited unless authorized in writing If you have received this document in error please con...

Page 2: ...ration antenna location altered to Suit Self Test NM 09 08 2016 K Updates to CAM RF Installations Chapter Ignition Power signals added Page 25 NM 23 09 2016 L Update Network Settings Image 05 10 2016...

Page 3: ...ies according to the packing list This will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photos are recommended Where practicable do not rem...

Page 4: ...DOCU0085 Revision Q Storage Where the equipment is not to be installed immediately proper storage is important to ensure protection of equipment and validity of warranty Storage Temperature 30 C to 8...

Page 5: ...DOCU0085 Revision Q Unpacking of Equipment The method of packing used will depend on the size and quantity of equipment Take care when unpacking the equipment to avoid damage to the equipment and ensu...

Page 6: ...etteur radio IC 8903A PROD08422 IC 8903A PROD08472 a t approuv par Industrie Canada pour fonctionner avec les types d antenne num r s ci dessous avec le gain maximal admissible indiqu types d antennes...

Page 7: ...firm all equipment mounting locations and power connections Do not weld on ROPs Do not drill through ROPs Note It is solely the responsibility of the Installer to ensure the installation is compliant...

Page 8: ...y Tools Adhesives Required Coax Crimpers TOOL0112 TOOL0254 for RG 58 214 Coax Cable Stripper TOOL0113 for RG 58 59 Coax Cable Stripper For RG 214 Soldering Iron Butane Heat gun Torx Security Bit T25 M...

Page 9: ...eutsch pin Crimping Tool TOOL0068 or TOOL0101 TOOL0102 Digital Multi Meter Hole Saws 20mm 25mm Self Amalgamating Tape PLAS0684 Loctite 243 CHEM0002 Loctite 248 CHEM0044 30 Metre tape measure Coaxial c...

Page 10: ...10 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q In Vehicle Unit IVU Note All IVUs have their PRODXXXX part number labelled on the flat underside of the housing PROD0842 PROD0847...

Page 11: ...AL DOCU0085 Revision Q Input Power Signal Connections Service Panel SIM Card USB Card Auxiliary USB External Cables LAN Display RF Antenna GPS Antenna GSM Antenna PROD0847 only V2V Antenna WiFi WAN An...

Page 12: ...S IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 24 Way Deutsch Vehicle Electrical Connections Status LEDs Power Signal connector Shown with cover in place IVU Display Input Power Signal Co...

Page 13: ...n the preferred location for that vehicle type It is easily accessible for servicing It is protected against rock fall and other damaging hazards It does not obstruct walkways access or egress It is n...

Page 14: ...les Ensure the correct size Stauff Clamp is used and matched to the specific handrail for that machine and antenna mounting post diameter Regular clamp bodies are available in the following sizes 38mm...

Page 15: ...unning cables near hot spots and pinch points Glands should be used on cables running through bulkheads It is recommended that a service loop be created on all the Antenna Coax Cables this will especi...

Page 16: ...inside the Operator s cabin Notes Antennas must be kept a minimum of 37 cm away from occupants in accordance with MPE Radiation Regulations Consideration must be given to EMI with the vehicle s ECU wh...

Page 17: ...17 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Bracket used here is ATOM0033 V2V GPS GPRS Note Antenna Spacing between V2V and GPRS should be a minimum of 300mm Light Vehicle...

Page 18: ...unted inside the Operator s cabin or the electrical compartment Notes Antennas must be kept a minimum 37 cm away from occupants in accordance with MPE Radiation Regulations Consideration must be given...

Page 19: ...trude above the tray by 100mm Ensure the antennas will clear any working obstacles Standard fitment on opposite side of the vehicle from the operator s cabin OPERATOR S CABIN TRAY Adjust the mast leng...

Page 20: ...20 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Haul Truck...

Page 21: ...iFI or GPRS GSM ANTENNA Note An extended depth socket spanner may be required to tighten the antenna fixing nuts within the bracket channel STEE0690 WASHER NOTE 1 WHERE No WiFi OR GPRS ANTENNA IS DEPL...

Page 22: ...22 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Note TOOL0264 is required to tighten the antenna coax within the bracket channel Haul Truck...

Page 23: ...be correctly chosen for the handrail tube size from the Size 6 heavy series Stauff clamping system Available rubber inserts are 32mm 33 7mm 35mm 38 7mm 40mm 42mm 45 5mm 48mm 51mm 53 4mm 56 4mm Availa...

Page 24: ...ly mounted inside the Operator s cabin Notes Antennas must be kept a minimum of 37 cm away from occupants in accordance with MPE Radiation Regulations Consideration must be given to EMI with the vehic...

Page 25: ...IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Note An extended depth socket spanner may be required to tighten the antenna fixing nuts within the bracket channel Heavy vehicle excluding H...

Page 26: ...26 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Display Unit PROD0839A Serial number Hardware build letter code...

Page 27: ...the field of view of the operator It is not a hazard when operator is entering exiting the machine cabin It has appropriate support so as not to damage any part of the machine Cable routes are careful...

Page 28: ...ision Q Status Bar Current status of system components Approaching Vehicle Vehicle ID Speed Indicator and Distance Your Vehicle Vehicle ID and Speed Indicator Special Functions Buttons Menu Configurat...

Page 29: ...CU0085 Revision Q Screen 7 High Brightness LCD Touch Screen with auto dimming for all lighting conditions Audio Voice and tone output Sensors Light sensor for automatic screen dimming LED LED output f...

Page 30: ...30 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Connector Electrical connection for power and signals RAM Mount Multi axis adjustable mounting bracket Display Unit PROD0839A...

Page 31: ...N MANUAL DOCU0085 Revision Q CAS CAM RF Installations This section describes the interconnections between the CASCAM RF system and CAS GPS system Refer to the CASCAM RF installation documentation for...

Page 32: ...Display All cables may be reused provided they are in a serviceable condition Some power input requirements may change depending on the requested functionality of the system In this case modifications...

Page 33: ...33 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Interconnections 4CAM 4RF...

Page 34: ...D M WHITE BLA CK 11 FWD DI4 22 FWD N PINK BLAC K 12 FWD DI4 23 Ignition DI1 4 Connections on PROD0179 Expansion Unit inputs Signal Wire Colour Signal Wire Marking Deutsch Connector CONN0340 Deutsch Co...

Page 35: ...ECTOR INTERFACE CASGPS IN VEHICLE UNIT IVU CASGPS DISPLAY PROD0850 xM CASGPS IVU TO DISPLAY CABLE PROD0118 CAMERA UNIT 24 WAY DEUTSCH CONNECTOR INTERFACE IGNITION SIGNAL PROD0182 DISPLAY TO IVU CAMERA...

Page 36: ...7 REV DI3 16 VIOLET 8 REV DI3 17 WHITE BLACK 11 FWD DI4 22 PINK BLACK 12 FWD DI4 23 ORANGE 9 BRAKE DI2 10 Ignition DI1 4 Camera RF Cable PROD0182 6 way Deutsch connector PROD0182 24 Way Deutsch Conne...

Page 37: ...Q Interconnections Light Vehicle VEHICLE POWER VIA FUSE 6 WAY DEUTSCH CONNECTOR INTERFACE LIGHT VEHICLE RF UNIT PROD0295 CASGPS IN VEHICLE UNIT IVU CASGPS DISPLAY PROD0850 xM CASGPS IVU TO DISPLAY CA...

Page 38: ...r CASGPS IVU 6 way Deutsch connector PROD0296 6 way Military connector RF Unit PROD0296 PWR RED PWR 6 1 Vin RED GND BLACK GND 5 2 GND BLACK 3 12 BROWN 4 BUZZER BLUE COM1 RX 7 5 RS232 TX GREEN COM1 TX...

Page 39: ...39 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Input Power Signal Connections Basic CAS GPS...

Page 40: ...40 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Input Power Signal Connections Gear Decoder...

Page 41: ...Rxd in SmartCap or CASCAMRF LV 8 CAN CAN Low CAN Low Self Test Node or LFM 9 USBD USBD N USBD N 10 Blue DI2 Input 2 Reverse ve Brake ve Vehicle reverse ve 11 GND Ground Ground SmartCap or CASCAMRF LV...

Page 42: ...it breakers from installation kit 4A Resettable Circuit Breaker to be used on all vehicles for Ignition 4A Resettable Circuit Breaker to be used on all vehicles for VIN Fuse location should be accessi...

Page 43: ...se signal should be obtained from the vehicle s reverse buzzer or alternatively the reverse lights The forward signal may be wired from a suitable forward gear indicator with the forward negative sign...

Page 44: ...splices should be soldered and heat shrink insulation applied All wires are to be labelled i e IGN VIN GND REV using the supplied labels DO NOT use clamp type splice devices to tee into vehicle wirin...

Page 45: ...LLATION MANUAL DOCU0085 Revision Q Antenna cable terminations You need to have received the proper training before attempting to terminate antenna cables Antenna cable terminations are one of the most...

Page 46: ...tric to dimensions in the table below for the appropriate cable and connector All cuts are to be sharp and square Important Do not nick braid dielectric and centre conductor Cable Type A mm B mm C mm...

Page 47: ...Flare slightly end of cable braid as shown to facilitate insertion of inner ferrule Important Do not comb out braid 4 Place contact on cable centre conductor so that it butts against cable dielectric...

Page 48: ...errule portion slides under braid Push cable assembly forward until contact snaps into place in insulator The tip of the centre contact should be level with the face of the connector 6 Slide outer fer...

Page 49: ...0085 Revision Q 7 Move the heatshrink up over the ferrule and shrink into place using a heat gun This will aid in preventing moisture ingress to the termination Heatshrink here 8 Repeat steps 1 7 for...

Page 50: ...vision Q Test completed cable for continuity and short circuits by completing the following 1 With both ends of the cable disconnected Measure the resistance between the inner and outer conductors Mus...

Page 51: ...pposite end Must be low resistance 1 4 If available measure the SWR of the completed cable with a 50 dummy load installed in place of the antenna SWR of cable should remain around 1 in the frequency r...

Page 52: ...n antenna cable connections with adequate force to prevent loosening Apply self amalgamating tape over the cable antenna connection This will prevent loosening and provide environmental protection Cau...

Page 53: ...instruct on the configuration process for CAS GPS They are straight forward with no laptop being required Configuration is programmed through the Graphic User Interface Display Note The Installer wil...

Page 54: ...Measurements Vehicle Length m Vehicle Width m GPS Antenna Length from front The measurements indicated here are the dimensions of the machine and GPS Antenna location These measurements are crucial f...

Page 55: ...55 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q A Truck Length Measurements shown here are an example of a Haul truck Configuration Installation Measurements...

Page 56: ...56 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q B Truck Width C GPS antenna height Measurements shown here are an example of a Haul truck Configuration Installation Measurements...

Page 57: ...U must be recorded so that the 3 axis accelerometer can be correctly calibrated The table right should be used to determine the orientation number of the installed IVU The orientation is referenced to...

Page 58: ...VU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Orientation Number 1 IVU mounted on the internal floor surface Orientation Number 7 IVU mounted inside cabin behind the rear seat IVU Orientati...

Page 59: ...59 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Configuration Button Use the button at bottom of Display to access CAS GPS CAS Installer window Configuration...

Page 60: ...e Select the Object type by clicking on the object type drop down box and select the correct vehicle for the installation Once the object type is selected it automatically populates the typical dimens...

Page 61: ...reen this configuration is now stored and system is now ready to use Note Refer also DOCU0139 CASWeb User manual Wi Fi IP Enter the assigned Wi Fi IP Address for the Vehicle The Network button shows c...

Page 62: ...node can be installed to provide another position from which a heading can be determined To provide the minimum error the antenna connected to the IVU and the node should be installed as far apart as...

Page 63: ...not including the boom Width The width of the body of the Shovel Rotation point from front is the distance from the front of the body to the center of the rotation point Boom length The maximum length...

Page 64: ...s To change this box you must enter the passcode Location This is the location of the node GPS antenna B relative to the front left corner of the body Sync Press this button to synchronise the stored...

Page 65: ...65 CAS GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Node Installation Refer to DOCU0088 CAS GPS SELF TEST SUB SYSTEM INSTALLATION MANUAL...

Page 66: ...The second status icon indicates the communication status to the node Green indicates good Yellow indicates warning no message received in the last 5 seconds Red indicates error no message received i...

Page 67: ...and operating If the GPS icon change to yellow this indicates that the IVU no longer has a valid heading Potential causes Loss of communication between IVU and node will be indicated by the status ico...

Page 68: ...completion of the physical installation Complete the Installation Checklist to ensure record that the system is installed correctly and is operating as expected Complete the Installation Record carefu...

Page 69: ...YSTEMS INSTALLATION MANUAL DOCU0085 Revision Q Record Keeping Take photographs of the completed installation for future reference and record of installation Provide all completed installation records...

Page 70: ...the IVU Contact an authorized representative to inspect the system Connect charge and retest Replace retest If fuse blowsagain contact authorized representative to inspect Replace cable and retest Th...

Page 71: ...view of the sky Isthe antenna in good condition Are the connectors securely tightened at the antenna and the IVU Contact an authorized representative to inspect the system No fault detected by the sys...

Page 72: ...error detected IsV2Vicon Red Isthe antenna in good condition Are the connectors securely tightened at the antenna and the IVU Isthe antenna cable in good condition no cutsor breaks Contact an authoriz...

Page 73: ...carried out by trained and authorised personnel every 6 months or 1500hrs which ever occurs first Software Updates Software updates are automatically pushed out to all IVU S connected to the CAS serve...

Page 74: ...damage to screen surface Check the cable connector is securely connected at the rear of the screen finger tighten only if loose Check the mounting bracket is secure finger tighten only if loose Syste...

Page 75: ...uld only be performed if authorised by the owner of the vehicle Removal should only be performed by a qualified Auto Electrician All system components and wiring should be removed All vehicle wiring s...

Page 76: ...or disposed of into landfill By ensuring that this product is disposed of correctly you will be helping to prevent potentially negative consequences for the environment and human health which could o...

Page 77: ...p mining pit near a high wall or under a workshop roof Consideration should be given to supplementing GPS with RF proximity detection and visual aids using cameras Alarm logic should be determined via...

Page 78: ...S OR IMPLIED WARRANTY REGARDING ANY PRODUCTS DESCRIBED IN THESE MATERIALS TO THE MAXIMUM EXTENT PERMITTED BY LAW WABTEC CORPORATION DISCLAIMS ANY AND ALL IMPLIED WARRANTIES THAT MIGHT OTHERWISE ARISE...

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