"service manual"
Contents
1. 0 5 About the Vehicle Information Unit VIU eee eeeeeeete eter eeeeeenteeeeeeeeeee 6 About the Vehicle Identification Terminal VIT 6 Bypassing Fl tLINK 2 2 5 7 00 M tanhbetyecans danteieateteagetesdecatectamnads 6 Recording Transactions aip iride aaa 7 Vehicle Information Unit VIU 9 Fuel Inlet Transceiver Loop Antenna www 9 Serial Data Link Optional wiisc on rire asi radente pae 10 Universal Vehicle Speed Sensors 11 What IS PR ara e e eaa E 11 Installing the Speed Sensor on REAR Wheel Drive Vehicles 12 Installing the Speed Sensor on FRONT Wheel Drive Vehicles 14 Inside the Vehicle eri ei a 15 Determining VIU Mileage Factor 16 Preterred MONA iaia iraniana 16 Altemate Method x intr css tele ili nale iii nisi 16 li FUEL MANAGEMENT SYSTEMS VIU Mileage vs Real Mileage ii 16 Calculating a New Mileage Factor i 16 Where VIU Components Go In Typical Vehicles 17 VIU in a Passenger Automobile ii 17 VIC ina Tr ck or BUS siii iaia 18 Installing the VIU s ii 19 Tools amp Instruments You Will Need 19 Before YOU BIS D Ne une 20 Planning the VIU installation ss nan 20 VIU Placement sornes onteren ar iene 20 Wiring Harness Placement 22 Transceive2. Timed Delay Errors e Check for loose connections If OK replace VIU unit Vehicle Cannot Be Refueled e Ifit cannot be fueled at any approved FleetLINK refueling station check for incorrect programming of any of the following parameters e Vehicle identity check and correct e Fleet and user codes try to reprogram using other Programmer e Check LEDs on VIT board e Possible defective VIU VIU Maintenance amp Service In Case of Problems 6 22 04 Warning 6 22 04 Vehicle Information Unit Installation amp Service Manual 41 Two tank Vehicle One tank cannot be filled e Check ground connection on transceiver loop cable installed on the tank e Disconnect transceiver loop of bad tank and connect another good loop to the two pin connector and to VIU body If signal appears the original loop is defective and must be replaced Radio Frequency Interference RFI Problem e Check ground connection on VIU and transceiver loop cable e Check if radio cables are routed near the FleetLINK wiring harnesses Reroute if necessary Vehicle Odometer Does Not Work e Remove FleetLINK connection if vehicle odometer works replace the VIU e Ifchecks listed above do not reveal the source of a problem the fault is probably not related to the FleetLINK installation Have the vehicle repaired If a VIU unit is replaced it must be programmed with the parameters appropriate to the system user operat ing the veh
3. fuel type vehicle engine hours and odometer reading optional Information from the VIU is transmitted from an antenna coil installed on the fuel tank inlet to a receiving antenna on the pump nozzle VIU programming is required whenever a VIU is installed in a vehicle The programming is done with a Programmer a Palm M_0S based PDA explained fully in the VIU Programming Manual our part number M00 047 20 About the Vehicle Identification Terminal VIT The site based VIT is installed in either the Fuel Island Terminal FIT pedestal in front of the pump control board in the indoor Pump Control Terminal PCT cabinet or in a special outdoor enclosure The VIT can be up to 1 000 feet from the fuel dispenser The unit receives data from the VIU through coils on the fuel filler pipe and nozzle The VIT acts as a bridge between the OPW Fuel Management Systems Fuel Site Controller FSC and the FleetLINK VIU sending and receiving data from the two components over twisted pair wire Each VIT can communicate with up to eight fueling nozzles Each FSC can communicate with four VITs After verifying vehicle identity and authorization from the VIT the FSC instructs the fuel dispenser to supply the required amount of fuel of the type indicated by the received data Bypassing FleetLINK Fuel station operators can also manually activate a dispenser to fuel vehi cles without a FleetLINK VIU unit The station operator must send a priv
4. inches of the front universal joint but away from exhaust components or moving parts The sensor must be within ONE INCH of the magnet to reliably detect the magnetic field Bend the bracket so the sensor is properly positioned near the drive shaft Using the bracket as a template mark the floor pan for two self tapping screws Confirm that the screws will not damage anything inside the vehicle before drilling 6 7 8 Carefully punch or drill two holes in the floor pan to secure the bracket Mark the drive shaft directly inline with the sensor Attach the magnet to the drive shaft with the notch facing out Use the supplied plastic wire tie and secure the magnet with RTV to keep the magnet from shifting Route the wires into the vehicle You can use an existing hole prefera bly one with a grommet already installed or drill a new hole Remove sharp edges after drilling then install a grommet or sleeve to protect the wires You can extend the wiring if needed with wire of a similar gauge and type Make sure your splices are clean and tight 6 22 04 Universal Vehicle Speed Sensors Installing the Speed Sensor on FUEL MANAGEMENT SYSTEMS FleetLINK Fuel Control System Installing the Speed Sensor on FRONT Wheel Drive Vehicles TRANSAXLE 1 2 to 1 00 Inboard CV Joint Magnet Figure 5 Typical Front Wheel Drive Installation Step By Step Procedure FRONT Wheel Drive 1 Raise
5. CONTROLLER 6 PIN CONNECTOR TRANSCEIVE FUEL TANK HARNESS _LOOP INLET Figure 6 Typical VIU Installation in Passenger Automobile The VIU is installed in the vehicle trunk or passenger compartment at least 3 feet from the fuel tank inlet Power for controller operation can be taken from any nearby 12V positive non accessory i e that is on all the time battery line e g from a nearby lighting point The transceiver loop is located over the fuel tank inlet and its cable is connected to the VIU Usually the transceiver loop is located on the outside of the car and should be visible from the outside when fuel tank cap is removed Typically a shielded three wire section of the harness connects the VIU to the engine compartment In the engine compartment the harness is connected to the output from the speed sensor The optional transducer is installed on the odometer cable or on the gearbox odometer output and the flexible cable is connected to its other end 6 22 04 Universal Vehicle Speed Sensors Where VIU Components Go In Typ 18 O P VV FeciLiNK Fuel Control System FUEL MANAGEMENT SYSTEMS VIU in a Truck or Bus Figure 7 shows a typical VIU installation in a truck or bus and illustrates the location of the various sub system components within a typical truck Transceiver VIU Transducer Connector option Figure 7 Typical VIU Installation in a Truck In a truck or a bus the VIU is usually installed
6. Station Code federal state and local codes and any other applicable safety codes and regulations Do not smoke Aside from it being bad for your health smoking around hydrocarbon vapors might cause an explosion Do not perform metal work with fuel tank cover removed or when any fuel leakage is sus pected and do not perform any operation that may impair fuel tank of fuel pipe safety Use pneumatic tools for metal work Be sure you work in a well ventilated area Installing the VIU VIU Step By Step Installation 26 CPVWV FeeflINK Fuel Control System FUEL MANAGEMENT SYSTEMS Installing the Transceiver Loop To reference item numbers see Figure 11 on page 27 1 Place the loop item 7 around fuel tank inlet 3 on the external side of the body sheet metal The fuel tank filler cap must be in place If you must remove the filler cap plug the fuel tank inlet with a rubber cork or stopper to prevent a dangerous accu mulation of vapors Prior to installation verify that fuel tank inlet is clean and free of any liq uid 2 For each vehicle type determine the appropriate routing of the cable 9 e Thread the cable through a flange hole 8 OR Route the cable between the flange and the body 11 OR 3 Thread the cable through a hole to be bored in plastic 10 In vehicles in which more than one option applies routing through a flange hole item 8 is preferred Otherwise try to route the cable be
7. Vehicle Information Unit The Vehicle Information Unit controller is a small computer which mounts in a vehicle and stores vehicle data The VIU continuously transmits this information through the transceiver loop antenna The VIU is powered by the vehicle battery consuming about 50 mA It operates continuously even when the vehicle s engine is off When the VIU is first installed in a vehicle it must be initialized with the basic parameters of the vehicle in which it is installed vehicle information system user identification type and grade of fuel initial mileage etc Fuel Inlet Transceiver Loop Antenna 6 22 04 The transceiver loop Figure 3 is installed around the fuel tank inlet and connects by means of a short cable to the VIU The loop transmits and receives information to and from the pump nozzle antenna Vehicle Information Unit VIU Fuel Inlet Transceiver Loop Antenna 10 C P VWV FleetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS For vehicles having two fuel tanks a transceiver loop is installed around each tank inlet The leads from the two loops are then connected in parallel to the VIU s two pin connector To fit various inlet sizes loops are avail able in several diameters Figure 3 Fuel Inlet Transceiver Loop Antenna Serial Data Link Optional Many diesel trucks and buses manufactured after 1995 require a serial data link SDL The SDL isolates the vehicle engine
8. installation troubleshooting and ser vice instructions for the FleetLINK Vehicle Information Unit subsystem VIU This manual tells you About the Vehicle Information Unit VIU How to install VIU components onto a passenger car or truck What a customer does to use the FleetLINK system Troubleshooting any problems you may have with the VIU compo nents FleetLINK equipment is also supported by the following manuals 6 22 04 Installing the VIT Kit manual manual part number M00 020 4262 tells you how to mount the VIT PC board s into a System2 pedestal a C OPT pedestal a remote PCT enclosure or a dedicated VIT enclosure VIT Enclosure Installation Guide manual M00 020 8226 explains installing and wiring the dedicated VIT box You don t need these instructions if your VIT s are going into a pedestal or PCT cabinet Nozzle Kit Installation Instructions manual M00 047 30 tells you how to attach the FleetLINK antenna loop device to your fueling noz zle VIU Programming Manual manual M00 047 20 explains the hand held Palm based programmer used to program the FleetLINK Vehi cle Information Unit System2 for FleetLINK Operator Manual manual M41 21 04A explains how to program OPT Fuel Management System s System2 Fuel Site Controller to work with the FleetLINK system What s In This Book 4 PW FleetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS What s In This Book 6 22 04 Vehicle Info
9. FUEL MANAGEMENT SYSTEMS FleetLINK Fuel Control System Vehicle Information Unit VIU Installation amp Service Manual 2004 OPW Fuel Management Systems Manual No M00 047 10 OPW Fuel Management Systems FleetLINK System and Replacement Parts Warranty Statement Effective May 1 2004 FleetLINK System Components OPW Fuel Management Systems warrants that all components of the OPW FleetLINK System excluding Pump Nozzle and Vehicle components supplied by OPW Fuel Management Systems to the Original Purchaser will be free from defects in material and or workmanship under normal use and service for a period of 12 months 90 days labor from the date of installation FleetLINK Pump and Nozzle Components OPW Fuel Management Systems warrants all FleetLINK Pump and Nozzle components for ONE YEAR parts 90 DAYS labor from the date of installation Pump and Nozzle Components include the Pump Barriers Nozzle coils and any associated wiring FleetLINK Vehicle Components OPW Fuel Management Systems warrants all FleetLINK Vehicle components for ONE YEAR parts ONLY from the date of installation Vehicle Components include the Vehicle Identification Unit VIU and the tank coil Replacement Parts New and Remanufactured OPW Fuel Management Systems warrants all upgrades and replacement parts new and remanufactured including Pump Nozzle and Vehicle components supplied by OPW Fuel Management Systems to be free from defects in material and wo
10. LINK Fuel Control System Installing the VIU This paragraph provides generic instructions for VIU installation and the connection of cables to that unit l 6 See Figure 8 on page 21 then drill four holes at intended VIU location at least 3 feet from the fuel tank inlet Position the VIU in place and fasten it with self tapping screws Connect the transceiver loop cable connector to pins 1 and 2 on the VIU Refer to the drawing on the VIU Attach female spade lugs to the wiring then attach the spade lugs to the VIU s terminals Connect vehicle battery POS to TERMINAL 3 and GROUND to TERMINAL 6 ofthe 6 pin VIU connector Figure 12 on page 29 Route the loop cable from the loop to the VIU keeping it away from existing wiring by attaching it to the vehicle frame with cable ties Use cable ties to attach loose existing wiring to the frame away from the transceiver loop cable Inspect your installation Perform this inspection before power is connected to system Make at least the following checks Check the installation layout by comparing it to the original installation plan Check your connections from the wiring harness to the dashboard Check the wiring harness routing and fastening Specifically check clearances from moving parts exhaust components and ignition leads Make sure harness is not attached to steering column brake cables or hydraulic or pneumatic lines Check where the wiring harness
11. ST TIME INSTALLATION PROBLEMS Carefully follow each wire and check that it is correctly routed and connected according to the approved installation plan VIU Maintenance amp Service In Case of Problems 6 22 04 Vehicle Information Unit Installation amp Service Manual 39 Troubleshooting Procedure This section explains the following common problems and their likely solutions e No Output Signal From Transceiver Loop e Odometer Reading From VIU Does Not Change e Engine Hours Reading Does Not Change e Odometer Reading Does Not Correspond to Registered Mileage e Programmed Parameters are Lost e Timed Delay Errors e Vehicle Cannot Be Refueled e Two Tank Vehicle One Tank Cannot Be Refueled Radio Frequency Interference RFI Problem Vehicle Odometer Does Not Work No Output Signal from Transceiver Loop 6 22 04 Check ground connection on transceiver loop cable Check resistance of the loop It should be between 11 and 17 ohms Connect a known good transceiver loop to the two pin connector on the VIU If signal appears the original loop is defective and must be replaced Connect a scope between pin 1 of connector J2 and the VIU body and monitor the signal Correct waveform consists of 2 millisecond bursts of data separated by intervals of up to 6 milliseconds Signal amplitude should be at least 1 volt peak to peak Compare with the signal gener ated by a known good VIU in another vehicle Check for batte
12. Service This section contains information on Tools amp Instruments Periodic Inspec tion and Troubleshooting Repair of VIU sub system Explosion Hazard Danger Maintenance or service must be performed by quali fied people who are aware of all safety issues During servicing of harness and or transceiver loop around fuel tank inlet and during work in engine com partment installers MUST comply with all applicable requirements of the National Fire Protection Associa tion NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service Station Code federal state and local codes and any other applicable safety codes and regulations Do not smoke do not perform metal work with fuel tank cover removed or when any fuel leakage is sus pected and do not perform any operation that may impair fuel tank of fuel pipe safety Use pneumatic tools for metal work Be sure you work in a well ventilated area Standard Test equipment is not suitable for use in a Hazardous Area Do not perform any tests within 3 feet from vehicle s gas tank or when VIU coil is con nected to the VIU Tools and Test Equipment 6 22 04 No special tools are required for VIU sub system maintenance and service A standard tool kit is necessary the contents of which are listed on page 19 Connector repairs are made using standard automotive connector crimping tools VIU Maintenance amp Service Tools and Test Eq
13. able fastener 4 holds the trans ceiver loop 7 in position Be careful to avoid any stress on the loop 7 Thread the cable through a hole made in plastic Note This installation method is applicable only if the fuel tank hous ing inlet is made of plastic Use a screwdriver or punch to bore a hole in the housing 8 Using a screwdriver carefully bore a hole in the housing inlet 10 Warning During the hole boring process be careful not to damage the fuel lines fuel entry line fuel vent line and excess fuel line 9 Insert a neoprene compression gland or apply RTV sealant around loop cable and insert the cable through hole 10 Using a wrench unscrew all screws 5 that secure flange 2 to body 1 11 Place transceiver loop 7 around fuel tank inlet 3 12 Using a wrench torque all screws 5 securing the flange to the body and make sure that the cable fastener 4 holds the transceiver loop 7 in position Be careful to avoid any stress on the loop Warning Make sure tank cap is tightly secured so that no fuel can be spilled Installing the VIU VIU Step By Step Installation 6 22 04 Vehicle Information Unit Installation amp Service Manual 29 e4 Ae 4 L Figure 12 VIU Wiring Diagram 13 Connect the center contact of the loop coaxial cable to the appropriate connector on the VIU 6 22 04 Installing the VIU VIU Step By Step Installation FUEL MANAGEMENT SYSTEMS Fleet
14. and safely support the vehicle so you can work near the front drive axle Attach the sensor to the mounting bracket using the hardware supplied with the sensor 3 Locate the inner CV joint Universal Vehicle Speed Sensors Locate a spot on the frame or trans axle near the inboard CV joint but away from exhaust components or moving parts The sensor must be within ONE INCH of the magnet to reliably detect the magnetic field Using the bracket as a template mark the frame for two self tapping screws Drill and install the bracket sensor assembly OR use existing transaxle hardware to mount the bracket Bend the bracket so the sensor is properly positioned near the axle Installing the Speed Sensor on FRONT Wheel Drive Vehicles 6 22 04 Note Vehicle Information Unit Installation amp Service Manual 15 Mount the bracket in a secure location but away from exhaust components or moving parts like the steering gear 7 Mark the CV housing directly in line with the sensor Attach the magnet with the RTV compound to the CV housing with the notch facing out Secure the magnet to the driveshaft with the supplied plastic wire tie Route the wires into the vehicle Tie wiring up and out of the way of moving or hot parts Use an existing hole preferably one with a grom met already installed or drill a new hole Remove sharp edges after drilling then install a grommet or sleeve to protect the wires You can extend t
15. aw Small hammer Digital Multi meter Power drill and drill bits Test lamp 6 24V Installing the VIU Tools amp Instruments You Will Need 20 O P VWV FietLINK Fuel Control System FUEL MANAGEMENT SYSTEMS Explosion Hazard Installation must be performed by qualified people M who are aware of all safety issues a During installation of harness and or transceiver loop around fuel tank inlet and during work in engine com partment installers MUST comply with all applicable requirements of the National Fire Protection Associa tion NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service Station Code federal state and local codes and any other applicable safety codes and regulations Do not smoke Aside from it being bad for your health Lv smoking around hydrocarbon vapors might cause an explosion Do not perform metal work with a fuel tank cover removed or when any fuel leakage is sus pected Do not perform any operation that could impair fuel tank of fuel pipe safety Use only pneu matic tools for metal work Before You Begin A typical installation consists of the following steps e Determine installation layout e Transducer installation if required e Route wiring harness from transducer or dashboard to the VIU e Transceiver loop installation VIU installation e Inspection Planning the VIU installation VIU Placement The VIU must be located
16. behind the driver s seat in the cab Power for VIU operation can be taken from the truck s fuse panel usually located under the dashboard The transceiver loop is located over the fuel tank inlet and its cable is con nected to the VIU In trucks with two fuel tanks two transceiver loops are installed and are connected in parallel to the VIU A shielded section of the harness connects the VIU to the engine compart ment In the engine compartment the harness is connected to a transducer or the transmission speed sensor Universal Vehicle Speed Sensors Where VIU Components Go In Typical Vehicles 6 22 04 Vehicle Information Unit Installation amp Service Manual 19 Installing the VIU This section provides standard installation programming and start up instructions for the FleetLink VIU sub system Installation procedures and requirements depend to some extent on the specific vehicle model Use the information appearing in this chapter to develop installation plans for each specific vehicle model Tools amp Instruments You Will Need The following is needed to install and service the FleetLINK system 6 22 04 Open ended wrench set Nuts and washers small amp medium sizes Allen wrench set Phillips screwdrivers various sizes Regular screwdrivers various sizes Wire cutters small and regular sizes Pliers long nose and regular Cutting blade Crimping tool Fine toothed file round and flat Small hand s
17. brake or steering system components Keep the transducer wiring AT LEAST 4 inches 10 cm from ignition wiring particularly high voltage cabling like spark plug wires and other secondary ignition cabling Never attach the harness to moving parts to hydraulic or pneumatic lines or to clutch or brake cables If the harness is run along the chassis protect it from objects that may strike vehicle bottom and locate it away from regions where lifts or jacks may be applied Finally keep it away from exhaust pipes Use a neoprene grommet to pro tect and secure the harness at the trunk reentry point Transceiver Loop Placement The transceiver loop is placed around the fuel tank inlet on the outside of the sheet metal It is held in place with four cable ties the adaptive loops need no installation hardware Use an entry hole with a neoprene grommet for the loop cable Transceiver loops come in various sizes to fit on most cars and trucks For vehicles with two fuel tanks two loops are connected in parallel to the two pin connector A typical installation for a transceiver loop in a passenger automobile is shown in Figure 9 Installing the VIU Planning the VIU installation 6 22 04 6 22 04 Vehicle Information Unit Installation amp Service Manual 23 A typical installation in a truck is shown in Figure 10 on page 24 TRANSCEIVE LOOP x FASTENER FUEL INLET GROMMET 4 PLACES COVER Figure 9 Typical T
18. computer from outside devices and is typically required by the vehicle manufacturer to maintain vehicle warranty SDL equipped vehicles have a round diagnostic connector under the dash on the driver s side The SDL requires constant 12 volts and a ground Two wires BUSS and BUSS attach to the vehicle s diagnostic connector The SDL gener ates a vehicle speed output of 8 000 pulses per mile Complete instructions are included with the SDL Vehicle Information Unit VIU Serial Data Link Optional 6 22 04 Vehicle Information Unit Installation amp Service Manual 11 Universal Vehicle Speed Sensors Warning Never work on or get under a vehicle supported only by a jack Use jack stands or ramps designed to sup port the weight of the vehicle Always chock the vehi cle wheels and set the parking brake Failure to follow safe jacking procedures endangers your life What Is It The universal speed sensor kit supplies mileage and speed data for Fleetlink systems The kit is required on the following vehicles e Vehicles that do not have access to the factory speed sensor or difficult to install vehicles Vehicles which because of warranty or other concerns the manufac turer prohibits attachment of third party devices to its speed sensor sub system The universal speed sensor is a Hall effect device that sends pulses to the FleetLINK Vehicle Information Unit VIU The pulses are counted and co
19. d lug to VIU unit If connections were made to the dashboard or car cruise con trol circuit check these connections as well Repeat all steps for each loop installed on the vehicle 6 22 04 VIU Maintenance amp Service Inspection Procedure 38 O P VV FieetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS In Case of Problems This section provides procedures that allow trained peoples to repair a mal functioning VIU sub system Repair is performed by isolating the malfunc tion to one of the sub system components and replacing the defective component Caution Do not open the VIU box The box is a sealed protective enclo sure which contains delicate microelectronic components These components will be damaged by incorrect handling Opening the box will void your warranty For required tools and test equipment see Tools amp Instruments You Will Need on page 19 Before You Begin Troubleshooting Before beginning your actual troubleshooting do the following 1 Perform a complete visual inspection of the VIU sub system nspec tion Procedure on page 37 Pay particular attention for the following e Mechanical damage e Unauthorized modifications or tampering e Worn wire insulation Loose connections Torn wires e Corrosion 2 Use a multi meter to measure battery voltage at the point to which VIU power connection is made Voltage should be the same as the vehicle s battery voltage 3 FIR
20. d the mileage and mul tiply by 100 this is the factor VIU Mileage vs Real Mileage If the mileage that you read from the VIU is higher than the actual mile age the vehicle travelled raise the Mileage Factor If the mileage that you read from the VIU is ower than the actual mile age the vehicle travelled lower the Mileage Factor Calculating a New Mileage Factor l Read the distance traveled since VIU installation or last synchroniza tion try to travel at least 1 000 miles from both the VIU and the vehi cle odometer Note the difference between the VIU mileage and the odometer mile age Divide the difference by the odometer mileage traveled to get the of error move the decimal point 2 places to the right Add the percent error to the factor if the VIU mileage is higher than the odometer or subtract it if the VIU mileage is lower After adjusting the factor synchronize VIU mileage with the vehicle odometer mileage Universal Vehicle Speed Sensors Determining VIU Mileage Factor 6 22 04 Vehicle Information Unit Installation amp Service Manual 17 Where VIU Components Go In Typical Vehicles VIU in a Passenger Automobile Figure 6 shows a typical VIU installation in a passenger automobile by illustrating the location of the VIU sub system components INTERNAL TRUNK LIGHT l ODOMETER POWER TO SPEED SENSOR CONTROLLER FLEXIBLE SHAFT CONTROLLER POWER LINE CONTROLLER UNIT FUSE
21. enters into the trunk and also where it connects to the VIU Check the transceiver loop installation Check the loop location on the external side of vehicle body Check all the fasteners Make sure there are no signs of fuel leakage Test also for fuel vapors which might indi cate damage to fuel pipe Inspect loop cable entry and all connections to the VIU Make sure tank cap is secured tightly so that no fuel can be spilled Check VIU installation and fastening to mounting surface Installing the VIU VIU Step By Step Installation 6 22 04 Vehicle Information Unit Installation amp Service Manual 31 Only after inspection shows the VIU to be correctly installed should you apply power to the VIU sub sys tem After installation the FleetLINK system is transparent to the station opera tor and to the customer Self service operation is the same with one excep tion transactions performed by authorized vehicles are automatically recorded and charged therefore no attendant is required for recording vehi cles and supplied fuel volumes or for accepting payment 6 22 04 Installing the VIU VIU Step By Step Installation 32 BPW FieetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS Installing the VIU VIU Step By Step Installation 6 22 04 Vehicle Information Unit Installation amp Service Manual 33 Basic FleetLINK Operation Most aspects of FleetLINK are transparent to your fueling customers Th
22. er Loop Installation Automobile 27 Figure 12 VIU Wiring Diagram 29 iv PVV FeetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS 6 22 04 Vehicle Information Unit Installation amp Service Manual 1 Warnings Read these and all warnings and instructions care fully They are included to help you install and main tain the FleetLINK equipment safely in the highly flammable environment of a fueling station Disregarding these warnings and instructions might lead to death serious injury and property loss or dam age to you and others It is YOUR responsibility to install operate and maintain the equipment according to the instructions appearing in this manual and to conform to all applicable codes regulations and safety measures Failure to do so could void all your warranties connected with this equipment Explosion Hazard 6 22 04 During installation of harness and or transceiver loop around fuel tank inlet and during work in engine com partment comply with all applicable requirements of the National Fire Protection Association NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service Station Code fed eral state and local codes and any other applicable codes or regulations Do not smoke Aside from it being bad for your health smoking around hydrocarbon vapors might cause an explosion Do not perform metal work with
23. fuel tank cover removed or when any fuel leakage is sus pected Do not perform any operation that may impair fuel tank of fuel pipe safety Use pneumatic NEVER electric tools for metal work inside the hazardous area Warnings 2 PW FleetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS For Driver s Safety During installation of FleetLINK equipment DO NOT tamper with vehicle brake and steering systems This may affect vehicle safety Never attach wires or cables to the steering column brake system cables and conduits or to any mov ing mechanical part Route cables safely and securely use wire ties in SAFE locations under dash For Installer s Safety Warnings When performing work in the engine compartment STOP THE VEHICLE ENGINE to prevent severe injury or death Make sure no one will start engine while any work is in progress Remove the ignition keys if possible Use only adequately rated properly approved equipment to elevate vehicles Observe all safety precautions when working under vehicles NEVER WORK UNDER A VEHICLE SUPPORTED ONLY BY A TIRE CHANGING JACK Use tire blocks chocks whenever vehicle is parked for installation procedures Use traffic safety cones to warn other drivers of stationary vehicles Vent exhaust from enclosed areas 6 22 04 Vehicle Information Unit Installation amp Service Manual 3 What s In This Book This manual M00 047 10 provides
24. he wiring if needed with wire of a similar gauge and type Make sure your splices are clean and tight Inside the Vehicle The speed sensor has 3 wires pe ge AI E 6 22 04 Red DC IN 5 VDC Black GROUND White SIGNAL OUT to VIU Connect the red wire to VIU connector position 2 Connect the black wire to a solid chassis ground Connect the white wire to VIU connector position 1 Route all wires out of the way of moving parts and passengers keep the wires away from the exhaust system Make all connections in a secure and permanent manner and when running wires and making connec tions outside the vehicle be sure to keep the connections dry to prevent corrosion from damaging the installation Universal Vehicle Speed Sensors Inside the Vehicle FUEL MANAGEMENT SYSTEMS FleetLINK Fuel Control System Determining VIU Mileage Factor After installing the VIU you must determine mileage factor a value that ties the vehicle s characteristics to those of the VIU Preferred Method See your VIU Programing Manual for complete details on the following procedure Calculate the factor with the following method which can verify any vehi cle factor 1 2 3 4 Read the mileage from the VIU this is the approzimate factor for that Set VIU mileage to 0 zero Set the factor to 0 Drive the vehicle exactly 1 mile vehicle Alternate Method You can also drive the vehicle 52 feet 10 inches rea
25. i leged System2 SET PUMP ON command to the FSC As you might expect this option should be limited to more advanced and or authorized users About FleetLINK About the Vehicle Information Unit VIU 6 22 04 Vehicle Information Unit Installation amp Service Manual 7 Recording Transactions The System2 FSC records each refueling transaction together with relevant information vehicle identity or manual authorization system user station code fueling date and time fuel type and optionally vehicle engine hours or odometer reading See the System2 For FleetLINK Operator Manual number M41 21 04X X depending upon your firmware version for details on these bookkeep ing functions 6 22 04 About FleetLINK Recording Transactions 8 PW FleetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS About FleetLINK Recording Transactions 6 22 04 Vehicle Information Unit Installation amp Service Manual 9 Vehicle Information Unit VIU Caution The VIU described in this section is installed in all vehicles that are authorized to use the FleetLINK system The VIU must be mounted inside the vehicle The VIU Figure 2 is a small vehicle mounted device that provides vehicle identity fuel type vehicle engine hours and odometer reading optional The information is transmitted from a coil on the vehicle s fuel tank fill pipe to a receiving antenna on the pump nozzle Figure 2 VIU
26. icle with the replaced VIU VIU Maintenance amp Service In Case of Problems 42 CO P VV FeeflINK Fuel Control System FUEL MANAGEMENT SYSTEMS VIU Maintenance amp Service In Case of Problems 6 22 04 Index C Controller Fuse 21 Mounting 20 Mounting template 20 D Driver errors 33 F Filler cap warnings 26 Fuse 24 Inspection 30 6 22 04 Maintenance 35 O Operation 31 Oscilloscope 36 P Passenger car installs 17 T Test eguipment 36 Tools reguired 35 Transceiver loop Installation 25 Vehicle Information Unit Installation amp Service Manual 43 Overview 9 Transducer Harness 22 Placement 20 Troubleshooting 35 V VIU Vehicle Information Unit Installation 30 W Wiring diagram 21 Wiring harness 26 O P We FUEL MANAGEMENT SYSTEMS OPW Fuel Management Systems 6900 Santa Fe Drive Hodgkins IL 60525 708 485 4200
27. inside the vehicle at least THREE feet from the fuel tank inlet Select a location that protects the VIU and cables connected to it from direct impact during normal vehicle operation and from exces sive heat water oil and other agents harmful to electronic equipment Installing the VIU Before You Begin 6 22 04 Vehicle Information Unit Installation amp Service Manual 21 You must supply the VIU with 12 24 VDC There is an internal 1A fuse Figure 8 shows mounting dimensions for the controller For best results trace the outline of the actual controller on the mounting surface using the controller itself as the template A 83 in 4 65 cm 5 80 in 14 7 cm 4 50 in 0 180 dia for 8 hardware Y lt 2 35 in gt 6 0 cm Figure 8 VIU Mounting Template Figure 12 on page 29 is a VIU sub system wiring diagram 6 22 04 Installing the VIU Planning the VIU installation FUEL MANAGEMENT SYSTEMS FleetLINK Fuel Control System Wiring Harness Placement This wiring harness typically consists of three wires see Figure 12 on page 29 running from the engine compartment or transmission gear box to the trunk The harness should run along the vehicle side on which the fuel tank inlet is located Whenever feasible use existing conduit runs other wise attach the harness to chassis supports When determining routing consider slack and be sure to provide sufficient clearance from moving parts
28. is is all that the driver has to do 1 Stop his or her vehicle near a FleetLINK equipped dispenser pump 2 Turn OFF the engine 3 Open the vehicle fuel tank cap 4 Remove dispensing nozzle from dispenser and raise the dispenser con trol lever 5 Insert the dispenser nozzle into the vehicle fuel tank inlet wait for authorization then squeeze handle to start fueling 6 Like any other dispenser fuel dispensing stops when the tank is full Return nozzle to dispenser and close fuel tank cap 7 Vehicle may now be driven away If No Fuel Is Delivered Set dispenser lever to off then raise lever again Check that the nozzle is fully inserted into fuel tank inlet Check with the station personnel if any are there to see if the dispenser is working If this particular vehicle cannot be refueled at other FleetLINK dispensers have the station operator check that it is authorized to refuel If problem persists see In Case of Problems on page 38 Check the Nozzle LED Is it flashing red or green See the FleetLINK Installing the VIT Kit docu ment part number M00 020 4262 for information on what the flashing means 6 22 04 Basic FleetLINK Operation VIU Step By Step Installation 34 C P VWV FeciLiNK Fuel Control System FUEL MANAGEMENT SYSTEMS Basic FleetLINK Operation VIU Step By Step Installation 6 22 04 Vehicle Information Unit Installation amp Service Manual 35 VIU Maintenance amp
29. liabilities on OPW Fuel Management Systems part Further OPW Fuel Management Systems neither assumes nor authorizes any other person to assume for it any other liability in connection with the sale of the systems or any new replacement part that has been subject to any damage from any act of nature or any force majeure The term Original Purchaser as used in these warranties shall be deemed to mean the authorized OPW Fuel Management Systems distributor to which the system or any new replacement part was originally sold These warranties may be assigned by the original purchaser to any of its customers who purchase any OPW Fuel Management Systems systems or new replacement parts The sole liability of OPW Fuel Management Systems for any breach of warranty shall be as set forth above OPW Fuel Management Systems does not warrant against damage caused by accident abuse faulty or improper installation or operation In no event shall manufacturer s liability on any claim for damages arising out of the manufacture sale delivery or use of the goods exceed the original purchase price of the goods In no event shall OPW Fuel Management Systems be liable for any direct indirect incidental or consequential damage or loss of product Vehicle Information Unit Installation amp Service Manual i Contents 6 22 04 Warnings 1 What s In This BOOK 3 About FleetLINK
30. n working under vehicles e NEVER WORK UNDER A VEHICLE SUPPORTED ONLY BY A TIRE CHANGING JACK VIU Maintenance amp Service Tools and Test Equipment 6 22 04 Vehicle Information Unit Installation amp Service Manual 37 e Use tire blocks chocks whenever vehicle is parked for installation procedures Use traffic safety cones to warn other drivers of stationary vehicles e Vent exhaust from enclosed areas Inspection Procedure Check VIU installation and fastening to mounting surface e Check that the VIU is securely fastened to a flat mounting surface e Check that all connector pins are seated firmly and that wires con nected to them are not loose Check for corrosion on pins Check harness routing and fastening e Clearances from moving parts exhaust tubes and ignition leads e Harness is NOT attached to steering column brake cables or hydraulic or pneumatic lines e Wire insulation for abrasion cuts cracks and other possible damage especially near fastening points e Harness entry into trunk or cab and connection to VIU Check the transceiver loop installation e Check the positioning of the loop it must be on the outside of the body sheet metal Check the snugness of the wire ties that secure the loop to the body e Make sure there are no signs of fuel leakage e Test for absence of fuel vapors which might indicate damage to fuel pipe e Inspect loop cable entry and connection of connector an
31. nverted into miles driven The speed sensor generates a digital switch output a pulse each time the supplied magnet secured to the drive shaft passes by the sensor Note Cars light trucks and vans manufactured after 1988 use a speed sensor to drive the dashboard instrumentation This is the most accurate method You will find the speed sensor wire either at the speedometer itself or at the vehicle s computer Use the vehicle s service or maintenance manual to determine which wire contains the speed signal 6 22 04 Universal Vehicle Speed Sensors What Is It 12 O P VWV FleetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS Installing the Speed Sensor on REAR Wheel Drive Vehicles Attach Magnet with Strap Front Universal CS Joint 12 Max Bend Bracket if Necessary to Make Coil Axis Point to Center of Drive Shaft Sensor 1 4 x 3 4 Tapping Screws Bracket 1 2 to 1 Wires Figure 4 Typical Rear Wheel Drive Installation Universal Vehicle Speed Sensors Installing the Speed Sensor on REAR Wheel Drive Vehicles 6 22 04 Vehicle Information Unit Installation amp Service Manual 13 Step By Step Procedure REAR Wheel Drive l Caution Raise and support the vehicle so you can work at the rear of the trans mission Attach the sensor to the mounting bracket using the hardware supplied with the sensor See Figure 4 on page 12 Locate a spot on the drive shaft within 12
32. r Loop Placement 22 VIU Step By Step Install eee eeeneeeeneerrenereenreerreere ee 24 Connecting the Vehicle Speed Sensor to the VIU 24 Installing the Transceiver Loop rt ruriri r ESETE EEEE 26 Installing WA iaia leider ia 30 Basic FleetLINK Operation 33 VIU Maintenance amp Service 35 Tools and Test Equipment wawa 35 Inspection Procedure ss 37 In Case of Problems 38 Before You Begin Troubleshooting wwssmewmssanwwaazemnaanumzaaazi zwa 38 Troubleshooting Procedure 39 6 22 04 Figures 6 22 04 Vehicle Information Unit Installation 8 Service Manual iii Figure 1 Overall FleetLINK System 5 Figure 2 VIU Vehicle Information Unit 9 Figure 3 Fuel Inlet Transceiver Loop Antenna 10 Figure 4 Typical Rear Wheel Drive Installation 12 Figure 5 Typical Front Wheel Drive Installation 14 Figure 6 Typical VIU Installation in Passenger Automobile 17 Figure 7 Typical VIU Installation in a Truck 18 Figure 8 VIU Mounting Template 21 Figure 9 Typical Transceiver Loop Installation Passenger Automobile 23 Figure 10 Typical Transceiver Loop Installation Trucks 24 Figure 11 Typical Transceiv
33. ransceiver Loop Installation Passenger Automobile Installing the VIU Planning the VIU installation 24 OP WWV FietLINK Fuel Control System FUEL MANAGEMENT SYSTEMS LOOP CABLE LARGE PLASTIC TIE TRANSCEIVE LOOP A PREPARATION SMALL PLASTIC TIES PROTECTIVE PS CONDUIT FUEL INLET CAP Wa UF NEEOEO 7 6 Ky di eee T GENERAL VIEW i on AFTER INSTALLATION Figure 10 Typical Transceiver Loop Installation Trucks VIU Step By Step Installation Connecting the Vehicle Speed Sensor to the VIU 1 STOP THE ENGINE 2 Findthe wire that carries the mileage signal Usually this wire is con nected between vehicle s ECM and speedometer or cruise control unit 3 Connecta white wire from VIU PIN 1 to the mileage signal wire using a tap connector Make sure that tap connector is crimped all the way and there is a good connection Installing the VIU VIU Step By Step Installation 6 22 04 Vehicle Information Unit Installation amp Service Manual 25 Explosion Hazard 6 22 04 Installation must be performed by qualified people who are aware of all safety issues During installation of harness and or transceiver loop around fuel tank inlet and during work in engine com partment installers MUST comply with all applicable requirements of the National Fire Protection Associa tion NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service
34. rkmanship under normal use and service for a period of 90 days from the date of installation or for the remainder of the system s original warranty whichever is greater The foregoing warranties will not extend to goods subjected to misuse neglect accident or improper installation or maintenance or which have been altered or repaired by anyone other than OPW Fuel Management Systems or its authorized representative The buyer s acceptance of delivery of the goods constitutes acceptance of the foregoing warranties and remedies and all conditions and limitations thereof If a claim is made within the warranted time period that any equipment and or remanufactured part is defective in material or workmanship under normal use and service such equipment and or remanufactured part shall be returned to OPW Fuel Management Systems freight prepaid If such equipment or remanufactured part is found by OPW Fuel Management Systems in its sole judgment to be defective in material or workmanship under normal use and service OPW Fuel Management Systems shall at its sole option repair or replace such equipment and or remanufactured part excluding in all instances fuses batteries other consumable items etc The warranties as set forth above are made expressly in lieu of all other warranties either expressed or implied including without limitation warranties of merchantability and fitness for any particular purpose and of all other obligations or
35. rmation Unit Installation amp Service Manual 5 About FleetLINK 6 22 04 FleetLINK is an automated vehicle refueling system for organizations with vehicle fleets that have their own refueling facilities and for fleet servicing stations FleetLINK controls and monitors 24 hour refueling of authorized vehicles simply and efficiently without attendants and without driver intervention FleetLINK can record both a vehicle s odometer and engine hours readings when a FleetLINK equipped vehicle is refueled FleetLINK consists of two main sub systems e The Vehicle Information Unit VIU subsystem e The Vehicle Identification Terminal VIT subsystem The System2 Fuel Site Controller the FSC inside the site office is the data processing device attached to the VIT The FSC saves the data for all fuel ing transactions Figure 1 shows the two main FleetLINK subsystems and their basic components Trunk mounted Vehicle Information Unit VIU Fuel Dispenser Nozzle with VIU Receiver Figure 1 Overall FleetLINK System AboufleetLINK 6 Ps FleetLINK Fuel Control System FUEL MANAGEMENT SYSTEMS Figure 1 does NOT show the System2 portions of the installa tion The System2 FIT would be mounted near the fuel dis penser and the System2 FSC would be inside the building About the Vehicle Information Unit VIU The VIU is a small vehicle mounted device that provides information on a vehicle s identity
36. ry voltage in the VIU six pin connector between pin 3 and pin 6 GND If not present check the internal fuse and the wiring to the pin connector Replace VIU unit if all else fails VIU Maintenance amp Service In Case of Problems 40 O P VV FeeflINK Fuel Control System FUEL MANAGEMENT SYSTEMS Odometer Reading from VIU Does Not Change e Check that the signal at the dashboard connection points is correct according to vehicle manufacturer specification Recalibrate pulse level if necessary e Check harness connections Replace VIU if nothing else works Engine Hours Reading Does Not Change e Confirm correct polarity e Start then stop vehicle engine Check for a large voltage change up to 12V between pins 1 and 5 of the 6 pin connector while engine is started and stopped e Ifthere is no change check for good wiring connections to the VIU For first time installations check that wiring is correct If wiring is good the problem is in the VIU Odometer Reading Does Not Correspond to Registered Mileage If mileage increases from refueling to refueling this problem could be caused by several factors Remember to take into consideration any optional or custom made transmission gear box that could be installed in this vehicle model e Defective vehicle equipment e Incorrect odometer factor see VIU Programming Manual Programmed Parameters Are Lost e Check for loose connections If OK replace VIU unit
37. tween the flange and the body 11 If this is not possible use a screwdriver or a punch to bore a hole in the inlet if the fuel tank housing inlet is made of plastic 4 Thread the cable through any of the holes 8 in the flange as follows e Use a wrench to unscrew all screws 5 that secure flange 2 to body 1 e Place the loop 7 around fuel tank inlet 3 e Thread the cable through any of the flange holes 8 e Insert neoprene compression gland or apply RTV sealant around loop cable Installing the VIU VIU Step By Step Installation 6 22 04 Vehicle Information Unit Installation amp Service Manual 27 5 Using a wrench torque all screws 5 securing the flange to the body 1 and make sure that the cable fastener 4 holds the transceiver loop 7 in position Be careful to avoid any stress on the loop Figure 11 Typical Transceiver Loop Installation Automobile 6 22 04 Installing the VIU VIU Step By Step Installation 28 O P VV FeeflINK Fuel Control System FUEL MANAGEMENT SYSTEMS 6 Route the cable between the flange 2 and the body 1 as follows e Unscrew all screws 5 that secure flange 2 to body 1 Release the fuel inlet by pulling it out e Carefully thread the cable between the flange 2 and the body 1 e Place transceiver loop 7 around fuel tank inlet 3 e Using a wrench torque all screws 5 securing the flange 2 to the body 1 and make sure that the c
38. uipment FUEL MANAGEMENT SYSTEMS Note Warnings FleetLINK Fuel Control System The test equipment required for VIU sub system maintenance and service includes e Digital multi meter Fluke 75 or equivalent e Oscilloscope Any oscilloscope model can be used provided it meets the following minimum requirements e Bandwidth 10 MHz minimum e Input impedance 10 MEG ohm minimum e Sensitivity 10 mV div 10V div e AC and DC coupling The purposes of the periodic inspection of VIU installation is to ensure that the various components of the VIU sub system are in good mechanical and electrical condition and are securely installed The inspection schedule should take into consideration vehicle mileage vehicle working environ ment and climatic conditions Inspection should be carried out at least once per year Inspect the installation as instructed in this section and correct or replace any questionable parts An approved plan for FleetLINK VIU installation in the inspected vehicle should be available during inspection so that installation errors and unauthorized modifications can be detected e When performing work in the engine compartment STOP THE VEHICLE ENGINE to prevent severe injury or death Make sure no one will start engine while any work is in progress remove ignition keys if possible e Use only adequately rated properly approved equipment to elevate vehicles Observe all safety precautions whe
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