Kysor Instrumentation Troubleshooting Guide
Contents
1. E GNE SERVICE MANUAL Pesh Kysor Instrumentation Troubleshooting Guide Troubleshooting Emergency One Commercial System The Medallion Il instrumentation system is a Microprocessor based system utilizing both sensor and Data bus information to display both gauge and warning information With a microprocessor system the need for a good clean Ground is very important Whenever the system is giving erratic behavior please check the grounds between the VDC Pin J amp H and Battery Ground post Knowing that the Ground is good as well as the Battery and Ignition connections are good will save a lot of trouble shooting time Gauge Troubleshooting All the gauges are built the same way They all have a Microprocessor Stepper Motor and LED for lighting Knowing this will add in trouble shooting for a faulty gauge The gauges get their information by a single data line connection to the VDC This is important because now the Gauge harness is a universal harness This means you can plug any connector into any gauge and it should work assuming that the information is coming across that data line If none of the gauges function these checks can be made 1 Measure battery voltage on pin F at the VDC connector 2 Turn the ignition key on There should be 12 volts at pin E of the VDC 3 Check to be sure Pin J and H of the VDC goes to battery ground These two pins are internally connected on the VDC 4 f the gauges will not power up check t2. J1587 data bus C Gauge Data O RS488 D JQGaugeDaaBus RS BS PE Ignition A Switcht2VDC F Batey __ i AJ 12VDC TT G Message Center Power Control Switch to ground Hf Ground Battery ground J Ground Battery ground K Single Wire Instrument Bus Data for rear instruments FGHJK OOOOO 010101010 EDCBA V iew from bottom of connector on harness Page 9 of 15 04 25 00 E raz SERVICE MANUAL Troubleshooting the Kysor Medallion Message Center x STOP CHECK CAB Ces ATC ENG CHECK GEN AERIAL ENG ENG AJAR W WARN RUN TRANS ENGAGEENGAG OK GRID ENG r Low AIR Low PuMP penas ca e n E eno i System Operation When the key is in the off position the gauges will not be on The Message Center may be indication left and right turn signal lights if the hazards are on The high beam indicator will be on if the headlights are on with the high beams enabled With key on and battery voltage above 10 VDC all the gauges will return to the left and vibrate for a moment then begin to operate At the same time all the lights on the Message Center will light up for one second Except for the Turn Signal indicators and High beam indicator After on second several icons may stay lit until the engine is running or the fault is corrected naza Left Turn Signal Golo
3. Volt Indicator Color Red Activates when voltage is less the 11 8 or greater than 14 5 volts and resets at 12 volts and 14 3 volts Activates buzzer Low Fuel Color Yellow Activated when resistance is 22 ohms and off when 26 4 ohms or higher Transmission Temperature Color Yellow Activates when temperature reaches 250 degrees F and turns off at 245 degrees F High Engine Temperature Color Red Activates when temperature reaches 220 degrees F and resets at 215 degrees F Activates buzzer Oil Pressure Color Red Activates when oil pressure drops below 5 psi and resets at 10 psi Activates buzzer Page 12 of 15 04 25 00 E ONE SERVICE MANUAL she 53089G 21 Air Filter AIR Color Yellow FILTER Activates by switch to 12 VDC 22 Low Air LOW Color Red AIR Activates when air pressure drops below 70 psi and resets at 72 psi Activates buzzer 23 Pump Engage PUMP Color Green ENGAGE Activated by switch to 12 VDC OK 24 OK to Pump TO Color Green PUMP Activated by switch to 12 VDC Page 13 of 15 04 25 00 E wurmz SERVICE MANUAL so 195 580065 589740 SE 100 1s 240 ms A COOLANT 589739 580064 589741 580069 577206 commercial 576528 custom Page 14 of 15 04 25 00 E ONE SERVICE MANUAL s 70 100 120 WL RN VET wei REAR AIR 589676 70 100 120 576520 576507 ME AP 0 7 150 H r FRONT AIR 9896
4. 75 150 195 210 WY a3 F COOLANT 976530 989680 589677 9 6522 0 6521 989679 089678 dm STOP CHECK CAB an ATC ENG CHECK GEN AERIAL ENG ENG AJAR ass WARN RUN TRANS ENGAGEENGAG OK GRID ENG r Low AIR Low PUMP penas cn e j E en e er kesl 9 6529 Page 15 of 15 04 25 00
5. are good will save a lot of trouble shooting time Gauge Troubleshooting All the gauges are built the same way They all have a Microprocessor Stepper Motor and LED for lighting Knowing this will add in trouble shooting a faulty gauge The gauges get their information by a single data line Pin 9 of 15 pin connector of the Message Center This is important because now the gauge harness is a universal harness This means you can plug any connector into any gauge and it should work assuming that the information is coming across that data line Perform the following tests to determine if you have a harness or instrument failure 1 As you turn on key switch watch gauges All the gauges should go fully counter clockwise and vibrate This is what we call reset 2 At this point the vehicle is not running and the key is on The gauges that have information will start working 3 If any of the instruments do not reset swap instrument connectors with a gauge that did reset and repeat process 4 f the same instruments do not reset swap instrument connectors with a gauge that did reset and repeat process Pin G H J K L DC Voltage 12 VDC 3 7VDC GND 7 5 VDC N A When lights are on 5 If all gauges reset and seem to work properly start the engine and use the following chart to test the inputs that drive the gauges Page 4 of 15 04 25 00 E ONE SERVICE MANUAL oo Gauge Input Test Pin 16 of the 24 pin connector on the VDC betw
6. een 88 to Fuel Gauge Fuel sender 0 ohms If you ground this pin the gauge will go to full scale The two gauges use direct air pressure into the computer Pri and Sec Air Air Pressure Insure that there is air pressure at two inputs by unplugging the airline to see if pressure is at the computer Temperature Engine ECM Use engine diagnostic tools to compare the gauge Gauge g readings with the readings from the engine computer Use engine diagnostic tools to compare gauge readings Oil Pressure Gauge Engine ECM Id E eH Use engine diagnostic tools to compare gauge readings Wi daa dk eng with the engine computer Engine ECM ka engine diagnostic tools to compare gauge readings rom engine computer Transmission Oil Transmission Use transmission diagnostic tools to compare gauge Gauge ECM reading with transmission computer Replace any gauge that has different readings than what the test equipment reads 6 If you perform all the tests and a single instrument seems to reset fine but will not respond after the signal has been confirmed good the instrument is bad Troubleshooting the Medallion ll Computer and Message Center The computer VDC and the Message Center are the brains of the system The VDC was designed to take the inputs some digital some analog and convert them into an all digital signals that the Message Center can use to turn on the warning lights and drive the gauges A good portion of the information that the VDC uses
7. gnition Battery 7Vdc Power Sensor Ground Module Ground Single Wire Instr Bus Switch to ground to activate Switch to ground to activate Not used Not used Not used Not used Switch to ground to activate Not used Not used Not used Not used Switch to ground to activate Not used Not used Not used Resistive sender type Not used Not used Not used Not used Not used Not used Not used Not used J1708 J1587 J1708 J1587 RS 485 RS 485 Switched 12 V 12V Nominal 7Vdc power supol Sensor Return To Chassis Ground To instruments cq Q3 C _ I N J2 H J2 K _J1 10 _J1 11 31 12 _J1 13 _J1 14 _J1 15 J1 16 31 17 31 18 J1 19 _J1 20 _J1 21 J1 22 31 23 31 24 J2 A JB J2 G J2 H _J2 K___ j mm 13 J1 24 IN V iew is looking at V DC housing Page 3 of 15 04 25 00 E wurz SERVICE MANUAL 5 Troubleshooting Emergency One Custom System The Medallion Il instrumentation system is a Microprocessor based system utilizing both sensor and Data bus information to display both instrumentation and warning information With a microprocessor system the need for a good clean Ground is very important Whenever the system is giving erratic behavior please check the grounds between the VDC Pin J Message Center Pin 4 on 15 pin connector and Battery Ground Post Knowing that the Ground is good as well as the Battery and Ignition connections
8. he connection at pin E of the VDC If this pin is shorted to the battery with power off the system will not power up If the system powers up but a single gauge or several gauges don t function perform the following tests to determine if you have a harness or a gauge failure 1 As you turn on the key switch have someone watch the gauges on the pump panel All the gauges should go fully counter clockwise and vibrate This is what we call reset or zero calibration and they do this every time the ignition key is turned on 2 If any of the gauges do not reset swap instrument connectors with a gauge that did reset and repeat process 3 At this point the Vehicle is not running and the key is on The gauges that have information will start working Fuel level and Voltage The other gauges will not work until the engine is running 4 f the same gauge still fails to reset the instrument is bad but if it now does reset the harness may be bad Look for the following voltage information on the suspect 5 pin gauge connector with key on If a gauge will not light up check for 12 volts at pin G of the gauge harness connector with the headlight switch on Page 1 of 15 04 25 00 E ONE SERVICE MANUAL n 53089G Pin G H J K L DC Voltage 12vdc 3 7vdc GND 742 5 vdc N A When lights are on Voltage supplied directly from chassis and not through the VDC 5 If all gauges reset and seem to work properly start the engine and use follow
9. ing chart to test the inputs that drive the gauges Gauge Input Test Volt Gauge Use a meter to insure gauge matches battery Eust oU Pin 16 of the 24 pin connector on the VDC between 88 to Mie Fuel sender 0 ohms If you ground this pin the gauge will go to full optional S E Coolant Use engine diagnostic tools to compare the gauge ueris engine M readings with the readings from the engine computer Use engine diagnostic tools to compare gauge readings Oil Pressure Gauge Engine ECM MOM ED QI REDE Engine ECM X engine diagnostic tools to compare gauge readings rom engine computer Transmission Oil Transmission Use transmission diagnostic tools to compare gauge Gauge optional ECM reading with transmission computer Replace any gauge that has different readings than what the test equipment reads 6 If you perform all the tests and a single instrument seems to reset fine but will not respond after the sender has been confirmed good the instrument is bad Page 2 of 15 04 25 00 E 0NE SERVICE MANUAL k E One VDC I O Connections COMMERCIAL Name of input Input Characteristic C _ High water Low Oil Pressure light Not Used Not Used Not Used Not Used Warning Buzzer Not Used Not Used Not Used Not Used Low Voltage light Not Used Not Used Not Used Fuel Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Vehicle Data Bus Pos Vehicle Data Bus Neo Not Used Not Used I
10. is directly from the engine data bus If for any reason the data bus is lost at the VDC for 18 seconds the odometer will start flashing After 23 seconds the gauges will return to zero reset and after 45 seconds the Message Center will start scrolling the lights which we call the return to normal If for any reason the gauges and the Message Center fails to power up you can ground pin 8 of the 15 pin connector on the Message Center and the gauges and lights should go through the power up sequence This is a helpful hint to help eliminate half the system when trying to diagnose a dead system Use the pin out guides to help trouble shoot the system and the input characteristics as suggestions for testing Page 5 of 15 04 25 00 E raz SERVICE MANUAL Emergency One 24 Pin VDC Connector CUSTOM PIN Name of Input Input Characteristic High Water Outputs 12 VDC to activate 2 Low Oil Pressure Light Outputs 12 VDC to activate OK to Pump Switched to 12 VDC to activate 6 EngneRun Switched to 12 VDC to activate Not used Not used Not used Not used 15 Not used Not used Switched to 12 VDC to activate Not used Not used Not used Not used Not used Not used N N NO PO N 12 l 0101010100101001 01 010 0101010101010101 0101010 24 13 V iew from bottom of connector on harness Page 6 of 15 04 25 00 E GNE SERVICE MANUAL Emergency One Message Center Connector Pinout
11. r Green Left turn signal is controlled by a twelve volt switched signal Stop Engine STOP Color Red Activated by a switch to ground from ECM Activates buzzer e Check Engine CHECK Color Yellow Activated by a switch to ground from ECM gt Cab Ajar Color Red AJAR Activated by a switch to ground O m m 1 gt Z E El El t N Page 10 of 15 04 25 00 E um ONE SERVICE MANUAL es ATC WARN ENG RUN CHECK TRANS GEN AERIAL m m Z Z G G gt gt G G m m 10 11 12 ABS Warning Color Yellow Controlled by a switch to ground High Beam Color Blue Activated by 12 VDC switched signal ATC Warning Indicator Color Yellow Activated by signal from ECM J1587 Engine Run Color Blue Activated by switch to 12 VDC Check Transmission Color Red Activated by switch to ground Generator Engage Color Green Activated by switch to ground Aerial Engage Color Green Activated by switch to ground Right Turn Color Green Activated by 12 VDC switched signal Page 11 of 15 04 25 00 E wurz SERVICE MANUAL 13 GRID HEATER ENG MAINT La e LOW FUEL S he e Li 14 15 16 17 18 19 20 Park Color Red Activated by switch to 12 VDG Grid Heater Color Yellow Activated by signal from ECM J1587 Engine Maintenance Color Yellow Activated by switch to ground
12. s PIN Name of Input Input Characteristic From VDC J1587 pin A Ground Chassis ground L55 insument Power 7 VDO provided by message canter 4 Gowd J Ground for instruments 5 Battery 0 12VDCfrombattey 6 NoConecio Switched to ground to activate 8 Message Center Power Control 1 Tr VDC pin G Ground to activate __ Gauge Data Instrumentation data Hel ae A 13 No Comnection J o oo O 14 NoComecion J o o O 15 NoComecion L o O V iew from bottom of connector on harness Page 7 of 15 04 25 00 E GNE SERVICE MANUAL n Emergency One Message Center Connector Pinouts PIN Name of Input Input Characteristic Switched to ground to activate Right Turn Signal Switched signal to 12 VDC to activate EN Left Turn Signal Switched signal to 12 VDC to activate 4 HighBeam Switch to 12 VDC to activate 5 Air Filter A Switched to 12 VDC to activate 6 Aerial Engage Switched to ground to activate B 1 Chem Engine ________ _____Switched to ground to activate Gheck Transmission owitched to ground to activate Cab Ajar aT _ HHR V iew from bottom of connector on harness Page 8 of 15 04 25 00 E GNE SERVICE MANUAL Emergency One 10 Pin VDC Connector PIN Name of Input Input Characteristic Bt __ WS Daa muet T587 date busi ______ Vehicle Data Bus
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