DIXSON inc. In TERLINK What It Is. The Interlink System is a new ‘and innovative approach to instru ‘mentation. A two-wire data bus transmits information both to the Data Collection Unit (OCU) from electronic devices and from the OCU to the instrumentation. Data bus standards evolved ‘rom the need to control engine ‘emissions to meet Federal regulations. Engine and transmission ‘manufacturers share information via a data bus to accomplish the ‘control. As a result, some normally monitored parameters are available cn this data bus. The Dixson inteink ‘System utlizes this information and ‘adds more parameter monitoring through the use of the OCU. The system reduces complex wi?= reduces instalation costs, an, fers maximum flextilty for ‘adding opto gauges. The system consists of a Data Collection Unit Dixson Data Gauges, and an optional Message Center. PROBLEMS Dashboard Problem Big, costly wire hamess with too many variations for options Ditcut 0 wire High failure rate of light bar Bumed out incandescent bulbs Hard to troubleshoot Behind-pane! mounting hardware Proliferation of option gauges Ugly stck-on function labels “ir/uel gauge hoses behind dash Remote instrumentation SOLVED SYSTEM How It Works. The Interlink System uses a J17081J1587 data bus to greatly reduce the wiring hamess required for sensors and instrumentation. The Data Collection Unit (OCU) receives serial data from the engine, transmission, and ABS control modules via a public data bus. The DCU collects addtional data from analog sensors, status information (switched inputs such as ‘engine fan on’) and pressure! vacuum lines. This data is transmitted to the ‘gauges on the 2 wire data bus. The Dixson Data Gauge incorporates an easily recognizable red waming LED in each (gauge. Light bars can be eliminated or reduced in size and cost. The DCU, Data Gauges, and Message Center are wired by ‘daisy chaining’ together to greatly reduce dash wiring and simplify troubleshooting. Siandardized jumpers allow quick rerouting of wiring to isolate gauges or wiring, i needed. Location ofthe Data Collection Unit outside ofthe cab area increases the use of space in the cab. Each gauge includes sel-clagnostic. If problems are detected, they are incicated by 4 ‘wipering’ action ofthe pointer, INTERLINK SOLUTION (One 5 conductor cable to interconnected devices Wire gauges in any order with ‘common jumpers’ Waring ights in each gauge LEDS - Life of Vehicle lighting Self diagnostics Zero force lock ring Programmable gauges Legends behind glass All hoses terminate at DCU ‘One data cable ‘wagner SENSOR FUEL LEVEL SENDER Vaile diets ‘ox PRESSURE SENDER SENSOR INPUTS ‘TEVPERATURE SENDERess a PRIVATE BUS PUBLIC BUS DATA COLLECTION UNIT 35 electrical input/output pins > 5 pressure/vacuum modules (2 inputs per module) ixcan:intorlink.quetam:x.s!DATA GAUGES Akey feature of the Interlink System is versatity of each gauge. With the exception ofthe decal scaleplat, all parts are common to each gauge. The gauge is designed to alow quick removalinstalation ofthe decal. This allows a reduction in service parts inventory, easy OEM and dealer configuration, and quick meantime to repair. Each decal includes a barcode «and corresponding hole assembly (ee photo) that, when inserted on the Circuit board, distinguishes the gauge function to an on board computer chip ‘Superior lighting is achieved by lightpipeitumination for both scale art and pointers, an improvement over hard-to-ead floolighting approaches. ‘Many other features ite twist on bezel, keyed components, LED lte-oruck backiightng, 2-stage twist an lock ring, minimum insertion force connector and others contribute to a highly reliable, cost effective solution to current gauge problem areas. MESSAGE CENTER Features key Functions Replaces warning light bar ‘Odometer ‘Standard 2° mounting Hourmeter Displays messages/wamings Clock Provides auclble alarm ‘Alarm clock Tip odos (2) Diagnostic displaySPECIFICATIONS INTERLINK SYSTEM Voltage 9-18 VDC Operating e 14 VDC Nominal Over Voltage and Reverse Polanly Protected Temperature -40C to +85C (Q5C availabe) Tested to SAE J1455, section 4.1.3.1 Thermal Shock — -40C to +85C, ested to SAE J1455, section 4.1.32 Humidity Tested 10 SAE J1455, secon 42.3 90% RH @ 38C Salt Spray Tested to SAE J1485, section 4.3.3 Transients Load Dump: +100V Peak, 400ms duration inductive Load Switching: +600Y Mutual Coupling: +300V Electrostatic Discharge: *15KV, applied randomly Shock Tested to SAE J1455, section 4.10.3 Vibration Tested to SAE J1455, section 4.94 Dust Tested to SAE J1455, section 4.7.3 DATA COLLECTOR UNIT InputOutput Analog inputs Pyrometer Ammeter 7 resistive ‘Sutiched inputs (16) e 44 Normally open / Switched to Ground 12 Normally open / Switched to +12 Volts +12 Volts Ground Communication Ports Data Bus 1 (2 pins) - J1708U1587 Data Bus 2 (2 pins) ~ Modified J1708U1587 ‘Mechanical Inputs Pressure Module (10 inputs ~ compatible with air, ol, fuel and other fuids (consut factory) ‘Magnetic Sensor and Sender Generator inputs via dual Frequency to Voltage Module (replaces 1 pressure module). Consult factory for frequency ranges. Outputs 1 Pulsed 1 Switched DIXSON. inc. 287 27 Road Grand Junction CO 81503-1900 C placement 303/244-1241 Appication assistance 303/244-1242 e Order status 303/244-1249 xx 303 / 245-6267 IN 07440197 ‘AFTER APRIL 2, 1995, USE AREA CODE 970 Pot 8 taeINTERFACE MODULE The interface module is the heart and brain of the system (see Figures 2 and 3). All gauge and vehicle information is directed through the interface module and is processed by the module's microprocessor. This module is located on the left fender bracket. *+ The module collects sensor data (such as "engine oil temp") and status indicators (such as “coolant temp") directly from sending units and switch inputs (Engine Shut Down is a switched output), * Solid-state pressure or vacuum transducer modules attach directly to the interface module, *+ Engine and ground speed inputs are achieved via vehicle sensors and a frequency-to-voltage converter attached to the module (mechanical engines only). Electronic engines generate these inputs directly for reading by the system from the engine's J1708 data bus. * Signals are received, decoded, converted to digital format and transmitted serially to 2" SmartGage™ ‘gauges on a private data bus, *+ The module communicates with the MMC over the public data bus. It republishes the function being displayed on the MMC every 20 seconds. When it does, it cancels any alarm override action that may be temporarily in effect (see Section 3). PRIVATE DATA BUS © 3: 33 ay ‘se00 r rt r r 8g Ee PUBLIC DATA BUS ‘ fo VF woo RESET SELECT uc 2-WAY COMMUNICATION BETWEEN VF MOD AND ucsmartcace® MECHANICAL INTERFACE MODULE OUTLINE DRAWING E1 PIN-OUTSPEEDOMETER and TACHOMETER, The speedometer and tachometer both use an internal microprocessor to read data from the interface module's private data bus and drive an aircore meter movement. They each contain two telltale LED's: + The speedometer contains the Right Turn and ABS telltales. + The tachometer contains the Left Turn and High Beam telltales. Calibration for the speedometer and the tachometer is stored within the interface module. It may be changed for either gauge through the public data bus and interface module setup program. The speedometer and tachometer use the same connectors as the 2" gauges, allowing them to be part of the "daisy chain” wiring arrangement. TACHOMETER ‘SPEEDOMETER Pw vouts'N nMINI MESSAGE CENTER The Mini Message Center (MMC) contains the odometer, two trip odometers, hourmeter, clock with alarm, and diagnostics display for the SmartGage™ system. It is packaged in a 2" gauge housing. Two switches (Select and Reset) are provided on the front of the MMC to allow setting and resetting of clocks, alarm and trip odometer. The normal display is the odometer. The other functions can be selected by pressing the Select button. The Reset button is used in the clock and the alarm setting modes as well as to reset the trip odometers. NOTE: There are no serviceable parts in the MMC. Opening the MMC voids the warranty. 1 ew-ouT are PIN 2 SACK LiGHT PN 3: GAA PIN & GND PM § DATA — PIN 8: artery PINOUT PIN 1: SELECT PIN 2: RESET PIN 3: BUZZER EI PIN 1 MINI MESSAGE CENTER £2 PINT 122" SMARTGAGE™ GAUGE The 2” SmartGage™ gauge is an "air core" meter movement that is driven by an internal microprocessor chip. ‘The gauge receives data from the interface module's private data bus. Each 2" gauge is identical in design and hardware with the exception of the scaleplate. Changing the scaleplate automatically reprograms the instrument to the function represented by the scaleplate. Each gauge has two identical connectors with identical pin-outs. One connector receives incoming data from the private data bus; the other completes the "daisy chain" to other gauges (see Figure 7). 2” GAUGE PINOUT PIN 1: BACK LIGHT PIN 2: DATA — PIN 3: GROUND PIN 4: DATA + PIN S: VOLTS IN BMULTIPLE 2" GAUGE PROBLEM(S) WHAT TO LOOK FOR ACTIONS ADDITIONAL COMMENTS Some or all of the gauges are inoperative at startup ot at any time during the vehicle operation. A. Check all connectors to the gauges on the "daisy-chain” 5 pin harness to make sure the pinouts are correct and have a solid connection.* B. Check the 12 volts and ground to the gauges. * The following is a pinout and color code for the "daisy-chain” hamess: Blue - backlighting pin 1 Green - data- pin 2 Black - Ground pin 3 Purple - data* pin 4 Red - 12 volts pin 5 Pointers move back and forth in a windshield wiper motion, it indicates that the gauges have power and ground but they have no signal (this will last for 60 seconds and then stop). This can happen at any time during the vehicle operation as well, A. Check all connectors between the interface module and the gauges. ‘Make sure they are in place and have a solid connection. B. Check the "daisy-chain” 5 pin harness for problems in the Data lines by using a volt/ohm meter.* C. Check the Data lines (Green, Data- and Purple, datat) to make sure they haven't been reversed. D. Check the wiring between the interface module and the gauges (Data bus ckts 636 & 637). E. Check for loss of power (ckt 242) ‘or ground (ckt 239) going into the interface module on the 30 pin connector.’ F. Only after everything else checks ‘out good, replace the interface module. *There should be a resistance value greater than 2K but not infinite between the following wires on the "daisy-chain": Red(12V)to Purple(data+) Red(12V)to Green(data-) Black(gnd)to Purple(data+) Black(gnd)to Green(data-) Purple(data*)to Green (data-) refer to the pin outs on the 2" ‘gauges above. ** - Power - ckt 242, pin A-2 = Ground - ckt 239, pin C-1 A dynamic problem that comes and goes based on some action happening , such as turning the headlights on or off, using the C.B. Radio, etc... A. Check ALL of the ground connections to ensure good grounding of both the cab and the chassis. B. Check for intermittent connections on ALL of the connectors from the interface module to the gauges. The problem is most likely related to wiring associated with the action which causes the All gauges go fo zero.and ‘fay there at any time during the vehicle operat A. Replace the interface module. problem.SINGLE 2" GAUGE PROBLEMS IF THE FOLLOWING ACTIONS DO NOT CORRECT THE PROBLEM, SEE THE SPECIFIC INDIVIDUAL GAUGE FOR FURTHER TROUBLESHOOTING GUIDANCE. WHAT TO LOOK FOR ACTIONS ADDITIONAL COMMENTS Gauge is inoperative at ‘A. Check the "daisy-chain" $ pin * The following is a pinout of Startup ot at any time during | harness and connector to the gauge. | the color coded "daisy-chain”: the vehicle operation. Make sure it is secured into the keyed | Pin 1, Blue, Backlighting connector on the gauge. Pin 2, Green, data- B. Check the 12 volt and the ground | Pin 3, Black, Ground to the gauge for broken wire(s) or Pin 4, Purple, Data+ shorted wire(s).* Pin 5, Red, 12 volts C. Replace the gauge. Gauge does a windshield | A. A single gauge displaying these _| * There should be a resistance wiper motion at start up or | symptoms must be the last gauge in a | value greater that 2K between at any time during the chain, Check 5 pin connector fora —_| the following pins (see color vehicle operation. broken wire or a short in the data lines | code above): by using a voltohm meter.* Data+ and Data- 12V to datat 12V to data- 12V to gnd Gnd to data+ Gnd to data- Gauge starts reading A. I it is the last gauge on the "daisy. | *See above for color code of pin exratically, (See the chain" check the 5 pin jumper hamess | outs and resistance values. individual gauges if the for broken wires or a short with a action does not correct the | volt/ohm meter.* problem.) Gauge stops working while | A. Check the inputs to the interface | the vehicle is operating, the | module, the wiring and/or the ‘pointer goes to zero and the | sensor/sender. The condition of LED flashes continuously, | pointer at 0 and LED flashing indicates either an open circuit in the sensor wiring or a faulty sensor. 9OTHER THINGS TO LOOK FOR IN INDIVIDUAL GAUGES A. Verify that the pressure on the pressure | SINGLE PSI GAUGE 1. Ifa pressure gauge PROBLEM reads wrong or is erratic. | port is a steady value different from the 2, See Pressure ‘gauge reading. Transducer Problems, _| B. If both ports of the pressure module are page 23 being used, reverse it's mounting. If the gauge now appears to be working, replace the pressure module. C. Replace the gauge. D. Asa last resort, replace the interface module, SINGLE TEMPERATURE | If atemperature gauge | A. Check the sensor. Be sure the correct, GAUGE PROBLEM reads wrong or is erratic. sensor is being used. B. If the correct sensor is being used, check for A bad sensor, shorts or broken wires. This can be done by removing the 30 pin connector from the interface module and checking the resistance from the suspected input pin to pin #7(gnd - ckt 239). All sensors should have a resistance of between 1500 ohms (cold) and 30 ohms (hot). C. If the sensor and wires are goad, replace the gauge. D. As a last resort, replace the interface module. AMMETER PROBLEM Ifthe ammeter gauge reads wrong or erratic. ‘A. Check the shunt wiring. B. Replace the gauge. C. Asa last resort, replace the interface module. PYROMETER PROBLEMS If the pyro gauge reads wrong or erratic, A. Check the thermocouple part number. B. If the correct thermocouple is being used, check to make sure the probe is installed correctly. Check thermocouple wiring. C. Replace the gauge. D. Asa last resort, replace the interface module. VOLTMETER PROBLEMS If the volt gauge reads wrong or erratic. 20 A, Measure the voltage to make sure it is the correct voltage coming into the interface ‘module at the 30 pin connector. Pin 2 (ckt 242) to pin 7 gnd (ckt 239). B. Replace the gauge. C. Asa last resort, replace the interface module.MMC PROBLEMS backwards.* B. Check wiring to make sure the battery and ignition lines. haven’t been crossed, WHAT TO LOOK FOR ACTIONS ADDITIONAL COMMENTS Ifthe MMC is not counting | A. Check the polarity ofthe | * El PIN OUT- miles, data wires to see ifthey are | Pin 1, IGNITION,red PIN 2, BACKLIGHTING, blue PIN 3, DATA+,purple PIN 4, GROUND, black PIN 5, DATA-, green PIN 6, BATTERY, yellow E2 PIN OUT- PIN I, SELECT, PIN 2, RESET, PIN 3, BUZZER, If the odometer, trip-meters or hourmeter Aave no displox. This condition indicates the MMC is not receiving data. A. Check the hamess for broken wires or reversed data lines.* *See above for pinouts. Ifthe MMC is inoperative, ‘A. Check the ignition, battery and ground lines.* *See above for pinouts, If the MMC is missing. ‘Segments on the LCD, or the buttons on the reset and select are not working. ‘A. Replace the MMC. If the backlighting on the MMC doesn't come on when it should. ‘A. Check the 12 Volts and backlighting wires too make sure they are not crossed.* “See above for pinouts. 2SPEEDOMETER AND TACHOMETER PROBLEMS WHAT TO LOOK FOR ACTIONS ADDITIONAL COMMENTS The pointer moves back and forth in a "windshield wiper" motion and the LED flashes. ‘A. Check the “daisy-chain” 5 pin harness for broken wires or a short in the data lines from the speedo/tach to the interface module by using a volvohm meter to check the resistance." * The following is a pinout and color code for the "daisy-chain". There should be a resistance value greater than 2K between the lines. Pin I, backlighting, blue Pin 2, data-, green Pin 3, Ground, black Pin 4, datat, purple Pin 5 12 volts, red The gauge reads incorrectly. ‘A. Check calibration.* B. Check wiring between IM and sensor.*** C. Check for bad sensor.** D. Check for dragging pointer. E, Replace gauge. F, Replace frequency to voltage converter. G. Replace interface module. * Any time you make a change in the tire size, rear end axle ration or change the gear teeth. The interface module MUST be recalibrate. *** Check the speedo/tach inputs at the F/V on the interface module. FREQUENCY TO VOLTAGE CONVERTER PROBLEMS WHAT TO LOOK FOR ACTIONS ADDITIONAL COMMENTS The speedometer or tachometer doesn’t work right. A. Check to make sure the interface module is calibrated correctly.** B, Cheek 4 pin connector for solid connection. Check to make sure the signal source (sensor/sender) are working properly. C. Check to make sure the frequency to voltage converter is mounted to the interface module at port #4 in the proper orientation.* D. Check to see ifthe correct range of the frequency to voltage converter is installed. E. Replace the frequency to voltage converter. * Refer to page 8, interface module illustration, ** Correct engine and transmission programmed into the interface module.PRESSURE TRANSDUCER MODULE PROBLEMS WHAT TO LOOK FOR ACTIONS ADDDITIONAL COMMENTS Any of the PSI gauges are | A. Check to ensure that pressure is | * See page 8, interface module not working. present. illustration, B. Check to see if the interface module is programed for the proper ‘gauge to port assignment.* C. Check the small orifice pressure module to see if it is clogged. D. Replace the pressure transducer module.** E. Asa last resort replace the interface module. the ** You can change the PSI lines from the left to the right side to help prove that the pressure transducer is defective. VACUUM TRANSDUCER MODULE PROBLEM WHAT TO LOOK FOR ACTIONS ADDITIONAL COMMENTS ‘The air filter restriction or the fuel filter restriction are not working, A. Check to make sure that the ‘vacuum lines are working properly. B. Check to make sure that the vacuum transducer module is mounted to the interface module at port #5 * C. Check to make sure the small orifice is not clogged. D. Replace the vacuum transducer module. E. Asa last resort, replace the interface module. * See page 8, interface module illustration,