E and F-Series Service Manual

Transcription

1 Utilimaster Access System E and F-Series Service Manual Introduction This information describes service and maintenance information for the E-Series and F-Series Utilimaster Access System (UAS) developed and supplied by Utilimaster Corporation. The E-Series UAS uses a transmitter (FOB) to unlock the driver's and passenger's cab doors. The F-Series UAS uses a FOB to unlock the bulkhead and rear roll-up doors. Contents Introduction...1 Notes, Cautions, and Warnings...2 E-Series System Operation...3 F-Series System Operation...4 Programming Switch Location...5 Module Location...5 Switch Light Patterns...6 Programming and Erasing FOBs...6 Maintenance Check List...9 Lock Box Combination...9 Wiring Schematic...10 Troubleshooting Guide...11 Serviceable Parts...13 Contacting Utilimaster...15 Ordering Parts...15 Vehicle Identification...16 Compliance Statements...17 Revision Control...19 Important Notices...19

2 Notes, Cautions, and Warnings Reading through the procedures, you will see NOTES, CAUTIONS, and WARNINGS. Each is there for a specific purpose. NOTES give additional information that will help you complete the procedure. CAUTIONS warn against making an error that could damage the vehicle. WARNINGS remind you to be careful when there is risk of personal injury. When you see this symbol, read this statement first! This alert highlights information that may reduce the risk of personal injury or vehicle damage. Below are some basic WARNINGS that you should heed when you work on the vehicle s body. They are not all-inclusive and common sense must be used when servicing vehicles. Always read and understand all instructions before starting a repair. Always wear safety glasses and other appropriate protective equipment (gloves, steel-toed shoes, face shields, knee pads, hearing protection). Put the transmission in Park and set the parking brake before working on the vehicle. Be sure that the ignition switch is Off unless otherwise required by the procedure. Only operate engines in a well-ventilated area. Read and understand all warning labels. Always remove rings, watches, hanging jewelry, and loose clothing before working in tight areas. Always make sure tools are in proper working condition and have guards and safety devices in place. Use only the recommended tools for a specific job. If at any time you lack confidence in performing a specific repair procedure or in operating the tools safely to perform the repair, STOP! Call your local dealer or a Utilimaster representative. 2

3 E-Series System Operation Door locks will only respond to a transmitter (FOB) specifically programmed to that vehicle. Unlock the Driver s Door A. Press and hold the FOB button for one second and release. The door will unlock once the button is released. B. From the inside, slide latch at the door post forward. Unlock the Passenger Door A. Press and release the FOB button twice in succession. B. From the inside, slide the latch at the door post forward. Emergency Entrance In case of a dead battery, use the manual key override at the passenger s side door post. Transmitter (FOB) RELEASE LATCH Door Post Latch Manual key override 3

4 F-Series System Operation Door locks will only respond to a transmitter (FOB) specifically programmed to that vehicle. Unlock the Bulkhead Door A. Press and hold the FOB button for one second and release. The door will unlock once the button is released. B. From the inside the cargo area, slide the latch away from the door. Unlock the Rear Door A. Press and release the FOB button twice in succession. B. From the cargo area, press the unlock switch on the rear door. C. From the cargo area, slide the latch away from the door. D. From the outside, use the manual key override. Each door automatically locks when securely closed. Transmitter (FOB) RELEASE LATCH Sliding Door Latch Rear Door Unlock Switch Rear Door Key Override 4

5 Programming Switch Location The programming switch is located below the left-hand side lower dash panel on the steering support plate and faces down. DOWN START STOP Module Location Dash mount programming switch The UAS module is mounted at the top of the driver's side bulkhead wall in the cargo area. Module mounted to bulkhead wall 5

6 Switch Light Patterns The green light on the START/STOP switch indicates the system's mode by its different light sequences. It is important to know what the various patterns mean in order to respond appropriately to what the system is prompting. STEADY ON When the ignition switch lights are on (and not flashing) the ignition is either in READY (Accessory) mode or RUN mode (engine running). This is similar to having a regular ignition key in the ON position. The light will stay on until the STOP switch is pressed. BLINKING FLASH When the lights on the ignition switch are BLINKING (single flash on and off), this indicates that the system is in READY mode. READY mode lasts for only 8 seconds while it waits for the next command before timing out and turning itself off. FLICKER FLASH When the lights on the ignition switch are FLICKERING (flashing rapidly), this indicates that the system is in LEARN mode. DOUBLE FLASH Programming switch START STOP When the lights on the ignition switch DOUBLE FLASH (flash twice and stop), this indicates that the system has acknowledged the program function. It typically exits the LEARN mode after a DOUBLE FLASH. Programming and Erasing FOBs This section describes the steps to add and delete FOBs. NOTE: It is important to know what the various switch light patterns mean in order to respond appropriately to what the system is prompting. NOTE: Pre-programmed FOBs are assigned to each vehicle system from the factory and nothing needs to be done upon arrival or installation. Up to (31) FOBs can be programmed to operate a single vehicle. (Where multiple drivers could access a single vehicle.) A single FOB can be assigned to operate any number of vehicles. (A service mechanic may program a "master" FOB to access multiple vehicles.) In each case, the depot managers should review the needs and risks of multiple and cross-functional FOBs. 6

7 Adding a New FOB NOTE: A valid FOB that is presently recognized by the system has to be used to start the programming sequence in order for the system to recognize new FOB. NOTE: Each FOB has to be added individually. 1. Stop the vehicle and turn off the engine. 2. Using a FOB currently programmed to the vehicle, press the button once to prompt the READY mode (BLINKING FLASH). READY mode will last for 8 seconds while it waits for the next command before timing out. 3. Press and hold the STOP switch for 5 seconds to enter the LEARN mode. The switch will FLICKER FLASH to indicate that it is in LEARN mode. 4. Release the switch. 5. Press the button on the FOB to be added. The START switch will DOUBLE FLASH to indicate the acknowledged FOB and immediately exit the LEARN mode. 6. Now the original FOB and the added FOB are programmed to the vehicle. 7. Test the new FOB to verify that it has been enrolled correctly. 8. Repeat the steps to add another FOB. Erasing FOBs This section explains how to delete (deny access to) all FOBs that have been programmed to a single vehicle. If a FOB is lost or stolen, this process will disable its access. NOTE: A valid FOB that is presently recognized by the system has to be used to start the programming sequence. The FOB used to start this sequence will be the only one programmed to the vehicle when completed. 1. Stop the vehicle and turn off the engine. 2. Using a FOB currently programmed to the vehicle, press the button once to prompt the READY mode. It will stay in READY mode for only eight seconds before timing out. 3. Press and hold the STOP switch for 20 seconds to erase all of the programmed FOBs except the one that was used to enter the READY mode. The vehicle will now only recognize the one FOB. 4. Additional FOBs can now be added using the Adding a New FOB process. NOTE: If the lost FOB was programmed to multiple vehicles, each vehicle will need be reprogrammed separately. 7

8 Erase ALL This section explains how to delete (deny access to) all FOBs that have been programmed to a single vehicle. Use this process only on the occasion NO recognized FOBs are available to erase FOBs. NOTE: A FOB is NOT required or used to start this process, but at lease one FOB will be needed to assign to the vehicle. 1. Stop the vehicle and turn off the engine. 2. Remove the TACT switch plug. 3. Press and hold the TACT switch for 20 seconds. The LED next to the switch will turn on to indicate that it is in ALL ERASE mode. After 20 seconds, the LEARN LED will FLASH indicating that all FOBs have been erased. (Do NOT let go of the TACK switch.) 4. Continue to hold the TACK switch for approximately 1-1/2 minutes to enter the STANDBY mode. The LED will FLICKER FLASH once it is in LEARN MODE. 5. Release the switch. 6. Press the button on the FOB to be added. The ignition switch lights will DOUBLE FLASH to indicate the acknowledged FOB and immediately exit the LEARN mode. 8. Test the FOB to verify that it has been enrolled correctly. NOTE: Only one FOB can be programmed using the ERASE ALL process. 9. Reinstall the plug. 10. Additional FOBs can now be added using the Adding a New FOB process. TACT SWITCH PLUG LIGHT UAS module 8

9 Maintenance Check List Check that the doors open easily and close tightly. Check alignment of latches and catches. Check the operation of the locks. Lubricate the door rollers to minimize drag. Lubricate lock cylinders with a lightweight oil (like Exxon Hydraulic oil type NUTO 68, or equivalent.) If the lock cylinders become dirty, use ZEP 45 penetrating lubricant to clean the cylinders before applying the NUTO 68. Lubricate the actuator zerk fittings with #2 grease at six-month intervals or three-month intervals in hot, dusty conditions. Lock Box Combination Instructions for setting the lock box combination are on a card covering the combination tabs. 1. Remove the plastic instruction card. 2. Use the tab on the card to rotate the numbers 180 to be active or inactive in the combination. 3. Test the new combination BEFORE closing the lid. 4. Return the card to the storage location. 9

10 Wiring Schematic C848 C WT C866 BLUNT CUT C841 C C819 C820 A C862 C863 A MODULE LOGIC MODULE P/N: C814 C OR 1013 PK 936 RD 940 YL 941 LG 110 PK/BK 942 OR/BK 991 DB 992 YL/BK C810 C RD 110 PK/BK 942 OR/BK 991 DB 992 YL/BK A C865 C864 C824 BLUNT CUT C823 BLUNT CUT 936 RD 110 PK C827 TO POWER FEED HARNESS C849 RING TERM. C843 C RD 500 WT OR/BK DB 992 YL/BK RD 500 WT 942 OR/BK 991 DB 992 YL/BK C830 SWITCH P/N START STOP 10

11 Troubleshooting Guide Trouble Shooting Guide Series Remote Control Use a digital or analog voltmeter to check power and voltage! Do NOT use a test light Symptom 1.0 No output from one or more outputs on receiver when transmitter buttons are pressed Possible Cause 1.1 No signal from transmitter 1.2 One or more of the outputs have failed. 1.3 Receiver outputs OK, but relays or equipment do not operate. 1.4 Fuse is blown. 1.5 Wire harness problem Corrective Action Verify that transmitter is sending a signal and that transmitter is coded correctly. See Symptom Open receiver and observe yellow LEDs. The output LED should turn ON as long as relay is ON Press each transmitter button in sequence. Using a volt meter, check each output. There should be +12V present anytime the corresponding transmitter button is pressed. If no outputs, call factory for RMA number Check wire and equipment for problem Check the fuse in fuse block. If fuse is blown, replace it Check input wire harness connections on J2-6 and J2-7. If no voltage, correct wiring. Symptom Possible Cause Corrective Action 2.0 Receiver is dead. Does not operate, no heart beat LED. 2.1 Logic ground or power connection to receiver has failed 2.2 Chassis ground connection has failed Check logic ground and logic power. Use a voltmeter probe when checking voltage If either ground or power is not present, then locate failure in wire harness and repair Check chassis ground connection, it should be clean and tight, no paint on metal, an external tooth star washer should be present, no rust or dirt in connection Chassis ground should be located on vehicle frame or directly to battery. Symptom 3.0 No signal (code) being transmitted 2.3 Receiver and / or microprocessor has failed. Possible Cause 3.1 Transmitter battery voltage low 3.2 Transmitter code is incorrect 3.3 Not all buttons send a signal when pressed Check yellow output LEDs. If they DO NOT flash each time corresponding channel is activated, the receiver has failed. Call factory to get RMA number Check heart beat LED. If it is not flashing, the microprocessor has failed. Call factory to get RMA number. Corrective Action Check battery voltage, should be 3.0 VDC. Replace battery if voltage is 2.8 VDC or less. (Signal strength is dependent upon battery voltage.) Transmitter LED does not turn on if battery voltage is low If transmitter is sending a signal (LED turns ON) and no signal is being received, re-enroll transmitter to receiver. If unable to enroll transmitter, call factory for RMA number If a signal is not transmitted on all buttons, send back to factory for repair or replacement. 11

12 Symptom Possible Cause Corrective Action 4.0 Poor range 0 to 25 (pulsating 0 to 25 ) 4.1 Receiver installed in poor location near motor, large bundle of wires. 4.2 Receiver logic power input or ground is exposed to radiated noise from wire harness or motors 4.3 Poor ground connection 4.4 Transmitter 3-volt battery is low 4.5 Interference 4.6 Receiver component damaged or defective Disconnect motor and recheck range If range is ok, then electrical noise from motors is causing interference with RF signal Move module a minimum of 6 feet from the motors Disconnect receiver logic power input or logic ground from main wire harness Run new wire from vehicle battery to red wire Remove black wire on receiver from vehicle wire harness and install on the vehicle frame for a new chassis ground or battery ground Remove any paint or residue from metal, use an external tooth star washer and tighten new chassis ground terminal securely to vehicle frame Replace battery if voltage is 2.8 volts or below (All transmitters use: Lithium Coin Style - #CR2032) Electromagnetic interference (EMI) can be generated by motors, welding equipment, relays, RF from other radio frequency devices, etc. which may be in close proximity to the receiver or transmitter Move closer to module or move vehicle out of range of EMI caused by high levels of radio frequency from devices such as welding equipment, as this is a temporary problem If EMI is caused by relays, door motors or lift motors then the receiver must be moved or shielded or the EMI noise diverted to ground. Call the factory for details Call factory for RMA number and return unit for repair Other equipment installed in vehicle causing voltage drop when initially turning on Remove all other equipment from logic ground and power. Check range. If ok, run power & ground directly from battery. 12

13 Serviceable Parts This section describes some of the serviceable parts available from Utilimaster Part Department. NOTE: This information is generic. Details in illustrations and procedures may differ from the system in your vehicle. Use this information as a guideline where it applies. One-button Transmitter (FOB) The transmitter or Frequency Operated Button (key FOB) is the hand held control device used to unlock the vehicle doors and turn the engine ignition ON. When a door is unlocked with the FOB, it will remain unlocked for only a few seconds before locking again. KEY FOB SINGLE BUTTON BATTERY ONLY 2032 Adapter Rod with Set Screw The adapter rod attaches the rear roll-up door release cable to the door actuator. ADAPTER ROD W/SET SCREW Actuator, Bulkhead and Side Door This automatic latch that unlocks the bulkhead or side sliding doors. It also has a manually operated lock release lever that allows for exiting the door. BULKHEAD LATCH PASSENGER SIDE DOOR LATCH Actuator, Roll-up Door The door actuator is an automatic catch that unlocks the door. It also has a manually operated lock release lever that allows exiting the vehicle. REAR DOOR LATCH

14 Serviceable Parts Door Release Cable The rear door release cable is attached to the Best cam lock at one end and the door actuator at the other. CABLE DOOR OVERRIDE Lock Box The lock box is an added security feature for safely carrying an ignition key or additional FOB on board the vehicle. It has a pushbutton combination lock and includes the weather resistant rubber cover. Programming Switch LOCK BOX PUSH BUTTON The switch is mounted on or near the dash panel or on the overhead shelf. The two buttons are used as follows. The programming switch switch starts sets the system in accessory mode. It is illuminated green or flashes to indicate the different modes. Pressing the illuminated red STOP switch takes it out of Accessory Mode. SWITCH START/STOP

15 Contacting Utilimaster Browse our web site for more information about Utilimaster and its products, or contact Utilimaster Customer Service by using one of the following methods: Call to Write to the following address: Utilimaster Attn: Customer Service Department 603 Earthway Blvd. Bristol, IN U.S.A. Ordering Parts Utilimaster has an electronic parts catalog and ordering system that will save your team time and money by providing 24-hour access to vehicle parts and the OEM bill of material. Go to: How to Order To order parts for this vehicle, gather the following information: Chassis VIN. Complete description of all the parts necessary. Shipping information. NOTE: Customer Service prefers payment by Visa, MasterCard, Discover, or American Express credit cards. Purchase orders from customers with established open accounts are also accepted. 15

16 Vehicle Identification VIN The 17-digit chassis Vehicle Identification Number (VIN) is the legal identifier for this vehicle and is the number recorded in the license plate registration. The VIN appears on a small label on or beside the dash on the driver s side. You can read the VIN if you look through the quarterpanel window. The number is also recorded on the Federal Certification Label. Body Serial Number The 15-digit Utilimaster Body (or Unit) Serial Number is recorded on the Federal Certification Label. This label is a plastic decal (about 11" long and 2" high) that contains a variety of manufacturing information (including the VIN). This label is found between the quarter window and door. Work Order Number A 7-digit Work Order Number appears below the Unit Serial Number on the Federal Certification Label. Label on quarter-post VIN plate Federal certification label 16

17 Compliance Statements FCC Compliance and Advisory Statement This hardware device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed or used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: 1) reorient or relocate the receiving antenna; 2) increase the separation between the equipment and the receiver 3) connect the equipment to an outlet on a circuit different from that to which the receiver is connected; 4) consult the dealer or an experienced radio/tv technician for help. Any changes or modifications not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment. Where shielded interface cables have been provided with the product or specified additional components or accessories elsewhere defined to be used with the installation of the product, they must be used in order to ensure compliance with FCC regulations. Canadian DOC Statement This digital device does not exceed the Class B limits for radio noise emissions from digital apparatus specified in the interference-causing equipment standard entitled Digital Apparatus, ICES-003 of the Department of Communications. This device complies with RSS-210 of Industry Canada. Operation is subject to the following two conditions: 1) this device may not cause interference, and 2) this device must accept any interference, including interference that may cause undesired operation of the device. 17

18 Déclaration FCC Cet équipement a été testé et déclaré conforme à la section 15 du règlement de la FCC. Son fonctionnement est soumis aux conditions suivantes: 1) l équipement concerné ne doit pas causer d interférences dangereuses, et 2) il doit accepter toute interférence reçue, y compris les interférences risquant d engendrer un fonctionnement indésirable. Cet équipement a été testé et déclaré conforme aux limitations prévues dans le cadre de la catégorie B des appareils numériques défini par la section 15 du règlement de la FCC. Ces limitations sont stipulées aux fins de garantir une protection raisonnable contre les interférences gênantes en installation résidentielle. Cet équipement génère, utilise et diffuse des ondes radio, et s il n est pas installé ni utilisé en conformité avec les instructions dont il fait l objet, peut causer des interférences gênantes avec les communications radio. Cependant, nous ne pouvons vous garantir qu une interférence ne se produira pas dans une installation particulière. Si cet équipement produit des interférences graves lors de réceptions radio ou télévisées qui peuvent être détectées en allumant et en éteignant l équipement, vous êtes invités à les supprimer de plusieurs manières: 1) Réorienter ou déplacer l antenne de réception; 2) Augmenter la distance séparant l équipement et le récepteur 3) Connecter l équipement à un circuit différent de celui auquel le récepteur est connecté; 4) Contacter votre revendeur ou un technicien radio/tv qualifié. Toutes modifications ou tous changements effectués sans l accord exprès de la partie responsable de la conformité aux normes pourraient contraindre l utilisateur à ne plus utiliser son équipement. Afin d assurer la conformité avec les règlements FCC, les câbles d interface blindés fournis avec le produit doivent être utilisés, ainsi que tout autres composants ou accessoires également spécifiés, lors de l installation du produit. Déclaration du Ministère des Communications Canadien Cet appareil numérique est conforme aux limitations concernant l émission d interférences radio par des appareils numériques de catégorie B, telles que stipulées dans le cadre de la norme Appareils numériques ICES-003 édictée par le Ministère canadien de l industrie. Cet équipement a été déclaré conforme à la norme RSS-210 édictée par le Ministère canadien de l industrie. Son fonctionnement est soumis aux conditions suivantes: 1) l équipement concerné ne doit pas causer d interférences, et 2) il doit accepter toute interférence reçue, y compris les interférences risquant d engendrer un fonctionnement indésirable. 18

19 Revision Control Document Part Number: VY14EN Revision A April 2015 Important Notices 2015, Utilimaster. Title: UAS E and F-Series Service Manual Utilimaster Corporation attempts to provide information that is accurate, complete, and useful. All information contained in this manual is based on the latest product information available at the time of publication. However, because of the Utilimaster policy of continual product improvement, Utilimaster reserves the right to amend the information in this document at any time without prior notice. This material is confidential and the property of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equipment. Utilimaster makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Utilimaster shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Utilimaster expressly disclaims all responsibility and liability for the installation, use, performance, maintenance, and support of third-party products. Customers are advised to make their independent evaluation of such products. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Utilimaster. Utilimaster is a registered trademark of Utilimaster Corporation. All other products or name brands mentioned in this document are trademarks of their respective owners. Utilimaster Customer Service Parts@utilimaster.com Utilimaster Corp., 603 Earthway Boulevard, Bristol, Indiana USA