SPEEDOMETER.pdf

SPEEDOMETER/TACHOMETER DIAGNOSTICS AND SERVICE

APPLIES TO

Model: 1000 Start Date: 01/01/1989 End Date: 11/01/1997 2000 Start Date: 01/01/1989 End Date: 11/01/1997 3000 Start Date: 01/01/1989 End Date: 11/01/1997 4000 Start Date: 01/01/1989 End Date: 11/01/1997 8000 Start Date: 01/01/1989 End Date: 11/01/1997 5000 Start Date: 01/01/1989 9100 Start Date: 01/01/1989 9200 Start Date: 01/01/1989 9300 Start Date: 01/01/1989 9400 Start Date: 01/01/1989 9600 Start Date: 01/01/1989 9700 Start Date: 01/01/1989 9800 Start Date: 01/01/1989 9900 Start Date: 01/01/1989

DESCRIPTION

This service manual section applies to all heavy duty models starting January 1, 1989 and all medium duty models from January 1, 1989 to November 1, 1997.

1000, 2000, 3000, 4000, 8000 MODELS

January 1989 to March 1992 - All Engines

The electronic speedometer, odometer, tachometer and hourmeter are microprocessor driven gauges. The microprocessor is programmable to be compatible with different tire sizes, axle ratios, and a variety of engines. The gauges are located in the instrument panel gauge cluster and can be quickly detached from the instrument panel for quick access to any of its components. Refer to REMOVE AND INSTALL .

The system consists of the gauges, the microprocessor, speedometer and tachometer sensor units, circuits in the wiring harness that connect the system, and the DIP switches, used to manually program the microprocessor. Refer to PROGRAMMING .

March 1992 to January 1994 - All Engines



The speedometer, odometer, tachometer and hourmeter have self-testing capabilities that will identify various failures in the electronic portions of the unit. The self-testing diagnostics provide a strong indication of exactly what is wrong with the unit, without removing the cluster from the vehicle or spending a large amount of time troubleshooting. Refer to CLUSTER FAILURE DIAGNOSIS .

January 1994 and Later - Mechanical Engines




January 1994 to November 1997 - Electronic Engines

The electronic speedometer, odometer, tachometer and hourmeter are microprocessor driven gauges. The microprocessor is factory programmed to operate from data link signals generated by the engine Electronic Control Module (ECM), with Big Bore engines, or the Vehicle Personality Module (VPM) with International 3-box engines. Gauges are located in the instrument panel gauge cluster and can be quickly detached from the instrument panel for quick access to any of its components. Refer to REMOVE AND INSTALL .

The system consists of the gauges, the microprocessor, vehicle speed and engine speed sensors, the engine ECM, and a Vehicle Personality Module (VPM) (International engines only). The system also consists of circuits in the wiring harness that connect the system components, and the DIP switches, which can be used to manually program the microprocessor. Refer to PROGRAMMING .


5000, 9100, 9200, 9300, 9400, 9900, MODELS

January 1989 to January 1991 - All Engines

The electronic speedometer is a microprocessor-based instrument. Utilizing the DIP switches located on the back of the speedometer head, it is programmable to different tire sizes and axle ratios. Refer to PROGRAMMING . The unit is also adaptable to cover two-speed axle applications.

The system consists of the speedometer head (mounted between the gauge cluster panels), the sensor unit (mounted in the transmission rear bearing cover) and the circuits in the wiring harness that connect the two.

The electronic tachometer is a microprocessor-based instrument. Utilizing the DIP switches located on the back of the tachometer head, it is programmable to a variety of engines. Refer to PROGRAMMING .

The system consists of the tachometer head (mounted between the gauge cluster panels), the sensor unit (mounted in the engine flywheel housing) and the circuits in the wiring harness that connect the two.


The electronic speedometer, odometer, tachometer and hourmeter are microprocessor driven gauges. The microprocessor is programmable to be compatible with different tire sizes, axle ratios, and a variety of engines. The module can be quickly detached from the instrument panel for quick access to any of its components. Refer to REMOVE AND INSTALL .


January 1994 to June 1994 - Mechanical Engines


The system consists of the gauges, the microprocessor, speedometer and tachometer sensor units, circuits in the wiring harness that connect the system, and the DIP switches used to manually program the microprocessor. Refer to PROGRAMMING .

January 1994 to June 1994 - Electronic Engines

The electronic speedometer, odometer, tachometer and hourmeter are microprocessor driven gauges. The microprocessor is factory programmed to operate from data link signals generated by the engine Electronic Control Module (ECM). The module can be quickly detached from the instrument panel for quick access to any of its components. Refer to REMOVE AND INSTALL .

The system consists of the gauges, the microprocessor, vehicle speed and engine speed sensors, and the engine ECM. The system also consists of circuits in the wiring harness that connect the system components, and the DIP switches, which can be used to manually program the microprocessor. Refer to PROGRAMMING .

June 1994 and Later - Mechanical Engines



The speedometer, odometer, tachometer and hourmeter have self-testing capabilities that will identify various failures in the electronic portions of the unit. The self- testing diagnostics provide a strong indication of exactly what is wrong with the unit, without

removing the cluster from the vehicle or spending a large amount of time troubleshooting. Refer to CLUSTER FAILURE DIAGNOSIS .

June 1994 and Later- Electronic Engines

The electronic speedometer, odometer, tachometer and hourmeter are microprocessor driven gauges. The microprocessor is factory programmed to operate from data link signals generated by the engine Electronic Control Module (ECM). The module can be quickly detached from the instrument panel for quick access to any of its components. Refer to REMOVE AND INSTALL .

The system consists of the gauges, the microprocessor, vehicle speed and engine speed sensors, and the engine ECM. The system also consists of circuits in the wiring harness that connect the system components, and the DIP switches, which can be used to manually program the microprocessor. Refer to PROGRAMMING .

The speedometer, odometer, tachometer and hourmeter have self-testing capabilities that will identify various failures in the electronic portions of the unit. The self- testing diagnostics provide a strong indication of exactly what is wrong with the unit, without removing the cluster from the vehicle or spending a large amount of time troubleshooting. Refer to CLUSTER FAILURE DIAGNOSIS .

1000, 2000, 3000, 4000, 8000 MODELS


Speedometer/Tachometer Gauges

The speedometer and tachometer gauges are driven by inputs from the microprocessor which is driven by the vehicle speed sensor, located at the transmission, and an engine speed sensor, located at the engine flywheel housing.

The sensors are magnetic pick-up devices which sense the rotation of the speedometer gear and the flywheel ring gear. A permanent magnet located in these sensors establishes a magnetic field at the tip of the sensor. The magnetic field is repeatedly interrupted by the gear teeth, creating voltage impulses that are transmitted to the microprocessor.

January 1994 and Later - Mechanical Engines

Speedometer/Tachometer Gauges

The speedometer and tachometer gauges are driven by inputs from the microprocessor which is driven by the vehicle speed sensor, located at the transmission, and an engine speed sensor, located at the engine flywheel housing.

The sensors are magnetic pick-up devices which sense the rotation of the speedometer gear and the flywheel ring gear. A permanent magnet located in these sensors establishes a magnetic field at the tip of the sensor. The magnetic field is repeatedly interrupted by the gear teeth, creating voltage impulses that are transmitted to the microprocessor.

January 1994 to November 1997 - Electronic Engines

Cummins, Caterpillar, Detroit Diesel

The speedometer and tachometer sensor output signals originate at the engine speed sensor (Engine manufacturers component) and at the vehicle speed sensor located at the transmission. These signals are sent to the engine Electronic Control Module (ECM). The engine ECM receives the input signals, processes them, and sends signals in the form of serial data transmissions over data link circuits to the speedo/tach microprocessor. The microprocessor then outputs the information to the speedometer and tachometer gauges.

The engine ECM has been factory programmed with the information for various components a vehicle is equipped with, such as tire size, axle ratio, and engine model.

NOTE: Any changes in vehicle components such as tire size, axle ratio, etc. requires the engine ECM to be reprogrammed and not the speedo/tach microprocessor. Refer to engine manufacturers service manual for information on reprogramming.

International

The speedometer and tachometer sensor output signals originate at the engine speed sensor installed in the engine (Engine manufacturers component) and at the vehicle speed sensor located at the transmission.

The engine speed sensor transmits a signal to the engine Electronic Control Module (ECM) which calculates the engine speed. The engine ECM sends the calculated engine speed (RPM) as a digital signal to the engine Vehicle Personality Module (VPM). The engine VPM buffers this signal and sends a signal to the speedo/tach microprocessor.

The vehicle speed sensor sends an AC signal to the engine VPM. The engine VPM has been programmed with the correct rear axle ratio and tire size information. The engine VPM uses this programmed information and the speed sensor input to create the vehicle speed signal which is sent to the speedo/tach microprocessor.

NOTE: Any changes in vehicle components such as tire size, axle ratio, etc. requires the engine VPM to be reprogrammed and not the speedo/tach microprocessor. Refer to engine manufacturers service manual for information on reprogramming.

1000, 2000, 3000, 4000, 8000 MODELS

January 1989 to March 1992 - Instrument Cluster, Remove

CAUTION:

Static electricity can cause permanent damage to the cluster. Before working on the cluster, be sure to remove all static electricity from your body by touching metal that is grounded. Do not wear clothing that causes static electric build up (nylon).

NOTE: Before replacing a speedometer/tachometer gauge cluster, refer to CLUSTER FAILURE DIAGNOSIS to verify cluster needs replacing.

1. Always place the ignition in the OFF position (not ACC) prior to working on the cluster, due to potential shorting between the ground and ignition pins, which will damage the circuit board and gauges.

2. Protect the bezel during removal by placing a soft cloth on the forward side of the steering column.

3. Remove the four cluster mounting screws ( Figure 1 ).

(Right click on graphic to bring up an option list) 1000, 2000, 3000, 4000, 8000 Models Instrument Cluster Bezel, January

1989 to March 1992 1. PAN HEAD SCREWS 2. INSTRUMENT CLUSTER BEZEL 3. CLUSTER 4. WIRING HARNESS CONNECTOR 5. INSTRUMENT PANEL

4. Tilt or lift out cluster assembly from instrument panel. 5. Disconnect the three wiring harness connectors from the back of the cluster assembly ( Figure 1 ). 6. Disconnect the fitting on the back of the oil pressure gauge ( Figure 2 ). The oil gauge elbow must be held with a wrench while disconnecting the oil line.

(Right click on graphic to bring up an option list)

1000, 2000, 3000, 4000, 8000 Models Air or Oil Gauge Fittings and Lines, January 1989 to March 1992

1. CLUSTER ASSEMBLY 2. AIR OR OIL GAUGE FITTING 3. AIR OR OIL LINE

CAUTION:

When disconnecting or tightening air pressure and oil pressure line fittings, be sure to use two wrenches. One wrench must be on the gauge elbow to prevent it from turning.

7. After bleeding the air system, disconnect the air lines from the fittings on the back of the air gauges ( Figure 2 ). Two air pressure gauges are used on vehicles with air brakes. The air gauge elbow must be held while disconnecting the air line. CAUTION:

Note the color of the air lines. The green line is for the primary system and the orange line is for the secondary system.

8. Disconnect the fuel-tach connections if the vehicle is so equipped. 9. The instrument cluster assembly is now free to be removed from the instrument panel. January 1989 to March 1992 - Instrument Cluster, Install CAUTION:


CAUTION: When disconnecting or tightening air pressure and oil pressure line fittings, be sure to use two wrenches. One wrench must be on the gauge elbow to prevent it from turning.

CAUTION: Note the color of the air lines. The green line is for the primary system and the orange line is for the secondary system.

1. Protect the instrument cluster bezel during installation by placing a soft cloth on the forward side of the steering column. 2. Place the instrument cluster by the instrument panel opening. 3. Connect and tighten the fuel-tach fittings if so equipped. 4. Connect and tighten the air line fittings to the back of the air gauges. Be sure to observe air line color coding. The air gauge elbow must be held with a wrench while tightening the air line fitting to prevent it from turning. 5. Connect and tighten the oil pressure line to the fitting on the back of the oil pressure gauge ( Figure 2 ). The oil gauge elbow must be held with a wrench while tightening the oil line fitting to prevent it from turning. 6. Connect the three wiring harness connectors to the back of the cluster assembly ( Figure 1 ). 7. Position the cluster assembly into the instrument panel opening. 8. Install and tighten the (4) four cluster mounting screws ( Figure 1 ). January 1989 to March 1992 - Speedometer/Tachometer Gauges, Remove It is recommended that the entire cluster be removed from the instrument panel to perform gauge removal and/or installation. This provides more work room and minimizes the risk of damaging the cluster or the instruments. 1. Place the instrument cluster face up on a clean, horizontal surface to prevent loss of unused gauge covers, gauges, etc. Remove the center cluster screw that retains the bezel to the cluster housing. 2. Remove the bezel assembly from the housing and put it in a safe place to prevent scratching. Take care not to damage the gauge pointers when removing the bezel. 3. The speedo/tach gauges are plug-in type gauges. To remove, grasp the edge of the gauge and pull straight out. CAUTION:

After a gauge is removed from the cluster, it is important that the exposed pin terminals attached to the circuit board are not touched or shorted across. Static electricity or shorting between power and ground terminals can damage the cluster.

CAUTION: When removing or installing the hourmeter or odometer, do not touch the metal portion of the leads that fasten to the circuit board. A static discharge could damage the cluster.

CAUTION: Individual gauge dials are not protected by a lens. When removing or installing gauges, handle them by the edge of the dial face only. Do not touch the gauge pointer.

January 1989 to March 1992 - Speedometer/Tachometer Gauges, Install CAUTION:



CAUTION: Individual gauge dials are not protected by a lens. When removing or installing gauges, handle them by the edge of the dial face only. Do not touch the gauge pointer.

It is recommended that the entire cluster be removed from the instrument panel to perform gauge removal and/or installation. This provides more work room and minimizes the risk of damaging the cluster or the instruments. 1. The speedo/tach gauges are plug-in type gauges. To install, grasp the edge of the gauge and align the gauge pins with the pin terminals on the circuit board and push straight in. 2. Position and align the bezel assembly to the cluster housing. 3. Install the center cluster screw that retains the bezel to the cluster housing. March 1992 and Later - Instrument Cluster, Remove CAUTION:


NOTE: Before replacing a speedometer/tachometer gauge cluster, refer to CLUSTER FAILURE DIAGNOSIS to verify cluster needs replacing.

1. Always place the ignition in the OFF position (not ACC) prior to working on the cluster, due to potential shorting between the ground and ignition pins, which will damage the circuit board and gauges. 2. Protect the bezel during removal by placing a soft cloth on the forward side of the steering column. 3. Remove the two cluster mounting screws located on the lower front face of the cluster ( Figure 3 ).


1000, 2000, 3000, 4000, 8000 Models Instrument Cluster Bezel, March 1992 and Later

1. PAN HEAD SCREWS 2. INSTRUMENT CLUSTER BEZEL 3. CLUSTER 4. WIRING HARNESS CONNECTOR 5. INSTRUMENT PANEL 6. RELEASE TABS

4. Depress the two gray retaining tabs located on the top corners of the bezel ( Figure 3, Item 6 ). 5. Holding the tabs depressed, pull the cluster forward and gently release it from the frame. If the cluster does not come loose easily, put more pressure on the tabs and continue to pull gently. Do not attempt to pry the cluster from the frame as damage will result. 6. Disconnect the three wiring harness connectors from the back of the cluster assembly ( Figure 3 ). 7. Disconnect the oil line fitting on the back of the oil pressure gauge ( Figure 4 ). The oil gauge elbow must be held with a wrench while disconnecting the oil line to prevent it from turning.


1000, 2000, 3000, 4000, 8000 Models Oil Gauge Fitting and Line, March 1992 and Later

1. CLUSTER ASSEMBLY 2. OIL GAUGE FITTING 3. OIL LINE

CAUTION:

When disconnecting or tightening oil pressure line fittings, be sure to use two wrenches. One wrench must be on the gauge elbow to prevent it from turning.

8. After bleeding the air system, disconnect the air line fittings from the back of the air gauge. A double needle air pressure gauge is used on vehicles with air brakes ( Figure 5 ).


1000, 2000, 3000, 4000, 8000 Models Air Line Fittings, March 1992 and Later

CAUTION:

Note the color of the air gauge air lines. The green line is for the primary system and the orange line is for the secondary system.

9. The instrument cluster assembly is now free to be removed from the instrument panel. March 1992 and Later - Instrument Cluster, Install CAUTION:


CAUTION: When disconnecting or tightening oil pressure line fittings, be sure to use two wrenches. One wrench must be on the gauge elbow to prevent it from turning.

CAUTION: Note the color of the air gauge air lines. The green line is for the primary system and the orange line is for the secondary system.

1. Protect the instrument cluster bezel during installation by placing a soft cloth on the forward side of the steering column. 2. Place the instrument cluster by the instrument panel opening. 3. Connect and tighten the air line fittings to the back of the air gauges. Be sure to observe air line color coding. 4. Connect and tighten the oil pressure line to the fitting on the back of the oil pressure gauge. The oil gauge elbow must be held with a wrench while tightening the oil line fitting to prevent it from turning. NOTE: Do not exceed 36 in-lbs. (4.0 Nm) of torque when tightening the air and oil lines.

5. Connect the three wiring harness connectors to the back of the cluster. These connectors are color-coded for proper orientation. 6. Align the cluster in the instrument panel frame and push the cluster gently until the retaining tabs snap into place. 7. Install the two cluster mounting screws on the lower front face of the cluster. March 1992 and Later - Speedometer/Tachometer Gauges, Remove It is recommended that the entire cluster be removed from the instrument panel to perform gauge removal and/or installation. This provides more work room and minimizes the risk of damaging the cluster or the instruments. 1. Remove the three bezel screws that fasten the bezel to the cluster housing ( Figure 6 ). Place the instrument cluster face up on a clean, horizontal surface to prevent loss of unused gauge covers, gauges, etc.


1000, 2000, 3000, 4000, 8000 Models Instrument Cluster Housing, March 1992 and Later

2. Remove the bezel lens assembly from the housing and put it in a safe place to prevent scratching. Take care not to damage the gauge pointers with the bezel or lens. CAUTION:

Individual gauge dials are not protected by a lens. When removing or installing gauges handle them by the edge of the dial face only. Do not touch the gauge pointer.

3. The speedo/tach gauges are plug-in type gauges. To remove, locate the hole in the back of the cluster behind the gauge and using a small, blunt tool such as a small screwdriver handle, push the gauge out of the housing. Once the gauge has cleared the retaining snaps, it may be removed from the front. CAUTION:


4. To remove the hourmeter and/or odometer, disconnect the wiring plugs from the circuit board at the back of the cluster. At the front of the cluster, remove the adhesive-backed mask covering the gauge, then retract the two fingers that hold the gauges in the cluster and lift the gauge out of the cluster. CAUTION:

When removing or installing the hourmeter or odometer, do not touch the metal portion of the leads that fasten to the circuit board. A static discharge could damage the cluster.

March 1992 and Later - Speedometer/Tachometer Gauges, Install CAUTION:

Individual gauge dials are not protected by a lens. When removing or installing gauges handle them by the edge of the dial face only. Do not touch the gauge pointer.

CAUTION: After a gauge is removed from the cluster, it is important that the exposed pin terminals attached to the circuit board are not touched or shorted across. Static electricity or shorting between power and ground terminals can damage the cluster.


1. To install the hourmeter and/or odometer, route the wiring plug through the appropriate cluster opening and through the circuit panel. Position the gauge in the opening and push down until the retaining tabs snap into place. Align the adhesive-backed mask to the gauge opening and press into place. Plug the wiring connector into the circuit board terminal. 2. The speedo/tach gauges are plug-in type gauges. To install, grasp the gauge by the edge of the dial face. Align the gauge pins with the pin terminals on the circuit board and push straight in until the retaining tabs snap into place. 3. Assemble the bezel and lens to the cluster assembly and install three screws that attach the bezel to the cluster housing.

1000, 2000, 3000, 4000, 8000 MODELS

January 1989 to March 1992 - All Engines

The speedo/tach cluster has two sets of DIP switches with eight switches in each bank. The DIP switches are located at the top, rear of the cluster and are used to manually program the speedo/tach microprocessor with vehicle component information by physically setting the DIP switches ( Figure 15 ).


1000, 2000, 3000, 4000, 8000 Models DIP Switches, January 1989 to March 1992

A. LEFT SIDE DIP SWITCH B. RIGHT SIDE DIP SWITCH 1. INSTRUMENT CLUSTER BEZEL 2. CLUSTER 3. WIRING HARNESS CONNECTOR 4. INSTRUMENT PANEL 5. DIP SWITCH COVER 6. TEN SPEEDOMETER SETTING SWITCHES (1-8 ON LEFT, 1, 2 ON RIGHT) 7. ONE AXLE RATED SETTING SWITCH (3 ON RIGHT)

8. THREE TACHOMETER SETTING SWITCHES (4, 5, 6 ON RIGHT) 9. ONE ENGLISH/METRIC CONVERSION SWITCH (8 ON RIGHT)

The original speedometer DIP switch settings are shown on the vehicle linesetting ticket in the 010000 code, Speedo - last ten (10) digits ( Figure 16 ). The DIP switch settings can also be determined by following the DIP Switch Configuration section below.


Vehicle Lineset Ticket Component Changes Any changes in vehicle components like tire size or axle ratio requires recalibration of the ten (10) speedometer switches. The prop shaft revolutions per mile must be calculated and the DIP switches physically set to the positions shown on the Switch Setting Chart. Refer to PROGRAMMING, CALCULATION AND SWITCH SETTING . Cluster Replacement Replacing the speedo/tach cluster requires that all DIP switches be physically set to match the settings of the cluster being removed. The original speedometer DIP switch settings can be found on the vehicle linesetting ticket. All DIP switch settings can be determined by following the DIP Switch Configuration section below. DIP Switch Configuration - Speedometer Programming the speedometer DIP switches involves setting the first ten (10) switches (Number 1 thru 8 on the left, plus 1 and 2 on the right bank) to positions based on the revolutions per mile of the propeller shaft. Refer to PROGRAMMING, CALCULATION AND SWITCH SETTING . DIP Switch Configuration - Two Speed Axle Ratio The number 3 switch position on the right bank is for calibration of the two available two-speed axle ratios. This switch position is "0" for a 1.36:1, or "1" for a 1.39:1 axle ratio.

To calculate two-speed axle ratio, divide the high speed gear ratio by the low speed gear ratio. These ratios are stamped into a tag located on the differential carrier. This switch is not active if not equipped with a two-speed axle and the lineset ticket or cluster label will be marked with an "*". DIP Switch Configuration - Tachometer The number 4, 5, and 6 switch positions on the right bank are for programming the tachometer RPM settings. The DIP switch settings are based on engine model and flywheel gear teeth per revolution and are shown in the Tachometer DIP Switch Settings Chart.

Tachometer DIP Switch Settings Chart

Switch

Position

Teeth Per

Revolution

Engine or Output

4 5 6 - -

1 1 0 103 Cummins

0 0 1 113 Caterpillar

1 0 1 118 Detroit Diesel

0 1 0 126 Perkins, T6-354; Cummins, VT-

155; Export

1 1 1 133 Mercedes (Export)

0 1 1 138 International

DIP Switch Configuration - Switch Number 7 on Right Bank - This switch is not used and the switch position is not a factor in the speedo/tach operation. DIP Switch Configuration - Odometer - The number 8 switch on the right bank is for setting the odometer to show either miles or kilometers. This switch must be set to "0" for miles, or "1" for kilometers. March 1992 to February 1994 - All Engines The speedo/tach cluster has two sets of DIP switches with eight switches in each bank. The DIP switches are located at the top, rear of the cluster and can be used to manually program speedo/tach module information. ( Figure 17 ).


1000, 2000, 3000, 4000, 8000 Models Speedometer/Tachometer Cluster DIP Switches, March 1992 to February 1994

SWITCH 1. LEFT SIDE DIP SWITCH BANK SWITCH 2. RIGHT SIDE DIP SWITCH BANK 1. CLUSTER 2. WIRING HARNESS CONNECTORS 3. DIP SWITCHES 4. TEN SPEEDOMETER SETTING SWITCHES (1-8 ON LEFT, 1-2 ON RIGHT) 5. ONE AXLE RATIO SETTING SWITCH (3 ON RIGHT) 6. THREE TACHOMETER SETTING SWITCHES (4-5-6 ON RIGHT) 7. ONE TACHOMETER RANGE SWITCH (7 ON RIGHT) 8. ONE ENGLISH-METRIC ODOMETER SWITCH (8 ON RIGHT)

IMPORTANT: The original speedo/tach cluster microprocessor is electronically programmed, when the vehicle is built, to match the component configuration of the vehicle. However, the physical positions of all the DIP switches remain in the "0" position.

The original electronically programmed settings are shown on the vehicle linesetting ticket in the 010000 code, Speedo & Misc - last sixteen (16) digits ( Figure 18 ), and on a label attached to the top of the original cluster ( Figure 19 ).


Vehicle Lineset Ticket


DIP Switch Setting Label DIP switch settings can also be determined by following the DIP Switch Configuration section. IMPORTANT: Physically moving any of the DIP switches from the "0" position disables all of the electronically programmed settings of the cluster. If any DIP switch is moved for any reason, then ALL of the DIP switches must be physically moved to the appropriate positions shown on the vehicle linesetting ticket, or the label attached to the top of the cluster. Physically moving all the DIP switches

back to the "0" position of an electronically programmed cluster will enable the original programmed settings.

Component Changes Any changes in vehicle components like tire size or axle ratio requires recalibration of the speedometer. The prop shaft revolutions per mile must be calculated and the DIP switches physically set. Refer to PROGRAMMING, CALCULATION AND SWITCH SETTING . NOTE: Physically setting the new DIP switch settings for the speedometer disables all of the electronically programmed settings. This requires that the rest of the switches also be physically set to the positions shown on the vehicle linesetting ticket, the cluster label, or can be determined by following the DIP Switch Configuration section below.

Cluster Replacement Replacing the speedo/tach cluster requires that the new module be manually programmed by physically setting all DIP switches to match the vehicle component configuration. The original DIP switch settings are found on the vehicle linesetting ticket, on the label attached to the top of the original cluster, or can be determined by following the DIP Switch Configuration section below. DIP Switch Configuration - Speedometer DIP Switch Configuration - Speedometer - Programming the speedometer DIP switches involves setting the first ten (10) switches (Number 1 thru 8 on left, plus 1 and 2 on right bank) to positions based on the revolutions per mile of the propeller shaft. Refer to PROGRAMMING, CALCULATION AND SWITCH SETTING . DIP Switch Configuration - Two Speed Axle Ratio - The number three switch position on the right bank is for calibration of the two available two-speed axle ratios. This switch position is "0" for a 1.36:1, or "1" for a 1.39:1 axle ratio. To calculate two-speed axle ratio, divide the high speed gear ratio by the low speed gear ratio. These ratios are stamped into a tag located on the differential carrier. This switch is not active if not equipped with a two-speed axle and the lineset ticket or cluster label will be marked with an "*". DIP Switch Configuration - Tachometer - The number 4, 5, and 6 switch positions on the right bank are for programming the tachometer RPM settings. These settings are based on engine model and flywheel gear teeth per revolution and are shown in the Tachometer DIP Switch Settings Chart.


Switch Position Teeth Per Revolution Engine or Output

4 5 6 - -

1 1 0 103 Cummins




1 0 0 173 Cummins B (Export) (C92 Rev.)

DIP Switch Configuration - Tachometer Range - The number 7 switch is to set the tachometer range scale. This switch is always set to the "0" position for 0-3500 RPM readings. DIP Switch Configuration - Odometer - The number 8 switch on the right bank is for setting the odometer to show either miles or kilometers. This switch must be set to "0" for miles, or "1" for kilometers.

February 1994 and Later - Mechanical Engines The speedo/tach cluster has two sets of DIP switches with eight switches in each bank. The DIP switches are located at the top, rear of the cluster and can be used to manually program speedo/tach module information ( Figure 17 ). IMPORTANT: The original speedo/tach cluster microprocessor is electronically programmed, when the vehicle is built, to match the component configuration of the vehicle. However, the physical positions of all the DIP switches remain in the "0" position.

The original electronically programmed settings are shown on the vehicle linesetting ticket in the 010000 code, Speedo & Misc - last sixteen (16) digits ( Figure 18 ), and on a label attached to the top of the original cluster ( Figure 19 ). DIP switch settings can also be determined by following the DIP Switch Configuration section. IMPORTANT: Physically moving any of the DIP switches from the "0" position disables all of the electronically programmed settings of the cluster. If any DIP switch is moved for any reason, then ALL of the DIP switches must be physically moved to the appropriate positions shown on the vehicle linesetting ticket, or the label attached to the top of the cluster. Physically moving all the DIP switches back to the "0" position of an electronically programmed cluster will enable the original programmed settings.

Component Changes Any changes in vehicle components like tire size or axle ratio requires recalibration of the speedometer. The prop shaft revolutions per mile must be calculated and the DIP switches physically set. Refer to PROGRAMMING, CALCULATION AND SWITCH SETTING. NOTE: Physically setting the new DIP switch settings for the speedometer disables all of the electronically programmed settings. This requires that the rest of the switches also be physically set to the positions shown on the vehicle linesetting ticket, the cluster label, or can be determined by following the DIP Switch Configuration section.

Cluster Replacement Replacing the speedo/tach cluster requires that the new module be manually programmed by physically setting all DIP switches to match the vehicle component configuration. The original DIP switch settings are found on the vehicle linesetting ticket, on the label attached to the top of the original cluster, or can be determined by following the DIP Switch Configuration section below. DIP Switch Configuration - Speedometer DIP Switch Configuration - Speedometer - Programming the speedometer DIP switches involves setting the first ten (10) switches (Number 1 thru 8 on left plus 1 and 2 on right bank) to positions based on the revolutions per mile of the propeller shaft. Refer to PROGRAMMING, CALCULATION AND SWITCH SETTING . DIP Switch Configuration - Two Speed Axle Ratio - The number three switch position on the right bank is for calibration of the two available two-speed axle ratios. This switch position is "0" for a 1.36:1, or "1" for a 1.39:1 axle ratio. To calculate two-speed axle ratio, divide the high speed gear ratio by the low speed gear ratio. These ratios are stamped into a tag located on the differential

carrier. This switch is not active if not equipped with a two-speed axle and the lineset ticket or cluster label will be marked with an "*". DIP Switch Configuration - Tachometer - The number 4, 5, and 6 switch positions on the right bank are for programming the tachometer RPM settings. These settings are based on engine model and flywheel gear teeth per revolution and are shown in the Tachometer DIP Switch Settings Chart.


Switch Position Teeth Per Revolution Engine or Output

4 5 6 - -

1 1 0 103 Cummins




1 0 0 173 Cummins B (Export) (C92 Rev.)

DIP Switch Configuration - Tachometer Range - The number seven switch is to set the tachometer range scale. This switch is always set to the "0" position for 0-3500 RPM readings. DIP Switch Configuration - Odometer - The number 8 switch on the right bank is for setting the odometer to show either miles or kilometers. This switch must be set to "0" for miles, or "1" for kilometers.

January 1994 to November 1997 - Electronic Engines: Caterpillar, Cummins, and Detroit Diesel The speedo/tach cluster has two sets of DIP switches with eight switches in each bank. The DIP switches are located at the top, rear of the cluster and can be used to manually program the speedo/tach microprocessor to receive data link signals generated by the engine Electronic Control Module (ECM) ( Figure 17 ). Information on engine, axle ratio, tire revolutions per mile, number of teeth on the transmission speedometer gear, etc. are programmed into the engine ECM and not the speedo/tach module. IMPORTANT: The original speedo/tach cluster microprocessor is electronically programmed, when the vehicle is built, to receive data link signals generated by the engine ECM. However, the physical positions of all the DIP switches remain in the "0" position.

The original electronically programmed settings are shown on the vehicle linesetting ticket in the 010000 code, Speedo & Misc - last sixteen (16) digits ( Figure 18 ), and on a label attached to the top of the original cluster ( Figure 19 ). DIP switch settings can also be determined by following the DIP Switch Configuration section. IMPORTANT: Physically moving any of the DIP switches from the "0" position disables all of the electronically programmed settings of the cluster. If any DIP switch is moved for any reason, then ALL of the DIP switches must be physically moved to the appropriate positions shown on the vehicle linesetting ticket, or the label attached to the top of the cluster. Physically moving all the DIP switches back to the "0"

position of an electronically programmed cluster will enable the original programmed settings.

Component Changes If there are any changes in vehicle components, such as tire size or axle ratio, etc., the engine ECM must be reprogrammed with the correct data. NOTE: The speedo/tach module microprocessor or DIP switches do not get reprogrammed.

The Pro-Link 9000 Electronic Service Tool (EST), or the EZ-Tech with the authorized engine manufacturer's software must be used for reprogramming the engine ECM. Refer to the Pro-Link® 9000 manual or the engine manufacturer's service literature for instructions. Cluster Replacement If a cluster is to be replaced, the service cluster must be programmed either electronically or manually. Electronic Programming NOTE: An electronic service tool (EST) such as the Pro-Link 9000 with the Instrument Panel Cartridge Kit, or the EZ-Tech with the instrument cluster software, are used to program the speedometer/tachometer module microprocessor, through the J1708 data link . Refer to the Pro-Link or EZ-Tech instrument cluster software manual for instructions. This method requires that all of the DIP switches be physically set in the " 0 " position.

Manual Programming If manually programming the cluster, the DIP switches must be physically set to the positions shown on the vehicle linesetting ticket, or on the label attached to the top of the original cluster. DIP switch settings can also be determined by following the DIP Switch Configuration section below. DIP Switch Configuration The physical settings of the DIP switch positions for these engines is as follows: Ten Speedometer Switches - 1111111111 (Number 1 thru 8 on left bank, plus 1 and 2 on right bank). One, Two-Speed Axle Ratio Switch - 0 or 1 (number 3 on right bank) "0" for 1.36:1 - "1" for 1.39:1 ratios. To calculate two-speed axle ratio, divide the high speed gear ratio by the low speed gear ratio. These ratios are stamped into a tag located on the differential carrier. This switch is not active if not equipped with a two-speed axle and the lineset ticket or cluster label will be marked with an "*". Three Tachometer Switches - 111 (Number 4, 5, and 6 on right bank). One Tachometer Scale Switch - 0 (Number 7 on right bank). One Odometer Switch - 0 or 1 (Number 8 on right bank) "0" for miles or "1" for kilometers.

January 1994 to November 1997 - Electronic Engines: International The speedo/tach cluster has two sets of DIP switches with eight switches in each bank. The DIP switches are located at the top, rear of the cluster and can be used to manually program the speedo/tach microprocessor to receive signals from the engine Vehicle Personality Module (VPM) ( Figure 17 ). Information on engine, axle ratio, tire revolutions per mile, number of teeth on the transmission speedometer gear, etc. are programmed into the engine VPM and not the speedo/tach module. IMPORTANT: The original speedo/tach cluster microprocessor is electronically programmed, when the vehicle is built, to receive signals generated by the engine VPM. However, the physical positions of all the DIP switches remain in the "0" position.

The original electronically programmed settings are shown on the vehicle linesetting ticket in the 010000 code, Speedo & Misc - last sixteen (16) digits ( Figure 18 ), and on a label attached to the top of the original cluster ( Figure 19 ). DIP switch settings can also be determined by following the DIP Switch Configuration section. IMPORTANT: Physically moving any of the DIP switches from the "0" position disables all of the electronically programmed settings of the cluster. If any DIP switch is moved for any reason, then ALL of the DIP switches must be physically moved to the appropriate positions shown on the vehicle linesetting ticket, or the label attached to the top of the cluster. Physically moving all the DIP switches back to the "0" position of an electronically programmed cluster will enable the original programmed settings.

Component Changes If there are any changes in vehicle components, such as tire size or axle ratio etc., the engine VPM must be reprogrammed with the correct data. NOTE: The speedo/tach module microprocessor or DIP switches cannot be electronically reprogrammed.

The Pro-Link 9000 or the EZ-Tech Electronic Service Tool (EST) can be used for reprogramming the engine VPM. Refer to the Pro-Link manual or EZ-Tech documentation for programming instructions. Cluster Replacement Replacing the speedo/tach cluster requires the module to be manually programmed by physically setting all DIP switches. This enables the microprocessor to accept signals from the engine VPM. The original DIP switch settings are found on the vehicle linesetting ticket, on the label attached to the top of the original cluster, or can be determined by following the DIP Switch Configuration section below. DIP Switch Configuration The physical settings of the DIP switch positions for these engines is as follows: Ten Speedometer Switches - 0101111100 (Number 1 thru 8 on left bank, plus 1 and 2 on right bank). One, Two-Speed Axle Ratio Switch - 0 or 1 (Number 3 on right bank) "0" for 1.36:1 - "1" for 1.39:1 ratios. To calculate two-speed axle ratio, divide the high speed gear ratio by the low speed gear ratio. These ratios are stamped into a tag located on the differential carrier. This switch is not active if not equipped with a two-speed axle and the lineset ticket or cluster label will be marked with an "*". Three Tachometer Switches - 000 (Number 4, 5, and 6 on right bank). One Tachometer Scale Switch - 0 (Number 7 on right bank). One Odometer Switch - 0 or 1 (Number 8 on right bank) "0" for miles or "1" for kilometers.

PROGRAMMING, CALCULATION AND SWITCH SETTING

NOTE: These calculations and the Speedometer DIP Switch Setting Charts are not for use with "electronically" controlled engines after Jan. 1, 1994. The component changes for those vehicles are to be programmed through the Engine Control Module (ECM) or the Vehicle Personality Module (VPM) (International engines), and not through the speedo/tach DIP switches.

The Speedo/Tach module is programmed for an input signal reflecting the number of pulses per mile from the vehicle speed sensor. The chart in this section factors in the speedometer gear pulse information, but the number of revolutions per mile of the propeller shaft (same as the output shaft) must be calculated.

The calculation requires two numbers: the number of revolutions per mile for the vehicle tire size, and the rear axle ratio.

The tire revolutions per mile can be obtained from:

A. The tire supplier. B. International Sales Data Book - Components. C. Calculating the figure using the measured distance (in feet) that the truck travels in

exactly one revolution of the wheels. 5280 divided by the measured distance = tire revolutions per mile.

The axle ratio can be obtained from: 1. The lineset ticket. 2. Axle data stamped on the differential carrier. 3. Counting the number (including fractions) of prop shaft revolutions for one tire revolution. Prop revolutions per mile = axle ratio multiplied by the tire revolutions per mile. EXAMPLE: Tire Revs/Mile - 471 (12.00 R 20 tire) Axle Ratio - 3.70:1 471 X 3.70 = 1742.7 Prop Revs per mile Look this number up in the Switch Settings Chart and use the switch settings in the column to the right of the prop rev/mile (1742 in the example) for the new switch positions. The setting for the speedometer switches in this example would be 0001011100 as shown in Figure 24 , for a typical Medium Duty 16 DIP switch pattern.


Switch Setting Example NOTE: To determine 2-SPD, RPM, Tachometer Scale, and Odometer DIP Switch Settings, refer to the appropriate DIP Switch Configuration section.

SWITCH SETTINGS CHART

Switch Settings Chart

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

1077-1083

1084-1091

1092-1098

1099-1106

1107-1113

0000100100

1000100100

0100100100

1100100100

0010100100

1414-1421

1422-1428

1429-1436

1437-1443

1444-1451

1011110100

0111110100

1111110100

0000001100

1000001100

1752-1758

1759-1766

1767-1773

1774-1781

1782-1788

0101011100

1101011100

0011011100

1011011100

0111011100

2089-2096

2097-2103

2104-2111

2112-2118

2119-2126

1110100010

0001100010

1001100010

0101100010

1101100010

1114-1121

1122-1128

1129-1136

1137-1143

1144-1151

1010100100

0110100100

1110100100

0001100100

1001100100

1452-1458

1459-1466

1467-1473

1474-1481

1482-1488

0100001100

1100001100

0010001100

1010001100

0110001100

1789-1796

1797-1803

1804-1811

1812-1818

1819-1826

1111011100

0000111100

1000111100

0100111100

1100111100

2127-2133

2134-2141

2142-2148

2149-2156

2157-2163

0011100010

1011100010

0111100010

1111100010

0000010010


REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

1152-1158

1159-1166

1167-1173

1174-1181

1182-1188

0101100100

1101100100

0011100100

1011100100

0111100100

1489-1496

1497-1503

1504-1511

1512-1518

1519-1526

1110001100

0001001100

1001001100

0101001100

1101001100

1827-1833

1834-1841

1842-1848

1849-1856

1857-1863

0010111100

1010111100

0110111100

1110111100

0001111100

2164-2171

2172-2178

2179-2186

2187-2193

2194-2201

1000010010

0100010010

1100010010

0010010010

1010010010

1189-1196

1197-1203

1204-1211

1212-1218

1219-1226

1111100100

0000010100

1000010100

0100010100

1100010100

1527-1533

1534-1541

1542-1548

1549-1556

1557-1563

0011001100

1011001100

0111001100

1111001100

0000101100

1864-1871

1872-1878

1879-1886

1887-1893

1894-1901

1001111100

0101111100

1101111100

0011111100

1011111100

2202-2208

2209-2216

2217-2223

2224-2231

2232-2238

0110010010

1110010010

0001010010

1001010010

0101010010

1227-1233

1234-1241

1242-1248

1249-1256

1257-1263

0010010100

1010010100

0110010100

1110010100

0001010100

1564-1571

1572-1578

1579-1586

1587-1593

1594-1601

1000101100

0100101100

1100101100

0010101100

1010101100

1902-1908

1909-1916

1917-1923

1924-1931

1932-1938

0111111100

1111111100

0000000010

1000000010

0100000010

2239-2246

2247-2253

2254-2261

2262-2268

2269-2276

1101010010

0011010010

1011010010

0111010010

1111010010

1264-1271

1272-1278

1279-1286

1287-1293

1294-1301

1001010100

0101010100

1101010100

0011010100

1011010100

1602-1608

1609-1616

1617-1623

1624-1631

1632-1638

0110101100

1110101100

0001101100

1001101100

0101101100

1939-1946

1947-1953

1954-1961

1962-1968

1969-1976

1100000010

0010000010

1010000010

0110000010

1110000010

2277-2283

2284-2291

2292-2298

2299-2306

2307-2313

0000110010

1000110010

0100110010

1100110010

0010110010

1302-1308

1309-1316

1317-1323

1324-1331

1332-1338

0111010100

1111010100

0000110100

1000110100

0100110100

1639-1646

1647-1653

1654-1661

1662-1668

1669-1676

1101101100

0011101100

1011101100

0111101100

1111101100

1977-1983

1984-1991

1992-1998

1999-2006

2007-2013

0001000010

1001000010

0101000010

1101000010

0011000010

2314-2321

2322-2328

2329-2336

2337-2343

2344-2351

1010110010

0110110010

1110110010

0001110010

1001110010

1339-1346

1347-1353

1354-1361

1362-1368

1369-1376

1100110100

0010110100

1010110100

0110110100

1110110100

1677-1683

1684-1691

1692-1698

1699-1706

1707-1713

0000011100

1000011100

0100011100

1100011100

0010011100

2014-2021

2022-2028

2029-2036

2037-2043

2044-2051

1011000010

0111000010

1111000010

0000100010

1000100010

2352-2358

2359-2366

2367-2373

2374-2381

2382-2388

0101110010

1101110010

0011110010

1011110010

0111110010

1377-1383

1384-1391

1392-1398

1399-1406

1407-1413

0001110100

1001110100

0101110100

1101110100

0011110100

1714-1721

1722-1728

1729-1736

1737-1743

1744-1751

1010011100

0110011100

1110011100

0001011100

1001011100

2052-2058

2059-2066

2067-2073

2074-2081

2082-2088

0100100010

1100100010

0010100010

1010100010

0110100010

2389-2396

2397-2403

2404-2411

2412-2418

2419-2426

1111110010

0000001010

1000001010

0100001010

1100001010

2427-2433 0010001010 2764-2771 1000111010 3102-3108 0111100110 3439-3446 1101001110


REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

2434-2441

2442-2448

2449-2456

2457-2463

1010001010

0110001010

1110001010

0001001010

2772-2778

2779-2786

2787-2793

2794-2801

0100111010

1100111010

0010111010

1010111010

3109-3116

3117-3123

3124-3131

3132-3138

1111100110

0000010110

1000010110

0100010110

3447-3453

3454-3461

3462-3468

3469-3476

0011001110

1011001110

0111001110

1111001110

2464-2471

2472-2478

2479-2486

2487-2493

2494-2501

1001001010

0101001010

1101001010

0011001010

1011001010

2802-2808

2809-2816

2817-2823

2824-2831

2832-2838

0110111010

1110111010

0001111010

1001111010

0101111010

3139-3146

3147-3153

3154-3161

3162-3168

3169-3176

1100010110

0010010110

1010010110

0110010110

1110010110

3477-3483

3484-3491

3492-3498

3499-3506

3507-3513

0000101110

1000101110

0100101110

1100101110

0010101110

2502-2508

2509-2516

2517-2523

2524-2531

2532-2538

0111001010

1111001010

0000101010

1000101010

0100101010

2839-2846

2847-2853

2854-2861

2862-2868

2869-2876

1101111010

0011111010

1011111010

0111111010

1111111010

3177-3183

3184-3191

3192-3198

3199-3206

3207-3213

0001010110

1001010110

0101010110

1101010110

0011010110

3514-3521

3522-3528

3529-3536

3537-3543

3544-3551

1010101110

0110101110

1110101110

0001101110

1001101110

2539-2546

2547-2553

2554-2561

2562-2568

2569-2576

1100101010

0010101010

1010101010

0110101010

1110101010

2877-2883

2884-2891

2892-2898

2899-2906

2907-2913

0000000110

1000000110

0100000110

1100000110

0010000110

3214-3221

3222-3228

3229-3236

3237-3243

3244-3251

1011010110

0111010110

1111010110

0000110110

1000110110

3552-3558

3559-3566

3567-3573

3574-3581

3582-3588

0101101110

1101101110

0011101110

1011101110

0111101110

2577-2583

2584-2591

2592-2598

2599-2606

2607-2613

0001101010

1001101010

0101101010

1101101010

0011101010

2914-2921

2922-2928

2929-2936

2937-2943

2944-2951

1010000110

0110000110

1110000110

0001000110

1001000110

3252-3258

3259-3266

3267-3273

3274-3281

3282-3288

0100110110

1100110110

0010110110

1010110110

0110110110

3589-3596

3597-3603

3604-3611

3612-3618

3619-3626

1111101110

0000011110

1000011110

0100011110

1100011110

2614-2621

2622-2628

2629-2636

2637-2643

2644-2651

1011101010

0111101010

1111101010

0000011010

1000011010

2952-2958

2959-2966

2967-2973

2974-2981

2982-2988

0101000110

1101000110

0011000110

1011000110

0111000110

3289-3296

3297-3303

3304-3311

3312-3318

3319-3326

1110110110

0001110110

1001110110

0101110110

1101110110

3627-3633

3634-3641

3642-3648

3649-3656

3657-3663

0010011110

1010011110

0110011110

1110011110

0001011110

2652-2658

2659-2666

2667-2673

2674-2681

2682-2688

0100011010

1100011010

0010011010

1010011010

0110011010

2989-2996

2997-3003

3004-3011

3012-3018

3019-3026

1111000110

0000100110

1000100110

0100100110

1100100110

3327-3333

3334-3341

3342-3348

3349-3356

3357-3363

0011110110

1011110110

0111110110

1111110110

0000001110

3664-3671

3672-3678

3679-3686

3687-3693

3694-3701

1001011110

0101011110

1101011110

0011011110

1011011110

2689-2696

2697-2703

1110011010

0001011010

3027-3033

3034-3041

0010100110

1010100110

3364-3371

3372-3378

1000001110

0100001110

3702-3708

3709-3716

0111011110

1111011110


REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

2704-2711

2712-2718

2719-2726

1001011010

0101011010

1101011010

3042-3048

3049-3056

3057-3063

0110100110

1110100110

0001100110

3379-3386

3387-3393

3394-3401

1100001110

0010001110

1010001110

3717-3723

3724-3731

3732-3738

0000111110

1000111110

0100111110

2727-2733

2734-2741

2742-2748

2749-2756

2757-2763

0011011010

1011011010

0111011010

1111011010

0000111010

3064-3071

3072-3078

3079-3086

3087-3093

3094-3101

1001100110

0101100110

1101100110

0011100110

1011100110

3402-3408

3409-3416

3417-3423

3424-3431

3432-3438

0110001110

1110001110

0001001110

1001001110

0101001110

3739-3746

3747-3753

3754-3761

3762-3768

3769-3776

1100111110

0010111110

1010111110

0110111110

1110111110

3777-3783

3784-3791

3792-3798

3799-3806

3807-3813

0001111110

1001111110

0101111110

1101111110

0011111110

4114-4121

4122-4128

4129-4136

4137-4143

4144-4151

1010010001

0110010001

1110010001

0001010001

1001010001

4452-4458

4459-4466

4467-4473

4474-4481

4482-4488

0100101001

1100101001

0010101001

1010101001

0110101001

4789-4796

4797-4803

4804-4811

4812-4818

4819-4826

1111111001

0000000101

1000000101

0100000101

1100000101

3814-3821

3822-3828

3829-3836

3837-3843

3844-3851

1011111110

0111111110

1111111110

0000000001

1000000001

4152-4158

4159-4166

4167-4173

4174-4181

4182-4188

0101010001

1101010001

0011010001

1011010001

0111010001

4489-4496

4497-4503

4504-4511

4512-4518

4519-4526

1110101001

0001101001

1001101001

0101101001

1101101001

4827-4833

4834-4841

4842-4848

4849-4856

4857-4863

0010000101

1010000101

0110000101

1110000101

0001000101

3852-3858

3859-3866

3867-3873

3874-3881

3882-3888

0100000001

1100000001

0010000001

1010000001

0110000001

4189-4196

4197-4203

4204-4211

4212-4218

4219-4226

1111010001

0000110001

1000110001

0100110001

1100110001

4527-4533

4534-4541

4542-4548

4549-4556

4557-4563

0011101001

1011101001

0111101001

1111101001

0000011001

4864-4871

4872-4878

4879-4886

4887-4893

4894-4901

1001000101

0101000101

1101000101

0011000101

1011000101

3889-3896

3897-3903

3904-3911

3912-3918

3919-3926

1110000001

0001000001

1001000001

0101000001

1101000001

4227-4233

4234-4241

4242-4248

4249-4256

4257-4263

0010110001

1010110001

0110110001

1110110001

0001110001

4564-4571

4572-4578

4579-4586

4587-4593

4594-4601

1000011001

0100011001

1100011001

0010011001

1010011001

4902-4908

4909-4916

4917-4923

4924-4931

4932-4938

0111000101

1111000101

0000100101

1000100101

0100100101

3927-3933

3934-3941

3942-3948

3949-3956

3957-3963

0011000001

1011000001

0111000001

1111000001

0000100001

4264-4271

4272-4278

4279-4286

4287-4293

4294-4301

1001110001

0101110001

1101110001

0011110001

1011110001

4602-4608

4609-4616

4617-4623

4624-4631

4632-4638

0110011001

1110011001

0001011001

1001011001

0101011001

4939-4946

4947-4953

4954-4961

4962-4968

4969-4976

1100100101

0010100101

1010100101

0110100101

1110100101

3964-3971

3972-3978

3979-3986

1000100001

0100100001

1100100001

4302-4308

4309-4316

4317-4323

0111110001

1111110001

0000001001

4639-4646

4647-4653

4654-4661

1101011001

0011011001

1011011001

4977-4983

4984-4991

4992-4998

0001100101

1001100101

0101100101


REV/MI

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SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

3987-3993

3994-4001

0010100001

1010100001

4324-4331

4332-4338

1000001001

0100001001

4662-4668

4669-4676

0111011001

1111011001

4999-5006

5007-5013

1101100101

0011100101

4002-4008

4009-4016

4017-4023

4024-4031

4032-4038

0110100001

1110100001

0001100001

1001100001

0101100001

4339-4346

4347-4353

4354-4361

4362-4368

4369-4376

1100001001

0010001001

1010001001

0110001001

1110001001

4677-4683

4684-4691

4692-4698

4699-4706

4707-4713

0000111001

1000111001

0100111001

1100111001

0010111001

5014-5021

5022-5028

5029-5036

5037-5043

5044-5051

1011100101

0111100101

1111100101

0000010101

1000010101

4039-4046

4047-4053

4054-4061

4062-4068

4069-4076

1101100001

0011100001

1011100001

0111100001

1111100001

4377-4383

4384-4391

4392-4398

4399-4406

4407-4413

0001001001

1001001001

0101001001

1101001001

0011001001

4714-4721

4722-4728

4729-4736

4737-4743

4744-4751

1010111001

0110111001

1110111001

0001111001

1001111001

5052-5058

5059-5066

5067-5073

5074-5081

5082-5088

0100010101

1100010101

0010010101

1010010101

0110010101

4077-4083

4084-4091

4092-4098

4099-4106

4107-4113

0000010001

1000010001

0100010001

1100010001

0010010001

4414-4421

4422-4428

4429-4436

4437-4443

4444-4451

1011001001

0111001001

1111001001

0000101001

1000101001

4752-4758

4759-4766

4767-4773

4774-4781

4782-4788

0101111001

1101111001

0011111001

1011111001

0111111001

5089-5096

5097-5103

5104-5111

5112-5118

5119-5126

1110010101

0001010101

1001010101

0101010101

1101010101

5127-5133

5134-5141

5142-5148

5149-5156

5157-5163

0011010101

1011010101

0111010101

1111010101

0000110101

5464-5471

5472-5478

5479-5486

5487-5493

5494-5501

1001101101

0101101101

1101101101

0011101101

1011101101

5802-5808

5809-5816

5817-5823

5824-5831

5832-5838

0110000011

1110000011

0001000011

1001000011

0101000011

6139-6146

6147-6153

6154-6161

6162-6168

6169-6176

1100110011

0010110011

1010110011

0110110011

1110110011

5164-5171

5172-5178

5179-5186

5187-5193

5194-5201

1000110101

0100110101

1100110101

0010110101

1010110101

5502-5508

5509-5516

5517-5523

5524-5531

5532-5538

0111101101

1111101101

0000011101

1000011101

0100011101

5839-5846

5847-5853

5854-5861

5862-5868

5869-5876

1101000011

0011000011

1011000011

0111000011

1111000011

6177-6183

6184-6191

6192-6198

6199-6206

6207-6213

0001110011

1001110011

0101110011

1101110011

0011110011

5202-5208

5209-5216

5217-5223

5224-5231

5232-5238

0110110101

1110110101

0001110101

1001110101

0101110101

5539-5546

5547-5553

5554-5561

5562-5568

5569-5576

1100011101

0010011101

1010011101

0110011101

1110011101

5877-5883

5884-5891

5892-5898

5899-5906

5907-5913

0000100011

1000100011

0100100011

1100100011

0010100011

6214-6221

6222-6228

6229-6236

6237-6243

6244-6251

1011110011

0111110011

1111110011

0000001011

1000001011

5239-5246

5247-5253

5254-5261

5262-5268

1101110101

0011110101

1011110101

0111110101

5577-5583

5584-5591

5592-5598

5599-5606

0001011101

1001011101

0101011101

1101011101

5914-5921

5922-5928

5929-5936

5937-5943

1010100011

0110100011

1110100011

0001100011

6252-6258

6259-6266

6267-6273

6274-6281

0100001011

1100001011

0010001011

1010001011


REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

5269-5276 1111110101 5607-5613 0011011101 5944-5951 1001100011 6282-6288 0110001011

5277-5283

5284-5291

5292-5298

5299-5306

5307-5313

0000001101

1000001101

0100001101

1100001101

0010001101

5614-5621

5622-5628

5629-5636

5637-5643

5644-5651

1011011101

0111011101

1111011101

0000111101

1000111101

5952-5958

5959-5966

5967-5973

5974-5981

5982-5988

0101100011

1101100011

0011100011

1011100011

0111100011

6289-6296

6297-6303

6304-6311

6312-6318

6319-6326

1110001011

0001001011

1001001011

0101001011

1101001011

5314-5321

5322-5328

5329-5336

5337-5343

5344-5351

1010001101

0110001101

1110001101

0001001101

1001001101

5652-5658

5659-5666

5667-5673

5674-5681

5682-5688

0100111101

1100111101

0010111101

1010111101

0110111101

5989-5996

5997-6003

6004-6011

6012-6018

6019-6026

1111100011

0000010011

1000010011

0100010011

1100010011

6327-6333

6334-6341

6342-6348

6349-6356

6357-6363

0011001011

1011001011

0111001011

1111001011

0000101011

5352-5358

5359-5366

5367-5373

5374-5381

5382-5388

0101001101

1101001101

0011001101

1011001101

0111001101

5689-5696

5697-5703

5704-5711

5712-5718

5719-5726

1110111101

0001111101

1001111101

0101111101

1101111101

6027-6033

6034-6041

6042-6048

6049-6056

6057-6063

0010010011

1010010011

0110010011

1110010011

0001010011

6364-6371

6372-6378

6379-6386

6387-6393

6394-6401

1000101011

0100101011

1100101011

0010101011

1010101011

5389-5396

5397-5403

5404-5411

5412-5418

5419-5426

1111001101

0000101101

1000101101

0100101101

1100101101

5727-5733

5734-5741

5742-5748

5749-5756

5757-5763

0011111101

1011111101

0111111101

1111111101

0000000011

6064-6071

6072-6078

6079-6086

6087-6093

6094-6101

1001010011

0101010011

1101010011

0011010011

1011010011

6402-6408

6409-6416

6417-6423

6424-6431

6432-6438

0110101011

1110101011

0001101011

1001101011

0101101011

5427-5433

5434-5441

5442-5448

5449-5456

5457-5463

0010101101

1010101101

0110101101

1110101101

0001101101

5764-5771

5772-5778

5779-5786

5787-5793

5794-5801

1000000011

0100000011

1100000011

0010000011

1010000011

6102-6108

6109-6116

6117-6123

6124-6131

6132-6138

0111010011

1111010011

0000110011

1000110011

0100110011

6439-6446

6447-6453

6454-6461

6462-6468

6469-6476

1101101011

0011101011

1011101011

0111101011

1111101011

6477-6483

6484-6491

6492-6498

6499-6506

6507-6513

0000011011

1000011011

0100011011

1100011011

0010011011

6777-6783

6784-6791

6792-6798

6799-6806

6807-6813

0001000111

1001000111

0101000111

1101000111

0011000111

7077-7083

7084-7091

7092-7098

7099-7106

7107-7113

0000110111

1000110111

0100110111

1100110111

0010110111

7377-7383

7384-7391

7392-7398

7399-7406

7407-7413

0001101111

1001101111

0101101111

1101101111

0011101111

6514-6521

6522-6528

6529-6536

6537-6543

6544-6551

1010011011

0110011011

1110011011

0001011011

1001011011

6814-6821

6822-6828

6829-6836

6837-6843

6844-6851

1011000111

0111000111

1111000111

0000100111

1000100111

7114-7121

7122-7128

7129-7136

7137-7143

7144-7151

1010110111

0110110111

1110110111

0001110111

1001110111

7414-7421

7422-7428

7429-7436

7437-7443

7444-7451

1011101111

0111101111

1111101111

0000011111

1000011111


REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

REV/MI

PROPELLER

SHAFT

FROM-TO

SWITCH

POSITIONS

12343567890

SETTINGS

6552-6558

6559-6566

6567-6573

6574-6581

6582-6588

0101011011

1101011011

0011011011

1011011011

0111011011

6852-6858

6859-6866

6867-6873

6874-6881

6882-6888

0100100111

1100100111

0010100111

1010100111

0110100111

7152-7158

7159-7166

7167-7173

7174-7181

7182-7188

0101110111

1101110111

0011110111

1011110111

0111110111

7452-7458

7459-7466

7467-7473

7474-7481

7482-7488

0100011111

1100011111

0010011111

1010011111

0110011111

6589-6596

6597-6603

6604-6611

6612-6618

6619-6626

1111011011

0000111011

1000111011

0100111011

1100111011

6889-6896

6897-6903

6904-6911

6912-6918

6919-6926

1110100111

0001100111

1001100111

0101100111

1101100111

7189-7196

7197-7203

7204-7211

7212-7218

7219-7226

1111110111

0000001111

1000001111

0100001111

1100001111

7489-7496

7497-7503

7504-7511

7512-7518

7519-7526

1110011111

0001011111

1001011111

0101011111

1101011111

6627-6633

6634-6641

6642-6648

6649-6656

6657-6663

0010111011

1010111011

0110111011

1110111011

0001111011

6927-6933

6934-6941

6942-6948

6949-6956

6957-6963

0011100111

1011100111

0111100111

1111100111

0000010111

7227-7233

7234-7241

7242-7248

7249-7256

7257-7263

0010001111

1010001111

0110001111

1110001111

0001001111

7527-7533

7534-7541

7542-7548

7549-7556

7557-7563

0011011111

1011011111

0111011111

1111011111

0000111111

6664-6671

6672-6678

6679-6686

6687-6693

6694-6701

1001111011

0101111011

1101111011

0011111011

1011111011

6964-6971

6972-6978

6979-6986

6987-6993

6994-7001

1000010111

0100010111

1100010111

0010010111

1010010111

7264-7271

7272-7278

7279-7286

7287-7293

7294-7301

1001001111

0101001111

1101001111

0011001111

1011001111

7564-7571

7572-7578

7579-7586

7587-7593

7594-7601

1000111111

0100111111

1100111111

0010111111

1010111111

6702-6708

6709-6716

6717-6723

6724-6731

6732-6738

0111111011

1111111011

0000000111

1000000111

0100000111

7002-7008

7009-7016

7017-7023

7024-7031

7032-7038

0110010111

1110010111

0001010111

1001010111

0101010111

7302-7308

7309-7316

7317-7323

7324-7331

7332-7338

0111001111

1111001111

0000101111

1000101111

0100101111

7602-7608

7609-7616

7617-7623

7624-7631

7632-7638

0110111111

1110111111

0001111111

1001111111

0101111111

6739-6746

6747-6753

6754-6761

6762-6768

6769-6776

1100000111

0010000111

1010000111

0110000111

1110000111

7039-7046

7047-7053

7054-7061

7062-7068

7069-7076

1101010111

0011010111

1011010111

0111010111

1111010111

7339-7346

7347-7353

7354-7361

7362-7368

7369-7376

1100101111

0010101111

1010101111

0110101111

1110101111

7639-7646

7647-7653

7654-7661

7662-7668

7669-7676

1101111111

0011111111

1011111111

0111111111

1111111111

CLUSTER FAILURE DIAGNOSIS

1000, 2000, 3000, 4000, 8000 MODELS

January 1989 to March 1992

Speedometer, Odometer, Tachometer or Hourmeter Display Failure

If any of the speedometer, odometer, tachometer or hourmeter displays is indicating a failure, the circuits serving the instrument in question must be checked for clean, tight, unbroken and non-shorted connections.

IMPORTANT: Be sure all relays in the vehicle are the suppressed type.

IMPORTANT: Make sure the accessory voltage to the cluster is within a range of 11 to 16 volts.

Refer to table below for possible conditions and corrective actions.

Engine RPM must be greater than 300 RPM for the hourmeter to count time.

Speedometer, Odometer, Tachometer and Hourmeter Display Failure Chart

Condition First Action Second Action

1. Speedometer and

tachometer needles

do not move when

driving.

Remove cluster and

verify ignition voltage

and ground is provided

to cluster. Refer to

ELECTRICAL CIRCUIT

DIAGRAMS MANUAL.

Replace cluster.

2. Speedometer or

tachometer needle

does not move or

moves erratically

when driving.

Remove cluster and

switch the speedometer

and tachometer in the

cluster. If the defect

follows the meter,

replace the meter.

If the defect stays at

the same meter

location, replace the

cluster.

3. Speedometer

does not work when

driving.

Check speedometer

sensor wiring continuity

and sensor output signal

levels. Refer to

ELECTRICAL CIRCUIT

DIAGRAMS MANUAL.

Verify correct

speedometer DIP

switch setting. Refer to

PROGRAMMING .

Speedometer, Odometer, Tachometer and Hourmeter Display Failure Chart


4. Tachometer does

not work when

driving.

Check tachometer

sensor wiring continuity

and sensor output signal

levels. Refer to

ELECTRICAL CIRCUIT

DIAGRAMS MANUAL.

Verify correct

tachometer DIP switch

setting. Refer to

PROGRAMMING .

5. Odometer does

not work when

driving.

Remove odometer and

momentarily touch leads

across battery voltage. If

the odometer operates,

replace the cluster.

Replace the odometer.

6. Hourmeter does

not work when

driving.

Remove hourmeter and


across battery voltage. If

the hourmeter operates,

replace the cluster.

Replace the

hourmeter.

After March 1992

Speedometer, Odometer, Tachometer or Hourmeter Display Failure

If any of the speedometer, odometer, tachometer or hourmeter displays is indicating a failure, the circuits serving the instrument in question must be checked for clean, tight, unbroken and non-shorted connections.

IMPORTANT: Be sure all relays in the vehicle are the suppressed type.

IMPORTANT: Make sure the accessory voltage to the cluster is within a range of 11 to 16 volts.

Speedometer, Odometer, Tachometer and Hourmeter Failure Isolation

The instrument cluster has self-testing capabilities that will identify various failures in the electronic portions of the unit. The self testing diagnostics provide a strong indication of exactly what is wrong with the unit, without removing the cluster from the vehicle or spending a large amount of time troubleshooting.

NOTE: Operation and accuracy of the speedometer and tachometer can be verified with an EST without removing the cluster. The Pro-Link 9000 with the Instrument Panel Cartridge Kit, or the EZ-Tech with the instrument cluster software can be used to exercise the speedometer/tachometer, through the J1708 data link . Refer to the Pro-Link or EZ-Tech instrument cluster software manual for instructions.

Pass Indications

The cluster will test itself each time the vehicle is powered up. If all tests pass, the unit will drive both the speedometer and tachometer needles through one complete sweep. This indicates that all output circuits are good and tells the driver that the gauges are good.

Fail Indications

The cluster will provide failure indications in two ways:

1. Does not provide a proper gauge sweep on power up.

2. The speedometer and tachometer needles "wave" on power up.

If the unit senses a circuit problem at power up, the speedometer and tachometer needles will simultaneously wave from 0 and one of the numbers on the speedometer and tachometer dial faces three times. The "bad" gauge will be parked at full scale and the other gauge will be operable.

Conditions and corrective action are defined in the Speedometer, Odometer, Tachometer and Hourmeter Failure Chart below.

Engine RPM must be greater than 300 RPM for the hourmeter to count time.

Speedometer, Odometer, Tachometer and Hourmeter Failure Chart


1. Speedometer

and tachometer

needles do not

move on power

up.

Remove cluster and verify

ignition voltage and ground is

provided to cluster. Refer to

ELECTRICAL CIRCUIT

DIAGRAMS MANUAL.

Replace cluster.

2. Speedometer

or tachometer

needle moves

erratically on

power up sweep.

Swap the speedometer and

tachometer in the cluster. If the

defect follows the meter,

replace the meter.

If the defect stays

at the same meter

location, replace

the cluster.

3. Speedometer

and tachometer

needles point to

the 5 on the

tachometer three

times.

Speedometer input circuit

failure. Replace the cluster.

4. Speedometer

and tachometer

needles point to

the 10 on the

tachometer three

Tachometer input circuit

failure. Replace the cluster.



times.

5. Speedometer

and tachometer

needles point to

15 on the

tachometer three

times.

J1708 Data Link failure. Insure

that the vehicle Data Link is

not shorted or wired

incorrectly. With the igniton on,

voltage from Positive data link

circuit to ground should be

approximately 4 volts. Voltage

from Negative data link circuit

to ground should be

approximately 1 volt. Refer to

ELECTRICAL CIRCUIT

DIAGRAM MANUAL.

Verify data from

the ECM by using

an electronic

service tool (EST),

such as the EZ-

Tech or Pro-Link

9000, with the

applicable engine

software. If data is

present replace

cluster.

6. Speedometer

and tachometer

needles point to

20 on the

tachometer three

times.

Cluster electronics failed.

Replace cluster.

7. Speedometer

and tachometer

needles point to

25 on the

tachometer three

times.

Odometer drive circuit failed,

odometer is disconnected, or

odometer coil is open. Insure

odometer connector is

properly seated to the printed

wiring board connector.

Disconnect

odometer

connector.

Momentarily

connect 12VDC

across odometer

wires. If odometer

advances, replace

cluster. If odometer

does not advance,

replace odometer.

8. Speedometer

and tachometer

go through a

good power up

sweep, but

speedometer

does not work

when driving.

Check speedometer sensor

wiring continuity and sensor

output signal levels. Refer to

ELECTRICAL CIRCUIT

DIAGRAMS MANUAL.

Go to Step 10.

9. Speedometer

and tachometer

Check tachometer sensor

wiring continuity and sensor

Go to Step 10.



go through a

good power up

sweep, but

tachometer does

not work when

driving.

output signal levels. Refer to

ELECTRICAL CIRCUIT

DIAGRAMS MANUAL.

10. Speedometer

or tachometer

fails to operate or

operate

inaccurately

when driving.

Manually program the cluster

by physically setting all DIP

switches. Refer to

PROGRAMMING . Check

operation.

Replace cluster.

11. Speedometer

and tachometer

go through a

good power up

sweep, but

odometer does

not work when

driving.

Remove odometer and


across battery voltage. If the

odometer operates, replace

the cluster.

Replace the

odometer.

12. Speedometer

and tachometer

go through a

good power up

sweep, but

hourmeter does

not work when

driving.

Remove hourmeter and


across battery voltage. If the

hourmeter operates, replace

the cluster.

Replace the

hourmeter.

TSI: 04-08-07

TSI Fecha: Septiembre, 2004

Archivo Sujeto: SISTEMA ELÉCTRICO

TEMA Tablero de Instrumentos, Reemplazo de Circuitos de Instrumentos Individuales

APLICAR

Modelo de Camión: 2000 Fecha de inicio: 01/01/1989 Fecha de terminación: 11/01/2002 3400 Fecha de inicio: 01/01/1989 Fecha de terminación: 11/01/2002 3600 Fecha de inicio: 01/01/1989 Fecha de terminación: 11/01/2002 3700 Fecha de inicio: 01/01/1989 Fecha de terminación: 11/01/2002 4000 Fecha de inicio: 01/01/1989 Fecha de terminación: 11/01/2002 8000 Fecha de inicio: 01/01/1989 Fecha de terminación: 11/01/2002 3800 Fecha de inicio: 01/01/1989 3000 FE Fecha de inicio: 01/01/1989 3000 RE Fecha de inicio: 01/01/1989 IC Bus Fecha de inicio: 11/01/1999

DESCRIPCION

Antes de esta fecha, la única forma de reparar el tablero de instrumentos fue reemplazar todo el bastidor y el conjunto del tablero de circuitos. Ahora es posible reemplazar solamente el tablero de circuito con problema, sea el izquierdo, derecho, o central sin tener que reemplazar todo el conjunto. Los vehículos construidos antes de Noviembre de 1997, deben tener tableros de instrumentos central con interruptores "Profundos" como se muestra en la Figura 6. Después de Noviembre de 1997, ellos deben tener Tableros con Enlace de Datos sin interruptores "profundos". La remoción e instalación del conjunto del tablero de instrumentos no ha cambiado. Vea el Manual de Servicio, Sección S08034 para información sobre el método apropiado para remover e instalar el tablero de instrumentos en el tablero del vehículo.

PARTS INFORMATION

Modelo Tablero

Izquierdo

Tablero Central Tablero

Derecho

Anteriores a

Noviembre/97

2587517C1 2587520C1- Con

Interruptores

"Profundos"

2587519C1

Autobús RE No Aplicable 2587521C1-Con

Enlace de Datos

No

Disponible

Posterior a

Noviembre/97

2587517C1 2587521C1- Con

Enlace de Datos

2587519C1

NOTA: Los tableros izquierdo y derecho son designados por su localización vista desde el asiento del conductor.

Procedimiento

ADVERTENCIA:

La baterías expelen gases explosivos. Mantenga alejados en todo momento las chispas, llamas, cigarrillos encendidos, u otras fuentes de ignición. Cuando trabaje cerca de baterías, use siempre anteojos de seguridad y máscaras para la cara para evitar daños a la propiedad, lesiones personales, o la muerte.

ADVERTENCIA:

Para prevenir descargas eléctricas que puedan resultar en daños a la propiedad, lesiones personales o la muerte, desconecte siempre el terminal negativo de la batería antes de trabajar en el sistema eléctrico.

PRECAUCION:

La electricidad estática puede causar daños permanentes del tablero de instrumentos. Antes de trabajar con el tablero de instrumentos asegúrese de remover toda la electricidad estática de su cuerpo tocando alguna parte metálica del tablero.

1. Desconecte el terminal negativo de la batería del vehículo, de la batería del vehículo. 2. Remueva el tablero de instrumentos de acuerdo con las instrucciones del Manual de

Servicio, Sección S08034. 3. Coloque el tablero de instrumentos boca abajo sobre una superficie suave y adecuada

que no raspe la cara del tablero, tal como se muestra en la Figura 1. Para mantener localizados los instrumentos cuando el circuito de los tableros es removido, deje los cristales frontales y los biseles de los instrumentos en su lugar y orden.

NOTA: Los tableros de circuitos están etiquetados "izquierdo" y "derecho" por su localización vista desde el asiento del conductor.

Figura 1.

Reemplazo del Tablero PC del Lado Izquierdo 1. Remueva los cinco tornillos de cabeza en estrella mostrados en la Figura 2. 2. Anote si hay o no instrumentos instalados en el tablero de circuitos que va a ser removido. 3. Si no hay instrumentos instalados, simplemente levante y separe el tablero del circuito del bastidor.

a. Si hay instrumentos, palanquee cuidadosamente el tablero del circuito hacia arriba para separarlo del bastidor, mueva la palanquilla poco a poco alrededor del tablero del circuito para que éste se levante en forma uniforme en todos sus lados y se liberen las clavijas de las conexiones adheridas al tablero de circuitos.

4. Remueva los soportes de luces del tablero que se está reemplazando e instálelos en el nuevo tablero de circuito.

Figura 2.

Figura 3.

5. Ubique cuidadosamente el nuevo tablero del circuito sobre las clavijas de los instrumentos (o agujeros de montaje si no hay instrumento) y presione uniformemente el tablero del circuito nuevo sobre las clavijas de los instrumentos hasta que el tablero nuevo quede plano a nivel del bastidor de los instrumentos. 6. Reinstale los cinco tornillos de cabeza de estrella removidos previamente. NO APRIETE DEMASIADO LOS TORNILLOS! Reemplazo del Tablero PC del Lado Derecho 1. Remueva los cuatro tornillos de cabeza de estrella del tablero de circuitos grande mostrado en la Figura 3. 2. Remueva los dos tornillos de cabeza de estrella del tablero de circuitos pequeño mostrado en la Figura 3. 3. Si no hay instrumentos instalados, simplemente levante y separe el tablero del circuito del bastidor.

a. Si hay instrumentos, palanquee cuidadosamente el tablero del circuito hacia arriba para separarlo del bastidor, mueva la palanquilla poco a poco alrededor del tablero del circuito para que éste se levante en forma uniforme en todos sus lados y se liberen las clavijas de las conexiones adheridas al tablero de circuitos.

4. Los tableros de repuesto grande y pequeño han sido moldeados unidos y se debe cortar para separarlos antes de su instalación. NO CORTE LOS DOS CABLES ENTRE LOS TABLEROS! 5. Remueva los soportes de luces del tablero que se está reemplazando e instálelos en el lugar correcto en los nuevos tableros de circuito. 6. Ubique cuidadosamente el nuevo tablero grande del circuito sobre las clavijas de los instrumentos (o agujeros de montaje si no hay instrumento) y presione uniformemente el tablero del circuito nuevo sobre las clavijas de los instrumentos hasta que el tablero nuevo quede plano a nivel del bastidor de los instrumentos. 7. Reinstale los cuatro tornillos de cabeza en estrella removidos previamente del tablero grande del circuito y los dos tornillos del tablero pequeño montado encima. NO APRIETE DEMASIADO LOS TORNILLOS! Reemplazo del Tablero PC Central 1. Remueva los seis tornillos de cabeza de estrella que aseguran la cubierta metálica sobre el tablero de instrumentos, y remueva la cubierta metálica, como se muestra en la Figura 4. 2. Remueva los dos tornillos cabeza de estrella remanentes debajo de la cubierta metálica removida en el paso 1. Vea la Figura 5. NOTA: La Figura 5 muestra un tablero de circuito central para vehículos construidos en o después de Noviembre de 1997, con el tablero de circuito central con "enlace de datos" sin interruptores "Profundos". La Figura 6 muestra un tablero central de un vehículo construido antes de Noviembre de 1997 con interruptores "Profundos". Si el tablero que va a ser reemplazado tiene interruptores "Profundos" y todos los interruptores están colocados en "0", el tablero es una unidad original y fue programado en la planta de ensamble. El tablero de reemplazo no está programado en la fábrica y tendrá que tener interruptores "Profundos" configurados de acuerdo a la etiqueta de interruptores "Profundos" adherida al tablero viejo. Si el tablero que se está reemplazando tiene interruptores en posiciones distintas a "0", registre la posición de los interruptores y coloque los interruptores "Profundos" del nuevo tablero de reemplazo en la misma posición del tablero reemplazado. Vea las instrucciones específicas en el Manual de Servicio 08034x, INSTRUMENTOS, VELOCÍMETRO, PROGRAMACIÓN MANUAL.

3. Remueva los conectores eléctricos conectados al odómetro y/u horómetro localizados en la parte trasera del tablero del circuito central. 4. Palanquee cuidadosamente para levantar los bordes del tablero del circuito. En este momento, las únicas cosas agarradas al tablero son las clavijas de los instrumentos, los que continúan retenidos por el bisel y los cristales en el frente del conjunto del tablero. Cuando el borde esté levantado, continúe palanqueando individualmente cerca de las clavijas de cada instrumento para levantar el tablero. Cuando el tablero del circuito esté flojo, levante y sepárelo cuidadosamente del conjunto del tablero

asegurándose que los cables y conectores de alimentación del odómetro y el horómetro salgan por los agujeros del tablero.

Figura 4.

5. Coloque los cables del odómetro y horómetro a través de los agujeros del nuevo tablero del circuito (Figura 5). 6. Instale el nuevo tablero central por medio de una cuidadosa alineación de las clavijas de los instrumentos con los agujeros del tablero de circuitos y los agujeros de montaje con los espárragos de la estructura del tablero. Una vez en su lugar, empuje cuidadosamente hacia abajo el tablero dentro de las clavijas de los instrumentos, asegurándose que el tablero nuevo quede plano y a nivel contra el bastidor del tablero. 7. Reinstale los dos tornillos con cabeza en estrella que sujetan el tablero contra el bastidor del tablero (Figura 5). 8. Remueva el puente de conexión del velocímetro KPH/MPH y/o el puente de conexión de resolución del engranaje de la transmisión, del tablero del circuito viejo (usado en los tableros centrales sin interruptores "Profundos") e instálelos en la misma posición en el tablero nuevo, tal como se muestra en la Figura 5. Para las aplicaciones, vea el Manual de Servicio, Sección S08155x. 9. Reinstale los conectores del odómetro y/u horómetro en las clavijas del tablero de circuitos. 10. Reinstale la cubierta metálica sobre el tablero central y reemplazando y asegurando con los seis tornillos de cabeza en estrella que fueron removidos en el paso 1. NO APRIETE DEMASIADO LOS TORNILLOS.

Figura 5. Noviembre 1997 y Posteriores

Figura 6. Anteriores a Noviembre de 1997

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