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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 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 .
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
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 .
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 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 .
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 .
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.
January 1991 to January 1994 - 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 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, 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 - Mechanical 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 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, 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 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 .
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 .
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
January 1989 to January 1994 - All 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 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:
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).
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:
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.
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:
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 two cluster mounting screws located on the lower front face of the cluster ( Figure 3 ).
(Right click on graphic to bring up an option list)
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.
(Right click on graphic to bring up an option list)
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 ).
(Right click on graphic to bring up an option list)
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:
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).
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.
(Right click on graphic to bring up an option list)
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:
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.
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.
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.
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 ).
(Right click on graphic to bring up an option list)
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.
(Right click on graphic to bring up an option list)
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 ).
(Right click on graphic to bring up an option list)
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 ).
(Right click on graphic to bring up an option list)
Vehicle Lineset Ticket
(Right click on graphic to bring up an option list)
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.
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 1 138 International
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.
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 1 138 International
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.
(Right click on graphic to bring up an option list)
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
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
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
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
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
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3364-3371
3372-3378
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3702-3708
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1001011010
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3042-3048
3049-3056
3057-3063
0110100110
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3379-3386
3387-3393
3394-3401
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3717-3723
3724-3731
3732-3738
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2727-2733
2734-2741
2742-2748
2749-2756
2757-2763
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3064-3071
3072-3078
3079-3086
3087-3093
3094-3101
1001100110
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3402-3408
3409-3416
3417-3423
3424-3431
3432-3438
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3739-3746
3747-3753
3754-3761
3762-3768
3769-3776
1100111110
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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
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0001011001
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4939-4946
4947-4953
4954-4961
4962-4968
4969-4976
1100100101
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1010100101
0110100101
1110100101
3964-3971
3972-3978
3979-3986
1000100001
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1100100001
4302-4308
4309-4316
4317-4323
0111110001
1111110001
0000001001
4639-4646
4647-4653
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4977-4983
4984-4991
4992-4998
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4324-4331
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4662-4668
4669-4676
0111011001
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4999-5006
5007-5013
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4002-4008
4009-4016
4017-4023
4024-4031
4032-4038
0110100001
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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
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5014-5021
5022-5028
5029-5036
5037-5043
5044-5051
1011100101
0111100101
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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
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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
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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
Condition First Action Second Action
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
momentarily touch leads
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
Condition First Action Second Action
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.
Speedometer, Odometer, Tachometer and Hourmeter Failure Chart
Condition First Action Second Action
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.
Speedometer, Odometer, Tachometer and Hourmeter Failure Chart
Condition First Action Second Action
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
momentarily touch leads
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
momentarily touch leads
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