Corporation Training

Document Sample
Corporation Training Powered By Docstoc
					      FREIGHTLINER CUSTOM CHASSIS CORPORATION

                         TRAINING SESSION



                      M-LINE INSTRUMENT PANEL




52765 Bridger Court          www.actia.com      Phone: (574) 264 2373
Elkhart, IN 46514                               Fax: (574) 293-7539
                                                                                                  Page 2

       Freightliner Custom Chassis Corporation
       Technical Service Guide for M-Line
       Instrument Clusters

                                         GENERAL INFORMATION

           1.       With the ignition key turned “on” and the engine not running:
                    Speedometer should read 0
                    Odometer should show mileage
                    Oil Pressure should read 0
                    Tachometer should read 0
                    Water Temperature should reflect engine temperature
                    Voltmeter should read voltage at instrument panel
                    Fuel should reflect the amount of fuel in the tank

       SPECIFIC GAUGE INFORMATION

       The following information applies to all cluster families, unless noted otherwise.

                1. Fuel Gauge
                      · Matched to standard 240 (empty) – 33 (full) ohm sender.
                      · Approximate readings:
                               Empty = 240 ohms
                               Full = 33 ohms
                      · Removing the sender wire (open circuit condition) will cause the needle to register
                          at the “empty” end of the scale. Low fuel warning light should be illuminated.
                      · Temporarily connecting the sender wire to ground (short circuit condition) will
                          cause the needle to register at the “full” end of the scale. Low Fuel warning light
                          should be off.
                      · Note that fuel tank on FCCC product may need to be dropped to get to sender for
                          testing or replacement.
                      · Low fuel warning light will illuminate at approximately 1/8 tank and turn off at
                          approximately a ¼ tank. This light is controlled by the circuit card installed on the
                          back of the fuel gauge.

                2. Water Temperature Gauge
                     · Matched to VDO sender #323-099 (1 531 004 291), 250 F range, ½-14 NPT.
                     · No identifying numbers stamped on the sender body.
                     · Sender connections: G = sender terminal, WK = warning contact terminal
                     · Warning contact trip point = 217 F.
                     · Approximate readings:
                              160 F = 100 ohms
                              220 F = 31 ohms
                     · Removing the sender wire (open circuit condition) will cause the needle to register
                         at the “cold” end of the scale.


52765 Bridger Court                            www.actia.com                                Phone: (574) 264 2373
Elkhart, IN 46514                                                                           Fax: (574) 293-7539
                                                                                              Page 3

                      ·   Temporarily connecting the sender terminal wire to ground (short circuit
                          condition) will cause the needle to register at the “Hot” end of the scale.
                      ·   Temporarily connecting the warning contact switch wire to ground will turn on
                          the High Water Temperature light (if included in the warning bank)
                      ·   The sender will measure an infinite resistance between the warning contact
                          terminal and ground until the temperature reaches the switch trip point
                          (approximately 217 F).
                      ·   The sender should not be sealed with pipe joint tape or compound. Proper
                          operation requires metal to metal contact from the sender body to the engine
                          (ground) to complete the electrical circuit.
                      ·   Sender resistance can only be accurately calculated after measuring the sender
                          voltage and current.
                              -Sender performance is determined by the entire circuit (gauge and sender);
                              simply measuring the resistance from the sender terminal to ground will only
                              give approximate resistance.
                              -Resistance measurements of the sender when not connected to the gauge may
                              vary from those listed above depending on how the resistance was measured.
                              -The approximate sender resistance should be measured immediately after
                              removing the sender wire from the sender terminal. This allows you to check
                              that the sender is operating – as the sender warms up, the sender terminal to
                              ground resistance will decrease.

              3. Oil Pressure Gauge
                 Style A Electrical Gauge (older chassis, front and rear engine units)
                     · Matched to VDO sender #360-023 (1 521 002 010), 150 psi range, M10 x 1 thread
                         (essentially the same as 1/8 – 27 NPT).
                     · Identifying numbers stamped on the sender body = 30/9.
                     · Warning contact trip point = 7 psi.
                     · Approximate readings
                              - 0 psi = 10 ohms = pointer at the bottom end of the scale
                              - 58 psi =88 ohms = pointer at 12 0’clock position
                              - 129 psi = 164 ohms = pointer at the top end of the scale
                     · Sender connections: G = gauge sender, WK = warning contact terminal.
                     · Removing the sender wire (open circuit condition) will cause the needle to register
                         at the “high” end of the scale.
                     · Temporarily connecting the sender terminal wire to ground (short circuit
                         condition) will cause the needle to register at the “low” end of the scale.
                     · Temporarily connecting the warning contact switch wire to ground will turn on
                         the Low Oil Pressure warning light (if included in the warning bank).
                     · The sender should not be sealed with pipe joint tape or compound. Proper
                         operation requires metal to metal contact from the sender body to the engine
                         (ground) to complete the electrical circuit.
                     · When the engine and key switch are turned off, the sender should measure
                         approximately 10 ohms between the sender terminal and ground, and 0 ohms
                         between the warning contact terminal and ground.


52765 Bridger Court                         www.actia.com                              Phone: (574) 264 2373
Elkhart, IN 46514                                                                      Fax: (574) 293-7539
                                                                                                 Page 4

                      ·   With the engine running, the sender resistance between the sender terminal and
                          ground will increase as the oil pressure increases. Maximum resistance will be
                          approximately 180 ohms at 150 psi.
                      ·   With the engine running, the resistance between the warning contact terminal and
                          ground should be an open circuit (infinite resistance) at oil pressures above 7 psi.

                  Style B Electrical Gauge (newer chassis, primarily rear engine units)
                      · Matched to Datcon Severe Duty sender #109491, 150 psi range, 1/8 – 27 NPT
                      · Approximate readings
                               - 0 psi = 250 ohms = pointer at the bottom end of the scale
                               - 60 psi = 118 ohms = pointer at 12 o’clock position
                               - 120 psi = 75 ohms = pointer at the top end of the scale
                      · Sender connections: single terminal connects to sender terminal on gauge;
                          separate Low Oil Pressure switch is installed.
                      · Removing the sender wire (open circuit condition) will cause the needle to register
                          at the Low end of the scale.
                      · Temporarily connecting the sender terminal wire to ground (short circuit
                          condition) will cause the needle to register at the High end of the scale.
                      · Temporarily connecting the warning contact switch wire to ground will turn on
                          the Low Oil Pressure warning light (if included in the warning bank).
                      · The sender should not be sealed with pipe joint tape or compound. Proper
                          operation requires metal to metal contact from the sender body to the engine
                          (ground) to complete the electrical circuit.
                      · When the engine and key switch are turned off, the sender should measure
                          approximately 250 ohms between the sender terminal and ground, and 0 ohms
                          between the warning contact terminal and ground.
                      · With the engine running, the sender resistance between the sender terminal and
                          ground will decrease as the oil pressure increases. Maximum resistance will be
                          approximately 75 ohms at 150psi.
                      · With the engine running, the resistance between the warning contact terminal and
                          ground should be an open circuit (infinite resistance) at oil pressures above 7 psi.

                  Style C Mechanical Gauge (new chassis, primarily front engine units)
                      · There is no sender for this mechanical gauge (therefore, no sender connections,
                          resistances or electrical checks that can be performed)
                      · Separate Low Oil Pressure switch is installed on chassis
                      · Temporarily connecting the warning contact switch wire to ground will turn on
                          the Low Oil Pressure warning light (if included in the warning bank).
                      · When the engine and key switch are turned off, the pressure switch should read 0
                          ohms between the warning contact terminal and ground.
                      · With the engine running, the resistance between the warning contact terminal and
                          ground should be an open circuit (infinite resistance) at oil pressures above 7 psi.




52765 Bridger Court                           www.actia.com                               Phone: (574) 264 2373
Elkhart, IN 46514                                                                         Fax: (574) 293-7539
                                                                                            Page 5
              4. Voltmeter
                    · No sender to match for this gauge
                    · Gauge indicates the DC voltage from the ignition circuit to chassis ground at the
                       cluster to chassis wire harness connection.

              5. Speedometer with internal odometer
                    · Calibrations for the various chassis pulse counts are achieved with DIP switches.
                       The speedometer has two six position DIP switches in line with each other, and
                       are accessible from the back of the gauge by removing the oval plug from the
                       gauge case.
                            -DIP switches are set at the factory for the standard pulse count. DIP switches
                            may need to reset if the driveline components have changed from those
                            originally installed on the chassis (i.e. changing tire size, rear axle ratio, etc.)
                            -Make sure the DIP switches are properly set for the particular chassis
                            application.
                    · Verifying the output signal from the speedometer sender is best measured with an
                       oscilloscope.
                    · Other systems associated with the speedometer signal or that might produce
                       interfering signals of their own could be influencing the speedometer signal.
                       These can include the cruise control, engine/transmission signals and controllers,
                       alternator and charging system components, etc.

              6. Speedometer without internal odometer (used with External Odometer)
                    · Calibrations for the various chassis pulse counts are achieved by adjusting the
                        macro range switch and the calibration potentiometer on the gauge.
                             -These units are calibrated at Actia and require a frequency generator to be
                             accurately calibrated.
                             -Field adjustment is possible, but may not result in an accurate calibration.
                             Field adjustments are best made while the vehicle is moving or on a
                             dynamometer. Adjustments made while the vehicle is in motion should be
                             made with caution. An additional technician should be used so the driver may
                             pay full attention to driver safety.
                             -Speedometers will need to be recalibrated if the driveline components
                             have changed from those originally installed on the chassis (i.e. changing
                             tire size, rear axle ratio, etc.).
                    · Verifying the output signal from the speedometer sender is best done with an
                        oscilloscope.
                    · Other systems associated with the speedometer signal or that might produce
                        interfering signals of their own could be influencing the speedometer signal.
                        These can include the cruise control, engine/transmission signals and controllers,
                        alternator and charging system components, etc.
              7. External Odometer (used with Speedometers without internal odometers)
                    · External odometers are programmed at Actia to match the specific pulse count of
                        the chassis.
                    · Odometer may be reprogrammed in the field to match new chassis pulse count
                        after changing driveline components from those originally supplied on the chassis
                        (i.e. changing tire size, rear axle ratio, etc.).

52765 Bridger Court                           www.actia.com                                Phone: (574) 264 2373
Elkhart, IN 46514                                                                          Fax: (574) 293-7539
                                                                                                Page 6

                      ·   Odometer uses the same signal as the speedometer. Verifying the output signal
                          from the speedometer sender is best done with an oscilloscope.
                      ·   Other systems associated with the speedometer signal or that might produce
                          interfering signals of their own could be influencing the speedometer signal.
                          These can include the cruise control, engine/transmission signals and controllers,
                          alternator and charging system components, etc.

              8. Tachometer
                    · Tachometers are matched for the particular chassis application (electronic engine
                       or magnetic pickup signal sources), and are not interchangeable.
                    · Calibrations for the various chassis pulse counts are achieved by adjusting the
                       macro range switch and the calibration potentiometer on the gauge.
                           -These units are calibrated at Actia and require a frequency generator to be
                           accurately calibrated.
                           -Field adjustments are best made with a stroboscope to determine the actual
                           engine speed.
                    · Verifying the output signal from the tachometer sender is best done with an
                       oscilloscope.

          WARNING BANK LIGHT BULBS

              1. Testing
                    · Light bulbs may be tested individually or by connecting +12 VDC and ground to
                         the appropriate terminals in the instrument panel connector housings.

              2. Replacement
                    · Remove the socket from the appropriate warning bank symbol by tipping base out
                        of metal bank shell.
                    · Pull old bulb straight out of lamp socket assembly.
                    · Insert new bulb. Be sure to use only #161 (T-3 ¼ wedge base bulb, Actia p/n LB-
                        0106) light bulb. Other light bulbs may cause damage to the cluster.
                    · Replace bulb/lamp socket assembly into the metal bank shell.




52765 Bridger Court                          www.actia.com                               Phone: (574) 264 2373
Elkhart, IN 46514                                                                        Fax: (574) 293-7539
                                                                                                Page 7


          TROUBLESHOOTING

          In-depth troubleshooting of an instrument panel is best done at the Actia factory/Authorized
          Service Center. Simple electrical troubleshooting can be done in the field by using test probes,
          multimeters and clip leads. +12 VDC can be supplied from a bench top supply or a storage
          battery.

          Careful checking of wire continuity, wire connections and terminations, sender function and gauge
          operation should be done to determine which component has failed.

          Symptom                                Possible Cause
          ___________________________________________________________________________
          Gauges do not respond when ignition    - Missing or broken ignition or ground wires
          is turned on.
          ___________________________________________________________________________
          Gauge(s) read erratically              - Loose connections at sender, gauge and/or
                                                   connectors
          ___________________________________________________________________________
          Speedometer reads too fast or too slow - Speedometer not properly calibrated to the
                                                   correct pulse/mile or pulse/kilometer count.
          ___________________________________________________________________________
          Speedometer does not indicate speed    - Missing or broken sender wire(s)
                                                 - Sender has failed internally
          ____________________________________________________________________________
          Speedometer indicates speed, but is    - Electrical noise from alternator, power and/or
          Erratic                                  ground distribution panel studs, transmission
          ___________________________________________________________________________
          External Odometer accumulates          - Odometer is not programmed for the correct
          mileage too fast or too slow              pulse/mile or pulse/kilometer count
          ___________________________________________________________________________
          External Odometer display says         - Odometer detected an internal failure during
          “ERR 1”                                   power-up. (Odo will need to be replaced)
          ___________________________________________________________________________
          Tachometer does not indicate engine    - Missing or broken sender wire(s)
          Speed
          ___________________________________________________________________________
          Fuel Gauge reads Empty all the time    - Fuel tank empty
                                                 - Sender wire missing, cut or broken
                                                 - Sender broken, missing float, etc.
                                                 - Internal failure of gauge
          ____________________________________________________________________________




52765 Bridger Court                          www.actia.com                               Phone: (574) 264 2373
Elkhart, IN 46514                                                                        Fax: (574) 293-7539
                                                                                           Page 8


           Symptom                                  Possible Cause
          ___________________________________________________________________________
          Fuel Gauge reads Full all the time        - Sender wires shorted to ground
                                                    - Sender wiper shorted to ground
                                                    - Sender stuck in Full position
                                                    - Internal failure of gauge
          ____________________________________________________________________________
          Water Temperature gauge reads Hot         - Sender internally shorted to ground
          all the time                              - Sender wire shorted to ground
                                                    - Internal failure of gauge
          ____________________________________________________________________________
          Water Temperature gauge reads Cold        - Sender has internal open circuit
          all the time                              - Sender wire missing, cut or broken
                                                    - Sender wire fell off of sender terminal
                                                    - Sender wire connected to warning light
                                                       terminal
                                                    - Internal failure of gauge
          ___________________________________________________________________________
          High Water Temperature warning light      - Sender and warning contact wires are switched
          turns on dim, then brightens as the          at the sender
          engine warms up. Gauge reads Cold.
          ____________________________________________________________________________
          Oil Pressure gauge reads Low all the time Oil Pressure Gauge Style A:
                                                    - Sender internally shorted to ground
                                                    - Sender wire shorted to ground
                                                    - Internal failure of gauge

                                                    Oil Pressure Gauge Style B:
                                                    - Sender has internal open circuit
                                                    - Sender wire missing, cut or broken
                                                    - Internal failure of gauge

                                                  Oil Pressure Gauge Style C:
                                                  - Pressure line missing, cut or broken
                                                  - Internal failure of gauge
       _______________________________________________________________________________
       Oil Pressure gauge reads High all the time Oil Pressure Gauge Style A:
                                                  - Sender has internal open circuit
                                                  - Sender wire missing, cut or broken
                                                  - Sender wire fell off of sender terminal
                                                  - Internal failure of gauge




52765 Bridger Court                        www.actia.com                             Phone: (574) 264 2373
Elkhart, IN 46514                                                                    Fax: (574) 293-7539
                                                                                        Page 9


       Symptom                                   Possible Cause

       Oil Pressure gauge read High all          Oil Pressure Gauge Style B:
       The time (continued from Page 7)          -Sender internally shorted to ground
                                                 -Sender wires shorted to ground
                                                 -Internal failure of gauge

                                               Oil Pressure Gauge Style C:
                                               -Internal failure of gauge
       ______________________________________________________________________________
       Oil Pressure Gauge Style A:             - Sender and warning contact wires are
       Oil pressure gauge reads Low with          switched at the sender
       engine off, then only reads High
       with engine running. Low Oil
       Pressure Warning light is also on
       bright with the engine off,
       then dims/goes out with engine
       running
       __________________________________________________________________________________
       Oil Pressure Gauge Style B:             - Sender and warning contact wires are
       Oil pressure gauge reads High with         switched
       engine off, then only reads Low with
       engine running. Low Oil Pressure
       Warning light is also on dimly with
       the engine off, then gets brighter with
       engine running.
       __________________________________________________________________________________
       Voltmeter does not register voltage,     - Missing or broken ignition or ground wires
       other gauges do not function.              between cluster and chassis wiring
       __________________________________________________________________________________
       Backlighting does not operate           - Headlight switch not in “Parking Lights”
                                                  position
                                               - Dimmer control turned all the way down
                                               -All backlighting bulbs burnt out
       __________________________________________________________________________________
       Warning lights do not operate           - Burnt out light bulb
                                               - Failure of signaling system on the engine,
                                                  chassis, etc.
       __________________________________________________________________________________




52765 Bridger Court                       www.actia.com                           Phone: (574) 264 2373
Elkhart, IN 46514                                                                 Fax: (574) 293-7539
                                                  M2000 Instrument Panel



                                     Circuit board Assembly (No
                                     field serviceability)

                                                    Speedo Head
                Chassis                             Drive circuit
                Harness
                                   Dip-Switch                                                                 Field
                                   Calibration                                  Speedo Head                 Serviceable
                                                                                                            components



                                                      Odometer
                                                    counter circuit

Speed Sensor
                                      Self Test
                                       circuit                                  Odometer Module




           The M2000 Instrument Assembly was designed with internal self diagnostics and more servicable
           components than earlier versions. All diagnostic and servicing information should be addressed on the
           back panel of the unit.
           The above diagram represents the speed circuitry which is the most complex portion of this unit.
           I. Diagnostic steps for the speed and odometer functions.

           1. Follow the steps for the self test as listed on the back of the Instrument Assembly. For most
              situations, this self test will indicate if the problem exists in the Instrument Assembly or upstream
              in the Sender & Chassis harness.

                 Ø Failure of the circuit board assembly has been very rare, so the most susceptible
                   components (Speedo Head & Odometer module) can be easily serviced without replacing
                   the entire assembly.

           2.     If both the Speedometer head and Odometer module are showing the same characteristics, than
                 the problem is most likely with the speed sensor or chassis harness.
           3.     Accurate Switch calibration should be checked if the odometer or speedo head appear to be
                 operating at the incorrect rate.

           Continued next page

   52765 Bridger Court                             www.actia.com                               Phone: (574) 264 2373
   Elkhart, IN 46514                                                                           Fax: (574) 293-7539
       II. Small gauge diagnostics.
       1. Again follow the diagnostic steps on the back of the unit.
       2. For Fuel & Coolant Temperature gauges, Removing the wire lead at the sender (engine or fuel
          tank) and touching it to ground will quickly isolate whether the sender or gauge is at fault. (Never
          touch the sender lead to ignition + 12 volt)
       3. The volt gauge can be checked by placing a voltmeter across the volt gauge terminals and
          comparing the meter reading with the gauge.
       4. Again the (4) small gauges are field servicable without replacing the entire assembly.
       C:\datafiles\worddocs\fcc m2K diagnostic info 6-12-02.doc                         Page 10




52765 Bridger Court                                        www.actia.com                  Phone: (574) 264 2373
Elkhart, IN 46514                                                                         Fax: (574) 293-7539
                               M-Line Wired Gauge Panel (54009000)
                               Dip Switch Settings (Basic Calculations)

       The goal to setting the DIP switches is to get the divide number. Once the divide number is found
       using a value chart can quickly determine switch settings. Below are two examples that will allow for
       correct settings. Note for this unit the pulses per mile is divided by 1000.

       Example 1 : Pulses per mile is 42,000.
       Calculated divide number = 42,000 / 1,000
       Calculated divide number = 42 Use this number along with the chart below to get proper DIP settings

                         DIP Switch                                   Value
                              1                                         1
                              2                                         2
                              3                                         4
                              4                                         8
                              5                                         10
                              6                                         20
                              7                                         40
                              8                                         80

       Now that we have the Divide number (in the example- 42) we need to breakdown which switches
       would get us to 42 the fastest.
                        Divide Number = 42
                                       -40 for Dip 7
                                         2 is the remainder
                                        -2 for Dip 2
                                         0 always break down the number to zero.

       So in the above scenario the DIP settings 2 and 7 need to be on.

       Example 2 : Pulses per mile is 65,000.
       Calculated divide number = 65,000 / 1,000
       Calculated divide number = 65

                        Divide Number = 65
                                       -40      for Dip 7
                                         25     is the remainder
                                        -20     for Dip 6
                                          5
                                         -4     for Dip 3
                                          1
                                         -1     for Dip 1
                                          0

    To equate to a 65 divide number switches 1, 3, 6, and 7 need to be on.
                                                                                               Page 11


52765 Bridger Court                           www.actia.com                             Phone: (574) 264 2373
Elkhart, IN 46514                                                                       Fax: (574) 293-7539
                         M-Line w/PCB Gauge Panel (54466000/54464000)
                             Dip Switch Settings (Basic Calculations)

       The goal to setting the DIP switches is to get the divide number. Once the divide number is found
       using a value chart can quickly determine switch settings. Below is an example that will allow for
       correct settings. Note for this unit the pulses per mile is divided by 4000.

       Example 1 : Pulses per mile is 62,000.
       Calculated divide number = 62,000 / 4,000
       Calculated divide number = 15.5 Use this number along with the chart below to get proper DIP
       settings

                          DIP Switch                                    Value
                               1                                         16
                               9                                         8
                               10                                        4
                               11                                        2
                               12                                        1
                               13                                        0.5
                               14                                        0.25
                               15                                        0.125

       Now that we have the Divide number (in the example 15.5) we need to breakdown which switches
       would get us to 15.5 the fastest.
                        Divide Number = 15.5
                                         -8 for Dip 2
                                          7.5 is the remainder
                                         -4 for Dip 3
                                          3.5
                                          2 for Dip 4
                                          1.5
                                          1 for Dip 5
                                          0.5
                                          0.5 for Dip 6
                                          0


       So in the above scenario the DIP settings 2, 3, 4, 5, and 6 need turned on.




                                                                                                Page 12

52765 Bridger Court                            www.actia.com                             Phone: (574) 264 2373
Elkhart, IN 46514                                                                        Fax: (574) 293-7539

				
DOCUMENT INFO
Description: Corporation Training document sample