Just noting some info I found from good source.
BLUE BIRD
MY 99
Instrument Cluster
Electrical, Mechanical, &
Functional Description
Approved for Blue Bird DATE
Approved for VDO DATE
Author: Clifford Cantrell, et al VDO Des.Eng.Dept. 53
Release: September 3, 1998
Print Date: 4/15/2011 Revision 1.1
1. Scope 1
2. History 1
3. Overview 1
3.1. Cluster Versions 1
3.2. Cluster Functions 3
4. Functional Description 4
4.1. Functional Block Diagram 4
4.2. Speedometer 4
4.2.1. General Function 4
4.2.2. Scale / Accuracy / Calibration 5
4.2.3. Fault Conditions 5
4.3. Tachometer 5
4.3.1. General Function 5
4.3.2. Scale / Accuracy / Calibration 6
4.3.3. Fault Modes 6
4.4. Multi-function Gauge Operation 6
4.4.1. Multi-function - Fuel 7
4.4.2. Multi-function - Coolant Temperature 8
4.4.3. Multi-function - Oil Pressure 9
4.4.4. Multi-function - Voltage 10
4.5. Liquid Crystal Display 12
4.5.1. General Function 12
4.5.2. Accuracy 12
4.5.3. Electronic Dual Air Pressure Gauge 12
4.6. Warning Chirp 13
4.6.1. General Function 13
4.6.2. Frequency and Duration 13
4.7. Telltales 14
4.7.1. Telltale illumination 15
4.7.2. Telltale Location 15
5. Electrical Interconnection 16
5.1. Connector 16
5.1.1. Electrical Pin-out Production 16
5.1.2. Electrical Pin-out Service 17
5.2. Electrical Characteristics 18
5.3. Input Signals 18
5.3.1. Overview 18
5.3.2. Analog Inputs 20
5.3.3. Frequency Inputs 20
5.4. Output Signals 22
5.4.1. Overview 22
6. Mechanical Interface 22
6.1. Cluster - Exploded View 22
6.2. Outline 23
6.3. Mounting 23
6.4. Connection 23
6.5. Assembly 23
6.5.1. Air Box Assembly 23
6.5.2. Back Housing 23
6.5.3. PC Board 23
6.5.4. Chimney Assembly 24
6.5.5. Light Conductor 24
6.5.6. Dial 24
6.5.7. Pointers 24
6.5.8. Mask 24
1. Scope
This specification defines the electrical, mechanical, and functional characteristics for Blue Bird Model Year 1999 Instrument Cluster. It describes the whole variety of functions and features.
2. History
The following table shows the history of this document and describes extensions and modifications.
Revision Revision Date Description
1.0 9/03/98 Initial Release to customer. Based on MY99 Clusters
1.1 9/08/98 Revised Section 4.4.1.1, 4.4.2.3, & 4.5.3.1
3. Overview
The Instrument Cluster is used to communicate information on the operation and performance of the vehicle to the operator. At the same time it is designed to issue warnings if abnormal conditions occur.
3.1. Cluster Versions
There are twelve cluster versions. There is one housing and one lens. The cluster shall be designed to use a single printed circuit board. The mask shall be available in two colors: black and gray. There are two dials: English and Metric. The dual air brake models have an air box attached to the back of the cluster, the hydraulic brake models do not. Delco replacement clusters have a connector attached to the rear of the cluster and are also supplied with a black polycarbonate strip, which replaces the telltale strip in the instrument panel above the cluster.
Blue Bird Cluster Part Numbers and Configurations
VDO Part Number Blue Bird PN Replaces Delco PN Brakes Units Tacho Mask
1 911 220 477B 000 4094 Dual Air English 0-4500 RPM Black
1 911 220 532B 000 4095 Hydraulic English 0-4500 RPM Black
1 911 220 484B 000 4096 Dual Air Metric 0-4500 RPM Black
1 911 220 549B 000 4097 Hydraulic Metric 0-4500 RPM Black
1 911 220 491B 000 4099 Dual Air English 0-4500 RPM Gray
1 911 220 518B 000 4100 Hydraulic English 0-4500 RPM Gray
1 911 220 501B 000 4103 Dual Air Metric 0-4500 RPM Gray
1 911 220 525B 000 4102 Hydraulic Metric 0-4500 RPM Gray
1 911 220 453D 000 4104 186 1764
186 0014 Dual Air English 0-4500 RPM Black
1 911 220 460D 000 4105 186 0022
186 1731 Hydraulic English 0-4500 RPM Black
1 911 220 439D 000 4107 186 1772
186 1756 Dual Air Metric 0-4500 RPM Black
1 911 220 446D 000 4106 186 0030
186 1749 Hydraulic Metric 0-4500 RPM Black
3.2. Cluster Functions
The Cluster provides the following functions:
• Speedometer- 270#61616; cross-coil movement
• Tachometer- 270#61616; cross-coil movement
• Multi-function Gauge- 90#61616; cross-coil movement
Displays:
#61485; Fuel
#61485; Battery Voltage
#61485; Oil Pressure
#61485; Coolant Temperature
• LCD
#61485; Odometer- Single row, 7 digit, 7 segment
#61485; Hourmeter - 4 digit, 7 segment, displayed on odometer
#61485; Dual Air Pressure - Two row, 10 segment, bar graph
• Warning buzzer - Variable pitch unit
• 24 telltales locations ( see telltale section )
4. Functional Description
4.1. Functional Block Diagram
4.2. Speedometer
4.2.1. General Function
The speed is measured and calculated by counting a pulse train from the transmission. The number of pulses per mile is configurable via the serial date link and can be programmed into the cluster EEPROM. The number of pulses per mile can be configured either at 4000 ppm or from 10,001 to 72,000 pulses per unit distance in 1-pulse/mile increments. 39,540 is the default setting.
Speed will be indicated on a ~200#61616; cross-coil movement with a primary scale and a secondary scale. For English unit vehicles mph will be the primary and km/h will be the secondary. For metric unit vehicles km/h will be the primary and mph will be the secondary. The speedometer will return to zero on ignition off.
Some vehicles have a dual speed differential. This means that when the dual speed differential (underdrive) signal is asserted (pulled to ground) the speedometer revs/ miles are reduced by a programmable factor between 0.5 and 1. The default factor is 0.73
4.2.2. Scale / Accuracy / Calibration
min. indicated speed 3 mph (5 km/h)
max. indicated speed 80 mph (130 km/h)
speedometer accuracy ±1.6 mph (±2.6 km/h)
4.2.3. Fault Conditions
Following conditions are regarded as faults:
• Frequency of engine speed sensor below fmin.
• Frequency of engine speed sensor above fmax.
If a frequency below the minimum frequency is detected, the pointer will move back to its zero position.
If a frequency above the maximum valid frequency is detected, it will be considered to be noise and the pointer will stay at the position of the last valid measurement until detection of a valid frequency or power off.
4.3. Tachometer
4.3.1. General Function
The engine speed is measured and calculated by measuring the period of the alternator signal. The number of pulses per rev is configurable via the serial data link and can be programmed into the cluster EEPROM. The number of pulses per rev can be configured from 12.0 to 75.0 in 0.1 increments. Engine speed will be indicated on a ~200#61616; cross-coil movement. The tachometer pulses per rev can be configured over the serial link and programmed into the EEPROM. The default value is 17.4 ppr. The tachometer will return to zero on power off.
4.3.2. Scale / Accuracy / Calibration
min. indicated engine speed 300 rpm
max. indicated engine speed 4500 rpm
tachometer accuracy ±140 rpm
4.3.3. Fault Modes
Following conditions are regarded as faults:
• Frequency of engine speed sensor below fmin.
• Frequency of engine speed sensor above fmax.
If a frequency below the minimum frequency is detected, the pointer will move back to its zero position.
If a frequency above the maximum valid frequency is detected, it will be considered to be noise and the pointer will stay at the position of the last valid measurement until detection of a valid frequency or power off.
4.4. Multi-function Gauge Operation
The multi-function gauge is a 90#61616; cross-coil movement that can display fuel level, oil pressure, coolant temperature, or battery voltage.
In the event that one or more of the gauges is out of limits i.e., warning or error conditions (levels are programmable and can be saved in the EEPROM), the multi-function gauge will display the out of limit gauge. If more than one gauge is out of limit, the gauges will sequence.
Every time the multi-function gauge changes function, the warning beeper chirps to indicate the change.
An external Mode Switch (not provided by VDO) can be connected to allow the user to manually change the gauge function. After 30 seconds, if no new default gauge is selected, the gauge display will return to the default gauge. Upon start-up, fuel is the default gauge.
By selecting a gauge and holding the Mode Switch for 5 seconds, a new default gauge is selected. If a warning or error condition arises, the multi-function gauge will display the condition until all gauges are clear. At that time, the multi-function gauge will return to the selected default gauge.
White dead front telltales are used to indicate the current function and scale. Red dead front telltales are used for warning (redline) areas.
On power-up all four gauges are displayed in sequence for a period of 15 seconds each.
4.4.1. Multi-function - Fuel
4.4.1.1. General Function - Fuel Level
The fuel gauge will display the amount of fuel remaining in the tank. In the event the gauge is less than a programmable level (default is 1/8 tank, 15#61617;3#61527;) the cluster will sound a chirp and light the fuel telltale. The limits on the warning are 8 to 90#61527;.
The fuel sensor input signal type is resistive. The measured value is indicated on a ~90#61616; scale with a cross-coil movement (clockwise rotation).
A 5-point programmable linearization curve is provided in software to allow for the use of different tank geometry. The tank level at E and F stays the same, but the value for sender reading 1/4, 1/2, 3/4 (from table) can be entered as a percentage of full scale.
The dampening of the fuel indication is of a PT1 (software) type. It does not allow the pointer to swing over the target position. The dampening constant is stored in the non-volatile memory and is configured during manufacturing. A 5-point calibration will also be conducted during manufacturing and the resulting corrections stored in EEPROM.
The low fuel level is a customer configurable parameter that may be adjusted by the customer. Adjustment of the low fuel level does not affect the gauge. When the low fuel level is detected, the “Low Fuel” warning telltale illuminates and stays on until end of ignition cycle.
4.4.1.2. Scale / Accuracy / Calibration - Fuel Level
Mark Angle
[#61616;] Resistance [#61527;] Tolerance [#61527;] Direction
E 0 8 +4,-0 Falling
Low
Red Band 16.9 15* (10-25 programmable) ±3 Falling
(1/4) 22.5 28.5* (varies based on other programming) ±3 Reference
(1/2) 45 49* (35-65 programmable) ±3 Falling
(3/4) 67.5 69.5* (varies based on other programming) ±3 Reference
High
Red Band 73.1 80*(70-85 programmable) ±3 Rising
F 90 90 +0,-4 Rising
*Factory default - customer configuration changes may affect this value.
4.4.1.3. Fault Modes - Fuel Level -
The Following condition is regarded as faults:
• fuel sensor signal more than 100#61527; for more than 5 sec
When a fault is detected during normal operation, the cluster will sound a beep. The pointer moves back to its zero position (= indication ‘EMPTY’) and stays there while the fuel telltale flashes to indicate a problem. When a valid reading is detected, the pointer will then move to the corresponding position.
4.4.2. Multi-function - Coolant Temperature
4.4.2.1. General Function - Coolant Temperature
The coolant temperature is based on resistance of the coolant temperature sensor input signal. The measured value is indicated on a ~90#61616; scale with a cross-coil movement (clockwise orientation).
The damping of the Coolant temperature indication is of a PT1 type. The damping constant is stored in the non-volatile memory and is programmed during manufacturing. A one-point calibration will be conducted during manufacture and the resulting corrections will be stored in EEPROM, also the coolant temperature-warning limit will be programmable in the EEPROM. The default value is 210#61616; F (40#61617;3#61527;). When this limit is passed, the beeper will sound and the telltale will come on, as well as the multi-function gauge displaying the Coolant Temperature function. The coolant temperature-warning limit will be customer configurable in the range 25-40#61527;. The edge of the High Red Band will move with the telltale limit such that the telltale always comes on at the edge of the red band.
One temperature sensor characteristic is used.
4.4.2.2. Scale / Accuracy / Calibration - Coolant Temperature
Mark Angle
[#61616;] Resistance
[#61527;] Tolerance
[#61527;] Temp.
[ #61616;F] Direction
L 0 287.4 +0,-28 100 Falling
Low Red Band 16.9 170 ±12 131 Falling
22.5 130 ±8 150 Reference
45 54 ±6 194 Falling
67.5 45* (varies based on programming) ±5 205* Reference
High Red Band 73.1 40* (25-40 programmable) ±4 210* Rising
H 90 22 +4,-0 250 Rising
*Factory default – customer configuration changes may affect this value.
4.4.2.3. Fault Modes - Coolant Temperature
The following conditions are regarded as faults:
• coolant temperature sensor signal less than 20#61527; for more than 5 sec
• coolant temperature sensor signal more than 100k#61527; for more than 5 sec
When a fault is detected during normal operation, the cluster will sound a beep. The pointer moves back to its zero position (= indication ‘L’) and stays there while the coolant temperature telltale flashes to indicate a problem. When a valid reading is detected, the pointer will then move to the corresponding position.
4.4.3. Multi-function - Oil Pressure
4.4.3.1. General Function - Oil Pressure
The oil pressure is measured and calculated based on resistance of the oil pressure sensor input signal. The measured value is indicated on a ~90#61616; scale with a cross-coil movement (clockwise orientation).
The dampening of the oil pressure indication is of a PT1 type. It does not allow the pointer to swing over the target position. The dampening constant is stored in the non-volatile memory and configured during manufacturing. A five-point calibration will also be conducted during manufacturing and the resultant calibration curve stored in EEPROM.
One oil pressure sensor characteristic is used. It is stored in the non-volatile memory. An oil pressure telltale threshold will also be stored in non-volatile memory. The default value is 8-psi (22.8#61527; ±3#61527;). This is user programmable from (15-40#61527;). The telltale will light and the multi-function gauge will display Oil Pressure if the pressure is below the threshold for more than 10 seconds.
The oil pressure telltale value is a customer configurable parameter, and changing this parameter also changes the calibration curve shown below.
4.4.3.2. Scale / Accuracy / Calibration - Oil Pressure
Mark Angle
[#61616;] Resistance
[#61527;] Tolerance
[#61527;] Pressure (Linearized)
[psi] Direction
L 0 10 +8,-0 0 Falling
Low Red Band 16.9 22.8*(15-40 programmable) ±5 8* Falling
22.5 55* (varies based programming) ±5 37.5* Reference
45 100 ±3 75 Falling
67.5 145 ±5 112.5 Reference
High Red Band 73.1 160 ±5 122 Rising
H 90 190 +0,-8 150 Rising
*Factory default – customer configuration changes may affect this value.
4.4.3.3. Fault Conditions - Oil Pressure
Following conditions will be detected and regarded as faults:
• pressure sensor resistance below 7#61527; for more than 5 sec
• pressure sensor resistance above 195#61527; for more than 5 sec
When a failure is detected during normal operation, the cluster will sound a beep and the oil telltale will flash. The pointer moves back to its zero position and stays there until a valid sensor signal is present. The pointer will then move to the corresponding position.
4.4.4. Multi-function - Voltage
4.4.4.1. General Function - Voltage
The voltage is measured and calculated based on the cluster ignition voltage. The measured value is indicated on a ~90#61616; scale with a cross-coil movement (clockwise orientation). The dampening of the voltage indication is of a PT1 type. It does not allow the pointer to swing over the target position. The dampening constant is stored in the non-volatile memory and configured during manufacturing. A five-point calibration will be conducted at the factory during manufacture and will be stored in EEPROM. A high and low threshold for the voltage telltale will also be stored in memory. The default warning values are 11.5V and 15.3 volts.
4.4.4.2. Scale / Accuracy / Calibration - Voltage
Mark Angle
[#61616;] Voltage Tolerance
Direction
9 0 9 +0.5,-0 Falling
16.9 10.9 ±0.5 Falling
22.5 11.5 ±0.5 Reference
45 14 ±0.5 Falling
67.5 16.5 ±0.5 Reference
73.1 17.1 ±0.5 Rising
19 90 19 +0,-0.5 Rising
4.4.4.3. Fault Conditions - Voltage
Following conditions will be detected and regarded as faults:
• voltage above 19.5V for more than 5 sec
When a failure is detected during normal operation, the cluster will sound a beep. The pointer moves to its zero position for both under-scale and for over-voltage. It stays there until a valid sensor signal is present. The pointer will then move to the corresponding position. In the event of an over voltage condition the cluster will shut down completely in order to prevent its voltage regulator from overheating.
Voltages between 6.5 and 8.5V will be regarded as illumination voltage and the cluster will operate as if the illumination is on.
4.5. Liquid Crystal Display
4.5.1. General Function
The liquid crystal display is a 7 digit, seven segment display that is used to display odometer (tenths of mile) and hourmeter (whole hour) functions. Under normal conditions the odometer is displayed. At power-up and when the ignition is off and the lights on a hourmeter function will be displayed instead with a corresponding indicator. The multi-function gauge switch will toggle between hourmeter and odometer when the ignition is off. The hourmeter can be disabled in the EEPROM.
The hourmeter is used to accumulate time when the ignition is on and the tachometer is displaying non-zero engine rpm (>300 rpm).
4.5.2. Accuracy
The odometer is saved every mile to a tenth mile accuracy (kilometers for metric clusters). The hourmeter is saved every hour in minutes and is displayed in whole hours.
4.5.3. Electronic Dual Air Pressure Gauge
4.5.3.1. General Operation - Air Pressure
The cluster may have a dual electronic air pressure gauge. The air pressure function may be disabled in the EEPROM. The air pressure is displayed in 15-psi increments between 0 and 150 psi. For pressures below 60 psi 1 to 4 red segments are shown. For pressures above 60 psi 1 to 6 green segments are on. The cluster has the ability to provide a visual check for air leaks. To enter this test mode, the vehicle must be in a stationary position. Depress the multifunction button during ignition cycle, a numeric pressure for the front and the rear air will be displayed in place of the odometer. Display will be in “psi” (with no decimal point) for English clusters and “tenths of bar” (with no decimal point) for Metric clusters. Push the multifunction button once again to return to normal mode. During this test mode, other cluster functions are disabled.
4.5.3.2. Scale / Accuracy / Calibration - Air Pressure
Pos. Segments Mark
English /
(metric)** Pressure
psi /
(BAR)** Tolerance psi Direction
1 0 0 0 (0) +3 -0 Falling
2 1 15 (1) Reference
3 2 30 (2) Reference
4 3 45 (3) Reference
5 4 60 (4) 60 (4) ±5 Falling
6 5 75 (5) Reference
7 6 90 (6) Reference
8 7 105 (7) Reference
9 8 125 (
±8.4 Rising
10 9 135 (9) Reference
11 10 150 (10) 150 (10) Reference
**Metric Units Only
4.5.3.3. Fault Conditions - Air Pressure
Following conditions will be detected and regarded as faults:
• pressure reading 3 counts over the maximum calibrated value
When a failure is detected during normal operation, the cluster will sound a beep and the low air telltale will flash. The display shows 0 pressure and stays there until a valid sensor signal is present. The display will then move to the corresponding position.
4.6. Warning Chirp
4.6.1. General Function
The warning chirp is used to indicate that the multi-function gauge has changed function or that one of the sensors is in fault. The warning chirp will also repeatedly sound to indicate that the lights are on and the ignition off.
4.6.2. Frequency and Duration
The frequency of the warning chirp will be 2500 Hz in a 100 ms burst.
4.7. Telltales
The following telltales (24) are integrated in the instrument cluster:
Fig. Telltale Color Input Source Active Status Description
1 Left Turn Green direct driven On to indicate left turn.
2 Fuel Amber microprocessor driven On to indicate low fuel.
3 Anti-lock Amber direct driven On to indicate an anti-lock brake fault.
4 Sander Refill Red direct driven On to indicate sander is low.
5 Parking Brake Red direct driven On to indicate that the parking brake is engaged.
6 Oil Pressure Red microprocessor driven On to indicate that the oil pressure is low.
7 Stop Light Red direct driven On to indicate that the brake is engaged.
8 Engine Preheat Green direct driven On to indicate diesel engine preheat.
9 High Beams Blue direct driven On to indicate lights are in High Beam.
10 Low Coolant Red direct driven On to indicate coolant is low.
11 Brake Warning Red direct driven On to indicate brake pressure is low.
12 Engine Over-speed Amber direct driven On to indicate that the engine is over speed.
13 Service Engine Soon Amber direct driven On to indicate that the engine requires service soon.
14 Coolant Temperature Red microprocessor driven On to indicate that the coolant temperature is out of limits
15 Low Air Red microprocessor driven On to indicate that air brake pressure is low.
16 Right Turn Green direct driven On to indicate right turn.
17 Fuel Filter Amber direct driven On to indicate that the fuel filter needs checking.
18 Stop Engine Red direct driven On to indicate that the engine must be stopped immediately.
19 Engine Retard Red direct driven On to indicate that the engine retarder is engaged.
20 Hydraulic Oil Temp Amber direct driven On to indicate that the Hydraulic Oil Temp. is out of limits
21 Traction Control “ETC” Amber direct driven On to indicate that the Traction Control is engaged
22 Engine Maintenance “Service” Amber direct driven On to indicate that regular Maintenance should be performed
Spares (1) N/A direct driven Space allowance for future function.
4.7.1. Telltale illumination
All telltales will be illuminated by a 1.4w, 14V, T-5 bulb. With the exception of the engine over-speed, air preheat, illumination bulbs, and the multi-function gauge fuel telltale all telltales will have bulbs installed for the life of the cluster and will require disassembly for replacement. The air preheat bulb will be shipped in the cluster and must be removed and placed in the engine over-speed socket for gas engines.
4.7.2. Telltale Location
Cont....