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Ametek 387 Service Manual

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  • Page 2 Revision Date Description 01/27/99 Initial release. 05/14/99 Changed all occurrences of “2100” to “387”, and of “self test” to “initialization”; Fig. 5-22, corrected pin designations on J3 illus- tration. 9/28/99 Added Chapter 6, “Using the Handheld Diagnostic Tool"; re- moved all references to PTM/VTM replacement and to the ABS system;...
  • Page 9 The purpose of this manual is to provide Peterbilt with the knowledge required to produce their own repair procedures. This manual contains the technical repair informa- tion necessary to diagnose and repair the Model 387 Instrument System (also referred to as simply the “instrumentation”). The information in this manual is not propri- etary and can be used as Peterbilt sees fit.
  • Page 10 60 separate wires. By comparison, the Model 387 Instrument System uses a single 5-wire cable to con- nect all the gauges together. This significantly reduces the number of wires behind the instrument panel and makes the system much easier to troubleshoot and service.
  • Page 11 Turning on the ignition activates the instrumentation and starts the initialization de- scribed in Figure 2-1. Service the vehicle if any of the following conditions occur after the initialization: • The speedometer or tachometer pointer sweeps back and forth in a wind- shield wiper motion.
  • Page 12 To view a different function, press and release the Select switch until the desired function appears. The message center goes into a “sleep” mode (i.e. goes blank) when the ignition is turned off. Each time you press the Select switch, the message center is “awakened” for 10 seconds.
  • Page 13 To display the Trip 1 or 2 Odometer, press and release the Select switch until XXXXT1 or XXXXT2 is displayed (XXXX = the actual mileage reading). To reset a trip odometer to zero - 1. Display the odometer to be reset (Trip 1 or Trip 2) 2.
  • Page 14 The audible alarm will continue to sound. A system fault message indicates a problem exists with the Model 387 Instrument System that does not directly affect vehicle safety. These occur when the ignition is first switched on.
  • Page 15 Gauge Indication When Led Is On Activating Condition Air Cleaner Restriction Clogged More than 25" of water (H2O) Air Tank 1 Too low Less than 66 psi Air Tank 2 Too low Less than 66 psi Air Starter Air Pressure No indication Not activated Ammeter...
  • Page 16 Warning Condition Associated Reset Message Gauge LED Message H2O TMP Coolant temperature high Water Temperature H2OT OK LOW AIR1 Air tank #1 pressure low Primary Air Pressure AIR1 OK LOW AIR2 Air tank #2 pressure low Secondary Air Pressure AIR2 OK OILPRES Engine oil pressure low Engine Oil Pressure...
  • Page 17 This section describes the instrumentation on a functional level. It is not necessary to read this section to troubleshoot and service the system. It is intended to provide a more detailed understanding of how the system works. Figure 3-1 illustrates the ma- jor components and signal flow.
  • Page 18 The Interface Module controls the instrumentation by collecting information from various sources and converting that information into gauge pointer information which it then sends to the gauges. It is an environmentally sealed unit and it is usu- ally mounted beneath the cab and against the frame rail. It is connected to the J1708 data bus, and to switches, sensors and pressure/vacuum hoses throughout the vehicle.
  • Page 19 Other pressure inputs are connected to port 5A or 5B, whichever is available depend- ing upon whether an Air Filter or a Fuel Filter Restriction gauge is present. Whenever the Interface Module is replaced, you must reprogram it recognize the pressure gauges.
  • Page 20 A vacuum transducer module (VTM) contains two vacuum transducers. The VTM is used for the Air Filter Restriction and Fuel Filter Restriction gauges. The VTM must be mounted at port 5A/5B only. The vacuum transducers are not identical. The Air Filter Restriction end must go to port 5A, and the Fuel Filter Restriction end must go to port 5B as shown in Figure 3- Two types of combination modules are available.
  • Page 21 format, refer to SAE J1708 document Standard For Data Communications Interface and to SAE J1587 document, Standard For Data Interchange. Electronic Control Units (sometimes called ECUs) are computerized units that control a particular vehicle subsystem. For example, an Engine ECU helps maximize engine efficiency, a Transmission ECU helps control transmission operation, and an ABS (Anti-lock Brake System) ECU maximizes braking performance.
  • Page 22 The Select and Reset switches select, set, and reset the clock, the alarm clock, and the trip odometers. Their inputs are connected to the SMC by a 4-pin connector on the rear of the speedometer housing. If these inputs are not connected, the SMC will display odometer information and warning messages only.
  • Page 23 The diagnostic connector allows test equipment such as the Handheld Diagnostic Tool described in Chapter 6 to be connected to the J1708 data bus. The diagnostic connector is usually located underneath the driver’s side of the dashboard. Note - The diagnostic connector is not part of the instrumentation and is men- tioned for reference only.
  • Page 24 The sensors for the Tachometer, Engine Oil Pressure, Engine Coolant, Engine Oil Temperature, Engine Load %, and Manifold Boost gauges are connected to the En- gine ECU. The Engine ECU converts these sensor inputs into data which it sends to the Interface Module over the J1708 data bus.
  • Page 25 meter data which it places on the private data bus. The tachometer receives the data and converts it into pointer drive signals. Connections are shown in Figure 3-7. The signal for the ammeter begins at a sense wire coiled up in the battery box (be- tween the battery’s positive terminal and the megafuse leading to the alternator).
  • Page 26 Battery voltage is fed to the Interface Module through the ignition switch. The Inter- face Module converts the voltage into data that it places on the private data bus. See Figure 3-9 for the actual wire connections.
  • Page 27 The signal for the pyrometer begins at a Type K thermocouple that is mounted in the exhaust stream and connected to the Interface Module. A thermocouple creates a small voltage (less than 33 millivolts) that changes depending upon its temperature. As the exhaust temperature rises, the thermocouple output voltage increases.
  • Page 28 Temperature senders installed in the appropriate axle or transmission housing and connected to the Interface Module sense the temperature of the gear oil. Each sender contains a thermistor whose value decreases as the temperature increases. The Inter- face Module converts the thermistor resistance and into data that it places on the pri- vate data bus.
  • Page 29 The signal for the fuel level comes from a sender unit that is mounted inside the fuel tank and connected to the Interface Module. The sender unit contains a float device attached to a variable resistor. As the fuel level drops, the float drops and the resis- tance of the variable resistor increases.
  • Page 31 All components of the instrumentation are easily replaceable in the field. This chap- ter describes the correct method of removing and replacing the system’s components. For troubleshooting information, see Chapter 5. For a functional description of the instrument system, see Chapter 3. Note - None of the instrumentation’s components can be repaired in the field.
  • Page 32 The SMC and tachometer are mounted using standard U-brackets. To replace the SMC or tachometer: 1. Unplug the connectors from the rear of the gauge by depressing their tabs while pulling the connector straight out. 2. Remove the two nuts and lock washers holding the U-bracket and remove the U- bracket.
  • Page 33 Note - If installing an additional pressure gauge, ensure that the correct Vacuum or Pressure Transducer Modules are installed on the Interface Module, and that the Interface Module has been programmed to recognize the new gauge. 1. With your hand, turn the bezel counter-clockwise about turn and remove the bezel, glass, gasket, and mask ring.
  • Page 35 Two-inch gauges are identical in design and hardware with the exception of their scale- plates. This allows any 2-inch gauge to serve a variety of functions simply by changing its scaleplate. To reprogram a 2-inch gauge to a different function, simply attach the appropriate scaleplate as shown in Figure 4-2.
  • Page 36 Part Number Description 17-05068-001 Interface Module (PPPP) with modules 17-05068-002 Interface Module (PPVV) with modules 17-05068-003 Interface Module (PPVP) with modules 17-05068-004 Interface Module (PPPV) with modules 17-05068-005 Interface Module (PPCC) with one pressure module 17-05066-001 SMC, MPH/kph, black bezel 17-05066-002 SMC, MPH/kph, satin bezel 17-05066-003...
  • Page 37 Section 5.2. Note - If you cannot find the problem after following the procedures in this chap- ter, please call the AMETEK Dixson Heavy Duty Service Department. Free telephone assistance is available between 7 a.m. and 5:30 p.m. MST, Mon- day through Thursday, or between 7:00 a.m.
  • Page 38 The first thing you should do when troubleshooting the instrumentation is switch the ignition on and observe all the gauges during the initialization period. Locate the general symptom in Table 5-1, then follow the instructions: General Symptom Action Problem with 2-inch gauge. Proceed to Section 5.3 on page 5-4.
  • Page 39 Each time power is applied to a 2-inch gauge or to the SMC (usually by switching the ignition on), the instrument performs an initialization. The initialization is described in Figure 5-1. Note - A gauge does not need other gauges or the Interface Module to perform its initialization.
  • Page 40 5-25. stops at 10:00 position with the LED on. tive Interface Module. Passes initialization, but the LED stays 387 System okay and Go to Section 5.6 on on and the SMC displays a warning indicating a vehicle or page 5-33.
  • Page 41 Probable Causes - No +12 volts or ground to the gauge; defective gauge. Procedure: (see Figure 5-2) 1. Verify the 5-wire cable plug is fully inserted into the rear of the affected gauge. If more than one gauge is affected, locate the first gauge in the chain with the prob- lem and inspect at that point.
  • Page 42 Symptoms - Pointer at 7:00 and LED flashes, gauge is inaccurate in normal opera- tion; false warning message appears. Probable Cause - Sensor or sender unit failure; open or shorted wire from sensor to Interface Module. Procedure: If you have arrived at this section, the gauge in question has passed its initialization. Find the gauge in question in Table 5-3 and follow the instructions.
  • Page 43 Symptom - Gauge passes initialization but is inaccurate in actual use; pointer stays at 7:00 position with flashing LED; false warning message or alarm. Probable Cause - Clogged or damaged pressure line; Interface Module defective. Gauge Types - Air Tank 1, Air Tank 2, Brake Saver Air, Air Starter, Fuel Pressure, Load Air, Pusher Suspension, Tractor Brake, Tag Suspension, Trailer Brake.
  • Page 44 4. If the standard test gauge reads low or not at all, the problem lies outside the 387 system. Check for leaks, breaks, kinks, or clogs in the pressure line from the pres- sure source. 5. If the standard test gauge reads correctly, compare its reading to the suspect gauge reading.
  • Page 45 Symptom - Gauge passes initialization but is inaccurate in actual use; pointer stays at 7:00 position with flashing LED; false warning message or alarm. Probable Cause - Defective sensor or sensor wiring; defective Interface Module. Gauge Types - Forward Axle, Rear Axle, Center Axle, 6X6 Front Axle, Main Trans- mission, Auxiliary Transmission, Brake Saver Oil.
  • Page 46 If the reading is less than 10 ohms, the wiring is probably good—replace the Interface Module. If the reading is greater than 10 ohms, the problem is outside the 387 sys- tem. Check the wires that connect the sensor to the Interface Module for cuts, shorts, loose connections, broken connector pins, etc.
  • Page 47 Symptom - Gauge passes initialization but is inaccurate in actual use; false warning message or alarm present. Probable Cause - Incorrect data being sent by the Engine ECU. Gauge Types - SMC, Tachometer, Engine Oil Pressure, Engine Coolant Temperature, Engine Oil Temperature, % Engine Load, Manifold Boost Pressure. Procedure: 1.
  • Page 48 3. If the suspect gauge reads as indicated in the table, the problem lies outside the instrumentation. Check the vacuum line for leaks, breaks, or clogs. 4. If the suspect gauge does not read as indicated in the table, or does not read at all, connect the HDT to the private data bus and compare its reading to the sus- pect gauge’s reading.
  • Page 49 Symptom - Gauge passes initialization, but is inaccurate in actual use; pointer stays at 7:00 and its red LED is on; false warning message. Probable Cause - Defective Interface Module or gauge. Procedure: (see Figure 5-6) 1. With the ignition off, unplug 10-pin connector J3 from the Interface Module. 2.
  • Page 50 Symptom - Gauge passes initialization but is inaccurate in actual use; pointer stays at 7:00 with flashing LED; false warning message. Probable Cause - Defective sense wire; defective wiring to Interface Module; defec- tive Interface Module. Procedure: (see Figure 5-7 on page 5-15) Check the wiring from the sense wire connector as described in Step 1 of Figure 5-7.
  • Page 52 Symptom - Gauge passes initialization but is inaccurate in actual use; pointer stays at 7:00 position and the red LED flashes; false warning message. Probable Cause - Defective sender unit, wiring to Interface Module, or Interface Module. Gauge Types - Left Fuel, Right Fuel, Main Fuel Procedure: Follow the steps in Figure 5-8.
  • Page 53 Symptom - Gauge passes initialization but is inaccurate in actual use; pointer stays at 7:00 with flashing LED; false warning message. Probable Cause - Defective thermocouple; defective wiring to Interface Module; de- fective Interface Module. Procedure: Follow the steps in Figures 5-9 and 5-10.
  • Page 55 Observe all gauges during the initialization period. Then pick the symptom in Table 5-4 that best describes what you see. SMC Fails Initialization Probable Cause Action No pointer movement, message center Power connection to Go to Section 5.4.1 on does not display the odometer, and no SMC.
  • Page 56 Symptom - Fails initialization; pointer never moves, message center is blank. Probable Cause - No +12 volts or ground to the gauge due to a bad connection in the wiring, blown fuse, open connector; defective SMC. Procedure: Follow the steps in Figure 5-11.
  • Page 57 Possible Causes - Engine ECU not calibrated; 2-speed axle switch engaged. Procedure: 1. If the vehicle is equipped with a 2-speed axle and switch, check the 2-speed input to the SMC as described in Section 5.4.5; if not, continue with next step. 2.
  • Page 58 Symptom - The odometer continues to add miles, and the speedometer indicates a speed reading when the PTO (Power Take-Off) is engaged and the vehicle is not moving. Probable Causes - Input from the PTO to the SMC is open; defective SMC Procedure: Follow the steps in Figure 5-12.
  • Page 59 Possible Causes - Open input from the two-speed axle switch to the SMC; defective SMC. Procedure: Follow the steps in Figure 5-13.
  • Page 60 Symptoms - Engine hours do not change, or the value is always zero. Probable Cause - The Engine ECU is not sending engine hour data to the SMC. Procedure: 1. Use an engine diagnostic tool and follow the engine manufacturer’s procedures to verify the Engine ECU is sending engine hour data over the J1708 data bus.
  • Page 61 Run the initialization again and observe all gauge pointers. Then find the symptom in Table 5-5 that best describes what you see and follow the instructions. Symptom Probable Cause Action A J1708 data bus gauge* pointer No data from Engine Go to Section 5.5.1 on sweeps.
  • Page 62 Probable Cause - No data from Engine ECU. Procedure: 1. Start the vehicle’s engine and use the Select button to scroll through the SMC messages. If DIAG appears, the Interface Module is defective and must be re- placed. If not, go to the next step. 2.
  • Page 63 verify the Interface Module is correctly configured for that gauge. If not, reconfigure as appropriate. d. If the Interface Module is correctly programmed for that pressure gauge and data is still not present on the private data bus, replace the Interface Module.
  • Page 64 3. After disconnecting all devices except the Engine ECU, use the engine manufac- turer’s diagnostic procedures to verify the Engine ECU is working properly. 4. If the Engine ECU is good, reconnect each device one at a time, verifying the En- gine ECU is still working after each device is connected.
  • Page 65 Probable Cause - J1708 data bus is open between the Engine ECU and the Interface Module. Procedure: Follow the steps in Figure 5-15.
  • Page 66 Possible Causes - Private bus is open between the Interface Module and the gauges; Interface Module defective or not receiving power; defective gauge. Procedure: 1. Connect the HDT to the diagnostic connector. 2. Switch the ignition on and verify that the HDT establishes a communications link with the Interface Module.
  • Page 68 Probable Cause - No speed messages from the Engine ECU. Procedure: 1. Switch the ignition on and wait for the initialization to end. 2. When the SMC pointer begins to sweep, wait for 3 minutes to see if a NO DATA message appears.
  • Page 69 Probable Cause - This usually indicates that a specific problem on the vehicle needs attention or that something is not operating within normal limits. Warning messages are listed in Table 5-6. Read the message and determine what con- dition is causing it. Repair as necessary following normal vehicle maintenance and repair procedures.
  • Page 70 Probable Causes - No lamp power to the gauge’s backlight pin (pin 1). Procedure: Switch the ignition and the headlights on. Turn the backlight dimming control to full brightness and check the backlighting in all gauges and in the tachometer. Find the results in the following table and take the appropriate action: Symptom Action...
  • Page 71 Procedure: Follow the steps in Figure 5-18.
  • Page 72 Symptom - SMC backlighting does not light when headlights are switched on. Probable Cause - No backlighting power to the SMC. Note - When the headlights are first turned on, the message center’s LCD backlighting will turn off momentarily and then turn back on. This is nor- mal and is not a problem.
  • Page 74 Figure 5-21 shows how the vehicle harness connects to the instrumentation. Figures 5-22 and 5-23 identify the system connector signals and pin numbers.
  • Page 77 The Handheld Diagnostic Tool (HDT) is designed to be used with the procedures in Chapter 5 of this manual. This chapter describes the HDT and how to use it. Instru- ment System troubleshooting information is found in Chapter 5. The following subjects are covered: Care and Cleaning Section 6.1 on page 6-1.
  • Page 78 The HDT is designed to help troubleshoot the 387 Instrument System by letting you see the data on the J1708 and private data buses. You will need this tool when install- ing a new Interface Module. Connecting the HDT to the diagnostic connector (6- or 9-pin) on the vehicle allows Engine ECU data on the J1708 data bus to be read and allows the Interface Module to be programmed.
  • Page 79 This section describes how to use the HDT to see gauge data from the Engine ECU on the J1708 data bus. This is useful while troubleshooting to help determine if the Engine ECU is broadcasting gauge data to the Interface Module and SMC. If no gauge data is being broadcast, the Engine ECU, the J1708 data bus wiring, or another device connected to the J1708 data bus could be defective.
  • Page 80 If communications are established, the HDT will display: b. If communications are not established after 2 minutes, and repeat this procedure starting at Step 1 with the ignition off. If the HDT fails to es- tablish communications after three attempts, there may be a problem with the J1708 data bus.
  • Page 81 5. With the pointer at READ PUBLIC BUS, press the Select key. The HDT will dis- play the following: 6. To see the names of the J1708 data bus gauges the for which the Interface Module has been programmed, use the Up and Down keys to scroll through the list. The J1708 data bus gauge names are: TACHOMETER, ENGINE LOAD, ENGINE OIL PSI, BOOST PRESSURE, ENG/BRAKESAV OIL TP, COOLANT TEMPERA- TURE, and SPEEDOMETER.
  • Page 82 This section describes how to use the HDT to see gauge data on the private bus. This is useful while troubleshooting by determining if the Interface Module is broadcast- ing data for a particular gauge. If no gauge data is being broadcast for a particular gauge, the Interface Module may be defective or incorrectly programmed.
  • Page 83 If communications are established, the HDT will display: b. If communications are not established after 15 seconds, repeat this step. If still unsuccessful there may be a problem with the private data bus. Choose the symptom from Chapter 5 that best describes the original in- strument system failure and follow the troubleshooting procedures.
  • Page 84 The HDT can be used to see what conditions turn on the warning lights in non-J1708 gauges. (The information in this section is presented as additional information not necessary to the operation of the HDT or to the servicing of the vehicle). 1.
  • Page 85 b. If the HDT cannot read the configuration data, it will tell you so. First repeat this procedure from Step 1 with the ignition off. If still unsuc- cessful, one-at-a-time disconnect other devices that use the J1708 data bus and repeat this procedure each time to isolate the faulty component. Press the Select key when the pointer is at NORMAL.
  • Page 86 This section describes how to use the HDT to program and/or verify the program- ming of Ports 5A and 5B, but only if they are being used as pressure ports. Ports 5A and 5B only need to be programmed when the Interface Module has been replaced or if it was found during troubleshooting that the port is incorrectly programmed.
  • Page 87 If the HDT reads the configuration data successfully, it will display: b. If the HDT cannot read the configuration data, it will tell you so. First, repeat this procedure from Step 1with the ignition off. If still un- successful, one-at-a-time disconnect other devices that use the J1708 data bus and repeat this procedure each time to isolate the faulty component.
  • Page 88 7. To reprogram a port or to see to which port a gauge is programmed: Use the Up or Down keys to move the pointer alongside its name. b. Press the Select key. The HDT will display: Press the Up or Down key to scroll through the list of gauge names. d.
  • Page 89 This section describes how to program the correct turn-on temperature of the Main Transmission Temperature gauge warning LED.This procedure is only required when the Interface Module has been replaced or a different type of transmission has been installed in the vehicle. The temperature at which the warning LED lights depends upon the type of trans- mission that is installed in the vehicle.
  • Page 90 4. After communications are established, press the Select key. The HDT will read the configuration data and display: If the HDT reads the configuration data successfully, it will display: b. If the HDT cannot read the configuration data, it will tell you so. First, repeat this procedure from Step 1 with the ignition off.
  • Page 91 8. Move the pointer to MAIN TRANS TEMP:XXX and press the Select key. The HDT will display a list of transmissions that may be installed in the vehicle: 9. Move the pointer next to the name of the transmission type that is installed in the vehicle, then press the Select key.

  • Page 92: End Of Document

    Part Name Part Number Hand-held Diagnostic Tool, complete 000-49856 Handheld Diagnostic Tool 220-12237 Carrying Case 240-12309 Diagnostic Cable with 6-Pin Connector 220-12234 Diagnostic Cable with 9-Pin Connector 220-12233 Private Bus Adapter 240-11204 Reprogramming Cable Adapter 220-12235 END OF DOCUMENT...