Ametek PST-2000 Manual de usuario

Using the PST-2000

with

Freightliner Trucks

Document Number

072-40236-B

Every effort has been made to keep the information in this document current and accurate

as of the date of publication or revision. However, no guarantee is given or implied that the

document is error-free or that it is accurate with regard to any specification. AMETEK

Dixson reserves the right to modify product designs and specifications without notice.

Free telephone assistance is available Monday through Thursday between 7 a.m. and 5:30

p.m. Mountain Time, and Friday between 7:00 a.m. and noon.

AMETEK Dixson Product Support Department

287 27 Road, Grand Junction, CO 81503

FAX: (970) 245-6267

Phone: (970) 244-1243

Toll-Free: (800) 205-7710

Revision Table

Revision Date Description

12/14/99 Initial release.

-A 01/27/00 Additions and enhancements: Sections 1, 7, 10; Figures 1, 2; Tables 1,2.

-B 8/15/00 Add fuse and connector information to Figure 1.

ii 072-40236-B

1 Introduction

This guide explains how to use the PST-2000 (Product Support Tool) to test, troubleshoot,

and check the accuracy of AMETEK Dixson gauges installed in Freightliner trucks.

Note - You must read and follow the test procedures in this document to

successfully test a gauge. Failure to do so may cause you to reject

properly functioning gauges.

2 Care and Cleaning

The PST-2000 is a precision instrument and is designed for trouble-free operation in a

normal vehicle repair environment. It will operate between 14 and 122 degrees Fahren-

heit and is spill-resistant.

Use only a soft cloth and a mild, non-abrasive soap to clean the PST-2000. Do not use gas-

oline, alcohol, or solvents because they will damage the instrument and void its warranty.

Always return the tool to its carrying case when not in use.

3 Warranty

AMETEK Dixson warrants the PST-2000 to be free from manufacturing and material de-

fects for one year from the date of sale to the end-user. To obtain service, call the AMETEK

Dixson Product Support Department and ask for instructions and a Returned Material

Authorization (RMA).

Using the PST-2000 with Freightliner Trucks

072-40236-B Page 1 of 10

4 PST-2000 Kit Contents

You may order replacement parts or optional equipment by calling the AMETEK Dixson

Sales Department at (970) 244-1241.

Page 2 of 10 072-40236-B

Part Name Part Number

PST-2000, complete kit 00041133

PST-2000, tester only 243-12833

Carrying Case 243-14028

Standard Input Cable, 900/6/7 Panel Speedo/Tach 180-12840

Input Cable, Cigarette Lighter Socket Adapter 180-12848

Input Cable, External Power Supply 180-12847

Optional Input Cable, AC Adapter to 12 VDC 240-12915

Optional Input Cable, AC Adapter to 24 VDC 240-12916

Standard Output Cable, Speedo/Tach/6/7 Panel 180-12841

Standard Output Cable, Temperature, Ammeter 180-12842

Table 1 PST-2000 Spare Parts

5 Description

The PST-2000 is designed to help test and troubleshoot the vehicle instrument system by

simulating the information normally fed to the gauges from the gauge sensors and sender

units. The unit receives power from an input cable that plugs into the speedometer or tach-

ometer harness connector. Optional input cables for bench testing are available that de-

rive their power from a cigarette lighter socket, an external power source, or an AC/DC

adapter. The output cables plug into the gauges to be tested.

The tool lets you vary the frequency of pulses sent to the speedometer and tachometer.

You vary the output frequency as stated in the procedures and observe the speedometer

or tachometer reading.

The tool also contains a variable resistance source to test temperature and fuel level

gauges, and current and millivolt signals to test ammeters.

Using the PST-2000 with Freightliner Trucks

072-40236-B Page 3 of 10

Figure 1 PST-2000 Controls

6 Connecting the PST-2000

The PST-2000 comes with a standard input cable that provides power to the tool, and two

standard output cables that send signals to the gauges. Optional input and output cables

are available. The cables are connected as shown in Figure 2.

Page 4 of 10 072-40236-B

Figure 2 Connecting the PST-2000

7 General Test Procedure

Use the following table to find the section for the gauge you wish to test.

If, after testing according to the appropriate procedure, the gauge does not function as

described, replace it. If the gauge is functioning properly and is accurate, refer to the ap-

propriate AMETEK Dixson Product Information Note (PIN) for troubleshooting tips.

To test this gauge, See Section: PIN: Gauge Identification

900 Series Speedometer 8 072-40283 Blue plastic housing, or

mounted in 6/7 instrument

cluster.

900 Series Tachometer 9 072-40284 Blue plastic housing, or

mounted in 6/7 instrument

cluster.

Fuel and Temperature

Gauges

10 072-40289 2-inch metal housing, or

mounted in 6/7 instrument

cluster.

Ammeter 11 072-40288 2-inch metal housing.

Notes - You can obtain the Accuracy Tables and Product Information Notes

referred to in this document by calling our Product Support Depart-

ment or by downloading them from our website at

www.ametekdixson.com.

The PST-2000 cannot test voltmeter gauges. See AMETEK Dixson

Product Information Note 072-40287 for information about trouble-

shooting voltmeter gauges.

Important!

The PST-2000 cannot calibrate gauges. Do not set the tool to a par-

ticular frequency or resistance value and then check the pointer

position. Instead, use the tool to position the pointer as directed in

the procedure, note the value indicated on the tool and verify it

falls within the given frequency range listed in the Accuracy Table

referenced by that procedure.

When using the tool to position the pointer to full scale, the fre-

quency displayed on the tool corresponds to the values given in

the Accuracy Tables called out in these procedures and not with

other calibration charts and booklets.

Using the PST-2000 with Freightliner Trucks

072-40236-B Page 5 of 10

8 900 Series Speedometer

1. Connect the PST-2000 as described in Figure 2.

2. Turn the PST-2000 Input Voltage switch to either 12 volts or 24 volts, whatever is

appropriate for your vehicle.

3. Turn the ignition on.

a. If the green Battery Voltage LED is on, continue this procedure.

b. If one of the red LEDs is on, the Input Voltage switch may not be set to

the vehicle’s battery voltage, or the battery voltage is too high or too low.

c. If no LED is on, the PST-2000 fuse may be blown, the PST-2000 or its in-

put cable may be defective, or you may have a bad power connection.

Recheck your connections.

Note - If using an AC/DC adapter input cable, the High LED may light when

no gauge is connected to the tester. Disregard this indication.

4. Set the Signal switch down (square wave).

5. Note which switches on the back of the speedometer are closed (on), then verify

they are completely closed by using a sharp, pointed object such as a scribe.

6. Write down which switches are closed (on) and locate this switch combination in

the “Switches Closed” column of Accuracy Table 072-40319.

7. Check the speedometer’s accuracy at 50 mph as follows:

a. Read across the row that contains your speedometer’s switch combina-

tion to the column headed “Hertz @ 50 MPH” to obtain the 50 mph input

frequency value.

b. Set the Signal Range knob to the correct range based on the 50 mph fre-

quency value you just found. (For most speedometers, this will be 187 to

2k.) This simulates the frequency input from the vehicle’s speed sensor.

c. Adjust the Signal Adjust knob until the speedometer pointer indicates 50

mph.

d. After a 5-second stabilization time, the displayed value should be within

the values given in the column headed “Range, 50 MPH” for your switch

setting.

8. Check the accuracy at 25 mph as previously described, but use the values in the

“Hertz @ 25 MPH” and “Range, 25 MPH” columns, and adjust the Signal Adjust

knob to position the pointer at 25.

9. Check the accuracy at 80 (or 85) mph as previously described, but use the values

in the “Hertz @ 80 MPH” and “Range, 80 MPH” columns (or “Hertz @ 85 MPH”

and “Range, 85 MPH” columns), and adjust the Signal Adjust knob to position

the pointer at 80 (or 85).

Page 6 of 10 072-40236-B

10. Verify the odometer and built-in trip odometer (if applicable) are advancing prop-

erly by adjusting the Signal Adjust knob until the pointer reads 60 mph. The

odometers should then advance one mile every 59 to 61 seconds.

The following example will help you understand the procedure:

Your speedometer’s switches S1, S3, S5, and S8 are on (closed). After looking up that

switch combination in the “Switches Closed” column of Accuracy Table 072-40314

and reading across to the “Hertz @ 50 MPH” column, your find that your frequency

value is “1456”. You would then set the Signal Range knob on the PST-2000 to the

187–2k range and adjust the Signal Adjust knob to position the pointer at 50 mph. If

the speedometer is accurate at 50 mph, the PST-2000 will display between 1409 and

1502 as given in the “Range, 50 MPH” column.

9 900 Series Tachometer

1. Connect the PST-2000 as described in Figure 2.

2. Turn the PST-2000 Input Voltage switch to either 12 volts or 24 volts, whatever is

appropriate for your vehicle.

3. Turn the ignition on.

a. If the green Battery Voltage LED is on, continue this procedure.

b. If one of the red LEDs is on, the Input Voltage switch may not be set to

the vehicle’s battery voltage, or the battery voltage is too high or too low.

c. If no LED is on, the PST-2000 fuse may be blown, the PST-2000 or its in-

put cable may be defective, or you may have a bad power connection.

Recheck your connections.

Note - If using an AC/DC adapter input cable, the High LED may light when

no gauge is connected to the tester. Disregard this indication.

4. Set the Signal switch down (square wave).

5. Note which switches on the back of the tachometer are closed (on), then verify

they are completely closed by using a sharp, pointed object such as a scribe.

6. Write down which switches are closed (on) and locate this switch combination in

the “Switches Closed” column of Accuracy Table 072-40315.

7. Check the tachometer’s accuracy at full scale as follows:

a. Read across the row that contains your tachometer’s switch combination

to the column headed “Full Scale Hertz” to obtain the full scale input fre-

quency value.

b. Set the Signal Range knob to the correct range based on the full scale fre-

quency value you just found. (For most tachometers, this will be 880 to

10k.) This simulates the frequency signal from the vehicle’s engine speed

sensor.

Using the PST-2000 with Freightliner Trucks

072-40236-B Page 7 of 10

c. Adjust the Signal Adjust knob to position the pointer to your tachome-

ter’s full scale reading (2400 or 3000 rpm). If your full scale reading is

3500, position the pointer to 3000 rpm.

d. After a 5-second stabilization time, the displayed value should be within

the values given in the column headed “Full Scale Range” for your switch

setting.

8. Check the accuracy at half scale (1200 or 1500 rpm) as previously described, but

use the values in the “Half Scale Hertz” and “Half Scale Range”, and adjust the

Signal Knob to position the pointer at 1200 or 1500. If your full scale reading is

3500, position the pointer to 1500 rpm.

9. Verify the hourmeter (if applicable) is advancing properly. The tenths wheel

should advance every 6 seconds while power is applied.

The following example will help you understand the procedure:

Your tachometer’s switches S1, S3, and S5 are on (closed). After looking up that

switch combination in the “Switches Closed” column of Accuracy Table 072-40315

and reading across to the “Full Scale Hertz” column, your find that your frequency

value is “8400”. You would then set the Signal Range knob on the PST-2000 to the

880–10k range and adjust the Signal Adjust knob to position the pointer at 3000 rpm.

If the tachometer is accurate at full scale, the PST-2000 will display between 8232 and

8568 as given in the Full Scale Range column.

10 Fuel Level and Temperature Gauges

1. Unplug the gauge to be tested (or remove it from the 6/7 instrument panel) and

connect the PST-2000 as described in Figure 2.

2. Turn the PST-2000 Input Voltage switch to either 12 volts or 24 volts, whatever is

appropriate for your vehicle.

3. Turn the ignition on.

a. If the green Battery Voltage LED is on, continue this procedure.

b. If one of the red LEDs is on, the Input Voltage switch may not be set to

the vehicle’s battery voltage, or the battery voltage is too high or too low.

c. If no LED is on, the PST-2000 fuse may be blown, the PST-2000 or its in-

put cable may be defective, or you may have a bad power connection.

Recheck your connections.

Note - If using an AC/DC adapter input cable, the High LED may light when

no gauge is connected to the tester. Disregard this indication.

4. Configure the PST-2000 Resistance Out switches until the gauge pointer aligns

with the gauge test point value given in Table 2 for the type of gauge you are test-

ing.

5. Important! Tap the gauge while adjusting the switches to accurately align the

pointer.

Page 8 of 10 072-40236-B

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