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IC-RE
Top Member

USA
4117 Posts

Posted - 02/18/2007 :  8:24:46 PM  Show Profile  Visit IC-RE's Homepage  Reply with Quote
CHECK OUT this dash, I haven't seen anything like it, I REALLY like it, does anybody have pics of a similar dash?? http://buscrazy.net/upload/5464.htm

Rich
Top Member

United States
5768 Posts

Posted - 02/18/2007 :  8:32:12 PM  Show Profile  Reply with Quote
That was pretty much a one year run on the All American REs, I believe. The same instrument cluster was used on the TC/2000s, and it was rather problematic. Basically, the middle gauge is multifunction, so it serves as a fuel gauge, battery gauge, oil pressure gauge, tranny temp gauge, and other necessities. It was a bad idea, as they always were corrupt.



http://www.schoolbuscentral.com/gallery/updates/oct04/bb_1_tcfe_00_ny.htm



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IC-RE
Top Member

USA
4117 Posts

Posted - 02/18/2007 :  8:34:31 PM  Show Profile  Visit IC-RE's Homepage  Reply with Quote
I knew the cluster was the same, and I like the way it looks, but I never saw a covering like that, you have to admit it looks nice though eh? haha.


bus 1980, a 2008 IC RE 300 for Fairfax County Public Schools, Fairfax, Virginia.

Edited by - IC-RE on 02/18/2007 8:36:53 PM
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Rich
Top Member

United States
5768 Posts

Posted - 02/18/2007 :  8:36:33 PM  Show Profile  Reply with Quote
I agree that the dash cover on that All American RE does look pretty sweet. If only it had a "normal" sytle instrument cluster, it'd be all set.

The bus you linked to is an All American, and the bus I linked to is a TC/2000. Blue Bird used that instrument cluster on all of it's transit buses during the 1999-2000 area.



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IC-RE
Top Member

USA
4117 Posts

Posted - 02/18/2007 :  8:38:59 PM  Show Profile  Visit IC-RE's Homepage  Reply with Quote
Ahh, ok thanks, yeah I edited my previous post because I read your's closer. That dash seems like ones of the more easier to read ones, however I do like the white-face gauges on the IC transits, they are easy too.

How are the gauges on the newer BBs are they just as easy?

bus 1980, a 2008 IC RE 300 for Fairfax County Public Schools, Fairfax, Virginia.
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Buskid
Top Member

USA
3368 Posts

Posted - 02/18/2007 :  8:41:31 PM  Show Profile  Visit Buskid's Homepage  Reply with Quote
quote:
Originally posted by Richard

If only it had a "normal" sytle instrument cluster, it'd be all set.

All of our 2000 Blue Bird All American REs had that setup, and I never cared for that multifunction "gauge."
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IC-RE
Top Member

USA
4117 Posts

Posted - 02/18/2007 :  8:44:57 PM  Show Profile  Visit IC-RE's Homepage  Reply with Quote
How did it work? Did you push a button to change it's function? Do you have any closer pictures?

bus 1980, a 2008 IC RE 300 for Fairfax County Public Schools, Fairfax, Virginia.
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B. Busguy33
Top Member

USA
3444 Posts

Posted - 02/18/2007 :  8:51:21 PM  Show Profile  Visit B. Busguy33's Homepage  Send B. Busguy33 an AOL message  Send B. Busguy33 a Yahoo! Message  Reply with Quote
Personally, I hate that dashboard/gauge design. Probably one of the worst set-ups I've seen and have had to deal with. International/IC by far has the best dashboard/gauge design, in my opinion. Freightliner is a close second.

Anyway, when you start the bus, the "multi-function" gauge would run thru all the various readings for fuel, battery, oil, and engine temperature. After that, it would just read fuel. There was a momentary switch you would have to press to the right of the gauges to check your battery, oil, and engine temperature. Each time you hit the switch, it would beep and show a different reading for a different function. I drove a '99 TC/2000 FE with this set-up, and ran into several occasions where the switch did not work.

I prefer the GM dashboard they were using on their transits from 1994-1998. That was a nice set-up.
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Kodie
Top Member

United States
1995 Posts

Posted - 02/18/2007 :  11:24:37 PM  Show Profile  Reply with Quote
The bus I rode in 6th 7th and 8th grade had that set up. There is a button by the ignition that you press for each function. Personally I like that setup better than the pre 1998 models. Hope nobody finds that offensive if you know what I am refering to....Richard.
quote:
Originally posted by IC-RE

How did it work? Did you push a button to change it's function? Do you have any closer pictures?


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Thomas Ford 85-16
Top Member

USA
4170 Posts

Posted - 02/19/2007 :  06:00:45 AM  Show Profile  Visit Thomas Ford 85-16's Homepage  Send Thomas Ford 85-16 an AOL message  Reply with Quote
I'm glad you posted this. I have many brochures showing this dash and the wood-grain side panelling, but never knew if it made it to production.

I agree, the multifunction gauge is a pain! I leave it on oil pressure if I find myself using that cluster.
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CPCSC_TD
Top Member

USA
657 Posts

Posted - 02/19/2007 :  07:09:46 AM  Show Profile  Reply with Quote
Our AA from 1999 had them. From the driver stand point, the gauges are hard to see and read. We have had to replace them on every unit for electrical failure. The newer dash is much more respted by the drivers and easier to see. The angle of the new dash has a lot to d with this also. I prefer the newer style much more also. The older unit as pictured doesn't use needles also, it uses a bar type set-up- the bars light up as system grows (fuel, air pressure, etc...) so for many, that's confusing.

My vote is for the newer set-up.

My favorite dash of all times was on the thomas re engine from mid 90's. It wa s ahuge change when it came out- the wrap around style, looked sleek, was fresh looking. I do like the HDX set-up too.

I still think for gauges though, IC wins hats off with the white faced gauges. Those have been the easiet for me to read during the day and at night.

Now, if someone did blue, that would be the cats meow.
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Buskid
Top Member

USA
3368 Posts

Posted - 02/19/2007 :  08:30:48 AM  Show Profile  Visit Buskid's Homepage  Reply with Quote
quote:
Originally posted by Thomas Ford 85-16

I'm glad you posted this. I have many brochures showing this dash and the wood-grain side panelling, but never knew if it made it to production.

Oh, yeah. We had the wood-grain option. To me, it looked corny.
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CPCSC_TD
Top Member

USA
657 Posts

Posted - 02/19/2007 :  08:36:16 AM  Show Profile  Reply with Quote
I think they did the wood grain panel to match the optional wood grain siding which looked wonderful with the brown floor and brown seats. Such a popular option that was only 20 years outdated. I think these were parts from the old Caravans and LTD's that were in junkyards.
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IC-RE
Top Member

USA
4117 Posts

Posted - 02/19/2007 :  09:37:00 AM  Show Profile  Visit IC-RE's Homepage  Reply with Quote
This is an interesting topic! Thanks very much to all those who responded!

bus 1980, a 2008 IC RE 300 for Fairfax County Public Schools, Fairfax, Virginia.
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dem84skeeprollinup
Top Member

USA
888 Posts

Posted - 02/20/2007 :  09:57:47 AM  Show Profile  Click to see dem84skeeprollinup's MSN Messenger address  Reply with Quote
They have some nice buses over there. I found this 999 tc2000 re in there.

http://www.buscrazy.net/upload/5392.htm

Do the world a favor and bring back GMC and Ford conventional chassis......

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ILoveBlueBirdTC2000
Active Member

USA
30 Posts

Posted - 04/09/2011 :  5:22:21 PM  Show Profile  Click to see ILoveBlueBirdTC2000's MSN Messenger address  Reply with Quote
I find the 1999 Blue Bird TC2000 dash a piece of crap, because you have to push a button and it shows you certain nesseties. I LOVED the GM dash they used in the 1994-1998 TC2000's, i could see all of the guages at once, I loved that! I drive a 1996 Blue Bird TC2000 and i love that dash on it!!! Its sweet!!
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08 Thomas EF
Top Member

530 Posts

Posted - 04/09/2011 :  7:06:01 PM  Show Profile  Visit 08 Thomas EF's Homepage  Reply with Quote
Our #25, an '00 TC, had its gauge cluster custom-built by our mechanic at some point last calendar year because parts were unavailable because the original manufacturer went out of business. I'd love to see how that turned out, if it came out any differently than it was originally. Too bad it sprang a severe oil leak and we have no intention of fixing it; the bus is OOS until retirement unless something else tragic happens and there's a bus crisis.

I think that the early 2000s TCs/All Americans had the most aesthetically-pleasing dash/gauges/control panels out there.

http://schoolbuscentral.com/gallery/updates/dec05/bb/06_01tcfe_ma.htm

Although those gauges do look a bit small. I guess they decided to solve that issue for All Americans in 2006. Here's a 2007:

http://schoolbuscentral.com/gallery/updates/jul06/1_07aafe_ny.htm

Edited by - 08 Thomas EF on 04/09/2011 7:12:42 PM
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"Bus Man"
New Member

USA
0 Posts

Posted - 04/15/2011 :  10:36:38 AM  Show Profile  Reply with Quote
I used to be an engineer at Blue Bird and loved every minute before the sale to Henley's. Here is some information that can help you to retrofit the ol' cluster we have come to love. If you have a cluster that is still functioning, I can assist you to keep it that way. I have a few tricks that can save you from having a major headache! Use the word "Ohms" in place of some the boxes.

If you like this kind of stuff please let me know. I'll find a place to post such items where they can be utilized in their entirety.



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) ±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




5. Electrical Interconnection
5.1. Connector
Packard makes the cluster connector. The connector part number is given in the mechanical section. 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.


5.1.1. Electrical Pin-out Production

Pin No. Signal Pin
No. Signal
A1 Serial Data Transmit B1 Engine Retarder
A2 Brake Warning Telltale B2 Tachometer Input
A3 Fuel Filter Telltale B3 Engine Warning Out
A4 Service Engine Soon Telltale B4 Multi-function Gauge Button
A5 Engine Over-speed/Preheat TT B5 Fuel Sender
A6 Stop Engine Telltale B6 Speed Ground
A7 Low Coolant Telltale B7 Speed Signal
A8 Hydraulic Oil Temp. Telltale B8 Spare Telltale #1
A9 Ignition Power B9 Serial Data Receive
A10 Park Brake Telltale B10 Traction Control “ETC” Telltale
A11 Sander Refill Telltale B11 Illumination
A12 Antilock Brake Telltale B12 Dual Speed Differential
A13 DRL Out B13 Coolant Temperature Sender
A14 Stop Light Telltale B14 Oil Pressure Sender
A15 S-Ground B15 Power Ground
A16 Right Turn Telltale B16 Engine Maint. “Service” Telltale
A17 Left Turn Telltale B17 Hi Beam Telltale





5.1.2. Electrical Pin-out Service

Pin Number Function Connection
1 Serial Transmit Serial Transmit
2 Brake Light Brake Light
3 Low Air NC (internal)
4 Service Engine Soon SES
5 Engine Over Speed EOS
6 Blocked Blocked
7 Low Coolant Low Coolant
8 Intake Air NC
9 Ignition Ignition
10 Park Brake Park Brake
11 Sander Refill Sander Refill
12 Anti-lock Brake ABS
13 Park Brake Tied to 10
14 Stop Light Stop Light
15 Signal Ground S-Gnd
16 Right Turn Right Turn
17 Left Turn Left Turn
18 High Beam High Beam
19 Battery Light NC(internal)
20 Power Ground P-Gnd
21 Oil Pressure Gauge Oil
22 Coolant Temperature Gauge Temp
23 Blocked Blocked
24 Illumination Illumination
25 Illumination Ground P-Gnd
26 Engine Warning Out Engine Warning
27 Ignition Ignition
28 Speed Signal Speed
29 Speed Ground Speed Gnd
30 Fuel Gauge Fuel
31 Serial Data Receive Serial Receive
32 Ignition Ignition
33 Tachometer Tach
34 Blank NC

5.2. Electrical Characteristics

Condition minimum typical maximum
Operation Current From ignition circuit 0.5 amps 2 amps 2.75 amps
Operation Voltage 9 13.8 19
Operation Temperature -40 C* +70 C

*LCD will not operate below -20 C. At lower temperatures the cluster has 5 minutes to heat up the cluster enough to operate the LCD.
5.3. Input Signals
5.3.1. Overview

Input Signal Type Referenced to Switched to By Comment
Fuel Filter Telltale +12V Gnd External Switch
Brake Warning Telltale +12V Gnd External Switch
Service Engine Soon Telltale +12V Gnd External Switch
Engine Over-speed/Preheat Telltale +12V Gnd External Switch Powered by same input. Bulb placement selectable
Stop Engine Telltale +12V Gnd External Switch
Low Coolant Telltale +12V Gnd External Switch
Serial Receive TTL +5 Gnd Programming Adapter Serial Programming Input
Park Brake Telltale Above 3.75 (ON) and
Below 1.75 (ON) +12V

Gnd External Switch
Sander Refill Telltale +12V Gnd External Switch
Antilock Brake Telltale +12V Gnd ABS Electronics
Stop Light Telltale Gnd +12 External Switch
Right Turn Telltale Gnd +12 External Switch
Left Turn Telltale Gnd +12 External Switch
High Beam Telltale Gnd +12 External Switch
Engine Maint.
“Service” Telltale +12V Gnd Engine Electronics
Oil Pressure Gauge +12V Gnd Pressure Sender (resistive)
Coolant Temp Gauge +12V Gnd Temperature Sender (resistive)
Dual Speed Input +5V Gnd External Switch Electronic Overdrive
Illumination Voltage Gnd Headlamp Switch 5.5 volts required to operate LCD
Traction Control “ETC” Telltale +12V Gnd ABS Electronics
Hydraulic Oil Temp. Telltale +12V Gnd Electronic Switch
Spare #1 Telltale +12V Gnd External Switch spare
Speed Pulse Speed Gnd 400 mV +/- 12 External Frequency Speedometer
Speed Gnd
Fuel Gauge +12V Gnd Fuel Sender (resistive)
Multi-function Gauge Switch Momentary Switch +5V Gnd External Switch
Tachometer Pulse Gnd +/- Ign Alternator or engine ECU
Engine Retard Telltale +12V Gnd External Switch



5.3.2. Analog Inputs
5.3.2.1. Fuel Sender
The fuel signal is a resistance signal from the fuel sender. +12 volts excite the input across a voltage divider and the resultant voltage is routed to a 10 bit A/D.
5.3.2.2. Coolant Temperature
The water temperature signal is a resistance signal from the temperature sender. +12 volts excite the input across a voltage divider and the resultant voltage is routed to a 10 bit A/D.
5.3.2.3. Oil Pressure
The oil pressure signal is a resistance signal from the pressure sender. +12 volts excite the input across a voltage divider and the resultant voltage is routed to a 10 bit A/D.
5.3.2.4. Voltage
The ignition voltage is measured directly at the ignition power input of the cluster. The input is divided down to +12 volts maximum and routed to a 10 bit A/D.
5.3.3. Frequency Inputs
5.3.3.1. Speedometer Signal
The speedometer signal input is extracted from an inductive pickup on the transmission by a signal conditioning circuit.

Speedometer Signal Definition

pulses per mile 4,000 & 20,000-72000
input duty cycle 10 - 90 %
max. speed nmax = 80 mph
max. valid frequency fmax = 1600 Hz
Min. speed
(speedometer threshold) 3 mph
Min. frequency fmin = 3 Hz
Time-out threshold frequency ftime-out < 2 Hz
Upper limit detection threshold frequency fupper > 2000 Hz


5.3.3.2. Tachometer Signal
The tachometer signal input is extracted from the alternator or engine ECU by a signal conditioning circuit.

Tachometer Signal Definition

pulses per engine revolution 12-36
input duty cycle 10 - 90 %
max. engine speed nmax = 4500 rpm
max. frequency Fmax = 2700 Hz
min. engine speed
(engine on threshold) 300 rpm
min. frequency fmin = 100 Hz
time-out threshold frequency ftime-out < 80 Hz
upper limit detection threshold frequency fupper > 3000 Hz


5.4. Output Signals
5.4.1. Overview

Pin Input Signal Type Referenced to By Comment
3 Serial Transmit TTL Gnd Serial Programming Input
13 DRL Output Open Collector Gnd Tachometer Signal On 500 mA
32 Engine Warning Output Open Collector Gnd High Coolant Temp or
Low Oil Pressure 50 mA
6. Mechanical Interface
6.1. Cluster - Exploded View (to show basic construction, not details)

6.2. Outline
The cluster outline is shown in the customer interface drawing (VDO 1 911 22T 004 Sheets 1-3).
6.3. Mounting
The cluster mounts on four mounting tabs. Locations of the mounting tabs are shown in the customer interface drawing.
6.4. Connection
The electrical connection to the cluster is to a straight, board mounted connector that faces back out of the cluster. The connector is a Packard Micro-Pack, part number 1205 2419 Connector. The mating harness connector part number is 1206 5803.
6.5. Assembly
The cluster is assembled back to front with screws and consists of the following parts:


• Air Box Assembly
• Back Housing
• PC Board
• Telltale Chimney
• Light Conductor
• Dial
• Pointers
• Mask
• Lens
6.5.1. Air Box Assembly
The air box assembly is glass filled nylon and contains the interface from the vehicle air system to the main cluster electronics.
6.5.2. Back Housing
The back housing is 40% talc filled polypropylene.
6.5.3. PC Board
The PC Board is double sided FR-4 with both surface mount and through hole components.
6.5.4. Telltale Chimney
The telltale chimney is white 40% talc filled polypropylene and channels the telltale illumination to the correct spot on the dial.
6.5.5. Light Conductor
The light conductor is made of acrylic plastic and distributes light to the dial and pointers.
6.5.6. Dial
The dial is 0.5mm thick polycarbonate sheet stock with 12 printed passes:

• Black definition
• Black pinhole
• Dead Front
• White Graphic
• Blue (for night lighting color)
• Red Warning Bands and Telltales
• Green telltale
• Amber telltale
• Blue telltale
• White reflective
• Protective (scratch resistance) coating
• Selective adhesive

Dial to be in accordance with Blue Bird approved artwork.

6.5.7. Pointers
The pointers will be backlit with a polycarbonate arm and a polycarbonate hub. The pointers are two different sizes for the major and minor gauges. Pointers to be approved by Blue Bird.
6.5.8. Mask
The mask comes in both Gray and Black and is made of ABS plastic.
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bus63
Active Member

USA
20 Posts

Posted - 04/19/2011 :  04:23:42 AM  Show Profile  Reply with Quote
Does anyone know where to get an replacement or repair on this cluster? took mine out to replace bulbs and tach and fuel gauge not working properly when installed. Thanks, Kurt
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matts4290
Advanced Member

220 Posts

Posted - 04/19/2011 :  2:10:58 PM  Show Profile  Visit matts4290's Homepage  Reply with Quote
I contemplated this too when I was driving a TC with gauges like this. The multifunction no longer works, and the fuel gauge is always wrong. If it were up to me, I would probably just rip the whole thing out and put a piece of diamond plate in with some standard electronic gauges like my 90' TC. I'm not quite sure about the speedometer; to just use a mechanical one and be done, or to try and find one that works electronically.

Hey "Bus Man", Do you have an e-mail to get a hold of you?

We can't all be conventional!
http://www.youtube.com/user/matts4290

Edited by - matts4290 on 04/19/2011 2:22:06 PM
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bus63
Active Member

USA
20 Posts

Posted - 04/20/2011 :  09:16:39 AM  Show Profile  Reply with Quote
There is a place in N.Y called United Radio (315-446-5570)that repairs these clusters.....
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80 grit
Active Member

United States
47 Posts

Posted - 04/21/2011 :  08:57:21 AM  Show Profile  Reply with Quote
We have 2 '99s with that cluster, they are problematic. We got nailed by the CHP for the low air warning coming on at too low of pressure. I showed the officer that if you release the air slowly, it would alarm at 61 psi. 60 min. in our state.The problem is when the air is released quickly, the cluster is so slow to react that the air pressure would be around 50 before it would alarm. BB/VDO should be forced to replace these with something that works reliably.
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bus63
Active Member

USA
20 Posts

Posted - 04/28/2011 :  04:50:25 AM  Show Profile  Reply with Quote
I just got my cluster back from United Radio. They had it less than a week. My total was $155 and that included return postage. I did not drive the bus yet but all the gauges seem to be working properly and they also replaced the bulbs. So far I am "happy camper" with repair.
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