Ametek PST-2000 User manual

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: [phone]
Phone: [phone]
Toll-Free: [phone]
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 [phone].
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.
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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.
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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).
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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.
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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.
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