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MY09 Bluebird Corporate Cluster Service Manual

By Date ACTIA Ref. Revision

Written S Myers 2.9.09 BBCC

Reviewed Service Manual 111725 3
Approved
© 2009 Any reproduction of this document whether total or Page 1 Format
partial without the written consent of ACTIA is forbidden.
US Letter

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Revision Table
Rev By Date Software Description

- P English 2.6.09 1110940v00_00 Original Draft; for internal review

0 S Myers 2.9.09 1110940v00_00 Original Draft; Out for comment

1 S Myers 2.9.09 1110940v00_00 Section 3.2—Added Seatbelt Logic Config as it was missed in rev 0

2 Added document part number to header

3 S Myers 4.3.09 1110940v02_00 Updated grammatical errors throughout document per customer markups.

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Table of Content

1. CLUSTER OVERVIEW ......................................................................................................................................... 5

2. BUTTONS ............................................................................................................................................................. 5

3. DISPLAY ............................................................................................................................................................... 6
3.1. DRIVE MODE ......................................................................................................................................................... 6
3.1.1. Quadrant 1 .................................................................................................................................................. 7
3.1.2. Quadrant 2 .................................................................................................................................................. 7
3.1.3. Quadrant 3 .................................................................................................................................................. 8
3.1.4. Quadrant 4 .................................................................................................................................................. 8
3.1.5. Drive Mode Navigation................................................................................................................................ 8
3.1.6. Priority Messages...................................................................................................................................... 10
3.2. CONFIGURATION MODE ....................................................................................................................................... 13
3.2.1. Buzzer Time out Enable............................................................................................................................ 13
3.2.2. Test Panel ................................................................................................................................................. 13
3.2.3. Turn Signal Click ....................................................................................................................................... 13
3.2.4. Brake System Type................................................................................................................................... 13
3.2.5. Bus Configuration Type ............................................................................................................................ 14
3.2.6. Engine Configuration Type ....................................................................................................................... 14
3.2.7. Self Test .................................................................................................................................................... 14
3.2.8. Battery Controlled Lift................................................................................................................................ 14
3.2.9. Seatbelt Logic ........................................................................................................................................... 14
3.2.10. Configuration Mode Navigation............................................................................................................... 14
3.3. DIAGNOSTICS AND SETTING MODE ....................................................................................................................... 16
3.3.1. Air Brake PSI............................................................................................................................................. 16
3.3.2. Set Units.................................................................................................................................................... 16
3.3.3. Contrast..................................................................................................................................................... 16
3.3.4. Dimmer...................................................................................................................................................... 16
3.3.5. Backlight color........................................................................................................................................... 16
3.3.6. Set Clock ................................................................................................................................................... 16
3.3.7. Instrument Diagnostics.............................................................................................................................. 17
3.3.8. Data Link ................................................................................................................................................... 17
3.3.9. Read Parameters ...................................................................................................................................... 17
3.3.10. Engine Diagnostic ................................................................................................................................... 17
3.3.11. Trans Diagnostic ..................................................................................................................................... 18
3.3.12. ABS Diagnostic ....................................................................................................................................... 18
3.3.13. Diagnostics and Settings Navigation ...................................................................................................... 19

4. WARNING/INDICATORS.................................................................................................................................... 20

5. GAUGES ............................................................................................................................................................. 22
5.1. SPEEDOMETER ................................................................................................................................................... 22
5.2. TACHOMETER ..................................................................................................................................................... 22
5.3. COOLANT TEMP .................................................................................................................................................. 22
5.4. OIL PRESSURE .................................................................................................................................................... 23
5.5. FUEL LEVEL ........................................................................................................................................................ 23
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5.6. FRONT AIR (OPTIONAL) ....................................................................................................................................... 23

5.7. REAR AIR (OPTIONAL) ......................................................................................................................................... 23

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1. CLUSTER OVERVIEW

The BBCC can be configured to have up to 7 analog gauges and many warning or
indicator lights as well as several configurations of display information depending on what
application it is used in.

2. BUTTONS

The upper and lower buttons are used to access and navigate menus, acknowledge
warning alarms and displays, change display configuration options, etc.

Upper Button

Lower Button

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3. DISPLAY

3.1. Drive Mode

The drive mode screen is the default screen and has 4 basic variations. The
variation displayed is controlled by the options enabled on the vehicle through the
configuration menu (see Configuration Menu section for details).

Configured without Ammeter

Configured with Ammeter

Configured with Ammeter and Applied

Air

Configured with Ammeter and

Suspension Air

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3.1.1. QUADRANT 1
In this quadrant you can toggle between the odometer and 2 resettable trip
distances by pressing the lower button. When Trip 1 or Trip 2 is displayed they
can be reset by holding the upper button.

3.1.2. QUADRANT 2
You can only change the information in this quadrant from the configuration menu.
The current gear selected is always available in a PRNDL format in Quad 2A and
the system voltage level is always displayed in Quad 2B.

If the cluster is configured to display the Ammeter, it will share Quad 2B.

If the cluster is configured to display Applied Air, this will display in Quad 2C.

If the cluster is configured to display Suspension Air, this will display in Quad 2C
instead.

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3.1.3. QUADRANT 3
This area will be used to display one of several vehicle parameters which can be
toggled between using the buttons (see Navigation section). This information will
be temporarily replaced with Priority Interrupt Messages (PIM) if a system fault is
detected. Depending on the severity of the fault, these can be “acknowledged” by
pressing the lower button and they will cancel until the next ignition cycle.
3.1.4. QUADRANT 4
The clock is displayed here in either 12hr or 24hr format. These formats can be
toggled between using the buttons (see Navigation section).
3.1.5. DRIVE MODE NAVIGATION
Navigating from Quad to Quad can be done as detailed below. If no action is
taken for greater than 5 sec. any selection will timeout and return to normal display
functions.

If Park Brake is set with the headlights on, the buttons will convert to a dimmer
function for the cluster backlight. In this mode, you can still navigate from Quad to
Quad as normal after pressing both buttons.

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3.1.6. PRIORITY MESSAGES

These messages will temporarily replace any parameter displayed in Quad 3 until
the fault is removed or the PIM has been acknowledged with the lower button.

Display Example Function Trigger Logic

Engine Comm Engine communication not received for more then 1 second.
Fail

Trans Comm Fail Transmission communication not received for more then 1
second.

ABS Comm Fail ABS communication not received for more then 1 second.

Data Link No communication from device found on previous start ups

Warning

Vehicle Speed J1939 speed data is either N/A or in the error data range
Error

Engine Door Engine door input is reading Low

Open

Brake Interlock Logic satisfied and Brake Interlock is Active

Retarder Applied J1939 retarder spn is read as active

Alternator Fail RPM > 400 and VBAT < 12V for > 30 sec.

Stop Engine J1939 Red Stop Lamp is active

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Low Coolant Level J1939 is sending DM1 SPN 111_FMI 1, 11 or 18

Hi Trans Temp J1939 is sending DM1 SPN 177_FMI 15

Display Example Function Trigger Logic

Low Oil Pressure J1939 is sending DM1 SPN 100_FMI 1, 11 or 18

Hi Engine Temp J1939 is sending DM1 SPN 110_FMI 0, 11 or 16

Engine Warning J1939 is sending Amber Warning Lamp

Lift Not Stowed Lift stowed input is Low

Battery Voltage On ≤ 11.0V for > 30 sec (then off at 12.1V)

Error On ≥ 15.5V (then off at 15.3V)

Turn Signal When vehicle travels 1 mile with either turn signal on but not
Warning both

Water in Fuel J1939 Water in fuel message is active

Headlight Alert Ignition is OFF and Headlights input is active

ATC J1939 Traction Control message is active

DPF J1939 DPF message is:

000 = OFF
001 = ON
100 = Fast blink
Hi Exhaust Temp J1939 HET message is:
000 = OFF
001 = ON
100 = Fast blink

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Range Inhibit J1939 range inhibit message is active

Trans Oil Life J1939 is sending DM1 SPN 4177_FMI 17

Trans Oil Filter J1939 is sending DM1 SPN 3359_FMI 31

Display Example Function Trigger Logic

Trans Oil Service J1939 is sending DM1 SPN 4178_FMI 31

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3.2. Configuration Mode

To enter configuration mode, the ignition must first be turned off. Hold both
buttons and turn the ignition switch to the on position. You will immediately enter
the configuration menu. Here you can modify certain cluster configurations and
only view others.

3.2.1. BUZZER TIME OUT ENABLE

When this configuration is ENABLED the continuous 1 audible alarm (Buzzer)
would be allowed to timeout in 15 sec if the engine speed is < 400 RPM. When
this configuration is DISABLED the continuous audible alarm will not time out.
3.2.2. TEST PANEL
When this configuration is ENABLED the cluster is set as a manufacturing tool for
the chassis test fixture and the software will ignore the internal configuration for
BRAKE SYS TYPE and APPLIED/SUSP AIR. It will instead receive this
configuration information from the optional input module binary inputs. When this
configuration is DISABLED the cluster is set as a normal production part and will
use the internal configuration to determine BRAKE SYS TYPE and the presence of
APPLIED or SUSPENSION AIR. This feature is displayed in this menu but can
only be changed using a VCI and ACTIA provided software.
3.2.3. TURN SIGNAL CLICK
When this configuration is ENABLED the turn signal will use the simulated relay
click audible sound. When this configuration is DISABLED there will be no sound
for turn signal.
Ammeter Display
When this configuration is ENABLED the Ammeter value is shown in the display
beside the Voltmeter. When this configuration is DISABLED only the Voltmeter is
shown.
3.2.4. BRAKE SYSTEM TYPE
When this configuration is set to AIR, the software is configured to use the Front
and Rear Air inputs to display the front and rear air pressure on the appropriate
gauges. When configured as HYD the software will not drive these gauges and will
use the Front Air input to determine Suspension Air Pressure. This setting will
also effect how the Brake Interlock PIM logic works.
Applied/Suspension Air
When this configuration is ENABLED the software is configured to display Applied
Front and Rear Air Pressure (for Air Brake System) or Suspension Air (for

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Hydraulic Brake System) depending on Brake System Type Configuration. When

Applied air and Suspension air are NOT displayed.
3.2.5. BUS CONFIGURATION TYPE
The cluster can be configured to be one of two products, BBD3 or BBCV. This
setting will effect the binary logic for Park Brake and Fast Idle inputs. They will be
as follows:
Input BBD3 BBCV
Park Brake AL AH
Fast Idle AH AL

3.2.6. ENGINE CONFIGURATION TYPE

This configuration is set by internal logic based on Engine ID’s broadcast on the
data bus. It is only displayed here and cannot be changed from this menu. This
will effect what messages are sent for Throttle Interlock and Fast Idle functions. It
may also effect what Parameters are available to display in Quad 3 on the LCD.
3.2.7. SELF TEST
When this configuration is ENABLED the cluster will perform a startup self test at
Ignition. When the configuration is DISABLED the cluster will not perform a
startup self test.
3.2.8. BATTERY CONTROLLED LIFT
When this configuration is enabled it affects the logic of several of the outputs.
Seatbelt Logic When this configuration is ENABLED the Seatbelt Logic for the
alarm and lamp will adjust. If it is DISABLED no alarm or lamp will be triggered.
When disabled, if the seatbelt input is pulled low, this will automatically enable the
configuration.
3.2.9. SEATBELT LOGIC
When this configuration is ENABLED the Seatbelt Logic for the alarm and lamp
detailed in section 5.4.1 will apply. If it is DISABLED this logic will not apply. No
alarm or lamp will be triggered if this is the case. When disabled, if the seatbelt
input is pulled low, this will automatically enable the configuration.
3.2.10. CONFIGURATION MODE NAVIGATION
Follow the button labels on the display and the instructions on the bottom line for
navigation and configuration changes. The menu flow is shown below.

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3.3. Diagnostics and Setting Mode

Access this menu by setting the park brake and then from the Drive Mode Screen
hold the lower button for >5 seconds. This menu allows the user to change
settings from their default value and to use self diagnostic tools to trouble shoot
the system.
3.3.1. AIR BRAKE PSI
This is used to perform Pre-trip Brake Inspections. It will show Front and Rear
brake system PSI.
3.3.2. SET UNITS
The units for the values that are to be displayed can be changed between Metric
or English units. This will change the Speedo reading and KMH/MPH lamp,
display/menu items except Air which will always be displayed as PSI, and change
which brake system fail lamp is used.
3.3.3. CONTRAST
To make the display contrast Higher or Lower press the associated button
repeatedly to change this.
3.3.4. DIMMER
To make the display backlight darker or lighter press the associated button
repeatedly to change this.
3.3.5. BACKLIGHT COLOR
The cluster has several preset backlight colors to choose from. Highlight the color
you want and press both buttons to save.
3.3.6. SET CLOCK
To set the time for the display clock, press both buttons to select “hours”.
Subsequent presses of both the buttons will select minutes and the AM / PM
selections. Once any selection is highlighted, then the lower buttons will decrease
the setting and the upper button will increment the setting. Once all three
selections have been selected this menu will timeout to the previous menu after 15
seconds unless the operator enters back into any of the selections.

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3.3.7. INSTRUMENT DIAGNOSTICS

This menu will give access to the self diagnostic tools. These are described here.

Gauge Test
Each gauge will be driven through three positions pausing at each position as
shown in the LCD as a percentage of scale. Pressing the lower button (Exit) will
end the test and return to the previous menu.

Lamp Test
Each warning lamp on then off displaying the lamp name and status in the LCD.
Pressing the lower button (Exit) will end the test and return to the previous menu.

LCD Test
Displays the Bluebird logo in normal and reverse video three times and then return
to the previous menu. Pressing the lower button will end the test and return to the
previous menu.

I/O Status
Displays the module-pin number, and the status as received by the vehicle’s
electrical system. Scroll through all the status screen by screen using the up and
down arrows. Press both buttons to exit to the previous screen. The value “high”
and “low” refers to the voltage level at the connector pin for binary inputs. Warning
bank information will only be shown if warning bank is detected on the LIN data
bus. This information will be continuously updated to assist in troubleshooting
3.3.8. DATA LINK
The LIN communication will be checked at power up and each device found on
that data bus would be displayed here. If the device is saved automatically in this
list and is disconnected from the system a warning will be displayed. You can
delete the device from this list to avoid this warning by scrolling to the device in the
list and pressing both buttons.
3.3.9. READ PARAMETERS
Displays all of the converted values for the applications parameters in a table form
for vehicle troubleshooting. You can scroll though to view them and press both
buttons to exit to the previous screen.

3.3.10. ENGINE DIAGNOSTIC

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Displays engine DTC’s in a format dependant on engine type. Engine type and
number of active DTC’s is located in upper right corner. Press both buttons to exit
to previous screen.
3.3.11. TRANS DIAGNOSTIC
This screen displays J2012 DTC Display as received from the transmission for
active faults via J1939. Transmission type and number of active DTC’s is located
in upper right corner. Press both buttons to exit to previous screen.

3.3.12. ABS DIAGNOSTIC

This screen displays the Suspect Parameter Number (SPN) and Failure mode
Identifier (FMI) as received from the ABS for active faults via J1939. Brake system
type and number of active DTC’s is located in upper right corner. Press both
buttons to exit to previous screen.

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3.3.13. DIAGNOSTICS AND SETTINGS NAVIGATION

The diagnostics and settings menu has button labels and bottom line instructions
to guide you through the submenus. See below.

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4. WARNING/INDICATORS

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5. GAUGES

5.1. Speedometer
The Speedo functions as a Metric and English unit display by virtue of software
configuration and automatically will scale itself accordingly. The MPH/KMH lamp
shows current unit scaling.

5.2. Tachometer
The tachometer reading is multiplied by 1000 RPM.

5.3. Coolant Temp

The Coolant temp displays the range of engine coolant temperature.

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5.4. Oil Pressure

The Oil Pressure gauge displays the range of engine oil pressure.

5.5. Fuel Level

The Fuel Level Gauge displays the percentage of fuel in the tank.

5.6. Front Air (Optional)

The Front Air Gauge displays the Front Air system Pressure with indicators and 60
psi for Low Air and 120 psi for compressor cutoff.

5.7. Rear Air (Optional)

The Rear Air Gauge displays the Rear Air system Pressure with indicators and 60
psi for Low Air and 120 psi for compressor cutoff.

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