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Old 01-04-2010, 14:53   #1 (permalink)
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Default CUCV-Instrument Cluster Decoded

I was troubleshooting my instrument cluster and the TM are good but not very user friendly.

CUCV Instrument Cluster Repair

I compiled the following and thought I would share.

Make sure you read the DIAGRAM.TXT file at the bottom. It is a listing of all the wires, colors and pin numbers for both the diagrams and the cluster/wiring harness.
http://www.steelsoldiers.com/attachm...ed-diagram.txt

The wiring diagrams are located in Appendix F of the -20 Tech Manual.

***EDIT*** I added another picture, one with the fuse colors.

Without "opening" the pictures - If you right click on the picture and open it in a "Open Link in New Window" they are more readable.
Attached Images
File Type: jpg Cluster 003.jpg (80.0 KB, 376 views)
File Type: jpg Cluster 003a.jpg (80.0 KB, 372 views)
File Type: jpg Cluster 005.jpg (70.4 KB, 297 views)
File Type: jpg Cluster 005a.jpg (67.0 KB, 270 views)
File Type: jpg Cluster 006.jpg (76.1 KB, 281 views)
File Type: jpg DSC01909.jpg (45.1 KB, 313 views)
File Type: jpg DSC01910.jpg (38.5 KB, 333 views)
File Type: jpg CUCV Fuse block.jpg (32.2 KB, 414 views)
File Type: jpg Fuse Colors.jpg (35.4 KB, 3 views)
Attached Files
File Type: txt Diagram.txt (3.3 KB, 301 views)
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Last edited by Warthog; Yesterday at 18:23.
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Old 01-04-2010, 16:06   #2 (permalink)
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I appreciate the excellent info, particularly the "open in a new window" suggestion.

Bought a M1009 in October. It has several instrument panel problems. The work I've done so far leads me to believe dirty contacts may be the root cause at least some. e.g. idiot light not working - remove the bulb - check bulb continuity - is OK - plug bulb back in - bulb now works.

Voltmeter was dead - removed the gage - checked resistor - was OK - reinstalled voltmeter - started engine & voltmeter worked - shut it down but on next start the voltmeter was dead again.

Think I'll grind down an old ignition point file narrow enough to fit the female side of the pigtail connector female side and file them a bit. They're all kinda grungy.

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Old 01-04-2010, 16:11   #3 (permalink)
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Good info. A pencil eraser works good for cleaning contacts.
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Old 01-04-2010, 17:15   #4 (permalink)
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The pencil is a great tip ,also I like to use a product by permatex called Dielectric Grease... this will provide a better contact and keep the contacts from messing up again,,,,,
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Old 01-04-2010, 19:30   #5 (permalink)
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I use dielectric grease on trailer pigtails. Sheesh....never thought of using it elsewhere.

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Old 01-04-2010, 19:44   #6 (permalink)
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Warthog that text file is invaluable (and time saving). It just so happens that I have my dash on the kitchen table too! I was thinking about moving my GEN1 and GEN2 lights and was about to figure out the color scheme of the wires...thanks for saving me the time.

If you need those "button" sockets for the lights they are NAPA part # LS6501. I replaced one missing and one chewed up socket. I'm sure you already new the bulbs are 168 style (194's will work too).

Some rubbing compound buffed out most of the scratches out of the lens cover.

I also painted the front of the green instrument / printed circuit mounting panel gloss white to help reflect more light:

Krylon: Products: Fusion for PlasticŪ

While it was out I also scrubbed 25 years of grime off the outer bezel and painted it with Dupli-Color TP70 Trim Paint. It turned out awesome...not too shiny...not too flat...more of a satin:

Trim Paint

I replaced my ratty old voltmeter with a nice VDO. Just remember the 330 ohm resistor, in line with the positive, to knock down the voltage.

Among missing and incorrect fuses and blowing off dust and dirt it has turned into a real project. Thanks again for sharing the info!

Last edited by panama; 01-04-2010 at 21:09.
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Old 01-05-2010, 01:19   #7 (permalink)
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Can somebody tell me how to save the pic of the fuse block diagram? When i save it as normal it wont enlarge to view it... all pixels. I want to print one to put in the glove box.
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Old 01-05-2010, 02:30   #8 (permalink)
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Did you try 'right click- open in new window', then on image in new window 'right click - save as'..? Just worked for me, hope that helps.

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Old 01-05-2010, 09:57   #9 (permalink)
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Quote:
Originally Posted by Rustmaster View Post
Can somebody tell me how to save the pic of the fuse block diagram? When i save it as normal it wont enlarge to view it... all pixels. I want to print one to put in the glove box.

The diagram came from the TM 9-2320-289-20 manual. Chapter 4-12, Page 4-13 if you can't get it to save.
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Old 06-04-2010, 14:18   #10 (permalink)
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Panama, I would love to see a pic of the difference if you could.
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