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Service ManualTrucks

Group 381–500

InstrumentationVN (from 3/99),

VHD

PV776-TSP139790

Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to August 2000.

The products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair methods.When this is believed to have a significant bearing on this manual, supplementary ser-vice bulletins will be issued to cover the changes.

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave the vehicle or component function in the manner intended.

Caution: Indicates an unsafe practice where damage to the product could occur.

Warning: Indicates an unsafe practice where personal injury or severe damage to theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP139790

© 2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral ........................................................................ 3

Basic Description ....................................................... 3

Specifications ............................................................. 7Connector Pinouts ...................................................... 7

Connector Pinouts, Left Module .............................. 7Connector Pinouts, Center Module .......................... 9Connector Pinouts, Right Module .......................... 11

Tools .......................................................................... 13Special Tools ............................................................ 13Special Equipment ................................................... 15

Design and Function ................................................ 17Instrument Cluster ...................................................... 17

Communication ......................................................... 19Left Instrument Cluster Module (MID 234) .............. 23

Pyrometer ............................................................... 24Engine oil pressure gauge ..................................... 24Engine coolant temperature gauge ........................ 25Turbo boost (intake manifold) pressure gauge ...... 25Telltale bulbs, left section ....................................... 25Graphic Display ...................................................... 26Left CPU Board ...................................................... 27

Center Instrument Cluster Module (MID140) ........... 28Center Module ECU (MID 140) ............................. 29Tachometer ............................................................. 29Speedometer .......................................................... 30Odometer ............................................................... 30Telltale bulbs, center section .................................. 31Master Warning telltale .......................................... 31

Right Instrument Cluster Module ............................. 32Forward rear axle temperature gauge ................... 33Rear rear axle temperature gauge ........................ 33Fuel level gauge ..................................................... 33Application air pressure gauge .............................. 34Air suspension pressure gauge ............................. 34Front brake air pressure gauge ............................. 35Rear brake air pressure gauge .............................. 35Telltale bulbs, right section ..................................... 35

Graphic Display ........................................................ 36Graphic Display Layout .......................................... 36Graphic Display Symbols ....................................... 37

Graphic Display Control Buttons .............................. 38Using the Graphic Display Menus ........................... 38

Selecting a Menu ................................................... 38Changing Settings .................................................. 38Password Information ............................................. 39

Graphic Display Operation ....................................... 40Instrument Cluster Operation at Start-up ................. 40Graphic Display Menus, Driving Mode .................... 41Main Menu: Gauge (available while driving) ............ 42Main Menu: Fuel Economy (available while driving) 45Main Menu: Time/Distance (available when driving) 47Main Menu: FAULTS? (available while driving) ........ 49

Graphic Display Menus, Non-Driving Mode ............. 56Main Menu: Time/Distance (non-driving) ................. 57Main Menu: Set-up mode (non-driving) ................... 59Main Menu: System Diagnostic (non-driving) .......... 68Main Menu: Data Log mode (with Volvo enginesonly) (non-driving) .................................................... 81Main Menu: Password Input (non-driving) ............... 86

Troubleshooting ........................................................ 87Instrumentation Troubleshooting ................................ 87

General Work Practices ........................................... 88Instrument Cluster Diagnostic Tests ........................ 89

Instrument Cluster Self Test .................................. 89Instrument Cluster Tests with VCADS Pro ............ 90

Warning and Telltale Lamps, Troubleshooting ......... 92Instrument Cluster Self Test .................................. 92Instrument Cluster Tests using VCADS Pro .......... 92Troubleshooting ...................................................... 93LED Indicator Lamps ............................................. 93Telltale Lamps ........................................................ 96

Instrument Cluster Backlighting, Troubleshooting .. 106Graphic Display and Odometer, Troubleshooting .. 111

Instrument Cluster Self Test ................................ 111Instrument Cluster Tests using VCADS Pro ........ 111Troubleshooting, Odometer .................................. 112Troubleshooting, Graphic Display ........................ 114

Gauges, Troubleshooting ....................................... 115Instrument Cluster Self Test ................................ 115Gauge Tests, Accuracy and Calibration usingVCADS Pro .......................................................... 116Gauge Reaction to Short or Open Circuits ......... 116Intermittent Faults ................................................ 116Left Module Gauges ............................................. 117Center Module Gauges ........................................ 120Right Module Gauges .......................................... 122

Graphic Display Control Buttons, Troubleshooting 128Buzzer, Troubleshooting ......................................... 130Common Problems ................................................. 132

Service Procedures ................................................ 133Service Procedures .................................................. 133

General Work Practices ......................................... 133Housing and Front Panel Glass, Cleaning ............. 135Connector Terminals, Adding or Replacing ........... 135Bulb, Replacement ................................................. 137Instrument Cluster, Replacement ........................... 139Left Gauge Module, Replacement ......................... 141Center Module, Replacement ................................ 143Right Module, Replacement ................................... 145Air Gauge, Replacement ........................................ 148Graphic Display, Replacement ............................... 150Instrument Cluster Housing/Glass, Replacement .. 153Left CPU Board, Replacement .............................. 156Instrument Cluster Rear Cover, Replacement (Leftor Right) ................................................................. 159

1

Instrument Cluster, Programming .......................... 161Odometer, Programming ........................................ 162

Feedback

Operation Numbers

2

Group 38 Instrumentation, VN / VHD General

GeneralBasic Description

W3004310

About This ManualThis service manual describes the VN/VHD instrumentcluster which went into production in March 1999. Thiscluster is easily distinguished from earlier models by thetelltale lamps on the left side:

• Earlier models have ENGINE FLUIDS, CAUTIONand STOP telltales whereas this model has Preheat,INFO and STOP telltales. (The function of the EN-GINE FLUIDS telltale has transferred to the STOPtelltale.)

In September 2000 the instrument cluster was updatedwith 5 new telltale lamps on the right side:

• Earlier models had only a Traction Control telltalelamp on the right side where as this model has alsoTRANS OIL TEMP, TRANS MALFUNCTION, WAITSTART ENGINE1, and WATER IN FUEL1 telltalelamps.

This Service Information provides information about howto operate the instrument cluster’s display, as well aswhich information can be obtained via the display. It alsogives information about the function, troubleshooting andservicing of the instrument cluster’s other parts such asgauges and lamps.

For information about the vehicle’s Electronic ControlUnits, wiring diagrams, sensors and other components,please refer to the service information or electricalschematics for those components.

The instrument cluster is available in 7 configurations,with either an mph or km/h speedometer (see “AvailableConfigurations” page 4).

To find your way easily among the information that isavailable in the graphic display, it is recommended thatyou first read all the sections from “Communication”page 19 to “Information Messages” page 27. Thesesections describe the display’s function and operation,as well as how the instrument cluster communicates withthe vehicle electronic system.

In the section “Graphic Display Operation” page 40, thefollowing main headings can be found:

• “Instrument Cluster Operation at Start-up” page 40• “Graphic Display Menus, Driving Mode” page 41• “Graphic Display Menus, Non-Driving Mode” page 56

The main headings begin by listing the main menus. Thesub-menus and functions are then explained.

If the vehicle is in motion, use the display controlscarefully. Do not lose road concentration. Be familiarwith operation of the controls. Shifting concentrationto operating the controls can lead to losing control ofthe vehicle and may result in serious personal injuryor death.

1Not applicable to all models.

3


Available Configurations

T3009001

4


Available Configurations (contd.)

T3009002

5


Available Configurations (contd.)

T3009303

6

Group 38 Instrumentation, VN / VHD Specifications

SpecificationsConnector Pinouts

Connector Pinouts, Left ModuleThe left module has two connectors placed on the backof the instrument cluster.

Left module, LX connector

Pin Circuit Description

1 400-B SAE J1587/1708 data link (+)

2 183 Fuel level input from sensor

3 CJ1 Fuel level signal to gauge

4 219A Display control switch (ESCAPE)

5 NC

6 219B Display control switch (DOWN)

7 219D Display control switch (SELECT)

8 Sensor ground left

9 0XC-A Electronics ground

10 202-A Battery power supply, left module

11 401-B SAE J1587/1708 data link (-)

12 0P-A Ground, left module

13 NC

14 NC

15 NC

16 219C Display control switch (UP)

17 NC

18 CJ2 Center module wake up function

19 VSP Boot

20 141-G Backlighting, left module

21 219 Reference voltage for stalk switch

22 180-A Power supply (ignition feed), leftmodule

Pins marked NC (Not Connected) are not used.

W3003558

7


Left module, LY connector


1 199 Air filter restriction

2 NC

3 CJ3 Bulb test (+)

4 CJ4 Bulb test (-)

5 14 Battery charging

6 575 Red lamp, left module (STOP)

7 Cab tilt lock

8 NC

9 NC

10 576 Yellow lamp, left module (INFO)

11 Engine preheat sense

12 NC

13 191 Pyrometer (+)

14 NC

15 NC

16 469 Rear rear axle temp input fromsensor

17 Power take off

18 774-B Traction Control in off-road mode

19 Bootstrap enable

20 Trailer w/o ABS

21 CJ6 Rear rear axle temp output togauge

22 NC

23 387A Washer fluid level

24 CJ5 Forward rear axle temp output togauge

25 Remote display

26 Outdoor temp

27 NC

28 314 Transmission oil temp sensor

29 468 Forward rear axle temp input fromsensor

30 190 Pyrometer (-)


W3003558

8


Connector Pinouts, Center ModuleThe center module has two connectors placed on theback of the instrument cluster.

Center module, CX connector


1 400-H SAE J1587/1708 data link (+)

2 401-H SAE J1587/1708 data link (-)

3 CJ2 Center module wake up function

4 202-B Power supply, center module

5 0XC-B Ground


W3003557

9


Center module, CY connector

Pin Cavity Description

1 779 ABS Truck lamp

2 ABS Trailer

3 420 Parking brake lamp

4 702 Heated mirror lamp

5 CJ3 Bulb test (+), left module

6 CJ4 Bulb test (-), left module

7 NC

8 33B High beam lamp

9 113-AA Turn signal, right

10 422 Diff lock interaxle lamp

11 0P-B Power ground, center module

12 426 Diff lock wheels lamp

13 424 Fifth wheel lock lamp

14 112-AA Turn signal, left

15 431 Air suspension lamp

16 NC

17 NC

18 141-F Backlighting, center module

19 CJ7 Bulb test (+), right module

20 CJ8 Bulb test (–), right module

21 NC

22 180-B Power supply, center module

23 NC

24 Optional

25 CJ9 Master warning activation. Fromfront and rear air pressure gaugesin the right module

26 NC

27 NC

28 NC

29 NC

30 NC


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10


Connector Pinouts, Right ModuleThe right module has a connector placed on the back ofthe instrument cluster.

Right module, RX connector


1 141-E Backlighting, right module

2 NC

3 CJ5 Forward rear axle temp. input fromleft module

4 CJ1 Fuel level input from left module

5 NC

6 NC

7 NC

8 NC

9 NC

10 NC

11 CJ7 Telltale bulb test (+) from centermodule

12 NC

13 Wait to start engine

14 774B Traction Control in off-road Mode

15 0P-C Power ground, right module

16 NC

17 CJ6 Rear rear axle temp. input from leftmodule

18 180-C Power supply, right module

19 Water in fuel

20 NC

21 CJ9 Master warning activation to centermodule

22 Transmission in Neutral

23 NC

24 NC

25 NC

26 NC

27 NC


W3003560

11


Right module, RX connector


28 CJ8 Telltale bulb test (-) from centermodule

29 Transmission oil temp

30 Transmission malfunction


W3003560

12

Group 38 Instrumentation, VN / VHD Tools

ToolsSpecial Tools

The following items may be required for work on the instrument cluster. Tools with999.../98... numbers are available from Volvo Parts. Tools with J-... numbers are avail-able from Kent-Moore at (800) 328–6657.

W3000642

1089953 Lamp Removal Tool (Availablefrom Volvo Parts)

W0001608

9998551 andJ-43340

60–pin Breakout Box and Overlay

Overlay J-43340 is color coded blue or green tocorrespond to blue and green instrument clusterconnectors. The pin numbers on the overlay corre-spond to the specific connector pin numbers. Thetwo breakout harnesses J-43234 and J-43235 areused together with the breakout box and overlay.

W0001557

J-43234 30–pin Adapter for Green LY orRX and Blue CY Connectors

W0001556

J–43235 22–pin Adapter for Green LX Con-nector

W0001716

J-44274 Dash Air Pressure Gauge Tool

W0001198

J-42189 Air Hose Removal Tool

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Special Tools...

W0001709

1 VCADS PRO tool.

2 Digipass password generator, model 300 or500.

9998555 Communication interface unit: for connectionbetween the laptop PC and the vehicle’s di-agnostic connector.

9812331 Extension cable: for communication (22yards). Optional.

J-43999 6–pin Diagnostic Adaptor: for vehicles builtprior to 1999.

J-43939 9–pin Diagnostic Adaptor: for vehicles builtafter January 1999.

9998617 Programming Kit

9808635 Programming unit.

9808560 Cable for direct connectionto Engine ECU.

9808561 Cable for direct connectionto Vehicle ECU.

9808562 Cable for direct connectionto Instrument Cluster.

9808563 Cable for power supply.

14


Special EquipmentThe following items may be required for work on the instrument cluster. They can beordered from Kent-Moore at (800) 328-6657.

W0001904

J-42444-A Type 8501 Static Dissipative Grounding Kit.The kit shown includes both a wrist strapand anti-static mat. Use both when workingon the instrument cluster at a workbench.

BT-8639-B ESD Wrist Strap.Use a wrist strap when servicing the instru-ment cluster inside the vehicle. Use a wriststrap and anti-static mat when working onthe instrument cluster at a workbench.

J-44567 Probe adapter.Used with J-39200 for making reliable read-ings at the breakout box cavities.

J-39200 Fluke 87 Digital Multimeter (DMM).

J-42449 Terminal removal and probe kit.

J-42449–1 2 male test probes.

J-42449–2 2 female test probes.

J-42449–10 Terminal remover.

J-38125-8 Packard crimper.

J-25070 Heat gun.

15


Special Equipment...

The tools are available from Volvo Parts. Tools with J-... numbers are available fromKent-Moore at (800) 328–6657.

W3004317

104004 Pro Link 9000.

206040 Multi-Protocol Cartridge (MPC).

809112 PCMCIA.

501002 Power/Data Cable.

J–38500–60A 6–pin Deutsch Connector.

J–44012 9–pin Deutsch Connector.

16

Group 38 Instrumentation, VN / VHD Design and Function

Design and Function

Instrument Cluster

W3004310

IntroductionThe cluster is available in 7 configurations, with either amph or km/h speedometer (see “Available Configura-tions” page 4).

The instrument cluster consists of three combined mod-ules:

Left module

The left module consists of 3 separate components, leftgauge module, graphic display and CPU board. The leftmodule can include pyrometer, engine oil pressuregauge, engine coolant temperature gauge and turboboost pressure gauge, and a graphic display for driverinformation. There are telltales in the lower section of themodule. Please refer to “Left Instrument Cluster Module(MID 234)” page 23. For display operation, refer to thesections “Instrument Cluster Operation at Start-up” page40, “Graphic Display Menus, Driving Mode” page 41 and“Graphic Display Menus, Non-Driving Mode” page 56.

Center module

The center module contains a tachometer, speedometerand odometer. In the lower section of the center modulethere is a central warning lamp, and telltales for differenttruck functions. Please refer to “Center Instrument Clus-ter Module (MID140)” page 28.

Right module

The right module consists of an electrical gauge moduleand separate air gauges. The right module can includeforward and rear rear axle temperature gauges, fuel levelgauge, application air pressure gauge, front and rearbrake air pressure gauges. Trucks with an air suspen-sion may have an air suspension pressure gauge. Thereare telltales in the lower section of the module. Pleaserefer to “Right Instrument Cluster Module” page 32.

Graphic display control buttons

Control buttons for the graphic display menus are lo-cated on the wiper stalk on the right-hand side of thesteering wheel. Please refer to “Graphic Display ControlButtons” page 38.

If the vehicle is in motion, use the display controlscarefully. Do not lose road concentration. Be familiarwith operation of the controls. Shifting concentrationto operating the controls can lead to losing control ofthe vehicle and may result in serious personal injuryor death.

17


Instrument Cluster Programming

W0001632

Each instrument cluster (or CPU board) is programmedto correspond to the customer-ordered options for thatparticular vehicle. This dataset is stored in the CPUboard memory, making the instrument cluster unique toeach vehicle.

For this reason, it is not possible to ”swap” a suspectedfaulty instrument cluster (or CPU board) with another ve-hicle without reprogramming the instrument cluster.

When ordering a replacement instrument cluster (orCPU board) the Vehicle Identification Number (VIN) must

be supplied. Volvo will program the replacement part be-fore delivery based on the dataset stored in the VDA(Volvo Data Administration) database.

Authorized technicians can also update and/or alter soft-ware datasets with the VCADS Pro tool. See the mostcurrent VCADS Pro user information or the ”Help” menuin the VCADS Pro tool.

18


Communication

W3004303

1. Connections to the data link

2. Connections to components

3. Connections between the modules of the instrument cluster

The connections between the 3 modules of the instru-ment cluster and other components can be divided intothe following three groups according to the picture above:

1. Connections to the data link:

Connections to the J1587/J1708 information data linkconnect the instrument cluster center and left module tothe other electronic control units, e.g. the Engine ECU(MID 128) and the Vehicle ECU (MID 144). For more in-formation see “Data Link” page 22 and“Communication with Other ECUs/Sensors” page 23.

2. Connections to components:

Some components are connected to the instrument clus-ter modules via the microprocessor in the left module.Others components have inputs to each cluster module,e.g. air gauges. See the individual gauge descriptions inthe “Design and Function” section for more information.

3. Connections between the modules of the instru-ment cluster (control signals for gauges and lamps):

The non data link communication between the threemodules of the instrument cluster is carried out via theseconnections. They are hardwired connections labeledwith “CJ_” circuit numbers. Refer to the electricalschematic or “Connector Pinouts” page 7 for more infor-mation.

19


Data LinkThe communication between the vehicle’s ECUs and theinstrument cluster’s left and center modules is carriedout via the SAE J1587/J1708 information data link.

The system’s control signals are sent on the SAEJ1939 control data link. The SAE J1939 control datalink does not directly interface with the instrument cluster.

The information and diagnostic signals are sent onthe J1587/J1708 information data link. The link alsofunctions as a reserve system for the J1939 control link,if the control link for some reason does not function. Theinformation link keeps the system’s status continually up-dated and available for reading via the diagnosticssocket.

If a fault should occur and be detected by any of theECUs, the ECU will send out a message on both links.

Messages that are sent on the control data link informthe other ECUs that an error has occurred, for instancethat the engine ECU cannot grant the requested acceler-ation.

At the same time, the ECU that has indicated the faultwill broadcast a message on the information data linkabout what is wrong. On the instrument cluster’s graphicdisplay, the fault can then be read as a fault code, eitherin plain text or in standard SAE format.

Note that a fault code, whether it is shown in plain text orin standard SAE format, can only give a rough indicationof the fault. For example, a mechanical fault may pro-duce an engine temperature which exceeds the set limit(set in the engine ECU). This will generate a fault codestating that the engine temperature is too high. Thecause of the high engine temperature is not shown bythe fault code alone; symptoms from the vehicle are alsovery important to note.

Beyond fault codes, information and stop messages,there is a great deal of other information to be obtainedvia the graphic display. By selecting various menu op-tions the driver can choose which information is to beshown on the graphic display.

Instrument ClusterDisplayMID 234

Instrument ClusterCenter Module

MID 140

Vehicle ECUMID 144

Commu-nicationConnec-

tor*

Engine ECUMID 128

Anti-lock Brake (ABS) ECUMID 136

SAEJ1587/J1708

SAEJ1939

TransmissionMID 130

SRS Airbag ECUMID 232

Other units(Expansion capability)

Note: *The Communication Connector in some modelsis a 6–pin connector, which is connected to theJ1587/J1708 link, but not the J1939. On other models itis a 9–pin connector, which is connected to both theJ1587/J1708 and J1939 links.

20


Communication with Other ECUs/Sensors

The table below shows which electronic control units control the various gauges and the display via the infor-mation link. These ECUs can control the INFO and STOP lamps in the left module.

Center module

Odometer .................................................. Self-calculated from road speed and time

Speedometer ........................................... Vehicle ECU, Volvo engines

Engine ECU, other engines

Tachometer .............................................. Engine ECU

Left module

Engine oil pressure gauge ....................... Engine ECU

Engine coolant temperature gauge .......... Engine ECU

Boost pressure gauge .............................. Engine ECU

Display ...................................................... All the ECUs

Engine oil temp. ............................... Engine ECU

Transmission oil temp. ...................... Transmission sensor

Fuel economy ................................... Calculated from engine fuel rate and speed

Lamps INFO and STOP ........................... All the ECUs

Right module

Fuel level gauge ....................................... Electrical sensor (via left module)

Forward and rear rear axle temp ............. Electrical sensor (via left module)

Air suspension pressure gauge ............... Direct connection

Application air pressure gauge ................ Direct connection

Air pressure gauge, front brake circuit ..... Direct connection

Air pressure gauge, rear brake circuit ...... Direct connection

21


Warning Lamps, Telltale Lamps and BuzzerThe instrument cluster contains warning and telltalelamps, both at the bottom of the cluster and integratedinto the gauges, in order to indicate status and warnings.In the instrument cluster there is also a buzzer whichperforms three different functions: flasher indicator, re-

minder and caution. The caution buzzer warns the driverwhen a �STOP message is displayed or when there areabnormal measurement values.

Diagnostic CapabilitiesThe instrument cluster performs a self-test via the instru-ment cluster’s electronics, when the ignition key isturned to the ON position, but a self-test can also bemanually conducted via the menu System diagnos-tic/instrument cluster test.

In the System diagnostic/instrument cluster testmenu, the graphic display shows diagnostics of the vehi-

cle’s various ECUs. See “Fault diagnostic” page 68.Here you can select how the fault codes are to beshown: numerically, as text, or with a time stamp (withsome engines). Fault codes can also be reset, either oneby one, “Reset a fault code” page 72, or all at the sametime, “Reset all the fault codes” page 73.

Instrument Cluster LightingThe brightness of the gauges and the graphic displaycan be adjusted with an external rheostat on the dash.In the Set-up menu the degree of brightness between

gauge and display can be altered. Even the contrast andnormal or reverse video of the display can be changedvia the Set-up menu, see “Main Menu: Set-up mode(non-driving)” page 59.

22


Left Instrument Cluster Module (MID 234)The left module consists of 3 separate components:

• A left gauge module

• Graphic display

• Left CPU board

The left gauge module may have up to 4 gaugesdepending on the instrument cluster configuration:

• Pyrometer

• Engine oil pressure gauge

• Engine coolant temperature gauge

• Turbo boost pressure gauge

W3004369

Important: Individual gauges or modules in the VN/VHDinstrument cluster are not serviceable during the war-ranty period. Attempts to service or replace individualmodules or gauges during the warranty period will

void the cluster warranty. Instead, the whole instru-ment cluster may be exchanged.

After the warranty expires, individual modules can be re-placed.

23


PyrometerThe pyrometer indicates exhaust temperature from asensor in the exhaust system.

The pyrometer gauge is an electrical aircore metermovement driven by the cluster’s microprocessor. Themicroprocessor receives pyrometer sensor input from ahigh-temperature thermocouple.

If the pyrometer thermocouple fails, the pointer will moveto one end of the dial or the other, and a fault code willbe logged for loss of data. A reading of 300�F (149�C )or less indicates an open in the truck’s wiring or thermo-couple, and a reading of 1500�F (815�C) or moreindicates a short.

W3003632

Engine oil pressure gaugeThis gauge shows the actual oil pressure in the engine.The pointer must not move down into the red sectorwhile driving! If the oil pressure disappears, e.g. due tooil leakage, the engine could be seriously damaged. Thegauge gives a reading when the ignition key is in the ONposition.

The engine oil pressure gauge is an electrical aircoremeter movement that receives its signal from a senderunit mounted on the engine. The sender unit suppliesdata to the Engine ECU which sends engine oil pressureinformation to the instrument cluster via the J1587/J1708information data link.

In the absence of a data signal, the gauge pointer willmove to its minimum reading after a 10 second delay,and a fault code will be logged for loss of data.

The LED in the lower, right-hand corner lights up whenthe engine ECU sends a signal for low oil pressure, nomatter what value is shown on the gauge. The pressurewhich activates this LED is engine-dependent (set in theengine ECU). The measuring range of the gauge is 0–90psi.

W3003768

24


Engine coolant temperature gaugeThis gauge shows the temperature in the engine’s cool-ing system. The temperature, under normal drivingconditions, must be below the red sector. The gaugegives a reading when the ignition key is in the ON posi-tion and the coolant temperature exceeds 140�F (60�C).The measuring range of the gauge is 150–230�F.

The coolant temperature gauge is an electrical aircoremeter movement which receives its signal from the en-gine via the SAE J1587/J1708 information data link. Inthe absence of a data signal, the gauge pointer willmove to its minimum reading after a 10 second delay,and a fault code will be logged for loss of data.

The LED in the lower, right-hand corner lights up whenthe engine ECU sends a signal for high coolant tempera-ture, no matter what value is shown on the gauge. Thetemperature which activates this LED is engine-dependent (set in the engine ECU).

W3003769

Turbo boost (intake manifold) pressure gaugeThis gauge shows boost pressure (overpressure in theintake manifold). When driving with a constant load, thepointer should be stationary. The boost pressure gaugecan be used together with the speedometer to help thedriver maintain an even speed and even acceleration inorder to minimize fuel consumption. The gauge range is0–30 psi.

The turbo boost pressure gauge is an electrical aircoremeter movement driven by a signal from theJ1587/J1708 information data link. In the absence of adata signal, the gauge pointer will move to its minimumreading after a 10 second delay, and a fault code will belogged for loss of data.

W3003631

Telltale bulbs, left section1 Engine preheat telltale

2 Caution telltale

3 Stop telltale

4 No Charge telltale

W3003645

25


Graphic DisplayThe driver can choose information on the graphic displayby scrolling among the menus that are listed below.Menus in capital letters are available when driving andwhen stationary. Menus in lower case letters are onlyavailable when stationary. For detailed information aboutthese display menus see “Instrument Cluster Operationat Start-up” page 40, “Graphic Display Menus, DrivingMode” page 41 and “Graphic Display Menus,Non-Driving Mode” page 56.

GAUGE MODE

• TEMPERATURE, ENGINE OIL

• TEMPERATURE, TRANSMISSION OIL (optional)

• VOLTMETER

FUEL ECONOMY

• AVG/INST FUEL ECON

• LEG FUEL/DISTANCE TO EMPTY

TIME/DISTANCE

• CLOCK

• Alarm clock

• TRIPMETER #1 and #2

• AVERAGE SPEED

FAULTS?

• FAULTS?

Set-up mode

• Language

• Miles/�F/USgal or km/�C

• Clock format

• Contrast

• Backlight

• Night display

• Default language *

• Fleet limit: rpm * **

• Fleet limit: speed * **

• Fleet fuel target * **

• Odometer setting *

• Fleet id * **

• Password config *

System diagnostic (reset faults in this menu)

• Fault diagnostic

• Cluster self test

• Part number

• Status test *

Data log mode

• Vehicle id **

• Totals

• Trip data **

• Reset trip data * **

Password Input

• Enter password

* Only available when correct password has been given. ** With Volvo engines only

26


Left CPU BoardThe left CPU (Central Processing Unit) board contains amicroprocessor that processes various data and sensorinput to the instrument cluster and sends the informationto the appropriate display unit. MID 234 identifies the leftCPU board.

The left CPU board also contains the programming infor-mation that makes each instrument cluster unique to thevehicle it is installed in.If the instrument cluster or left CPU board is replaced itmust be programmed per the VIN (Vehicle IdentificationNumber) for proper operation. For programming instruc-tions see “Instrument Cluster, Programming” page 161.

Automatically Activated WarningsInformation and stop messages are shown automaticallyon the display if a fault should occur.

Information MessagesThe following functions can activate an information mes-sage with symbol in the display:

• SRS Airbag• Overheating, instrument cluster• Level, washer fluid• Air filter, clogged• Too cold for engine brake (VEB)• Fault in the pre-heating• No data• Temperature transmission oil• Voltmeter

STOP messagesThe following functions can activate a stop message withsymbol in the display:

• Level, coolant• Oil level, engine (only certain variants and when the

engine is running)• Temperature engine oil• Temperature transmission oil• Engine oil pressure too low• Coolant temp. too high

27


Center Instrument Cluster Module (MID140)The center module contains the following:

• Tachometer

• Speedometer

• Odometer

T3010615

Important: Individual gauges or modules in the VN/VHDinstrument cluster are not serviceable during the war-ranty period. Attempts to service or replace individualgauges or modules during the warranty period will

void the cluster warranty. Instead, the whole instru-ment cluster may be exchanged.

After the warranty expires, individual modules can be re-placed.

28


Center Module ECU (MID 140)Signals from the J1587/J1708 information data link areprocessed in the center module ECU, which controls thetachometer and the speedometer. The ECU also con-trols the activation of different sounds, e.g. indicator fordirection indicators and warning.

The center module ECU receives signals from the othertwo modules of the instrument cluster, from directly con-nected components and via the J1587/J1708 informationdata link.

TachometerThe tachometer is an electrical air core meter movementdriven by signals from the engine (MID 128) via theJ1587/J1708 information data link. In the absence ofdata link information, the gauge pointer will move to itsminimum reading after a 10 second delay. The gaugerange is 0–2800 r/min.

W3003639

29


SpeedometerThe speedometer is an electrical air core meter move-ment driven by signals from the SAE J1587/J1708information data link. In the absence of data link informa-tion, the gauge pointer will move to its minimum readingafter a 10 second delay. Note that the cluster does notperform speedometer calibration. Speedometer calibra-tion to compensate for tire sizes and other drivelinechanges is done during programming of the engineECU, vehicle ECU or transmission ECU.

The speed signal is sent to the center module ECU ei-ther from the vehicle ECU (MID 144) or the engine ECU(MID 128) depending on the engine manufacturer:

• The speed signal is sent from the vehicle ECU viathe J1587/J1708 information data link if the vehicleis equipped with a Volvo engine.

• The speed signal is sent from the engine ECU viathe J1587/J1708 information data link if the vehicleis equipped with a Cummins or Detroit Diesel en-gine.

The speedometer is also available in a version with thegraduation ”km/h” as the main scale.

Measuring range ....................... 0-80 mph(0-120 km/h)

W3003640

OdometerThe odometer is a Liquid Crystal Display (LCD) mountedbehind the speedometer dial. It has a full scale readingof 999999.9. Odometer information is calculated fromroad speed via the J1587/J1708 information data linkand is stored in the cluster’s microprocessor.

The odometer backlighting can be adjusted indepen-dently of gauge backlighting, via the menu “Set–upmode” in the graphic display.

During normal operation, the odometer display goesblank 30 seconds after the ignition is switched off. To re-activate the display, turn the ignition on or press any ofthe control buttons on the wiper stalk switch.

In the absence of speedometer data, the odometer dis-play will not change and the speedometer pointer willremain at zero.

The odometer value can be displayed either in “miles” or“km”. The unit selection is accessed via the menu Set-upmode in the graphic display in the left module. The ac-tual unit of measurement is indicated by the annunciator“miles” and “km”, respectively, above the mileage value.

If the instrument cluster or center module are replaced,the odometer may be programmed to reflect the actualvehicle miles. For programming instruction see“Odometer, Programming” page 162.

30


Telltale bulbs, center section

W3003646

1 Left Turn Indicator2 5th Wheel Lock Indicator3 Wheel Differential Lock Indicator4 Interaxle Differential Lock Indicator5 High Beam Indicator6 Safety Belt Indicator7 Parking Brake Indicator

8 Anti-Lock Brake System (Tractor) Indicator9 Anti-Lock Brake System (Trailer) Indicator10 Air Suspension System Indicator11 Mirror Defroster Indicator12 Right Turn Indicator

Note that all telltales may not be used in all vehicles.

Master Warning telltaleA red Master Warning telltale consisting of an exclama-tion mark (!) inside a triangle is located near the bottomand midway between the tachometer and the speedome-ter. It lights when the front or rear brake air pressure istoo low for safe operation (below 72 psi (496 kPa)).

W3000638

31


Right Instrument Cluster ModuleNote: The gauges and their positioning vary dependingon the truck variant, engine variant and the selection ofextra equipment.

The right module has space for the following:

• Forward rear axle temperature gauge

• Rear rear axle temperature gauge

• Fuel level gauge

• Application air pressure gauge

• Air suspension pressure gauge

• Front brake air pressure gauge

• Rear brake air pressure gauge

Important: Individual gauges or modules in the VN/VHDinstrument cluster are not serviceable during the war-ranty period. Attempts to service or replace individualgauges or modules during the warranty period willvoid the cluster warranty. Instead, the whole instru-ment cluster may be exchanged.

After the warranty expires, individual modules can bereplaced.

W3004301

32


Forward rear axle temperature gaugeThe forward rear axle temperature gauge is an electricalaircore meter movement. It is connected to a tempera-ture sender unit mounted on the axle housing. Thehigher the temperature, the lower the resistance of thesender unit. The sender signal is input to the micropro-cessor in the left module. In the microprocessor thesignal is changed to a pulse width modulated (PWM)signal. The PWM signal is sent to the gauge via a wire.

The gauge range is 90–310 �F. If the range is exceeded,a fault is logged.

W3003634

Rear rear axle temperature gaugeThe rear rear axle temperature gauge is an electrical air-core meter movement. It is connected to a temperaturesender unit mounted on the axle housing. The higher thetemperature, the lower the resistance of the sender unit.The sender signal is input to the microprocessor in theleft module. In the microprocessor the signal is changedto a pulse width modulated (PWM) signal. The PWM sig-nal is sent to the gauge via a wire.

The gauge range is 90–310 �F. If the range is exceeded,a fault is logged.

W3003635

Fuel level gaugeThis gauge shows the approximate amount of fuel in thetank. The red sector indicates that it is time to refuel.The gauge gives a reading when the ignition key is inthe ON position.

The fuel level gauge is an electrical aircore meter move-ment that receives its signal from a sensor in the fueltank.

The fuel level sensor signal is input to the cluster micro-processor. In the microprocessor the signal is changedfrom a resistance to a pulse width modulated (PWM) sig-nal. As the duty cycle of the signal increases, the levelshown on the gauge increases. If the operating range ofthe gauge is exceeded, a fault is logged.

W3003628

33


Application air pressure gaugeThe application air pressure gauge is a mechanical(Bourdon tube) gauge. It is attached to the service brakesystem by a hose going into a quick-disconnect fitting onthe rear of the gauge. It reads applied air pressure to theservice brake system. The air hoses and quick-disconnects are color-coded to avoid wrong connections.The gauge range is 0–150 psi.

W3004302

Air suspension pressure gaugeThis gauge shows the pressure in the air suspensionsystem. The vehicle must not be driven when the pointeris in the red sector.

The air suspension pressure gauge is a mechanical(Bourdon tube) gauge. It is attached to the air suspen-sion system by a hose going into a quick-disconnectfitting on the rear of the gauge. The air hoses and quick-disconnects are color-coded to avoid wrong connections.The gauge range is 0–100 psi.

W3003633

34


Front brake air pressure gaugeThis gauge shows the air pressure in the front brake cir-cuit. The air pressure gauges are mechanical (Bourdontube) gauges. They are attached to their air systems bya hose going into a quick-disconnect fitting on the rear ofthe gauge. The air hoses and quick-disconnects arecolor-coded to avoid wrong connections. The vehiclemust not be driven when the pointer is in the red sector.

The LED in the lower, right-hand corner lights up whenthe air pressure in the front brake circuit falls below 72psi. The Master Warning indicator will also light. TheMaster Warning indicator is supplied air pressure infor-mation via a wire going from the right to the centermodule.

W3003637

Rear brake air pressure gaugeThis gauge shows the air pressure in the rear brake cir-cuit. The air pressure gauges are mechanical (Bourdontube) gauges. They are attached to their air systems bya hose going into a quick-disconnect fitting on the rear ofthe gauge. The air hoses and quick-disconnects arecolor-coded to avoid wrong connections. The vehiclemust not be driven when the pointer is in the red sector.

The LED in the lower, right-hand corner lights up whenthe air pressure in the rear brake circuit falls below 72psi. The Master Warning indicator will also light. TheMaster Warning indicator is supplied air pressure infor-mation via a wire going from the right to the centermodule.

W3003638

Telltale bulbs, right section1 Transmission Temperature

2 Check Transmission

3 Traction Control System

4 Wait Start Engine2

5 Automatic Neutral

6 Water in Fuel2

W3004416

2Not applicable to all models.

35


Graphic DisplayThe graphic display in the lower left-hand corner of theinstrument cluster is used to present information to thedriver, both when driving and when the vehicle is station-ary. The graphic display replaces certain conventionalgauges, telltale and warning lamps. It is standard equip-ment in all versions of the instrument cluster.The information can be divided into two groups:

Preselected Information:The driver himself chooses what is to be shown. This in-cludes the clock, gauges, etc.

Automatically Generated Information:Information and stop messages are shown automaticallyon the graphic display at the same time as a yellow lamp(�INFO) or red lamp (�STOP) lights up at the bottom ofthe display. A fault code is also logged, and can beviewed in the FAULTS menu.

The seriousness of the fault determines which lamp is lit.Information and stop messages, shown during vehicleoperation, require immediate action by the driver.

When the red (�STOP) lamp lights up and the engine isrunning, a buzzer is also activated.

T3008860 T3008861

The section “Main Menu: FAULTS? (available while driv-ing)” page 49 gives a more general description of faultmessages. To see more details about information andstop messages see “Fault diagnostic” page 68.

The information available for the driver is different de-pending on whether the vehicle is being driven or isstationary.

Driving = speed above 5 mph (8 km/h) (see “GraphicDisplay Menus, Driving Mode” page 41).

Non–Driving = speed under 5 mph (8 km/h) (see“Graphic Display Menus, Non-Driving Mode” page 56).

Concerning various symbols used in the display, see“Graphic Display Symbols” page 37, “Information Mes-sages (with Icons)” page 51 and “Stop Messages (withIcons)” page 55.

Graphic Display Layout

Menusymbol T E X T F I E L D

Statussymbol

The display window is divided into three fields where thefield to the far left shows a symbol in conjunction withcertain messages.

The field in the center displays all the text and somesymbols, and the right-hand field shows the status sym-bols for the various functions. The status symbols are towarn the driver about which functions are active atpresent. A total of four symbols can be shown in theright-hand field at the same time. See “Graphic DisplaySymbols” page 37 for more information.

36


Graphic Display Symbols

W3004312

1 Voltmeter(see “Voltmeter” page 44 formore information)

2 Engine oil temperature(see “Temperature, engine oil”page 42 for more information)

3 Transmission oil temperature(see “Temperature, transmissionoil (option)” page 43 for more in-formation)

4 Pre-heating active

5 Acknowledged warning(see “Acknowledge Informationand Stop Messages” page 50 formore information)

6 Alarm clock on(see “Alarm clock” page 57 formore information)

7 PTO engaged

8 Cruise Control engaged

9 Airbag

10 Coolant level

11 Washer fluid level(see “Information Messages(with Icons)” page 51 for more in-formation)

12 Air filter, clogged(see “Information Messages(with Icons)” page 51 for more in-formation)

13 Too cold for engine brake (VEB)(see “Information Messages(with Icons)” page 51 for moreinformation)

14 Overheating, instrument cluster(see “Information Messages(with Icons)” page 51 for more in-formation)

15 Fault in the pre-heating

16 Engine oil pressure

17 Coolant temperature

37


Graphic Display Control ButtonsIn order to manually interact with the graphic display, thewiper stalk switch on the right-hand side of the steeringwheel is used.The following commands are available:

1 “Esc” (Escape) is used to return to the previousmenu and cancel a setting/operation.

2 “↵”or “SELECT” confirms a highlighted selection ofa menu or character.

3 “Up arrow” moves the cursor up and is used whensetting numerical values.

4 “Down arrow” moves the cursor down and is usedwhen setting numerical values.

T3008810

Using the Graphic Display Menus

Selecting a Menu1 Use the up/down buttons to move to a particular

menu, which is then highlighted. An up or down ar-row on the right side shows whether there are anymore menus available. If this is the case you cancontinue to step down through the list (see the adja-cent example).

2 Pressing ↵ confirms the choice.

3 Pressing ESC exits the chosen menu. By pressingEsc repeatedly the cursor is moved successivelyback to the main menus.

"

Set-up mode "

System diagnostic

Data log mode

Password Input #

Changing Settings1 The up/down buttons increase or reduce the set

values (e.g. hours and minutes in the adjacent ex-ample).

2 Pressing ↵ confirms the choice.

3 If there are several settings to change in the samemenu, move to the next setting using the up/downbuttons (e.g. the selection between ON, OFF andSET in the adjacent example).

4 Esc moves the highlighted area to the previousnumber or selection, if there is one. Otherwise thesetting is cancelled.

ALARM 08:20

CLOCK 08:00

ON OFF SET

38


Password InformationCertain functions are protected by a password. For thedisplay there are two passwords (or the alternative ofchoosing not to have any password protection):

1 The mechanic password

2 The owner password

Both these passwords give the user access to all pass-word protected functions with one exception:

The mechanic’s password does not give access to thepassword configuration, i.e. with this you cannot changeeither the mechanic’s nor the owner’s passwords.

See “Change password” page 67 to change the pass-word.

The following menus are protected by passwords:

• Default language• Fleet limit: rpm

• Fleet limit: speed• Fleet target: fuel• Odometer setting• Fleet ID• Reset faults (applies to a number of functions)• Status test• Password config.

When the ignition key has been in the off position formore than 60 seconds or when the batteries have beendisconnected the password must be entered again to ac-cess password-protected functions.

See “Main Menu: Password Input (non-driving)” page 86in order to enter your password.

No password protected functions: Owner/OperatorMode

For all menus to be available, you must go to the menuPassword Input and press ↵. The text Access Grantedis then shown instead of Password.

39


Graphic Display OperationThe three sections “Instrument Cluster Operation atStart-up” page 40, “Graphic Display Menus, DrivingMode” page 41 and “Graphic Display Menus,Non-Driving Mode” page 56 give a presentation of thedisplay functions.

Instrument Cluster Operation at Start-upKey ON

The following occurs automatically when the ignition keyis turned to the ON position:

• Bulb test for approximately 3–5 seconds.• Other bulbs may remain on due to other compo-

nents, such as the ABS or preheat.• Gauges return to zero or go to their appropriate po-

sition (for example, if the axles are still warm fromdriving the axle temperature gauges would show areading).

After 10 Seconds

After 10 seconds, if all functions are working properly,the cluster will act normally.

If there is a fault in one of the gauges in the graphic dis-play, the cluster will show the fault in the graphic display.

If the ignition key has been in the off position, what wason the display before the ignition was turned off isshown. (If the battery has been disconnected and recon-nected, a flashing clock display is shown instead.)

During Normal Operation

If a telltale light is on other than �INFO or �STOP, a de-vice other than the cluster has activated it.

If the �INFO or �STOP light is on, but there is no iconin the display, a device other than the cluster has acti-vated it.

40


Graphic Display Menus, Driving ModeFor a description of how the display is operated see“Graphic Display Control Buttons” page 38.

By ”driving” it is meant that the vehicle speed exceeds 5mph (8km/h).

GAUGE

FUEL ECONOMY

TIME/DIST

!

FAULTS?

• Esc leaves a chosen menu and by repeatedpressing of Esc the main menu, shown at right,is obtained. This presupposes that no fault codeis active. The arrows indicate how to go betweenthe various menus.

• If the menu FUEL ECONOMY is not included,the menu FAULTS? is under the menuTIME/DISTANCE.

• When the fault messages are acknowledged us-ing Esc, you are shown the menu FAULTS?

"# "# "#

GAUGE FUEL ECONOMY (option) TIME/DIST

!

TEMPERATURE,ENGINE OIL

!

AVG/INST FUEL!

CLOCK

"# "# "#

TEMPERATURE,TRANSMISSION OIL (op-tion)

LEG FUEL/DTE Alarm clock

"# "# "#

VOLTMETER TRIPMETER #1 and #2

"# "#

AVERAGE SPEED

"#

41


Main Menu: Gauge (available while driving)When the menu GAUGE has been selected, you switchbetween the various sub-menus with the up/downbuttons.

• TEMPERATURE, ENGINE OIL• TEMPERATURE, TRANSMISSION OIL

(Option)• VOLTMETER

Temperature, engine oilMENU: GAUGE, TEMPERATURE ENGINE OIL

The engine’s oil temperature is shown as in the diagram.

If the sensor data for Temperature, engine oil is notavailable, the symbol is shown as well as the text NODATA.

Action:

• Do a diagnostics test on the display and engine, see“Fault diagnostic” page 68.

T3008830 185 F

T3008830

NODATA

Information messageYellow �INFO lamp

If the engine oil temperature becomes too high an infor-mation message is shown automatically with the textHIGH. At the same time the yellow �INFO lamp underthe display lights up. The engine may also derate, if it isset up to do so in the engine ECU programming. Thetemperature which activates this warning varies for differ-ent engines. This temperature is set in the engine ECU.For Volvo engines, it is 275�F (135�C).

Esc acknowledges the information message, whichmeans that the warning becomes an icon in the display’supper right hand corner, and normal display functionsare available.

T3008830

HIGH280�F

T3008860

42


Temperature, transmission oil (option)MENU: GAUGE, TEMPERATURE, TRANSMISSION OIL

The transmission’s oil temperature is shown as in the di-agram.

If the sensor data for Transmission oil temperature isnot available, the symbol is shown as well as the text NODATA.

Action:

• Do a diagnostics test on the display, see “Fault di-agnostic” page 68.

T3008831 170 F

T3008831

NODATA

Information messageYellow �INFO lamp

If the temperature of the transmission oil becomes toohigh, an information message is shown automaticallywith the text HIGH. At the same time the yellow �INFOlamp under the display lights up. Esc acknowledges theinformation message, which means that the warning be-comes an icon in the display’s upper right hand corner,and normal display functions are available.

For HIGH to display with the �INFO lamp, the transmis-sion oil temperature must be 210�F (100�C) for 30minutes, or 250�F (120�C) for 10 minutes.

T3008831

HIGH250 �F

T3008860

Stop messageRed stop lamp

If the temperature of the transmission oil becomes toohigh, a flashing stop message is shown automaticallywith the text TOO HIGH. At the same time the red�STOP lamp under the display lights up and the warn-ing signal sounds. Esc acknowledges the stop message.

For TOO HIGH to display with the �STOP lamp, thetransmission oil temperature must be 285�F (140�C) for30 seconds.

T3008831

TOO HIGH285 �F

T3008861

43


VoltmeterMENU: GAUGE, VOLTMETER

The battery/charging voltage is shown as in the diagram.If the battery/charging voltage becomes too low (below9.5 V), the instrument cluster will lose power. T3008832 13.1 V

Information messageYellow information lamp

If the battery/charging voltage becomes too high, thevoltmeter’s value is shown automatically as well as thetext TOO HIGH. At the same time the yellow informationlamp under the display lights up.

T3008832

TOO HIGH17.9 V

T3008860

44


Main Menu: Fuel Economy (available while driving)Menu FUEL ECONOMY has 2 sub-menus:

• AVG/INST

• LEG FUEL/DTE

FUEL ECONOMY is chosen and then the up/down but-tons are used in order to change between the availablesub-menus.

AVG/INST Fuel EconomyMENU: FUEL ECONOMY, AVG/INST

For setting metric or English scales, see “Miles/�F/USgalor km/�C” page 60.

The following is shown on the display:

• Average trip fuel consumption (AVG):The value is presented numerically and as an arrowabove the bar. The arrow’s position shows the value.For a short time after resetting the following is shown“— — — “ instead of the average fuel consumption.

• Instantaneous fuel consumption (INST):The value is presented numerically as well as in theform of a bar.

• Target trip fuel consumption (TARGET):The value is presented as an arrow under the bar.The arrow’s position shows the value. For informa-tion about how this value is set, see “Fleet FuelTarget” page 65.

Note: When idling the bar is not shown and the fuel con-sumption is shown in gal/hour.

AVG 9.9 #

INST 8.0

"mpg TARGET

Note: If km and �C have been selected the consumptionis shown in liters. In the example above, L/100 km willthen be shown instead of mpg.

Reset fuel economy1 Press ↵ in the menu AVG/INST.

2 A new text message in the form of a question isshown:RESET FUEL DATA? Press ↵ to reset.

When the leg’s fuel consumption is reset, the averagefuel consumption will also be reset.

RESET

FUEL DATA?

PRESS ↵ FOR 1S

45


Leg Fuel/Distance to EmptyMENU: FUEL ECONOMY, LEG FUEL

Press the up/down buttons in the menu AVG/INST toreach the menu LEG FUEL.

The following is shown in the menu LEG FUEL on thedisplay:

• The Leg fuel consumption (amount of fuel usedsince the last resetting).

• Distance to Empty XXX mi (where XXX is the calcu-lated range using the present instantaneousconsumption).

Note: If km and �C have been selected, the consumptionis shown in liters. In the example below, L will then beshown instead of USg.

LEG FUEL

_ _ _

EMPTY _ _ mi

Note: Since the ”calculated range” is based on the in-stantaneous consumption, the correct value is firstshown shortly after start.

46


Main Menu: Time/Distance (available when driving)Menu TIME/DIST has 4 sub-menus.

• CLOCK

• ALARM CLOCK

• TRIPMETER

• AVERAGE SPEED

Note: Menu TIME/DIST is available even when the igni-tion key is in the off position. It is activated by keepingone of the control buttons on the wiper stalk presseddown for at least 1 second. The menu remains active for30 seconds after the last depressing of the button.

The alarm clock cannot be set while driving, but thebuzzer which sounds for the alarm call can be switchedoff. See “Switch off the alarm clock” page 58.

ClockMENU: TIME/DIST, CLOCK

Shows the current time. To set the time format 12h or24h, see “Clock format” page 60.

Setting1 To set the clock press ↵ when you are in the menu

TIME/DISTANCE and the clock function will beshown.

2 Set the hours with the up/down buttons. Confirm thechoice with ↵.

3 Set the first digit in the minutes with the up/downbuttons. Confirm the choice with ↵.

4 Set the second digit in the minutes with the up/downbuttons. Confirm the choice with ↵.

5 Set the AM/PM (if the time format is 12h) with theup/down buttons. Confirm the choice with ↵.

12:00

Cancel settingWhen setting hours Esc cancels the setting and the timeis shown according to the previous setting.

Esc after setting the minutes as well as after setting theAM/PM moves the cursor back to the previous selection.

Ignition key in the off positionIf setting the clock when the ignition key is in the OFF po-sition takes more than 30 seconds between pushing thebuttons, the time which has been entered then applies.

47


TripmeterMENU: TIME/DIST, TRIPMETER

On the display in the menu tripmeter the distance drivenfor Leg 1 and Leg 2 are shown.

TRIP

#1 43.6 mi

#2 507.3 mi

Reset tripmeter1 Press ↵ in the menu TRIPMETER.

2 A new text message with a question about the re-setting of the tripmeter is shown. The up/downbuttons move the cursor between Leg 1 and Leg 2.Confirm the choice with ↵ or press Esc in order tocancel the resetting.

RESET?

#1: #2:

PRESS ↵ FOR 1S

Average speedMENU: TIME/DIST, AVERAGE SPEED

The average speed is calculated using the distancedriven divided by the time the engine has been running(since the last resetting).

AVERAGE

SPEED

55.4 mph

Reset average speed1 Press ↵ when the menu AVERAGE SPEED is

shown.

2 A new text message with a question about the re-setting of the average speed is shown. Confirm thechoice with ↵ or press Esc in order to cancel theresetting.

RESET?

PRESS ↵ FOR 1S

48


Main Menu: FAULTS? (available while driving)

GeneralWhen a fault occurs a fault message is shown on thegraphic display. There are two types of fault messages:

1 Information messages

2 Stop messages

The stop message is always more urgent than informa-tion messages.

Any information and stop messages as well as the asso-ciated symbols are shown automatically on the graphicdisplay when driving. A summary of these symbols isshown in the illustration under “Graphic Display Sym-bols” page 37. Under the display there are two lamps (ayellow �INFO lamp and a red �STOP lamp) that attractthe driver’s attention when necessary. When the red(�STOP) lamp lights up and the engine is running, awarning signal is also activated.

Several messages may be active at the same time.When a new message is activated the new one is showninstead of the old one.

A down or up arrow on the graphic display’s right sidemeans that more messages are active.

Information messageThe yellow �INFO lamp lights up when an abnormalstate or a risk situation is indicated. In addition to thelamp, a symbol or text is shown on the graphic display atthe same time. For certain symbols, a measurementvalue is also shown.

Note: In the event of a warning for low air pressure nomessage is shown on the graphic display, the LED in thegauge and the Master Warning light illuminates instead.

Important: When the �INFO lamp lights up, the speci-fied fault must be checked at the next stop.

T3008860

Stop messageIn the event of serious faults, the red �STOP lamp lightsup and a buzzer sounds (if the engine is running). In ad-dition to the lamp, a symbol or text is shown on thegraphic display at the same time. For certain symbols, ameasurement value is also shown.

Failure to take the necessary action when the �STOPtelltale lamp is on can ultimately result in automaticengine shutdown and loss of power steering assist. Avehicle crash resulting in personal injury or death canoccur. Bring the vehicle to a safe stop where the prob-lem can be checked.

T3008861

49


Acknowledge Information and Stop MessagesBy pressing Esc you can override the fault message, andthe graphic display returns to the same status as beforethe error occurred. An acknowledged fault message isshown as a symbol on the right in the graphic displaywindow. All types of fault messages can be acknowl-edged. Acknowledged but active messages are shownagain when the ignition key is turned to the start position.

T3008852

Yellow �INFO lamp: The text message, yellow lampand the symbol can be acknowledged using Esc. Thiswarning is acknowledged until the next time the ignitionkey is turned to the start position.

Exceptions: The message can be shown again if thefault is de-activated and then becomes active again.

Example: If the engine oil temperature becomes too higha message is activated automatically. The driver ac-knowledges this message using Esc. If the temperaturethen drops to a normal level but then becomes too highagain the warning is activated again.

Red �STOP lamp: The buzzer, text message and thesymbol can be acknowledged using Esc, but are activeagain 10 seconds after pressing the button. The redlamp remains lit the whole time.

RecallAn acknowledged fault message can be recalled, i.e. beshown on the graphic display again.

MENU: FAULTS?

1 ↵confirms the choice of the menu FAULTS? Thelast acknowledged fault message is shown. If thereis more than one message, a down arrow is shownin the right-hand corner.

2 The up/down buttons move the cursor between thecurrent messages.

If an acknowledged fault message is still active at thenext occasion the ignition key is turned to the ON posi-tion this is shown as a non-acknowledged message. NOFAULTS is shown if there are no fault messages.

50


Information Messages (with Icons)The yellow �INFO lamp lights up and a symbol is shownon the graphic display.

Airbag

In the event of a problem in theSRS system, a telltale showson the graphic display in the in-strument cluster. This telltale,together with other telltales inthe cluster, also light up whenthe engine is started. Thetelltale should go out after ap-proximately 10 seconds whenthe starting key has beenturned to the drive position.

If a problem develops in thesystem, the�INFO telltale willcome on together with the SRStelltale.

T3008842

CAUTION

The vehicle should be taken to an authorized VolvoTruck dealer immediately if the SRS telltale stayson or lights up when the vehicle is being driven.

Overheating, instrumentsThe symbol will be shown whenthe temperature in the instru-ment cluster exceeds 92�C(198�F). The instrument lightingbecomes weaker and thegauges show the minimumreading. When the cab temper-ature cools the instrumentcluster functions will graduallybe restored.

T3008840

Level, washer fluidThe symbol is shown whenthere are approx. 1.4 gallons(5.3 liters) of fluid remaining inthe reservoir.

T3008838

Warning, transmission oil tempera-tureIf the temperature of the trans-mission oil becomes too high,an information message isshown automatically with thetext HIGH. The informationmessage will come on whenthe transmission oil is 250�F(120�C) for 10 minutes, or210�F (100�C) for 30 minutes.The temperature is displayedalong with the symbol. Note:The transmission oil tempera-ture will also generate a STOPmessage (see “Stop Messages(with Icons)” page 55).

T3008831

Warning, voltmeterIf the battery voltage becomestoo high, the voltmeter’s valueis shown automatically as wellas the text TOO HIGH. Thiswarning is triggered at 17 V.The voltage is displayed alongwith the symbol.

T3008832

Warning, engine oil temperatureIf the engine oil temperaturebecomes too high, an INFOmessage is shown automati-cally with the text HIGH. Theengine may derate, if it is set upto do so in the engine ECU pro-gramming. The temperaturewhich activates this warningvaries for different engines. Thistemperature is set in the engineECU. For Volvo engines, it is275�F (135�C).

T3008830

51


Air filter, cloggedThis symbol is shown when theair filter sensor is restricted.

T3008843

Too cold for engine brake (VEB)(Volvo engine only)Position 2 on the switch mustnot be engaged before the en-gine has reached operationaltemperature. If position 2 is en-gaged and the engine is toocold this symbol is shown and asignal sounds when enginebraking is carried out (VEB isnot engaged).

T3009913

Fault in the pre-heatingVolvo engines have a uniquecold start feature. Dependingon the ambient temperature, theengine cranks two to four turnswithout injecting fuel. The lightwill be engaged between 0 and50 seconds while pre-heating.

T3008841

52


Information Messages (Text and Lamp Only)The yellow lamp lights up and a message is shown onthe graphic display (for more information about faults see“Fault diagnostic” page 68). The text contains informationregarding where the fault has occurred as well as thefault type (applies to the data link).

Each ECU is identified by a MID number (MessageIDentifier).

• ABS Brakes, MID 136• Instrument Cluster Center Module, MID 140• Instrument Cluster Display, MID 234• SRS Airbag, MID 232• Vehicle ECU, MID 144• Engine, MID 128

Factory installed equipment:

CHECK

ENGINE

NEXT STOP

T3008860

Specific data link fault:

CHECK

ENGINE

DATA LINK

T3008860

Broken data link:

CHECK

DATA LINK

BROKEN

T3008860

Equipment not installed at factory:

If the bodybuilders or the customer have installed equip-ment afterwards which has been connected to the datalink, the following can be shown:

MID (Message IDentifier) = electronic control unit (ECU)

CHECK

ERROR IN

MID 140

T3008860

53


Stop Messages (Text and Lamp Only)The red �STOP lamp lights up and a flashing messageis shown on the graphic display (for more informationabout faults see “Fault diagnostic” page 68). A warningsignal sounds if the engine is running. The text containsinformation about where the fault has occurred.

Each ECU is identified by a MID number (MessageIDentifier).

• ABS Brakes, MID 136• Instrument Cluster Center Module, MID 140• Instrument Cluster Display, MID 234• SRS Airbag, MID 232• Vehicle ECU, MID 144• Engine, MID 128


Factory installed equipment:

STOP!

ENGINE

FAULT

T3008861

Equipment not installed at factory:

If the bodybuilders or the customer have installed equip-ment afterwards which has been connected to the datalink, the following can be shown:

MID (Message IDentifier) = electronic control unit

STOP!

ERROR IN

MID 144

T3008861

54


Stop Messages (with Icons)The red �STOP lamp lights up and a symbol (and insome cases a value) are shown on the graphic display.A warning signal sounds if the engine is running.


Warning, transmission oil temperatureIf the transmission oil temperature becomes too high the�STOP lamp lights up and the transmission oil tempera-ture icon displays with the text TOO HIGH. This warningwill come on when the oil temperature has been 285�F(140�C) for 30 sec. Note: a high transmission oil temp.can instead cause an information message to display(see “Information Messages (with Icons)” page 51).

T3008831

TOO HIGH285�F

T3008861

Warning, engine oil pressureIf the engine oil pressure becomes too low the �STOPlamp lights up and the oil pressure icon is shown in thedisplay. This warning will come on when the oil pressurefalls below the trip point set in the engine ECU (seerespective engine service information). A forced idle con-dition or an engine shutdown may accompany thiswarning, if programmed to do so in the engine ECU.

W3003613

T3008861

Warning, coolant temperatureIf the engine coolant temperature becomes too high the�STOP lamp lights up and the coolant temperature iconis shown in the graphic display. This warning will comeon when the temperature exceeds the trip point set inthe engine ECU (see respective engine service informa-tion). For the Volvo engine the trip point is 215�F(102�C). An engine torque derate may accompany thiswarning, if programmed to do so in the engine ECU.

W3003614

T3008861

55


Graphic Display Menus, Non-Driving ModeThis chapter describes the graphic display’s functionwhile the vehicle is stationary and for speeds under 5mph (8 km/h). Several non-driving sub-menus are pro-tected by password.

Note: If all the menus are to be shown, the correct pass-word must be given. This applies to each time theignition key is turned to the ON position (if more than 60

sec. has elapsed since the last time the ignition key wasin the ON position). See “Main Menu: Password Input(non-driving)” page 86.

While the vehicle is stationary, there are 5 main menus inaddition to the drive menus. The drive menus are shown incapitals in the following table (the menu TIME/DISTANCEhas one additional function while the vehicle is stationary).

GAUGE

FUEL ECONOMY (option) !

TIME/DIST

FAULTS?

"#

Set-up mode

System diagnostic

Data log mode!

Password Input

"# "# "#

Set-up mode System diagnostic Data log mode

Language Fault diagnostic Vehicle id (Volvo engineonly)

!

Mi/�F/USgal or km/�C

!!

Cluster self test

!

Totals

Clock format Part number Trip data (Volvo engine only)

Contrast "# "#

Backlight Password Password

Night display Status test Reset trip data

"# "# "#

Password

Default language

Fleet limit: rpm (Volvo en-gine only)

Fleet limit: speed (Volvoengine only)

Fleet fuel target (Volvoengine only)

Password config.

Odometer setting (N/A)

Fleet ID (Volvo engineonly)

"#

56


Main Menu: Time/Distance (non-driving)Menu TIME/DIST has 1 additional sub-menu while notdriving:

• ALARM CLOCK

Note: This menu is available even when the ignition keyis in the OFF position. It is activated by pressing any ofthe control buttons on the wiper stalk for at least 1 sec-ond. The menu remains active for 30 seconds afterpressing the button.

Alarm clockMENU: TIME/DIST, ALARM CLOCK

Setting the alarm clock:

1 To set the alarm clock press ↵ when the menuALARM CLOCK is shown in the menu TIME/DIST.

2 Move the cursor to SET using the up/down buttons.Press ↵.

ALARM 08:30 AM

CLOCK 08:00 AM

ON OFF SET

If the speed during the setting exceeds 5 mph(8km/h), the function is cancelled and the graphicdisplay returns to the last active display in the ONposition.

3 Set the hours with the up/down buttons. Confirm thechoice with ↵.

4 Set the first digit in the minutes with the up/downbuttons. Confirm the choice with ↵.

5 Set the second digit in the minutes with the up/downbuttons. Confirm the choice with ↵.

6 Set the AM/PM (if the format is 12h) with theup/down buttons. Confirm the choice with ↵.

7 Move the cursor to ON using the up/down buttons.Press ↵. A symbol is shown on the right in thegraphic display window’s status bar in order to high-light that the alarm clock is activated.

T3008833

8 Esc moves the highlight to the previous number orselection if there are any, otherwise the setting iscancelled.

Ignition key in the off positionIf setting the alarm clock when the ignition key is in theOFF position takes more than 30 seconds, the timewhich has been entered then applies.

57


Switch off the alarm clockWhen the alarm clock goes off the word ALARM flashes,the current time is shown and a warning signal sounds.The alarm is switched off after 60 seconds or when theup/down buttons, Esc or ↵ is pressed.

Activate alarm clock (without changing the time of the alarm call)

1 The cursor is moved with the up/down buttons toON.

2 ↵ activates the alarm clock and the symbol isshown on the graphic display.

Cancel settingPress Esc in order to cancel the setting.

ALARM 08:30 AMT3008833

CLOCK 08:00 AM

ON OFF SET

De-activate the alarm clock1 The cursor is moved with the up/down buttons to

OFF.

2 ↵ switches off the alarm clock and the symbol dis-appears from the graphic display.


ALARM 08:30 AM

CLOCK 08:00 AM

ON OFF SET

58


Main Menu: Set-up mode (non-driving)The menu Set-up mode has 14 sub-menus where 6 arenot protected by passwords and 8 are protected bypasswords.

• Language• Mi/�F/USgal or km/�C• Clock format• Contrast• Backlight• Night display

Password is required:

• Default language• Fleet limit: rpm• Fleet limit: speed• Fleet fuel target• Fleet ID• Password config.

LanguageMENU: Set-up mode, Language

This setting of language applies until vehicle batterypower is disconnected. To change the language perma-nently, see “Default Language” page 62.

1 To set the desired language press ↵ when you arein the menu Set-up mode, Language.

2 On the graphic display up to three different lan-guages will now be shown. Select the desiredlanguage by moving the cursor to the particular row.Confirm the choice with ↵.


59


Miles/�F/USgal or km/�CMENU: Set-up mode, Mi/F/USgal or km/C

Note: If Miles and Fahrenheit are chosen, the fuel con-sumption is shown in US gallons.

1 Select the menu Set-up mode, Mi/F/USgal or km/Cand the following diagram is shown on the graphicdisplay (with the particular setting highlighted):

km and �C

Mi/USgal and �F

The up/down buttons move the cursor between thealternatives.

2 Confirm the choice with ↵.

3 When km and �C are chosen the following is shownon the graphic display (with the particular settinghighlighted):

Select

fuel data unit

km/l l/100 km

The up/down buttons move the cursor between thealternatives.



Clock formatMENU: Set-up mode, Clock format

1 Select the menu Set-up mode, Clock format andthe following diagram is shown on the graphic dis-play (with the particular setting highlighted):

AM/PM

24 h

2 The up/down buttons move the cursor between thealternatives. Confirm the choice with ↵.AM/PM is the 12 hour display (AM = morning andPM = evening).


60


ContrastMENU: Set-up mode, Contrast

1 Select the menu Contrast and the following diagramis shown on the graphic display. The bar shows theparticular setting in relation to max/min. contrast:

+ increases the contrast.

– reduces the contrast.


Adjust contrast


BacklightMENU: Set-up mode, Backlight

The graphic display’s brightness is controlled by thedimmer rheostat setting (which also controls the other in-strument cluster lighting). In this menu, the displaylighting can be altered in relation to the other instrumentcluster lighting.

1 Select the menu Backlight and the following dia-gram is shown on the graphic display. The bar showsthe particular setting in relation to max/min. lighting:

the up arrow button increases the background light-ing.

the down arrow button reduces the backgroundlighting.


Adjust lighting


61


Night displayMENU: Set-up mode, Night display

1 Select the menu Night display and the following di-agram is shown on the display:

2 With the up/down buttons the setting switchesbetween Normal and Reverse. With the setting Nor-mal the text is dark and the background light. Thesetting Reverse makes the text light and the back-ground dark. This setting only applies when theheadlights or parking lights are on, and helps tostop glare on light bleed-through at night.


Night display

Normal

Reverse


Default LanguageMENU: Set-up mode, Default language

Only available when the correct password has beengiven.

This setting of the language is kept even when batterypower is lost. See also “Language” page 59 for more in-formation about setting the language.

1 To set the desired language press ↵ when you arein the menu Set-up mode, Default language.

2 On the graphic display, up to three different lan-guages will be shown. Select the desired languageby moving the cursor to the particular row. Confirmthe choice with ↵.


62


Fleet Limit: rpmMENU: Set-up mode, Fleet limit: rpm


This setting gives the ability to choose an engine speedlimit. If the vehicle is driven at a higher engine speedthan this rpm limit, the duration of the overspeed is reg-istered. See “Trip data” page 83.

1 When the menu Set-up mode, Fleet limit: rpm ischosen the following is shown on the graphic display:

Data transfer

in progress

please wait

2 The new engine speed is set using the up/down but-tons (one number at a time) followed by ↵:

Present

2000 r/m

1900 r/m

If an incorrect number has been given, press Escand the previous number is highlighted. If there isno previous number, the setting is cancelled and themenu Set-up mode is shown again.

3 The following message is shown:

Data transfer

completed

Press Esc to return to the previous menu.

4 If the transfer should fail, the following message isshown:

Operation

failed

Action:

• Press Esc and try to do the setting one moretime, see step 1.

• Otherwise perform a diagnostics test on thegraphic display and the engine ECU, see “Faultdiagnostic” page 68.

63


Fleet Limit: SpeedMENU: Set-up mode, Fleet limit: speed


This setting gives the ability to choose a speed limit. Ifthe vehicle is driven faster than the chosen speed limit,the duration of the overspeed is registered. See “Tripdata” page 83.

1 When the menu Set-up mode, Fleet limit: speed ischosen the graphic display first shows the following:

Data transfer

in progress

please wait

2 The new speed is set using the up/down buttons(one number at a time) followed by ↵:

Present

70 mph

65 mph

If an incorrect number has been given press Escand the previous number is highlighted. If there isno previous number, the setting is cancelled and themenu Set-up mode is shown again.

3 The following message is shown:

Data transfer

completed



Operation

failed

Action:



64


Fleet Fuel TargetMENU: Set-up mode, Fleet fuel target


This setting gives the fleet owner the ability to set a fueltarget. For information about fuel consumption for a trip,see “Trip data” page 83.

In order to compare the fuel consumption with the fueltarget set, see “AVG/INST Fuel Economy” page 45.

1 When the menu Set-up mode, Fleet fuel target ischosen the graphic display first shows the following:

Data transfer

in progress

please wait

2 The new fuel target is set using the up/down buttons(one number at a time) followed by ↵:

Now 10 mpg

New 14 mpg

Note: If metric scales have been selected, the con-sumption is shown in liters. In the example above,L/100 km will then be shown instead of mpg.

If an incorrect number has been given press Escand the previous number is highlighted. If there isno previous number, the setting is cancelled and themenu Set-up mode is shown again.

3 The following text message is shown when thetransfer is complete:

Data transfer

completed



Operation

failed

Action:


• Otherwise perform a diagnostics test on thedisplay and the engine ECU, see “Fault diag-nostic” page 68.

65


Fleet idMENU: Set-up mode, Fleet id


In this menu, the identification the vehicle has in the fleetcan be entered. Data registered in the engine ECU isthen registered for this ID.

1 Select the menu Set-up mode, Fleet id. The follow-ing text message is shown:

Data transfer

in progress

please wait

2 The new Fleet ID is set using the up/down buttons(one number/letter at a time followed by ↵). 13characters must be entered (spaces are entered inunused positions).

Fleet id:

ifkgoteborg

Enter Fleet id

If an incorrect number/letter has been given pressEsc and the previous number/letter is highlighted. Ifthere is no previous number/letter, the setting is can-celled and the menu Set-up mode is shown again.

3 The following message is shown when the setting iscomplete:

Data transfer

completed



Operationfailed

Action:



66


Change passwordMENU: Set-up mode, Password config.

Only available when the correct password has beengiven (the owner’s password). See “Password Infor-mation” page 39 for general information about thepassword.

If none of the functions are protected by passwords thismenu will not be available.

1 When the menu Set-up mode, Password config. ischosen the graphic display first shows the following:

Change password

Mechanic

Owner

2 Select Owner or Mechanic, a new text message isshown:

Enter password0000

3 The password is set with the up/down buttons (onenumber at a time) followed by ↵.

If an incorrect number has been given, press Escand the previous number is highlighted. If there isno previous number, the setting is cancelled and themenu Set-up mode is shown again.

67


Main Menu: System Diagnostic (non-driving)Menu System Diagnostic has 4 sub-menus where 3are not protected by passwords and 1 is protected bypassword.

• Fault diagnostic

• Cluster self test

• Part number

• Status test (password is required)

Fault diagnosticMENU: Diagnostic, Fault diagnostic

A list of the vehicle’s ECUs is shown in the menu Faultdiagnostic. Each ECU is identified by a MID number(Message IDentifier). In addition a menu for resetting allthe fault codes is shown.

For a list of common fault codes, see “Common FaultCodes” page 74.

• ABS Brakes, MID 136• Instrument cluster center module, MID 140• Instrument cluster left module, MID 234• SRS Airbag, MID 232• Cab controller (Vehicle ECU), MID 144• Engine, MID 128• Non specified system• Reset all (password)

1 The up/down buttons are used to move the cursorin the list.

2 ↵ confirms the selection of ECU or Reset all.

3 During the time that each respective ECU is beingcalled, the display shows the text:

Data transfer

in progress

please wait

4 No faults in the chosen system:

No faults


5 Not responding to Non spec. system:

Non spec. syst

MID (127)

Not responding


6 If the chosen system does not respond within 5seconds the following message is shown (in this ex-ample the engine has been called):

Engine

MID 128

Not responding

Action:

• Press Esc and try to do the operation one moretime, see step 1.

68


Fault codes are shown1 If there is a fault code or codes the following is

shown, for example:

Engine

Coolant temperature

Value too high

Active � 1 I #

Line 1: Identification of ECULine 2: Identification of parameter/componentLine 3: Identification of fault type

”� 1” shows how many times the fault has beenregistered since the last resetting. If there is no in-formation available for how many times the faultcode has been registered, only Active is shown (thefault remains). Or alternatively Inactive is shown(the fault was there previously).

The arrow in the lower, right-hand corner is shown ifthere is more than one fault code. The up/down but-tons move the cursor and the next faultcode/message is shown. If the right password hasbeen entered resetting can be done in Reset all, lastin the list. This resetting deletes only the fault codesfor the chosen ECU.

2 If more than 20 fault codes/messages are availablefor the chosen ECU the 21st message will be:

Engine

Too many

fault messages

To see those messages that are not shown, one ormore of the first messages must be reset, see“Reset a fault code” page 72.

The fault codes are presented in text format, but theuser can also choose to have the fault codes pre-sented numerically (if a fault code or ECU is notrecognized by the system, they will only be pre-sented in numeric format).

69


Numeric or text1 Press ↵ when there are fault codes and the follow-

ing menu is shown. Select numeric or text format(the function Reset will only be shown when the cor-rect password has been entered):

Numeric

Text

Time stamp

Reset

2 When Text has been selected, the fault codes areshown according to step number 1 under “Faultcodes are shown” page 69.

3 When Numeric has been selected the fault codesare shown with numbers:

MID 128

PID 110

FMI 0

Active � 1 I #

MID: Identification of ECUPID: Identification of parameterPPID: Volvo unique identification of parameterSID: Identification of componentPSID: Volvo unique identification of componentFMI: Identification of fault type

”� 1” shows how many times the fault occurredsince the last resetting. If there is no informationavailable for how many times the fault code hasbeen active, only Active is shown (the fault remains)or Inactive (the fault was there previously).

The arrow in the lower, right-hand corner is shown ifthere is more than one fault code. The up/down but-tons move the cursor and the next fault code isshown. If the correct password has been entered,resetting can be done in Reset all, last in the list.This resetting deletes only the fault codes for thechosen ECU.

4 If more than 20 fault codes/messages are availablefor the chosen ECU, the 21st message will be:

Too many

fault messages

To see those messages that are not shown, one ormore of the first messages must be reset, see“Reset a fault code” page 72.

70


Time stamp1 To show the time when the fault code was set for

the first and latest occasion respectively press ↵when the particular fault code is presented (doesnot apply to all MIDs, such as ABS brakes or SRSairbag). The following menu is shown:

Numeric

Text

Time stamp

Reset

2 Select Time stamp and the following text messageis shown:

Data transfer

in progress

please wait

3 The following is shown (time stamp is presented asthe number of hours the engine has been running):

First

X

Last

X



First

No data

Last

No data

Action:

• Check that the ABS brakes or the SRS airbaghave not been asked for a time stamp. If it is forother ECUs press Esc and attempt the opera-tion once again.

71


Reset fault codes

Reset a fault code

Only available when the correct password has beengiven. This function is not supported by all devices.

Note: Individual fault codes on brakes or airbags cannotbe reset. See “Reset all the fault codes” page 73 for re-setting these fault codes. Active fault codes cannot bereset – only inactive faults can be reset.

If you try to reset a fault code for brakes or airbagsthe following is shown:

This function

is not possible

1 In order to reset a fault code press ↵ when the par-ticular fault code is presented. The following menu isshown:

Numeric

Text

Time stamp

Reset

2 On the graphic display, a question about resetting isshown:

Reset?

Press ↵ FOR 1S

3 The following text message is shown on the graphicdisplay:

Data transfer

in progress

please wait

4 The text message that the resetting has been car-ried out is shown on the graphic display:

Data transfer

completed


5 If the resetting should fail, the following message isshown:

Operation

failed

Action:

• Press Esc and then do “Reset all the faultcodes” page 73.

Important: Note first any remaining fault codeson the other ECUs since even these will be re-set.

• Otherwise do the diagnostics test on the cho-sen system as well as the graphic display, see“Fault diagnostic” page 68. If there are activefaults, those faults cannot be reset until they arerepaired (until the fault becomes inactive).

72


Reset all the fault codes

Only available when the correct password has beengiven. This function is not supported by all devices.

In the menu “Fault diagnostic” page 68 Reset all is cho-sen last in the list using the up/down buttons . Via thismenu, the fault codes of all systems can be reset.

1 Place the cursor last in the list and select Reset all.A new text message in the form of a question isshown: Reset? Press ↵.

Reset?

Press ↵ FOR 1S

2 The following text message is shown on the graphicdisplay:

Data transfer

in progress

please wait

Esc cancels the setting and the menu Fault diag-nostics is shown again.

3 On the graphic display, a text message is shownwhen the resetting has been carried out:

Data transfer

completed



Operation

failed

Action:

• First press Esc and then reset each fault codeindividually. See “Reset a fault code” page 72.

• Otherwise do the diagnostics test on the cho-sen system as well as the graphic display. See“Fault diagnostic” page 68. If there are activefaults, those faults cannot be reset until they arerepaired (until the fault becomes inactive).

73


Common Fault Codes

MID’s (Message ID’s orsources)

Description

128 Engine

232 SRS (Airbag)

136 ABS

140 Instrument Cluster Center Module

234 Instrument Cluster Left Module

144 Cab Controller (Vehicle ECU)

130 Transmission

PID’s (Parameter ID’s) Description

84 Road speed

91 % Throttle pedal

100 Engine oil pressure

102 Boost pressure

105 Air inlet temperature

110 Engine coolant temp

111 Coolant level

173 Pyrometer

175 Engine oil temperature

190 Engine speed

74


PPID’s (Proprietary ParameterID’s)

Description

69 Buffered idle switch

70 Pedal switches, supply

71 Cruise control and retarder, supply switch

72 Accelerator pedal and retarder, supply sensors

73 Accelerator control 2 and primary tank, supply sensors

75 Range inhibitor, status solenoid valve

76 Brake lamps, status relay

77 Compressor, status solenoid valve

78 Interval wiper, status relay

79 Area inhibitor, status solenoid valve

86 Engine brake torque percent

109 EPG3 drive stage failure

121 MTE (Engine compressor control output) failure

122 VCB Engine compression brake

123 EPG2 Start and Warmhold

124 EPG1 Engine brake

125 EOL Enable failure

195 Proprietary Diagnostic Data Request/Clear Count

196 Proprietary Diagnostic Data/Count Clear Response

Common SID’s (SubsystemID’s)

Description

242 CC resume switch

243 CC set switch

244 CC enable switch

245 Clutch pedal switch

246 Brake pedal switch #1

247 Brake pedal switch #2

251 Power supply

75


Engine SID’s (SubsystemID’s)

Description

1 Injector #1

2 Injector #2

3 Injector #3

4 Injector #4

5 Injector #5

6 Injector #6

21 Engine position sensor

22 Timing sensor

25 Ext. Engine protection sig.

PSID’s (Proprietary Subsys-tem ID’s)

Description

PSID 1 Retarder Brake Control Set Switch

PSID 2 Idle Validation Switch #2

PSID 3 Idle Validation Switch #3

PSID 4 Retarder Brake Control Switch

PSID 5 Forward rear Axle Temperature

PSID 6 Rear rear Axle Temperature

Brake SID’s (Subsystem ID’s) Description

1 ABS Snsr axle 1 L

2 ABS Snsr axle 1 R

3 ABS Snsr axle 2 L

4 ABS Snsr axle 2 R

5 ABS Snsr axle 3 L

6 ABS Snsr axle 3 R

7 ABS valve axle 1 L

8 ABS valve axle 1 R





13 ABS rtrdr ctrl relay

18 ABS, dif 1 - ASR valve

76


Airbag SID’s (Subsystem ID’s) Description

1 Dr Airbag lgn Loop

FMI’s (Failure Modes) Description

0 Data valid, but high

1 Date valid, but low

2 Data erratic

3 Voltage shorted high

4 Voltage shorted low

5 Current low or open C

6 Current high or short C

7 Mech syst no response

8 Abnormal freq or PW

9 Abnormal update rate

10 Abnormal change rate

11 Failure unknown

12 Bad device

13 Out of calibration

14 Special instruction (see Note)

A complete list of MIDs, PIDs, SIDs and FMIs is pub-lished in the SAE J1708/1587 document.

Note: The special instruction FMI #14 is broadcast whenthe airbag has stored crash data.

77


Cluster self testMENU: System diagnostic, cluster self test

Four sub-menus are available:

• Bulb test

• Gauge test

• Display test

• Buzzer test

Cancel testPress Esc in order to cancel the test.

Bulb testMENU: System diagnostic, Cluster self test, Bulb test

1 Select Bulb test.

2 The telltale lamps light up for approx. 5 seconds.

3 Esc cancels the test and the menu Bulb test isshown again.

Changing bulbsChanging the instrument cluster’s telltale lamps can becarried out from the rear side, without the instrumentcluster needing to be opened. Use the bulb removal tool.

Important: Needle-nose pliers must not be used!

Gauge testMENU: System diagnostics, Cluster self test, Gauge test

1 Select Gauge test.

2 The pointers on the electrically controlled gaugesmove back and forth a few times, between the endpositions. They stop at the mid-point of the gaugebefore the test is complete, then return to zero. Thisis only a check that they can move (i.e. that thegauge functions). Note: mechanical (air) gauges arenot operated with this test.

3 Esc cancels the test and the menu Gauge test isshown again.

Display testMENU: System diagnostic, Cluster self test, Display test

1 Select Display test.

2 The display goes out, lights up, goes out. In theodometer display, all segments are shown, then off,back on, off again, and back to the normal display.

3 Esc cancels the test and the menu Display test isshown again.

Buzzer testMENU: System diagnostic, Cluster self test, Buzzer test

1 Select Buzzer test.

2 On the display, the name of the current sound isshown at the same time as the sound is activated.With the up/down buttons you can switch betweenthe different sounds.Three different sounds (flasher indicator, reminderand caution) are tested for 10 seconds each.

3 Esc cancels the test and the menu Buzzer test isshown again.

78


Part numberMENU: System diagnostics, Part number

A list of the vehicle’s electronic control units (ECUs) isshown in the menu Part number. Each ECU is identifiedby a MID number (Message IDentifier).

• ABS Brakes, MID 136• Instrument cluster center module, MID 140• Display, MID 234• SRS Airbag, MID 232• Vehicle ECU, MID 144• Engine, MID 128


2 ↵ confirms the selection of an ECU.

3 In the meantime, the display shows the text:

Data transfer

in progress

please wait

4 The following text is presented:

MID 128 SW ID

03163028P01

SW: The software’s part number


MID 128 HW ID

VOLVO08192949P06

HW: ECU part number

6 If there is a communication error, the following isshown No data (this example shows HW ID, butsame text applies to SW ID except that HW is re-placed by SW):

MID 128 HW ID

No data

Action:

• Press Esc to return to the previous menu andattempt the operation once again.

• Otherwise do the diagnostics test on the cho-sen system as well as the display, see “Faultdiagnostic” page 68.

79


Status testMENU: System diagnostic, Status test


Each ECU is identified by a MID number.

The parameter values are identified by the PID andPPID. The difference between PID and PPID is thatPPID is unique for Volvo. PID follows the SAE standard.

Status tests cannot be done on SID or PSID.

Data is displayed in decimal values, and must be trans-lated using the SAE J1587 specification. This function isdesigned for experienced technicians who are familiarwith J1587.

1 Select the menu System diagnostic, Status test.

MID1: XXX

PID/PPID1: YYY

MID2: ZZZ

PID/PPID2: VVV

2 Use the up/down buttons to highlight the desiredMID and PID and/or PPID (one number at a time)followed by ↵. If an incorrect number has been givenpress Esc and the previous number is highlighted. Ifthere is no previous number, the setting is cancelledand the menu System diagnostic is shown.

3 Select another MID if you want, otherwise select000.

4 Step 2 is repeated if an additional MID has been se-lected.

5 The display shows the text message:

Data transfer

in progress

please wait

6 If two MID’s have been given, the following is shown:

MID: XXX ZZZ

PID/PPID: YYY VVV

DATA1: AAAAAAAAAAAA

DATA2: BBBBBBBBBBBB

7 If one MID has been given, the following is shown:

MID: XXX

(P)PID: YYY

DATA1: AAAAAAAAAAAA


8 If it there is no data for the chosen PID/PPID, thefollowing is shown:

MID: XXX

(P)PID: YYY

DATA1: No data

Action:

• Check that the correct data has been givenwhen prompted (i.e. the correct MID, PID andPPID number).

• Press Esc to return to the previous menu andattempt the operation once again.

• Otherwise do the diagnostics test on the cho-sen system as well as the display. See “Faultdiagnostic” page 68.

80


Main Menu: Data Log mode (with Volvo engines only) (non-driving)Menu Data log mode has 4 sub-menus where 3 are notprotected by passwords and 1 is protected by a pass-word.

• Vehicle ID

• Totals

• Trip data

• Reset trip data (requires password)

Vehicle IDMENU: Data log mode, Vehicle ID

1 Select the menu Data log mode, Vehicle ID andthe following text message is shown:

Data transfer

in progress

please wait

2 The fleet ID that is shown has been entered in themenu “Fleet id” page 66.

Fleet ID:

XXX

Chassis no:

XXX



Operation

failed

Action:

• Press Esc and try to do the operation one moretime, see step 1.

81


TotalsMENU: Data log mode, Totals

1 Select the menu Data log mode, Totals.

2 The menus that show Totals can be scrolled to us-ing the up/down buttons.

3

Total distance

406.7 mi

4

Total fuel used

51.3 gal

Note: If km and �C have been selected, the con-sumption is shown in liters.

5

Total enginehours

7.3 h

6

Total idle time

0.3 h

7

Total PTO hours

0.5 h

8

Total engine revolutions

1 220 100 r


Operation

failed

Action:

• Press Esc and try to do the operation one moretime. See step 1.

• Otherwise perform a diagnostics test on thegraphic display and the engine ECU. See“Fault diagnostic” page 68.

Cancel operationPress Esc in order to cancel the operation.

82


Trip dataMENU: Data log mode, Trip data

1 Select the menu Data log mode, Trip.

2 The information below can be scrolled to using theup/down buttons.

3

Trip distance

203.5 mi

4

Trip fuel

Avg. 28 l/100 km

Acc. 57.0 gal

Note: If Miles and �F have been selected, the con-sumption is shown in US gallons.

5

Trip overrevs

0.8 h

6

Trip uneconomy rev’s

0.4 h

7

Trip fuel

uneconomy rev’s

8.5 gal


8

Trip average speed

67.4 km/h

9

Trip overspeed

0.2 h

10

Trip engine hours

3.0 h

83


11

Trip idle time

0.4 h

12

Trip idle fuel

2.5 gal

Note: If km and �C has been selected, the con-sumption is shown in liters.

13

Trip PTO hours

1.3 h

14

Trip PTO fuel

20.4 gal


15

Trip cruise

2.5 h


Operation

failed

Action:

• Press Esc and try to do the operation one moretime. See step 1.

• Otherwise perform a diagnostics test on thegraphic display and the engine ECU. See“Fault diagnostic” page 68.

Cancel operationPress Esc in order to cancel the operation.

84


Reset trip dataMENU: Data log, Reset trip data


1 Select the menu Data log, Reset trip data.

2 A new text message in the form of a question isshown: Reset? Press ↵.

Reset?

Press ↵ FOR 1S

3 When resetting is being carried out the following isshown:

Data transfer

in progress

please wait

4 The following message is shown when resetting iscomplete:

Data transfer

completed


Operation

failed

Action:

• Press Esc and try to do the reset one moretime. See step 1.


85


Main Menu: Password Input (non-driving)MENU:Password Input

1 Select the menu Password Input.

Set-up mode

System diagnostic

Data log mode

Password Input

2 The password consists of a four-figure number,0000–9999, that is scrolled forward with theup/down buttons on the wiper stalk (one number ata time) followed by ↵. The display shows the follow-ing text message:

Password input

0000

If an incorrect number has been given press Escand the previous number is highlighted. If there isno previous number, the setting is cancelled and themenu Password Input is shown again.

When the ignition key has been in the off positionfor more than 60 seconds or when the batterieshave been disconnected the password must be en-tered again.

3 If the wrong password is given, the following isshown the text message:

Error!

Password Input

0000

86

Group 38 Instrumentation, VN / VHD Troubleshooting

Troubleshooting

Instrumentation TroubleshootingWhen troubleshooting the instrument cluster, the graphicdisplay or Volvo’s VCADS Pro diagnostic tool can beused. VCADS Pro provides several features not availablewithin the cluster itself, such as the ability to test inputsignals and calibrate gauges individually.

Many of the components can be tested without disturb-ing the cluster by using the cluster self test function inthe graphic display’s Diagnostic Menu. This includes allthe telltale lamps, the graphic display, and all gauges ex-cept for the air gauges. The pivot-down mounting featureof the cluster allows troubleshooting of input signalswithout removing the cluster from the vehicle.

Note: Instrument cluster programming. Each instru-ment cluster (or CPU board) is programmed tocorrespond to the customer-ordered options for that par-ticular vehicle. This dataset is stored in the CPU boardmemory, making the instrument cluster unique to eachvehicle.For this reason, it is not possible to ”swap” a suspectedfaulty instrument cluster (or CPU board) with one fromanother vehicle without reprogramming the replacementinstrument cluster (or CPU board).Authorized technicians can update and/or alter software

datasets with the VCADS Pro tool.See the most current VCADS Pro user manual or the”Help” menu in the VCADS Pro tool.

Important: Warranty Information. Individual modules inthe instrument cluster are not serviceable during thewarranty period. Individual electrical gauges are not ser-viceable at any time. Attempts to service or replaceindividual modules during the warranty period willvoid the cluster warranty. Instead, the whole unit maybe exchanged.

This section contains the following:

• “Instrument Cluster Diagnostic Tests” page 89• “Warning and Telltale Lamps, Troubleshooting”

page 92• “Instrument Cluster Backlighting, Troubleshooting”

page 106• “Graphic Display and Odometer, Troubleshooting”

page 111• “Gauges, Troubleshooting” page 115• “Graphic Display Control Buttons, Troubleshooting”

page 128• “Buzzer, Troubleshooting” page 130

87


General Work Practices

CAUTION

Possible damage to electronic components. Turn thevehicle ignition switch OFF before disconnecting orconnecting electrical components. Failure tode-energize circuits may result in electronic equip-ment damage.

CAUTION

To prevent electrostatic discharge (ESD), which maydamage the sensitive electronic components in the in-strument cluster, a wrist grounding strap must beused when working on electronic equipment such asthe instrument cluster. Failure to use a wrist strap mayresult in permanent damage to the printed circuitboards in the instrument cluster. To use the wrist strapin a vehicle, attach the alligator clip to the nearestelectrical ground such as a metal mounting screw, aground terminal or preferably a ground stud.

CAUTION

To prevent electrostatic discharge (ESD), which maydamage the sensitive electronic components in the in-strument cluster, make sure the workbench has ananti-static mat which is grounded to the nearest elec-trical outlet when working on the instrument cluster.Failure to use an anti-static mat may result in perma-nent damage to the printed circuit boards in theinstrument cluster. When working at the anti-staticworkbench, always keep a wrist strap connected tothe anti-static mat.

CAUTION

When servicing or troubleshooting, do not leave thecluster face-down for more than 15 minutes, or dam-age to the gauges may occur. Gauge oil may run outof the front of the gauge faces and make the gaugesinaccurate.

88


Instrument Cluster Diagnostic Tests

Instrument Cluster Self Test

W3003624

The following tests can be performed via the graphic dis-play using the graphic display control buttons:

1 Esc is used to return to the previous menu and can-cel an operation.

2 ↵ or select confirms a highlighted menu selectionand displays the sub-menu for that selection.

3 The up arrow moves the cursor up through themenu selections.

4 The down-arrow moves the cursor down through themenu selections.

From the graphic display menu “System diagnostic” se-lect “Cluster self test.” The four sub-menus available are:

Bulb testThe test activates all telltale lamps and all red LEDwarning indicators. If the lamps do not light during thetest, the lamp may not be operating or there may be afault in the wiring used for the indicator lamp test.

Gauge testThis test checks that the electrically controlled gaugescan be activated (that the gauges and drivers operatecorrectly). The gauges will sweep to full and half scale.Mechanical (air) gauges are not operated with this test.

Display testThe entire display screen will alternate from dark to lightto check that all pixels on the display are operational.Additionally, the odometer display will illuminate all LEDsegments.

Buzzer testThis test checks the function of the buzzer. The graphicdisplay alternates from flasher indicator to reminder tocaution. A different tone will sound with each displaymessage. (The caution sound is connected to the yellowinformation lamp.)

These tests can also be run using the VCADS Pro tool.

89


Instrument Cluster Tests with VCADS Pro

W0001632

The VCADS Pro tool is a Windows 95® based PC toolthat can be used to perform instrument cluster testing,calibrations and programming. The tests are similar tothe self tests in the instrument cluster. In addition,VCADS Pro allows the status of the buttons on the con-trol lever to be checked, and individual gauges can becalibrated. The following is a brief description of the testsand calibration currently available. Additional tests maybe added as newer versions of VCADS Pro becomeavailable. More information about the tests can be foundin the most current VCADS Pro user manual or the”Help” menu in the VCADS Pro tool.

Note: Mechanical (air pressure) gauges are not oper-ated with these tests.

Instrument Cluster, TestThis test is intended to check instrument cluster func-tions. During these tests sensor inputs are ignored andthe instruments are driven by the instrument cluster mi-croprocessor (CPU). These tests can also be run usingthe graphic display control buttons.

Bulb testThe test activates all telltale lamps and all red LEDwarning indicators. If the lamps do not light during thetest, the lamp may not be operating or there may be afault in the wiring used for the indicator lamp test (see

“Telltale Lamps” page 96).

Gauge testThis test checks that the electrically controlled gaugescan be activated (that the gauges and drivers operatecorrectly). The gauges will sweep to full and half scale.Mechanical (air) gauges are not operated with this test.

Display testThe entire display screen will alternate from dark to lightto check that all pixels on the display are operational.Additionally, the odometer display will illuminate all LEDsegments.

Buzzer testThis test checks the function of the buzzer. The graphicdisplay alternates from flasher indicator to reminder tocaution. A different tone will sound with each displaymessage. (The caution sound is connected to the yellowinformation lamp.)

Graphic Display Control ButtonsThe VCADS Pro screen will illuminate indicators toconfirm that the graphic display control buttons are deliv-ering a signal. The graphic display control buttons areused to access all instrument cluster and graphic displayfunctions.

90


Gauge Accuracy CheckAccuracy checks can only be performed using VCADSPro. The VCADS Pro tool can display the value of signalscoming into the instrument cluster for most electricallyoperated gauges. These values can then be comparedto the reading displayed on each respective gauge.

If the reading displayed on the gauge appears not tomatch the value seen on the VCADS Pro tool, the gaugecan be adjusted with the “Gauge Calibration” feature ofthe VCADS Pro tool. See the most current VCADS Prouser manual or the ”Help” menu in the VCADS Pro tool.

The calibration allows the gauge pointer to be adjustedso that it is at the center of the reference marks on thegauge face. Plus and minus adjustment icons on theVCADS Pro tool allow incremental adjustment of thepointer to the left, right and center reference marks.

Note that if the gauge is calibrated at one point (such asthe center mark), it may affect the calibration at anotherpoint on the gauge. Gauges should not be calibrated un-less the readings are obviously inaccurate.

Note: VCADS Pro does not have the capability of cali-brating the speedometer or tachometer.

W3004300

91


Warning and Telltale Lamps, TroubleshootingTelltale lamps are positioned across the bottom of the instrument cluster. LED indicatorlamps are integrated into various individual gauges. Before troubleshooting, see“General Work Practices” page 88.

W3004319

Wiring, Instrument Cluster Telltale and LED Lamps.Note: All telltale lamps may not be used or wired in all vehicles.The schematic should be used to help clarify the warning and telltale lamp troubleshooting procedures in thismanual. For detailed, vehicle specific, wiring troubleshooting see:

ServiceManual

VN Series Electrical Schematics, Group 37or VHD Series Electrical Schematic, Group 37

IMPACT Function Group: 37Information Type: Electrical SchematicsModel: VN/VHD

Instrument Cluster Self TestThe graphic display control buttons can be used to select instrument cluster self tests.From the graphic display “System diagnostic” menu, select “Cluster self test”, then“Bulb test”.

• With the bulb test active all the telltale and LED indicator lamps will illuminate forapproximately 5 seconds.

Instrument Cluster Tests using VCADS ProWith the “Bulb test” selected in the VCADS Pro tool, all telltale and LED indicatorlamps will illuminate for approximately 5 seconds. See the most current VCADS Prouser manual or the ”Help” menu in the VCADS Pro tool.

92


TroubleshootingIf all the telltale and LED indicator lamps function correctly in the Instrument ClusterSelf Test or Instrument Cluster Tests using VCADS Pro, the lamps and instrument clus-ter electronics are working properly.

LED Indicator LampsLED lamps are integrated into the following gauges: engine oil pressure, enginecoolant temperature, front brake air pressure and rear brake air pressure. LEDs, orLight Emitting Diodes, cannot be replaced like the bulb-type telltale lamps.

Engine oil pressure LED and Engine coolant temperature LEDThe engine oil pressure and engine coolant temperature LEDs illuminate based on sig-nals received from the J15878/J1708 information data link. There are no sensorshardwired to warning LEDs.

LED Warning Lamp Check Key Posi-tion

MeasurementPoint

ExpectedValue

Note Measurementsnot expectedvalue? Check:

Engine oil pressureLED,

Engine coolant tem-perature LED

Run Clus-ter SelfTest (bulbtest) or testusingVCADSPro

On Visual check LEDs illumi-nate

If LEDs illumi-nate thecluster isfunctioningproperly.

If LEDs do not illu-minate, replacethe cluster (or leftgauge module orleft CPU board ifout of warranty).

Note: Problems with the left module gauges may be in the left CPU board or the leftgauge module. No tests are currently available to isolate the problem area.

93


Front and Rear Air Pressure LEDs

The front and rear air pressure LEDs illuminate based on air pressure delivered to the instrument cluster. There are nosensors hardwired to the warning LEDs. Note: LEDs should illuminate below approx. 70 psi.

Step 1. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument clus-ter electronics are working properly.

If only one of the LEDs comes on replace the cluster (or right module if out of warranty).If neither LED comes on, but the telltale lamps at the bottom do, replace the cluster (or right module if out of war-ranty).If no lamps illuminate go to step 2.

Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX andthe instrument cluster connector RX. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded green for the RX connector pins. Proceed to the chart below.

Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digi-tal multimeter J–39200 or an equivalent tool. See “Connectors, Back-probing” page 134.

LED Warning Lamp Function Key Posi-tion

MeasurementPoint

ExpectedValue

Note Measurements notexpected value?Check:

Front brake air pres-sure LED

12V Bulb testactive

Lamp Test(-)

On Check green28 (RX28) to+bat with me-ter <1V Bulb test

not active

Check wiring or con-nectors betweenconnector RX and CY

Rear brake air pres-sure LED

Power Sup-ply

On Check green18 (RX18) toground withmeter

+12V Fuse, connectors orwiring fault in powersupply circuit

Ground Off Check green15 (RX15) toground withmeter

<1 Connectors or wiringfault in ground circuit

94


If the measurements are outside the expected values, refer to (for circuitry information):

ServiceManual



If all the measurements are correct, replace

• The instrument cluster if within the warranty period. See “Instrument Cluster, Re-placement” page 139.

• The right module if the warranty has expired. See “Right Module, Replacement”page 145.

95


Telltale Lamps

The telltale lamps are incandescent bulb assemblies that can be easily replaced with the proper tool.

Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See “Bulb, Replacement” page137.

Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument clus-ter electronics are working properly. If not, go to step 3.

Step 3. If the bulb is still not working, connect breakout box 9998551 with adapter J-43235 in series betweenwiring harness connector LX and the instrument cluster connector LX. Install overlay J-43340 with the 22–PINBREAKOUT HARNESS side up. The overlay is color-coded green for the LX connector pins. Go to the next chart andperform the tests for the lamp in question.

Left Module Telltale Lamps

Telltale Lamp Function Key Posi-tion

MeasurementPoint

ExpectedValue


All Left Module tell-tale lamps

Power Sup-ply

On Green 22(LX22) toground withmeter

+12V Fuse, connectorsor wiring fault inpower supply cir-cuit

Ground Off Green 12(LX12) toground withmeter

<1 DisconnectLX connectorat cluster

Connectors orwiring fault inground circuit


ServiceManual



If all the measurements are correct, continue to the next troubleshooting chart.

Note: If the breakout box tooling is not available, the instrument cluster connector pinsmay be back-probed with digital multimeter J–39200 or an equivalent tool. See“Connectors, Back-probing” page 134.

96


Left Module Telltale Lamps (continued)

Step 1. Set-up: connect breakout box 9998551 with adapter J-43234 in series between wiring harness connectorsLY and CY and the instrument cluster connectors LY and CY. Install overlay J-43340 with the 30–PIN BREAKOUTHARNESS side up. The overlay is color-coded green for the LY connector pins, and blue for the CY connector pins.Proceed to chart below.



MeasuringPoint

ExpectedValue


Preheat Power Sup-ply to Lamp

Preheat Check green 11(LY11) toground with me-ter

12V (withpreheatactive)

Preheat lampnot designedto illuminatewith all vari-ants.

EECU or connec-tors or wiring faultin the circuit fromEECU.

Lamp test On Green 11(LY11) directconnection toBlue 22 (CY22)

Preheatlamp illu-minates

Preheat lampnot designedto illuminatewith all vari-ants.

Confirm Blue 22(CY22) is supply-ing 12V to Green11 (LY11). If so,probable left CPUboard fault.

Yellow lamp, INFO 12V Lamp offGround tolamp

On Check green 10(LY10) toground with me-ter

0V Lamp on


Lamp test On Green 10(LY10) directconnection toground

INFO lampilluminates

Confirm Green 10(LY10) is suppliedground. If so,probable left CPUboard fault.

Red lamp, STOP 12V Lamp offGround tolamp

On Check green 6(LY6) to groundwith meter 0V Lamp on


Lamp test On Green 6 (LY6)direct connec-tion to ground

STOPlamp illu-minates

Confirm Green 6(LY6) is suppliedground. If so, prob-able left CPU fault.

Charging Power sup-ply to lamp

On withenginerunning

Check green 5(LY5) to groundwith meter

Above+12V

Alternatorchargingabove batteryvoltage

Fuse, connectorsor wiring fault fromcharging circuit. Oralternator failure

Lamp test On Green 5 (LY5)direct connec-tion to ground

Charginglamp illu-minates

Probable left CPUboard fault.



• The left CPU board if the warranty has expired. See “Left CPU Board, Replace-ment” page 156.

97


Center Module Telltale Lamps


Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps are OK. If lamps donot illuminate go to step 3.

Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connectors CY andRX and the instrument cluster connectors LY and CY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESSside up. The overlay is color-coded blue for the CY connector pins, and green for the RX connector pins. Proceed tothe chart below.



MeasuringPoint

ExpectedValue


Left turn Power sup-ply to leftturn indicator

On Check blue 14(CY14) toground withmeter

Min: 0VMax: 12V

Left turn sig-nal active

Fuse, connectors,or wiring fault in leftturn circuit

Ground Off Check blue 11(CY11) toground withmeter

<1 Connectors orwiring fault inground circuit

Lamp test On Blue 14 (CY14)jumper wire toBlue 22 (CY22)

Left turnlamp illu-minates

Confirm Blue 22(CY22) is supplying12V to Blue 14(CY14). If so, prob-able center modulefault

5th wheel lock Power sup-ply


12V Fuse, connectors,or wiring fault inpower supply circuitto center module

0V 5th wheelslide switchactive

Ground to5th wheellock indicator


12V not active

5th wheel slideswitch or connec-tors/wiring fault inground circuitthrough 5th wheelslide switch

Lamp test On Blue 13 (CY13)jumper wire toground

5th wheellock indica-tor lampilluminates

Confirm Blue 13(CY13) is suppliedground. If so, prob-able center modulefault

98



MeasuringPoint

ExpectedValue


Wheel differentiallock

Power sup-ply


12V Fuse, connectors,or wiring fault inpower supply circuitto center module

0V Wheel differ-ential lockswitch active

Ground towheel differ-ential lockindicator


12V not active

Wheel differentiallock lamp switch orconnectors / wiringfault in ground cir-cuit through lampswitch


Wheel dif-ferentiallock indica-tor lampilluminates


12V Interaxle dif-ferential lockswitch active

Interaxle differen-tial lock

Power sup-ply tointeraxle dif-ferential lockindicator


0V not active

Fuse, interaxleswitch, connectorsor wiring fault inpower supply circuitto center module



Lamp test On Blue 10 (CY10)jumper wire toGreen 18(RX18)

Interaxledifferentiallock lampilluminates

Confirm Blue 10(CY10) is supplied12V. If so, probablecenter module fault

High beam 12V High beamactive

Power sup-ply to highbeam indica-tor

On Check blue 8(CY8) to groundwith meter

0V not active

Fuse, switch, con-nectors or wiringfault in power sup-ply circuit to highbeam indicator



Lamp test On Blue 8 (CY8)jumper wire togreen 18(RX18)

High beamindicatorlamp illu-minates

Confirm Blue 8(CY8) is supplied12V. If so, probablecenter module fault

99



MeasuringPoint

ExpectedValue


Safety belt Power sup-ply


12V Fuse, connectorsor wiring fault inpower supply circuitto center module



Parking brake Power sup-ply



0V Parking brakeapplied

Ground toparkingbrake indica-tor


12V not applied

Parking brakeswitch or connec-tors / wiring fault inground circuitthrough switch


Parkingbrake lampilluminates


Anti-lock brakingsystem (ABS),

tractor

Power sup-ply



0V ABS faultsactive

Ground toABS tractorindicator


12V not active

ABS system orconnectors / wiringfault in ground cir-cuit through ABSsystem


TractorABS lampilluminates


100



MeasuringPoint

ExpectedValue


Anti-lock brakingsystem (ABS),trailer

Power sup-ply



0V ABS faultsactive

Ground totrailer ABSindicator


12V not active

ABS system orconnectors / wiringfault in ground cir-cuit through ABSsystem


Trailer ABSlamp illu-minates


Air Suspension Power sup-ply



0V Suspensiondump switchactive

Ground toair suspen-sion systemindicator


12V not active

Suspension dumpswitch or connec-tors / wiring fault inground circuitthrough switch


Air suspen-sion lampilluminates


Heated mirrors 12V Mirror de-froster active

Power sup-ply to heatedmirror indica-tor


0V not active

Fuse, connectorsor wiring fault inpower supply circuitto center module



Lamp test On Blue 4 (CY4)jumper wire toGreen 18(RX18)

Mirror de-frosterlamp illu-minates

Momentaryconnectiononly. Fusemay blow.

Confirm Green 18(RX18) is supplying12V to Blue 4(CY4). If so, proba-ble center modulefault

101



MeasuringPoint

ExpectedValue


Right turn Power sup-ply to rightturn indicator


Min: 0VMax: 12V

Right turnsignal active

Fuse, connectorsor wiring fault inright turn circuit



Lamp test On Blue 9 (CY9)jumper wire toBlue 22 (CY22)

Right turnlamp illu-minates

Confirm Blue 22(CY22) is supplying12V to Blue 9(CY9). If so, proba-ble center modulefault

Power sup-ply



Master warning Ground Off Check blue 11(CY11) toground withmeter



Masterwarninglamp illu-minates


12V Brake pres-sure normal

Jumper fromright module

On Check blue 25(CY25) toground withmeter 0V Brake pres-

sure low

Wiring or connec-tors between centerand right module.Possible right mod-ule fault

Ground, rightmodule

Off Check green 15(RX15) toground withmeter




• The center module if the warranty has expired.See “Center Module, Replacement” page 143.

102


Right Module Telltale Lamps


Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument clus-ter electronics are working properly. If lamps do not illuminate go to step 3.




MeasuringPoint

ExpectedValue


Transmission tem-perature

Powersupply

On Check green 18(RX18) toground withmeter

12V Fuse, connectorsor wiring fault inright modulepower supplycircuit

12V TransmissiontemperatureOK

Ground totransmissiontemperatureindicator


0V Transmissiontemperatureto high

Transmission ECUor connectors /wiring fault inground circuitthrough transmis-sion ECU

W3004305

Lamp test On Green 29(RX29) jumperwire to ground

Transmis-siontempera-ture lampilluminates

Confirm Green 29(RX29) is suppliedground. If so,probable rightmodule fault

Check transmission Powersupply


12V Fuse, connectorsor wiring fault inright modulepower supply cir-cuit

12V No transmis-sion faults

Ground totransmissionindicator

On Check green 30(RX30) toground withmeter 0V Transmission

faults

Transmission ECUor connectors /wiring fault inground circuitthrough transmis-sion ECU

W3004306


Checktransmis-sion lampilluminates


103



MeasuringPoint

ExpectedValue


Traction control Powersupply



0V Tractioncontrol active

Ground totractioncontrol indi-cator

On Check green 14(RX14) toground withmeter 12V Traction

control not ac-tive

ABS system orconnectors / wiringfault in groundcircuit throughABS / tractioncontrol system

W3003668


Tractioncontrollamp illu-minates


Wait to start Powersupply



12V WAIT indica-tor not active

Ground toWAITindicator

On Check green 13(RX13) toground withmeter 0V WAIT indica-

tor active

Engine ECU orconnectors / wiringfault in groundcircuit throughengine ECU

W3004307


WAIT lampilluminates


Transmission inNeutral

12V Transmissionin neutral

Powersupply

On Check green 18(RX18) toground withmeter 0V Transmission

not in neutral

Fuse, connectors,switches or wiringfault in neutralswitch circuit

Ground Off Check green 15(RX15) toground withmeter

<1 Connectors /wiring fault inground circuit

W3004308

Lamp test On Green 22(RX22) jumperwire to green18 (RX18)

Transmis-sion inNeutrallamp illu-minates

Confirm Green 22(RX22) is supplied12V. If so, probableright module fault

104



MeasuringPoint

ExpectedValue


Water in fuel Powersupply



12V Water in fuelindicator notactive

Ground towater in fuelindicator


0V Water in fuelindicatoractive

Engine ECU orconnectors / wiringfault in groundcircuit throughengine ECU

W3004309


Water infuel lampilluminates


If all the measurements are correct, replace:



105


Instrument Cluster Backlighting, TroubleshootingThe instrument cluster backlighting receives power from a dimmer control located onthe vehicle dash. The backlighting is brightest when the control provides +12 volts, andgrows dimmer as the voltage drops toward zero.

Note: The graphic display backlighting is independent of the cluster backlighting. See“Graphic Display and Odometer, Troubleshooting” page 111.

Before troubleshooting, see “General Work Practices” page 88.

W3004335

Note: The schematic should be used to help clarify the instrument cluster backlighting troubleshooting proce-dures in this manual. For detailed vehicle specific, wiring troubleshooting refer to:

ServiceManual



106


Backlighting TestsTo test the instrument cluster backlighting, turn the parking/headlamps on and adjustthe dimmer control for maximum brightness.

Individual Backlighting

If individual backlights are not operating, replace the lamp. If a new lamp does not cor-rect the problem, see the troubleshooting procedures for the affected module below.

Cluster/Module Backlighting

Entire Cluster

If none of the backlighting operates, check for 0 to +12 volts at the output of thedimmer control switch on the dash. The voltage is variable with the dimmer control po-sition. Adjust the dimmer control for maximum brightness. If voltage is not present atthe output, check the dimmer switch, headlamp switch, fuses, connectors or wiring. Forlamp switch information refer to:

ServiceManual

Lighting System, Group 35PV776–TSP142952

IMPACT Function Group: 35Information Type: descrip-designfunc”Switches and Controls”

For other wiring information refer to:

ServiceManual



Graphic Display Module

The graphic display backlighting is independent of the cluster backlighting. See“Graphic Display and Odometer, Troubleshooting” page 111.

107


Left Module Backlighting


Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX andthe instrument cluster connector LX. Install overlay J-43340 with the 22–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded green for the LX connector pins. Proceed to the chart below.

Note: The headlamp switch should be ON with the dimmer control adjusted to maximum brightness unless otherwisenoted.


Function Key Posi-tion

Measuring Point ExpectedValue

Note Measurement not ex-pected value? Check:

Backlighting Input,Left Module

Off Green 20 (LX20)to ground withmeter

2.5 - 12 V Varies withdimmer position

Switches, connectors orwiring fault in power supplycircuit from dimmer

Ground, Left Module Off Green 12 (LX12)to ground withmeter

<1 Headlampswitch OFF.Disconnect LXconnector atcluster

Connectors or wiring faultin ground circuit


ServiceManual





• The left gauge module or left CPU board if the warranty has expired. See “LeftGauge Module, Replacement” page 141 or “Left CPU Board, Replacement” page156.

Note: Problems with the left module gauges may be in the left CPU board or the leftgauge module. No tests are currently available to isolate the problem area.

108


Center Module Backlighting


Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY andthe instrument cluster connector CY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded blue for the CY connector pins. Proceed to the chart below.






Backlighting Input,Center Module

Off Check blue 18(CY18) to groundwith meter



Ground, Center Mod-ule

Off Check blue 11(CY11) to groundwith meter

<1 Headlampswitch OFF



ServiceManual






109


Right Module Backlighting








Backlighting Input,Right Module

Off Check green 1(RX1) to groundwith meter



Ground, Right Mod-ule

Off Check green 15(RX15) to groundwith meter

<1 Headlampswitch OFF



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110


Graphic Display and Odometer, TroubleshootingThe graphic display, located in the left module, is activated by messages received onthe J1587/J1708 information data link. The odometer display is located in the centermodule. Before troubleshooting, see “General Work Practices” page 88.

W3003774

Note: The schematic should be used to help clarify the graphic display/odometer troubleshooting proceduresin this manual. For detailed, vehicle specific, wiring troubleshooting refer to:

ServiceManual



Instrument Cluster Self TestThe graphic display control buttons can be used to select instrument cluster self tests.From the graphic display “System diagnostic” menu, select “Cluster self test”, then“Display test”.

• With the display test active the graphic display screen will alternate from dark tolight to check that all pixels on the display are operational. Additionally, the odome-ter display will illuminate all LED segments. This test is independent of any datainput signals that may be displayed on the screens.

Instrument Cluster Tests using VCADS ProWith the “Display test” selected in the VCADS Pro tool, the graphic display screen willalternate from dark to light to check that all pixels on the display are operational. Addi-tionally, the odometer display will illuminate all LED segments. This test is independentof any data input signals that may be displayed on the screens. See the most currentVCADS Pro user manual or the ”Help” menu in the VCADS Pro tool.

111


Troubleshooting, OdometerOdometer Backlighting

The odometer backlighting is the same as the otherdash and instrumentation backlighting. See “InstrumentCluster Backlighting, Troubleshooting” page 106 for moreinformation.

Odometer Display

Step 1. Run cluster self-test. If the odometer display functions correctly in this test, the display is OK. This test isindependent of any data input signals that may be displayed on the screens.

If the odometer functions correctly in this test, but is not calculating:

Check if tachometer and speedometer are working. If yes, replace the cluster (or center module if out of war-ranty). If no, check the data link as shown in the chart below.If tachometer and odometer work, but not the speedometer, check the wiring for the speed signal input.

Step 2. If the odometer display does not function properly using the above test, go to step 3.

Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY andthe instrument cluster connector CY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded blue for the CY connector pins. Proceed to the chart below.

Note: There is no breakout harness for connector CX. To check CX measuring points, back-probe CX connector pins.See “Connectors, Back-probing” page 134.





Power supply On Check CX4 toground with meter

12V Fuse, connectors orwiring fault in powersupply circuit

Ground Off Check CX5 toground with meter

<1 Disconnect CXcluster connector

Connectors or wiringfault in ground circuit

Information DataLink(J1587/J1708)

On Check CX1 to CX2with meter

5V max.0V min.

Connectors or wiringfault in J1587/J1708information link (wires400, 401)

Power Supply On Check blue 22(CY22) to groundwith meter


Ground Off Check blue 11(CY11) to groundwith meter

<1 Disconnect CYcluster connector


112



ServiceManual






113


Troubleshooting, Graphic DisplayReplaceable lamps provide backlighting for the graphic display. The brightness of thedisplay can be adjusted with the graphic display control buttons. The graphic displaybacklighting is independent of the dash backlighting, but will increase or decreasewhen the dash dimmer control is adjusted.

Step 1. If a backlighting problem, replace the suspect lamp with a known good bulb. See “Bulb, Replacement” page137. If this is not the problem, or if the problem is not corrected, continue to step 2.

Step 2. Run cluster self-test. If the graphic display functions properly in the self-test, the display is OK. These testsare independent of any data input signals that may be displayed on the screens.

Step 3. If the graphic display does not function properly using the above tests, connect breakout box 9998551 withadapter J-43235 in series between wiring harness connector LX and the instrument cluster connector LX. Install over-lay J-43340 with the 22–PIN BREAKOUT HARNESS side up. The overlay is color-coded green for the LX connectorpins. Proceed to the chart below.





Cluster Back-lighting Signal

On Check green 20(LX20) to groundwith meter

2.5 to 12 V Head/parkinglamps on - varieswith dimmer posi-tion

Switch, connectors orwiring fault in back-lighting circuit fromdimmer control switch.

Power supply On Check green 10(LX10) to groundwith meter


Ground Off Check green 9(LX9) to ground withmeter

<1 Disconnect LXcluster connector


Information DataLink(J1587/J1708)

On Check green 1(LX1) to green 11(LX11) with meter

5V max.0V min.

Connectors or wiringfault in J1587/J1708information link (wires400, 401)


ServiceManual





• The graphic display or left CPU board if the warranty has expired. See “GraphicDisplay, Replacement” page 150 or “Left CPU Board, Replacement” page 156.

Note: Problems in the graphic display may be in thegraphic display or the left CPU board. No test are cur-rently available to isolate the problem area.

114


Gauges, TroubleshootingInstrument cluster gauges may operate based on inputs from hardwired sensors, sig-nals received via the J1587/J1708 information data link, or mechanical inputs. See the“Design and Function” section of this manual for an operating description of eachgauge.

Before troubleshooting, see “General Work Practices” page 88.

W3003773

Note: The schematic should be used to help clarify the gauge troubleshooting procedures in this manual. Fordetailed vehicle specific, wiring troubleshooting refer to:

ServiceManual



Instrument Cluster Self TestThe graphic display control buttons can be used to select instrument cluster self tests.From the graphic display “System diagnostic” menu, select “Cluster self test”, then“Gauge test”.

• With the gauge test active the electrically operated gauges will sweep to full andhalf travel. This test is independent of any inputs to the instrument cluster. If thegauge operates properly with this test it is likely the gauge itself is functioningproperly.

115


Gauge Tests, Accuracy and Calibration using VCADS ProGauge Test

With the “Gauge test” selected in the VCADS Pro tool, the electrically operated gaugeswill sweep to full and half travel. This test is independent of any inputs to the instru-ment cluster. If the gauge operates properly with this test it is likely the gauge itself isfunctioning properly. See the most current VCADS Pro user manual or the ”Help” menuin the VCADS Pro tool.

Gauge Calibration

Most electrically operated gauges can be calibrated using the VCADS Pro tool. In thecalibration process the gauge pointer can be set at the left, center and right gauge in-dex marks. See the most current VCADS Pro user manual or the ”Help” menu in theVCADS Pro tool.

Note: VCADS Pro does not have the capability of calibrating the speedometer ortachometer.

Gauge Checks

The VCADS Pro tool can display the value of signals coming to the instrument clusterfor most electrically operated gauges. These values can then be compared to the read-ing displayed on each respective gauge.

If the reading displayed on the gauge is within a pointer’s width of the value seen onthe VCADS Pro tool, the gauge is accurate. If the gauge accuracy is incorrect, it canbe adjusted with the “Gauge Calibration” feature of the VCADS Pro tool. See the mostcurrent VCADS Pro user manual or the ”Help” menu in the VCADS Pro tool.

Note that if the gauge is calibrated at one point, it may affect the calibration at anotherpoint on the gauge. Gauges should not be calibrated unless the readings are obviouslyinaccurate.

Gauge Reaction to Short or Open CircuitsThe gauges can be of assistance in the event of short and open circuits. This appliesto all gauges that can be activated by the gauge test. See “Instrument Cluster Diag-nostic Tests” page 89. In the event of a short-circuit to ground or supply voltage, thegauges display either the maximum or minimum readings. In the event of an open cir-cuit the gauges display the minimum reading.

Example: Pyrometer Gauge

The display reads 1500�F if there is a short-circuit in the pyrometer wiring. 300�F orless is displayed if there is an open circuit in the wiring.

Note that the fault can occur in wiring, connectors, sensors etc. The fault may occur asa result of mechanical faults, oxidation etc.

Intermittent FaultsIn the event of an intermittent fault, the cause may be connector related. For further in-formation on fault tracing of wiring and connectors, refer to (for circuitry information):

ServiceManual



Also check for fault codes using the instrument cluster diagnostic function. See “Faultdiagnostic” page 68.

116


Left Module GaugesNote: If the LEDs in the engine oil pressure and/orcoolant temperature gauges do not operate properly see“Warning and Telltale Lamps, Troubleshooting” page 92.

Step 1. Run cluster self-test. If an accuracy complaint, check accuracy with the Instrument Cluster Tests us-ing VCADS Pro.

If the gauge functions properly in these self-tests, the gauge is OK. Check engine diagnostics for fault codes.If the suspect gauge does not function properly, see step 2.



Gauge Function Key Posi-tion

MeasuringPoint

ExpectedValue


Power supply On Check green 10(LX10) to groundwith meter


All left mod-ule gauges

Ground Off Check green 9(LX9) to groundwith meter

1 Disconnect LXconnector atcluster



ServiceManual



If all the measurements are correct, continue in the following troubleshooting chart tothe section for the suspect gauge.

Engine oil pressure gauge, Engine coolant temperature gauge, Turbo boost pressure gauge


MeasuringPoint

ExpectedValue


Engine oilpressure

Informationdata link

On Check green 1(LX1) to green11 (LX11) withmeter

5V max.0V min.

Check for faultcodes inEECU relatedto oil pressuresensor signalfailure

Connectors orwiring fault inJ1587/J1708 infor-mation link fromEECU. Fault in sen-sor or circuit toEECU

117



MeasuringPoint

ExpectedValue


Enginecoolant tem-perature



5V max.0V min.

Check for faultcodes inEECU relatedto coolant tem-peraturesensor signalfailure


Turbo boostpressure



5V max.0V min.

Check for faultcodes in EECUrelated to turboboost pressuresensor signalfailure



ServiceManual






Note: Problems with the left module gauges may be in the graphic display module orthe left gauge module. No tests are currently available to isolate the problem area.

Pyrometer Gauge

Step 1. With the engine warm, run the cluster self test.

If the gauge does not move, replace the cluster (or left gauge module or graphic display module if out of warranty)If the gauge sweeps as it should, check for fault codes.

Step 2. If there are fault codes, check the area indicated. If no fault codes, go to step 3.

Step 3. Connect breakout box 9998551 with adapter J-43234 to wiring harness connector LY only. Do not connectthe instrument cluster connector LY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded green for the LY connector pins. Proceed to the chart below.


118



MeasuringPoint

ExpectedValue


Pyrometer Signal Off Check green 30(LY30) to green13 (LY13) withmeter

5-300 mV Engine warm.May show 0V ifengine is cold

Pyrometer thermo-couple, wiring orconnectors


ServiceManual






Note: Problems with the left module gauges may be in the graphic display module orthe left gauge module. No tests are currently available to isolate the problem area.

119


Center Module Gauges

Step 1. Run cluster self-test.

If both gauges function properly in the self-test, the gauges are OK. Check diagnostics for fault codes related tothe system. Also check the information link as shown in the chart below.If only one gauge functions replace the cluster (or center module if out of warranty).If neither gauge functions properly, see step 2.

Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY andthe instrument cluster connector CY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded blue for the CY connector pins. Proceed to the chart below.Note: There is no breakout harness for connector CX. To check CX measuring points back probe CX connector pins.See “Connectors, Back-probing” page 134.



MeasuringPoint

ExpectedValue


Speedometer Power supply On Check blue 22(CY22) to groundwith meter

12V Fuse, connectorsor wiring fault inpower supply cir-cuit

Ground Off Check blue 11(CY11) to groundwith meter

<1 Disconnect CYconnector atcluster



On Check CX1 toCX2 with meter

5V max.0V min.

Check for faultcodes relatedto vehiclespeed sensorsignal failure

Connectors orwiring fault inJ1587/J1708 infor-mation link. Faultin vehicle speedsensor circuit

Tachometer Power supply On Check CX4 toground with me-ter

12V Fuse, connectorsor wiring fault inpower supply cir-cuit

Ground Off Check CX5 toground with me-ter

<1 Disconnect CXconnector atcluster



On Check CX1 toCX2 with meter

5V max.0V min.

Check for faultcodes relatedto enginespeed sensorsignal failure

Connectors orwiring fault inJ1587/J1708 infor-mation link. Faultin engine speedsensor circuit

Odometer See “Graphic Display and Odometer, Troubleshooting” page 111.

120



ServiceManual






121


Right Module Gauges

Sensors for the right module electrical gauges are hardwired to the left module. From the left module, jumper wiresdeliver signals to the right module to operate the gauges. The right module also contains mechanically operated airpressure gauges.

Note: If the warning LEDs in the front and/or rear air pressure gauges do not operate properly see “LED IndicatorLamps” page 93.

Electrical Gauges

Step 1. Run cluster self test. If an accuracy problem, check gauge accuracy with the Instrument Cluster Tests us-ing VCADS Pro. If the gauge functions properly go to step 2. If it does not operate properly, go to step 3.

Note: Only electrically operated gauges will operate with these tests.

Step 2. Check for fault codes related to the system. If fault codes are present, repair fault condition, then recheck. Ifno fault codes related to the system are present go to step 3.




MeasuringPoint

ExpectedValue


Forward rearaxle tempera-ture

Power supply On Check green 18(RX18) to groundwith meter


Ground Off Green 15 (RX15)to ground withmeter


5V Gauge at max-imum reading

Signal fromleft module

On Green 3 (RX3)to ground withmeter

10V minimum

Left (graphic dis-play) module failureor connectors/wiringfrom left module

Rear rearaxle tempera-ture

Power supply On Green 18 (RX18)to ground withmeter







10V minimum


122



MeasuringPoint

ExpectedValue


Fuel level Power supply On Green 18 (RX18)to ground withmeter




5V Gauge readingfull



10V empty



ServiceManual






123


Mechanical Gauges

Step 1. Connect test gauge J-44274 in series between the air lines and the instrument cluster gauge fitting. The airlines and gauge fittings are color coded to aid in assembly.

If the test gauge tooling is not available, the air lines from two gauges may be “swapped” to help determine gaugefaults. Always reconnect the air line to the proper gauge. The air lines and gauge fittings are color coded to aid in in-stallation.

Gauge Measuring Point Expected Value Note Measurements not ex-pected value? Check:

Front brake airpressure

Front brake air pres-sure gauge fitting (red)

Approximatelysame value astest gauge

Vehicle air pressureat governor setting

Gauge failure

Rear brake airpressure

Rear brake air pressuregauge fitting (green)



Gauge failure

Application airpressure

Application air pressuregauge fitting (black)


Vehicle air pressureat governor settingwith foot brake pedalapplied

Gauge failure

Air suspensionpressure

Air suspension pres-sure gauge fitting(black)



Gauge failure

The tests above only check for consistent readings between the instrument clustergauge and test gauge. If air pressure seems out of normal operating range, the vehicleair system should be checked for proper operation.

If measurements indicate a faulty air gauge, replace:


• The affected air gauge if the warranty has expired. See “Air Gauge, Replacement”page 148.

124


Sensor Wiring / Axle Temperature Sensors

Step 1. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector LY andthe instrument cluster connector LY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded green for the LY connector pins.



MeasuringPoint

ExpectedValue


Forward rearaxle tempera-ture

Referencevoltage

On Check green 29(LY29) to groundwith meter

5V max.0V min.

Check power sup-ply to left module. IfOK and no outputfrom LY29, probableleft (graphic display)module failure

1000±10% @21�C (70�F)

430 ±10%@ 50�C(120�F)

Ground Off Check green 29(LY29) to groundwith meter

110 ±10%@ 95�C(200�F)

Disconnect LYconnector atcluster

Sensor, connectorsor wiring fault inground circuitthrough forward rearaxle temp. sensor


10V

If reference voltageand ground OK,probable left(graphic display)module failure

W3003735

Gauge signal On Check green 24(LY24) to groundwith meter

minimum

125



MeasuringPoint

ExpectedValue


Rear rearaxle tempera-ture

Referencevoltage

On Check green 16(LY16) to groundwith meter

5V max.0V min.

Check power sup-ply to left module. IfOK and no outputfrom LY16, probableleft (graphic display)module failure

1000±10% @21�C (70�F)

430 ±10%@ 50�C(120�F)

Ground Off Check green 16(LY16) to groundwith meter

110 ±10%@ 95�C(200�F)

Disconnect LYconnector atcluster

Sensor, connectorsor wiring fault inground circuitthrough rear rearaxle temp. sensor


W3003735

Gauge signal On Check green 21(LY21) to groundwith meter

10V minimum



ServiceManual



If all the measurements are correct, continue to the troubleshooting chart for Electricalgauges.

126


Sensor Wiring / Fuel Level Sensor

Step 1. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX andthe instrument cluster connector LX. Install overlay J-43340 with the 22–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded green for the LX connector pins.


Sen Function Key Posi-tion

MeasuringPoint

ExpectedValue


Fuel level Referencevoltage

On Check green 2(LX2) to groundwith meter

5V max.0V min.

Check power sup-ply to left module. IfOK and no outputfrom LX2, probableleft (graphic display)module failure

240 ±10%@ emptytank

153 ±10%@ 1/4 tank

103 ±10%@ 1/2 tank

67 ±10%@ 3/4 tank


33 ±10%@ full tank

Disconnect LXconnector atcluster

Sensor, connectorsor wiring fault inground circuitthrough fuel levelsensor

5V Gauge readingfull

Gauge signal On Check green 3(LX3) to groundwith meter

10V empty



ServiceManual



If all the measurements are correct, continue to the troubleshooting charts for electricalgauges.

127


Graphic Display Control Buttons, Troubleshooting

W3004326

Note: The schematic should be used to help clarify the graphic display control buttons troubleshooting proce-dures in this manual. For detailed vehicle specific, wiring troubleshooting refer to:

ServiceManual



The graphic display control buttons are used to manually communicate with and ma-nipulate the graphic display. Before troubleshooting, see “General Work Practices”page 88.

Test using VCADS ProThis test confirms that the control buttons on the wiper stalk are delivering a signal tothe instrument cluster. The indicator on the VCADS Pro tool will illuminate green whenthe buttons Esc, Select, Up Arrow, Down Arrow are pressed.

More information about the tests can be found in the most current VCADS Pro usermanual or the ”Help” menu in the VCADS Pro tool.

Troubleshooting

Step 1. Run cluster test using the VCADS Pro tool. If the wiper stalk control buttons function correctly in this test,they are working properly. If not, see step 2.



Function Key Position MeasurementPoint

ExpectedValue

Note Measurement notexpected value?Check:

Power supply towiper stalk

On Check green21 (LX21) toground withmeter

12V Left module powersupply or internal leftmodule fault

Esc button On Check green 4(LX4) to groundwith meter

12V Button active Wiper stalk switch,connector or wiringfault

128


Function Key Position MeasurementPoint

ExpectedValue

Note Measurement notexpected value?Check:

Select button On Check green 7(LX7) to groundwith meter


Up button On Check green16 (LX16) toground withmeter


Down button On Check green 6(LX6) to groundwith meter


Power supply, leftmodule

On Check green10 (LX10) toground withmeter

12V Fuse, connectors, orwiring fault in powersupply circuit


<1 Disconnect LX con-nector at cluster



ServiceManual



• If the wiper stalk switch is suspected refer to:

ServiceManual

PV776–TSP143133”Windshield Wiper System”

IMPACT Function Group: 363Information Type: ”Windshield Wiper System”Model: VN/VHD



• The graphic display or the left CPU board if the warranty has expired. See“Graphic Display, Replacement” page 150 or “Left CPU Board, Replacement”page 156.

Note: Problems with the graphic display may be in the graphic display module or theleft CPU board. No test are currently available to isolate the problem area.

129


Buzzer, TroubleshootingThe buzzer is located on the center module and activated by messages received onthe J1587/1708 information data link. Before troubleshooting, see “General WorkPractices” page 88.

W3003627

Note: The schematic should be used to help clarify the buzzer troubleshooting procedures in this manual. Fordetailed vehicle specific, wiring troubleshooting refer to:

ServiceBulletin


IMPACT Function Group: 363Information Type: blnt-geninfo”Windshield Wiper System”

Instrument Cluster Self TestThe graphic display control buttons can be used to select instrument cluster self tests(see “Cluster self test” page 78). From the graphic display menu “System diagnostic”select “Cluster self test,” then “Buzzer test.”

• With the buzzer test active the graphic display will alternate from “flasher indicator”to “reminder” to “caution”. A different tone will sound with each display message.

Instrument Cluster Test using VCADS Pro• With the buzzer test active the graphic display will alternate from “flasher indicator”

to “reminder” to “caution”. A different tone will sound with each display message.See the most current VCADS Pro user manual or the ”Help” menu in the VCADSPro tool.

Buzzer Tests

Step 1. Run the cluster self test. If the buzzer functions correctly in the self test the buzzer is OK. If the buzzerdoes not function properly in these tests, go to step 2.

Step 2. Check for fault codes related to the system. If fault codes are present, repair fault condition, then recheck. Ifno fault codes related to the system are present go to step 3.

Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY andthe instrument cluster connector CY. Install overlay J-43340 with the 30–PIN BREAKOUT HARNESS side up. Theoverlay is color-coded blue for the CY connector pins. Proceed to the table below.

Note: If the breakout box tooling is not available, carefully back probe the instrument cluster connector pins with digitalmultimeter J–39200 or an equivalent tool. See “Connectors, Back-probing” page 134.Note: There is no breakout box tooling available for connector CX.

130



Measuring point ExpectedValue

Note Measurement not expectedvalue? Check:

Power Supply On Check CX4 toground with me-ter

12V Fuse, connectors or wiringfault in power supply circuit

Ground Off Check CX5 toground with me-ter

<1 DisconnectCX connector

Connectors or wiring fault inground circuit

Flasher, Reminder,Caution or AlarmClock Signal

On Check CX1 toCX2 (Data link)with meter

5V max.0V min.

Connectors or wiring fault inJ1587/1708 information link(400, 401 circuit numbers)

Left Turn AudibleSignal


12V max.0V min.

Left turn sig-nal active

Turn signal switch, connectorsor wiring fault in left turn sig-nal circuit

Right Turn AudibleSignal


12V max.0V min.

Right turn sig-nal active

Turn signal switch, connectorsor wiring fault in right turn sig-nal circuit


ServiceBulletin


IMPACT Function Group: 363Information Type: blnt-geninfo”Windshield Wiper System”




131


Common ProblemsSymptom Cause Correction

Transmission temperature warningactivates at 212 �F instead of 300 �F.

Faulty datasets. Reprogram the instrument cluster,see “Instrument Cluster, Program-ming” page 161.

One or more (datalink) gauges stopsworking (on vehicles equipped withCummins engine).

Faulty datasets or faulty J1587 circuit. If there are still any (datalink) gaugesworking the Cummins engine ECUneeds to be reprogrammed.If none of the (datalink) gauges areworking troubleshoot the J1587 cir-cuit.

Airbag icon stays on but the vehicle isnot equipped with an airbag.

Instrument cluster not programmed orfaulty datasets.

Reprogram the instrument cluster,see “Instrument Cluster, Program-ming” page 161.

132

Group 38 Instrumentation, VN / VHD Service Procedures

Service ProceduresService ProceduresGeneral Work PracticesImportant: Individual gauges or modules in the VN/VHDinstrument cluster are not serviceable during the war-ranty period. Attempts to service or replace individualmodules or gauges during the warranty period willvoid the cluster warranty. Instead, the whole instru-ment cluster may be exchanged.

After the warranty expires, individual modules and airgauges can be replaced. Electrical gauges cannot be re-placed individually.

CAUTION

Welding on trucks can damage the vehicle electricalsystem/components from the voltage and currentspikes that normally occur when welding. It is prefer-able to avoid welding on an assembled truck, but ifwelding must be done on any structure on or incontact with the vehicle, disconnect the electrical con-nectors at the rear of the instrument cluster, all ECU’sand the battery cables. When disconnecting the bat-tery cables, disconnect any other ground cablesconnected to the battery first, then the main batteryground. Attach the welder ground cable as close tothe weld as possible.

Preventing electrostatic discharge (ESD)

CAUTION

To prevent electrostatic discharge (ESD), which maydamage the sensitive electronic components in the in-strument cluster, a wrist grounding strap must beused when working on electronic equipment such asthe instrument cluster. Failure to use a wrist strap mayresult in permanent damage to the printed circuitboards in the instrument cluster. To use the wrist strapin a vehicle, attach the alligator clip to the nearestelectrical ground such as a metal mounting screw, aground terminal or preferably a ground stud.

CAUTION

To prevent electrostatic discharge (ESD), which maydamage the sensitive electronic components in the in-strument cluster, make sure the workbench has ananti-static mat which is grounded to the nearest elec-trical outlet when working on the instrument cluster.Failure to use an anti-static mat may result in perma-nent damage to the printed circuit boards in theinstrument cluster. When working at the anti-staticworkbench, always keep a wrist strap connected tothe anti-static mat.

When dealing with circuits designed to sense differencessmaller than 1 volt, electrostatic discharge can be a sub-tle but destructive problem. Circuit boards mounted inthe instrument cluster or in modules mounted elsewheremay not fail immediately after being hit with a static dis-charge. Rather they may work for a while, then fail for noapparent reason. The culprit then is often the normalwarming up and cooling down process of the module,engine or cab interior.

Grounding straps and anti-static mats are available forminimal cost from electronic supply stores. Groundingstraps consist of a wrist strap, a coiled extension wireand an alligator clip. Be sure to purchase one with a longenough extension wire to allow freedom of movement.

Anti-static wrist straps and mats are available fromKent-Moore (see Tools section of this manual). Call1-800-328-6657.

133


Connectors, Back-probingThe tests in the troubleshooting section of this manualsuggest the use of breakout boxes and harnesses. How-ever, if the breakout box tooling is not available, theinstrument cluster connector pins may be back-probedwith digital multimeter J-39200 (or equivalent tool). Fol-low these steps when back-probing connectors.

Before working on the vehicle, set the parking brakes,place the transmission in neutral, and block thewheels. Failure to do so can result in unexpected ve-hicle movement and cause serious personal injury ordeath.

CAUTION

Before beginning this procedure, see “General WorkPractices” page 133.

1Make certain the vehicle ignition isOFF before beginning this procedure.

2

W3003660

Wire Insertion Side

Use the pin-out charts in the “VN Se-ries Electrical Schematics” or thismanual to determine the exact locationof the measuring points. Note that alldrawings show the pins from the wireinsertion side.

3

W3003661

Use the digital multimeter test probesto contact the metal portion of the con-nector pins. Do not puncture the wireinsulation when probing. Do not allowthe test probes to contact each otherto avoid false readings and/or damageto the wiring, connectors or instrumentcluster.

4

W3003656

Front-probing: If it is necessary todisconnect a connector andfront-probe a pin, never use the mul-timeter probes to directly contactthe connector pins. Using theselarge probes can damage the connec-tor pins and result in intermittent faults.To avoid damage, use tool J-42449when front-probing connector pins.

J-42449

134


Housing and Front PanelGlass, CleaningTo clean the housing and front panel glass, use a soft,non-abrasive cloth and a mild soap-and-water solution.

Connector Terminals, Addingor Replacing


CAUTION


W3003654

To replace faulty terminals in instrument cluster electricalconnectors use the butt splice connectors listed below(available from Volvo):

• 3948725 (for black, numbered wires)

• 3948726 (for ground wires)

The butt splice connector should also be used for addingcircuitry for after-market functions i.e., extra telltale lightsto the instrument cluster.Special tools: Terminal removal and probe kit: J-42449(Kent-Moore),Packard crimper: J-38125–8 (Kent-Moore),Heat gun: J-25070 (Kent-Moore)

Removal


2

W3002866

Disconnect the connector with thefaulty terminal from the instrumentcluster. Pry open the lock on the maleportion of the connector using a smallflat screwdriver.

Note: The lock is not easy to see. Toopen the lock, pry just under the topledge of the connector (see figure).

135


3

W3002867

Remove the faulty terminal from theconnector as follows, using the re-moval tool from kit J-42449. (Note thatin each of these JAE connectors thereare two rows of terminals, and tworows of release holes. The releaseholes are on the outside, and areslightly larger than the ones containingterminals.) Insert the removal tool intothe release hole above the terminalbeing removed. It will take some pres-sure to make the terminal locksrelease.

Installation1Cut the faulty terminal wire to thesame length as the JAE terminal pig-tail replacement.

2

W3002868

Strip the insulation back approximately6 mm (1/4 in.) and install butt splice3948725 (or 3948726) to the wire.

39487253948726

3

W3002869

Crimp in the 18–20 anvil of crimperJ-38125–8 (this crimper can be foundin the VE D12 engine tool kit, VolvoP/N 3947553). Slightly pull the wire toconfirm a correct crimp.

J-38125–8

136


4

W3002870

Using heat gun J-25070, heat thesplice to shrink the tubing until the ad-hesive is visible for a good moistureseal.

J-25070

5Install the terminal into the correctconnector cavity. Pull back on the wireto make certain the terminal is lockedinto the connector. Push the connectorlock back into position.

6Connect the connector to the instru-ment cluster and check for properfunction.

7Note: If the terminal was installed toadd functions, it may be necessary toreprogram the instrument cluster. Seethe most current VCADS Pro usermanual or the help menu in theVCADS Pro tool.

Bulb, Replacement


CAUTION



2

CAUTION

When servicing or troubleshooting, do not leave thecluster face-down for more than 15 minutes, or dam-age to the gauges may occur. Gauge oil can run outthe front of the gauge faces and make the gauges in-accurate.

Adjust the steering column back wherepossible. Remove the two screws atthe top of the instrument cluster andlay the cluster face-down on the steer-ing column so that the bulbs areaccessible.

137


3

W3000642

CAUTION

Use only the Volvo bulb removal tool, P/N 1089953, toremove bulbs, or damage to the cluster may occur.

Insert removal tool, P/N 1089953, ontothe bulb assembly. Rotate 1/4 turn andpull the bulb assembly out of thesocket.

4Insert the new bulb assembly into theremoval tool, P/N 1089953. Insert theassembly into cluster socket and ro-tate 1/4 turn.

1089953

5Replace the instrument cluster in thedash and tighten the 2 screws at thetop of the cluster.Torque to 2 ± 0.3 Nm (17.5 ± 2.5 in-lb).

138


3811-03-02-01Instrument Cluster, Replace-ment


CAUTION


Note: Replacement instrument cluster should be or-dered from Volvo per VIN (Vehicle IdentificationNumber). Replacement instrument cluster will be pro-grammed before delivery.

Note: Replacement instrument clusters should be editedto reflect the current actual mileage of the vehicle. Thismay be accomplished by use of the VCADS PRO tool (orthe Pro Link 9000 tool). Under no circumstances shouldthe edit odometer functions be used to falsify the actualmileage. See “Odometer, Programming” page 162.


2

W3003659

CAUTION


Adjust the steering column back wherepossible. Remove the two screws atthe top of the instrument cluster andlay the cluster face-down on the steer-ing column.

3Cut the tie straps fastening the wiringharness to the back of the cluster forstress relief on the connectors. Dis-connect the electrical connectors fromthe back of the cluster.

139


4

W3003657

WARNING

Never disconnect an air system component unless allsystem pressure has been depleted. Failure to de-plete system pressure before disconnecting hoses orcomponents may result in them separating violentlyand causing serious eye and/or bodily injury.

Bleed all pressure from the vehicle airsystem. Using tool J-42189 push in onthe air tubing collars while pulling backon the air tubing to disconnect. Re-move the cluster from the vehicle.

5Position the replacement instrumentcluster face-down on the steering col-umn in the mounting position. Connectthe air tubing. Note the color codes forproper installation.

6Connect all electrical connectors, not-ing color codes to aid in installation.

7Important: Reprogram the odometerto the current actual mileage. See“Odometer, Programming” page 162.

8For stress relief on the connectors, tiestrap the wiring to the back of the in-strument cluster.

9Position the instrument cluster in thedash and tighten the 2 screws at thetop of the cluster.Torque to 2 ± 0.3 Nm (17.5 ± 2.5 in-lb).

2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

140


3811-03-02-04Left Gauge Module, Replace-ment


CAUTION


Important: Individual gauges or modules in the VN/VHDinstrument cluster are not serviceable during the war-ranty period. Attempts to service or replace individualmodules or gauges during the warranty period willvoid the cluster warranty. Instead, the whole instru-ment cluster may be exchanged.

After the warranty expires, individual modules can be re-placed. Individual gauges are not replaceable.


2

W3003659

CAUTION




141


4

W3003657

WARNING


Bleed all pressure from the vehicle airsystem. Using tool J-42189 push in onthe air tubing collars while pulling backon the air tubing to disconnect.

5Remove the cluster from the vehicle.Place it on a static mat for repairs. Astatic bracelet must be worn for allbench repairs.

6

W3003648

Remove the 3 left module mountingscrews. Remove the left module cover.Carefully lift the CPU/graphic displaymodule and disconnect the ribbon wireconnector to the left gauge module.Lay the CPU/graphic display to theside on the static mat.

7

W3003649

Remove the 4 mounting screws for theleft gauge module and remove fromthe cluster housing.

8Position the replacement left gaugemodule into the cluster housing. Se-cure with the 4 mounting screws.

142


9

W3003658

Carefully connect the ribbon wire con-nector from the CPU/graphic displaymodule to the left gauge module. Posi-tion the CPU/graphic display module inthe cluster housing.

10Install the left module cover with the 3mounting screws.

11Place the instrument cluster face downon the steering column in the mountingposition. Connect the air tubing, notingcolor codes for proper installation.

12Connect all electrical connectors, not-ing color codes to aid in installation.For stress relief on the connectors, tiestrap the wiring to the back of the in-strument cluster.


2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

3811-03-02-03Center Module, Replacement


Note: Replacement center modules should be edited toreflect the current actual mileage of the vehicle. Thismay be accomplished by use of the VCADS PRO tool (orthe Pro Link 9000 tool). Under no circumstances shouldthe edit odometer functions be used to falsify the actualmileage. See “Odometer, Programming” page 162.

CAUTION




143



2

W3003659

CAUTION




4

W3003657

WARNING




6

W3003650

Remove the 4 center module mountingscrews, and remove the center modulefrom the housing.

144


7Install the replacement center moduleinto the cluster housing with the 4mounting screws.



10Important: Reprogram the odometerto the current actual mileage. See“Odometer, Programming” page 162.



2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

3811-03-02-02Right Module, Replacement


CAUTION



After the warranty expires, individual modules and airgauges can be replaced. See “Air Gauge, Replacement”page 148 for more information.

145



2

W3003659

CAUTION




4

W3003657

WARNING


Bleed all pressure from the vehicle airsystem. Using tool J-42189 push in onthe air tubing collars on the back ofthe cluster while pulling back on theair tubing to disconnect.


146


6

W3003652

Remove the 3 right module mountingscrews. Remove the right modulecover, and remove the right modulefrom the housing.

7Remove the 2 air gauge mountingscrews from each gauge and removethe gauges from the right module cir-cuit board.

8Position the air gauges in the clusterhousing assembly to assure properalignment. Gauge blanks should alsobe in position.

9Place the replacement right modulescircuit board onto the gauges and se-cure each with the 2 mounting screws.

10The right module should now be posi-tioned in the cluster housing. Installthe right module cover and secure withthe 3 right module mounting screws.




2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

147


3851-03-02-01Air Gauge, Replacement


CAUTION



After the warranty expires, individual modules and airgauges can be replaced.


2

W3003659

CAUTION




148


4

W3003657

WARNING


Bleed all pressure from the vehicle airsystem. Using tool J-42189 push in onthe air tubing collars on the back ofthe cluster while pulling back on theair tubing to disconnect.


6

W3003652

Remove the 3 right module mountingscrews. Remove the right modulecover, and remove the right modulefrom the housing.

7Remove the 2 air gauge mountingscrews and remove the gauge fromthe circuit board.

8

W3004299

Position the new air gauge in the clus-ter housing assembly to assure properalignment.

9Place the right module circuit boardonto the gauge and secure with the 2mounting screws.

10The right module should now be posi-tioned in the cluster housing. Installthe right module cover and secure withthe 3 right module mounting screws.

149





2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

3811-03-02-09Graphic Display, Replacement


CAUTION


Important: Individual gauges or modules, including thegraphic display, in the VN/VHD instrument cluster are notserviceable during the warranty period. Attempts to ser-vice or replace individual modules or gauges duringthe warranty period will void the cluster warranty. In-stead, the whole instrument cluster may be exchanged.


150



2

W3003659

CAUTION




4

W3003657

WARNING




151


6

W3003648

Remove the 3 left module mountingscrews. Remove the left module cover.Carefully lift the CPU/graphic displaymodule and disconnect the ribbon wireconnector to the left gauge module.Remove from the cluster.

7Remove the 2 screws securing thegraphic display to the CPU board.

8

W3004304

Carefully work the graphic display andthe CPU board apart.

9Align the connector pins in the replace-ment graphic display with the CPUboard and carefully push into position.Secure with the 2 mounting screws.

10

W3003658

Install the replacement CPU/graphicdisplay module by carefully connectingthe ribbon wire connector to the leftgauge module, and positioning theCPU/graphic display module in place.






2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

152


3811-03-02-08Instrument Cluster Hous-ing/Glass, Replacement


CAUTION



2

W3003659

CAUTION




153


4

W3003657

WARNING




6

W3003658

Remove the 3 left module mountingscrews. Remove the left module cover.Carefully lift the CPU/graphic displaymodule and disconnect the ribbon wireconnector to the left gauge module.Lay to the side on the static mat.

7Remove the 4 mounting screws for theleft gauge module and remove fromthe cluster housing. Lay to the side onthe static mat.

8Remove the 4 center module mountingscrews, and remove the center modulefrom the housing. Lay to the side onthe static mat.

9Remove the 3 right module mountingscrews. Remove the right modulecover, and remove the right modulefrom the housing. Lay to the side onthe static mat.

154


10

W3003651

Empty Replacement Cluster Housing

Install the right module into the re-placement cluster housing. Install thecover with the 3 mounting screws.

Note: If any gauge blanks are presentin the existing cluster housing positionthem correctly in the replacementhousing.

11Install the center module into the re-placement cluster housing. Install thecover with the 4 mounting screws.

12Install the left gauge module into thereplacement cluster housing. Securewith the 4 mounting screws.

13

W3003658

Install the CPU/graphic display moduleby carefully connecting the ribbon wireconnector to the left gauge module,and positioning the CPU/graphic dis-play module in place.





2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

155


3871-03-02-01Left CPU Board, Replacement


CAUTION


Note: Replacement left CPU board should be orderedfrom Volvo per Vehicle Identification Number (VIN). Re-placement left CPU boards will be programmed beforedelivery.


2

W3003659

CAUTION




156


4

W3003657

WARNING




6

W3003658

Remove the 3 left module mountingscrews. Remove the left module cover.Carefully lift the CPU/graphic displaymodule and disconnect the ribbon wireconnector to the left gauge module.Lay to the side on the static mat.

7Remove the 2 screws securing thegraphic display to the CPU board.

157


8

W3004304

Carefully work the graphic display andthe CPU board apart.

9Align the connector pins in the graphicdisplay module with the replacementCPU board and carefully push into po-sition. Secure with the 2 mountingscrews.

10Install the replacement CPU/graphicdisplay module by carefully connectingthe ribbon wire connector to the leftgauge module, and positioning theCPU/graphic display module in place.






2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

158


3811-03-02-11Instrument Cluster Rear Cover,Replacement (Left or Right)


CAUTION


Note: The center rear cover is part of the center moduleand not replaceable as a single part.


2

W3003659

CAUTION




159


4

W3003657

WARNING




6Remove the 3 right or left rear covermounting screws. Remove the leftmodule cover.

7

W3004316

Compare the hole pattern in the exist-ing cover with the replacement cover.Due to different configuration, it maybe necessary to ”knock out” openingsin the replacement cover to accommo-date the existing gauges and lamps.Use a 1/2 inch punch or drill to modifythe replacement cover as needed.

8Install the cover with the 3 mountingscrews.




160



2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

Instrument Cluster, Program-ming


Note: Replacement instrument cluster and/or left CPUboard should be ordered from Volvo per Vehicle Identifi-cation Number (VIN). Replacement instrument clusterand/or left CPU boards will be programmed before deliv-ery.

Note: Only authorized technicians can update and/or al-ter software datasets with the VCADS Pro tool. See“Instrument Cluster Programming” page 18.

W0001632

The VCADS Pro tool is a Windows 95 based PC toolthat can be used to program the instrument cluster. Thefollowing is a brief description of the current program-ming procedure. For more detailed programminginformation consult the most current VCADS Pro usermanual or the “Help” menu in the VCADS Pro tool.


2Remove the 2 instrument clustermounting screws.

3Connect telephone or network line tothe VCADS Pro tool.

Note: Make sure to select the rightconnection type in the VCADS Protool.

161


4Start the VCADS Pro tool. Select Pro-gramming / Vehicle Electronics ’98 /Replace ECU. Then, select Driver In-formation Display and the properVIN. Follow the on screen prompts un-til the programming is completed.

5Disconnect all VCADS Pro tool cablesfrom the vehicle. Connect the instru-ment cluster to the harness connector.

6Secure instrument cluster with themounting screws.

Odometer, Programming


Note: Replacement instrument clusters and center mod-ules should be edited to reflect the current actualmileage of the vehicle. Under no circumstances shouldthe odometer programming function be used to falsifythe actual vehicle mileage.

W0001632

The VCADS Pro tool is a Windows 95 based PC toolthat can be used to program the instrument cluster. Thefollowing is a brief description of the current program-ming procedure. For more detailed programminginformation consult the most current VCADS Pro usermanual or the “Help” menu in the VCADS Pro tool.

The Pro Link 9000 can also be used to program the in-strument cluster odometer. See “Pro Link 9000” page163 for programming instructions.

VCADS Pro Tool


2Connect telephone or network line tothe VCADS Pro tool.

Note: Make sure to select the rightconnection type in the VCADS Protool.

3Start the VCADS Pro tool. Select Pro-gramming / Vehicle Electronics ’98 /Instrument Mileage. Follow the onscreen prompts until the programmingis completed.

162


4Disconnect all VCADS Pro tool cablesfrom the vehicle.

Pro Link 9000

1Note: The following is a brief descrip-tion of the current odometerprogramming procedure. For more de-tailed information consult the mostcurrent Pro Link 9000 user manual.


3

W3004318

Connect the Pro Link 9000 tool to thecommunication connector in the vehi-cle.

4Turn the ignition key ON.

5Select 99 INST CLUSTER / PRO-GRAM NEW ODOMETER, enter thedesired mileage.

Note: The Pro Link 9000 will only pro-gram in miles. Kilometers must beconverted to miles before entering. (1mile = 1.61 km)

6Disconnect the Pro Link from the vehi-cle.

163

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

(336) 393-3241

From

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Operation Numbers

3811-03-02-01 Instrument Cluster, Replacement . . . . . . . . . . . . . . . . . . . . . . . 1393811-03-02-02 Right Module, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 1453811-03-02-03 Center Module, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1433811-03-02-04 Left Gauge Module, Replacement . . . . . . . . . . . . . . . . . . . . . . . 1413811-03-02-08 Instrument Cluster Housing/Glass, Replacement . . . . . . . . . . . . . . . . 1533811-03-02-09 Graphic Display, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1503811-03-02-11 Instrument Cluster Rear Cover, Replacement (Left or Right) . . . . . . . . . . . 1593851-03-02-01 Air Gauge, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1483871-03-02-01 Left CPU Board, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 156

Volvo Trucks North America, Inc.P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8

http://www.volvotrucks.volvo.com

PV776-TSP139790 (1000) 8.00 © Volvo Trucks North America, Inc., 2000

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