Trucks
Group
381500
Instrumentation
VN (from 3/99),
VHD
PV776-TSP139790
Foreword
The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to August 2000.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary service 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 reference to an S.R.T. (Standard Repair Time).
Service procedures which do not include an operation number in the title are for general information and no reference is made to an S.R.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have 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 the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could occur.
Contents
General ........................................................................ 3
Basic Description ....................................................... 3
Specifications ............................................................. 7
Connector Pinouts ...................................................... 7
Connector Pinouts, Left Module .............................. 7
Connector Pinouts, Center Module .......................... 9
Connector Pinouts, Right Module .......................... 11
Tools .......................................................................... 13
Special Tools ............................................................ 13
Special Equipment ................................................... 15
Design and Function ................................................
Instrument Cluster ......................................................
Communication .........................................................
Left Instrument Cluster Module (MID 234) ..............
Pyrometer ...............................................................
Engine oil pressure gauge .....................................
Engine coolant temperature gauge ........................
Turbo boost (intake manifold) pressure gauge ......
Telltale bulbs, left section .......................................
Graphic Display ......................................................
Left CPU Board ......................................................
Center Instrument Cluster Module (MID140) ...........
Center Module ECU (MID 140) .............................
Tachometer .............................................................
Speedometer ..........................................................
Odometer ...............................................................
Telltale bulbs, center section ..................................
Master Warning telltale ..........................................
Right Instrument Cluster Module .............................
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 ..............................
Telltale bulbs, right section .....................................
Graphic Display ........................................................
Graphic Display Layout ..........................................
Graphic Display Symbols .......................................
Graphic Display Control Buttons ..............................
Using the Graphic Display Menus ...........................
Selecting a Menu ...................................................
Changing Settings ..................................................
Password Information .............................................
Graphic Display Operation .......................................
Instrument Cluster Operation at Start-up .................
Graphic Display Menus, Driving Mode ....................
Main Menu: Gauge (available while driving) ............
Main Menu: Fuel Economy (available while driving)
Main Menu: Time/Distance (available when driving)
Main Menu: FAULTS? (available while driving) ........
17
17
19
23
24
24
25
25
25
26
27
28
29
29
30
30
31
31
32
33
33
33
34
34
35
35
35
36
36
37
38
38
38
38
39
40
40
41
42
45
47
49
56
57
59
68
81
86
Troubleshooting ........................................................ 87
Instrumentation Troubleshooting ................................ 87
General Work Practices ........................................... 88
Instrument Cluster Diagnostic Tests ........................ 89
Instrument Cluster Self Test .................................. 89
Instrument Cluster Tests with VCADS Pro ............ 90
Warning and Telltale Lamps, Troubleshooting ......... 92
Instrument Cluster Self Test .................................. 92
Instrument Cluster Tests using VCADS Pro .......... 92
Troubleshooting ...................................................... 93
LED Indicator Lamps ............................................. 93
Telltale Lamps ........................................................ 96
Instrument Cluster Backlighting, Troubleshooting .. 106
Graphic Display and Odometer, Troubleshooting .. 111
Instrument Cluster Self Test ................................ 111
Instrument Cluster Tests using VCADS Pro ........ 111
Troubleshooting, Odometer .................................. 112
Troubleshooting, Graphic Display ........................ 114
Gauges, Troubleshooting ....................................... 115
Instrument Cluster Self Test ................................ 115
Gauge Tests, Accuracy and Calibration using
VCADS Pro .......................................................... 116
Gauge Reaction to Short or Open Circuits ......... 116
Intermittent Faults ................................................ 116
Left Module Gauges ............................................. 117
Center Module Gauges ........................................ 120
Right Module Gauges .......................................... 122
Graphic Display Control Buttons, Troubleshooting 128
Buzzer, Troubleshooting ......................................... 130
Common Problems ................................................. 132
Service Procedures ................................................
Service Procedures ..................................................
General Work Practices .........................................
Housing and Front Panel Glass, Cleaning .............
Connector Terminals, Adding or Replacing ...........
Bulb, Replacement .................................................
Instrument Cluster, Replacement ...........................
Left Gauge Module, Replacement .........................
Center Module, Replacement ................................
Right Module, Replacement ...................................
Air Gauge, Replacement ........................................
Graphic Display, Replacement ...............................
Instrument Cluster Housing/Glass, Replacement ..
Left CPU Board, Replacement ..............................
Instrument Cluster Rear Cover, Replacement (Left
or Right) .................................................................
133
133
133
135
135
137
139
141
143
145
148
150
153
156
159
1
General
General
Basic Description
W3004310
General
Available Configurations
T3009001
General
T3009002
General
T3009303
Specifications
Specifications
Connector Pinouts
Connector Pinouts, Left Module
The left module has two connectors placed on the back
of the instrument cluster.
Circuit
Description
400-B
183
CJ1
219A
NC
219B
219D
0XC-A
Electronics ground
10
202-A
11
401-B
12
0P-A
13
NC
14
NC
15
NC
16
219C
17
18
CJ2
19
20
141-G
21
219
22
180-A
W3003558
Specifications
Circuit
199
Description
Air filter restriction
NC
CJ3
CJ4
14
Battery charging
575
NC
NC
10
576
11
12
NC
13
191
Pyrometer (+)
14
NC
15
NC
16
469
17
18
774-B
19
Bootstrap enable
20
21
CJ6
22
23
387A
24
CJ5
25
Remote display
26
Outdoor temp
27
NC
28
314
29
468
30
190
Pyrometer (-)
W3003558
Specifications
Circuit
Description
400-H
401-H
CJ2
202-B
0XC-B
Ground
W3003557
Specifications
Cavity
779
Description
ABS Truck lamp
ABS Trailer
420
702
CJ3
CJ4
NC
33B
113-AA
10
422
11
0P-B
12
426
13
424
14
112-AA
15
431
16
NC
17
NC
18
141-F
19
CJ7
20
CJ8
21
22
NC
180-B
23
NC
24
Optional
25
CJ9
26
NC
27
NC
28
NC
29
NC
30
NC
10
W3003557
Specifications
Cavity
Description
141-E
NC
CJ5
CJ1
NC
NC
NC
NC
NC
10
NC
11
CJ7
12
NC
13
14
774B
15
0P-C
16
NC
17
CJ6
18
180-C
19
Water in fuel
20
NC
21
CJ9
22
Transmission in Neutral
23
NC
24
NC
25
NC
26
NC
27
NC
W3003560
11
Specifications
Cavity
28
CJ8
Description
Telltale bulb test (-) from center
module
29
30
Transmission malfunction
W3003560
12
Tools
Tools
Special Tools
The following items may be required for work on the instrument cluster. Tools with
999.../98... numbers are available from Volvo Parts. Tools with J-... numbers are available from Kent-Moore at (800) 3286657.
W3000642
1089953
9998551 and
J-43340
W0001556
J43235
J-44274
J-42189
W0001608
W0001716
W0001557
J-43234
13
Tools
Special Tools...
W0001709
14
9998555
9998617
Programming Kit
9808635
Programming unit.
9808560
9808561
9812331
9808562
J-43999
9808563
J-43939
Tools
Special Equipment
The following items may be required for work on the instrument cluster. They can be
ordered from Kent-Moore at (800) 328-6657.
W0001904
J-42444-A
BT-8639-B
J-44567
Probe adapter.
Used with J-39200 for making reliable readings at the breakout box cavities.
J-39200
J-42449
J-424492
J-4244910
Terminal remover.
J-38125-8
Packard crimper.
J-25070
Heat gun.
15
Tools
Special Equipment...
The tools are available from Volvo Parts. Tools with J-... numbers are available from
Kent-Moore at (800) 3286657.
W3004317
104004
206040
809112
PCMCIA.
501002
16
Power/Data Cable.
J3850060A
J44012
W3004310
Introduction
The cluster is available in 7 configurations, with either a
mph or km/h speedometer (see Available Configurations page 4).
The instrument cluster consists of three combined modules:
Left module
The left module consists of 3 separate components, left
gauge module, graphic display and CPU board. The left
module can include pyrometer, engine oil pressure
gauge, engine coolant temperature gauge and turbo
boost pressure gauge, and a graphic display for driver
information. There are telltales in the lower section of the
module. Please refer to Left Instrument Cluster Module
(MID 234) page 23. For display operation, refer to the
sections Instrument Cluster Operation at Start-up page
40, Graphic Display Menus, Driving Mode page 41 and
Graphic Display Menus, Non-Driving Mode page 56.
Center module
The center module contains a tachometer, speedometer
and odometer. In the lower section of the center module
there is a central warning lamp, and telltales for different
truck functions. Please refer to Center Instrument Cluster Module (MID140) page 28.
Right module
The right module consists of an electrical gauge module
and separate air gauges. The right module can include
forward and rear rear axle temperature gauges, fuel level
gauge, application air pressure gauge, front and rear
brake air pressure gauges. Trucks with an air suspension may have an air suspension pressure gauge. There
are telltales in the lower section of the module. Please
refer to Right Instrument Cluster Module page 32.
Graphic display control buttons
Control buttons for the graphic display menus are located on the wiper stalk on the right-hand side of the
steering wheel. Please refer to Graphic Display Control
Buttons page 38.
17
W0001632
18
be supplied. Volvo will program the replacement part before delivery based on the dataset stored in the VDA
(Volvo Data Administration) database.
Authorized technicians can also update and/or alter software datasets with the VCADS Pro tool. See the most
current VCADS Pro user information or the Help menu
in the VCADS Pro tool.
Communication
W3004303
1.
2.
Connections to components
3.
The connections between the 3 modules of the instrument cluster and other components can be divided into
the following three groups according to the picture above:
1. Connections to the data link:
Connections to the J1587/J1708 information data link
connect the instrument cluster center and left module to
the other electronic control units, e.g. the Engine ECU
(MID 128) and the Vehicle ECU (MID 144). For more information see Data Link page 22 and
Communication with Other ECUs/Sensors page 23.
2. Connections to components:
Some components are connected to the instrument cluster 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 in
the Design and Function section for more information.
3. Connections between the modules of the instrument cluster (control signals for gauges and lamps):
The non data link communication between the three
modules of the instrument cluster is carried out via these
connections. They are hardwired connections labeled
with CJ_ circuit numbers. Refer to the electrical
schematic or Connector Pinouts page 7 for more information.
19
Data Link
The communication between the vehicles ECUs and the
instrument clusters left and center modules is carried
out via the SAE J1587/J1708 information data link.
Instrument Cluster
Display
MID 234
Instrument Cluster
Center Module
MID 140
Vehicle ECU
MID 144
Communication
Connector
*
Engine ECU
MID 128
SAE
J1939
Transmission
MID 130
Other units
(Expansion capability)
20
Center module
Odometer ..................................................
Speedometer ...........................................
Tachometer ..............................................
Engine ECU
Left module
Engine oil pressure gauge .......................
Engine ECU
Engine ECU
Engine ECU
Display ......................................................
...............................
Engine ECU
Transmission sensor
Right module
Fuel level gauge .......................................
Direct connection
Direct connection
Direct connection
Direct connection
21
Diagnostic Capabilities
The instrument cluster performs a self-test via the instrument clusters electronics, when the ignition key is
turned to the ON position, but a self-test can also be
manually conducted via the menu System diagnostic/instrument cluster test.
In the System diagnostic/instrument cluster test
menu, the graphic display shows diagnostics of the vehi-
22
Graphic display
Pyrometer
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be replaced.
23
Pyrometer
The pyrometer indicates exhaust temperature from a
sensor in the exhaust system.
The pyrometer gauge is an electrical aircore meter
movement driven by the clusters microprocessor. The
microprocessor receives pyrometer sensor input from a
high-temperature thermocouple.
If the pyrometer thermocouple fails, the pointer will move
to one end of the dial or the other, and a fault code will
be logged for loss of data. A reading of 300 F (149 C )
or less indicates an open in the trucks wiring or thermo
couple, and a reading of 1500 F (815 C) or more
indicates a short.
W3003632
24
W3003768
W3003769
W3003631
Caution telltale
Stop telltale
No Charge telltale
W3003645
25
Graphic Display
The driver can choose information on the graphic display
by scrolling among the menus that are listed below.
Menus in capital letters are available when driving and
when stationary. Menus in lower case letters are only
available when stationary. For detailed information about
these display menus see Instrument Cluster Operation
at Start-up page 40, Graphic Display Menus, Driving
Mode page 41 and Graphic Display Menus,
Non-Driving Mode page 56.
GAUGE MODE
FUEL ECONOMY
TIME/DISTANCE
CLOCK
Alarm clock
TRIPMETER #1 and #2
AVERAGE SPEED
FAULTS?
FAULTS?
Set-up mode
Language
Fault diagnostic
Cluster self test
Part number
Status test *
Vehicle id **
Totals
Trip data **
Reset trip data * **
Password Input
26
Enter password
Information Messages
STOP messages
The following functions can activate an information message 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
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
Tachometer
Speedometer
Odometer
T3010615
28
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be replaced.
Tachometer
The tachometer is an electrical air core meter movement
driven by signals from the engine (MID 128) via the
J1587/J1708 information data link. In the absence of
data link information, the gauge pointer will move to its
minimum reading after a 10 second delay. The gauge
range is 02800 r/min.
W3003639
29
Speedometer
The speedometer is an electrical air core meter movement driven by signals from the SAE J1587/J1708
information data link. In the absence of data link information, the gauge pointer will move to its minimum reading
after a 10 second delay. Note that the cluster does not
perform speedometer calibration. Speedometer calibration to compensate for tire sizes and other driveline
changes is done during programming of the engine
ECU, vehicle ECU or transmission ECU.
The speed signal is sent to the center module ECU either from the vehicle ECU (MID 144) or the engine ECU
(MID 128) depending on the engine manufacturer:
W3003640
0-80 mph
(0-120 km/h)
Odometer
The odometer is a Liquid Crystal Display (LCD) mounted
behind the speedometer dial. It has a full scale reading
of 999999.9. Odometer information is calculated from
road speed via the J1587/J1708 information data link
and is stored in the clusters microprocessor.
The odometer backlighting can be adjusted independently of gauge backlighting, via the menu Setup
mode in the graphic display.
During normal operation, the odometer display goes
blank 30 seconds after the ignition is switched off. To reactivate the display, turn the ignition on or press any of
the control buttons on the wiper stalk switch.
In the absence of speedometer data, the odometer display will not change and the speedometer pointer will
remain at zero.
The odometer value can be displayed either in miles or
km. The unit selection is accessed via the menu Set-up
mode in the graphic display in the left module. The actual 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 actual
vehicle miles. For programming instruction see
Odometer, Programming page 162.
30
W3003646
1
2
3
4
5
6
7
8
9
10
11
12
31
32
W3004301
W3003628
33
W3004302
34
W3003637
W3003638
Transmission Temperature
Check Transmission
Automatic Neutral
Water in Fuel2
W3004416
35
Graphic Display
The graphic display in the lower left-hand corner of the
instrument cluster is used to present information to the
driver, both when driving and when the vehicle is stationary. The graphic display replaces certain conventional
gauges, telltale and warning lamps. It is standard equipment 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 includes the clock, gauges, etc.
Automatically Generated Information:
Information and stop messages are shown automatically
on the graphic display at the same time as a yellow lamp
( INFO) or red lamp ( STOP) lights up at the bottom of
the display. A fault code is also logged, and can be
viewed in the FAULTS menu.
T3008860
T3008861
The section Main Menu: FAULTS? (available while driving) page 49 gives a more general description of fault
messages. To see more details about information and
stop messages see Fault diagnostic page 68.
The information available for the driver is different depending on whether the vehicle is being driven or is
stationary.
Driving = speed above 5 mph (8 km/h) (see Graphic
Display Menus, Driving Mode page 41).
NonDriving = 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 Messages (with Icons) page 51 and Stop Messages (with
Icons) page 55.
36
TEXTFIELD
Status
symbol
W3004312
Voltmeter
(see Voltmeter page 44 for
more information)
PTO engaged
Airbag
10 Coolant level
16 Engine oil pressure
Pre-heating active
Acknowledged warning
(see Acknowledge Information
and Stop Messages page 50 for
more information)
Alarm clock on
(see Alarm clock page 57 for
more information)
17 Coolant temperature
37
T3008810
Pressing
Changing Settings
1
Pressing
38
"
"
Set-up mode
System diagnostic
Data log mode
Password Input
ALARM
08:20
CLOCK
08:00
ON
OFF
SET
Password Information
Certain functions are protected by a password. For the
display there are two passwords (or the alternative of
choosing not to have any password protection):
1
Both these passwords give the user access to all password protected functions with one exception:
The mechanics password does not give access to the
password configuration, i.e. with this you cannot change
either the mechanics nor the owners passwords.
See Change password page 67 to change the password.
Default language
Fleet limit: rpm
When the ignition key has been in the off position for
more than 60 seconds or when the batteries have been
disconnected the password must be entered again to access password-protected functions.
See Main Menu: Password Input (non-driving) page 86
in order to enter your password.
No password protected functions: Owner/Operator
Mode
For all menus to be available, you must go to the menu
Password Input and press . The text Access Granted
is then shown instead of Password.
39
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 display, the cluster will show the fault in the graphic display.
If the ignition key has been in the off position, what was
on the display before the ignition was turned off is
shown. (If the battery has been disconnected and reconnected, a flashing clock display is shown instead.)
During Normal Operation
If a telltale light is on other than INFO or STOP, a device other than the cluster has activated it.
40
When the fault messages are acknowledged using Esc, you are shown the menu FAULTS?
GAUGE
FUEL ECONOMY
TIME/DIST
FAULTS?
"#
"#
"#
GAUGE
TIME/DIST
TEMPERATURE,
ENGINE OIL
"#
TEMPERATURE,
TRANSMISSION OIL (option)
"#
VOLTMETER
"#
AVG/INST FUEL
CLOCK
"#
LEG FUEL/DTE
"#
"#
Alarm clock
"#
TRIPMETER #1 and #2
"#
AVERAGE SPEED
"#
41
185 F
T3008830
NO
DATA
T3008830
HIGH
280 F
Information message
Yellow
1INFO lamp
If the engine oil temperature becomes too high an information message is shown automatically with the text
HIGH. At the same time the yellow INFO lamp under
the display lights up. The engine may also derate, if it is
set up to do so in the engine ECU programming. The
temperature which activates this warning varies for different engines. This temperature is set in the engine ECU.
For Volvo engines, it is 275 F (135 C).
42
T3008860
170 F
T3008831
NO
DATA
Information message
Yellow
1INFO lamp
T3008831
HIGH
250 F
Stop message
Red stop lamp
If the temperature of the transmission oil becomes too
high, a flashing stop message is shown automatically
with the text TOO HIGH. At the same time the red
STOP lamp under the display lights up and the warning signal sounds. Esc acknowledges the stop message.
T3008831
TOO HIGH
285 F
T3008861
43
Voltmeter
MENU: GAUGE, VOLTMETER
The battery/charging voltage is shown as in the diagram.
If the battery/charging voltage becomes too low (below
9.5 V), the instrument cluster will lose power.
T3008832
13.1 V
T3008832
TOO HIGH
17.9 V
Information message
Yellow information lamp
If the battery/charging voltage becomes too high, the
voltmeters value is shown automatically as well as the
text TOO HIGH. At the same time the yellow information
lamp under the display lights up.
T3008860
44
AVG/INST
LEG FUEL/DTE
FUEL ECONOMY is chosen and then the up/down buttons are used in order to change between the available
sub-menus.
Note: When idling the bar is not shown and the fuel consumption is shown in gal/hour.
AVG 9.9
INST 8.0
TARGET
mpg
"
RESET
FUEL DATA?
PRESS FOR 1S
45
Distance to Empty XXX mi (where XXX is the calculated range using the present instantaneous
consumption).
LEG FUEL
___
EMPTY _ _ mi
Note: Since the calculated range is based on the instantaneous consumption, the correct value is first
shown shortly after start.
46
CLOCK
ALARM CLOCK
TRIPMETER
AVERAGE SPEED
Note: Menu TIME/DIST is available even when the ignition key is in the off position. It is activated by keeping
one of the control buttons on the wiper stalk pressed
down for at least 1 second. The menu remains active for
30 seconds after the last depressing of the button.
The alarm clock cannot be set while driving, but the
buzzer which sounds for the alarm call can be switched
off. See Switch off the alarm clock page 58.
Clock
MENU: TIME/DIST, CLOCK
Shows the current time. To set the time format 12h or
24h, see Clock format page 60.
Setting
1
Set the AM/PM (if the time format is 12h) with the
up/down buttons. Confirm the choice with .
12:00
Cancel setting
When setting hours Esc cancels the setting and the time
is shown according to the previous setting.
Esc after setting the minutes as well as after setting the
AM/PM moves the cursor back to the previous selection.
47
Tripmeter
MENU: TIME/DIST, TRIPMETER
On the display in the menu tripmeter the distance driven
for Leg 1 and Leg 2 are shown.
TRIP
#1
43.6 mi
#2
507.3 mi
Reset tripmeter
1 Press in the menu TRIPMETER.
2
A new text message with a question about the resetting of the tripmeter is shown. The up/down
buttons move the cursor between Leg 1 and Leg 2.
Confirm the choice with or press Esc in order to
cancel the resetting.
RESET?
#1:
#2:
PRESS FOR 1S
Average speed
MENU: TIME/DIST, AVERAGE SPEED
The average speed is calculated using the distance
driven divided by the time the engine has been running
(since the last resetting).
AVERAGE
SPEED
55.4 mph
48
A new text message with a question about the resetting of the average speed is shown. Confirm the
choice with or press Esc in order to cancel the
resetting.
RESET?
PRESS FOR 1S
Information messages
Stop messages
Information message
T3008860
Important: When the INFO lamp lights up, the specified fault must be checked at the next stop.
Stop message
T3008861
Recall
An acknowledged fault message can be recalled, i.e. be
shown on the graphic display again.
MENU: FAULTS?
1
50
T3008852
Airbag
T3008842
T3008831
Warning, voltmeter
CAUTION
The vehicle should be taken to an authorized Volvo
Truck dealer immediately if the SRS telltale stays
on or lights up when the vehicle is being driven.
T3008832
Overheating, instruments
T3008840
T3008830
T3008838
51
T3009913
52
T3008841
CHECK
DATA LINK
CHECK
BROKEN
T3008860
ENGINE
NEXT STOP
CHECK
ERROR IN
MID 140
T3008860
CHECK
T3008860
ENGINE
DATA LINK
T3008860
53
STOP!
ENGINE
FAULT
T3008861
If the bodybuilders or the customer have installed equipment afterwards which has been connected to the data
link, the following can be shown:
MID (Message IDentifier) = electronic control unit
STOP!
ERROR IN
MID 144
T3008861
54
T3008831
TOO HIGH
285 F
T3008861
W3003613
T3008861
W3003614
T3008861
55
sec. has elapsed since the last time the ignition key was
in the ON position). See Main Menu: Password Input
(non-driving) page 86.
While the vehicle is stationary, there are 5 main menus in
addition to the drive menus. The drive menus are shown in
capitals in the following table (the menu TIME/DISTANCE
has one additional function while the vehicle is stationary).
Note: If all the menus are to be shown, the correct password must be given. This applies to each time the
ignition key is turned to the ON position (if more than 60
GAUGE
FUEL ECONOMY (option)
TIME/DIST
FAULTS?
"#
Set-up mode
System diagnostic
Data log mode
Password Input
"#
"#
Set-up mode
System diagnostic
Clock format
Part number
Language
!! Fault diagnostic
"#
Contrast
Backlight
Password
Night display
Status test
"#
Password
Default language
Fleet limit: rpm (Volvo engine only)
Fleet limit: speed (Volvo
engine only)
Fleet fuel target (Volvo
engine only)
Password config.
Odometer setting (N/A)
Fleet ID (Volvo engine
only)
"#
56
"#
!
"#
Password
"#
"#
ALARM CLOCK
Alarm clock
MENU: TIME/DIST, ALARM CLOCK
ALARM
CLOCK
ON
08:30 AM
08:00 AM
OFF SET
T3008833
57
Activate alarm clock (without changing the time of the alarm call)
1
Cancel setting
ALARM
08:30
AM
T3008833
CLOCK
ON
08:00 AM
OFF SET
ALARM
CLOCK
ON
08:30
08:00
OFF
switches off the alarm clock and the symbol disappears from the graphic display.
Cancel setting
Press Esc in order to cancel the setting.
58
AM
AM
SET
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.
Language
MENU: Set-up mode, Language
This setting of language applies until vehicle battery
power is disconnected. To change the language permanently, see Default Language page 62.
1
On the graphic display up to three different languages will now be shown. Select the desired
language by moving the cursor to the particular row.
Confirm the choice with .
Cancel setting
Press Esc in order to cancel the setting.
59
Select
km and C
km/l
Mi/USgal and F
Cancel setting
Press Esc in order to cancel the setting.
Clock format
MENU: Set-up mode, Clock format
1
AM/PM
24 h
Cancel setting
Press Esc in order to cancel the setting.
60
l/100 km
Contrast
MENU: Set-up mode, Contrast
1
Adjust contrast
Cancel setting
Press Esc in order to cancel the setting.
Backlight
MENU: Set-up mode, Backlight
The graphic displays brightness is controlled by the
dimmer rheostat setting (which also controls the other instrument cluster lighting). In this menu, the display
lighting can be altered in relation to the other instrument
cluster lighting.
1
Adjust lighting
Select the menu Backlight and the following diagram is shown on the graphic display. The bar shows
the particular setting in relation to max/min. lighting:
the up arrow button increases the background lighting.
the down arrow button reduces the background
lighting.
Cancel setting
Press Esc in order to cancel the setting.
61
Night display
MENU: Set-up mode, Night display
1
Select the menu Night display and the following diagram is shown on the display:
Night display
Normal
Cancel setting
Press Esc in order to cancel the setting.
Default Language
MENU: Set-up mode, Default language
Only available when the correct password has been
given.
This setting of the language is kept even when battery
power is lost. See also Language page 59 for more information about setting the language.
1
On the graphic display, up to three different languages will be shown. Select the desired language
by moving the cursor to the particular row. Confirm
the choice with .
Cancel setting
Press Esc in order to cancel the setting.
62
Reverse
Data transfer
Data transfer
in progress
completed
please wait
2
The new engine speed is set using the up/down buttons (one number at a time) followed by :
Present
2000 r/m
Operation
1900 r/m
If an incorrect number has been given, press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.
failed
Action:
63
Data transfer
Data transfer
in progress
completed
please wait
2
Present
70 mph
Operation
65 mph
failed
If an incorrect number has been given press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.
64
Action:
Data transfer
in progress
Data transfer
please wait
completed
Now 10 mpg
New 14 mpg
Operation
failed
Note: If metric scales have been selected, the consumption 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 Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.
Action:
65
Fleet id
MENU: Set-up mode, Fleet id
Only available when the correct password has been
given.
In this menu, the identification the vehicle has in the fleet
can be entered. Data registered in the engine ECU is
then registered for this ID.
1
Select the menu Set-up mode, Fleet id. The following text message is shown:
Data transfer
in progress
Data transfer
please wait
completed
Fleet id:
ifkgoteborg
Operation
failed
Enter Fleet id
66
Action:
Change password
MENU: Set-up mode, Password config.
Only available when the correct password has been
given (the owners password). See Password Information page 39 for general information about the
password.
If none of the functions are protected by passwords this
menu will not be available.
1
Change password
Enter password
0000
Mechanic
Owner
67
Fault diagnostic
Cluster self test
Part number
Status test (password is required)
Fault diagnostic
MENU: Diagnostic, Fault diagnostic
No faults
MID (127)
Not responding
Data transfer
in progress
please wait
Engine
MID 128
Not responding
Action:
68
Engine
Engine
Coolant temperature
Too many
fault messages
Active
69
Numeric or text
1 Press when there are fault codes and the follow-
Numeric
Text
Time stamp
Reset
4
2
Too many
fault messages
MID 128
PID 110
FMI 0
Active
70
Time stamp
1
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 (does
not apply to all MIDs, such as ABS brakes or SRS
airbag). The following menu is shown:
First
No data
Numeric
Last
Text
No data
Time stamp
Reset
Action:
Data transfer
in progress
please wait
3
First
X
Last
X
Press Esc to return to the previous menu.
71
The text message that the resetting has been carried out is shown on the graphic display:
Data transfer
completed
This function
5
is not possible
Operation
In order to reset a fault code press when the particular fault code is presented. The following menu is
shown:
failed
Numeric
Text
Action:
Time stamp
Reset
2
Reset?
Press FOR 1S
Data transfer
in progress
please wait
72
Otherwise do the diagnostics test on the chosen system as well as the graphic display, see
Fault diagnostic page 68. If there are active
faults, those faults cannot be reset until they are
repaired (until the fault becomes inactive).
Place the cursor last in the list and select Reset all.
A new text message in the form of a question is
shown: Reset? Press .
Data transfer
Reset?
completed
Press FOR 1S
Data transfer
in progress
Operation
please wait
failed
Esc cancels the setting and the menu Fault diagnostics is shown again.
Action:
Otherwise do the diagnostics test on the chosen system as well as the graphic display. See
Fault diagnostic page 68. If there are active
faults, those faults cannot be reset until they are
repaired (until the fault becomes inactive).
73
74
Description
128
Engine
232
SRS (Airbag)
136
ABS
140
234
144
130
Transmission
Description
84
Road speed
91
% Throttle pedal
100
102
Boost pressure
105
110
111
Coolant level
173
Pyrometer
175
190
Engine speed
Description
69
70
71
72
73
75
76
77
78
79
86
109
121
122
123
124
125
195
196
Description
242
CC resume switch
243
CC set switch
244
CC enable switch
245
246
247
251
Power supply
75
Description
Injector #1
Injector #2
Injector #3
Injector #4
Injector #5
Injector #6
21
22
Timing sensor
25
Description
PSID 1
PSID 2
PSID 3
PSID 4
PSID 5
PSID 6
76
Description
10
11
12
13
18
Description
Dr Airbag lgn Loop
Description
Data erratic
Abnormal freq or PW
10
11
Failure unknown
12
Bad device
13
Out of calibration
14
A complete list of MIDs, PIDs, SIDs and FMIs is published in the SAE J1708/1587 document.
77
Bulb test
Gauge test
Display test
Buzzer test
Cancel test
Press Esc in order to cancel the test.
Bulb test
Gauge test
Display test
Buzzer test
Changing bulbs
Changing the instrument clusters telltale lamps can be
carried out from the rear side, without the instrument
cluster needing to be opened. Use the bulb removal tool.
78
Part number
MENU: System diagnostics, Part number
A list of the vehicles electronic control units (ECUs) is
shown in the menu Part number. Each ECU is identified
by a MID number (Message IDentifier).
MID 128
HW ID
VOLVO08192949P06
Data transfer
in progress
HW: ECU part number
please wait
6
4
MID 128
SW ID
03163028P01
MID 128
HW ID
No data
Otherwise do the diagnostics test on the chosen system as well as the display, see Fault
diagnostic page 68.
79
Status test
MENU: System diagnostic, Status test
Only available when the correct password has been
given.
Each ECU is identified by a MID number.
The parameter values are identified by the PID and
PPID. The difference between PID and PPID is that
PPID 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 translated using the SAE J1587 specification. This function is
designed for experienced technicians who are familiar
with J1587.
1
MID1: XXX
MID: XXX
PID/PPID1: YYY
(P)PID: YYY
MID2: ZZZ
DATA1: AAAAAAAAAAAA
PID/PPID2: VVV
2
MID: XXX
(P)PID: YYY
DATA1: No data
Data transfer
in progress
Action:
Otherwise do the diagnostics test on the chosen system as well as the display. See Fault
diagnostic page 68.
please wait
6
Main Menu: Data Log mode (with Volvo engines only) (non-driving)
Menu Data log mode has 4 sub-menus where 3 are not
protected by passwords and 1 is protected by a password.
Vehicle ID
Totals
Trip data
Reset trip data (requires password)
Vehicle ID
MENU: Data log mode, Vehicle ID
1
Data transfer
in progress
please wait
2
Fleet ID:
XXX
Chassis no:
XXX
Press Esc to return to the previous menu.
3
Operation
failed
Action:
Totals
MENU: Data log mode, Totals
1
The menus that show Totals can be scrolled to using the up/down buttons.
0.5 h
Total distance
406.7 mi
1 220 100 r
Total fuel used
51.3 gal
Operation
failed
Total engine
hours
Action:
7.3 h
6
Cancel operation
82
Trip data
MENU: Data log mode, Trip data
1
Trip fuel
uneconomy revs
8.5 gal
Trip distance
203.5 mi
Trip fuel
67.4 km/h
Avg. 28 l/100 km
Acc. 57.0 gal
Trip overspeed
Note: If Miles and F have been selected, the consumption is shown in US gallons.
0.2 h
Trip overrevs
10
83
15
11
Trip cruise
2.5 h
0.4 h
12
Operation
failed
2.5 gal
Action:
13
84
Cancel operation
Press Esc in order to cancel the operation.
Data transfer
completed
Reset?
Press FOR 1S
5
Operation
failed
Data transfer
in progress
Action:
please wait
85
Set-up mode
System diagnostic
Data log mode
Password Input
2
Password input
0000
If an incorrect number has been given press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Password Input is shown again.
When the ignition key has been in the off position
for more than 60 seconds or when the batteries
have been disconnected the password must be entered again.
3
Error!
Password Input
0000
86
Troubleshooting
Troubleshooting
Instrumentation Troubleshooting
When troubleshooting the instrument cluster, the graphic
display or Volvos VCADS Pro diagnostic tool can be
used. VCADS Pro provides several features not available
within the cluster itself, such as the ability to test input
signals and calibrate gauges individually.
Many of the components can be tested without disturbing the cluster by using the cluster self test function in
the graphic displays Diagnostic Menu. This includes all
the telltale lamps, the graphic display, and all gauges except for the air gauges. The pivot-down mounting feature
of the cluster allows troubleshooting of input signals
without removing the cluster from the vehicle.
Note: Instrument cluster programming. Each instrument cluster (or CPU board) is programmed to
correspond to the customer-ordered options for that particular vehicle. This dataset is stored in the CPU board
memory, making the instrument cluster unique to each
vehicle.
For this reason, it is not possible to swap a suspected
faulty instrument cluster (or CPU board) with one from
another vehicle without reprogramming the replacement
instrument cluster (or CPU board).
Authorized technicians can update and/or alter software
87
Troubleshooting
CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, make sure the workbench has an
anti-static mat which is grounded to the nearest electrical outlet when working on the instrument cluster.
Failure to use an anti-static mat may result in permanent damage to the printed circuit boards in the
instrument cluster. When working at the anti-static
workbench, always keep a wrist strap connected to
the anti-static mat.
CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, a wrist grounding strap must be
used when working on electronic equipment such as
the instrument cluster. Failure to use a wrist strap may
result in permanent damage to the printed circuit
boards in the instrument cluster. To use the wrist strap
in a vehicle, attach the alligator clip to the nearest
electrical ground such as a metal mounting screw, a
ground terminal or preferably a ground stud.
88
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil may run out
of the front of the gauge faces and make the gauges
inaccurate.
Troubleshooting
W3003624
The following tests can be performed via the graphic display using the graphic display control buttons:
1
2
3
4
From the graphic display menu System diagnostic select Cluster self test. The four sub-menus available are:
Bulb test
The test activates all telltale lamps and all red LED
warning indicators. If the lamps do not light during the
test, the lamp may not be operating or there may be a
fault in the wiring used for the indicator lamp test.
Gauge test
This test checks that the electrically controlled gauges
can be activated (that the gauges and drivers operate
correctly). The gauges will sweep to full and half scale.
Mechanical (air) gauges are not operated with this test.
Display test
The entire display screen will alternate from dark to light
to check that all pixels on the display are operational.
Additionally, the odometer display will illuminate all LED
segments.
Buzzer test
This test checks the function of the buzzer. The graphic
display alternates from flasher indicator to reminder to
caution. A different tone will sound with each display
message. (The caution sound is connected to the yellow
information lamp.)
These tests can also be run using the VCADS Pro tool.
89
Troubleshooting
W0001632
Bulb test
The test activates all telltale lamps and all red LED
warning indicators. If the lamps do not light during the
test, the lamp may not be operating or there may be a
fault in the wiring used for the indicator lamp test (see
90
Gauge test
This test checks that the electrically controlled gauges
can be activated (that the gauges and drivers operate
correctly). The gauges will sweep to full and half scale.
Mechanical (air) gauges are not operated with this test.
Display test
The entire display screen will alternate from dark to light
to check that all pixels on the display are operational.
Additionally, the odometer display will illuminate all LED
segments.
Buzzer test
This test checks the function of the buzzer. The graphic
display alternates from flasher indicator to reminder to
caution. A different tone will sound with each display
message. (The caution sound is connected to the yellow
information lamp.)
Troubleshooting
W3004300
91
Troubleshooting
W3004319
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
With the bulb test active all the telltale and LED indicator lamps will illuminate for
approximately 5 seconds.
Troubleshooting
Troubleshooting
If all the telltale and LED indicator lamps function correctly in the Instrument Cluster
Self Test or Instrument Cluster Tests using VCADS Pro, the lamps and instrument cluster electronics are working properly.
Check
Key Position
Measurement
Point
Expected
Value
Note
Measurements
not expected
value? Check:
On
Visual check
LEDs illuminate
Note: Problems with the left module gauges may be in the left CPU board or the left
gauge module. No tests are currently available to isolate the problem area.
93
Troubleshooting
Step 1. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument cluster 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 warranty).
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 and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measurement
Point
Expected
Value
Note
Measurements not
expected value?
Check:
Lamp Test
(-)
On
Check green
28 (RX28) to
+bat with meter
12V
Bulb test
active
<1V
Bulb test
not active
+12V
Power Supply
On
Check green
18 (RX18) to
ground with
meter
Ground
Off
Check green
15 (RX15) to
ground with
meter
Fuse, connectors or
wiring fault in power
supply circuit
94
<1
Connectors or wiring
fault in ground circuit
Troubleshooting
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The right module if the warranty has expired. See Right Module, Replacement
page 145.
95
Troubleshooting
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
137.
Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument cluster 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 between
wiring harness connector LX and the instrument cluster connector LX. Install overlay J-43340 with the 22PIN
BREAKOUT HARNESS side up. The overlay is color-coded green for the LX connector pins. Go to the next chart and
perform the tests for the lamp in question.
Function
Key Position
Measurement
Point
Expected
Value
Power Supply
On
Green 22
(LX22) to
ground with
meter
+12V
Ground
Off
Green 12
(LX12) to
ground with
meter
<1
Note
Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
power supply circuit
Disconnect
LX connector
at cluster
Connectors or
wiring fault in
ground circuit
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
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 pins
may be back-probed with digital multimeter J39200 or an equivalent tool. See
Connectors, Back-probing page 134.
96
Troubleshooting
Step 1. Set-up: connect breakout box 9998551 with adapter J-43234 in series between wiring harness connectors
LY and CY and the instrument cluster connectors LY and CY. Install overlay J-43340 with the 30PIN BREAKOUT
HARNESS side up. The overlay is color-coded green for the LY connector pins, and blue for the CY connector pins.
Proceed to chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Note
Measurements
not expected
value? Check:
Preheat
Preheat
Check green 11
(LY11) to
ground with meter
12V (with
preheat
active)
Preheat lamp
not designed
to illuminate
with all variants.
Lamp test
On
Green 11
(LY11) direct
connection to
Blue 22 (CY22)
Preheat
lamp illuminates
Preheat lamp
not designed
to illuminate
with all variants.
Confirm Blue 22
(CY22) is supplying 12V to Green
11 (LY11). If so,
probable left CPU
board fault.
Ground to
lamp
On
Check green 10
(LY10) to
ground with meter
12V
Lamp off
0V
Lamp on
Lamp test
On
Green 10
(LY10) direct
connection to
ground
INFO lamp
illuminates
Ground to
lamp
On
Check green 6
(LY6) to ground
with meter
12V
Lamp off
0V
Lamp on
Lamp test
On
Green 6 (LY6)
direct connection to ground
STOP
lamp illuminates
On with
engine
running
Check green 5
(LY5) to ground
with meter
Above
+12V
Lamp test
On
Green 5 (LY5)
direct connection to ground
Charging
lamp illuminates
Charging
Confirm Green 10
(LY10) is supplied
ground. If so,
probable left CPU
board fault.
EECU or connectors or wiring fault
in the circuit from
EECU.
Confirm Green 6
(LY6) is supplied
ground. If so, probable left CPU fault.
Alternator
charging
above battery
voltage
Fuse, connectors
or wiring fault from
charging circuit. Or
alternator failure
Probable left CPU
board fault.
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The left CPU board if the warranty has expired. See Left CPU Board, Replacement page 156.
97
Troubleshooting
137.
Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps are OK. If lamps do
not illuminate go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connectors CY and
RX and the instrument cluster connectors LY and CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS
side up. The overlay is color-coded blue for the CY connector pins, and 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Note
Measurements not
expected value?
Check:
Left turn
On
Check blue 14
(CY14) to
ground with
meter
Min: 0V
Max: 12V
Fuse, connectors,
or wiring fault in left
turn circuit
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Lamp test
On
Blue 14 (CY14)
jumper wire to
Blue 22 (CY22)
Left turn
lamp illuminates
Confirm Blue 22
(CY22) is supplying
12V to Blue 14
(CY14). If so, probable center module
fault
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Fuse, connectors,
or wiring fault in
power supply circuit
to center module
Ground to
5th wheel
lock indicator
On
Check blue 13
(CY13) to
ground with
meter
0V
5th wheel
slide switch
active
12V
not active
Blue 13 (CY13)
jumper wire to
ground
5th wheel
lock indicator lamp
illuminates
Lamp test
98
On
<1
Connectors or
wiring fault in
ground circuit
Troubleshooting
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Wheel differential
lock
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Ground to
wheel differential lock
indicator
On
Check blue 12
(CY12) to
ground with
meter
0V
12V
not active
Lamp test
On
Blue 12 (CY12)
jumper wire to
ground
Wheel differential
lock indicator lamp
illuminates
Power supply to
interaxle differential lock
indicator
On
Check blue 10
(CY10) to
ground with
meter
12V
0V
not active
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Lamp test
On
Blue 10 (CY10)
jumper wire to
Green 18
(RX18)
Interaxle
differential
lock lamp
illuminates
On
Check blue 8
(CY8) to ground
with meter
12V
High beam
active
0V
not active
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Lamp test
On
Blue 8 (CY8)
jumper wire to
green 18
(RX18)
High beam
Note
Fuse, connectors,
or wiring fault in
power supply circuit
to center module
High beam
indicator
lamp illuminates
Wheel differential
lock lamp switch or
connectors / wiring
fault in ground circuit through lamp
switch
Confirm Blue 12
(CY12) is supplied
ground. If so, probable center module
fault
<1
<1
Measurements not
expected value?
Check:
Fuse, interaxle
switch, connectors
or wiring fault in
power supply circuit
to center module
Connectors or
wiring fault in
ground circuit
Confirm Blue 10
(CY10) is supplied
12V. If so, probable
center module fault
Fuse, switch, connectors or wiring
fault in power supply circuit to high
beam indicator
Connectors or
wiring fault in
ground circuit
Confirm Blue 8
(CY8) is supplied
12V. If so, probable
center module fault
99
Troubleshooting
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Safety belt
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Ground to
parking
brake indicator
On
Check blue 3
(CY3) to ground
with meter
0V
Parking brake
applied
12V
not applied
Lamp test
On
Blue 3 (CY3)
jumper wire to
ground
Parking
brake lamp
illuminates
Confirm Blue 3
(CY3) is supplied
ground. If so, probable center module
fault
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Fuse, connectors
or wiring fault in
power supply circuit
to center module
Ground to
ABS tractor
indicator
On
Check blue 1
(CY1) to ground
with meter
0V
ABS faults
active
12V
not active
Lamp test
On
Blue 1 (CY1)
jumper wire to
ground
Tractor
ABS lamp
illuminates
Parking brake
Anti-lock braking
system (ABS),
tractor
100
Note
Measurements not
expected value?
Check:
Fuse, connectors
or wiring fault in
power supply circuit
to center module
<1
Connectors or
wiring fault in
ground circuit
Fuse, connectors
or wiring fault in
power supply circuit
to center module
Parking brake
switch or connectors / wiring fault in
ground circuit
through switch
ABS system or
connectors / wiring
fault in ground circuit through ABS
system
Confirm Blue 1
(CY1) is supplied
ground. If so, probable center module
fault
Troubleshooting
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Anti-lock braking
system (ABS),
trailer
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Ground to
trailer ABS
indicator
On
Check blue 2
(CY2) to ground
with meter
0V
ABS faults
active
12V
not active
Lamp test
On
Blue 2 (CY2)
jumper wire to
ground
Trailer ABS
lamp illuminates
Confirm Blue 2
(CY2) is supplied
ground. If so, probable center module
fault
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Fuse, connectors
or wiring fault in
power supply circuit
to center module
Ground to
air suspension system
indicator
On
Check blue 15
(CY15) to
ground with
meter
0V
Suspension
dump switch
active
12V
not active
Lamp test
On
Blue 15 (CY15)
jumper wire to
ground
On
Check blue 4
(CY4) to ground
with meter
12V
0V
not active
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Lamp test
On
Blue 4 (CY4)
jumper wire to
Green 18
(RX18)
Air Suspension
Heated mirrors
Note
Fuse, connectors
or wiring fault in
power supply circuit
to center module
ABS system or
connectors / wiring
fault in ground circuit through ABS
system
Suspension dump
switch or connectors / wiring fault in
ground circuit
through switch
Confirm Blue 15
(CY15) is supplied
ground. If so, probable center module
fault
<1
Mirror defroster
lamp illuminates
Measurements not
expected value?
Check:
Fuse, connectors
or wiring fault in
power supply circuit
to center module
Connectors or
wiring fault in
ground circuit
Momentary
connection
only. Fuse
may blow.
Confirm Green 18
(RX18) is supplying
12V to Blue 4
(CY4). If so, probable center module
fault
101
Troubleshooting
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Note
Measurements not
expected value?
Check:
Right turn
On
Check blue 9
(CY9) to ground
with meter
Min: 0V
Max: 12V
Right turn
signal active
Fuse, connectors
or wiring fault in
right turn circuit
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Lamp test
On
Blue 9 (CY9)
jumper wire to
Blue 22 (CY22)
Right turn
lamp illuminates
Confirm Blue 22
(CY22) is supplying
12V to Blue 9
(CY9). If so, probable center module
fault
Power supply
On
Check blue 22
(CY22) to
ground with
meter
12V
Fuse, connectors
or wiring fault in
power supply circuit
to center module
Ground
Off
Check blue 11
(CY11) to
ground with
meter
Lamp test
On
Blue 25 (CY25)
jumper wire to
ground
Master
warning
lamp illuminates
Jumper from
right module
On
Check blue 25
(CY25) to
ground with
meter
12V
0V
Master warning
Ground, right
module
Off
Check green 15
(RX15) to
ground with
meter
<1
Connectors or
wiring fault in
ground circuit
<1
<1
Connectors or
wiring fault in
ground circuit
Confirm Blue 25
(CY25) is supplied
ground. If so, probable center module
fault
Wiring or connectors between center
and right module.
Possible right module fault
Connectors or
wiring fault in
ground circuit
102
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
Troubleshooting
137.
Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument cluster electronics are working properly. If lamps do not illuminate go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Transmission temperature
Power
supply
On
Check green 18
(RX18) to
ground with
meter
12V
Ground to
transmission
temperature
indicator
On
Check green 29
(RX29) to
ground with
meter
12V
Transmission
temperature
OK
0V
Transmission
temperature
to high
Lamp test
On
Green 29
(RX29) jumper
wire to ground
Transmission
temperature lamp
illuminates
Confirm Green 29
(RX29) is supplied
ground. If so,
probable right
module fault
Power
supply
On
Check green 18
(RX18) to
ground with
meter
12V
Fuse, connectors
or wiring fault in
right module
power supply circuit
Ground to
transmission
indicator
On
Check green 30
(RX30) to
ground with
meter
12V
No transmission faults
0V
Transmission
faults
Lamp test
On
Green 30
(RX30) jumper
wire to ground
Check
transmission lamp
illuminates
W3004305
Check transmission
W3004306
Note
Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
right module
power supply
circuit
Transmission ECU
or connectors /
wiring fault in
ground circuit
through transmission ECU
Transmission ECU
or connectors /
wiring fault in
ground circuit
through transmission ECU
Confirm Green 30
(RX30) is supplied
ground. If so,
probable right
module fault
103
Troubleshooting
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Traction control
Power
supply
On
Check green 18
(RX18) to
ground with
meter
12V
Ground to
traction
control indicator
On
Check green 14
(RX14) to
ground with
meter
0V
Traction
control active
12V
Traction
control not active
Lamp test
On
Green 14
(RX14) jumper
wire to ground
Traction
control
lamp illuminates
Confirm Green 14
(RX14) is supplied
ground. If so,
probable right
module fault
Power
supply
On
Check green 18
(RX18) to
ground with
meter
12V
Fuse, connectors
or wiring fault in
right module
power supply
circuit
Ground to
WAIT
indicator
On
Check green 13
(RX13) to
ground with
meter
12V
0V
Lamp test
On
Green 13
(RX13) jumper
wire to ground
WAIT lamp
illuminates
Power
supply
On
Check green 18
(RX18) to
ground with
meter
12V
Transmission
in neutral
0V
Transmission
not in neutral
W3003668
Wait to start
W3004307
Transmission in
Neutral
Ground
Off
Check green 15
(RX15) to
ground with
meter
Lamp test
On
Green 22
(RX22) jumper
wire to green
18 (RX18)
<1
Note
Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
right module
power supply
circuit
ABS system or
connectors / wiring
fault in ground
circuit through
ABS / traction
control system
Engine ECU or
connectors / wiring
fault in ground
circuit through
engine ECU
Confirm Green 13
(RX13) is supplied
ground. If so,
probable right
module fault
Fuse, connectors,
switches or wiring
fault in neutral
switch circuit
Connectors /
wiring fault in
ground circuit
W3004308
104
Transmission in
Neutral
lamp illuminates
Confirm Green 22
(RX22) is supplied
12V. If so, probable
right module fault
Troubleshooting
Telltale Lamp
Function
Key Position
Measuring
Point
Expected
Value
Water in fuel
Power
supply
On
Check green 18
(RX18) to
ground with
meter
12V
Ground to
water in fuel
indicator
On
Check green 19
(RX19) to
ground with
meter
12V
Water in fuel
indicator not
active
0V
Water in fuel
indicator
active
Green 19
(RX19) jumper
wire to ground
Water in
fuel lamp
illuminates
W3004309
Lamp test
On
Note
Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
right module
power supply
circuit
Engine ECU or
connectors / wiring
fault in ground
circuit through
engine ECU
Confirm Green 19
(RX19) is supplied
ground. If so,
probable right
module fault
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The right module if the warranty has expired. See Right Module, Replacement
page 145.
105
Troubleshooting
W3004335
Note: The schematic should be used to help clarify the instrument cluster backlighting troubleshooting procedures in this manual. For detailed vehicle specific, wiring troubleshooting refer to:
106
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
Troubleshooting
Backlighting Tests
To test the instrument cluster backlighting, turn the parking/headlamps on and adjust
the dimmer control for maximum brightness.
Individual Backlighting
If individual backlights are not operating, replace the lamp. If a new lamp does not correct 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 the
dimmer control switch on the dash. The voltage is variable with the dimmer control position. Adjust the dimmer control for maximum brightness. If voltage is not present at
the output, check the dimmer switch, headlamp switch, fuses, connectors or wiring. For
lamp switch information refer to:
Service
Manual
IMPACT
Function Group: 35
Information Type: descrip-designfunc
Switches and Controls
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
107
Troubleshooting
137.
Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay 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 otherwise
noted.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measuring Point
Expected
Value
Note
Backlighting Input,
Left Module
Off
Green 20 (LX20)
to ground with
meter
2.5 - 12 V
Varies with
dimmer position
Switches, connectors or
wiring fault in power supply
circuit from dimmer
Off
Green 12 (LX12)
to ground with
meter
Headlamp
switch OFF.
Disconnect LX
connector at
cluster
<1
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The left gauge module or left CPU board if the warranty has expired. See Left
Gauge Module, Replacement page 141 or Left CPU Board, Replacement page
156.
Note: Problems with the left module gauges may be in the left CPU board or the left
gauge module. No tests are currently available to isolate the problem area.
108
Troubleshooting
137.
Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded blue for the CY connector pins. Proceed to the chart below.
Note: The headlamp switch should be ON with the dimmer control adjusted to maximum brightness unless otherwise
noted.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measuring Point
Expected
Value
Note
Backlighting Input,
Center Module
Off
Check blue 18
(CY18) to ground
with meter
2.5 - 12 V
Varies with
dimmer position
Switches, connectors or
wiring fault in power supply
circuit from dimmer
Off
Check blue 11
(CY11) to ground
with meter
Headlamp
switch OFF
<1
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
109
Troubleshooting
137.
Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the RX connector pins. Proceed to the chart below.
Note: The headlamp switch should be ON with the dimmer control adjusted to maximum brightness unless otherwise
noted.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measuring Point
Expected
Value
Note
Backlighting Input,
Right Module
Off
Check green 1
(RX1) to ground
with meter
2.5 - 12 V
Varies with
dimmer position
Switches, connectors or
wiring fault in power supply
circuit from dimmer
Off
Check green 15
(RX15) to ground
with meter
Headlamp
switch OFF
<1
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
110
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The right module if the warranty has expired. See Right Module, Replacement
page 145.
Troubleshooting
W3003774
Note: The schematic should be used to help clarify the graphic display/odometer troubleshooting procedures
in this manual. For detailed, vehicle specific, wiring troubleshooting refer to:
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
With the display test active the graphic display screen will alternate from dark to
light to check that all pixels on the display are operational. Additionally, the odometer display will illuminate all LED segments. This test is independent of any data
input signals that may be displayed on the screens.
Troubleshooting
Troubleshooting, Odometer
Odometer Backlighting
The odometer backlighting is the same as the other
dash and instrumentation backlighting. See Instrument
Cluster Backlighting, Troubleshooting page 106 for more
information.
Odometer Display
Step 1. Run cluster self-test. If the odometer display functions correctly in this test, the display is OK. This test is
independent 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 warranty). 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 and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay 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.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measuring Point
Expected
Value
Power supply
On
Check CX4 to
ground with meter
12V
Ground
Off
Check CX5 to
ground with meter
Information Data
Link
(J1587/J1708)
On
5V max.
0V min.
Connectors or wiring
fault in J1587/J1708
information link (wires
400, 401)
Power Supply
On
Check blue 22
(CY22) to ground
with meter
12V
Fuse, connectors or
wiring fault in power
supply circuit
Ground
Off
Check blue 11
(CY11) to ground
with meter
112
<1
<1
Note
Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit
Disconnect CX
cluster connector
Disconnect CY
cluster connector
Connectors or wiring
fault in ground circuit
Connectors or wiring
fault in ground circuit
Troubleshooting
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
113
Troubleshooting
Step 1. If a backlighting problem, replace the suspect lamp with a known good bulb. See
137. 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 tests
are 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 with
adapter J-43235 in series between wiring harness connector LX and the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The overlay is color-coded green for the LX 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measuring Point
Expected
Value
Note
Measurements not
expected value?
Check:
On
Check green 20
(LX20) to ground
with meter
2.5 to 12 V
Head/parking
lamps on - varies
with dimmer position
Switch, connectors or
wiring fault in backlighting circuit from
dimmer control switch.
Power supply
On
Check green 10
(LX10) to ground
with meter
12V
Ground
Off
Check green 9
(LX9) to ground with
meter
Information Data
Link
(J1587/J1708)
On
Check green 1
(LX1) to green 11
(LX11) with meter
<1
Fuse, connectors or
wiring fault in power
supply circuit
Disconnect LX
cluster connector
5V max.
0V min.
Connectors or wiring
fault in ground circuit
Connectors or wiring
fault in J1587/J1708
information link (wires
400, 401)
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The graphic display or left CPU board if the warranty has expired. See Graphic
Display, Replacement page 150 or Left CPU Board, Replacement page 156.
Troubleshooting
Gauges, Troubleshooting
Instrument cluster gauges may operate based on inputs from hardwired sensors, signals 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 each
gauge.
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. For
detailed vehicle specific, wiring troubleshooting refer to:
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
With the gauge test active the electrically operated gauges will sweep to full and
half travel. This test is independent of any inputs to the instrument cluster. If the
gauge operates properly with this test it is likely the gauge itself is functioning
properly.
115
Troubleshooting
The display reads 1500 F if there is a short-circuit in the pyrometer wiring. 300 F or
less 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 as
a result of mechanical faults, oxidation etc.
Intermittent Faults
In the event of an intermittent fault, the cause may be connector related. For further information on fault tracing of wiring and connectors, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
Also check for fault codes using the instrument cluster diagnostic function. See Fault
diagnostic page 68.
116
Troubleshooting
Step 1. Run cluster self-test. If an accuracy complaint, check accuracy with the Instrument Cluster Tests using 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.
Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Power supply
On
Check green 10
(LX10) to ground
with meter
12V
Ground
Off
Check green 9
(LX9) to ground
with meter
Note
Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit
Disconnect LX
connector at
cluster
Connectors or
wiring fault in
ground circuit
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
If all the measurements are correct, continue in the following troubleshooting chart to
the section for the suspect gauge.
Engine oil pressure gauge, Engine coolant temperature gauge, Turbo boost pressure gauge
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Note
Measurements not
expected value?
Check:
Engine oil
pressure
Information
data link
On
Check green 1
(LX1) to green
11 (LX11) with
meter
5V max.
0V min.
Connectors or
wiring fault in
J1587/J1708 information link from
EECU. Fault in sensor or circuit to
EECU
117
Troubleshooting
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Note
Measurements not
expected value?
Check:
Engine
coolant temperature
Information
data link
On
Check green 1
(LX1) to green
11 (LX11) with
meter
5V max.
0V min.
Connectors or
wiring fault in
J1587/J1708 information link from
EECU. Fault in sensor or circuit to
EECU
Turbo boost
pressure
Information
data link
On
Check green 1
(LX1) to green
11 (LX11) with
meter
5V max.
0V min.
Connectors or
wiring fault in
J1587/J1708 information link from
EECU. Fault in sensor or circuit to
EECU
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The left gauge module or left CPU board if the warranty has expired. See Left
Gauge Module, Replacement page 141 or Left CPU Board, Replacement page
156.
Note: Problems with the left module gauges may be in the graphic display module or
the 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 connect
the instrument cluster connector LY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LY 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
118
Troubleshooting
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Note
Measurements not
expected value?
Check:
Pyrometer
Signal
Off
Check green 30
(LY30) to green
13 (LY13) with
meter
5-300 mV
Engine warm.
May show 0V if
engine is cold
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The left gauge module or left CPU board if the warranty has expired. See Left
Gauge Module, Replacement page 141 or Left CPU Board, Replacement page
156.
Note: Problems with the left module gauges may be in the graphic display module or
the left gauge module. No tests are currently available to isolate the problem area.
119
Troubleshooting
Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay 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.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Speedometer
Power supply
On
Check blue 22
(CY22) to ground
with meter
12V
Ground
Off
Check blue 11
(CY11) to ground
with meter
Information
data link
On
Check CX1 to
CX2 with meter
5V max.
0V min.
Power supply
On
Check CX4 to
ground with meter
12V
Ground
Off
Check CX5 to
ground with meter
Information
data link
On
Check CX1 to
CX2 with meter
Tachometer
Odometer
120
<1
<1
5V max.
0V min.
Note
Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
power supply circuit
Disconnect CY
connector at
cluster
Connectors or
wiring fault in
ground circuit
Connectors or
wiring fault in
J1587/J1708 information link. Fault
in vehicle speed
sensor circuit
Fuse, connectors
or wiring fault in
power supply circuit
Disconnect CX
connector at
cluster
Connectors or
wiring fault in
ground circuit
Connectors or
wiring fault in
J1587/J1708 information link. Fault
in engine speed
sensor circuit
Troubleshooting
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
121
Troubleshooting
Electrical Gauges
Step 1. Run cluster self test. If an accuracy problem, check gauge accuracy with the Instrument Cluster Tests using 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. If
no 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 RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Forward rear
axle temperature
Power supply
On
Check green 18
(RX18) to ground
with meter
12V
Ground
Off
Green 15 (RX15)
to ground with
meter
Signal from
left module
On
Green 3 (RX3)
to ground with
meter
Rear rear
axle temperature
122
Power supply
On
Green 18 (RX18)
to ground with
meter
Ground
Off
Green 15 (RX15)
to ground with
meter
Signal from
left module
On
Green 17 (RX17)
to ground with
meter
Note
Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit
<1
Connectors or
wiring fault in
ground circuit
5V
10V
minimum
12V
Fuse, connectors or
wiring fault in power
supply circuit
<1
Connectors or
wiring fault in
ground circuit
5V
10V
minimum
Troubleshooting
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Fuel level
Power supply
On
Green 18 (RX18)
to ground with
meter
12V
Ground
Off
Green 15 (RX15)
to ground with
meter
Signal from
left module
On
Green 4 (RX4)
to ground with
meter
Note
Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit
<1
Connectors or
wiring fault in
ground circuit
5V
Gauge reading
full
10V
empty
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The right module if the warranty has expired. See Right Module, Replacement
page 145.
123
Troubleshooting
Mechanical Gauges
Step 1. Connect test gauge J-44274 in series between the air lines and the instrument cluster gauge fitting. The air
lines 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 gauge
faults. Always reconnect the air line to the proper gauge. The air lines and gauge fittings are color coded to aid in installation.
Gauge
Measuring Point
Expected Value
Note
Approximately
same value as
test gauge
Gauge failure
Approximately
same value as
test gauge
Gauge failure
Application air
pressure
Approximately
same value as
test gauge
Gauge failure
Air suspension
pressure
Approximately
same value as
test gauge
Gauge failure
The tests above only check for consistent readings between the instrument cluster
gauge and test gauge. If air pressure seems out of normal operating range, the vehicle
air system should be checked for proper operation.
If measurements indicate a faulty air gauge, replace:
124
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
The affected air gauge if the warranty has expired. See Air Gauge, Replacement
page 148.
Troubleshooting
Step 1. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector LY and
the instrument cluster connector LY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LY connector pins.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Forward rear
axle temperature
Reference
voltage
On
Check green 29
(LY29) to ground
with meter
5V max.
0V min.
Ground
Off
Check green 29
(LY29) to ground
with meter
W3003735
1000
10% @
21 C (70 F)
Note
Measurements not
expected value?
Check:
Check power supply to left module. If
OK and no output
from LY29, probable
left (graphic display)
module failure
Disconnect LY
connector at
cluster
Sensor, connectors
or wiring fault in
ground circuit
through forward rear
axle temp. sensor
5V
10V
minimum
If reference voltage
and ground OK,
probable left
(graphic display)
module failure
430
10%
@ 50 C
(120 F)
110
10%
@ 95 C
(200 F)
Gauge signal
On
Check green 24
(LY24) to ground
with meter
125
Troubleshooting
Gauge
Function
Key Position
Measuring
Point
Expected
Value
Rear rear
axle temperature
Reference
voltage
On
Check green 16
(LY16) to ground
with meter
5V max.
0V min.
Ground
Off
Check green 16
(LY16) to ground
with meter
W3003735
1000
10% @
21 C (70 F)
Note
Measurements not
expected value?
Check:
Check power supply to left module. If
OK and no output
from LY16, probable
left (graphic display)
module failure
Disconnect LY
connector at
cluster
Sensor, connectors
or wiring fault in
ground circuit
through rear rear
axle temp. sensor
5V
10V
minimum
If reference voltage
and ground OK,
probable left
(graphic display)
module failure
430
10%
@ 50 C
(120 F)
110
10%
@ 95 C
(200 F)
Gauge signal
On
Check green 21
(LY21) to ground
with meter
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
If all the measurements are correct, continue to the troubleshooting chart for Electrical
gauges.
126
Troubleshooting
Step 1. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX connector pins.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Sen
Function
Key Position
Measuring
Point
Expected
Value
Fuel level
Reference
voltage
On
Check green 2
(LX2) to ground
with meter
5V max.
0V min.
Ground
Off
Check green 2
(LX2) to ground
with meter
240
10%
@ empty
tank
Note
Measurements not
expected value?
Check:
Check power supply to left module. If
OK and no output
from LX2, probable
left (graphic display)
module failure
Disconnect LX
connector at
cluster
Sensor, connectors
or wiring fault in
ground circuit
through fuel level
sensor
5V
Gauge reading
full
10V
empty
If reference voltage
and ground OK,
probable left
(graphic display)
module failure
153
10%
@ 1/4 tank
103
10%
@ 1/2 tank
67
10%
@ 3/4 tank
33
10%
@ full tank
Gauge signal
On
Check green 3
(LX3) to ground
with meter
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
If all the measurements are correct, continue to the troubleshooting charts for electrical
gauges.
127
Troubleshooting
W3004326
Note: The schematic should be used to help clarify the graphic display control buttons troubleshooting procedures in this manual. For detailed vehicle specific, wiring troubleshooting refer to:
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
The graphic display control buttons are used to manually communicate with and manipulate the graphic display. Before troubleshooting, see General Work Practices
page 88.
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.
Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX 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 digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Function
Key Position
Measurement
Point
Expected
Value
Power supply to
wiper stalk
On
Check green
21 (LX21) to
ground with
meter
12V
Esc button
On
Check green 4
(LX4) to ground
with meter
12V
128
Note
Measurement not
expected value?
Check:
Left module power
supply or internal left
module fault
Button active
Troubleshooting
Function
Key Position
Measurement
Point
Expected
Value
Note
Measurement not
expected value?
Check:
Select button
On
Check green 7
(LX7) to ground
with meter
12V
Button active
Up button
On
Check green
16 (LX16) to
ground with
meter
12V
Button active
Down button
On
Check green 6
(LX6) to ground
with meter
12V
Button active
On
Check green
10 (LX10) to
ground with
meter
12V
Ground
Off
Check green 9
(LX9) to ground
with meter
<1
Fuse, connectors, or
wiring fault in power
supply circuit
Disconnect LX connector at cluster
Connectors or wiring
fault in ground circuit
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Manual
IMPACT
Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD
PV776TSP143133
Windshield Wiper System
IMPACT
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
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 the
left CPU board. No test are currently available to isolate the problem area.
129
Troubleshooting
Buzzer, Troubleshooting
The buzzer is located on the center module and activated by messages received on
the J1587/1708 information data link. Before troubleshooting, see General Work
Practices page 88.
W3003627
Note: The schematic should be used to help clarify the buzzer troubleshooting procedures in this manual. For
detailed vehicle specific, wiring troubleshooting refer to:
Service
Bulletin
PV776TSP109322
Windshield Wiper System
IMPACT
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.
Buzzer Tests
Step 1. Run the cluster self test. If the buzzer functions correctly in the self test the buzzer is OK. If the buzzer
does 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. If
no 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 and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay 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 digital
multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Note: There is no breakout box tooling available for connector CX.
130
Troubleshooting
Function
Key Position
Measuring point
Expected
Value
Power Supply
On
Check CX4 to
ground with meter
12V
Ground
Off
Check CX5 to
ground with meter
Flasher, Reminder,
Caution or Alarm
Clock Signal
On
Check CX1 to
CX2 (Data link)
with meter
5V max.
0V min.
On
Check blue 14
(CY14) to ground
with meter
12V max.
0V min.
On
Check blue 9
(CY9) to ground
with meter
12V max.
0V min.
<1
Note
Disconnect
CX connector
If the measurements are outside the expected values, refer to (for circuitry information):
Service
Bulletin
PV776TSP109322
Windshield Wiper System
IMPACT
The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.
131
Troubleshooting
Common Problems
Symptom
Cause
Correction
Faulty datasets.
132
Service Procedures
Service Procedures
Service Procedures
When dealing with circuits designed to sense differences
General Work Practices
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules and air
gauges can be replaced. Electrical gauges cannot be replaced individually.
CAUTION
Welding on trucks can damage the vehicle electrical
system/components from the voltage and current
spikes that normally occur when welding. It is preferable to avoid welding on an assembled truck, but if
welding must be done on any structure on or in
contact with the vehicle, disconnect the electrical connectors at the rear of the instrument cluster, all ECUs
and the battery cables. When disconnecting the battery cables, disconnect any other ground cables
connected to the battery first, then the main battery
ground. Attach the welder ground cable as close to
the weld as possible.
smaller than 1 volt, electrostatic discharge can be a subtle but destructive problem. Circuit boards mounted in
the instrument cluster or in modules mounted elsewhere
may not fail immediately after being hit with a static discharge. Rather they may work for a while, then fail for no
apparent reason. The culprit then is often the normal
warming up and cooling down process of the module,
engine or cab interior.
Grounding straps and anti-static mats are available for
minimal cost from electronic supply stores. Grounding
straps consist of a wrist strap, a coiled extension wire
and an alligator clip. Be sure to purchase one with a long
enough extension wire to allow freedom of movement.
Anti-static wrist straps and mats are available from
Kent-Moore (see Tools section of this manual). Call
1-800-328-6657.
CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, a wrist grounding strap must be
used when working on electronic equipment such as
the instrument cluster. Failure to use a wrist strap may
result in permanent damage to the printed circuit
boards in the instrument cluster. To use the wrist strap
in a vehicle, attach the alligator clip to the nearest
electrical ground such as a metal mounting screw, a
ground terminal or preferably a ground stud.
CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, make sure the workbench has an
anti-static mat which is grounded to the nearest electrical outlet when working on the instrument cluster.
Failure to use an anti-static mat may result in permanent damage to the printed circuit boards in the
instrument cluster. When working at the anti-static
workbench, always keep a wrist strap connected to
the anti-static mat.
133
Service Procedures
Connectors, Back-probing
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
W3003661
W3003656
W3003660
Front-probing: If it is necessary to
disconnect a connector and
front-probe a pin, never use the multimeter probes to directly contact
the connector pins. Using these
large probes can damage the connector pins and result in intermittent faults.
To avoid damage, use tool J-42449
when front-probing connector pins.
J-42449
Service Procedures
Removal
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
W3002866
W3003654
135
Service Procedures
Installation
1
Cut the faulty terminal wire to the
same length as the JAE terminal pigtail replacement.
2
W3002867
W3002868
3948725
3948726
W3002869
136
J-381258
Service Procedures
Bulb, Replacement
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
W3002870
J-25070
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column so that the bulbs are
accessible.
137
Service Procedures
W3000642
CAUTION
Use only the Volvo bulb removal tool, P/N 1089953, to
remove bulbs, or damage to the cluster may occur.
Insert removal tool, P/N 1089953, onto
the bulb assembly. Rotate 1/4 turn and
pull the bulb assembly out of the
socket.
4
Insert the new bulb assembly into the
removal tool, P/N 1089953. Insert the
assembly into cluster socket and rotate 1/4 turn.
5
Replace the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
138
1089953
3811-03-02-01
Instrument Cluster, Replacement
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Note: Replacement instrument cluster should be ordered from Volvo per VIN (Vehicle Identification
Number). Replacement instrument cluster will be programmed before delivery.
Note: Replacement instrument clusters should be edited
to reflect the current actual mileage of the vehicle. This
may be accomplished by use of the VCADS PRO tool (or
the Pro Link 9000 tool). Under no circumstances should
the edit odometer functions be used to falsify the actual
mileage. See Odometer, Programming page 162.
W3003659
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
139
Service Procedures
8
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
9
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
W3003657
WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect. Remove the cluster from the vehicle.
5
Position the replacement instrument
cluster face-down on the steering column in the mounting position. Connect
the air tubing. Note the color codes for
proper installation.
6
Connect all electrical connectors, noting color codes to aid in installation.
7
Important: Reprogram the odometer
to the current actual mileage. See
Odometer, Programming page 162.
140
2 0.3 Nm
(17.5 2.5 inlb)
3811-03-02-04
Left Gauge Module, Replacement
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be replaced. Individual gauges are not replaceable.
W3003659
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
141
Service Procedures
W3003648
WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.
W3003649
142
Service Procedures
3811-03-02-03
Center Module, Replacement
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
W3003658
Carefully connect the ribbon wire connector from the CPU/graphic display
module to the left gauge module. Position the CPU/graphic display module in
the cluster housing.
10
Install the left module cover with the 3
mounting screws.
11
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
12
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
13
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
2 0.3 Nm
(17.5 2.5 inlb)
143
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
W3003657
W3003659
WARNING
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.
W3003650
Service Procedures
3811-03-02-02
Right Module, Replacement
7
Install the replacement center module
into the cluster housing with the 4
mounting screws.
8
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
9
Connect all electrical connectors, noting color codes to aid in installation.
CAUTION
10
Important: Reprogram the odometer
to the current actual mileage. See
Odometer, Programming page 162.
11
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
12
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
2 0.3 Nm
(17.5 2.5 inlb)
145
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
W3003657
W3003659
WARNING
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
146
Service Procedures
13
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
2 0.3 Nm
(17.5 2.5 inlb)
W3003652
147
3851-03-02-01
Air Gauge, Replacement
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules and air
gauges can be replaced.
W3003659
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
148
Service Procedures
W3003652
WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars on the back of
the cluster while pulling back on the
air tubing to disconnect.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.
W3004299
Position the new air gauge in the cluster housing assembly to assure proper
alignment.
9
Place the right module circuit board
onto the gauge and secure with the 2
mounting screws.
10
The right module should now be positioned in the cluster housing. Install
the right module cover and secure with
the 3 right module mounting screws.
149
Service Procedures
3811-03-02-09
Graphic Display, Replacement
11
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
12
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
13
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
2 0.3 Nm
(17.5 2.5 inlb)
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Important: Individual gauges or modules, including the
graphic display, in the VN/VHD instrument cluster are not
serviceable during the warranty period. Attempts to service or replace individual modules or gauges during
the warranty period will void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be
replaced.
150
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
W3003657
W3003659
WARNING
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
151
Service Procedures
10
W3003648
13
Connect all electrical connectors, noting color codes to aid in installation.
14
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
15
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
152
2 0.3 Nm
(17.5 2.5 inlb)
3811-03-02-08
Instrument Cluster Housing/Glass, Replacement
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
W3003659
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
153
Service Procedures
W3003657
WARNING
W3003658
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.
154
Service Procedures
10
13
W3003651
Install the right module into the replacement cluster housing. Install the
cover with the 3 mounting screws.
Note: If any gauge blanks are present
in the existing cluster housing position
them correctly in the replacement
housing.
11
Install the center module into the replacement cluster housing. Install the
cover with the 4 mounting screws.
12
Install the left gauge module into the
replacement cluster housing. Secure
with the 4 mounting screws.
W3003658
14
Install the left module cover with the 3
mounting screws.
15
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
16
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
17
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
2 0.3 Nm
(17.5 2.5 inlb)
155
3871-03-02-01
Left CPU Board, Replacement
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Note: Replacement left CPU board should be ordered
from Volvo per Vehicle Identification Number (VIN). Replacement left CPU boards will be programmed before
delivery.
W3003659
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
156
Service Procedures
W3003657
WARNING
W3003658
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.
157
Service Procedures
15
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
W3004304
9
Align the connector pins in the graphic
display module with the replacement
CPU board and carefully push into position. Secure with the 2 mounting
screws.
10
Install the replacement CPU/graphic
display module by carefully connecting
the ribbon wire connector to the left
gauge module, and positioning the
CPU/graphic display module in place.
11
Install the left module cover with the 3
mounting screws.
12
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
13
Connect all electrical connectors, noting color codes to aid in installation.
14
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
158
2 0.3 Nm
(17.5 2.5 inlb)
3811-03-02-11
Instrument Cluster Rear Cover,
Replacement (Left or Right)
Service Procedures
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Note: The center rear cover is part of the center module
and not replaceable as a single part.
W3003659
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.
159
Service Procedures
W3003657
WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.
6
Remove the 3 right or left rear cover
mounting screws. Remove the left
module cover.
W3004316
Compare the hole pattern in the existing cover with the replacement cover.
Due to different configuration, it may
be necessary to knock out openings
in the replacement cover to accommodate the existing gauges and lamps.
Use a 1/2 inch punch or drill to modify
the replacement cover as needed.
8
Install the cover with the 3 mounting
screws.
9
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
10
Connect all electrical connectors, noting color codes to aid in installation.
11
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
160
12
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).
Service Procedures
2 0.3 Nm
(17.5 2.5 inlb)
W0001632
161
4
Start the VCADS Pro tool. Select Programming / Vehicle Electronics 98 /
Replace ECU. Then, select Driver Information Display and the proper
VIN. Follow the on screen prompts until the programming is completed.
5
Disconnect all VCADS Pro tool cables
from the vehicle. Connect the instrument cluster to the harness connector.
6
Secure instrument cluster with the
mounting screws.
Service Procedures
Odometer, Programming
W0001632
Service Procedures
4
Disconnect all VCADS Pro tool cables
from the vehicle.
W3004318
163
164
Feedback
One of our objectives is that workshop personnel should have access to correct and
appropriate service manuals where it concerns fault tracing, repairs and maintenance
of Volvo trucks.
In order to maintain the high standards of our literature, your opinions and experience
when using this manual would be greatly appreciated.
If you have any comments or suggestions, make a copy of this page, write down your
comments and send them to us, either via telefax or mailing directly to the address
listed below.
To
From
..........................................................................
..........................................................................
..........................................................................
..........................................................................
Greensboro, NC 27402-6115
..........................................................................
USA
..........................................................................
(336) 393-3241
..........................................................................
Comments/proposals
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Concerns Service Manual: ...............................................................................................................................
Operation Numbers
3811-03-02-01
3811-03-02-02
3811-03-02-03
3811-03-02-04
3811-03-02-08
3811-03-02-09
3811-03-02-11
3851-03-02-01
3871-03-02-01
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