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Instrumentation - VNL,VNM - Heavy Haulers RV Resource Guide

1. Engine related Warnings Volvo VE D12 Conditions Engine Caution Stop Lamp Display Gauge LED Engine Fluids Lamp Lamp icon Protection message Note 5 Low Coolant Level On Solid On Solid Icon Blinking N A Shutdown Source switch Data Con Active centrator Low Oil Pressure with Oil Blinking Message on On Shutdown Pressure lt 36 2 psi and Request Inactive gt 1000 RPM for 2 sec Note 4 Low Oil Pressure with Oil Blinking Message on On Shutdown Pressure lt 9 psi Source Request Inactive Data Concentrator Note 4 Low Oil Pressure with Oil On Solid On Solid Message on On Shutdown Pressure lt 6 0 5 psi Request Active Source Data Concentra Note 4 tor High Coolant Temperature Blinking Blinking Message on On Engine Hp Source Engine Note 3 Request Output Note 1 Note 4 Derated High Oil Temperature On Solid Icon On N A N A Source Engine Sender Other Engine Related Blinking Message on N A N A Fault Codes Note 1 Request Note 4 During Programming On Solid On Solid N A N A N A Note 2 Audible Buzzer Yes N A Yes N A N A N A Note When Key switch Ignition position Engine Fluids lamp is on Caution lamp is on solid for 3 5 seconds 1 Lamp remains flashing even when the fault becomes inactive The key switch must be cycled to turn off the lamp 2 Ignition on engine not running Engine related warnings Ca
2. W3000990 Note Early production models may have gauge blanks as shown in the illustration If replacing any blank use the newer gauge blank support assem bly shown in the Installation procedure When adding a gauge blank remove the gauge or gauge blank to be re placed 59 Group 38 Instrumentation VNL VNM Installation 1 To avoid damaging the gauge do not push on the needle when in stalling the gauge Pushing on the needle can make the gauge inaccu rate Install the replacement gauge by grasping the opposite corners of the gauge face plate and pushing the gauge pins into the socket onto the circuit board Do not push on the nee dle For gauge blanks see the following steps It is correctly installed when its face plate is flush with the other gauges face plates Air pressure gauges only Connect the 2 pin connector into the board it is not polarity sensitive so it can go in either way and secure the gauge to the board with a self tapping Phillips screw Adding gauge blanks 2 W3000820 1 Gauge Blank 2 Blank Support Assembly 3 Pins 4 Terminals Install the new blank 1 into the clus ter housing Install the blank support 2 in the PC board into the terminals 4 where the gauge was removed 60 Service Procedures 3 Install the Right Circuit Board assem bly into the housing 4 Place the cover over the board as sembly and secure with three machi
3. Clock Trip Odometer 1 and 2 Diagnostic Messages Engin x Voltmeter Gauge Pres Fuel Economy Engine Coolant Tachometer Speedometer Temp Graphic Performance Cluster MODE CD cs up Clock sr gt CE DOWN Trip Odometer 1 and 2 Diagnostic Messages Voltmeter Gauge Transmission Temp Gauge Engine Oil Temp Gauge Engine Fuel Economy Coclant i akt Temp Graphic Display Driveline Single Axle Cluster W3000832 Group 38 Instrumentation VNL VNM General Available configurations contd Clock Trip Odometer 1 and 2 Diagnostic Messages Voltmeter Gauge Transmission Temp Gauge Engine Oil Temp Gauge Fuel Economy Engine Engine Coolant Oil Tachometer Temp MODE CO c UP sr Co Cc down Graphic Display Driveline Tandem Axle Cluster Clock Trip Odometer 1 and 2 Diagnostic Messages Voltmeter Gauge Transmission Temp Gauge Engine Oil Temp Gauge Fuel Economy Engine Coolant Tachometer Speedometer Temp MODE CEO e uP sr Co C _DownN Graphic Loaded Single Axle Cluster Clock Trip Odometer 1 and 2 Diagnostic Messages Voltmeter Gauge Transmission Temp Gauge Engine Oil Temp Gauge Fuel Economy Engine Coolant Tachometer Speedometer Temp MODE CD cup ser Co Cc down Graphic Loaded Tandem Axle Cluster W3000833 Group 38 Instrumentation VNL VNM Tools Tools Special tools The fo
4. 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 When probing connector terminals do not insert probes into the terminals This will spread the ter minals apart causing permanent damage Probe the insertion side of the connector Gain access to the back of the instrument cluster Disconnect connector LX and use an ohmmeter to measure the resistance between pins 2 and 12 on the harness connector insertion side The reading should be between 33 and 240 ohms depending upon the fuel level in the tank see Table A for values e f resistance is as shown in Table A go to step 4 e f resistance is not as shown in Table A check the connectors and wiring from the LX connector to the fuel level sender Refer to the VNL VNM Electrical Schematics for wiring information Group 38 Instrumentation VNL VNM 4 Turn the ignition ON and use a voltmeter to measure the voltage between pins 2 and 4 on the RX connec tor Measurements should be as follows Table B Voltage Check Fuel Level Expected Reading RX 2 to RX 4 and RX 2 to LX 3 Empty tank 0 19 volts 10 1 4 tank 1 1 volts 10 1 2 tank 2 3 volts 10 3 4 tank 3 5 volts 10 Full tank 4 7 volts 10 If voltage is as shown in Table B replace the cluster If voltage is n
5. e The low coolant sensor is a normally open switch and is closed by a low coolant level To clear the low coolant display check for proper coolant level If 16 Design and Function adding coolant does not correct the problem check the coolant sensor for continuity between pins A and B then check the wiring Air filter restriction e The air filter restriction display and a buzzer will sound ONLY during the first 10 seconds after ignition The air filter restriction sensor is a normally open switch closed by approx 25 Hg e If this warning appears check the air filter restriction gauge at the air filter assembly to see that it has an approximate reading of 25 Hg If so replace the filter and reset the mechanical gauge at the air filter If the gauge is not reset the warning will still appear in the instrument cluster e If the warning still appears after these steps check the air filter restriction gauge for continuity between pins A and C If there is continuity between pins A and C replace the air filter restriction gauge e If the warning still appears after these steps trou bleshoot the air filter restriction gauge circuit Washer fluid low e The washer fluid low warning will be displayed when the washer fluid drops below a predetermined level The washer fluid low warning is a normally open switch located on the washer fluid pump assembly which is closed by a low washer fluid condition e The warning acti
6. Press any of the four buttons while the reminder is sounding Trip Odometer displays Two independent trip odometers are available Trip Odometer 1 and Trip Odometer 2 Each one displays the distance traveled since it was last reset 1 To display a trip odometer a Use the Mode button to select the Multi Function mode b Use the Up and Down buttons to display either TRIP ODOMETER 1 or TRIP ODOMETER 2 2 To reset a trip odometer a Display the trip odometer to be reset 1 or 2 b Press and hold the Set button for 1 second Hourmeter display The hourmeter accumulates and displays the total time the engine has been running It is not resettable by the driver To display the hourmeter 1 Use the Mode button to select the Multi Function mode 2 Use the Down button to scroll to HOURMETER Group 38 Instrumentation VNL VNM Diagnostics mode The Diagnostics mode provides two functions e Diagnostic Messages Reports the status of various vehicle sub systems e Cluster Self Test Mode Contains several tests to check the cluster Diagnostic messages Engine ECU MIDs SIDs mu Sender Units i J1587 Data Link setssssicesasE Oil PSI l l i di l l L I Volvo engine only I Cluster Microprocessor Graphic Display W3000851 Data Concentrator Diagnostic message path The vehicle contains one or more Electronic Control Units ECU s Each ECU monitors or c
7. 6 Press the Set button to begin the displayed test The test will end automatically Group 38 Instrumentation VNL VNM Set up mode The Set up mode allows the driver to choose between English or metric units between 12 or 24 hour time and to set the Graphic Display contrast the Graphic Display and odometer brightness and optionally to set a fuel economy target value Settings are retained when the ignition is off and also when the battery is disconnected If battery power is lost while in the Set Up mode the instrument cluster will go back to its default values Units The units function configures the cluster to display data in the English or metric mode English Distances are displayed in miles tempera tures are displayed in Fahrenheit degrees and Fuel Economy is displayed in miles per gallon e Metric Distances are displayed in kilometers tem peratures are displayed in Celsius degrees and Fuel Economy is displayed in liters per kilometer To configure the cluster for English or metric 1 Use the Mode button to display SET UP MENU 2 Press the Up or Down button to scroll to UNITS 3 Use the Set button to toggle between ENGLISH and METRIC Clock mode The clock mode configures the clock to display 12 hour am pm or 24 hour time To change the clock format 1 Use the Mode button to display SET UP MENU 2 Press the Down button to scroll to CLOCK MODE 3 Use the Set button to toggle between the 12 and
8. Note 1 4 Fuel Level Jumper from LX 3 Left Module IPJ5 Pulse width modu lated signal 7 Master Warning output Jumper to Center Module IPJ8 Ground 11 Power Ground OP 4 Ground 12 5V Jumper from LY 15 Left Module IPJ3 5 V 13 Rear Axle Temperature Rear 469 Variable resistance Note 1 14 Ignition 180 12V 15 Return to Zero Jumper from LY 16 Left Module IPJ4 Ground 18 Bulb Test Input Jumper from Center Module IPJ6 12V during bulb test 19 Bulb Test Input Jumper from Center Module IPJ7 ee during bulb es 20 Engine Preheat Volvo engine only 361 Ground 21 Traction Control System 774 B Bendix Ground Pins not listed are not used Note 1 Axle temperature measurements must be made with the RX connector disconnected All resistance measurements must be made with power removed from the circuit 37 38 Group 38 Instrumentation VNL VNM Troubleshooting Troubleshooting This chapter describes how to test the instrument cluster and troubleshoot the cluster as a whole General service information Many of the components can be tested without disturbing the cluster by using the Cluster Self Test Mode function in the Graphic Display s Diagnostics Menu This includes all telltale lamps the soeedometer tachometer oil pressure gauge coolant temperature gauge and Graphic Display unit The pivot down mounting feature of the cluster allows troubleshooting of input signals without removing th
9. REMOVA sani ja A A bi aeer 61 MSTANSNOME E e a E E O E er tener rer etree 63 Gauge replacement left circuit board gauges 00000aaaaa vana 64 ja o M vej a nr re 64 ARAIN lt odak a A E i A a k 66 Group 38 Instrumentation VNL VNM General General General cautions 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 Welding on trucks can damage the vehicle electri cal system components from the voltage and current spikes that normally occur when welding It is prefer able 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 Preventing electrostatic discharge ESD 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 To prevent electrostatic di
10. pulses mile tire rev mile x rear axle ratio x no of teeth on chopper wheel on transmission 46 W3000720 for example pulses mile 501 rev mi x 4 10 x 16 pulses rev 32866 pulses mile Test the speedometer by using the Gauge Test function in the Cluster Self Test Mode of the Diagnostics Menu Use the service tool for the engine in your vehicle to compare any diagnostic messages shown in the instrument cluster If a sensor problem is indicated check the wiring from the sensor for opens or shorts according to the engine manufacturer s service literature Also refer to the VNL VNM Electrical Schematics for wiring information If the speedometer pointer sweeps back and forth across its full range its meter movement and associated circuitry within the cluster are working If the gauge pointer does not move during the self test and a sensor problem has been ruled out replace the cluster Odometer During normal operation the odometer display remains on for 30 seconds after the ignition is switched off To reactivate the display turn the ignition on In the absence of speedometer data the odometer display will not change and the speedometer pointer will remain at zero e f there is a problem with the odometer but the speedometer works replace the cluster e f the odometer is inaccurate check the engine ECU speed calibration If correct replace the cluster Group 38 Instrumentation VNL VNM
11. 400 401 wiring and connectors Intermittent function e If this and other gauges on the J1587 data link appear to twitch or function intermittently check the 400 401 circuit for a loose connection e f this gauge only appears to function intermittently the data link could be overloaded with data from ECUs in the vehicle system In this case check the data link using the MPSI Pro Link Snapshot function W3000869 Incorrect gauge reading If the gauge does not appear to indicate the correct engine oil pressure test it using the Gauge Test function in the Cluster Self Test Mode of the Diagnostics Menu 1 Ifthe gauge pointer sweeps back and forth across the full range the meter movement and its associated cir cuitry in the cluster are working Use the Diagnostic Messages function of the Diagnostics Menu to check for oil pressure related messages Use the service tool for the engine in your vehicle to compare any di agnostic messages shown in the instrument cluster 2 Ifa sensor problem is indicated check the wiring from the sensor for opens or shorts according to the engine manufacturer s service literature Also refer to the VNL VNM Electrical Schematics for wiring information 3 If the pointer fails to sweep and a sensor problem has been ruled out replace the cluster 43 Group 38 Instrumentation VNL VNM Engine coolant temperature gauge From Engine Coolant l Engine Temperature Sender Unit 1 Coolant
12. 6 Press the Mode button to return to the SET UP MENU display Fuel economy target adjust function This function allows a fuel economy target to be set To change the fuel economy target value do the following 1 Use the Mode button to display SET UP MENU 2 Press the Down button to scroll to FUEL ECONOMY TARGET 3 Press the Set button 4 Use the Up and Down buttons to increase or de crease the desired value 5 When the desired value is displayed press the Set button If you do not press the Set button here the setting won t be saved the setting will remain in effect until the ignition is turned off and will return to its previous setting when the ignition is turned back on 6 Press the Mode button to return to the SET UP MENU display 27 Group 38 Instrumentation VNL VNM Gauge mode The Gauge mode provides additional gauge displays A voltage display is standard Engine oil temperature and transmission oil temperature displays are optional and are enabled by End of Line programming Gauge displays contain a symbol and a value such as volts or degrees and text messages when appropriate OIL TEMP TRANS TEMP VOLTAGE ayi Stock 310 F 17 VOLTS TOO HIGH HIGH TOO HIGH W3000712 Gauge displays Note When a condition requiring attention occurs the symbol identifying that condition will automatically replace the current gauge display To choose a gauge display 1 Press the Mode button until a gaug
13. Axle gauge and pin 11 ground Axle Temp Expected Reading 70 F 1000 ohms 10 120 F 430 ohms 10 200 F 110 ohms 10 3 Ifthe resistance readings are correct reconnect the connectors and turn the key on There should be battery voltage between connector RX pins 11 and 14 If not and the rest of the cluster works the wire from RX 14 is probably open 4 Ifthe readings are off more than 10 the sender unit should be checked The sender is mounted on the axle Refer to the VNL VNM Electrical Schematics for wiring information 48 Group 38 Instrumentation VNL VNM Air pressure gauges LED Switch 3 Contacts Quick Disconnect Ring LED Connector W3000836 Note The LED connector wires are not polarity sensitive Inaccurate or erratic gauge readings are usually caused by dirt or other contamination in the gauge The gauges and their warning LEDs can be tested as shown A DANGER 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 bodily injury Air Gauge Test 1 Drain the air pressure from both air systems 2 1 W3000842 Remove the two screws at the top of the instrument cluster and lay the cluster face down on the steering column Troubleshooting W3000834 1 Rear Brake Pres
14. Tachometer In the absence of data link information the tachometer gauge pointer will move to its minimum reading after a 3 5 second delay If the pointers on all the gauges on the J1587 data bus move to the minimum reading there is a problem in the data link circuit Troubleshoot the 400 401 wiring and connectors Intermittent function e If this and other gauges on the J1587 data link appear to twitch or function intermittently check the 400 401 circuit for a loose connection e f this gauge only appears to function intermittently the data link could be overloaded with data from ECUs in the vehicle system In this case check the data link using the MPSI Pro Link Snapshot function Troubleshooting Incorrect gauge reading Test the tachometer by using the Gauge Test function in the Cluster Self Test Mode function of the Diagnostics Menu Use the service tool for the engine in your vehicle to compare any diagnostic messages shown in the instrument cluster If a sensor problem is indicated check the wiring from the sensor for opens or shorts according to the engine manufacturer s service literature Also refer to the VNL VNM Electrical Schematics for wiring information If the tachometer pointer sweeps back and forth across its full range its meter movement and associated circuitry within the cluster are working If the gauge pointer does not move during the self test and a sensor problem has been ruled out repla
15. a metal table or any metal surface while servicing 61 Group 38 Instrumentation VNL VNM 3 Remove the Phillips screws at the top of the left rear cover and the two at the bottom then lift the left rear cover from the cluster 4 Remove the four Phillips cover screws W3000845 1 Connector E1 A CAUTION Do not bend the printed circuit board Bending the board can re sult in damage to the board or components Grasp the top and bottom of connector E1 over the Left Circuit Board with your thumb and forefinger Rock the Center Module from top to bottom while pulling up to unseat E1 6 Remove the Center Module by lifting it off of the cluster 62 Service Procedures Group 38 Instrumentation VNL VNM Installation je A LEA 6CHARAEAASAAEG ram alalaananaalaalamal W3000846 1 Button extensions Before reinstalling the Center Module make sure that all four plastic button extensions are installed in the top of the housing the short ends stick out the front of the housing Service Procedures E1 o W3000731 2 To reinstall the Center Module line up connector E1 pins with connector E2 holes on the Center Circuit Board then carefully seat E2 while lowering the Center Module into the housing 3 Verify that all E1 pins are in connector E2 holes then use your thumb to
16. fully seat E2 onto the Left Circuit Board 4 Secure the Center Module to the housing with four machine screws 63 Group 38 Instrumentation VNL VNM Gauge replacement left circuit board gauges Important Individual gauges on the VN instrument cluster are not serviceable Attempts to remove and replace individual gauges during the warranty period will void the cluster warranty Instead the whole unit may be exchanged ONLY when a certified technician is repopulating a re placement instrument cluster may the cluster be opened during the warranty period Removal 1 To prevent electrostatic discharge ESD which can damage the sen sitive electronic components in the instrument cluster use a wrist grounding strap and an anti static mat when working on the instru ment cluster Failure to do so can result in permanent damage to the printed circuit boards in the instru ment cluster Remove cluster from vehicle see pre vious procedure Place cluster on anti static mat The anti static mat must be grounded to the nearest elec trical outlet When working at the anti static workbench always keep a wrist strap connected to the anti static mat Do not place the cluster on a metal table or any metal surface while servicing 64 Service Procedures N W3000734 1 Connector E2 part of the center circuit board 2 Top cover screw location 3 Bottom cover screw location 4 Connector E4 to Grap
17. mensa Note The Diagnostic Adjust and Set Up modes are only accessible with the ignition on Fuel Economy and the vehicle not Target moving W3000867 Graphic display modes GD 00 am CHED s am W3000639 Mode button Pressing the Mode button moves from one mode to another For example press MODE to change from the Set Up mode to the Gauge mode Up and Down buttons Pressing the Up or Down buttons scrolls to the next or to the previous available function within a mode For example if the Trip 1 odometer is displayed pressing Down scrolls to the Trip 2 odometer and pressing Up scrolls to the Alarm Clock The Up and Down buttons are also used to change the displayed time and alarm Set button If the current display contains a value which can be changed using the Up and Down buttons the Set button enables the change and selects the digit to be changed The Set button also resets the Trip Odometer 1 and Trip Odometer 2 readings to zero when pressed for 1 second To use the menu system 18 A DANGER If the vehicle is in motion reach around the steering wheel with the right hand to access the control buttons to avoid possible personal injury Accessing the control buttons through the steering wheel can result in injury or death due to loss of vehicle control 1 Turn the ignition on 2 Using the right hand reach around the steering wheel and press the Mode button to select the desired mo
18. reading down to 5 millivolts 1 Make certain the vehicle ignition is OFF 42 Troubleshooting 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 When probing connector terminals do not insert probes into the terminals This will spread the ter minals apart causing permanent damage Probe the insertion side of the connector Gain access to the back of the cluster With the ignition on there should be 5 to 50 millivolts between connector LY pins 30 and 13 a If the voltage is incorrect replace the thermo couple or the wire to it b If the voltage is correct replace the cluster Group 38 Instrumentation VNL VNM Engine oil pressure gauge From Engine Oil Troubleshooting Pressure Sender Unit i Module I I rakija menu aude S DO oD ea kb i tso hin eee ee BRE I I l Loge ee oH meee Ss i i i 14 LX 1 3 Engine i From Engine Oil Engine J1587 I es Oil Pressure Sender Unit ECU LI Data Link _LX 11 si Gauge I I I I Engine Oil Pressure gauge signal flow In the absence of an engine oil pressure data signal the gauge pointer will move to its minimum reading after a 3 5 second delay If the pointers on all the gauges on the J1587 data bus move to the minimum reading there is a problem in the data link circuit Troubleshoot the
19. second delay Red Warning LED illuminates when coolant temperature is too high for safe operation The temperature which activates this LED is engine dependent Turbo Boost Pressure optional The turbo boost pressure gauge is an electrical aircore meter movement driven by a signal from the J1587 data link In the absence of a data signal the gauge pointer will move to its minimum reading after a 3 5 second delay Design and Function W3000601 170 190 210 Iso of REA 230 o W3000602 W3000604 Group 38 Instrumentation VNL VNM Engine Oil Pressure The engine oil pressure gauge is an electrical aircore meter movement that receives its signal from a sender unit mounted on the engine For Caterpillar Cummins and Detroit Diesel engines the sender unit supplies data to the Engine ECU which sends engine oil pressure information to the instrument cluster via the J1587 data link For the Volvo VE D12 engine the sender supplies a signal to the Data Concentrator Module which then broadcasts engine oil pressure data to the cluster via the J1587 data link In the absence of a data signal the gauge pointer will move to its minimum reading after a 3 5 second delay Note Engine oil operating pressure is engine dependent A Red Warning LED illuminates when engine oil pressure is too low for safe operation The pressure which activates this LED is engine dependent Telltale lamps left section
20. should be inspected for damage If the Graphic Display does not receive a response from any of the individual modules on the J1587 data link it will display the name of the system and NOT RESPONDING Group 38 Instrumentation VNL VNM Line 1 Message Identifier Line 2 Parameter or Sub system Identifier PID or SID Line 3 Fault Mode Indicator Engine Coolant Temp Data valid but high Active Count 5 Message from Cluster Design and Function Pressing SET toggles Nu between these two displays J for each message Actual received data from J1587 data link Example of a diagnostic message in the Graphic Display Graphic display messages supported Pressing DOWN scrolls to next message W3000866 MID s Message ID s or Description sources 128 Engine 130 Transmission 136 ABS 140 Instrument 178 Data Conc Note VE D12 engine only 232 SRS Airbag Additional MIDs text message w ill not be displayed MID s Message ID s or Description sources 137 Brakes Trailer 1 138 Brakes Trailer 2 139 Brakes Trailer 3 141 Trip Recorder 162 Vehicle Navigation Unit 166 Tires Power Unit 171 Driver Information Center 172 Off board Diagnostics 1 179 Data Logging Computer 181 Communication Unit Satellite 191 Vehicle Location Unit 231 Communication unit Satellite GPS cellular 21 Group 38 Ins
21. temperature gauge signal flow The coolant temperature gauge is an electrical aircore meter movement which receives its signal from the engine via the J1587 data bus In the absence of a data signal the gauge pointer will move to its minimum reading after a 3 5 second delay If the pointers on all the gauges on the J1587 data bus move to the minimum reading there is a problem in the data link circuit Troubleshoot the 400 401 wiring and connectors Intermittent function e If this and other gauges on the J1587 data link appear to twitch or function intermittently check the 400 401 circuit for a loose connection e f this gauge only appears to function intermittently the data link could be overloaded with data from ECUs in the vehicle system In this case check the data link using the MPSI Pro Link Snapshot function 44 LX 1 J1587 LI ECU ata Link LX 11 I l D Troubleshooting Engine Coolant Temperature Gauge W3000718 Incorrect gauge reading The gauge can be tested by activating the Cluster Self Test Mode function of the Diagnostics Menu 1 If the gauge pointer sweeps back and forth across the full range the gauge and its associated circuitry in the cluster are working a Check for coolant related messages using the Diagnostic Messages function of the Diagnostics Menu Use the service tool for the engine in your vehicle to compare any diagnostic messages shown in the instrument cl
22. 12 volts between LY 3 and LY 4 during the Bulb Test function If missing replace the cluster Telltale bulbs Telltale bulbs W3000986 2 If the suspect bulb lights during the self test the problem is not in the cluster Check the signal source for individual telltale bulbs 3 If the suspect bulb fails but other bulbs light during the self test replace the suspect bulb 4 If none of the bulbs in the center section light during the Bulb Test function check for 12 volts between CY 5 and CY 6 or between CY 19 and CY 20 If missing there is an open wire in the wiring harness 5 If none of the bulbs in the right section light during the Bulb Test function check for 12 volts between RX 18 and RX 19 If missing there is an open wire in the wiring harness For more information refer to the VNL VNM Electrical Schematics 41 Group 38 Instrumentation VNL VNM Left section Pyrometer gauge Pyrometer Sender Unit 17 LY 13 5 f I eee e a Pyrometer Gauge Left Circuit Board 1 W3000870 Pyrometer gauge signal flow If the pyrometer thermocouple fails the pointer will move to one end of the dial or the other A reading of 300 F or less indicates an open in the truck s wiring or thermocouple and a reading of 1500 F or more indicates a short If the Pyrometer gauge fails to indicate within 100 F of a known true value check the thermocouple and wiring with a digital voltmeter capable of
23. 24 hour formats Contrast adjust function This function adjusts the contrast of the Graphic Display To adjust the display contrast level do the following 1 Use the Mode button to display SET UP MENU 2 Use the Down button to scroll to CONTRAST AD JUST 3 Press the Set button 4 Use the Up and Down buttons to increase or de crease the contrast 5 When the contrast is at the desired level press the Set button If you do not press the Set button here Design and Function the setting won t be saved the setting will remain in effect until the ignition is turned off and will return to its previous setting when the ignition is turned back on 6 Press the Mode button to return to the SET UP MENU display Backlighting adjust function This function allows the odometer and graphic display backlighting brightness to be adjusted independently of the gauge backlighting To adjust the backlighting do the following 1 Use the Mode button to display SET UP MENU 2 Press the Down button to scroll to BACKLIGHTING ADJUST 3 Press the Set button 4 Use the Up and Down buttons to increase or de crease the backlighting 5 When the backlighting is at the desired level press the Set button Note If you do not press the Set button here the setting won t be saved the setting will remain in effect until the ignition is turned off and will return to its previous setting when the ignition is turned back on
24. ENGINE FLUIDS AN caution Engine Fluids lamp Caution lamp Stop lamp No Charge lamp honD Engine Fluids llluminates when engine oil pressure or coolant level is too low or when engine coolant temperature is too high Hard wired to the Data Concentrator Module Volvo engine or to the engine ECU Cummins engine Note The Engine Fluids lamp is not used in vehicles with Caterpillar or Detroit Diesel engines Caution llluminates to indicate a control system or component malfunction for example throttle position sensor boost pressure sensor For the VE D12 engine only it will also illuminate solid during engine ECU programming Also for the VE D12 only the Caution lamp is always on for 3 5 seconds when the key switch is turned to the Ignition position Note This lamp replaces the Check Engine lamp in earlier model vehicles 14 Design and Function W3000983 Aso EA 3 4 W3000768 Stop llluminates to alert the driver that an engine problem has been detected by the engine ECU and that action may be taken by the ECU to protect the engine for example engine oil pressure low coolant level No Charge llluminates when a problem exists in the charging system A voltage output decrease of 1 2 volts from normal will cause this lamp to illuminate dimly As the voltage output decreases more the illumination goes from dim to bright Group 38 Instrumentation VNL VNM Design and Function
25. PSI Coolant Tem perature Fuel and Turbo Boost gauges to sweep from minimum scale to full scale and back briefly stopping at mid scale each way This occurs three times The pyrometer axle temperature and air pressure gauges are excluded from the self test Cycle the ignition key off and on after the gauge test to return the gauges to normal function Note Each time power is applied to the cluster the speedometer and tachometer pointers return to zero taking the shortest path usually counter clockwise If during shipment for example the pointers are at the high end of their scales they will move clockwise towards zero when power is applied and will be prevented from reaching zero by the gauge housing In this case use the Gauge Test function to return the tachometer and speedometer pointers counter clockwise to zero Design and Function Display test To help identify defects in the Graphic Display the display will alternate between all dark and all light for about 10 seconds CLJICoJC C W3000719 Buzzer test Sounds each of the three buzzer signals for 10 seconds each 1 To access the Cluster Self Test 2 Use the Mode button to display DIAGNOSTICS MENU 3 Press the Up or Down button to scroll to CLUSTER SELF TEST MODE 4 Press the Set button to activate the Cluster Self Test mode 5 Press the Up or Down button to display the de sired test name Bulb Test Gauge Test Display Test or Buzzer Test
26. Service Manual Trucks Group 38 Instrumentation VNL VNM PV776 TSP23762 1 VOLNO Foreword The descriptions and service procedures contained in this manual are based on design and method studies up to June 1996 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 Volvo GM Heavy Truck Greensboro NC USA Order number PV776 TSP23762 1 1996 V
27. This is activated by the alarm clock function in the Graphic Display and works whether the ignition is on or off The clock reminder will override a Turn signal buzzer e Warning signal Two beeps every second This is activated when any red telltale except No Charge and Park Brake are on and the engine is running faster than 300 rpm idle The Warning signal will override all other signals While in the cluster self test or diagnostic mode the buzzers do not sound 33 Group 38 Instrumentation VNL VNM Connector pinouts LX and LY connectors oOo o00000 99000000 BOR Te Se Ree S 10 22 W3000849 Design and Function Left Module LX Connector Pin Description Circuit No Input 1 Data Link J1587 400 mV reading 2 Fuel Sensor 183 33 250 ohms 3 Fuel Level Jumper to Right Module IPJ5 Pulse width modulated signal 5V 9 Battery OX 1 Ground 10 Battery 202 12 V 11 Data Link J1587 401 mV reading 12 Power Ground OP 1 Ground 20 Illumination 141 J 0 12 V 22 Ignition 180 12 V Pins not listed are not used 34 Note All resistance measurements must be made with power removed from the circuit Group 38 Instrumentation VNL VNM Design and Function Left Module LY Connector Pin Description Cir
28. air connectors from the back of the cluster and remove the cluster from the vehicle Installation 1 Connect electrical connectors and air lines at the back of the instrument cluster For stress relief on the con nectors tie wrap the wiring to the back of the instrument cluster 2 Install the instrument cluster in dash and tighten the 2 screws at the top of the cluster Torque to 2 0 3 Nm 17 5 2 5 in lb 57 Group 38 Instrumentation VNL VNM 277777 Gauge replacement right cir cuit board gauges Important Individual gauges on the VN instrument cluster are not serviceable Attempts to service or replace individual gauges during the warranty period will void the cluster warranty Instead the whole unit should be exchanged ONLY when a certified technician is repopulating a re placement instrument cluster may the cluster be opened during the warranty period Removal 1 To prevent electrostatic discharge ESD which can damage the sen sitive electronic components in the instrument cluster use a wrist grounding strap and an anti static mat when working on the instru ment cluster Failure to do so can result in permanent damage to the printed circuit boards in the instru ment cluster Do not place the cluster on a metal table or any metal surface while servicing Remove cluster from vehicle see pre vious procedure Place cluster on anti static mat The anti static mat must be grounded to the ne
29. anual for these trip points In some cases the yellow Caution telltale or red Stop telltale may also light and the buzzer may also sound 28 Design and Function when a trip point is reached These warnings will continue until the ignition is turned off or until the condition causing the warning no longer exists The visual and audible warnings will return if the condition that caused the warning still exists when the ignition is turned back on The Engine Oil Temperature gauge in Volvo applications uses an analog sensor In other applications this gauge receives its display data from the engine electronic control unit These trip points are set to the engine manufacturer s specifications Fuel Economy mode The Fuel Economy mode allows the driver to see his fuel economy during a trip Information is updated continually and is presented in the form of a bargraph Average fuel economy during the trip AVG and the fuel economy under the current conditions INST can be seen at a glance along with the fuel economy target value set using the Set Up menu The Fuel Economy mode contains a Avg Inst Target display and a Trip Fuel Meter display function To select one of these displays 1 Use the Mode button to select the Fuel Economy display 2 Use the Up and Down buttons to display the bargraph or TRIP FUEL METER Avg Inst Target Display AVG 6 0 l TARGET 8 5 T W3000713 The Avg Inst Target Display shows the vehicle
30. arest elec trical outlet When working at the anti static workbench always keep a wrist strap connected to the anti static mat 58 Service Procedures 3 W3000835 1 Gauge mounting screws do not remove at this time 2 Top cover screw location 3 Bottom cover screw location Right printed circuit board PCB with cover re moved Remove the Phillips screw at the top of the right rear cover and the two at the bottom then lift off the cover Note Do not remove any of the three Phillips screws in the board at this time They secure the air pressure gauges to the board Group 38 Instrumentation VNL VNM 3 Lift out the Right Circuit Board assem bly with gauges W3000989 To avoid damaging the gauge do not push on the needle when re moving the gauge Pushing on the needle can make the gauge inaccu rate Air pressure gauges only These are each secured by one Phillips screw Remove the screw pull the gauge out of the board and disconnect the 2 pin LED connector Other gauges Gauges are held tightly by their pin sockets To remove grasp the side of the gauge face plate with your thumb place your 2nd and 3rd fingers underneath the face plate see illustration Carefully rock the gauge from side to side while applying upward pressure until the gauge pins are free of the board sockets Service Procedures Removing a gauge blank 5
31. ay location Design and Function The icon on the left side is the primary icon during multiple displays If as in the illustration the washer fluid low icon is in the primary position it may be cleared by pressing the Set button The text displayed above the icons is always that of the icon in the primary position If the icon is in the right or secondary position it cannot be cleared Note that the low coolant icon cannot be cleared until the problem is corrected Every 8 seconds the display will change and the primary and secondary icons will switch positions If a gauge warning occurs while a telltale warning is displayed the CAUTION lamp will illuminate A gauge warning will not automatically replace a telltale warning To view the gauge warning in the display the Mode button must be pressed For troubleshooting the diagnostic mode may be entered while any of these warnings are displayed 17 Group 38 Instrumentation VNL VNM Design and Function Using the Graphic Display MODE Multi Function Diagnostic Set Up Gauge Fuel Economy Display 12 00 00AM Diagnostics Set Up ee VOLTAGE Fuel Economy Top Level Display aos gt eee Alarm Diagnostic Units eee Trip Fuel Meter ase CEnghortetig WF gee mo Trip Odometer 1 Cluster Clock Mode FY TRANS TEMP Self Test Mode 12 24 Hour HIGH Bulb Test Trip Odometer 2 Gauge Test Contrast Adjust Display Test Graphic Display Buzzer Test Hourmeter Backlighting
32. ce the cluster 47 Group 38 Instrumentation VNL VNM Troubleshooting Right section Axle temperature gauges forward and rear Testing the axle temperature gauges 1 Make certain the vehicle ignition is OFF I From Sender Unit RX 3 i I From Sender Unit RX 13 I I I I I I 2 eae a am I RX 1 A CAUTION Power Ground gt _Right Circuit Board pa i ws000715 When servicing or troubleshooting do not leave Front and Rear Drive Axle Temperature gauge sig the cluster face down for more than 15 minutes nal flow or damage to the gauges may occur Gauge oil can run out the front of the gauge faces and make the gauges inaccurate Fault indications A constant gauge reading of 90 F or less can be caused by a defective sender unit or gauge or an open wire between the cluster and the sender unit A CAUTION A constant reading of 270 F or more can be caused by a When probing connector terminals do not insert defective gauge or sender unit or by a wire that is shorted probes into the terminals This will spread the ter to ground between the gauge and the sender unit minals apart causing permanent damage Probe the insertion side of the connector Inaccuracies greater than 10 F usually indicate a defec tive sender unit or gauge f y gaug Gain access to the rear of the instrument cluster Dis connect connector RX and measure the resistance between harness pin 13 Front Axle gauge or pin 3 Rear
33. cuit No Input 1 Air Filter Restriction Gauge 199 Ground when activated 3 Bulb Test Output Jumper to Center Module IPJ1 12V during bulb test 4 Bulb Test Output Jumper to Center Module IPJ2 Ground during bulb test 5 No Charge Warning Lamp 14 Ground Note 1 6 Stop Engine Warning Lamp Caterpillar Cummins 575 Ground and Detroit Diesel engines only Volvo is not hardwired 10 Caution Lamp 576 Ground Note 2 11 Engine Fluids Warning Lamp Volvo and Cummins 577 Ground engines only 13 Pyrometer 190 Ground 15 5V Output Reference Jumper to Right Module IPJ3 5V 16 Return to Zero Jumper to Right Module IPJ4 Ground 19 End Of Line Programming Enable 403A Ground used only when programming 23 Washer Fluid Level 387A Ground when activated 27 Engine Oil Temperature Volvo engine only 204 Sensor Input 28 Transmission Oil Temperature 314 Sensor Input 30 Pyrometer 191 0 100 mV Pins not listed are not used All resistance measurements must be made with power removed from the circuit Note 1 The No Charge Warning Lamp will begin to illuminate dimly when the engine is running and the input on this pin drops below 12 V It will illuminate fully when it drops below 8 V Note 2 The Caution lamp illuminates when engine RPM is above 500 and there is a fault in the graphic display for Engine Oil Temperature Transmission Oil Temperature or Voltage The Caution lamp will also illuminate if other engine ECU fault cod
34. d In this example the fault still exists and has occurred five times To see diagnostic messages 1 Turn on the ignition The engine may be started Diagnostic messages from all J1708 1587 supported vehicle systems are accessible 2 Use the Mode button to display DIAGNOSTICS MENU 3 Use the Up and Down buttons to display DIAGNOS TIC MESSAGES 4 When DIAGNOSTIC MESSAGES is displayed press the Set button RECEIVING DATA PLEASE WAIT will be displayed while the systems on the J1587 data link are polled 5 When the first message appears the Set button can be pressed to toggle the display between the text description and the received data If the display shows UNKNOWN in any line press the Set button to display the MID PID or SID and FMI a If the condition that caused the currently displayed fault still exists the cluster will display ACTIVE b If the condition that caused the currently displayed fault has gone away the cluster will display INACTIVE c The number of times a fault has occurred will be displayed when available In some cases a short message may also be displayed 6 Record all codes displayed 7 To display the next stored fault press the Down button If the Graphic Display detects a complete failure of the J1587 data link between the instrument cluster and the other system modules it will display DATA LINK BROKEN In this case the actual wires used for the J1587 data link
35. de 3 When the desired mode appears use the Up and Down buttons to select the desired function in that mode Note The Diagnostic and Set up Modes are not available when the vehicle is in motion If these modes are in use and the vehicle reaches a speed of 5 mph the Graphic Display will automatically change to the clock display Group 38 Instrumentation VNL VNM Multi Function mode The Multi Function mode contains a clock an alarm clock two independent trip odometers and an engine hourmeter Clock display The clock displays the current time in either a 12 hour format 12 00 00 am to 12 59 59 pm or a 24 hour format 00 00 00 to 23 59 59 The choice is made in the Set Up Menu 1 To display the clock a Use the Mode button to select the Multi Function mode b Use the Up or Down button to display the time 2 To change the time display a When the clock time is displayed press the Set button to select the hours digits The hours digits will flash when selected b When the hours digits flash use the Up and Down buttons to set the desired hour c Press the Set button a second time to select the minutes digits The minutes digits will flash when selected d When the minutes digits flash use the Up and Down buttons to set the desired minute e To accept the displayed time and exit the set time function press the Set button a third time 3 To change the time format Use the Clock Mode function of t
36. e cluster from the vehicle Storing the cluster 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 The electrical gauges contain an oil that can start to run out if the gauge is left upside down longer than 15 minutes If the oil runs out the gauge becomes inaccurate For this reason always store clusters and gauges face up Tools and test equipment For the procedures described in this chapter you will need the following tools T25 Torx head driver cluster mounting screws e Telltale lamp removal tool Volvo P N 1608077 e Digital multi meter which can measure down to 5 millivolts Hose connections to the air pressure gauges are quick disconnect and the air hoses to them can be disconnected and reconnected without tools A DANGER 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 bodily injury 39 Group 38 Instrumentation VNL VNM Troubleshooting individual gauges Cluster backlighting Troubleshooting The cluster backlighting receives power from a dimmer 2 If only the right center or left section of the cluster control located on the vehicle dash The backlighting i
37. e display appears 2 Use the Up and Down buttons to display the desired gauge e Voltmeter This standard gauge display moni tors the battery voltage If the voltage exceeds 16 volts TOO HIGH will be displayed e Engine Oil Temperature The range of this optional gauge display is 90 to 310 F If the temperature exceeds the trip point TOO HIGH will be displayed and the yellow Caution telltale will light e Transmission Oil Temperature This optional gauge display monitors the transmission oil tem perature Its range is 90 to 310 F If the tem perature exceeds the trip point HIGH will be dis played and the yellow Caution telltale will light Preset trip points for Graphic Display gauges Each of the gauges in the Graphic Display has a preset trip point A trip point represents a critical condition when reached The Engine Oil Temperature gauge display may have a trip point of 270 F for example Should a trip point be reached the Graphic Display will automatically replace the current gauge display or any other display for that matter with a symbol or message identifying the critical condition Trip points for clusters to be used with Volvo engines are preset at the factory during End of Line programming When the cluster is installed with a Caterpillar Cummins or Detroit Diesel engine the trip points are sent via the J1587 data link according to each manufacturer s specifications Refer to the appropriate m
38. e stored in the cluster Whenever a new cluster is installed these values must be updated to reflect the mileage and engine hours of the vehicle in which the cluster is installed This is done using the MPSI Pro link 9000 tool with the Volvo cartridge version 2 0 To reset either of these readings follow the Pro link menus to the Reprogram EEPROM menu then select either the Odometer or Hourmeter Total Change to the appropriate total Note Reprogramming the Odometer or Hourmeter is a password protected function Cleaning the housing and front panel glass To clean the housing and front panel glass use a soft non abrasive cloth and a mild soap and water solution 22222 2 Bulb replacement Removal 1 Make certain the vehicle ignition is OFF before beginning this procedure W3000842 When servicing or troubleshooting do not leave the cluster face down for more than 15 minutes or dam age 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 steer ing column so that the bulbs are accessible 55 Group 38 Instrumentation VNL VNM W3000642 A CAUTION 1089953 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
39. er calibration Speedometer calibration to compensate for tire sizes and other driveline changes is done during programming of the engine or transmission ECU 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 data link and is stored in the W3000844 cluster s microprocessor The odometer backlighting can be adjusted independently of gauge backlighting 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 the odometer display can be reactivated by pressing any of the buttons In the absence of speedometer data the odometer display will not change and the speedometer pointer will remain at zero 29 Group 38 Instrumentation VNL VNM Design and Function Telitale lamps center section 2 4 6 8 10 12 DEN OP PIG sth Z 5 Q e FA FA 5 00 gy 13 1 3 5 T 9 11 W3000840 1 Left Turn Indicator 8 Parking Brake Indicator 2 5th Wheel Lock Indicator 9 Anti Lock Brake System Tractor Indicator 3 Wheel Differential Lock Indicator 10 Anti Lock Brake System Trailer Indicator 4 Interaxle Differential Lock Indicator 11 Air Suspension System Indicator 5 High Beam Indicator 12 Bogie Lift Indicator 6 Safety Belt Indicator 13 Mirror Defroster Indicator 7 SRS Airbag Indicator 14 Right Turn Ind
40. es instruct the lamp to illuminate 35 Group 38 Instrumentation VNL VNM Design and Function CY connector Center Module CY Connector Eee Bie eg gs Pin Description Circuit Input Qo0oo0000090 00000900 No 1 ABS Truck 779 Ground 3 Park Brake 420 Ground 4 Heated Mirror 702 12V 5 Bulb Test from LY 3 IPJ1 6 Bulb Test from LY 4 IPJ2 8 High Beam 33 12V 9 Right Turn Indicator 113 12V 10 Interaxle Differential 422 12V Lock 11 Power Ground OP 3 Ground 12 Interwheel Differential 426 Ground Lock 13 Fifth Wheel Lock 424 Ground 14 Left Turn Indicator 112 12V w3000765 15 Air Suspension 431 Ground Pressure 18 Backlighting 141 H 0 12V 19 Bulb Test to Right IPJ6 Module 20 Bulb Test to Right IPJ7 Module 22 Ignition 180 12V 24 SRS Airbag Warning OX 3 Ground Needs open circuit to turn on 25 Master Warning from IPJ8 Ground Right Module Pins not listed are not used All resistance measurements must be made with power removed from the circuit 36 Group 38 Instrumentation VNL VNM RX connector W3000847 Design and Function Right Module RX Connector 774 A Wabco Pin Description Circuit No Input 1 Ilumination 141 G 0 12 V 2 Ground OX 2 Ground 3 Rear Axle Temperature Front 468 Variable resistance
41. fuel gauge is reading incorrectly it can be tested by activating the Cluster Self Test Mode function of the Diagnostics Menu 50 If the pointer sweeps back and forth across its full range during the cluster self test the meter and its associated circuitry in the cluster are working Go to step 1 below If the pointer does not sweep during the cluster self test the most likely cause is a defective Fuel Level gauge or a wiring problem in the harness Go to step 4 If the pointer does not sweep during the cluster self test AND the pointer falls below the empty mark or constantly stays on the Full mark or constantly stays on the 1 2 mark Go to step 6 Make certain the vehicle ignition is OFF If gauge failure is suspected check for mechanical failure of the fuel level sender If the sender is in good physical condition disconnect the connector and measure resistance at the fuel level sender The reading should be between 33 and 240 ohms depending upon the fuel level in the tank see Table A e f resistance is as shown in Table A reconnect the sender connector and proceed to step 3 e f resistance is not as shown in Table A replace the fuel level sender Troubleshooting W3000873 Table A Resistance Check Fuel Level Expected Reading at sender and LX 2 to LX 12 Empty tank 240 ohms 10 1 4 tank 153 ohms 10 1 2 tank 103 ohms 10 3 4 tank 67 ohms 10 Full tank 33 ohms 10
42. he Set Up Menu Alarm clock display The Alarm Clock function determines when the alarm reminder sounds Set the reminder time and enable the alarm by using the Alarm Clock function 1 To display the alarm clock a Use the Mode button to select the Multi Function mode b Use the Up or Down button to display ALARM 2 To change the alarm time a Display the alarm clock b When the alarm time is displayed press the Set button to select the hours digits The hours digits will flash when selected c When the hours digits flash use the Up and Down buttons to set the desired hour Design and Function d Press the Set button a second time to select the minutes digits The minutes digits will flash when selected e When the minutes digits flash use the Up and Down buttons to set the desired minute f To accept the displayed alarm time and exit the set function press the Set button a third time The alarm will automatically be enabled and the Bell symbol will appear 3 To enable the reminder tone Press and hold the Mode button The next mode display will appear when the reminder is set The clock display with a bell will appear on screen OR Select the Alarm Clock display as previously described 4 To disable the reminder tone When the bell symbol is displayed press and hold the Mode button until the next mode display appears The clock display will appear without the bell symbol 5 To silence the reminder
43. hic Display board un derneath Remove the Phillips screw at the top of the left rear cover and the two at the bottom then lift off the cover Note Connector E2 is part of the Center Circuit Board Group 38 Instrumentation VNL VNM Do not bend the printed circuit board Bending the board can re sult in damage to the board or components The Center Circuit Board connector E2 is holding the Left Circuit Board as sembly in at this point so you will have to remove the Center Module before continuing see previous procedure 4 Carefully lift out the Left Circuit Board assembly by lifting straight up It is at tached to the Graphic Display board below at connector E4 L N ex gn x O S Q RAS G ERY To avoid damaging the gauge do W3000991 not push on the needle when re moving the gauge Pushing on the needle can make the gauge inaccu rate Service Procedures Gauges are held tightly by their pin sockets To remove grasp the side of the gauge face plate with your thumb place your 2nd and 3rd fingers under neath the face plate see illustration Carefully rock the gauge from side to side while applying upward pressure until the gauge pins are free of the board sockets Removing a gauge blank 6 W3000990 Note Early production models may have gauge blanks like the above If replacing a blank use the newer gauge blank support assembly shown in the Installation p
44. hting is indepen 2 If neither the Graphic Display nor the odometer dent of the rest of the cluster Test the odometer and backlighting work or if the backlighting will not dim Graphic Display backlighting as follows replace the cluster 1 Use the Backlighting Adjust function in the Set Up Menu to set the odometer and Graphic Display backlighting to maximum brightness 40 Group 38 Instrumentation VNL VNM Buzzer problems The buzzer can be tested by performing the Buzzer Test in the Cluster Self Test Mode of the Diagnostics Menu Troubleshooting The buzzer is not serviceable If it fails to sound replace the cluster Buzzer Signal Turn signal beep momentary beep Clock reminder double beep every other second Warning signal two beeps every second Telltale indicators 12 volts during Bulb Test Telltale bulbs 12 return during Bulb Test not a ground Telltale bulb signal flow Telltale indicators are lighted by bulbs positioned across the bottom of the instrument cluster Testing the telltale bulbs Test the telltale bulbs by using the Bulb Test function in the Cluster Self Test Mode of the Diagnostics menu When probing connector terminals do not insert probes into the terminals This will spread the ter minals apart causing permanent damage Probe the insertion side of the connector If none of the telltale bulbs light during the Bulb Test function check for
45. icator Note that all gauges and telltales may not be used in all vehicles Master Warning telltale A red Master Warning telltale consisting of an exclamation point inside a triangle is located near the bottom and midway between the tachometer and the speedometer It lights when the front or rear brake air pressure is too low for safe operation below 72 psi 30 W3000638 Group 38 Instrumentation VNL VNM Design and Function Right section Forward and rear drive axle temperature optional The forward and rear axle temperature gauges are elec trical aircore meter movements They are connected to temperature sender units mounted on the axle housings The higher the temperature the lower the resistance of the sender unit and the farther the gauge pointer moves to the right W3000984 Forward Axle Temperature Gauge Fuel level The fuel level gauge is an electrical aircore meter move ment that receives its signal from a sensor in the fuel tank The fuel level sensor signal is input to the cluster micro processor through the left module connector In the mi croprocessor the signal is changed from a resistance to a pulse width modulated signal It is then sent to the right module via jumper IPJ5 As the duty cycle of the signal increases the level shown on the gauge increases W3000814 Application air pressure optional The application air pressure gauge is a mechanical gauge It is attached to the ser
46. ite Communication System etc 12 Center Circuit Board Tachometer 20 Speedometer Sensors in eG Operator H r Tandem Axle Sac 55 switches Right Circuit Board 4 15 al 50 70 Applic al 25 AirPsi Telltale Indicators From External Air System Inputs from switches and sensors ad Coolant Level Cat Cummins Detriot Diesel 7 Non Electronic Trans Vehicle Speed Sensor Speedometer ECU u ECU Coolant Temp Oil Temp Turbo Boost Senders Engine Speed Sensor Engine dependent Drives Tachometer Oil PSI Sender W3000865 Group 38 Instrumentation VNL VNM Gauges and indicators Left section Pyrometer optional The pyrometer indicates exhaust temperature from a sensor in the exhaust system The pyrometer gauge is an electrical aircore meter move ment driven by a small electric current from a high temperature thermocouple If the pyrometer thermocouple fails the pointer will move to one end of the dial or the other A reading of 149 C 300 F or less indicates an open in the truck s wiring or thermocouple and a reading of 815 C 1500 F or more indicates a short Engine Coolant Temperature The coolant temperature gauge is an electrical aircore meter movement which receives its signal from the engine via the SAE J1587 data bus In the absence of a data signal the gauge pointer will move to its minimum reading after a 3 5
47. llowing special tools are required for work on the instrument cluster The tools can be ordered from Volvo GM Heavy Truck Corporation e W3000642 1608077 Lamp removal tool Group 38 Instrumentation VNL VNM Special equipment The following items are required for work on the instrument cluster They can be ordered as shown below Tools W3000572 ESD Wrist Strap Use a wrist strap when servicing the instru ment cluster inside the vehicle Use a wrist strap and anti static mat when working on the cluster at a workbench Several differ ent wrist straps are available from Kent Moore at 1 800 328 6657 W2001014 Fluke 87 Digital Multi meter DMM Available from Kent Moore P N J 39200 at 1 800 328 6657 W3000704 Type 8501 Static Dissipative Grounding Kit Available from Kent Moore P N J 42444 at 1 800 328 6657 The kit shown includes both a wrist strap and anti static mat Use both when working on the instrument cluster at a workbench Group 38 Instrumentation VNL VNM Tools MPSI Pro Link 9000 The Pro Link 9000 with the VOLVO cartridge is available from Kent Moore at 1 800 328 6657 1 MPSI Pro Link 9000 Kent Moore P N J 38500 1 Pro Link is a registered trademark of MPSI W3000752 VOLVO Cartridge version 2 0 Kent Moore P N J 38500 2000 Power Data Cable Kent Moore P N J 38500 2 Diagnostic Adaptor Cable Kent Moore P N J 38500 60A Group 38 Instrumentation VNL VNM Desig
48. med with the Pro Link 9000 and the Volvo cartridge version 2 0 see Tools for ordering information Gauge tests These gauges can be individually driven Speedometer The speedometer gauge can be driven in steps of 5 mph from 0 80 mph Tachometer The tachometer gauge can be driven in steps of 100 RPM from 0 2500 RPM Engine Oil Pressure The engine oil pressure gauge can be driven in steps of 15 psi from 0 90 psi Engine Oil Temperature The engine oil temperature gauge can be driven in steps of 10 F from 50 to 270 F Turbo boost The turbo boost pressure gauge can be driven in steps of 5 psi from 0 30 psi Coolant temp The coolant temp gauge can be driven in steps of 5 F from 150 to 230 F Pro Link is a registered trademark of MPSI 52 Lamp circuitry tests The following tests check the function of the telltale lamp circuitry High Coolant Temperature Low Engine Oil Pressure High Engine Oil Temperature Caution Low Coolant Level Stop Group 38 Instrumentation VNL VNM View EEPROM Read functions Clock Mode 12 or 24 hour mode Operating Volts 12 or 24 volts Turbo Gauge indicates whether the turbo gauge is installed Voltmeter indicates whether the voltmeter display is enabled or disabled Eng Oil Temp indicates whether the engine oil tempera ture display is enabled or disabled Reprogram EEPROM Read write functions Clock Mode set 12 or 24 hour mode Operating Volts se
49. n and Function Instrument cluster block diagram for Volvo engine Left Circuit Board Engine Beenie Center Circuit Board 2 Engine 10 15 Coolant Temp 5 Tachometer 20 Graphic 25 Display Unit Microprocessor AAA AAA J sro Pyrometer Sensor ul Fuel Level Sender J1587 I Data Link Trans Temp Air Filter 1 Restriction nal Washer Fluid Voltmeter Low d To from other ECU s ABS module Vehicle Info System Road Relay Satellite Communication System etc Cam Sensor Drives Tachometer C Operator ESE switches 50 Speedometer 70 Telltale Indicators Inputs from switches and sensors Coolant Temp Turbo Boost Senders Design and Function Sensors in i l Tandem Axle Applic Air PSI From External Air System Non Electronic Trans Vehicle Speed Sensor Speedometer W3000864 11 Group 38 Instrumentation VNL VNM Design and Function Instrument cluster block diagram for Caterpillar Cummins Detroit Diesel engines Left Circuit Board Engine Oil Pressure Engine Coolant Temp Graphic Display Unit Microprocessor Pyrometer Sensor i Fuel Level J1587 Send p na Data Link I Trans Temp Air Filter Restriction 1 a Washer Fluid Voltmeter Low Alternator te cay To from other ECU s ABS module Vehicle Info System Cummins Road Relay Caterpillar Information Display Detroit Diesel ProDriver Satell
50. ne screws 5 Install the cluster into the dash see previous procedure 6 If installing a gauge blank into the En gine Oil Pressure or Turbo Boost Pressure gauges use the MPSI Pro Link 9000 with the VOLVO cartridge to enable the gauge which is being added or to disable the gauge which is being removed Group 38 Instrumentation VNL VNM Service Procedures 22222 2 Center module replacement W3000739 1 Center Module screw locations Removal 2 1 Important Individual gauges on the AN CAUTION VN instrument cluster are not service able Attempts to remove and To prevent electrostatic discharge replace individual gauges during ESD which can damage the sen the warranty period will void the sitive electronic components in the cluster warranty Instead the whole instrument cluster use a wrist _ unit should be exchanged ONLY grounding strap and an anti static when a certified technician is repopu mat when working on the instrument lating a replacement instrument cluster cluster Failure to do so can result may the cluster be opened during the in permanent damage to the cluster warranty period Remove cluster from vehicle see pre vious procedure Place cluster on anti static mat The anti static mat must be grounded to the nearest elec trical outlet When working at your anti static workbench always keep your wrist strap connected to the anti static mat Do not place the cluster on
51. ng Speedometer odometer and tachometer From Tachometer Sender Unit f f LX 1 Engine or a From Speedometer Transmission pata Link LX 11 a cts Sender Unit ECU Speedometer Odometer Tachometer signal flow Speedometer The speedometer gauge is an electrical aircore meter movement which receives its signal from the engine via the J1587 data bus In the absence of a data signal the gauge pointer will move to its minimum reading after a 3 5 second delay If the pointers on all the gauges on the J1587 data bus move to the minimum reading there is a problem in the data link circuit Troubleshoot the 400 401 wiring and connectors Intermittent function e If this and other gauges on the J1587 data link appear to twitch or function intermittently check the 400 401 circuit for a loose connection e f this gauge only appears to function intermittently the data link could be overloaded with data from ECUs in the vehicle system In this case check the data link using the MPSI Pro Link Snapshot function Incorrect gauge reading If the speedometer accuracy is off more than 10 check the calibration of the engine ECU Compare the results of the ECU calibration with readings obtained with the diagnostic service tool recommended by the engine manufacturer Each engine manufacturer formats calibration differently For the Volvo engine only the engine ECU calibrates the speedometer with the following formula
52. noid valve 2 C2 Solenoid valve 3 C3 Solenoid valve 4 C4 Solenoid valve 5 C5 Solenoid valve 6 C6 Solenoid valve 7 Lockup solenoid valve 16 Neutral start output 18 Shift selector 1 27 Lockup clutch PSI sw 28 Forward range PSI sw 29 Neutral range PSI sw 30 Reverse range PSI sw Vehicle Navigation SID s Subsystem ID s Description 1 Dead reckoning unit Loran receiver Global positioning system GPS 2 3 4 Integrated navigation unit 23 Group 38 Instrumentation VNL VNM Design and Function Brake SID s Subsystem ID s Description 1 ABS Snsr axle 1 L 2 ABS Snsr axle 1 R 3 ABS Snsr axle 2 L 4 ABS Snsr axle 2 R 5 ABS Snsr axle 3 L 6 ABS Snsr axle 3 R 7 ABS valve axle 1 L 8 ABS valve axle 1 R 9 ABS valve axle 2 L 10 ABS valve axle 2 R 11 ABS valve axle 3 L 12 ABS valve axle 3 R 13 ABS rtrdr ctrl relay 14 ABS relay diagonal 1 15 ABS relay diagonal 2 18 ABS dif 1 ASR valve 19 ABS dif 2 ASR valve 22 Speed signal input 23 Warning light bulb 24 ASR light bulb 31 Trailer brake slack out of adjustment forward axle left 32 Forward axle right 33 Rear axle left 34 Rear axle right 35 Trailer brake slack out of adjustment axle 1 left 36 Axle 1 right 37 Axle 2 left 38 Axle 2 right 39 Axle 3 left 40 A
53. olvo GM Heavy Truck Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo GM Heavy Truck Contents Kio eno me e a ne 3 E gli gp nn e na 3 Basi SSN isao adja opise ai ski aa 4 S DBSOMEANONE orian 4 jE an a a a aaa F seo Moc shan om mmen nomen maa mm m e e T Special SHUMER ozna doka a did aji seers 8 Design and Function esisiini a aea 11 Gauges and poje lt o pona 13 SL g ji e e m a vn ma 34 TPAUBle hostiNij aan ind adado aie meee 39 General service IMONNANGN ch e sada sode o al jedi sna 39 Troubleshooting individual gauges 0 00 aaa 40 LE SECR s a cs eis O 42 Cemer eco a o e A 46 leg mm m m o e pro na 48 Troubleshooting with the MPSI Pro Link 9000 and VOLVO Cartridge 52 se ji i o o 55 Updating the odometer reading after replacing the cluster 55 Cleaning the housing and front panel glass ooo eee eeeeeeeeeeeeeeee 55 Made 1 o o a 55 zoo Me o o e o ep 55 IMS SIH a sa ogadila lt ka a al dkg SA o o 56 Instrument cluster replacemiarii 2o oaaosaae kada ika anata uju 56 zi jaje e M a m m ore o or re jane 56 ji en o or evo 57 Gauge replacement right circuit board gauges 0aaaaaaaaaa akan 58 zove pen e e e e e rene 58 lit zi me m vr o vr 60 Center module replacement onodi oi iak 61
54. onto the bulb assembly Rotate 1 4 turn and pull the bulb assembly out of the socket Installation 1 Insert the new bulb assembly into the 1089953 removal tool P N 1089953 Insert the assembly into cluster socket and ro tate 1 4 turn 2 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 Ib 56 Service Procedures 22222 2 Instrument cluster replacement Removal 1 Make certain the vehicle ignition is OFF before beginning this procedure W3000842 When servicing or troubleshooting do not leave the cluster face down for more than 15 minutes or dam age 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 steer ing column 3 Cut the tie wraps fastening the wiring harness to the back of the cluster for stress relief on the connectors Group 38 Instrumentation VNL VNM Service Procedures A DANGER Never disconnect an air system component unless all system pressure has been depleted Failure to de plete system pressure before disconnecting hoses or components may result in them separating violently and causing serious bodily injury Bleed all pressure from the vehicle air system Disconnect the electrical and
55. ontrols a particular vehicle sub system For example an Engine ECU monitors engine conditions a Anti lock Brake System ECU monitors ABS conditions and so on The ECU s are connected to each other and to the cluster by a pair of wires known as the SAE J1708 1587 data link The ECU s communicate with each other by sending and receiving messages in a format specified by SAE J1587 Note SAE J1587 is an industry standard which defines the format of electronic signals and information transmit ted between truck and bus electronic components SAE J1708 defines the hardware and basic protocol data formatting requirements for the truck and bus electronic communications system The cluster can display active and inactive fault codes in the Graphic Display The message path from the J1587 data link to the Graphic Display is shown in the figure Each diagnostic message consists of a Message Identifier MID code a Sub system Identifier SID or Parameter Identifier PID code and a Fault Mode Indicator FMI code An FMI describes the type of failure detected in the subsystem identified by the PID or SID The codes are standardized and are listed in the SAE J1708 1587 Specification A list of codes which may be displayed as text messages is shown in the following section 20 Design and Function The figure on the following page is an example of a message indicating that a problem with the engine coolant temperature has been detecte
56. ools section of this manual Call 1 800 328 6657 An anti static mat is also available from Kent Moore see Tools section of this manual Group 38 Instrumentation VNL VNM General Basic description SS E gt Ca C E em aril gt a i 179 20 ao N 4 40 8 BALL 320 lt gt IO IS a 30 4 70 4 s g o 20 No pan 80 60 RPM x100 zo 2 m o B gt ey pO 10 120 70 30 0 iny 0 r 80 r Se e ganang ET A caumon A sTo Vie ka FI EO A ar Pi mc Ge o0 mi DY W3000787 This manual describes the 1996 AMETEK Dixson Instrument Cluster for VN Series vehicles and how to service it For information about the vehicle s Electronic Control Units wiring diagrams sensors and other components please refer to the service manual for that component The cluster is available in 6 configurations with either an mph or km h speedometer The instrument cluster is divided into the following sections e Left Section Contains a Coolant Temperature and an Oil Pressure gauge and optionally a Pyrometer and a Turbo Boost gauge A Graphic Display module at the bottom provides additional information about the vehicle Also contains four telltale indicators Engine Fluids Caution Stop and No Charge e Center Section Contains a tachometer speedomete
57. ot as shown in Table B go to step 5 5 Check voltage between RX 2 and LX 3 If voltage is as shown in the Table B check the circuit connector terminals and wiring from RX 4 to LX 3 and replace components as necessary If voltage is not as shown in Table B replace the instrument cluster 6 If the pointer constantly stays on the 1 2 mark Full mark or falls below the empty mark the most likely cause is a wiring problem a If the pointer stays below E AND the pointer moves slightly during the gauge test there is no signal on the ground input Check for an open circuit on RX 2 Note that RX 2 is associated with the axle tem perature circuit so that gauge may be affected also W3000871 Troubleshooting b If the pointer stays above F AND does not move during the cluster self test there is no signal on the 5V input to the cluster Check LY 15 and RX 12 for an open circuit W3000872 c If the pointer stays at the 1 2 mark AND the pointer does not move during the cluster self test there is no signal on the fuel level input Check RX 4 for an open circuit W3000814 51 Group 38 Instrumentation VNL VNM Troubleshooting Troubleshooting with the MPSI Pro Link 9000 and VOLVO Cartridge Special tests The MPSI Pro Link 9000 with the Volvo cartridge provides easy diagnosis of faults with more information than instrument cluster self diagnostics The following tests can be perfor
58. r and odometer Also contains a buzzer fourteen telltale indicators and a Master Warning indicator Telltales in this section are Left and Right Turn Indicators Fifth Wheel Lock Wheel Differential Lock Interaxle Differential Lock High Beam Indicator SRS Air Bag Parking Brake Anti Lock Brake System ABS for Tractor and ABS for Trailer for future use Air Suspension Bogie and Mirror Defroster e Right Section Contains a Fuel Level gauge a Front Brake Air Pressure gauge and a Rear Brake Air Pressure gauge It may also contain an optional Application Air Pressure gauge and a Forward Axle and a Rear Axle Temperature gauge It can also contain up to six telltale indicators Standard telltales are Preheat Traction Control System and APADS Air Conditioning Protection and Diagnostic System for future use Note that all gauges and telltales may not be used in all vehicles Four push buttons above the speedometer allow the driver to access and display information in the Graphic Display Specifications This instrument cluster is designed to operate with an input voltage of between 10 and 18 volts Group 38 Instrumentation VNL VNM General Available configurations MODE CEO vp sz Co CE down Clock Trip Odometer 1 and 2 Diagnostic Messages Voltmeter Gauge Fuel Economy Engine Coolant Oil Tachometer Temp Graphic Display Standard Cluster MODE CD cup sr gt CE DOWN
59. rocedure When adding a gauge blank remove the gauge or gauge blank to be re placed 65 Group 38 Instrumentation VNL VNM Installation 1 To avoid damaging the gauge do not push on the needle when in stalling the gauge Pushing on the needle can make the gauge inaccu rate Install the replacement gauge by grasping the opposite corners of the gauge face plate and pushing the gauge pins into the socket onto the circuit board Do not push on the nee dle For gauge blanks see the following steps It is correctly installed when its face plate is flush with the other gauges face plates Adding gauge blanks 2 Gauge Blank Blank Support Assembly Pins Terminals Install the new blank 1 into the clus ter housing Install the blank support 2 in the PC board into the terminals 4 where the gauge was removed 66 W3000820 Service Procedures Important Before installing the Left Circuit Board assembly check con nector E4 pins and make sure they are all perfectly straight and parallel to each other 4 Place the Left Circuit Board assembly into the housing while lining up E4 pins into the Graphic Display connector 5 Install the Center Module paying par ticular attention to connector E1 on the Left Circuit Board assembly 6 Install the left rear cover and secure it with three machine screws 7 Install the cluster into the dash see previous procedure 8 If in
60. rs a fuel economy display and diagnostic information Optional displays in clude engine and transmission oil temperature gauges Displayed data can come from e the J1587 data link e external switches e external sensors The display can be customized to suit individual prefer ences For example its backlighting can be adjusted in dependently of gauge backlighting When the ignition is on and the vehicle is not moving the Graphic Display can also be used to help diagnose the cluster and external problems If battery power is lost the Graphic Display will default to the clock display When power is regained the clock will come on flashing and will need to be reset Automatically activated warnings Low Air Filter Washer Fluid Coolant Restriction Low 7 m aki W3000709 Automatically Activated Telltale Warnings Appear ing in the Graphic Display Should a condition requiring attention occur a telltale warning message identifying that condition will override the current display For example if the engine coolant level drops below a predetermined point while the clock is displayed a low coolant display will replace the clock display Telltale warnings Low coolant e The low coolant warning display is activated by an input from the low coolant sensor and will stay on until the problem is corrected e Note that engine shutdown mode may be engaged by a low coolant condition this is an engine dependent parameter
61. s average instantaneous and target fuel economy The range is 0 to 99 9 miles per gallon or O to 999 liters per 100 kilometers selectable using the Set Up menu The data is calculated by the microprocessor on the Left Circuit Board using inputs from the J1587 data link The AVG value can be reset by pressing the Set button while in this display the Trip Fuel Meter value will also be reset Trip Fuel Meter The Trip Fuel meter displays the amount of fuel used since the last time it was reset Its range is from 0 to 9999 gallons or liters driver selectable and the data is calculated by the microprocessor on the Left Circuit Board using inputs from the J1587 data link The Trip Fuel value can be reset to zero by pressing the Set button while in this display the AVG fuel economy value will also be reset Group 38 Instrumentation VNL VNM Design and Function Center section Tachometer The tachometer is an electrical aircore meter movement N idly 4 driven by signals from the J1587 data link In the absence N 4 of data link information the gauge pointer will move to its lO IS iS minimum reading after a 3 5 second delay W3000843 Speedometer and odometer The speedometer is an electrical aircore meter movement driven by signals from the J1587 data link In the absence of data link information the gauge pointer will move to its minimum reading after a 3 5 second delay Note that the cluster does not perform speedomet
62. s case check the data link using the MPSI Pro Link Snapshot function Graphic Display Use the Display Test function in the Cluster Self Test Mode of the Diagnostics Menu to test the graphic display If the display is defective replace the instrument cluster During the Display Test all pixels in the display will alternate from dark to light 2 times LX 1 3 J1587 Troubleshooting Turbo Be ee ee a W3000723 Incorrect gauge reading To test the gauge 1 Check for messages using the Diagnostic Messages function of the Diagnostics Menu Use the engine service tool to compare any diagnostic messages shown in the instrument cluster If a sensor prob lem is indicated check the wiring from the sensor for opens or shorts according to the engine manufac turer s service literature Also refer to the VNL VNM Electrical Schematics for wiring information Use the Gauge Test function in the Cluster Self Test Mode of the Diagnostics Menu a If the Turbo Boost Pressure gauge pointer sweeps back and forth across its full range its meter movement and associated circuitry in the cluster are working b If the gauge pointer does not move during the self test and a sensor problem has been ruled out replace the cluster CSCIC W3000719 Check for missing pixels and for pixels that are always dark If defective replace the cluster 45 Group 38 Instrumentation VNL VNM Center section Troubleshooti
63. s has no backlighting check the input pin for 12 volts brightest when the control provides 12 volts and grows dimmer as the voltage drops toward zero The cluster Left Section pin LX 20 backlighting is independent of the odometer and Graphic Display backlighting Center Section pin CY 18 Testing the cluster backlighting Right Seeon pin RI To test the cluster backlighting turn the dash lights on and adjust the dimmer control for maximum brightness a If present replace the cluster 1 If none of the backlights light check for 12 volts at b If not present check the input to the control the output of the dimmer control on the vehicle dash and ke tise a If present replace the cluster 3 If only one bulb of a particular board is affected b If not present there could be a short in the cluster One at a time unplug each cluster connector and recheck for 12 volts If present replace the cluster if not check the input to the dimmer control and the fuse NIZ Backlights mie Center Circuit Board 0 12 volts from Dimmer Backlights NIZ Backlights Ground Right Circuit Board Cluster backlighting signal flow Odometer and graphic display backlighting gt sen Ground RX 1 Left Circuit Board fiat gt gt Ground replace the lamp socket assembly as described in Service Procedures in this manual persists replace the cluster If the problem W3000716 Odometer and Graphic Display backlig
64. scharge ESD which may damage the sensitive electronic components in the in strument cluster make sure the workbench has an anti static mat which is grounded to the nearest electri cal outlet when working on the instrument cluster Fail ure 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 Human skin can hold more than 1000 volts of static electricity Although getting a static shock is annoying it is not dangerous because there is so little energy stored by clothing But when dealing with circuits designed to sense differences 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 An anti static wrist strap is available from Kent Moore see T
65. stalling a gauge blank into the En gine Oil Pressure or Turbo Boost Pressure gauges use the MPSI Pro Link 9000 with the VOLVO cartridge to enable the gauge which is being added or to disable the gauge which is being removed 9 Important If the Left Circuit Board has been replaced update the odome ter and hourmeter values to reflect the vehicle s actual mileage and engine hours This is done with the MPSI Pro Link 9000 W3000750 67 VOLVO Volvo GM Heavy Truck Volvo GM Heavy Truck Corporation 7825 National Service Road P O Box 26115 Greensboro NC 27402 6115 Volvo GM Canada Heavy Truck Corp 6490 Vipond Drive Mississauga Ontario L5T 1W8 PV776 TSP23762 1 7 95 8 95
66. sure Air Line Red 2 Front Brake Pressure Air Line Green 3 Application Air Pressure Air Line Black Remove the air lines from the Front and Rear Brake Air Pressure gauges Connect the air lines back into the opposite gauges start the engine and build the air pressure in the systems Compare the sweep of both gauges to see if the problem still exists or if the problem is now in the other gauge If the problem is in the other gauge troubleshoot the air line for a kink or restriction If the problem still exists in the same gauge replace the cluster Air Gauge LED Test To test the red warning LED in the Front or Rear Brake Air Pressure gauge pump the brake pedal while the ignition is on and engine is off to lower the system air pressure When the pressure drops below 60 psi the LED must light If not check the LED circuitry by using the Bulb Test function If the LED does not light during the Bulb Test replace the cluster Start the engine When the air pressure rises above 70 10 psi the LED should turn off If not replace the cluster 49 Group 38 Instrumentation VNL VNM Fuel Level gauge i i 1 From Fuel Level__ 1x2 gt gt cru Sender Unit i Fuel level gauge signal flow The Fuel Gauge is an electrical aircore meter movement that receives its signal from a sensor in the fuel tank This signal is input to the microprocessor on the instrument cluster which drives the gauge If the
67. t 12 or 24 volts Turbo Gauge enable or disable Voltmeter enable or disable Eng Oil Temp Allows checking of whether the engine oil temperature gauge is enabled or disabled Also allows changing of the status from enabled to disabled or vice versa Trans Temp Allows checking of whether the transmission oil temperature gauge is enabled or disabled Also allows changing of the status from enabled to disabled or vice versa Fuel Econ Allows checking of whether the fuel economy gauge is enabled or disabled Also allows changing of the status from enabled to disabled or vice versa Troubleshooting Trans Temp indicates whether the transmission oil temp is enabled or disabled Fuel Econ indicates whether the fuel economy feature is enabled or disabled Eng Oil F Src indicates the signal source for the engine oil temperature from data bus or sensor VE D12 engine Hourmeter This allows the hourmeter total to be checked Odometer This allows the odometer total to be checked Eng Oil F Src Allows checking of whether the engine oil temperature signal source is from the data bus Caterpil lar Cummins Detroit Diesel engines or from a sensor Volvo engine If installing a new cluster into a vehicle this variable will need to be set for the appropriate engine Password protected read write functions The password for instrument cluster software version 6 5 and above use four dashes for the password Earlier
68. terpillar 3406E and Detroit Diesel Series 60 11 1 12 7 Caution and Stop Lamp signals are sourced from the Engine ECU hard wired Caterpillar and Detroit Diesel do not use the Engine Fluids lamp Refer to the engine manufacturer s literature for informa tion on the conditions which activate individual lamps in the instrument cluster 3 Source Data Concentrator Module DCM when an above normal operational range for coolant tempera ture condition is broadcast on the data bus 4 Message on Request Cluster Diagnostic Mes sages which are displayed in the Graphic Display Diagnostic Mode 5 Engine Protection is not controlled by the instrument cluster It is a programmable parameter For more information refer to the Electronic Control System VE D12 VOLVO manual Engine related warnings Cummins M11 N14 The Engine Fluids Caution and Stop Lamp signals are sourced from the Engine ECU hard wired Refer to the engine manufacturer s literature for informa tion on the conditions which activate individual lamps in the instrument cluster Group 38 Instrumentation VNL VNM Graphic Display The Graphic Display is located below the gauges in the left section of the instrument cluster It displays vehicle system information not available from the other gauges and helps the driver obtain maximum efficiency from the vehicle Standard displays include an alarm clock voltmeter en gine hours two resettable trip odomete
69. trumentation VNL VNM Design and Function PID s Parameter ID s Description 62 Retarder inh status 71 Idle shutdn status 84 Road speed 91 Throttle pedal 100 Engine oil pressure 102 Boost pressure 105 Air inlet temperature 106 Air inlet pressure 108 Barometric pressure 110 Engine coolant temp 111 Coolant level 127 Transmission oil PSI 160 Main shaft speed 161 Input shaft speed 175 Engine oil temperature 177 Transmission oil temperature 190 Engine speed 191 Transm output RPM Common SID s Subsystem Description ID s 233 Controller 2 236 Power contact device 237 Start enable solenoid 242 CC resume switch 243 CC set switch 244 CC enable switch 245 Clutch pedal switch 246 Brake pedal switch 1 247 Brake pedal switch 2 248 Proprietary data link 249 SAE J1922 data link 250 SAE J1708 data link Note J1708 J1587 251 Power supply 252 Calibration module 253 Calibration memory 254 Controller 1 22 Group 38 Instrumentation VNL VNM Design and Function Engine SID s Subsystem Description ID s 1 Injector 1 2 Injector 2 3 Injector 3 4 Injector 4 5 Injector 5 6 Injector 6 21 Engine position sensor 22 Timing sensor 25 Ext Engine protection sig Transmission SID s Subsystem ID s Description 1 C1 Sole
70. uster b If a sensor problem is indicated check the wiring from the sensor for opens or shorts according to the engine manufacturer s service literature Also refer to the VNL VNM Electrical Schematics for wiring information 2 If the gauge pointer does not move during the self test and a sensor problem has been ruled out replace the cluster Group 38 Instrumentation VNL VNM Turbo boost pressure gauge From Turbo Boost Engine Boost Pressure Sender Unit ECU DataLink LX 11 E I I Turbo Boost Pressure gauge signal flow The Turbo Boost Pressure gauge is an electrical aircore meter movement which receives its signal from the engine via the J1587 data bus In the absence of a data signal the gauge pointer will move to its minimum reading after a 3 5 second delay If Turbo Boost Pressure data is missing during normal operating conditions the Turbo Boost Pressure gauge pointer will move to the low end of the scale zero pressure If the pointers on all the gauges on the J1587 data bus move to the minimum reading there is a problem in the data link circuit Troubleshoot the 400 401 wiring and connectors Intermittent function If this and other gauges on the J1587 data link appear to twitch or function intermittently check the 400 401 circuit for a loose connection If this gauge only appears to function intermittently the data link could be overloaded with data from ECUs in the vehicle system In thi
71. vation has a 10 second delay to allow for fluid slosh e This warning may be cleared by pressing the instru ment cluster s Set button The warning will reappear each time the key is cycled off and on e f adding washer fluid does not clear the warning check the washer fluid pump assembly for continuity between connector pins B and C If there is continuity replace the pump assembly If the warning is still displayed troubleshoot the washer fluid pump circuit Gauge warnings e lf agauge warning such as voltmeter engine or trans mission oil temperature occurs the CAUTION lamp will come on and the gauge warning will be displayed But if a telltale warning is already displayed the Mode button must be pressed to display the warning on the Graphic Display screen e Gauge warnings are activated when the input ex ceeds a pre set trip point The trip points are as fol lows shown in order of priority Note Engine oil temperature trip point varies by engine 1 Engine oil temp VE D12 130 C 265 F 2 Transmission oil temp 140 C 285 F 3 Voltmeter 16 volts Group 38 Instrumentation VNL VNM Multiple warnings e f more than one telltale warning message is acti vated 2 or 3 warning icons may be displayed at the same time A multiple display appears as shown in the illustration Washer Fluid Low W3000848 1 Washer Fluid Low icon in the Primary dis play location 2 Low Coolant icon in the Secondary displ
72. versions of software used four zeros 0000 The software version can be looked up in the engine ECU Hourmeter This allows the hourmeter total to be checked and changed It is used when installing a new instrument cluster into a vehicle which already has miles on the engine Odometer This allows the odometer total to be checked and changed It is used when installing a new instrument cluster into a vehicle which already has miles on it 53 54 Group 38 Instrumentation VNL VNM Service Procedures Service Procedures Important Individual gauges on the VN instrument cluster are not serviceable Attempts to service or replace individual gauges during the warranty period will void the cluster warranty Instead the whole unit may be exchanged ONLY when a certified technician is repopulating a re placement instrument cluster may the cluster be opened during the warranty period To prevent electrostatic discharge ESD which can damage the sensitive electronic components in the instrument cluster do the following Use a wrist grounding strap and an anti static mat when working on the instrument cluster Work in a clean environment Do not place the cluster on a metal table or any metal surface while servicing Failure to do the above can result in permanent damage to the printed circuit boards in the instrument cluster Updating the odometer reading after replacing the cluster The odometer and hourmeter values ar
73. vice brake system by a hose going into a quick disconnect fitting on the rear of the gauge It reads applied air pressure to the service brake system The air hoses and quick disconnects are color coded to avoid wrong connections W3000608 31 Group 38 Instrumentation VNL VNM Design and Function Front and rear brake air pressure The air pressure gauges are mechanical gauges They are attached to their air systems by a hose going into a quick disconnect fitting on the rear of the gauge The air hoses and quick disconnects are color coded to avoid wrong connections The front and rear brake air pressure gauges contain mechanical contacts When the air pressure drops below a preset value the contacts close causing a warning buzzer to sound and a red warning LED in the lower right corner of the gauge to light The Master Warning indicator will also light W3000609 Front Brake Air Pressure Gauge Telltale lamps right section on bel Mr Ics W3000841 1 Pre heat 2 Traction Control System 3 APADS Air Conditioning Protection and Diagnostic System for future use Note that all gauges and telltales may not be used in all vehicles 32 Group 38 Instrumentation VNL VNM Design and Function Buzzer signals The buzzer is part of the cluster and has the following distinct signals e Turn signal Single short beep in time with the Turn Indicator telltales e Clock reminder A double beep every other second
74. xle 3 right 24 Group 38 Instrumentation VNL VNM Design and Function FMI s Failure Modes Description 0 Data valid but high 1 Date valid but low 2 Data erratic 3 Voltage shorted high 4 Voltage shorted low 5 Current low or open C 6 Current high or short C 7 Mech syst no respons 8 Abnormal freq or PW 9 Abnormal update rate 10 Abnormal change rate 11 Failure unknown 12 Bad device 13 Out of calibration 14 Special instruction see Note A complete list of MIDs PIDs SIDs and FMIs is published Note The special instruction FMI 14 is broadcast in the SAE J1708 1587 document when the airbag has stored crash data or by the data concentrator when the engine shutdown output has been activated 25 Group 38 Instrumentation VNL VNM Cluster self test mode As an aid in troubleshooting the cluster the cluster self test mode provides the following tests Note While in the cluster self test mode the engine ECU data link is disconnected Therefore the gauges will not function until the cluster is out of the self test mode 26 Bulb test Turns on all telltale indicators and red warning LEDs in the gauges which have them for ten seconds Note The gauges in the instrument cluster are not functional during the bulb test The ignition key can be cycled off and on to interrupt any test Gauge test This causes the pointers in the Tachometer Speedometer Oil

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