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Service Manual

Trucks
Group

381500

Instrumentation
VN (from 3/99),
VHD

PV776-TSP139790

Foreword
The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to August 2000.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary service bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a reference to an S.R.T. (Standard Repair Time).
Service procedures which do not include an operation number in the title are for general information and no reference is made to an S.R.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could occur.

Volvo Trucks North America, Inc.


Greensboro, NC USA

Order number: PV776-TSP139790

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

All rights reserved. No part of this publication may be reproduced, stored in


retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..

Contents
General ........................................................................ 3
Basic Description ....................................................... 3
Specifications ............................................................. 7
Connector Pinouts ...................................................... 7
Connector Pinouts, Left Module .............................. 7
Connector Pinouts, Center Module .......................... 9
Connector Pinouts, Right Module .......................... 11
Tools .......................................................................... 13
Special Tools ............................................................ 13
Special Equipment ................................................... 15
Design and Function ................................................
Instrument Cluster ......................................................
Communication .........................................................
Left Instrument Cluster Module (MID 234) ..............
Pyrometer ...............................................................
Engine oil pressure gauge .....................................
Engine coolant temperature gauge ........................
Turbo boost (intake manifold) pressure gauge ......
Telltale bulbs, left section .......................................
Graphic Display ......................................................
Left CPU Board ......................................................
Center Instrument Cluster Module (MID140) ...........
Center Module ECU (MID 140) .............................
Tachometer .............................................................
Speedometer ..........................................................
Odometer ...............................................................
Telltale bulbs, center section ..................................
Master Warning telltale ..........................................
Right Instrument Cluster Module .............................
Forward rear axle temperature gauge ...................
Rear rear axle temperature gauge ........................
Fuel level gauge .....................................................
Application air pressure gauge ..............................
Air suspension pressure gauge .............................
Front brake air pressure gauge .............................
Rear brake air pressure gauge ..............................
Telltale bulbs, right section .....................................
Graphic Display ........................................................
Graphic Display Layout ..........................................
Graphic Display Symbols .......................................
Graphic Display Control Buttons ..............................
Using the Graphic Display Menus ...........................
Selecting a Menu ...................................................
Changing Settings ..................................................
Password Information .............................................
Graphic Display Operation .......................................
Instrument Cluster Operation at Start-up .................
Graphic Display Menus, Driving Mode ....................
Main Menu: Gauge (available while driving) ............
Main Menu: Fuel Economy (available while driving)
Main Menu: Time/Distance (available when driving)
Main Menu: FAULTS? (available while driving) ........

17
17
19
23
24
24
25
25
25
26
27
28
29
29
30
30
31
31
32
33
33
33
34
34
35
35
35
36
36
37
38
38
38
38
39
40
40
41
42
45
47
49

Graphic Display Menus, Non-Driving Mode .............


Main Menu: Time/Distance (non-driving) .................
Main Menu: Set-up mode (non-driving) ...................
Main Menu: System Diagnostic (non-driving) ..........
Main Menu: Data Log mode (with Volvo engines
only) (non-driving) ....................................................
Main Menu: Password Input (non-driving) ...............

56
57
59
68
81
86

Troubleshooting ........................................................ 87
Instrumentation Troubleshooting ................................ 87
General Work Practices ........................................... 88
Instrument Cluster Diagnostic Tests ........................ 89
Instrument Cluster Self Test .................................. 89
Instrument Cluster Tests with VCADS Pro ............ 90
Warning and Telltale Lamps, Troubleshooting ......... 92
Instrument Cluster Self Test .................................. 92
Instrument Cluster Tests using VCADS Pro .......... 92
Troubleshooting ...................................................... 93
LED Indicator Lamps ............................................. 93
Telltale Lamps ........................................................ 96
Instrument Cluster Backlighting, Troubleshooting .. 106
Graphic Display and Odometer, Troubleshooting .. 111
Instrument Cluster Self Test ................................ 111
Instrument Cluster Tests using VCADS Pro ........ 111
Troubleshooting, Odometer .................................. 112
Troubleshooting, Graphic Display ........................ 114
Gauges, Troubleshooting ....................................... 115
Instrument Cluster Self Test ................................ 115
Gauge Tests, Accuracy and Calibration using
VCADS Pro .......................................................... 116
Gauge Reaction to Short or Open Circuits ......... 116
Intermittent Faults ................................................ 116
Left Module Gauges ............................................. 117
Center Module Gauges ........................................ 120
Right Module Gauges .......................................... 122
Graphic Display Control Buttons, Troubleshooting 128
Buzzer, Troubleshooting ......................................... 130
Common Problems ................................................. 132
Service Procedures ................................................
Service Procedures ..................................................
General Work Practices .........................................
Housing and Front Panel Glass, Cleaning .............
Connector Terminals, Adding or Replacing ...........
Bulb, Replacement .................................................
Instrument Cluster, Replacement ...........................
Left Gauge Module, Replacement .........................
Center Module, Replacement ................................
Right Module, Replacement ...................................
Air Gauge, Replacement ........................................
Graphic Display, Replacement ...............................
Instrument Cluster Housing/Glass, Replacement ..
Left CPU Board, Replacement ..............................
Instrument Cluster Rear Cover, Replacement (Left
or Right) .................................................................

133
133
133
135
135
137
139
141
143
145
148
150
153
156
159
1

Instrument Cluster, Programming .......................... 161


Odometer, Programming ........................................ 162
Feedback
Operation Numbers

Group 38 Instrumentation, VN / VHD

General

General
Basic Description

W3004310

About This Manual


This service manual describes the VN/VHD instrument
cluster which went into production in March 1999. This
cluster is easily distinguished from earlier models by the
telltale lamps on the left side:

Earlier models have ENGINE FLUIDS, CAUTION


and STOP telltales whereas this model has Preheat,
INFO and STOP telltales. (The function of the ENGINE FLUIDS telltale has transferred to the STOP
telltale.)

In September 2000 the instrument cluster was updated


with 5 new telltale lamps on the right side:

Earlier models had only a Traction Control telltale


lamp on the right side where as this model has also
TRANS OIL TEMP, TRANS MALFUNCTION, WAIT
START ENGINE1, and WATER IN FUEL1 telltale
lamps.

This Service Information provides information about how


to operate the instrument clusters display, as well as
which information can be obtained via the display. It also
gives information about the function, troubleshooting and
servicing of the instrument clusters other parts such as
gauges and lamps.

To find your way easily among the information that is


available in the graphic display, it is recommended that
you first read all the sections from Communication
page 19 to Information Messages page 27. These
sections describe the displays function and operation,
as well as how the instrument cluster communicates with
the vehicle electronic system.
In the section Graphic Display Operation page 40, the
following main headings can be found:

Instrument Cluster Operation at Start-up page 40


Graphic Display Menus, Driving Mode page 41
Graphic Display Menus, Non-Driving Mode page 56

The main headings begin by listing the main menus. The


sub-menus and functions are then explained.

If the vehicle is in motion, use the display controls


carefully. Do not lose road concentration. Be familiar
with operation of the controls. Shifting concentration
to operating the controls can lead to losing control of
the vehicle and may result in serious personal injury
or death.

For information about the vehicles Electronic Control


Units, wiring diagrams, sensors and other components,
please refer to the service information or electrical
schematics for those components.
The instrument cluster is available in 7 configurations,
with either an mph or km/h speedometer (see Available
Configurations page 4).
1

Not applicable to all models.

Group 38 Instrumentation, VN / VHD

General

Available Configurations

T3009001

Group 38 Instrumentation, VN / VHD

General

Available Configurations (contd.)

T3009002

Group 38 Instrumentation, VN / VHD

General

Available Configurations (contd.)

T3009303

Group 38 Instrumentation, VN / VHD

Specifications

Specifications
Connector Pinouts
Connector Pinouts, Left Module
The left module has two connectors placed on the back
of the instrument cluster.

Left module, LX connector


Pin

Circuit

Description

400-B

SAE J1587/1708 data link (+)

183

Fuel level input from sensor

CJ1

Fuel level signal to gauge

219A

Display control switch (ESCAPE)

NC

219B

Display control switch (DOWN)

219D

Display control switch (SELECT)

Sensor ground left

0XC-A

Electronics ground

10

202-A

Battery power supply, left module

11

401-B

SAE J1587/1708 data link (-)

12

0P-A

Ground, left module

13

NC

14

NC

15

NC

16

219C

17
18

Display control switch (UP)


NC

CJ2

19

Center module wake up function


VSP Boot

20

141-G

21

219

22

180-A

Backlighting, left module


Reference voltage for stalk switch
Power supply (ignition feed), left
module

Pins marked NC (Not Connected) are not used.

W3003558

Group 38 Instrumentation, VN / VHD

Specifications

Left module, LY connector


Pin

Circuit

199

Description
Air filter restriction
NC

CJ3

Bulb test (+)

CJ4

Bulb test (-)

14

Battery charging

575

Red lamp, left module (STOP)

Cab tilt lock

NC

NC

10

576

Yellow lamp, left module (INFO)

11

Engine preheat sense

12

NC

13

191

Pyrometer (+)

14

NC

15

NC

16

469

17
18

Rear rear axle temp input from


sensor
Power take off

774-B

Traction Control in off-road mode

19

Bootstrap enable

20

Trailer w/o ABS

21

CJ6

22

Rear rear axle temp output to


gauge
NC

23

387A

Washer fluid level

24

CJ5

Forward rear axle temp output to


gauge

25

Remote display

26

Outdoor temp

27

NC

28

314

Transmission oil temp sensor

29

468

Forward rear axle temp input from


sensor

30

190

Pyrometer (-)

Pins marked NC (Not Connected) are not used.

W3003558

Group 38 Instrumentation, VN / VHD

Specifications

Connector Pinouts, Center Module


The center module has two connectors placed on the
back of the instrument cluster.

Center module, CX connector


Pin

Circuit

Description

400-H

SAE J1587/1708 data link (+)

401-H

SAE J1587/1708 data link (-)

CJ2

202-B

Power supply, center module

0XC-B

Ground

Center module wake up function

Pins marked NC (Not Connected) are not used.

W3003557

Group 38 Instrumentation, VN / VHD

Specifications

Center module, CY connector


Pin

Cavity

779

Description
ABS Truck lamp
ABS Trailer

420

Parking brake lamp

702

Heated mirror lamp

CJ3

Bulb test (+), left module

CJ4

Bulb test (-), left module

NC

33B

High beam lamp

113-AA

Turn signal, right

10

422

Diff lock interaxle lamp

11

0P-B

Power ground, center module

12

426

Diff lock wheels lamp

13

424

Fifth wheel lock lamp

14

112-AA

15

431

Turn signal, left


Air suspension lamp

16

NC

17

NC

18

141-F

19

CJ7

Bulb test (+), right module

20

CJ8

Bulb test (), right module

21
22

Backlighting, center module

NC
180-B

Power supply, center module

23

NC

24

Optional

25

CJ9

Master warning activation. From


front and rear air pressure gauges
in the right module

26

NC

27

NC

28

NC

29

NC

30

NC

Pins marked NC (Not Connected) are not used.

10

W3003557

Group 38 Instrumentation, VN / VHD

Specifications

Connector Pinouts, Right Module


The right module has a connector placed on the back of
the instrument cluster.

Right module, RX connector


Pin

Cavity

Description

141-E

Backlighting, right module

NC

CJ5

Forward rear axle temp. input from


left module

CJ1

Fuel level input from left module

NC

NC

NC

NC

NC

10

NC

11

CJ7

Telltale bulb test (+) from center


module

12

NC

13

Wait to start engine

14

774B

Traction Control in off-road Mode

15

0P-C

Power ground, right module

16

NC

17

CJ6

18

180-C

Rear rear axle temp. input from left


module
Power supply, right module

19

Water in fuel

20

NC

21

CJ9

Master warning activation to center


module

22

Transmission in Neutral

23

NC

24

NC

25

NC

26

NC

27

NC

W3003560

Pins marked NC (Not Connected) are not used.

11

Group 38 Instrumentation, VN / VHD

Specifications

Right module, RX connector


Pin

Cavity

28

CJ8

Description
Telltale bulb test (-) from center
module

29

Transmission oil temp

30

Transmission malfunction

Pins marked NC (Not Connected) are not used.

W3003560

12

Group 38 Instrumentation, VN / VHD

Tools

Tools
Special Tools
The following items may be required for work on the instrument cluster. Tools with
999.../98... numbers are available from Volvo Parts. Tools with J-... numbers are available from Kent-Moore at (800) 3286657.

W3000642

1089953

Lamp Removal Tool (Available


from Volvo Parts)

9998551 and
J-43340

60pin Breakout Box and Overlay

W0001556

J43235

22pin Adapter for Green LX Connector

J-44274

Dash Air Pressure Gauge Tool

J-42189

Air Hose Removal Tool

W0001608
W0001716

Overlay J-43340 is color coded blue or green to


correspond to blue and green instrument cluster
connectors. The pin numbers on the overlay correspond to the specific connector pin numbers. The
two breakout harnesses J-43234 and J-43235 are
used together with the breakout box and overlay.
W0001198

W0001557

J-43234

30pin Adapter for Green LY or


RX and Blue CY Connectors

13

Group 38 Instrumentation, VN / VHD

Tools

Special Tools...

W0001709

14

VCADS PRO tool.

Digipass password generator, model 300 or


500.

9998555

Communication interface unit: for connection


between the laptop PC and the vehicles diagnostic connector.

9998617

Programming Kit
9808635

Programming unit.

9808560

Cable for direct connection


to Engine ECU.

9808561

Cable for direct connection


to Vehicle ECU.

9812331

Extension cable: for communication (22


yards). Optional.

9808562

Cable for direct connection


to Instrument Cluster.

J-43999

6pin Diagnostic Adaptor: for vehicles built


prior to 1999.

9808563

Cable for power supply.

J-43939

9pin Diagnostic Adaptor: for vehicles built


after January 1999.

Group 38 Instrumentation, VN / VHD

Tools

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

W0001904

J-42444-A

BT-8639-B

Type 8501 Static Dissipative Grounding Kit.


The kit shown includes both a wrist strap
and anti-static mat. Use both when working
on the instrument cluster at a workbench.
ESD Wrist Strap.
Use a wrist strap when servicing the instrument cluster inside the vehicle. Use a wrist
strap and anti-static mat when working on
the instrument cluster at a workbench.

J-44567

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

J-39200

Fluke 87 Digital Multimeter (DMM).

J-42449

Terminal removal and probe kit.


J-424491

2 male test probes.

J-424492

2 female test probes.

J-4244910

Terminal remover.

J-38125-8

Packard crimper.

J-25070

Heat gun.

15

Group 38 Instrumentation, VN / VHD

Tools

Special Equipment...
The tools are available from Volvo Parts. Tools with J-... numbers are available from
Kent-Moore at (800) 3286657.

W3004317

104004

Pro Link 9000.

206040

Multi-Protocol Cartridge (MPC).

809112

PCMCIA.

501002

16

Power/Data Cable.

J3850060A

6pin Deutsch Connector.

J44012

9pin Deutsch Connector.

Group 38 Instrumentation, VN / VHD

Design and Function

Design and Function


Instrument Cluster

W3004310

Introduction
The cluster is available in 7 configurations, with either a
mph or km/h speedometer (see Available Configurations page 4).
The instrument cluster consists of three combined modules:
Left module
The left module consists of 3 separate components, left
gauge module, graphic display and CPU board. The left
module can include pyrometer, engine oil pressure
gauge, engine coolant temperature gauge and turbo
boost pressure gauge, and a graphic display for driver
information. There are telltales in the lower section of the
module. Please refer to Left Instrument Cluster Module
(MID 234) page 23. For display operation, refer to the
sections Instrument Cluster Operation at Start-up page
40, Graphic Display Menus, Driving Mode page 41 and
Graphic Display Menus, Non-Driving Mode page 56.
Center module
The center module contains a tachometer, speedometer
and odometer. In the lower section of the center module
there is a central warning lamp, and telltales for different
truck functions. Please refer to Center Instrument Cluster Module (MID140) page 28.

Right module
The right module consists of an electrical gauge module
and separate air gauges. The right module can include
forward and rear rear axle temperature gauges, fuel level
gauge, application air pressure gauge, front and rear
brake air pressure gauges. Trucks with an air suspension may have an air suspension pressure gauge. There
are telltales in the lower section of the module. Please
refer to Right Instrument Cluster Module page 32.
Graphic display control buttons
Control buttons for the graphic display menus are located on the wiper stalk on the right-hand side of the
steering wheel. Please refer to Graphic Display Control
Buttons page 38.

If the vehicle is in motion, use the display controls


carefully. Do not lose road concentration. Be familiar
with operation of the controls. Shifting concentration
to operating the controls can lead to losing control of
the vehicle and may result in serious personal injury
or death.

17

Group 38 Instrumentation, VN / VHD

Design and Function

Instrument Cluster Programming

W0001632

Each instrument cluster (or CPU board) is programmed


to correspond to the customer-ordered options for that
particular vehicle. This dataset is stored in the CPU
board memory, making the instrument cluster unique to
each vehicle.
For this reason, it is not possible to swap a suspected
faulty instrument cluster (or CPU board) with another vehicle without reprogramming the instrument cluster.
When ordering a replacement instrument cluster (or
CPU board) the Vehicle Identification Number (VIN) must

18

be supplied. Volvo will program the replacement part before delivery based on the dataset stored in the VDA
(Volvo Data Administration) database.
Authorized technicians can also update and/or alter software datasets with the VCADS Pro tool. See the most
current VCADS Pro user information or the Help menu
in the VCADS Pro tool.

Group 38 Instrumentation, VN / VHD

Design and Function

Communication

W3004303

1.

Connections to the data link

2.

Connections to components

3.

Connections between the modules of the instrument cluster

The connections between the 3 modules of the instrument cluster and other components can be divided into
the following three groups according to the picture above:
1. Connections to the data link:
Connections to the J1587/J1708 information data link
connect the instrument cluster center and left module to
the other electronic control units, e.g. the Engine ECU
(MID 128) and the Vehicle ECU (MID 144). For more information see Data Link page 22 and
Communication with Other ECUs/Sensors page 23.

2. Connections to components:
Some components are connected to the instrument cluster modules via the microprocessor in the left module.
Others components have inputs to each cluster module,
e.g. air gauges. See the individual gauge descriptions in
the Design and Function section for more information.
3. Connections between the modules of the instrument cluster (control signals for gauges and lamps):
The non data link communication between the three
modules of the instrument cluster is carried out via these
connections. They are hardwired connections labeled
with CJ_ circuit numbers. Refer to the electrical
schematic or Connector Pinouts page 7 for more information.
19

Group 38 Instrumentation, VN / VHD

Design and Function

Data Link
The communication between the vehicles ECUs and the
instrument clusters left and center modules is carried
out via the SAE J1587/J1708 information data link.

Instrument Cluster
Display
MID 234

The systems control signals are sent on the SAE


J1939 control data link. The SAE J1939 control data
link does not directly interface with the instrument cluster.
The information and diagnostic signals are sent on
the J1587/J1708 information data link. The link also
functions as a reserve system for the J1939 control link,
if the control link for some reason does not function. The
information link keeps the systems status continually updated and available for reading via the diagnostics
socket.
If a fault should occur and be detected by any of the
ECUs, the ECU will send out a message on both links.
Messages that are sent on the control data link inform
the other ECUs that an error has occurred, for instance
that the engine ECU cannot grant the requested acceleration.
At the same time, the ECU that has indicated the fault
will broadcast a message on the information data link
about what is wrong. On the instrument clusters graphic
display, the fault can then be read as a fault code, either
in plain text or in standard SAE format.
Note that a fault code, whether it is shown in plain text or
in standard SAE format, can only give a rough indication
of the fault. For example, a mechanical fault may produce an engine temperature which exceeds the set limit
(set in the engine ECU). This will generate a fault code
stating that the engine temperature is too high. The
cause of the high engine temperature is not shown by
the fault code alone; symptoms from the vehicle are also
very important to note.
Beyond fault codes, information and stop messages,
there is a great deal of other information to be obtained
via the graphic display. By selecting various menu options the driver can choose which information is to be
shown on the graphic display.

Instrument Cluster
Center Module
MID 140
Vehicle ECU
MID 144
Communication
Connector
*

Engine ECU
MID 128

Anti-lock Brake (ABS) ECU


MID 136
SAE
J1587
/J1708

SAE
J1939
Transmission
MID 130

SRS Airbag ECU


MID 232

Other units
(Expansion capability)

Note: *The Communication Connector in some models


is a 6pin connector, which is connected to the
J1587/J1708 link, but not the J1939. On other models it
is a 9pin connector, which is connected to both the
J1587/J1708 and J1939 links.

20

Group 38 Instrumentation, VN / VHD

Design and Function

Communication with Other ECUs/Sensors


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

Center module
Odometer ..................................................

Self-calculated from road speed and time

Speedometer ...........................................

Vehicle ECU, Volvo engines


Engine ECU, other engines

Tachometer ..............................................

Engine ECU

Left module
Engine oil pressure gauge .......................

Engine ECU

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

Engine ECU

Boost pressure gauge ..............................

Engine ECU

Display ......................................................

All the ECUs

Engine oil temp.

...............................

Engine ECU

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

Transmission sensor

Fuel economy ...................................

Calculated from engine fuel rate and speed

Lamps INFO and STOP ...........................

All the ECUs

Right module
Fuel level gauge .......................................

Electrical sensor (via left module)

Forward and rear rear axle temp .............

Electrical sensor (via left module)

Air suspension pressure gauge ...............

Direct connection

Application air pressure gauge ................

Direct connection

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

Direct connection

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

Direct connection

21

Group 38 Instrumentation, VN / VHD

Design and Function

Warning Lamps, Telltale Lamps and Buzzer


The instrument cluster contains warning and telltale
lamps, both at the bottom of the cluster and integrated
into the gauges, in order to indicate status and warnings.
In the instrument cluster there is also a buzzer which
performs three different functions: flasher indicator, re-

minder and caution. The caution buzzer warns the driver


when a STOP message is displayed or when there are
abnormal measurement values.

Diagnostic Capabilities
The instrument cluster performs a self-test via the instrument clusters electronics, when the ignition key is
turned to the ON position, but a self-test can also be
manually conducted via the menu System diagnostic/instrument cluster test.
In the System diagnostic/instrument cluster test
menu, the graphic display shows diagnostics of the vehi-

Instrument Cluster Lighting


The brightness of the gauges and the graphic display
can be adjusted with an external rheostat on the dash.
In the Set-up menu the degree of brightness between

22

cles various ECUs. See Fault diagnostic page 68.


Here you can select how the fault codes are to be
shown: numerically, as text, or with a time stamp (with
some engines). Fault codes can also be reset, either one
by one, Reset a fault code page 72, or all at the same
time, Reset all the fault codes page 73.

gauge and display can be altered. Even the contrast and


normal or reverse video of the display can be changed
via the Set-up menu, see Main Menu: Set-up mode
(non-driving) page 59.

Group 38 Instrumentation, VN / VHD

Design and Function

Left Instrument Cluster Module (MID 234)


The left module consists of 3 separate components:

A left gauge module

Graphic display

Left CPU board


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

Pyrometer

Engine oil pressure gauge

Engine coolant temperature gauge

Turbo boost pressure gauge


W3004369

Important: Individual gauges or modules in the VN/VHD


instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will

void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be replaced.

23

Group 38 Instrumentation, VN / VHD

Design and Function

Pyrometer
The pyrometer indicates exhaust temperature from a
sensor in the exhaust system.
The pyrometer gauge is an electrical aircore meter
movement driven by the clusters microprocessor. The
microprocessor receives pyrometer sensor input from a
high-temperature thermocouple.
If the pyrometer thermocouple fails, the pointer will move
to one end of the dial or the other, and a fault code will


be logged for loss of data. A reading of 300 F (149 C )
or less indicates an open in the trucks wiring or thermo

couple, and a reading of 1500 F (815 C) or more
indicates a short.

W3003632

Engine oil pressure gauge


This gauge shows the actual oil pressure in the engine.
The pointer must not move down into the red sector
while driving! If the oil pressure disappears, e.g. due to
oil leakage, the engine could be seriously damaged. The
gauge gives a reading when the ignition key is in the ON
position.
The engine oil pressure gauge is an electrical aircore
meter movement that receives its signal from a sender
unit mounted on the engine. The sender unit supplies
data to the Engine ECU which sends engine oil pressure
information to the instrument cluster via the J1587/J1708
information data link.
In the absence of a data signal, the gauge pointer will
move to its minimum reading after a 10 second delay,
and a fault code will be logged for loss of data.
The LED in the lower, right-hand corner lights up when
the engine ECU sends a signal for low oil pressure, no
matter what value is shown on the gauge. The pressure
which activates this LED is engine-dependent (set in the
engine ECU). The measuring range of the gauge is 090
psi.

24

W3003768

Group 38 Instrumentation, VN / VHD

Design and Function

Engine coolant temperature gauge


This gauge shows the temperature in the engines cooling system. The temperature, under normal driving
conditions, must be below the red sector. The gauge
gives a reading when the ignition key is in the ON posi

tion and the coolant temperature exceeds 140 F (60 C).

The measuring range of the gauge is 150230 F.
The coolant temperature gauge is an electrical aircore
meter movement which receives its signal from the engine via the SAE J1587/J1708 information data link. In
the absence of a data signal, the gauge pointer will
move to its minimum reading after a 10 second delay,
and a fault code will be logged for loss of data.

W3003769

The LED in the lower, right-hand corner lights up when


the engine ECU sends a signal for high coolant temperature, no matter what value is shown on the gauge. The
temperature which activates this LED is enginedependent (set in the engine ECU).

Turbo boost (intake manifold) pressure gauge


This gauge shows boost pressure (overpressure in the
intake manifold). When driving with a constant load, the
pointer should be stationary. The boost pressure gauge
can be used together with the speedometer to help the
driver maintain an even speed and even acceleration in
order to minimize fuel consumption. The gauge range is
030 psi.
The turbo boost pressure gauge is an electrical aircore
meter movement driven by a signal from the
J1587/J1708 information data link. In the absence of a
data signal, the gauge pointer will move to its minimum
reading after a 10 second delay, and a fault code will be
logged for loss of data.

W3003631

Telltale bulbs, left section


1

Engine preheat telltale

Caution telltale

Stop telltale

No Charge telltale
W3003645

25

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display
The driver can choose information on the graphic display
by scrolling among the menus that are listed below.
Menus in capital letters are available when driving and
when stationary. Menus in lower case letters are only
available when stationary. For detailed information about
these display menus see Instrument Cluster Operation
at Start-up page 40, Graphic Display Menus, Driving
Mode page 41 and Graphic Display Menus,
Non-Driving Mode page 56.
GAUGE MODE

TEMPERATURE, ENGINE OIL


TEMPERATURE, TRANSMISSION OIL (optional)
VOLTMETER

FUEL ECONOMY

AVG/INST FUEL ECON


LEG FUEL/DISTANCE TO EMPTY

TIME/DISTANCE

CLOCK
Alarm clock
TRIPMETER #1 and #2
AVERAGE SPEED

FAULTS?

FAULTS?

Set-up mode

Language


Miles/ F/USgal or km/ C


Clock format
Contrast
Backlight
Night display
Default language *
Fleet limit: rpm * **
Fleet limit: speed * **
Fleet fuel target * **
Odometer setting *
Fleet id * **
Password config *

System diagnostic (reset faults in this menu)

Fault diagnostic
Cluster self test
Part number
Status test *

Data log mode

Vehicle id **
Totals
Trip data **
Reset trip data * **

Password Input

* Only available when correct password has been given.

26

Enter password

** With Volvo engines only

Group 38 Instrumentation, VN / VHD

Design and Function

Left CPU Board


The left CPU (Central Processing Unit) board contains a
microprocessor that processes various data and sensor
input to the instrument cluster and sends the information
to the appropriate display unit. MID 234 identifies the left
CPU board.
The left CPU board also contains the programming information that makes each instrument cluster unique to the
vehicle it is installed in.
If the instrument cluster or left CPU board is replaced it
must be programmed per the VIN (Vehicle Identification
Number) for proper operation. For programming instructions see Instrument Cluster, Programming page 161.

Automatically Activated Warnings


Information and stop messages are shown automatically
on the display if a fault should occur.

Information Messages

STOP messages

The following functions can activate an information message with symbol in the display:

The following functions can activate a stop message with


symbol in the display:

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

Level, coolant
Oil level, engine (only certain variants and when the
engine is running)
Temperature engine oil
Temperature transmission oil
Engine oil pressure too low
Coolant temp. too high

27

Group 38 Instrumentation, VN / VHD

Design and Function

Center Instrument Cluster Module (MID140)


The center module contains the following:

Tachometer
Speedometer
Odometer

T3010615

Important: Individual gauges or modules in the VN/VHD


instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
gauges or modules during the warranty period will

28

void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be replaced.

Group 38 Instrumentation, VN / VHD

Design and Function

Center Module ECU (MID 140)


Signals from the J1587/J1708 information data link are
processed in the center module ECU, which controls the
tachometer and the speedometer. The ECU also controls the activation of different sounds, e.g. indicator for
direction indicators and warning.
The center module ECU receives signals from the other
two modules of the instrument cluster, from directly connected components and via the J1587/J1708 information
data link.

Tachometer
The tachometer is an electrical air core meter movement
driven by signals from the engine (MID 128) via the
J1587/J1708 information data link. In the absence of
data link information, the gauge pointer will move to its
minimum reading after a 10 second delay. The gauge
range is 02800 r/min.

W3003639

29

Group 38 Instrumentation, VN / VHD

Design and Function

Speedometer
The speedometer is an electrical air core meter movement driven by signals from the SAE J1587/J1708
information data link. In the absence of data link information, the gauge pointer will move to its minimum reading
after a 10 second delay. Note that the cluster does not
perform speedometer calibration. Speedometer calibration to compensate for tire sizes and other driveline
changes is done during programming of the engine
ECU, vehicle ECU or transmission ECU.
The speed signal is sent to the center module ECU either from the vehicle ECU (MID 144) or the engine ECU
(MID 128) depending on the engine manufacturer:
W3003640

The speed signal is sent from the vehicle ECU via


the J1587/J1708 information data link if the vehicle
is equipped with a Volvo engine.

The speed signal is sent from the engine ECU via


the J1587/J1708 information data link if the vehicle
is equipped with a Cummins or Detroit Diesel engine.

The speedometer is also available in a version with the


graduation km/h as the main scale.
Measuring range .......................

0-80 mph
(0-120 km/h)

Odometer
The odometer is a Liquid Crystal Display (LCD) mounted
behind the speedometer dial. It has a full scale reading
of 999999.9. Odometer information is calculated from
road speed via the J1587/J1708 information data link
and is stored in the clusters microprocessor.
The odometer backlighting can be adjusted independently of gauge backlighting, via the menu Setup
mode in the graphic display.
During normal operation, the odometer display goes
blank 30 seconds after the ignition is switched off. To reactivate the display, turn the ignition on or press any of
the control buttons on the wiper stalk switch.
In the absence of speedometer data, the odometer display will not change and the speedometer pointer will
remain at zero.
The odometer value can be displayed either in miles or
km. The unit selection is accessed via the menu Set-up
mode in the graphic display in the left module. The actual unit of measurement is indicated by the annunciator
miles and km, respectively, above the mileage value.
If the instrument cluster or center module are replaced,
the odometer may be programmed to reflect the actual
vehicle miles. For programming instruction see
Odometer, Programming page 162.
30

Group 38 Instrumentation, VN / VHD

Design and Function

Telltale bulbs, center section

W3003646

1
2
3
4
5
6
7

Left Turn Indicator


5th Wheel Lock Indicator
Wheel Differential Lock Indicator
Interaxle Differential Lock Indicator
High Beam Indicator
Safety Belt Indicator
Parking Brake Indicator

8
9
10
11
12

Anti-Lock Brake System (Tractor) Indicator


Anti-Lock Brake System (Trailer) Indicator
Air Suspension System Indicator
Mirror Defroster Indicator
Right Turn Indicator

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

Master Warning telltale


A red Master Warning telltale consisting of an exclamation mark (!) 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 (496 kPa)).
W3000638

31

Group 38 Instrumentation, VN / VHD

Design and Function

Right Instrument Cluster Module


Note: The gauges and their positioning vary depending
on the truck variant, engine variant and the selection of
extra equipment.
The right module has space for the following:

Forward rear axle temperature gauge


Rear rear axle temperature gauge
Fuel level gauge
Application air pressure gauge
Air suspension pressure gauge
Front brake air pressure gauge
Rear brake air pressure gauge

Important: Individual gauges or modules in the VN/VHD


instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
gauges or modules during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be
replaced.

32

W3004301

Group 38 Instrumentation, VN / VHD

Design and Function

Forward rear axle temperature gauge


The forward rear axle temperature gauge is an electrical
aircore meter movement. It is connected to a temperature sender unit mounted on the axle housing. The
higher the temperature, the lower the resistance of the
sender unit. The sender signal is input to the microprocessor in the left module. In the microprocessor the
signal is changed to a pulse width modulated (PWM)
signal. The PWM signal is sent to the gauge via a wire.


The gauge range is 90310 F. If the range is exceeded,


a fault is logged.
W3003634

Rear rear axle temperature gauge


The rear rear axle temperature gauge is an electrical aircore meter movement. It is connected to a temperature
sender unit mounted on the axle housing. The higher the
temperature, the lower the resistance of the sender unit.
The sender signal is input to the microprocessor in the
left module. In the microprocessor the signal is changed
to a pulse width modulated (PWM) signal. The PWM signal is sent to the gauge via a wire.


The gauge range is 90310 F. If the range is exceeded,


a fault is logged.
W3003635

Fuel level gauge


This gauge shows the approximate amount of fuel in the
tank. The red sector indicates that it is time to refuel.
The gauge gives a reading when the ignition key is in
the ON position.
The fuel level gauge is an electrical aircore meter movement that receives its signal from a sensor in the fuel
tank.
The fuel level sensor signal is input to the cluster microprocessor. In the microprocessor the signal is changed
from a resistance to a pulse width modulated (PWM) signal. As the duty cycle of the signal increases, the level
shown on the gauge increases. If the operating range of
the gauge is exceeded, a fault is logged.

W3003628

33

Group 38 Instrumentation, VN / VHD

Design and Function

Application air pressure gauge


The application air pressure gauge is a mechanical
(Bourdon tube) gauge. It is attached to the service 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 quickdisconnects are color-coded to avoid wrong connections.
The gauge range is 0150 psi.

W3004302

Air suspension pressure gauge


This gauge shows the pressure in the air suspension
system. The vehicle must not be driven when the pointer
is in the red sector.
The air suspension pressure gauge is a mechanical
(Bourdon tube) gauge. It is attached to the air suspension system by a hose going into a quick-disconnect
fitting on the rear of the gauge. The air hoses and quickdisconnects are color-coded to avoid wrong connections.
The gauge range is 0100 psi.
W3003633

34

Group 38 Instrumentation, VN / VHD

Design and Function

Front brake air pressure gauge


This gauge shows the air pressure in the front brake circuit. The air pressure gauges are mechanical (Bourdon
tube) 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 vehicle
must not be driven when the pointer is in the red sector.
The LED in the lower, right-hand corner lights up when
the air pressure in the front brake circuit falls below 72
psi. The Master Warning indicator will also light. The
Master Warning indicator is supplied air pressure information via a wire going from the right to the center
module.

W3003637

Rear brake air pressure gauge


This gauge shows the air pressure in the rear brake circuit. The air pressure gauges are mechanical (Bourdon
tube) 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 vehicle
must not be driven when the pointer is in the red sector.
The LED in the lower, right-hand corner lights up when
the air pressure in the rear brake circuit falls below 72
psi. The Master Warning indicator will also light. The
Master Warning indicator is supplied air pressure information via a wire going from the right to the center
module.

W3003638

Telltale bulbs, right section


1

Transmission Temperature

Check Transmission

Traction Control System

Wait Start Engine2

Automatic Neutral

Water in Fuel2

W3004416

Not applicable to all models.

35

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display
The graphic display in the lower left-hand corner of the
instrument cluster is used to present information to the
driver, both when driving and when the vehicle is stationary. The graphic display replaces certain conventional
gauges, telltale and warning lamps. It is standard equipment in all versions of the instrument cluster.
The information can be divided into two groups:
Preselected Information:
The driver himself chooses what is to be shown. This includes the clock, gauges, etc.
Automatically Generated Information:
Information and stop messages are shown automatically
on the graphic display at the same time as a yellow lamp
( INFO) or red lamp ( STOP) lights up at the bottom of
the display. A fault code is also logged, and can be
viewed in the FAULTS menu.

The seriousness of the fault determines which lamp is lit.


Information and stop messages, shown during vehicle
operation, require immediate action by the driver.

When the red ( STOP) lamp lights up and the engine is


running, a buzzer is also activated.

T3008860

T3008861

The section Main Menu: FAULTS? (available while driving) page 49 gives a more general description of fault
messages. To see more details about information and
stop messages see Fault diagnostic page 68.
The information available for the driver is different depending on whether the vehicle is being driven or is
stationary.
Driving = speed above 5 mph (8 km/h) (see Graphic
Display Menus, Driving Mode page 41).
NonDriving = speed under 5 mph (8 km/h) (see
Graphic Display Menus, Non-Driving Mode page 56).
Concerning various symbols used in the display, see
Graphic Display Symbols page 37, Information Messages (with Icons) page 51 and Stop Messages (with
Icons) page 55.

36

Graphic Display Layout


Menu
symbol

TEXTFIELD

Status
symbol

The display window is divided into three fields where the


field to the far left shows a symbol in conjunction with
certain messages.
The field in the center displays all the text and some
symbols, and the right-hand field shows the status symbols for the various functions. The status symbols are to
warn the driver about which functions are active at
present. A total of four symbols can be shown in the
right-hand field at the same time. See Graphic Display
Symbols page 37 for more information.

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display Symbols

W3004312

Voltmeter
(see Voltmeter page 44 for
more information)

PTO engaged

Cruise Control engaged

Engine oil temperature


(see Temperature, engine oil
page 42 for more information)

Airbag

14 Overheating, instrument cluster


(see Information Messages
(with Icons) page 51 for more information)
15 Fault in the pre-heating

10 Coolant level
16 Engine oil pressure

Transmission oil temperature


(see Temperature, transmission
oil (option) page 43 for more information)

11 Washer fluid level


(see Information Messages
(with Icons) page 51 for more information)

Pre-heating active

Acknowledged warning
(see Acknowledge Information
and Stop Messages page 50 for
more information)

12 Air filter, clogged


(see Information Messages
(with Icons) page 51 for more information)

Alarm clock on
(see Alarm clock page 57 for
more information)

17 Coolant temperature

13 Too cold for engine brake (VEB)


(see Information Messages
(with Icons) page 51 for more
information)

37

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display Control Buttons


In order to manually interact with the graphic display, the
wiper stalk switch on the right-hand side of the steering
wheel is used.
The following commands are available:
1

Esc (Escape) is used to return to the previous


menu and cancel a setting/operation.

or SELECT confirms a highlighted selection of


a menu or character.

Up arrow moves the cursor up and is used when


setting numerical values.

Down arrow moves the cursor down and is used


when setting numerical values.

T3008810

Using the Graphic Display Menus


Selecting a Menu
1

Use the up/down buttons to move to a particular


menu, which is then highlighted. An up or down arrow on the right side shows whether there are any
more menus available. If this is the case you can
continue to step down through the list (see the adjacent example).

confirms the choice.

Pressing

Pressing ESC exits the chosen menu. By pressing


Esc repeatedly the cursor is moved successively
back to the main menus.

Changing Settings
1

The up/down buttons increase or reduce the set


values (e.g. hours and minutes in the adjacent example).

confirms the choice.

Pressing

If there are several settings to change in the same


menu, move to the next setting using the up/down
buttons (e.g. the selection between ON, OFF and
SET in the adjacent example).

Esc moves the highlighted area to the previous


number or selection, if there is one. Otherwise the
setting is cancelled.

38

"
"

Set-up mode
System diagnostic
Data log mode

Password Input

ALARM

08:20

CLOCK

08:00

ON

OFF

SET

Group 38 Instrumentation, VN / VHD

Password Information
Certain functions are protected by a password. For the
display there are two passwords (or the alternative of
choosing not to have any password protection):
1

The mechanic password

The owner password

Both these passwords give the user access to all password protected functions with one exception:
The mechanics password does not give access to the
password configuration, i.e. with this you cannot change
either the mechanics nor the owners passwords.
See Change password page 67 to change the password.

The following menus are protected by passwords:

Default language
Fleet limit: rpm

Design and Function

Fleet limit: speed


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

When the ignition key has been in the off position for
more than 60 seconds or when the batteries have been
disconnected the password must be entered again to access password-protected functions.
See Main Menu: Password Input (non-driving) page 86
in order to enter your password.
No password protected functions: Owner/Operator
Mode
For all menus to be available, you must go to the menu
Password Input and press . The text Access Granted
is then shown instead of Password.

39

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display Operation


The three sections Instrument Cluster Operation at
Start-up page 40, Graphic Display Menus, Driving
Mode page 41 and Graphic Display Menus,
Non-Driving Mode page 56 give a presentation of the
display functions.

Instrument Cluster Operation at Start-up


Key ON
The following occurs automatically when the ignition key
is turned to the ON position:

Bulb test for approximately 35 seconds.


Other bulbs may remain on due to other components, such as the ABS or preheat.
Gauges return to zero or go to their appropriate position (for example, if the axles are still warm from
driving the axle temperature gauges would show a
reading).

After 10 Seconds
After 10 seconds, if all functions are working properly,
the cluster will act normally.
If there is a fault in one of the gauges in the graphic display, the cluster will show the fault in the graphic display.
If the ignition key has been in the off position, what was
on the display before the ignition was turned off is
shown. (If the battery has been disconnected and reconnected, a flashing clock display is shown instead.)
During Normal Operation

If a telltale light is on other than INFO or STOP, a device other than the cluster has activated it.

If the INFO or STOP light is on, but there is no icon


in the display, a device other than the cluster has activated it.

40

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display Menus, Driving Mode


For a description of how the display is operated see
Graphic Display Control Buttons page 38.
By driving it is meant that the vehicle speed exceeds 5
mph (8km/h).

Esc leaves a chosen menu and by repeated


pressing of Esc the main menu, shown at right,
is obtained. This presupposes that no fault code
is active. The arrows indicate how to go between
the various menus.

If the menu FUEL ECONOMY is not included,


the menu FAULTS? is under the menu
TIME/DISTANCE.

When the fault messages are acknowledged using Esc, you are shown the menu FAULTS?

GAUGE

FUEL ECONOMY
TIME/DIST
FAULTS?

"#

"#

"#

GAUGE

FUEL ECONOMY (option)

TIME/DIST

TEMPERATURE,
ENGINE OIL

"#
TEMPERATURE,
TRANSMISSION OIL (option)

"#

VOLTMETER

"#

AVG/INST FUEL

CLOCK

"#
LEG FUEL/DTE

"#

"#
Alarm clock

"#
TRIPMETER #1 and #2

"#
AVERAGE SPEED

"#

41

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: Gauge (available while driving)


When the menu GAUGE has been selected, you switch
between the various sub-menus with the up/down
buttons.

TEMPERATURE, ENGINE OIL


TEMPERATURE, TRANSMISSION OIL
(Option)
VOLTMETER

Temperature, engine oil


MENU: GAUGE, TEMPERATURE ENGINE OIL
The engines oil temperature is shown as in the diagram.
T3008830

185 F

T3008830

NO
DATA

T3008830

HIGH

280 F

If the sensor data for Temperature, engine oil is not


available, the symbol is shown as well as the text NO
DATA.
Action:

Do a diagnostics test on the display and engine, see


Fault diagnostic page 68.

Information message
Yellow

1INFO lamp

If the engine oil temperature becomes too high an information message is shown automatically with the text
HIGH. At the same time the yellow INFO lamp under
the display lights up. The engine may also derate, if it is
set up to do so in the engine ECU programming. The
temperature which activates this warning varies for different engines. This temperature is set in the engine ECU.


For Volvo engines, it is 275 F (135 C).

Esc acknowledges the information message, which


means that the warning becomes an icon in the displays
upper right hand corner, and normal display functions
are available.

42

T3008860

Group 38 Instrumentation, VN / VHD

Design and Function

Temperature, transmission oil (option)


MENU: GAUGE, TEMPERATURE, TRANSMISSION OIL
The transmissions oil temperature is shown as in the diagram.
T3008831

170 F

If the sensor data for Transmission oil temperature is


not available, the symbol is shown as well as the text NO
DATA.
Action:

Do a diagnostics test on the display, see Fault diagnostic page 68.

T3008831

NO
DATA

Information message
Yellow

1INFO lamp

If the temperature of the transmission oil becomes too


high, an information message is shown automatically
with the text HIGH. At the same time the yellow INFO
lamp under the display lights up. Esc acknowledges the
information message, which means that the warning becomes an icon in the displays upper right hand corner,
and normal display functions are available.

T3008831

HIGH

250 F

For HIGH to display with the INFO lamp, the transmis



sion oil temperature must be 210 F (100 C) for 30


minutes, or 250 F (120 C) for 10 minutes.
T3008860

Stop message
Red stop lamp
If the temperature of the transmission oil becomes too
high, a flashing stop message is shown automatically
with the text TOO HIGH. At the same time the red
STOP lamp under the display lights up and the warning signal sounds. Esc acknowledges the stop message.

T3008831

TOO HIGH

285 F

For TOO HIGH to display with the STOP lamp, the




transmission oil temperature must be 285 F (140 C) for
30 seconds.

T3008861

43

Group 38 Instrumentation, VN / VHD

Design and Function

Voltmeter
MENU: GAUGE, VOLTMETER
The battery/charging voltage is shown as in the diagram.
If the battery/charging voltage becomes too low (below
9.5 V), the instrument cluster will lose power.

T3008832

13.1 V

T3008832

TOO HIGH
17.9 V

Information message
Yellow information lamp
If the battery/charging voltage becomes too high, the
voltmeters value is shown automatically as well as the
text TOO HIGH. At the same time the yellow information
lamp under the display lights up.

T3008860

44

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: Fuel Economy (available while driving)


Menu FUEL ECONOMY has 2 sub-menus:

AVG/INST
LEG FUEL/DTE

FUEL ECONOMY is chosen and then the up/down buttons are used in order to change between the available
sub-menus.

AVG/INST Fuel Economy


MENU: FUEL ECONOMY, AVG/INST


For setting metric or English scales, see Miles/ F/USgal



or km/ C page 60.
The following is shown on the display:

Average trip fuel consumption (AVG):


The value is presented numerically and as an arrow
above the bar. The arrows position shows the value.
For a short time after resetting the following is shown
instead of the average fuel consumption.

Instantaneous fuel consumption (INST):


The value is presented numerically as well as in the
form of a bar.

Target trip fuel consumption (TARGET):


The value is presented as an arrow under the bar.
The arrows position shows the value. For information about how this value is set, see Fleet Fuel
Target page 65.

Reset fuel economy


1 Press in the menu AVG/INST.
2

A new text message in the form of a question is


shown:
RESET FUEL DATA? Press to reset.

When the legs fuel consumption is reset, the average


fuel consumption will also be reset.

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

AVG 9.9
INST 8.0

TARGET

mpg

"

Note: If km and C have been selected the consumption


is shown in liters. In the example above, L/100 km will
then be shown instead of mpg.

RESET
FUEL DATA?
PRESS FOR 1S

45

Group 38 Instrumentation, VN / VHD

Leg Fuel/Distance to Empty


MENU: FUEL ECONOMY, LEG FUEL
Press the up/down buttons in the menu AVG/INST to
reach the menu LEG FUEL.
The following is shown in the menu LEG FUEL on the
display:

The Leg fuel consumption (amount of fuel used


since the last resetting).

Distance to Empty XXX mi (where XXX is the calculated range using the present instantaneous
consumption).

Design and Function

Note: If km and C have been selected, the consumption


is shown in liters. In the example below, L will then be
shown instead of USg.

LEG FUEL
___
EMPTY _ _ mi

Note: Since the calculated range is based on the instantaneous consumption, the correct value is first
shown shortly after start.

46

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: Time/Distance (available when driving)


Menu TIME/DIST has 4 sub-menus.

CLOCK
ALARM CLOCK
TRIPMETER
AVERAGE SPEED

Note: Menu TIME/DIST is available even when the ignition key is in the off position. It is activated by keeping
one of the control buttons on the wiper stalk pressed
down for at least 1 second. The menu remains active for
30 seconds after the last depressing of the button.
The alarm clock cannot be set while driving, but the
buzzer which sounds for the alarm call can be switched
off. See Switch off the alarm clock page 58.

Clock
MENU: TIME/DIST, CLOCK
Shows the current time. To set the time format 12h or
24h, see Clock format page 60.

Setting
1

To set the clock press when you are in the menu


TIME/DISTANCE and the clock function will be
shown.

Set the hours with the up/down buttons. Confirm the


choice with .

Set the first digit in the minutes with the up/down


buttons. Confirm the choice with .

Set the second digit in the minutes with the up/down


buttons. Confirm the choice with .

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

12:00

Cancel setting
When setting hours Esc cancels the setting and the time
is shown according to the previous setting.
Esc after setting the minutes as well as after setting the
AM/PM moves the cursor back to the previous selection.

Ignition key in the off position


If setting the clock when the ignition key is in the OFF position takes more than 30 seconds between pushing the
buttons, the time which has been entered then applies.

47

Group 38 Instrumentation, VN / VHD

Design and Function

Tripmeter
MENU: TIME/DIST, TRIPMETER
On the display in the menu tripmeter the distance driven
for Leg 1 and Leg 2 are shown.

TRIP
#1

43.6 mi

#2

507.3 mi

Reset tripmeter
1 Press in the menu TRIPMETER.
2

A new text message with a question about the resetting of the tripmeter is shown. The up/down
buttons move the cursor between Leg 1 and Leg 2.
Confirm the choice with or press Esc in order to
cancel the resetting.

RESET?
#1:

#2:

PRESS FOR 1S

Average speed
MENU: TIME/DIST, AVERAGE SPEED
The average speed is calculated using the distance
driven divided by the time the engine has been running
(since the last resetting).

AVERAGE
SPEED
55.4 mph

Reset average speed


1 Press when the menu AVERAGE SPEED is
shown.
2

48

A new text message with a question about the resetting of the average speed is shown. Confirm the
choice with or press Esc in order to cancel the
resetting.

RESET?
PRESS FOR 1S

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: FAULTS? (available while driving)


General
When a fault occurs a fault message is shown on the
graphic display. There are two types of fault messages:
1

Information messages

Stop messages

The stop message is always more urgent than information messages.


Any information and stop messages as well as the associated symbols are shown automatically on the graphic
display when driving. A summary of these symbols is
shown in the illustration under Graphic Display Symbols page 37. Under the display there are two lamps (a
yellow INFO lamp and a red STOP lamp) that attract
the drivers attention when necessary. When the red
( STOP) lamp lights up and the engine is running, a
warning signal is also activated.

Several messages may be active at the same time.


When a new message is activated the new one is shown
instead of the old one.
A down or up arrow on the graphic displays right side
means that more messages are active.

Information message

The yellow INFO lamp lights up when an abnormal


state or a risk situation is indicated. In addition to the
lamp, a symbol or text is shown on the graphic display at
the same time. For certain symbols, a measurement
value is also shown.

T3008860

Note: In the event of a warning for low air pressure no


message is shown on the graphic display, the LED in the
gauge and the Master Warning light illuminates instead.

Important: When the INFO lamp lights up, the specified fault must be checked at the next stop.

Stop message

In the event of serious faults, the red STOP lamp lights


up and a buzzer sounds (if the engine is running). In addition to the lamp, a symbol or text is shown on the
graphic display at the same time. For certain symbols, a
measurement value is also shown.

T3008861

Failure to take the necessary action when the STOP


telltale lamp is on can ultimately result in automatic
engine shutdown and loss of power steering assist. A
vehicle crash resulting in personal injury or death can
occur. Bring the vehicle to a safe stop where the problem can be checked.
49

Group 38 Instrumentation, VN / VHD

Design and Function

Acknowledge Information and Stop Messages


By pressing Esc you can override the fault message, and
the graphic display returns to the same status as before
the error occurred. An acknowledged fault message is
shown as a symbol on the right in the graphic display
window. All types of fault messages can be acknowledged. Acknowledged but active messages are shown
again when the ignition key is turned to the start position.

Yellow INFO lamp: The text message, yellow lamp


and the symbol can be acknowledged using Esc. This
warning is acknowledged until the next time the ignition
key is turned to the start position.
Exceptions: The message can be shown again if the
fault is de-activated and then becomes active again.
Example: If the engine oil temperature becomes too high
a message is activated automatically. The driver acknowledges this message using Esc. If the temperature
then drops to a normal level but then becomes too high
again the warning is activated again.

Red STOP lamp: The buzzer, text message and the


symbol can be acknowledged using Esc, but are active
again 10 seconds after pressing the button. The red
lamp remains lit the whole time.

Recall
An acknowledged fault message can be recalled, i.e. be
shown on the graphic display again.
MENU: FAULTS?
1

confirms the choice of the menu FAULTS? The

last acknowledged fault message is shown. If there


is more than one message, a down arrow is shown
in the right-hand corner.

The up/down buttons move the cursor between the


current messages.

If an acknowledged fault message is still active at the


next occasion the ignition key is turned to the ON position this is shown as a non-acknowledged message. NO
FAULTS is shown if there are no fault messages.

50

T3008852

Group 38 Instrumentation, VN / VHD

Design and Function

Information Messages (with Icons)

The yellow INFO lamp lights up and a symbol is shown


on the graphic display.

Airbag

Warning, transmission oil temperature

In the event of a problem in the


SRS system, a telltale shows
on the graphic display in the instrument cluster. This telltale,
together with other telltales in
the cluster, also light up when
the engine is started. The
telltale should go out after approximately 10 seconds when
the starting key has been
turned to the drive position.

If the temperature of the transmission oil becomes too high,


an information message is
shown automatically with the
text HIGH. The information
message will come on when

the transmission oil is 250 F

(120 C) for 10 minutes, or


210 F (100 C) for 30 minutes.
The temperature is displayed
along with the symbol. Note:
The transmission oil temperature will also generate a STOP
message (see Stop Messages
(with Icons) page 55).

T3008842

If a problem develops in the


INFO telltale will
system, the
come on together with the SRS
telltale.

T3008831

Warning, voltmeter
CAUTION
The vehicle should be taken to an authorized Volvo
Truck dealer immediately if the SRS telltale stays
on or lights up when the vehicle is being driven.

If the battery voltage becomes


too high, the voltmeters value
is shown automatically as well
as the text TOO HIGH. This
warning is triggered at 17 V.
The voltage is displayed along
with the symbol.

T3008832

Overheating, instruments

Warning, engine oil temperature

The symbol will be shown when


the temperature in the instru
ment cluster exceeds 92 C

(198 F). The instrument lighting
becomes weaker and the
gauges show the minimum
reading. When the cab temperature cools the instrument
cluster functions will gradually
be restored.

If the engine oil temperature


becomes too high, an INFO
message is shown automatically with the text HIGH. The
engine may derate, if it is set up
to do so in the engine ECU programming. The temperature
which activates this warning
varies for different engines. This
temperature is set in the engine
ECU. For Volvo engines, it is


275 F (135 C).

T3008840

Level, washer fluid


The symbol is shown when
there are approx. 1.4 gallons
(5.3 liters) of fluid remaining in
the reservoir.

T3008830

T3008838

51

Group 38 Instrumentation, VN / VHD

Design and Function

Air filter, clogged


This symbol is shown when the
air filter sensor is restricted.
T3008843

Too cold for engine brake (VEB)


(Volvo engine only)
Position 2 on the switch must
not be engaged before the engine has reached operational
temperature. If position 2 is engaged and the engine is too
cold this symbol is shown and a
signal sounds when engine
braking is carried out (VEB is
not engaged).

T3009913

Fault in the pre-heating


Volvo engines have a unique
cold start feature. Depending
on the ambient temperature, the
engine cranks two to four turns
without injecting fuel. The light
will be engaged between 0 and
50 seconds while pre-heating.

52

T3008841

Group 38 Instrumentation, VN / VHD

Design and Function

Information Messages (Text and Lamp Only)


The yellow lamp lights up and a message is shown on
the graphic display (for more information about faults see
Fault diagnostic page 68). The text contains information
regarding where the fault has occurred as well as the
fault type (applies to the data link).

Broken data link:

CHECK
DATA LINK

Each ECU is identified by a MID number (Message


IDentifier).

ABS Brakes, MID 136


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

Factory installed equipment:

CHECK

BROKEN

T3008860

Equipment not installed at factory:


If the bodybuilders or the customer have installed equipment afterwards which has been connected to the data
link, the following can be shown:
MID (Message IDentifier) = electronic control unit (ECU)

ENGINE
NEXT STOP

CHECK
ERROR IN
MID 140

T3008860

Specific data link fault:

CHECK

T3008860

ENGINE
DATA LINK

T3008860

53

Group 38 Instrumentation, VN / VHD

Design and Function

Stop Messages (Text and Lamp Only)

The red STOP lamp lights up and a flashing message


is shown on the graphic display (for more information
about faults see Fault diagnostic page 68). A warning
signal sounds if the engine is running. The text contains
information about where the fault has occurred.

Each ECU is identified by a MID number (Message


IDentifier).

ABS Brakes, MID 136


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

Factory installed equipment:

STOP!
ENGINE
FAULT

T3008861

Equipment not installed at factory:

Failure to take the necessary action when the STOP


telltale lamp is on can ultimately result in automatic
engine shutdown and loss of power steering assist. A
vehicle crash resulting in personal injury or death can
occur. Bring the vehicle to a safe stop where the problem can be checked.

If the bodybuilders or the customer have installed equipment afterwards which has been connected to the data
link, the following can be shown:
MID (Message IDentifier) = electronic control unit

STOP!
ERROR IN
MID 144

T3008861

54

Group 38 Instrumentation, VN / VHD

Design and Function

Stop Messages (with Icons)

The red STOP lamp lights up and a symbol (and in


some cases a value) are shown on the graphic display.
A warning signal sounds if the engine is running.

Failure to take the necessary action when the STOP


telltale lamp is on can ultimately result in automatic
engine shutdown and loss of power steering assist. A
vehicle crash resulting in personal injury or death can
occur. Bring the vehicle to a safe stop where the problem can be checked.

Warning, transmission oil temperature


If the transmission oil temperature becomes too high the
STOP lamp lights up and the transmission oil temperature icon displays with the text TOO HIGH. This warning

will come on when the oil temperature has been 285 F

(140 C) for 30 sec. Note: a high transmission oil temp.
can instead cause an information message to display
(see Information Messages (with Icons) page 51).

T3008831

TOO HIGH

285 F

T3008861

Warning, engine oil pressure

If the engine oil pressure becomes too low the STOP


lamp lights up and the oil pressure icon is shown in the
display. This warning will come on when the oil pressure
falls below the trip point set in the engine ECU (see
respective engine service information). A forced idle condition or an engine shutdown may accompany this
warning, if programmed to do so in the engine ECU.

W3003613

T3008861

Warning, coolant temperature


If the engine coolant temperature becomes too high the
STOP lamp lights up and the coolant temperature icon
is shown in the graphic display. This warning will come
on when the temperature exceeds the trip point set in
the engine ECU (see respective engine service informa
tion). For the Volvo engine the trip point is 215 F

(102 C). An engine torque derate may accompany this
warning, if programmed to do so in the engine ECU.

W3003614

T3008861

55

Group 38 Instrumentation, VN / VHD

Design and Function

Graphic Display Menus, Non-Driving Mode


This chapter describes the graphic displays function
while the vehicle is stationary and for speeds under 5
mph (8 km/h). Several non-driving sub-menus are protected by password.

sec. has elapsed since the last time the ignition key was
in the ON position). See Main Menu: Password Input
(non-driving) page 86.
While the vehicle is stationary, there are 5 main menus in
addition to the drive menus. The drive menus are shown in
capitals in the following table (the menu TIME/DISTANCE
has one additional function while the vehicle is stationary).

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

GAUGE
FUEL ECONOMY (option)

TIME/DIST
FAULTS?

"#

Set-up mode
System diagnostic
Data log mode
Password Input

"#

"#

Set-up mode

System diagnostic

Mi/ F/USgal or km/ C

Cluster self test

Data log mode


Vehicle id (Volvo engine
only)
Totals

Clock format

Part number

Trip data (Volvo engine only)

Language


!! Fault diagnostic
"#

Contrast
Backlight

Password

Night display

Status test

"#

Password
Default language
Fleet limit: rpm (Volvo engine only)
Fleet limit: speed (Volvo
engine only)
Fleet fuel target (Volvo
engine only)
Password config.
Odometer setting (N/A)
Fleet ID (Volvo engine
only)

"#

56

"#
!

"#

Password

"#

Reset trip data

"#

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: Time/Distance (non-driving)


Menu TIME/DIST has 1 additional sub-menu while not
driving:

ALARM CLOCK

Note: This menu is available even when the ignition key


is in the OFF position. It is activated by pressing any of
the control buttons on the wiper stalk for at least 1 second. The menu remains active for 30 seconds after
pressing the button.

Alarm clock
MENU: TIME/DIST, ALARM CLOCK

Setting the alarm clock:


1

To set the alarm clock press when the menu


ALARM CLOCK is shown in the menu TIME/DIST.

Move the cursor to SET using the up/down buttons.


Press .

ALARM
CLOCK
ON

Set the AM/PM (if the format is 12h) with the


up/down buttons. Confirm the choice with .

Move the cursor to ON using the up/down buttons.


Press . A symbol is shown on the right in the
graphic display windows status bar in order to highlight that the alarm clock is activated.

08:30 AM
08:00 AM
OFF SET

If the speed during the setting exceeds 5 mph


(8km/h), the function is cancelled and the graphic
display returns to the last active display in the ON
position.
3

Set the hours with the up/down buttons. Confirm the


choice with .

Set the first digit in the minutes with the up/down


buttons. Confirm the choice with .

Set the second digit in the minutes with the up/down


buttons. Confirm the choice with .

T3008833

Esc moves the highlight to the previous number or


selection if there are any, otherwise the setting is
cancelled.

Ignition key in the off position


If setting the alarm clock when the ignition key is in the
OFF position takes more than 30 seconds, the time
which has been entered then applies.

57

Group 38 Instrumentation, VN / VHD

Design and Function

Switch off the alarm clock


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

Activate alarm clock (without changing the time of the alarm call)
1

The cursor is moved with the up/down buttons to


ON.

activates the alarm clock and the symbol is

shown on the graphic display.

Cancel setting

ALARM

08:30

AM
T3008833

CLOCK
ON

08:00 AM
OFF SET

ALARM
CLOCK
ON

08:30
08:00
OFF

Press Esc in order to cancel the setting.

De-activate the alarm clock


1

The cursor is moved with the up/down buttons to


OFF.

switches off the alarm clock and the symbol disappears from the graphic display.

Cancel setting
Press Esc in order to cancel the setting.

58

AM
AM
SET

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: Set-up mode (non-driving)


The menu Set-up mode has 14 sub-menus where 6 are
not protected by passwords and 8 are protected by
passwords.

Language


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

Password is required:

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

Language
MENU: Set-up mode, Language
This setting of language applies until vehicle battery
power is disconnected. To change the language permanently, see Default Language page 62.
1

To set the desired language press when you are


in the menu Set-up mode, Language.

On the graphic display up to three different languages will now be shown. Select the desired
language by moving the cursor to the particular row.
Confirm the choice with .

Cancel setting
Press Esc in order to cancel the setting.

59

Group 38 Instrumentation, VN / VHD

Design and Function

Miles/ F/USgal or km/ C


MENU: Set-up mode, Mi/F/USgal or km/C
Note: If Miles and Fahrenheit are chosen, the fuel consumption is shown in US gallons.
1

Select the menu Set-up mode, Mi/F/USgal or km/C


and the following diagram is shown on the graphic
display (with the particular setting highlighted):

When km and C are chosen the following is shown


on the graphic display (with the particular setting
highlighted):

Select


fuel data unit

km and C


km/l

Mi/USgal and F

The up/down buttons move the cursor between the


alternatives.
2

Confirm the choice with

Cancel setting
Press Esc in order to cancel the setting.

Clock format
MENU: Set-up mode, Clock format
1

Select the menu Set-up mode, Clock format and


the following diagram is shown on the graphic display (with the particular setting highlighted):

AM/PM
24 h

The up/down buttons move the cursor between the


alternatives. Confirm the choice with .
AM/PM is the 12 hour display (AM = morning and
PM = evening).

Cancel setting
Press Esc in order to cancel the setting.

60

l/100 km

The up/down buttons move the cursor between the


alternatives.
4

Confirm the choice with

Group 38 Instrumentation, VN / VHD

Design and Function

Contrast
MENU: Set-up mode, Contrast
1

Select the menu Contrast and the following diagram


is shown on the graphic display. The bar shows the
particular setting in relation to max/min. contrast:

Adjust contrast

+ increases the contrast.


reduces the contrast.
2

Confirm the choice with

Cancel setting
Press Esc in order to cancel the setting.

Backlight
MENU: Set-up mode, Backlight
The graphic displays brightness is controlled by the
dimmer rheostat setting (which also controls the other instrument cluster lighting). In this menu, the display
lighting can be altered in relation to the other instrument
cluster lighting.
1

Adjust lighting

Select the menu Backlight and the following diagram is shown on the graphic display. The bar shows
the particular setting in relation to max/min. lighting:
the up arrow button increases the background lighting.
the down arrow button reduces the background
lighting.

Confirm the choice with

Cancel setting
Press Esc in order to cancel the setting.

61

Group 38 Instrumentation, VN / VHD

Design and Function

Night display
MENU: Set-up mode, Night display
1

Select the menu Night display and the following diagram is shown on the display:

Night display

With the up/down buttons the setting switches


between Normal and Reverse. With the setting Normal the text is dark and the background light. The
setting Reverse makes the text light and the background dark. This setting only applies when the
headlights or parking lights are on, and helps to
stop glare on light bleed-through at night.

Normal

Confirm the choice with

Cancel setting
Press Esc in order to cancel the setting.

Default Language
MENU: Set-up mode, Default language
Only available when the correct password has been
given.
This setting of the language is kept even when battery
power is lost. See also Language page 59 for more information about setting the language.
1

To set the desired language press when you are


in the menu Set-up mode, Default language.

On the graphic display, up to three different languages will be shown. Select the desired language
by moving the cursor to the particular row. Confirm
the choice with .

Cancel setting
Press Esc in order to cancel the setting.

62

Reverse

Group 38 Instrumentation, VN / VHD

Design and Function

Fleet Limit: rpm


MENU: Set-up mode, Fleet limit: rpm
Only available when the correct password has been
given.
This setting gives the ability to choose an engine speed
limit. If the vehicle is driven at a higher engine speed
than this rpm limit, the duration of the overspeed is registered. See Trip data page 83.
1

When the menu Set-up mode, Fleet limit: rpm is


chosen the following is shown on the graphic display:

The following message is shown:

Data transfer

Data transfer

in progress

completed

please wait
2

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

Press Esc to return to the previous menu.


4

Present

If the transfer should fail, the following message is


shown:

2000 r/m

Operation

1900 r/m
If an incorrect number has been given, press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.

failed
Action:

Press Esc and try to do the setting one more


time, see step 1.

Otherwise perform a diagnostics test on the


graphic display and the engine ECU, see Fault
diagnostic page 68.

63

Group 38 Instrumentation, VN / VHD

Design and Function

Fleet Limit: Speed


MENU: Set-up mode, Fleet limit: speed
Only available when the correct password has been
given.
This setting gives the ability to choose a speed limit. If
the vehicle is driven faster than the chosen speed limit,
the duration of the overspeed is registered. See Trip
data page 83.
1

When the menu Set-up mode, Fleet limit: speed is


chosen the graphic display first shows the following:

The following message is shown:

Data transfer

Data transfer

in progress

completed

please wait
2

The new speed is set using the up/down buttons


(one number at a time) followed by :

Press Esc to return to the previous menu.


4

If the transfer should fail, the following message is


shown:

Present
70 mph

Operation

65 mph

failed
If an incorrect number has been given press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.

64

Action:

Press Esc and try to do the setting one more


time, see step 1.

Otherwise perform a diagnostics test on the


graphic display and the engine ECU, see Fault
diagnostic page 68.

Group 38 Instrumentation, VN / VHD

Design and Function

Fleet Fuel Target


MENU: Set-up mode, Fleet fuel target
Only available when the correct password has been
given.
This setting gives the fleet owner the ability to set a fuel
target. For information about fuel consumption for a trip,
see Trip data page 83.
In order to compare the fuel consumption with the fuel
target set, see AVG/INST Fuel Economy page 45.
1

When the menu Set-up mode, Fleet fuel target is


chosen the graphic display first shows the following:

The following text message is shown when the


transfer is complete:

Data transfer

in progress

Data transfer

please wait

completed

The new fuel target is set using the up/down buttons


(one number at a time) followed by :
Press Esc to return to the previous menu.
4

Now 10 mpg

If the transfer should fail, the following message is


shown:

New 14 mpg

Operation
failed

Note: If metric scales have been selected, the consumption is shown in liters. In the example above,
L/100 km will then be shown instead of mpg.
If an incorrect number has been given press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.

Action:

Press Esc and try to do the setting one more


time, see step 1.

Otherwise perform a diagnostics test on the


display and the engine ECU, see Fault diagnostic page 68.

65

Group 38 Instrumentation, VN / VHD

Design and Function

Fleet id
MENU: Set-up mode, Fleet id
Only available when the correct password has been
given.
In this menu, the identification the vehicle has in the fleet
can be entered. Data registered in the engine ECU is
then registered for this ID.
1

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

The following message is shown when the setting is


complete:

Data transfer

in progress

Data transfer

please wait

completed

The new Fleet ID is set using the up/down buttons


(one number/letter at a time followed by ). 13
characters must be entered (spaces are entered in
unused positions).

Press Esc to return to the previous menu.


4

Fleet id:

If the transfer should fail, the following message is


shown:

ifkgoteborg

Operation
failed

Enter Fleet id

If an incorrect number/letter has been given press


Esc and the previous number/letter is highlighted. If
there is no previous number/letter, the setting is cancelled and the menu Set-up mode is shown again.

66

Action:

Press Esc and try to do the setting one more


time, see step 1.

Otherwise perform a diagnostics test on the


graphic display and the engine ECU, see Fault
diagnostic page 68.

Group 38 Instrumentation, VN / VHD

Design and Function

Change password
MENU: Set-up mode, Password config.
Only available when the correct password has been
given (the owners password). See Password Information page 39 for general information about the
password.
If none of the functions are protected by passwords this
menu will not be available.
1

When the menu Set-up mode, Password config. is


chosen the graphic display first shows the following:

Select Owner or Mechanic, a new text message is


shown:

Change password

Enter password
0000

Mechanic
Owner

The password is set with the up/down buttons (one


number at a time) followed by .
If an incorrect number has been given, press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Set-up mode is shown again.

67

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: System Diagnostic (non-driving)


Menu System Diagnostic has 4 sub-menus where 3
are not protected by passwords and 1 is protected by
password.

Fault diagnostic
Cluster self test
Part number
Status test (password is required)

Fault diagnostic
MENU: Diagnostic, Fault diagnostic

No faults in the chosen system:

A list of the vehicles ECUs is shown in the menu Fault


diagnostic. Each ECU is identified by a MID number
(Message IDentifier). In addition a menu for resetting all
the fault codes is shown.

No faults

For a list of common fault codes, see Common Fault


Codes page 74.

ABS Brakes, MID 136


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

The up/down buttons are used to move the cursor


in the list.

MID (127)

confirms the selection of ECU or Reset all.

Not responding

During the time that each respective ECU is being


called, the display shows the text:

Data transfer
in progress
please wait

Press Esc to return to the previous menu.


5

Not responding to Non spec. system:

Non spec. syst

Press Esc to return to the previous menu.


6

If the chosen system does not respond within 5


seconds the following message is shown (in this example the engine has been called):

Engine
MID 128
Not responding
Action:

68

Press Esc and try to do the operation one more


time, see step 1.

Group 38 Instrumentation, VN / VHD

Design and Function

Fault codes are shown


1

If there is a fault code or codes the following is


shown, for example:

If more than 20 fault codes/messages are available


for the chosen ECU the 21st message will be:

Engine

Engine

Coolant temperature

Too many

Value too high

fault messages

Active

Line 1: Identification of ECU


Line 2: Identification of parameter/component
Line 3: Identification of fault type
6 1 shows how many times the fault has been
registered since the last resetting. If there is no information available for how many times the fault
code has been registered, only Active is shown (the
fault remains). Or alternatively Inactive is shown
(the fault was there previously).

To see those messages that are not shown, one or


more of the first messages must be reset, see
Reset a fault code page 72.
The fault codes are presented in text format, but the
user can also choose to have the fault codes presented numerically (if a fault code or ECU is not
recognized by the system, they will only be presented in numeric format).

The arrow in the lower, right-hand corner is shown if


there is more than one fault code. The up/down buttons move the cursor and the next fault
code/message is shown. If the right password has
been entered resetting can be done in Reset all, last
in the list. This resetting deletes only the fault codes
for the chosen ECU.

69

Group 38 Instrumentation, VN / VHD

Design and Function

Numeric or text
1 Press when there are fault codes and the follow-

6 1 shows how many times the fault occurred


since the last resetting. If there is no information
available for how many times the fault code has
been active, only Active is shown (the fault remains)
or Inactive (the fault was there previously).

ing menu is shown. Select numeric or text format


(the function Reset will only be shown when the correct password has been entered):

Numeric

The arrow in the lower, right-hand corner is shown if


there is more than one fault code. The up/down buttons move the cursor and the next fault code is
shown. If the correct password has been entered,
resetting can be done in Reset all, last in the list.
This resetting deletes only the fault codes for the
chosen ECU.

Text
Time stamp
Reset
4
2

When Text has been selected, the fault codes are


shown according to step number 1 under Fault
codes are shown page 69.

When Numeric has been selected the fault codes


are shown with numbers:

If more than 20 fault codes/messages are available


for the chosen ECU, the 21st message will be:

Too many
fault messages

MID 128
PID 110
FMI 0
Active

MID: Identification of ECU


PID: Identification of parameter
PPID: Volvo unique identification of parameter
SID: Identification of component
PSID: Volvo unique identification of component
FMI: Identification of fault type

70

To see those messages that are not shown, one or


more of the first messages must be reset, see
Reset a fault code page 72.

Group 38 Instrumentation, VN / VHD

Design and Function

Time stamp
1

To show the time when the fault code was set for
the first and latest occasion respectively press
when the particular fault code is presented (does
not apply to all MIDs, such as ABS brakes or SRS
airbag). The following menu is shown:

If the transfer should fail, the following message is


shown:

First
No data

Numeric

Last

Text

No data

Time stamp
Reset

Action:

Select Time stamp and the following text message


is shown:

Check that the ABS brakes or the SRS airbag


have not been asked for a time stamp. If it is for
other ECUs press Esc and attempt the operation once again.

Data transfer
in progress
please wait
3

The following is shown (time stamp is presented as


the number of hours the engine has been running):

First
X
Last
X
Press Esc to return to the previous menu.

71

Group 38 Instrumentation, VN / VHD

Design and Function

Reset fault codes


Reset a fault code
Only available when the correct password has been
given. This function is not supported by all devices.

The text message that the resetting has been carried out is shown on the graphic display:

Note: Individual fault codes on brakes or airbags cannot


be reset. See Reset all the fault codes page 73 for resetting these fault codes. Active fault codes cannot be
reset only inactive faults can be reset.

Data transfer
completed

If you try to reset a fault code for brakes or airbags


the following is shown:

Press Esc to return to the previous menu.

This function
5

is not possible

If the resetting should fail, the following message is


shown:

Operation

In order to reset a fault code press when the particular fault code is presented. The following menu is
shown:

failed

Numeric
Text

Action:

Time stamp

Reset
2

Important: Note first any remaining fault codes


on the other ECUs since even these will be reset.

On the graphic display, a question about resetting is


shown:

Reset?
Press FOR 1S

The following text message is shown on the graphic


display:

Data transfer
in progress
please wait
72

Press Esc and then do Reset all the fault


codes page 73.

Otherwise do the diagnostics test on the chosen system as well as the graphic display, see
Fault diagnostic page 68. If there are active
faults, those faults cannot be reset until they are
repaired (until the fault becomes inactive).

Group 38 Instrumentation, VN / VHD

Design and Function

Reset all the fault codes


Only available when the correct password has been
given. This function is not supported by all devices.
In the menu Fault diagnostic page 68 Reset all is chosen last in the list using the up/down buttons . Via this
menu, the fault codes of all systems can be reset.
1

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

On the graphic display, a text message is shown


when the resetting has been carried out:

Data transfer

Reset?

completed

Press FOR 1S

Press Esc to return to the previous menu.


2

The following text message is shown on the graphic


display:

If the resetting should fail, the following message is


shown:

Data transfer
in progress

Operation

please wait

failed

Esc cancels the setting and the menu Fault diagnostics is shown again.
Action:

First press Esc and then reset each fault code


individually. See Reset a fault code page 72.

Otherwise do the diagnostics test on the chosen system as well as the graphic display. See
Fault diagnostic page 68. If there are active
faults, those faults cannot be reset until they are
repaired (until the fault becomes inactive).

73

Group 38 Instrumentation, VN / VHD

Design and Function

Common Fault Codes


MIDs (Message IDs or
sources)

74

Description

128

Engine

232

SRS (Airbag)

136

ABS

140

Instrument Cluster Center Module

234

Instrument Cluster Left Module

144

Cab Controller (Vehicle ECU)

130

Transmission

PIDs (Parameter IDs)

Description

84

Road speed

91

% Throttle pedal

100

Engine oil pressure

102

Boost pressure

105

Air inlet temperature

110

Engine coolant temp

111

Coolant level

173

Pyrometer

175

Engine oil temperature

190

Engine speed

Group 38 Instrumentation, VN / VHD

PPIDs (Proprietary Parameter


IDs)

Design and Function

Description

69

Buffered idle switch

70

Pedal switches, supply

71

Cruise control and retarder, supply switch

72

Accelerator pedal and retarder, supply sensors

73

Accelerator control 2 and primary tank, supply sensors

75

Range inhibitor, status solenoid valve

76

Brake lamps, status relay

77

Compressor, status solenoid valve

78

Interval wiper, status relay

79

Area inhibitor, status solenoid valve

86

Engine brake torque percent

109

EPG3 drive stage failure

121

MTE (Engine compressor control output) failure

122

VCB Engine compression brake

123

EPG2 Start and Warmhold

124

EPG1 Engine brake

125

EOL Enable failure

195

Proprietary Diagnostic Data Request/Clear Count

196

Proprietary Diagnostic Data/Count Clear Response

Common SIDs (Subsystem


IDs)

Description

242

CC resume switch

243

CC set switch

244

CC enable switch

245

Clutch pedal switch

246

Brake pedal switch #1

247

Brake pedal switch #2

251

Power supply

75

Group 38 Instrumentation, VN / VHD

Engine SIDs (Subsystem


IDs)

Description

Injector #1

Injector #2

Injector #3

Injector #4

Injector #5

Injector #6

21

Engine position sensor

22

Timing sensor

25

Ext. Engine protection sig.

PSIDs (Proprietary Subsystem IDs)

Description

PSID 1

Retarder Brake Control Set Switch

PSID 2

Idle Validation Switch #2

PSID 3

Idle Validation Switch #3

PSID 4

Retarder Brake Control Switch

PSID 5

Forward rear Axle Temperature

PSID 6

Rear rear Axle Temperature

Brake SIDs (Subsystem IDs)

76

Design and Function

Description

ABS Snsr axle 1 L

ABS Snsr axle 1 R

ABS Snsr axle 2 L

ABS Snsr axle 2 R

ABS Snsr axle 3 L

ABS Snsr axle 3 R

ABS valve axle 1 L

ABS valve axle 1 R

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

18

ABS, dif 1 - ASR valve

Group 38 Instrumentation, VN / VHD

Airbag SIDs (Subsystem IDs)


1

FMIs (Failure Modes)

Design and Function

Description
Dr Airbag lgn Loop

Description

Data valid, but high

Date valid, but low

Data erratic

Voltage shorted high

Voltage shorted low

Current low or open C

Current high or short C

Mech syst no response

Abnormal freq or PW

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 in the SAE J1708/1587 document.

Note: The special instruction FMI #14 is broadcast when


the airbag has stored crash data.

77

Group 38 Instrumentation, VN / VHD

Design and Function

Cluster self test


MENU: System diagnostic, cluster self test
Four sub-menus are available:

Bulb test
Gauge test
Display test
Buzzer test

Cancel test
Press Esc in order to cancel the test.

Bulb test

Gauge test

MENU: System diagnostic, Cluster self test, Bulb test

MENU: System diagnostics, Cluster self test, Gauge test

Select Bulb test.

Select Gauge test.

The telltale lamps light up for approx. 5 seconds.

Esc cancels the test and the menu Bulb test is


shown again.

The pointers on the electrically controlled gauges


move back and forth a few times, between the end
positions. They stop at the mid-point of the gauge
before the test is complete, then return to zero. This
is only a check that they can move (i.e. that the
gauge functions). Note: mechanical (air) gauges are
not operated with this test.

Important: Needle-nose pliers must not be used!

Esc cancels the test and the menu Gauge test is


shown again.

Display test

Buzzer test

MENU: System diagnostic, Cluster self test, Display test

MENU: System diagnostic, Cluster self test, Buzzer test

Select Display test.

Select Buzzer test.

The display goes out, lights up, goes out. In the


odometer display, all segments are shown, then off,
back on, off again, and back to the normal display.

Esc cancels the test and the menu Display test is


shown again.

On the display, the name of the current sound is


shown at the same time as the sound is activated.
With the up/down buttons you can switch between
the different sounds.
Three different sounds (flasher indicator, reminder
and caution) are tested for 10 seconds each.

Esc cancels the test and the menu Buzzer test is


shown again.

Changing bulbs
Changing the instrument clusters telltale lamps can be
carried out from the rear side, without the instrument
cluster needing to be opened. Use the bulb removal tool.

78

Group 38 Instrumentation, VN / VHD

Design and Function

Part number
MENU: System diagnostics, Part number
A list of the vehicles electronic control units (ECUs) is
shown in the menu Part number. Each ECU is identified
by a MID number (Message IDentifier).

ABS Brakes, MID 136


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

The up/down buttons are used to move the cursor


in the list.

confirms the selection of an ECU.

In the meantime, the display shows the text:

The up/down buttons are used to move the cursor


in the list.

MID 128

HW ID

VOLVO08192949P06

Data transfer
in progress
HW: ECU part number

please wait
6
4

The following text is presented:

MID 128

SW ID

03163028P01

If there is a communication error, the following is


shown No data (this example shows HW ID, but
same text applies to SW ID except that HW is replaced by SW):

MID 128

HW ID

No data

SW: The softwares part number


Action:

Press Esc to return to the previous menu and


attempt the operation once again.

Otherwise do the diagnostics test on the chosen system as well as the display, see Fault
diagnostic page 68.

79

Group 38 Instrumentation, VN / VHD

Design and Function

Status test
MENU: System diagnostic, Status test
Only available when the correct password has been
given.
Each ECU is identified by a MID number.
The parameter values are identified by the PID and
PPID. The difference between PID and PPID is that
PPID is unique for Volvo. PID follows the SAE standard.
Status tests cannot be done on SID or PSID.
Data is displayed in decimal values, and must be translated using the SAE J1587 specification. This function is
designed for experienced technicians who are familiar
with J1587.
1

Select the menu System diagnostic, Status test.

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

MID1: XXX

MID: XXX

PID/PPID1: YYY

(P)PID: YYY

MID2: ZZZ

DATA1: AAAAAAAAAAAA

PID/PPID2: VVV
2

Use the up/down buttons to highlight the desired


MID and PID and/or PPID (one number at a time)
followed by . If an incorrect number has been given
press Esc and the previous number is highlighted. If
there is no previous number, the setting is cancelled
and the menu System diagnostic is shown.

Press Esc to return to the previous menu.


8

If it there is no data for the chosen PID/PPID, the


following is shown:

MID: XXX

Select another MID if you want, otherwise select


000.

(P)PID: YYY

Step 2 is repeated if an additional MID has been selected.

DATA1: No data

The display shows the text message:

Data transfer
in progress

Action:

Check that the correct data has been given


when prompted (i.e. the correct MID, PID and
PPID number).

Press Esc to return to the previous menu and


attempt the operation once again.

Otherwise do the diagnostics test on the chosen system as well as the display. See Fault
diagnostic page 68.

please wait
6

If two MIDs have been given, the following is shown:

MID: XXX ZZZ


PID/PPID: YYY VVV
DATA1: AAAAAAAAAAAA
DATA2: BBBBBBBBBBBB
80

Group 38 Instrumentation, VN / VHD

Design and Function

Main Menu: Data Log mode (with Volvo engines only) (non-driving)
Menu Data log mode has 4 sub-menus where 3 are not
protected by passwords and 1 is protected by a password.

Vehicle ID
Totals
Trip data
Reset trip data (requires password)

Vehicle ID
MENU: Data log mode, Vehicle ID
1

Select the menu Data log mode, Vehicle ID and


the following text message is shown:

Data transfer
in progress
please wait
2

The fleet ID that is shown has been entered in the


menu Fleet id page 66.

Fleet ID:
XXX
Chassis no:
XXX
Press Esc to return to the previous menu.
3

If the transfer should fail, the following message is


shown:

Operation
failed

Action:

Press Esc and try to do the operation one more


time, see step 1.
81

Group 38 Instrumentation, VN / VHD

Design and Function

Totals
MENU: Data log mode, Totals
1

Select the menu Data log mode, Totals.

The menus that show Totals can be scrolled to using the up/down buttons.

Total PTO hours

0.5 h
Total distance
406.7 mi

Total engine revolutions

1 220 100 r
Total fuel used
51.3 gal

If the transfer should fail, the following message is


shown:

Note: If km and C have been selected, the consumption is shown in liters.

Operation
failed

Total engine
hours

Action:

Press Esc and try to do the operation one more


time. See step 1.

Otherwise perform a diagnostics test on the


graphic display and the engine ECU. See
Fault diagnostic page 68.

7.3 h
6

Cancel operation

Total idle time


0.3 h

82

Press Esc in order to cancel the operation.

Group 38 Instrumentation, VN / VHD

Design and Function

Trip data
MENU: Data log mode, Trip data
1

Select the menu Data log mode, Trip.

The information below can be scrolled to using the


up/down buttons.

Trip fuel
uneconomy revs

8.5 gal
Trip distance
203.5 mi

Note: If km and C have been selected, the consumption is shown in liters.


8

Trip average speed


4

Trip fuel

67.4 km/h

Avg. 28 l/100 km
Acc. 57.0 gal

Trip overspeed


Note: If Miles and F have been selected, the consumption is shown in US gallons.

0.2 h

Trip overrevs

10

Trip engine hours


0.8 h
3.0 h

Trip uneconomy revs


0.4 h

83

Group 38 Instrumentation, VN / VHD

Design and Function

15

11

Trip cruise

Trip idle time

2.5 h

0.4 h

16 If the transfer should fail, the following message is


shown:

12

Operation

Trip idle fuel

failed
2.5 gal


Note: If km and C has been selected, the consumption is shown in liters.

Action:

Press Esc and try to do the operation one more


time. See step 1.

Otherwise perform a diagnostics test on the


graphic display and the engine ECU. See
Fault diagnostic page 68.

13

Trip PTO hours


1.3 h
14

Trip PTO fuel


20.4 gal


Note: If km and C have been selected, the consumption is shown in liters.

84

Cancel operation
Press Esc in order to cancel the operation.

Group 38 Instrumentation, VN / VHD

Design and Function

Reset trip data


MENU: Data log, Reset trip data
Only available when the correct password has been
given.
1

Select the menu Data log, Reset trip data.

A new text message in the form of a question is


shown: Reset? Press .

The following message is shown when resetting is


complete:

Data transfer
completed

Reset?
Press FOR 1S
5

If the resetting should fail, the following message is


shown:

Operation

When resetting is being carried out the following is


shown:

failed

Data transfer
in progress
Action:

please wait

Press Esc and try to do the reset one more


time. See step 1.

Otherwise perform a diagnostics test on the


graphic display and the engine ECU, see Fault
diagnostic page 68.

85

Group 38 Instrumentation, VN / VHD

Main Menu: Password Input (non-driving)


MENU:Password Input
1

Select the menu Password Input.

Set-up mode
System diagnostic
Data log mode
Password Input
2

The password consists of a four-figure number,


00009999, that is scrolled forward with the
up/down buttons on the wiper stalk (one number at
a time) followed by . The display shows the following text message:

Password input

0000
If an incorrect number has been given press Esc
and the previous number is highlighted. If there is
no previous number, the setting is cancelled and the
menu Password Input is shown again.
When the ignition key has been in the off position
for more than 60 seconds or when the batteries
have been disconnected the password must be entered again.
3

If the wrong password is given, the following is


shown the text message:

Error!
Password Input
0000

86

Design and Function

Group 38 Instrumentation, VN / VHD

Troubleshooting

Troubleshooting
Instrumentation Troubleshooting
When troubleshooting the instrument cluster, the graphic
display or Volvos VCADS Pro diagnostic tool can be
used. VCADS Pro provides several features not available
within the cluster itself, such as the ability to test input
signals and calibrate gauges individually.
Many of the components can be tested without disturbing the cluster by using the cluster self test function in
the graphic displays Diagnostic Menu. This includes all
the telltale lamps, the graphic display, and all gauges except for the air gauges. The pivot-down mounting feature
of the cluster allows troubleshooting of input signals
without removing the cluster from the vehicle.
Note: Instrument cluster programming. Each instrument cluster (or CPU board) is programmed to
correspond to the customer-ordered options for that particular vehicle. This dataset is stored in the CPU board
memory, making the instrument cluster unique to each
vehicle.
For this reason, it is not possible to swap a suspected
faulty instrument cluster (or CPU board) with one from
another vehicle without reprogramming the replacement
instrument cluster (or CPU board).
Authorized technicians can update and/or alter software

datasets with the VCADS Pro tool.


See the most current VCADS Pro user manual or the
Help menu in the VCADS Pro tool.
Important: Warranty Information. Individual modules in
the instrument cluster are not serviceable during the
warranty period. Individual electrical gauges are not serviceable at any time. Attempts to service or replace
individual modules during the warranty period will
void the cluster warranty. Instead, the whole unit may
be exchanged.
This section contains the following:

Instrument Cluster Diagnostic Tests page 89


Warning and Telltale Lamps, Troubleshooting
page 92
Instrument Cluster Backlighting, Troubleshooting
page 106
Graphic Display and Odometer, Troubleshooting
page 111
Gauges, Troubleshooting page 115
Graphic Display Control Buttons, Troubleshooting
page 128
Buzzer, Troubleshooting page 130

87

Group 38 Instrumentation, VN / VHD

General Work Practices


CAUTION
Possible damage to electronic components. Turn the
vehicle ignition switch OFF before disconnecting or
connecting electrical components. Failure to
de-energize circuits may result in electronic equipment damage.

Troubleshooting

CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, make sure the workbench has an
anti-static mat which is grounded to the nearest electrical outlet when working on the instrument cluster.
Failure to use an anti-static mat may result in permanent damage to the printed circuit boards in the
instrument cluster. When working at the anti-static
workbench, always keep a wrist strap connected to
the anti-static mat.

CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, a wrist grounding strap must be
used when working on electronic equipment such as
the instrument cluster. Failure to use a wrist strap may
result in permanent damage to the printed circuit
boards in the instrument cluster. To use the wrist strap
in a vehicle, attach the alligator clip to the nearest
electrical ground such as a metal mounting screw, a
ground terminal or preferably a ground stud.

88

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil may run out
of the front of the gauge faces and make the gauges
inaccurate.

Group 38 Instrumentation, VN / VHD

Troubleshooting

Instrument Cluster Diagnostic Tests


Instrument Cluster Self Test

W3003624

The following tests can be performed via the graphic display using the graphic display control buttons:
1
2
3
4

Esc is used to return to the previous menu and cancel an operation.


or select confirms a highlighted menu selection
and displays the sub-menu for that selection.
The up arrow moves the cursor up through the
menu selections.
The down-arrow moves the cursor down through the
menu selections.

From the graphic display menu System diagnostic select Cluster self test. The four sub-menus available are:

Bulb test
The test activates all telltale lamps and all red LED
warning indicators. If the lamps do not light during the
test, the lamp may not be operating or there may be a
fault in the wiring used for the indicator lamp test.

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

Display test
The entire display screen will alternate from dark to light
to check that all pixels on the display are operational.
Additionally, the odometer display will illuminate all LED
segments.

Buzzer test
This test checks the function of the buzzer. The graphic
display alternates from flasher indicator to reminder to
caution. A different tone will sound with each display
message. (The caution sound is connected to the yellow
information lamp.)
These tests can also be run using the VCADS Pro tool.

89

Group 38 Instrumentation, VN / VHD

Troubleshooting

Instrument Cluster Tests with VCADS Pro

W0001632

The VCADS Pro tool is a Windows 95 based PC tool


that can be used to perform instrument cluster testing,
calibrations and programming. The tests are similar to
the self tests in the instrument cluster. In addition,
VCADS Pro allows the status of the buttons on the control lever to be checked, and individual gauges can be
calibrated. The following is a brief description of the tests
and calibration currently available. Additional tests may
be added as newer versions of VCADS Pro become
available. More information about the tests can be found
in the most current VCADS Pro user manual or the
Help menu in the VCADS Pro tool.
Note: Mechanical (air pressure) gauges are not operated with these tests.

Instrument Cluster, Test


This test is intended to check instrument cluster functions. During these tests sensor inputs are ignored and
the instruments are driven by the instrument cluster microprocessor (CPU). These tests can also be run using
the graphic display control buttons.

Bulb test
The test activates all telltale lamps and all red LED
warning indicators. If the lamps do not light during the
test, the lamp may not be operating or there may be a
fault in the wiring used for the indicator lamp test (see

90

Telltale Lamps page 96).

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

Display test
The entire display screen will alternate from dark to light
to check that all pixels on the display are operational.
Additionally, the odometer display will illuminate all LED
segments.

Buzzer test
This test checks the function of the buzzer. The graphic
display alternates from flasher indicator to reminder to
caution. A different tone will sound with each display
message. (The caution sound is connected to the yellow
information lamp.)

Graphic Display Control Buttons


The VCADS Pro screen will illuminate indicators to
confirm that the graphic display control buttons are delivering a signal. The graphic display control buttons are
used to access all instrument cluster and graphic display
functions.

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauge Accuracy Check


Accuracy checks can only be performed using VCADS
Pro. The VCADS Pro tool can display the value of signals
coming into the instrument cluster for most electrically
operated gauges. These values can then be compared
to the reading displayed on each respective gauge.
If the reading displayed on the gauge appears not to
match the value seen on the VCADS Pro tool, the gauge
can be adjusted with the Gauge Calibration feature of
the VCADS Pro tool. See the most current VCADS Pro
user manual or the Help menu in the VCADS Pro tool.
The calibration allows the gauge pointer to be adjusted
so that it is at the center of the reference marks on the
gauge face. Plus and minus adjustment icons on the
VCADS Pro tool allow incremental adjustment of the
pointer to the left, right and center reference marks.
Note that if the gauge is calibrated at one point (such as
the center mark), it may affect the calibration at another
point on the gauge. Gauges should not be calibrated unless the readings are obviously inaccurate.
Note: VCADS Pro does not have the capability of calibrating the speedometer or tachometer.

W3004300

91

Group 38 Instrumentation, VN / VHD

Troubleshooting

Warning and Telltale Lamps, Troubleshooting


Telltale lamps are positioned across the bottom of the instrument cluster. LED indicator
lamps are integrated into various individual gauges. Before troubleshooting, see
General Work Practices page 88.

W3004319

Wiring, Instrument Cluster Telltale and LED Lamps.


Note: All telltale lamps may not be used or wired in all vehicles.
The schematic should be used to help clarify the warning and telltale lamp troubleshooting procedures in this
manual. For detailed, vehicle specific, wiring troubleshooting see:

Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

Instrument Cluster Self Test


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

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

Instrument Cluster Tests using VCADS Pro


With the Bulb test selected in the VCADS Pro tool, all telltale and LED indicator
lamps will illuminate for approximately 5 seconds. See the most current VCADS Pro
user manual or the Help menu in the VCADS Pro tool.
92

Group 38 Instrumentation, VN / VHD

Troubleshooting

Troubleshooting
If all the telltale and LED indicator lamps function correctly in the Instrument Cluster
Self Test or Instrument Cluster Tests using VCADS Pro, the lamps and instrument cluster electronics are working properly.

LED Indicator Lamps


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

Engine oil pressure LED and Engine coolant temperature LED


The engine oil pressure and engine coolant temperature LEDs illuminate based on signals received from the J15878/J1708 information data link. There are no sensors
hardwired to warning LEDs.
LED Warning Lamp

Check

Key Position

Measurement
Point

Expected
Value

Note

Measurements
not expected
value? Check:

Engine oil pressure


LED,
Engine coolant temperature LED

Run Cluster Self


Test (bulb
test) or test
using
VCADS
Pro

On

Visual check

LEDs illuminate

If LEDs illuminate the


cluster is
functioning
properly.

If LEDs do not illuminate, replace


the cluster (or left
gauge module or
left CPU board if
out of warranty).

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

93

Group 38 Instrumentation, VN / VHD

Troubleshooting

Front and Rear Air Pressure LEDs


The front and rear air pressure LEDs illuminate based on air pressure delivered to the instrument cluster. There are no
sensors hardwired to the warning LEDs. Note: LEDs should illuminate below approx. 70 psi.

Step 1. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument cluster electronics are working properly.
If only one of the LEDs comes on replace the cluster (or right module if out of warranty).
If neither LED comes on, but the telltale lamps at the bottom do, replace the cluster (or right module if out of warranty).
If no lamps illuminate go to step 2.

Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the RX connector pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

LED Warning Lamp

Function

Key Position

Measurement
Point

Expected
Value

Note

Measurements not
expected value?
Check:

Front brake air pressure LED

Lamp Test
(-)

On

Check green
28 (RX28) to
+bat with meter

12V

Bulb test
active

<1V

Bulb test
not active

Check wiring or connectors between


connector RX and CY

+12V

Power Supply

On

Check green
18 (RX18) to
ground with
meter

Ground

Off

Check green
15 (RX15) to
ground with
meter

Fuse, connectors or
wiring fault in power
supply circuit

Rear brake air pressure LED

94

<1

Connectors or wiring
fault in ground circuit

Group 38 Instrumentation, VN / VHD

Troubleshooting

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

95

Group 38 Instrumentation, VN / VHD

Troubleshooting

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

Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See

Bulb, Replacement page

137.

Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument cluster electronics are working properly. If not, go to step 3.
Step 3. If the bulb is still not working, connect breakout box 9998551 with adapter J-43235 in series between
wiring harness connector LX and the instrument cluster connector LX. Install overlay J-43340 with the 22PIN
BREAKOUT HARNESS side up. The overlay is color-coded green for the LX connector pins. Go to the next chart and
perform the tests for the lamp in question.

Left Module Telltale Lamps


Telltale Lamp

Function

Key Position

Measurement
Point

Expected
Value

All Left Module telltale lamps

Power Supply

On

Green 22
(LX22) to
ground with
meter

+12V

Ground

Off

Green 12
(LX12) to
ground with
meter

<1

Note

Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
power supply circuit

Disconnect
LX connector
at cluster

Connectors or
wiring fault in
ground circuit

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, continue to the next troubleshooting chart.
Note: If the breakout box tooling is not available, the instrument cluster connector pins
may be back-probed with digital multimeter J39200 or an equivalent tool. See
Connectors, Back-probing page 134.

96

Group 38 Instrumentation, VN / VHD

Troubleshooting

Left Module Telltale Lamps (continued)

Step 1. Set-up: connect breakout box 9998551 with adapter J-43234 in series between wiring harness connectors
LY and CY and the instrument cluster connectors LY and CY. Install overlay J-43340 with the 30PIN BREAKOUT
HARNESS side up. The overlay is color-coded green for the LY connector pins, and blue for the CY connector pins.
Proceed to chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Note

Measurements
not expected
value? Check:

Preheat

Power Supply to Lamp

Preheat

Check green 11
(LY11) to
ground with meter

12V (with
preheat
active)

Preheat lamp
not designed
to illuminate
with all variants.

EECU or connectors or wiring fault


in the circuit from
EECU.

Lamp test

On

Green 11
(LY11) direct
connection to
Blue 22 (CY22)

Preheat
lamp illuminates

Preheat lamp
not designed
to illuminate
with all variants.

Confirm Blue 22
(CY22) is supplying 12V to Green
11 (LY11). If so,
probable left CPU
board fault.

Ground to
lamp

On

Check green 10
(LY10) to
ground with meter

12V

Lamp off

0V

Lamp on

EECU or connectors or wiring fault


in the circuit from
EECU.

Lamp test

On

Green 10
(LY10) direct
connection to
ground

INFO lamp
illuminates

Ground to
lamp

On

Check green 6
(LY6) to ground
with meter

12V

Lamp off

0V

Lamp on

Lamp test

On

Green 6 (LY6)
direct connection to ground

STOP
lamp illuminates

Power supply to lamp

On with
engine
running

Check green 5
(LY5) to ground
with meter

Above
+12V

Lamp test

On

Green 5 (LY5)
direct connection to ground

Charging
lamp illuminates

Yellow lamp, INFO

Red lamp, STOP

Charging

Confirm Green 10
(LY10) is supplied
ground. If so,
probable left CPU
board fault.
EECU or connectors or wiring fault
in the circuit from
EECU.
Confirm Green 6
(LY6) is supplied
ground. If so, probable left CPU fault.
Alternator
charging
above battery
voltage

Fuse, connectors
or wiring fault from
charging circuit. Or
alternator failure
Probable left CPU
board fault.

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The left CPU board if the warranty has expired. See Left CPU Board, Replacement page 156.
97

Group 38 Instrumentation, VN / VHD

Troubleshooting

Center Module Telltale Lamps


Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See

Bulb, Replacement page

137.

Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps are OK. If lamps do
not illuminate go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connectors CY and
RX and the instrument cluster connectors LY and CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS
side up. The overlay is color-coded blue for the CY connector pins, and green for the RX connector pins. Proceed to
the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Note

Measurements not
expected value?
Check:

Left turn

Power supply to left


turn indicator

On

Check blue 14
(CY14) to
ground with
meter

Min: 0V
Max: 12V

Left turn signal active

Fuse, connectors,
or wiring fault in left
turn circuit

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Lamp test

On

Blue 14 (CY14)
jumper wire to
Blue 22 (CY22)

Left turn
lamp illuminates

Confirm Blue 22
(CY22) is supplying
12V to Blue 14
(CY14). If so, probable center module
fault

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Fuse, connectors,
or wiring fault in
power supply circuit
to center module

Ground to
5th wheel
lock indicator

On

Check blue 13
(CY13) to
ground with
meter

0V

5th wheel
slide switch
active

12V

not active

Blue 13 (CY13)
jumper wire to
ground

5th wheel
lock indicator lamp
illuminates

5th wheel lock

Lamp test

98

On

<1

Connectors or
wiring fault in
ground circuit

5th wheel slide


switch or connectors/wiring fault in
ground circuit
through 5th wheel
slide switch
Confirm Blue 13
(CY13) is supplied
ground. If so, probable center module
fault

Group 38 Instrumentation, VN / VHD

Troubleshooting

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Wheel differential
lock

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Ground to
wheel differential lock
indicator

On

Check blue 12
(CY12) to
ground with
meter

0V

Wheel differential lock


switch active

12V

not active

Lamp test

On

Blue 12 (CY12)
jumper wire to
ground

Wheel differential
lock indicator lamp
illuminates

Power supply to
interaxle differential lock
indicator

On

Check blue 10
(CY10) to
ground with
meter

12V

Interaxle differential lock


switch active

0V

not active

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Lamp test

On

Blue 10 (CY10)
jumper wire to
Green 18
(RX18)

Interaxle
differential
lock lamp
illuminates

Power supply to high


beam indicator

On

Check blue 8
(CY8) to ground
with meter

12V

High beam
active

0V

not active

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Lamp test

On

Blue 8 (CY8)
jumper wire to
green 18
(RX18)

Interaxle differential lock

High beam

Note

Fuse, connectors,
or wiring fault in
power supply circuit
to center module

High beam
indicator
lamp illuminates

Wheel differential
lock lamp switch or
connectors / wiring
fault in ground circuit through lamp
switch
Confirm Blue 12
(CY12) is supplied
ground. If so, probable center module
fault

<1

<1

Measurements not
expected value?
Check:

Fuse, interaxle
switch, connectors
or wiring fault in
power supply circuit
to center module
Connectors or
wiring fault in
ground circuit
Confirm Blue 10
(CY10) is supplied
12V. If so, probable
center module fault
Fuse, switch, connectors or wiring
fault in power supply circuit to high
beam indicator
Connectors or
wiring fault in
ground circuit
Confirm Blue 8
(CY8) is supplied
12V. If so, probable
center module fault

99

Group 38 Instrumentation, VN / VHD

Troubleshooting

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Safety belt

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Ground to
parking
brake indicator

On

Check blue 3
(CY3) to ground
with meter

0V

Parking brake
applied

12V

not applied

Lamp test

On

Blue 3 (CY3)
jumper wire to
ground

Parking
brake lamp
illuminates

Confirm Blue 3
(CY3) is supplied
ground. If so, probable center module
fault

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Fuse, connectors
or wiring fault in
power supply circuit
to center module

Ground to
ABS tractor
indicator

On

Check blue 1
(CY1) to ground
with meter

0V

ABS faults
active

12V

not active

Lamp test

On

Blue 1 (CY1)
jumper wire to
ground

Tractor
ABS lamp
illuminates

Parking brake

Anti-lock braking
system (ABS),
tractor

100

Note

Measurements not
expected value?
Check:
Fuse, connectors
or wiring fault in
power supply circuit
to center module

<1

Connectors or
wiring fault in
ground circuit

Fuse, connectors
or wiring fault in
power supply circuit
to center module
Parking brake
switch or connectors / wiring fault in
ground circuit
through switch

ABS system or
connectors / wiring
fault in ground circuit through ABS
system
Confirm Blue 1
(CY1) is supplied
ground. If so, probable center module
fault

Group 38 Instrumentation, VN / VHD

Troubleshooting

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Anti-lock braking
system (ABS),
trailer

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Ground to
trailer ABS
indicator

On

Check blue 2
(CY2) to ground
with meter

0V

ABS faults
active

12V

not active

Lamp test

On

Blue 2 (CY2)
jumper wire to
ground

Trailer ABS
lamp illuminates

Confirm Blue 2
(CY2) is supplied
ground. If so, probable center module
fault

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Fuse, connectors
or wiring fault in
power supply circuit
to center module

Ground to
air suspension system
indicator

On

Check blue 15
(CY15) to
ground with
meter

0V

Suspension
dump switch
active

12V

not active

Lamp test

On

Blue 15 (CY15)
jumper wire to
ground

Air suspension lamp


illuminates

Power supply to heated


mirror indicator

On

Check blue 4
(CY4) to ground
with meter

12V

Mirror defroster active

0V

not active

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Lamp test

On

Blue 4 (CY4)
jumper wire to
Green 18
(RX18)

Air Suspension

Heated mirrors

Note

Fuse, connectors
or wiring fault in
power supply circuit
to center module
ABS system or
connectors / wiring
fault in ground circuit through ABS
system

Suspension dump
switch or connectors / wiring fault in
ground circuit
through switch
Confirm Blue 15
(CY15) is supplied
ground. If so, probable center module
fault

<1

Mirror defroster
lamp illuminates

Measurements not
expected value?
Check:

Fuse, connectors
or wiring fault in
power supply circuit
to center module
Connectors or
wiring fault in
ground circuit

Momentary
connection
only. Fuse
may blow.

Confirm Green 18
(RX18) is supplying
12V to Blue 4
(CY4). If so, probable center module
fault

101

Group 38 Instrumentation, VN / VHD

Troubleshooting

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Note

Measurements not
expected value?
Check:

Right turn

Power supply to right


turn indicator

On

Check blue 9
(CY9) to ground
with meter

Min: 0V
Max: 12V

Right turn
signal active

Fuse, connectors
or wiring fault in
right turn circuit

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Lamp test

On

Blue 9 (CY9)
jumper wire to
Blue 22 (CY22)

Right turn
lamp illuminates

Confirm Blue 22
(CY22) is supplying
12V to Blue 9
(CY9). If so, probable center module
fault

Power supply

On

Check blue 22
(CY22) to
ground with
meter

12V

Fuse, connectors
or wiring fault in
power supply circuit
to center module

Ground

Off

Check blue 11
(CY11) to
ground with
meter

Lamp test

On

Blue 25 (CY25)
jumper wire to
ground

Master
warning
lamp illuminates

Jumper from
right module

On

Check blue 25
(CY25) to
ground with
meter

12V

Brake pressure normal

0V

Brake pressure low

Master warning

Ground, right
module

Off

Check green 15
(RX15) to
ground with
meter

<1

Connectors or
wiring fault in
ground circuit

<1

<1

Connectors or
wiring fault in
ground circuit
Confirm Blue 25
(CY25) is supplied
ground. If so, probable center module
fault
Wiring or connectors between center
and right module.
Possible right module fault
Connectors or
wiring fault in
ground circuit

If all the measurements are correct, replace

102

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The center module if the warranty has expired.


See Center Module, Replacement page 143.

Group 38 Instrumentation, VN / VHD

Troubleshooting

Right Module Telltale Lamps


Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See

Bulb, Replacement page

137.

Step 2. Run cluster self-test (bulb test). If the lamps function correctly in this test, the lamps and instrument cluster electronics are working properly. If lamps do not illuminate go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the RX connector pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Transmission temperature

Power
supply

On

Check green 18
(RX18) to
ground with
meter

12V

Ground to
transmission
temperature
indicator

On

Check green 29
(RX29) to
ground with
meter

12V

Transmission
temperature
OK

0V

Transmission
temperature
to high

Lamp test

On

Green 29
(RX29) jumper
wire to ground

Transmission
temperature lamp
illuminates

Confirm Green 29
(RX29) is supplied
ground. If so,
probable right
module fault

Power
supply

On

Check green 18
(RX18) to
ground with
meter

12V

Fuse, connectors
or wiring fault in
right module
power supply circuit

Ground to
transmission
indicator

On

Check green 30
(RX30) to
ground with
meter

12V

No transmission faults

0V

Transmission
faults

Lamp test

On

Green 30
(RX30) jumper
wire to ground

Check
transmission lamp
illuminates

W3004305

Check transmission

W3004306

Note

Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
right module
power supply
circuit
Transmission ECU
or connectors /
wiring fault in
ground circuit
through transmission ECU

Transmission ECU
or connectors /
wiring fault in
ground circuit
through transmission ECU
Confirm Green 30
(RX30) is supplied
ground. If so,
probable right
module fault

103

Group 38 Instrumentation, VN / VHD

Troubleshooting

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Traction control

Power
supply

On

Check green 18
(RX18) to
ground with
meter

12V

Ground to
traction
control indicator

On

Check green 14
(RX14) to
ground with
meter

0V

Traction
control active

12V

Traction
control not active

Lamp test

On

Green 14
(RX14) jumper
wire to ground

Traction
control
lamp illuminates

Confirm Green 14
(RX14) is supplied
ground. If so,
probable right
module fault

Power
supply

On

Check green 18
(RX18) to
ground with
meter

12V

Fuse, connectors
or wiring fault in
right module
power supply
circuit

Ground to
WAIT
indicator

On

Check green 13
(RX13) to
ground with
meter

12V

WAIT indicator not active

0V

WAIT indicator active

Lamp test

On

Green 13
(RX13) jumper
wire to ground

WAIT lamp
illuminates

Power
supply

On

Check green 18
(RX18) to
ground with
meter

12V

Transmission
in neutral

0V

Transmission
not in neutral

W3003668

Wait to start

W3004307

Transmission in
Neutral

Ground

Off

Check green 15
(RX15) to
ground with
meter

Lamp test

On

Green 22
(RX22) jumper
wire to green
18 (RX18)

<1

Note

Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
right module
power supply
circuit
ABS system or
connectors / wiring
fault in ground
circuit through
ABS / traction
control system

Engine ECU or
connectors / wiring
fault in ground
circuit through
engine ECU
Confirm Green 13
(RX13) is supplied
ground. If so,
probable right
module fault
Fuse, connectors,
switches or wiring
fault in neutral
switch circuit
Connectors /
wiring fault in
ground circuit

W3004308

104

Transmission in
Neutral
lamp illuminates

Confirm Green 22
(RX22) is supplied
12V. If so, probable
right module fault

Group 38 Instrumentation, VN / VHD

Troubleshooting

Telltale Lamp

Function

Key Position

Measuring
Point

Expected
Value

Water in fuel

Power
supply

On

Check green 18
(RX18) to
ground with
meter

12V

Ground to
water in fuel
indicator

On

Check green 19
(RX19) to
ground with
meter

12V

Water in fuel
indicator not
active

0V

Water in fuel
indicator
active

Green 19
(RX19) jumper
wire to ground

Water in
fuel lamp
illuminates

W3004309

Lamp test

On

Note

Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
right module
power supply
circuit
Engine ECU or
connectors / wiring
fault in ground
circuit through
engine ECU

Confirm Green 19
(RX19) is supplied
ground. If so,
probable right
module fault

If all the measurements are correct, replace:

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

105

Group 38 Instrumentation, VN / VHD

Troubleshooting

Instrument Cluster Backlighting, Troubleshooting


The instrument cluster backlighting receives power from a dimmer control located on
the vehicle dash. The backlighting is brightest when the control provides +12 volts, and
grows dimmer as the voltage drops toward zero.
Note: The graphic display backlighting is independent of the cluster backlighting. See
Graphic Display and Odometer, Troubleshooting page 111.
Before troubleshooting, see General Work Practices page 88.

W3004335

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

106

Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

Group 38 Instrumentation, VN / VHD

Troubleshooting

Backlighting Tests
To test the instrument cluster backlighting, turn the parking/headlamps on and adjust
the dimmer control for maximum brightness.

Individual Backlighting
If individual backlights are not operating, replace the lamp. If a new lamp does not correct the problem, see the troubleshooting procedures for the affected module below.

Cluster/Module Backlighting
Entire Cluster
If none of the backlighting operates, check for 0 to +12 volts at the output of the
dimmer control switch on the dash. The voltage is variable with the dimmer control position. Adjust the dimmer control for maximum brightness. If voltage is not present at
the output, check the dimmer switch, headlamp switch, fuses, connectors or wiring. For
lamp switch information refer to:
Service
Manual

Lighting System, Group 35


PV776TSP142952

IMPACT

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

For other wiring information refer to:


Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

Graphic Display Module


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

107

Group 38 Instrumentation, VN / VHD

Troubleshooting

Left Module Backlighting


Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See

Bulb, Replacement page

137.

Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX connector pins. Proceed to the chart below.
Note: The headlamp switch should be ON with the dimmer control adjusted to maximum brightness unless otherwise
noted.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Function

Key Position

Measuring Point

Expected
Value

Note

Measurement not expected value? Check:

Backlighting Input,
Left Module

Off

Green 20 (LX20)
to ground with
meter

2.5 - 12 V

Varies with
dimmer position

Switches, connectors or
wiring fault in power supply
circuit from dimmer

Ground, Left Module

Off

Green 12 (LX12)
to ground with
meter

Headlamp
switch OFF.
Disconnect LX
connector at
cluster

Connectors or wiring fault


in ground circuit

<1

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The left gauge module or left CPU board if the warranty has expired. See Left
Gauge Module, Replacement page 141 or Left CPU Board, Replacement page
156.

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

108

Group 38 Instrumentation, VN / VHD

Troubleshooting

Center Module Backlighting


Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See

Bulb, Replacement page

137.

Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded blue for the CY connector pins. Proceed to the chart below.
Note: The headlamp switch should be ON with the dimmer control adjusted to maximum brightness unless otherwise
noted.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Function

Key Position

Measuring Point

Expected
Value

Note

Measurement not expected value? Check:

Backlighting Input,
Center Module

Off

Check blue 18
(CY18) to ground
with meter

2.5 - 12 V

Varies with
dimmer position

Switches, connectors or
wiring fault in power supply
circuit from dimmer

Ground, Center Module

Off

Check blue 11
(CY11) to ground
with meter

Headlamp
switch OFF

Connectors or wiring fault


in ground circuit

<1

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The center module if the warranty has expired.


See Center Module, Replacement page 143.

109

Group 38 Instrumentation, VN / VHD

Troubleshooting

Right Module Backlighting


Step 1. Confirm that the suspect bulb has been replaced with a known good bulb. See

Bulb, Replacement page

137.

Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the RX connector pins. Proceed to the chart below.
Note: The headlamp switch should be ON with the dimmer control adjusted to maximum brightness unless otherwise
noted.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Function

Key Position

Measuring Point

Expected
Value

Note

Measurement not expected value? Check:

Backlighting Input,
Right Module

Off

Check green 1
(RX1) to ground
with meter

2.5 - 12 V

Varies with
dimmer position

Switches, connectors or
wiring fault in power supply
circuit from dimmer

Ground, Right Module

Off

Check green 15
(RX15) to ground
with meter

Headlamp
switch OFF

Connectors or wiring fault


in ground circuit

<1

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace

110

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

Group 38 Instrumentation, VN / VHD

Troubleshooting

Graphic Display and Odometer, Troubleshooting


The graphic display, located in the left module, is activated by messages received on
the J1587/J1708 information data link. The odometer display is located in the center
module. Before troubleshooting, see General Work Practices page 88.

W3003774

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

Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

Instrument Cluster Self Test


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

With the display test active the graphic display screen will alternate from dark to
light to check that all pixels on the display are operational. Additionally, the odometer display will illuminate all LED segments. This test is independent of any data
input signals that may be displayed on the screens.

Instrument Cluster Tests using VCADS Pro


With the Display test selected in the VCADS Pro tool, the graphic display screen will
alternate from dark to light to check that all pixels on the display are operational. Additionally, the odometer display will illuminate all LED segments. This test is independent
of any data input signals that may be displayed on the screens. See the most current
VCADS Pro user manual or the Help menu in the VCADS Pro tool.
111

Group 38 Instrumentation, VN / VHD

Troubleshooting

Troubleshooting, Odometer
Odometer Backlighting
The odometer backlighting is the same as the other
dash and instrumentation backlighting. See Instrument
Cluster Backlighting, Troubleshooting page 106 for more
information.

Odometer Display
Step 1. Run cluster self-test. If the odometer display functions correctly in this test, the display is OK. This test is
independent of any data input signals that may be displayed on the screens.
If the odometer functions correctly in this test, but is not calculating:
Check if tachometer and speedometer are working. If yes, replace the cluster (or center module if out of warranty). If no, check the data link as shown in the chart below.
If tachometer and odometer work, but not the speedometer, check the wiring for the speed signal input.

Step 2. If the odometer display does not function properly using the above test, go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded blue for the CY connector pins. Proceed to the chart below.
Note: There is no breakout harness for connector CX. To check CX measuring points, back-probe CX connector pins.
See Connectors, Back-probing page 134.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Function

Key Position

Measuring Point

Expected
Value

Power supply

On

Check CX4 to
ground with meter

12V

Ground

Off

Check CX5 to
ground with meter

Information Data
Link
(J1587/J1708)

On

Check CX1 to CX2


with meter

5V max.
0V min.

Connectors or wiring
fault in J1587/J1708
information link (wires
400, 401)

Power Supply

On

Check blue 22
(CY22) to ground
with meter

12V

Fuse, connectors or
wiring fault in power
supply circuit

Ground

Off

Check blue 11
(CY11) to ground
with meter

112

<1

<1

Note

Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit

Disconnect CX
cluster connector

Disconnect CY
cluster connector

Connectors or wiring
fault in ground circuit

Connectors or wiring
fault in ground circuit

Group 38 Instrumentation, VN / VHD

Troubleshooting

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The center module if the warranty has expired.


See Center Module, Replacement page 143.

113

Group 38 Instrumentation, VN / VHD

Troubleshooting

Troubleshooting, Graphic Display


Replaceable lamps provide backlighting for the graphic display. The brightness of the
display can be adjusted with the graphic display control buttons. The graphic display
backlighting is independent of the dash backlighting, but will increase or decrease
when the dash dimmer control is adjusted.

Step 1. If a backlighting problem, replace the suspect lamp with a known good bulb. See

Bulb, Replacement page

137. If this is not the problem, or if the problem is not corrected, continue to step 2.

Step 2. Run cluster self-test. If the graphic display functions properly in the self-test, the display is OK. These tests
are independent of any data input signals that may be displayed on the screens.
Step 3. If the graphic display does not function properly using the above tests, connect breakout box 9998551 with
adapter J-43235 in series between wiring harness connector LX and the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The overlay is color-coded green for the LX connector
pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Function

Key Position

Measuring Point

Expected
Value

Note

Measurements not
expected value?
Check:

Cluster Backlighting Signal

On

Check green 20
(LX20) to ground
with meter

2.5 to 12 V

Head/parking
lamps on - varies
with dimmer position

Switch, connectors or
wiring fault in backlighting circuit from
dimmer control switch.

Power supply

On

Check green 10
(LX10) to ground
with meter

12V

Ground

Off

Check green 9
(LX9) to ground with
meter

Information Data
Link
(J1587/J1708)

On

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

<1

Fuse, connectors or
wiring fault in power
supply circuit
Disconnect LX
cluster connector

5V max.
0V min.

Connectors or wiring
fault in ground circuit
Connectors or wiring
fault in J1587/J1708
information link (wires
400, 401)

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

Note: Problems in the graphic display may be in the


graphic display or the left CPU board. No test are currently available to isolate the problem area.
114

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauges, Troubleshooting
Instrument cluster gauges may operate based on inputs from hardwired sensors, signals received via the J1587/J1708 information data link, or mechanical inputs. See the
Design and Function section of this manual for an operating description of each
gauge.
Before troubleshooting, see General Work Practices page 88.

W3003773

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

Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

Instrument Cluster Self Test


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

With the gauge test active the electrically operated gauges will sweep to full and
half travel. This test is independent of any inputs to the instrument cluster. If the
gauge operates properly with this test it is likely the gauge itself is functioning
properly.
115

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauge Tests, Accuracy and Calibration using VCADS Pro


Gauge Test
With the Gauge test selected in the VCADS Pro tool, the electrically operated gauges
will sweep to full and half travel. This test is independent of any inputs to the instrument cluster. If the gauge operates properly with this test it is likely the gauge itself is
functioning properly. See the most current VCADS Pro user manual or the Help menu
in the VCADS Pro tool.
Gauge Calibration
Most electrically operated gauges can be calibrated using the VCADS Pro tool. In the
calibration process the gauge pointer can be set at the left, center and right gauge index marks. See the most current VCADS Pro user manual or the Help menu in the
VCADS Pro tool.
Note: VCADS Pro does not have the capability of calibrating the speedometer or
tachometer.
Gauge Checks
The VCADS Pro tool can display the value of signals coming to the instrument cluster
for most electrically operated gauges. These values can then be compared to the reading displayed on each respective gauge.
If the reading displayed on the gauge is within a pointers width of the value seen on
the VCADS Pro tool, the gauge is accurate. If the gauge accuracy is incorrect, it can
be adjusted with the Gauge Calibration feature of the VCADS Pro tool. See the most
current VCADS Pro user manual or the Help menu in the VCADS Pro tool.
Note that if the gauge is calibrated at one point, it may affect the calibration at another
point on the gauge. Gauges should not be calibrated unless the readings are obviously
inaccurate.

Gauge Reaction to Short or Open Circuits


The gauges can be of assistance in the event of short and open circuits. This applies
to all gauges that can be activated by the gauge test. See Instrument Cluster Diagnostic Tests page 89. In the event of a short-circuit to ground or supply voltage, the
gauges display either the maximum or minimum readings. In the event of an open circuit the gauges display the minimum reading.
Example: Pyrometer Gauge


The display reads 1500 F if there is a short-circuit in the pyrometer wiring. 300 F or
less is displayed if there is an open circuit in the wiring.
Note that the fault can occur in wiring, connectors, sensors etc. The fault may occur as
a result of mechanical faults, oxidation etc.

Intermittent Faults
In the event of an intermittent fault, the cause may be connector related. For further information on fault tracing of wiring and connectors, refer to (for circuitry information):
Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

Also check for fault codes using the instrument cluster diagnostic function. See Fault
diagnostic page 68.
116

Group 38 Instrumentation, VN / VHD

Troubleshooting

Left Module Gauges


Note: If the LEDs in the engine oil pressure and/or
coolant temperature gauges do not operate properly see
Warning and Telltale Lamps, Troubleshooting page 92.

Step 1. Run cluster self-test. If an accuracy complaint, check accuracy with the Instrument Cluster Tests using VCADS Pro.
If the gauge functions properly in these self-tests, the gauge is OK. Check engine diagnostics for fault codes.
If the suspect gauge does not function properly, see step 2.

Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX connector pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Gauge

Function

Key Position

Measuring
Point

Expected
Value

All left module gauges

Power supply

On

Check green 10
(LX10) to ground
with meter

12V

Ground

Off

Check green 9
(LX9) to ground
with meter

Note

Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit

Disconnect LX
connector at
cluster

Connectors or
wiring fault in
ground circuit

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

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

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

Function

Key Position

Measuring
Point

Expected
Value

Note

Measurements not
expected value?
Check:

Engine oil
pressure

Information
data link

On

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

5V max.
0V min.

Check for fault


codes in
EECU related
to oil pressure
sensor signal
failure

Connectors or
wiring fault in
J1587/J1708 information link from
EECU. Fault in sensor or circuit to
EECU
117

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Note

Measurements not
expected value?
Check:

Engine
coolant temperature

Information
data link

On

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

5V max.
0V min.

Check for fault


codes in
EECU related
to coolant temperature
sensor signal
failure

Connectors or
wiring fault in
J1587/J1708 information link from
EECU. Fault in sensor or circuit to
EECU

Turbo boost
pressure

Information
data link

On

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

5V max.
0V min.

Check for fault


codes in EECU
related to turbo
boost pressure
sensor signal
failure

Connectors or
wiring fault in
J1587/J1708 information link from
EECU. Fault in sensor or circuit to
EECU

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace:

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The left gauge module or left CPU board if the warranty has expired. See Left
Gauge Module, Replacement page 141 or Left CPU Board, Replacement page
156.

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

Pyrometer Gauge

Step 1. With the engine warm, run the cluster self test.
If the gauge does not move, replace the cluster (or left gauge module or graphic display module if out of warranty)
If the gauge sweeps as it should, check for fault codes.

Step 2. If there are fault codes, check the area indicated. If no fault codes, go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 to wiring harness connector LY only. Do not connect
the instrument cluster connector LY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LY connector pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
118

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Note

Measurements not
expected value?
Check:

Pyrometer

Signal

Off

Check green 30
(LY30) to green
13 (LY13) with
meter

5-300 mV

Engine warm.
May show 0V if
engine is cold

Pyrometer thermocouple, wiring or


connectors

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace:

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The left gauge module or left CPU board if the warranty has expired. See Left
Gauge Module, Replacement page 141 or Left CPU Board, Replacement page
156.

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

119

Group 38 Instrumentation, VN / VHD

Troubleshooting

Center Module Gauges


Step 1. Run cluster self-test.
If both gauges function properly in the self-test, the gauges are OK. Check diagnostics for fault codes related to
the system. Also check the information link as shown in the chart below.
If only one gauge functions replace the cluster (or center module if out of warranty).
If neither gauge functions properly, see step 2.

Step 2. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded blue for the CY connector pins. Proceed to the chart below.
Note: There is no breakout harness for connector CX. To check CX measuring points back probe CX connector pins.
See Connectors, Back-probing page 134.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Speedometer

Power supply

On

Check blue 22
(CY22) to ground
with meter

12V

Ground

Off

Check blue 11
(CY11) to ground
with meter

Information
data link

On

Check CX1 to
CX2 with meter

5V max.
0V min.

Power supply

On

Check CX4 to
ground with meter

12V

Ground

Off

Check CX5 to
ground with meter

Information
data link

On

Check CX1 to
CX2 with meter

Tachometer

Odometer

120

<1

<1

5V max.
0V min.

Note

Measurements
not expected
value? Check:
Fuse, connectors
or wiring fault in
power supply circuit

Disconnect CY
connector at
cluster

Connectors or
wiring fault in
ground circuit

Check for fault


codes related
to vehicle
speed sensor
signal failure

Connectors or
wiring fault in
J1587/J1708 information link. Fault
in vehicle speed
sensor circuit
Fuse, connectors
or wiring fault in
power supply circuit

Disconnect CX
connector at
cluster

Connectors or
wiring fault in
ground circuit

Check for fault


codes related
to engine
speed sensor
signal failure

Connectors or
wiring fault in
J1587/J1708 information link. Fault
in engine speed
sensor circuit

See Graphic Display and Odometer, Troubleshooting page 111.

Group 38 Instrumentation, VN / VHD

Troubleshooting

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace:

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The center module if the warranty has expired.


See Center Module, Replacement page 143.

121

Group 38 Instrumentation, VN / VHD

Troubleshooting

Right Module Gauges


Sensors for the right module electrical gauges are hardwired to the left module. From the left module, jumper wires
deliver signals to the right module to operate the gauges. The right module also contains mechanically operated air
pressure gauges.
Note: If the warning LEDs in the front and/or rear air pressure gauges do not operate properly see LED Indicator
Lamps page 93.

Electrical Gauges

Step 1. Run cluster self test. If an accuracy problem, check gauge accuracy with the Instrument Cluster Tests using VCADS Pro. If the gauge functions properly go to step 2. If it does not operate properly, go to step 3.
Note: Only electrically operated gauges will operate with these tests.

Step 2. Check for fault codes related to the system. If fault codes are present, repair fault condition, then recheck. If
no fault codes related to the system are present go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector RX and
the instrument cluster connector RX. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the RX connector pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Forward rear
axle temperature

Power supply

On

Check green 18
(RX18) to ground
with meter

12V

Ground

Off

Green 15 (RX15)
to ground with
meter

Signal from
left module

On

Green 3 (RX3)
to ground with
meter

Rear rear
axle temperature

122

Power supply

On

Green 18 (RX18)
to ground with
meter

Ground

Off

Green 15 (RX15)
to ground with
meter

Signal from
left module

On

Green 17 (RX17)
to ground with
meter

Note

Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit

<1

Connectors or
wiring fault in
ground circuit

5V

Gauge at maximum reading

10V

minimum

12V

Left (graphic display) module failure


or connectors/wiring
from left module

Fuse, connectors or
wiring fault in power
supply circuit

<1

Connectors or
wiring fault in
ground circuit

5V

Gauge at maximum reading

10V

minimum

Left (graphic display) module failure


or connectors/wiring
from left module

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Fuel level

Power supply

On

Green 18 (RX18)
to ground with
meter

12V

Ground

Off

Green 15 (RX15)
to ground with
meter

Signal from
left module

On

Green 4 (RX4)
to ground with
meter

Note

Measurements not
expected value?
Check:
Fuse, connectors or
wiring fault in power
supply circuit

<1

Connectors or
wiring fault in
ground circuit

5V

Gauge reading
full

10V

empty

Left (graphic display) module failure


or connectors/wiring
from left module

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If all the measurements are correct, replace:

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

123

Group 38 Instrumentation, VN / VHD

Troubleshooting

Mechanical Gauges

Step 1. Connect test gauge J-44274 in series between the air lines and the instrument cluster gauge fitting. The air
lines and gauge fittings are color coded to aid in assembly.
If the test gauge tooling is not available, the air lines from two gauges may be swapped to help determine gauge
faults. Always reconnect the air line to the proper gauge. The air lines and gauge fittings are color coded to aid in installation.

Gauge

Measuring Point

Expected Value

Note

Measurements not expected value? Check:

Front brake air


pressure

Front brake air pressure gauge fitting (red)

Approximately
same value as
test gauge

Vehicle air pressure


at governor setting

Gauge failure

Rear brake air


pressure

Rear brake air pressure


gauge fitting (green)

Approximately
same value as
test gauge

Vehicle air pressure


at governor setting

Gauge failure

Application air
pressure

Application air pressure


gauge fitting (black)

Approximately
same value as
test gauge

Vehicle air pressure


at governor setting
with foot brake pedal
applied

Gauge failure

Air suspension
pressure

Air suspension pressure gauge fitting


(black)

Approximately
same value as
test gauge

Vehicle air pressure


at governor setting

Gauge failure

The tests above only check for consistent readings between the instrument cluster
gauge and test gauge. If air pressure seems out of normal operating range, the vehicle
air system should be checked for proper operation.
If measurements indicate a faulty air gauge, replace:

124

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

Group 38 Instrumentation, VN / VHD

Troubleshooting

Sensor Wiring / Axle Temperature Sensors

Step 1. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector LY and
the instrument cluster connector LY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LY connector pins.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Forward rear
axle temperature

Reference
voltage

On

Check green 29
(LY29) to ground
with meter

5V max.
0V min.

Ground

Off

Check green 29
(LY29) to ground
with meter

W3003735

1000

10% @


21 C (70 F)

Note

Measurements not
expected value?
Check:
Check power supply to left module. If
OK and no output
from LY29, probable
left (graphic display)
module failure

Disconnect LY
connector at
cluster

Sensor, connectors
or wiring fault in
ground circuit
through forward rear
axle temp. sensor

5V

Gauge at maximum reading

10V

minimum

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

430
10%

@ 50 C

(120 F)
110
10%

@ 95 C

(200 F)
Gauge signal

On

Check green 24
(LY24) to ground
with meter

125

Group 38 Instrumentation, VN / VHD

Troubleshooting

Gauge

Function

Key Position

Measuring
Point

Expected
Value

Rear rear
axle temperature

Reference
voltage

On

Check green 16
(LY16) to ground
with meter

5V max.
0V min.

Ground

Off

Check green 16
(LY16) to ground
with meter

W3003735

1000

10% @


21 C (70 F)

Note

Measurements not
expected value?
Check:
Check power supply to left module. If
OK and no output
from LY16, probable
left (graphic display)
module failure

Disconnect LY
connector at
cluster

Sensor, connectors
or wiring fault in
ground circuit
through rear rear
axle temp. sensor

5V

Gauge at maximum reading

10V

minimum

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

430
10%

@ 50 C

(120 F)
110
10%

@ 95 C

(200 F)
Gauge signal

On

Check green 21
(LY21) to ground
with meter

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

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

126

Group 38 Instrumentation, VN / VHD

Troubleshooting

Sensor Wiring / Fuel Level Sensor

Step 1. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX connector pins.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Sen

Function

Key Position

Measuring
Point

Expected
Value

Fuel level

Reference
voltage

On

Check green 2
(LX2) to ground
with meter

5V max.
0V min.

Ground

Off

Check green 2
(LX2) to ground
with meter

240
10%
@ empty
tank

Note

Measurements not
expected value?
Check:
Check power supply to left module. If
OK and no output
from LX2, probable
left (graphic display)
module failure

Disconnect LX
connector at
cluster

Sensor, connectors
or wiring fault in
ground circuit
through fuel level
sensor

5V

Gauge reading
full

10V

empty

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

153
10%
@ 1/4 tank
103
10%
@ 1/2 tank
67
10%
@ 3/4 tank
33
10%
@ full tank
Gauge signal

On

Check green 3
(LX3) to ground
with meter

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

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

127

Group 38 Instrumentation, VN / VHD

Troubleshooting

Graphic Display Control Buttons, Troubleshooting

W3004326

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

Service
Manual

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

The graphic display control buttons are used to manually communicate with and manipulate the graphic display. Before troubleshooting, see General Work Practices
page 88.

Test using VCADS Pro


This test confirms that the control buttons on the wiper stalk are delivering a signal to
the instrument cluster. The indicator on the VCADS Pro tool will illuminate green when
the buttons Esc, Select, Up Arrow, Down Arrow are pressed.
More information about the tests can be found in the most current VCADS Pro user
manual or the Help menu in the VCADS Pro tool.

Troubleshooting
Step 1. Run cluster test using the VCADS Pro tool. If the wiper stalk control buttons function correctly in this test,
they are working properly. If not, see step 2.
Step 2. Connect breakout box 9998551 with adapter J-43235 in series between wiring harness connector LX and
the instrument cluster connector LX. Install overlay J-43340 with the 22PIN BREAKOUT HARNESS side up. The
overlay is color-coded green for the LX connector pins. Proceed to the chart below.
Note: If the breakout box tooling is not available, the instrument cluster connector pins may be back-probed with digital multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.

Function

Key Position

Measurement
Point

Expected
Value

Power supply to
wiper stalk

On

Check green
21 (LX21) to
ground with
meter

12V

Esc button

On

Check green 4
(LX4) to ground
with meter

12V

128

Note

Measurement not
expected value?
Check:
Left module power
supply or internal left
module fault

Button active

Wiper stalk switch,


connector or wiring
fault

Group 38 Instrumentation, VN / VHD

Troubleshooting

Function

Key Position

Measurement
Point

Expected
Value

Note

Measurement not
expected value?
Check:

Select button

On

Check green 7
(LX7) to ground
with meter

12V

Button active

Wiper stalk switch,


connector or wiring
fault

Up button

On

Check green
16 (LX16) to
ground with
meter

12V

Button active

Wiper stalk switch,


connector or wiring
fault

Down button

On

Check green 6
(LX6) to ground
with meter

12V

Button active

Wiper stalk switch,


connector or wiring
fault

Power supply, left


module

On

Check green
10 (LX10) to
ground with
meter

12V

Ground

Off

Check green 9
(LX9) to ground
with meter

<1

Fuse, connectors, or
wiring fault in power
supply circuit
Disconnect LX connector at cluster

Connectors or wiring
fault in ground circuit

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

VN Series Electrical Schematics, Group 37


or VHD Series Electrical Schematic, Group 37

IMPACT

Function Group: 37
Information Type: Electrical Schematics
Model: VN/VHD

If the wiper stalk switch is suspected refer to:


Service
Manual

PV776TSP143133
Windshield Wiper System

IMPACT

Function Group: 363


Information Type: Windshield Wiper System
Model: VN/VHD

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

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

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

129

Group 38 Instrumentation, VN / VHD

Troubleshooting

Buzzer, Troubleshooting
The buzzer is located on the center module and activated by messages received on
the J1587/1708 information data link. Before troubleshooting, see General Work
Practices page 88.

W3003627

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

Service
Bulletin

PV776TSP109322
Windshield Wiper System

IMPACT

Function Group: 363


Information Type: blnt-geninfo
Windshield Wiper System

Instrument Cluster Self Test


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

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

Instrument Cluster Test using VCADS Pro


With the buzzer test active the graphic display will alternate from flasher indicator
to reminder to caution. A different tone will sound with each display message.
See the most current VCADS Pro user manual or the Help menu in the VCADS
Pro tool.

Buzzer Tests
Step 1. Run the cluster self test. If the buzzer functions correctly in the self test the buzzer is OK. If the buzzer
does not function properly in these tests, go to step 2.
Step 2. Check for fault codes related to the system. If fault codes are present, repair fault condition, then recheck. If
no fault codes related to the system are present go to step 3.
Step 3. Connect breakout box 9998551 with adapter J-43234 in series between wiring harness connector CY and
the instrument cluster connector CY. Install overlay J-43340 with the 30PIN BREAKOUT HARNESS side up. The
overlay is color-coded blue for the CY connector pins. Proceed to the table below.
Note: If the breakout box tooling is not available, carefully back probe the instrument cluster connector pins with digital
multimeter J39200 or an equivalent tool. See Connectors, Back-probing page 134.
Note: There is no breakout box tooling available for connector CX.
130

Group 38 Instrumentation, VN / VHD

Troubleshooting

Function

Key Position

Measuring point

Expected
Value

Power Supply

On

Check CX4 to
ground with meter

12V

Ground

Off

Check CX5 to
ground with meter

Flasher, Reminder,
Caution or Alarm
Clock Signal

On

Check CX1 to
CX2 (Data link)
with meter

5V max.
0V min.

Left Turn Audible


Signal

On

Check blue 14
(CY14) to ground
with meter

12V max.
0V min.

Left turn signal active

Turn signal switch, connectors


or wiring fault in left turn signal circuit

Right Turn Audible


Signal

On

Check blue 9
(CY9) to ground
with meter

12V max.
0V min.

Right turn signal active

Turn signal switch, connectors


or wiring fault in right turn signal circuit

<1

Note

Measurement not expected


value? Check:
Fuse, connectors or wiring
fault in power supply circuit

Disconnect
CX connector

Connectors or wiring fault in


ground circuit
Connectors or wiring fault in
J1587/1708 information link
(400, 401 circuit numbers)

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

PV776TSP109322
Windshield Wiper System

IMPACT

Function Group: 363


Information Type: blnt-geninfo
Windshield Wiper System

If all the measurements are correct, replace

The instrument cluster if within the warranty period. See Instrument Cluster, Replacement page 139.

The center module if the warranty has expired.


See Center Module, Replacement page 143.

131

Group 38 Instrumentation, VN / VHD

Troubleshooting

Common Problems
Symptom

Cause

Correction

Transmission temperature warning




activates at 212 F instead of 300 F.

Faulty datasets.

Reprogram the instrument cluster,


see Instrument Cluster, Programming page 161.

One or more (datalink) gauges stops


working (on vehicles equipped with
Cummins engine).

Faulty datasets or faulty J1587 circuit.

If there are still any (datalink) gauges


working the Cummins engine ECU
needs to be reprogrammed.
If none of the (datalink) gauges are
working troubleshoot the J1587 circuit.

Airbag icon stays on but the vehicle is


not equipped with an airbag.

Instrument cluster not programmed or


faulty datasets.

Reprogram the instrument cluster,


see Instrument Cluster, Programming page 161.

132

Group 38 Instrumentation, VN / VHD

Service Procedures

Service Procedures
Service Procedures
When dealing with circuits designed to sense differences
General Work Practices
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules and air
gauges can be replaced. Electrical gauges cannot be replaced individually.

CAUTION
Welding on trucks can damage the vehicle electrical
system/components from the voltage and current
spikes that normally occur when welding. It is preferable to avoid welding on an assembled truck, but if
welding must be done on any structure on or in
contact with the vehicle, disconnect the electrical connectors at the rear of the instrument cluster, all ECUs
and the battery cables. When disconnecting the battery cables, disconnect any other ground cables
connected to the battery first, then the main battery
ground. Attach the welder ground cable as close to
the weld as possible.

smaller than 1 volt, electrostatic discharge can be a subtle but destructive problem. Circuit boards mounted in
the instrument cluster or in modules mounted elsewhere
may not fail immediately after being hit with a static discharge. Rather they may work for a while, then fail for no
apparent reason. The culprit then is often the normal
warming up and cooling down process of the module,
engine or cab interior.
Grounding straps and anti-static mats are available for
minimal cost from electronic supply stores. Grounding
straps consist of a wrist strap, a coiled extension wire
and an alligator clip. Be sure to purchase one with a long
enough extension wire to allow freedom of movement.
Anti-static wrist straps and mats are available from
Kent-Moore (see Tools section of this manual). Call
1-800-328-6657.

Preventing electrostatic discharge (ESD)

CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, a wrist grounding strap must be
used when working on electronic equipment such as
the instrument cluster. Failure to use a wrist strap may
result in permanent damage to the printed circuit
boards in the instrument cluster. To use the wrist strap
in a vehicle, attach the alligator clip to the nearest
electrical ground such as a metal mounting screw, a
ground terminal or preferably a ground stud.

CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the instrument cluster, make sure the workbench has an
anti-static mat which is grounded to the nearest electrical outlet when working on the instrument cluster.
Failure to use an anti-static mat may result in permanent damage to the printed circuit boards in the
instrument cluster. When working at the anti-static
workbench, always keep a wrist strap connected to
the anti-static mat.
133

Group 38 Instrumentation, VN / VHD

Service Procedures

Connectors, Back-probing

The tests in the troubleshooting section of this manual


suggest the use of breakout boxes and harnesses. However, if the breakout box tooling is not available, the
instrument cluster connector pins may be back-probed
with digital multimeter J-39200 (or equivalent tool). Follow these steps when back-probing connectors.

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

W3003661

Use the digital multimeter test probes


to contact the metal portion of the connector pins. Do not puncture the wire
insulation when probing. Do not allow
the test probes to contact each other
to avoid false readings and/or damage
to the wiring, connectors or instrument
cluster.
4

W3003656

W3003660

Wire Insertion Side

Use the pin-out charts in the VN Series Electrical Schematics or this


manual to determine the exact location
of the measuring points. Note that all
drawings show the pins from the wire
insertion side.
134

Front-probing: If it is necessary to
disconnect a connector and
front-probe a pin, never use the multimeter probes to directly contact
the connector pins. Using these
large probes can damage the connector pins and result in intermittent faults.
To avoid damage, use tool J-42449
when front-probing connector pins.

J-42449

Group 38 Instrumentation, VN / VHD

Service Procedures

Housing and Front Panel


Glass, Cleaning

The butt splice connector should also be used for adding


circuitry for after-market functions i.e., extra telltale lights
to the instrument cluster.

To clean the housing and front panel glass, use a soft,


non-abrasive cloth and a mild soap-and-water solution.

Special tools: Terminal removal and probe kit: J-42449


(Kent-Moore),
Packard crimper: J-381258 (Kent-Moore),
Heat gun: J-25070 (Kent-Moore)

Connector Terminals, Adding


or Replacing

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

Removal
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

CAUTION
Before beginning this procedure, see General Work
Practices page 133.

W3002866

W3003654

To replace faulty terminals in instrument cluster electrical


connectors use the butt splice connectors listed below
(available from Volvo):

3948725 (for black, numbered wires)

Disconnect the connector with the


faulty terminal from the instrument
cluster. Pry open the lock on the male
portion of the connector using a small
flat screwdriver.
Note: The lock is not easy to see. To
open the lock, pry just under the top
ledge of the connector (see figure).

3948726 (for ground wires)

135

Group 38 Instrumentation, VN / VHD

Service Procedures

Installation

1
Cut the faulty terminal wire to the
same length as the JAE terminal pigtail replacement.
2

W3002867

Remove the faulty terminal from the


connector as follows, using the removal tool from kit J-42449. (Note that
in each of these JAE connectors there
are two rows of terminals, and two
rows of release holes. The release
holes are on the outside, and are
slightly larger than the ones containing
terminals.) Insert the removal tool into
the release hole above the terminal
being removed. It will take some pressure to make the terminal locks
release.

W3002868

Strip the insulation back approximately


6 mm (1/4 in.) and install butt splice
3948725 (or 3948726) to the wire.

3948725
3948726

W3002869

Crimp in the 1820 anvil of crimper


J-381258 (this crimper can be found
in the VE D12 engine tool kit, Volvo
P/N 3947553). Slightly pull the wire to
confirm a correct crimp.

136

J-381258

Group 38 Instrumentation, VN / VHD

Service Procedures

Bulb, Replacement

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.

W3002870

Using heat gun J-25070, heat the


splice to shrink the tubing until the adhesive is visible for a good moisture
seal.
5
Install the terminal into the correct
connector cavity. Pull back on the wire
to make certain the terminal is locked
into the connector. Push the connector
lock back into position.
6
Connect the connector to the instrument cluster and check for proper
function.
7
Note: If the terminal was installed to
add functions, it may be necessary to
reprogram the instrument cluster. See
the most current VCADS Pro user
manual or the help menu in the
VCADS Pro tool.

J-25070
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column so that the bulbs are
accessible.

137

Group 38 Instrumentation, VN / VHD

Service Procedures

W3000642

CAUTION
Use only the Volvo bulb removal tool, P/N 1089953, to
remove bulbs, or damage to the cluster may occur.
Insert removal tool, P/N 1089953, onto
the bulb assembly. Rotate 1/4 turn and
pull the bulb assembly out of the
socket.

4
Insert the new bulb assembly into the
removal tool, P/N 1089953. Insert the
assembly into cluster socket and rotate 1/4 turn.
5
Replace the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

138

1089953

Group 38 Instrumentation, VN / VHD

3811-03-02-01
Instrument Cluster, Replacement

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Note: Replacement instrument cluster should be ordered from Volvo per VIN (Vehicle Identification
Number). Replacement instrument cluster will be programmed before delivery.
Note: Replacement instrument clusters should be edited
to reflect the current actual mileage of the vehicle. This
may be accomplished by use of the VCADS PRO tool (or
the Pro Link 9000 tool). Under no circumstances should
the edit odometer functions be used to falsify the actual
mileage. See Odometer, Programming page 162.

W3003659

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

139

Group 38 Instrumentation, VN / VHD

Service Procedures

8
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
9
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

W3003657

WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect. Remove the cluster from the vehicle.
5
Position the replacement instrument
cluster face-down on the steering column in the mounting position. Connect
the air tubing. Note the color codes for
proper installation.
6
Connect all electrical connectors, noting color codes to aid in installation.
7
Important: Reprogram the odometer
to the current actual mileage. See
Odometer, Programming page 162.

140

2 0.3 Nm
(17.5 2.5 inlb)

Group 38 Instrumentation, VN / VHD

3811-03-02-04
Left Gauge Module, Replacement

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be replaced. Individual gauges are not replaceable.

W3003659

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

141

Group 38 Instrumentation, VN / VHD

Service Procedures

W3003648

Remove the 3 left module mounting


screws. Remove the left module cover.
Carefully lift the CPU/graphic display
module and disconnect the ribbon wire
connector to the left gauge module.
Lay the CPU/graphic display to the
side on the static mat.
7
W3003657

WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.

5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

W3003649

Remove the 4 mounting screws for the


left gauge module and remove from
the cluster housing.
8
Position the replacement left gauge
module into the cluster housing. Secure with the 4 mounting screws.

142

Group 38 Instrumentation, VN / VHD

Service Procedures

3811-03-02-03
Center Module, Replacement

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.
Note: Replacement center modules should be edited to
reflect the current actual mileage of the vehicle. This
may be accomplished by use of the VCADS PRO tool (or
the Pro Link 9000 tool). Under no circumstances should
the edit odometer functions be used to falsify the actual
mileage. See Odometer, Programming page 162.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.

W3003658

Carefully connect the ribbon wire connector from the CPU/graphic display
module to the left gauge module. Position the CPU/graphic display module in
the cluster housing.

Important: Individual gauges or modules in the VN/VHD


instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be
replaced.

10
Install the left module cover with the 3
mounting screws.

11
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.

12
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.

13
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

2 0.3 Nm
(17.5 2.5 inlb)

143

Group 38 Instrumentation, VN / VHD

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.

W3003657

W3003659

WARNING
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.

3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

Never disconnect an air system component unless all


system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.

5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

W3003650

Remove the 4 center module mounting


screws, and remove the center module
from the housing.
144

Group 38 Instrumentation, VN / VHD

Service Procedures

3811-03-02-02
Right Module, Replacement

7
Install the replacement center module
into the cluster housing with the 4
mounting screws.
8
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

9
Connect all electrical connectors, noting color codes to aid in installation.

CAUTION
10
Important: Reprogram the odometer
to the current actual mileage. See
Odometer, Programming page 162.

Before beginning this procedure, see General Work


Practices page 133.
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.

11
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
12
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

2 0.3 Nm
(17.5 2.5 inlb)

After the warranty expires, individual modules and air


gauges can be replaced. See Air Gauge, Replacement
page 148 for more information.

145

Group 38 Instrumentation, VN / VHD

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.

W3003657
W3003659

WARNING
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

146

Never disconnect an air system component unless all


system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars on the back of
the cluster while pulling back on the
air tubing to disconnect.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

Group 38 Instrumentation, VN / VHD

Service Procedures

13
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

2 0.3 Nm
(17.5 2.5 inlb)

W3003652

Remove the 3 right module mounting


screws. Remove the right module
cover, and remove the right module
from the housing.
7
Remove the 2 air gauge mounting
screws from each gauge and remove
the gauges from the right module circuit board.
8
Position the air gauges in the cluster
housing assembly to assure proper
alignment. Gauge blanks should also
be in position.
9
Place the replacement right modules
circuit board onto the gauges and secure each with the 2 mounting screws.
10
The right module should now be positioned in the cluster housing. Install
the right module cover and secure with
the 3 right module mounting screws.
11
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
12
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.

147

Group 38 Instrumentation, VN / VHD

3851-03-02-01
Air Gauge, Replacement

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Important: Individual gauges or modules in the VN/VHD
instrument cluster are not serviceable during the warranty period. Attempts to service or replace individual
modules or gauges during the warranty period will
void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules and air
gauges can be replaced.

W3003659

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

148

Group 38 Instrumentation, VN / VHD

Service Procedures

W3003652

Remove the 3 right module mounting


screws. Remove the right module
cover, and remove the right module
from the housing.
7
Remove the 2 air gauge mounting
screws and remove the gauge from
the circuit board.
W3003657

WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars on the back of
the cluster while pulling back on the
air tubing to disconnect.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

W3004299

Position the new air gauge in the cluster housing assembly to assure proper
alignment.
9
Place the right module circuit board
onto the gauge and secure with the 2
mounting screws.
10
The right module should now be positioned in the cluster housing. Install
the right module cover and secure with
the 3 right module mounting screws.
149

Group 38 Instrumentation, VN / VHD

Service Procedures

3811-03-02-09
Graphic Display, Replacement

11
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
12
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
13
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

2 0.3 Nm
(17.5 2.5 inlb)

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Important: Individual gauges or modules, including the
graphic display, in the VN/VHD instrument cluster are not
serviceable during the warranty period. Attempts to service or replace individual modules or gauges during
the warranty period will void the cluster warranty. Instead, the whole instrument cluster may be exchanged.
After the warranty expires, individual modules can be
replaced.

150

Group 38 Instrumentation, VN / VHD

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.

W3003657
W3003659

WARNING
CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

Never disconnect an air system component unless all


system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.
5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

151

Group 38 Instrumentation, VN / VHD

Service Procedures

10

W3003648

Remove the 3 left module mounting


screws. Remove the left module cover.
Carefully lift the CPU/graphic display
module and disconnect the ribbon wire
connector to the left gauge module.
Remove from the cluster.
7
Remove the 2 screws securing the
graphic display to the CPU board.
8
W3003658

Install the replacement CPU/graphic


display module by carefully connecting
the ribbon wire connector to the left
gauge module, and positioning the
CPU/graphic display module in place.
11
Install the left module cover with the 3
mounting screws.
12
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.
W3004304

Carefully work the graphic display and


the CPU board apart.
9
Align the connector pins in the replacement graphic display with the CPU
board and carefully push into position.
Secure with the 2 mounting screws.

13
Connect all electrical connectors, noting color codes to aid in installation.
14
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
15
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

152

2 0.3 Nm
(17.5 2.5 inlb)

Group 38 Instrumentation, VN / VHD

3811-03-02-08
Instrument Cluster Housing/Glass, Replacement

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.

W3003659

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

153

Group 38 Instrumentation, VN / VHD

Service Procedures

W3003657

WARNING
W3003658

Never disconnect an air system component unless all


system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.

5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

Remove the 3 left module mounting


screws. Remove the left module cover.
Carefully lift the CPU/graphic display
module and disconnect the ribbon wire
connector to the left gauge module.
Lay to the side on the static mat.
7
Remove the 4 mounting screws for the
left gauge module and remove from
the cluster housing. Lay to the side on
the static mat.
8
Remove the 4 center module mounting
screws, and remove the center module
from the housing. Lay to the side on
the static mat.
9
Remove the 3 right module mounting
screws. Remove the right module
cover, and remove the right module
from the housing. Lay to the side on
the static mat.

154

Group 38 Instrumentation, VN / VHD

Service Procedures

10

13

W3003651

Empty Replacement Cluster Housing

Install the right module into the replacement cluster housing. Install the
cover with the 3 mounting screws.
Note: If any gauge blanks are present
in the existing cluster housing position
them correctly in the replacement
housing.
11
Install the center module into the replacement cluster housing. Install the
cover with the 4 mounting screws.

12
Install the left gauge module into the
replacement cluster housing. Secure
with the 4 mounting screws.

W3003658

Install the CPU/graphic display module


by carefully connecting the ribbon wire
connector to the left gauge module,
and positioning the CPU/graphic display module in place.

14
Install the left module cover with the 3
mounting screws.

15
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.

16
Connect all electrical connectors, noting color codes to aid in installation.
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.

17
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

2 0.3 Nm
(17.5 2.5 inlb)

155

Group 38 Instrumentation, VN / VHD

3871-03-02-01
Left CPU Board, Replacement

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Note: Replacement left CPU board should be ordered
from Volvo per Vehicle Identification Number (VIN). Replacement left CPU boards will be programmed before
delivery.
W3003659

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

156

Group 38 Instrumentation, VN / VHD

Service Procedures

W3003657

WARNING
W3003658

Never disconnect an air system component unless all


system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.

Remove the 3 left module mounting


screws. Remove the left module cover.
Carefully lift the CPU/graphic display
module and disconnect the ribbon wire
connector to the left gauge module.
Lay to the side on the static mat.
7
Remove the 2 screws securing the
graphic display to the CPU board.

5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

157

Group 38 Instrumentation, VN / VHD

Service Procedures

15
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

W3004304

Carefully work the graphic display and


the CPU board apart.

9
Align the connector pins in the graphic
display module with the replacement
CPU board and carefully push into position. Secure with the 2 mounting
screws.

10
Install the replacement CPU/graphic
display module by carefully connecting
the ribbon wire connector to the left
gauge module, and positioning the
CPU/graphic display module in place.

11
Install the left module cover with the 3
mounting screws.

12
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.

13
Connect all electrical connectors, noting color codes to aid in installation.

14
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
158

2 0.3 Nm
(17.5 2.5 inlb)

Group 38 Instrumentation, VN / VHD

3811-03-02-11
Instrument Cluster Rear Cover,
Replacement (Left or Right)

Service Procedures

1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.

CAUTION
Before beginning this procedure, see General Work
Practices page 133.
Note: The center rear cover is part of the center module
and not replaceable as a single part.
W3003659

CAUTION
When servicing or troubleshooting, do not leave the
cluster face-down for more than 15 minutes, or damage to the gauges may occur. Gauge oil can run out
the front of the gauge faces and make the gauges inaccurate.
Adjust the steering column back where
possible. Remove the two screws at
the top of the instrument cluster and
lay the cluster face-down on the steering column.
3
Cut the tie straps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors. Disconnect the electrical connectors from
the back of the cluster.

159

Group 38 Instrumentation, VN / VHD

Service Procedures

W3003657

WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to deplete system pressure before disconnecting hoses or
components may result in them separating violently
and causing serious eye and/or bodily injury.
Bleed all pressure from the vehicle air
system. Using tool J-42189 push in on
the air tubing collars while pulling back
on the air tubing to disconnect.

5
Remove the cluster from the vehicle.
Place it on a static mat for repairs. A
static bracelet must be worn for all
bench repairs.

6
Remove the 3 right or left rear cover
mounting screws. Remove the left
module cover.

W3004316

Compare the hole pattern in the existing cover with the replacement cover.
Due to different configuration, it may
be necessary to knock out openings
in the replacement cover to accommodate the existing gauges and lamps.
Use a 1/2 inch punch or drill to modify
the replacement cover as needed.

8
Install the cover with the 3 mounting
screws.

9
Place the instrument cluster face down
on the steering column in the mounting
position. Connect the air tubing, noting
color codes for proper installation.

10
Connect all electrical connectors, noting color codes to aid in installation.

11
For stress relief on the connectors, tie
strap the wiring to the back of the instrument cluster.
160

Group 38 Instrumentation, VN / VHD

12
Position the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster.
Torque to 2 0.3 Nm (17.5 2.5 in-lb).

Service Procedures

2 0.3 Nm
(17.5 2.5 inlb)

Instrument Cluster, Programming

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.
Note: Replacement instrument cluster and/or left CPU
board should be ordered from Volvo per Vehicle Identification Number (VIN). Replacement instrument cluster
and/or left CPU boards will be programmed before delivery.
Note: Only authorized technicians can update and/or alter software datasets with the VCADS Pro tool. See
Instrument Cluster Programming page 18.

W0001632

The VCADS Pro tool is a Windows 95 based PC tool


that can be used to program the instrument cluster. The
following is a brief description of the current programming procedure. For more detailed programming
information consult the most current VCADS Pro user
manual or the Help menu in the VCADS Pro tool.
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
Remove the 2 instrument cluster
mounting screws.
3
Connect telephone or network line to
the VCADS Pro tool.
Note: Make sure to select the right
connection type in the VCADS Pro
tool.

161

Group 38 Instrumentation, VN / VHD

4
Start the VCADS Pro tool. Select Programming / Vehicle Electronics 98 /
Replace ECU. Then, select Driver Information Display and the proper
VIN. Follow the on screen prompts until the programming is completed.
5
Disconnect all VCADS Pro tool cables
from the vehicle. Connect the instrument cluster to the harness connector.
6
Secure instrument cluster with the
mounting screws.

Service Procedures

Odometer, Programming

Before working on the vehicle, set the parking brakes,


place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or
death.
Note: Replacement instrument clusters and center modules should be edited to reflect the current actual
mileage of the vehicle. Under no circumstances should
the odometer programming function be used to falsify
the actual vehicle mileage.

W0001632

The VCADS Pro tool is a Windows 95 based PC tool


that can be used to program the instrument cluster. The
following is a brief description of the current programming procedure. For more detailed programming
information consult the most current VCADS Pro user
manual or the Help menu in the VCADS Pro tool.
The Pro Link 9000 can also be used to program the instrument cluster odometer. See Pro Link 9000 page
163 for programming instructions.

VCADS Pro Tool


1
Make certain the vehicle ignition is
OFF before beginning this procedure.
2
Connect telephone or network line to
the VCADS Pro tool.
Note: Make sure to select the right
connection type in the VCADS Pro
tool.
3
Start the VCADS Pro tool. Select Programming / Vehicle Electronics 98 /
Instrument Mileage. Follow the on
screen prompts until the programming
is completed.
162

Group 38 Instrumentation, VN / VHD

Service Procedures

4
Disconnect all VCADS Pro tool cables
from the vehicle.

Pro Link 9000


1
Note: The following is a brief description of the current odometer
programming procedure. For more detailed information consult the most
current Pro Link 9000 user manual.
2
Make certain the vehicle ignition is
OFF before beginning this procedure.
3

W3004318

Connect the Pro Link 9000 tool to the


communication connector in the vehicle.
4
Turn the ignition key ON.
5
Select 99 INST CLUSTER / PROGRAM NEW ODOMETER, enter the
desired mileage.
Note: The Pro Link 9000 will only program in miles. Kilometers must be
converted to miles before entering. (1
mile = 1.61 km)
6
Disconnect the Pro Link from the vehicle.

163

164

Feedback
One of our objectives is that workshop personnel should have access to correct and
appropriate service manuals where it concerns fault tracing, repairs and maintenance
of Volvo trucks.
In order to maintain the high standards of our literature, your opinions and experience
when using this manual would be greatly appreciated.
If you have any comments or suggestions, make a copy of this page, write down your
comments and send them to us, either via telefax or mailing directly to the address
listed below.

To

From

Volvo Trucks North America, Inc.

..........................................................................

Dept. 516 Service Publications

..........................................................................

7825 National Service Road

..........................................................................

P.O. Box 26115

..........................................................................

Greensboro, NC 27402-6115

..........................................................................

USA

..........................................................................

(336) 393-3241

..........................................................................

Comments/proposals
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Concerns Service Manual: ...............................................................................................................................

Operation Numbers
3811-03-02-01
3811-03-02-02
3811-03-02-03
3811-03-02-04
3811-03-02-08
3811-03-02-09
3811-03-02-11
3851-03-02-01
3871-03-02-01

Instrument Cluster, Replacement . . . . . . . . . . . .


Right Module, Replacement . . . . . . . . . . . . . . .
Center Module, Replacement . . . . . . . . . . . . . .
Left Gauge Module, Replacement . . . . . . . . . . . .
Instrument Cluster Housing/Glass, Replacement . . . . .
Graphic Display, Replacement . . . . . . . . . . . . . .
Instrument Cluster Rear Cover, Replacement (Left or Right)
Air Gauge, Replacement . . . . . . . . . . . . . . . .
Left CPU Board, Replacement . . . . . . . . . . . . . .

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Volvo Trucks North America, Inc.


P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.


6490 Vipond Drive, Mississauga, Ontario L5T 1W8
http://www.volvotrucks.volvo.com

PV776-TSP139790 (1000) 8.00 Volvo Trucks North America, Inc., 2000