Volvo VNL Service Manual
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Volvo VNL Service Manual

Volvo VNL Service Manual

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Service Manual
Trucks
38
Group
Instrumentation – 1996B
VNL, VNM — from 1/98
PV776-TSP106805/1

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  • Page 1 Service Manual Trucks Group Instrumentation – 1996B VNL, VNM — from 1/98 PV776-TSP106805/1...
  • Page 2 Greensboro, NC USA Order number: PV776-TSP106805/1 © 1998 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, me- chanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

  • Page 3: Table Of Contents

    Contents General ....................3 General Work Practices ................ 3 Basic Description ................... 4 Tools ......................9 Special Tools ..................9 Special Equipment ................10 Design and Function ................11 Instrument Cluster ................. 11 Instrument Cluster Functional Diagram ..........11 Gauges and Indicators ................ 13 Connector Pinouts ................

  • Page 5: General

    Group 38 Instrumentation, VNL, VNM General General General Work Practices CAUTION CAUTION When servicing or troubleshooting, do not leave the To prevent electrostatic discharge (ESD), which may cluster face-down for more than 15 minutes, or damage the sensitive electronic components in the in- damage to the gauges may occur.

  • Page 6: Basic Description

    Group 38 Instrumentation, VNL, VNM General Basic Description T3009000 Fig. 1: This information describes the 1996B AMETEK/Dixson Instrument Cluster for VN Se- ries vehicles and how to service it. This instrument cluster went into production in January 1998. It is distinguished from the earlier VN instrument cluster by the location of the Mode/Set and Up/Down buttons on the stalk arm.
  • Page 7 Group 38 Instrumentation, VNL, VNM General Available Configurations T3009001 Fig. 2:...
  • Page 8 Group 38 Instrumentation, VNL, VNM General Available Configurations (contd.) T3009002 Fig. 3:...
  • Page 9 Group 38 Instrumentation, VNL, VNM General Available Configurations (contd.) T3009303 Fig. 4:...

  • Page 11: Tools

    Group 38 Instrumentation, VNL, VNM Tools Tools Special Tools The following special tools are required for work on the instrument cluster. The tools can be ordered as listed below. W0001517 Fig. 5: 104004 Pro-link 9000 1089953 Bulb Removal Tool (available from MPSI at 1-800-...

  • Page 12: Special Equipment

    Group 38 Instrumentation, VNL, VNM Tools Special Equipment The following items are required for work on the instrument cluster. They can be or- dered as shown below. W0001518 Fig. 6: J-42444 Type 8501 Static Dissipative Grounding Kit, available from Kent-Moore (1-800-328-6657).

  • Page 13: Design And Function

    Group 38 Instrumentation, VNL, VNM Design and Function Design and Function Instrument Cluster Instrument Cluster Functional Diagram Volvo Engines W3002521 Fig. 7:...
  • Page 14 Group 38 Instrumentation, VNL, VNM Design and Function Caterpillar, Cummins, Detroit Diesel Engines W3002520 Fig. 8:...

  • Page 15: Gauges And Indicators

    Group 38 Instrumentation, VNL, VNM Design and Function Gauges and Indicators Left Section Pyrometer (optional) The pyrometer indicates exhaust temperature from a sensor in the exhaust system. The pyrometer gauge is an electrical aircore meter movement driven by a small electric current from a high- temperature thermocouple.
  • Page 16 For the Volvo D7/D12 engine only, it will also illuminate (solid) during Engine ECU programming. Also for the Volvo D7/D12 only, the Caution lamp is always on for 3– 5 seconds when the key switch is turned to the Ignition position.
  • Page 17 Group 38 Instrumentation, VNL, VNM Design and Function Engine-related Warnings: Volvo D7C / D12B Conditions Caution Lamp Stop Lamp Display icon Gauge LED Engine /message Protection (Note 2) Low Coolant Level, low indica- On, Solid — Icon and Shutdown In-...
  • Page 18 Group 38 Instrumentation, VNL, VNM Design and Function Graphic Display Telltale Warnings: The Graphic Display is located below the gauges in the left section of the instrument cluster. It displays vehicle Low coolant system information not available from the other gauges, and helps the driver obtain maximum efficiency from the...
  • Page 19 Group 38 Instrumentation, VNL, VNM Design and Function Gauge Warnings: Multiple Warnings: • • If a gauge warning such as voltmeter, engine or If more than one telltale warning message is acti- transmission oil temperature occurs, the CAUTION vated, 2 or 3 warning icons may be displayed at the lamp will come on and the gauge warning will be same time.
  • Page 20 Group 38 Instrumentation, VNL, VNM Design and Function Using the Graphic Display T3009140 Fig. 16: Graphic display modes To use the menu system: Set the parking brakes. T3009005 Turn the ignition on, but don’t start the engine. Fig. 17: Using the right hand, press the Mode button on the •...
  • Page 21 Group 38 Instrumentation, VNL, VNM Design and Function Multi-Function Mode The Multi-Function mode contains a clock, an alarm Down buttons to set the desired hour. clock, two independent trip odometers, and an engine d. Press the Set button a second time to select hourmeter.
  • Page 22 SAE J1708/1587 Specification. PPID and PSID • Diagnostic Messages - Reports the status of vari- are unique for Volvo and are listed in the following sec- ous vehicle sub-systems. tion. The following section also includes a list of MID, PID/SID and FMI codes which may be displayed as text •...
  • Page 23 Group 38 Instrumentation, VNL, VNM Design and Function W3002707 Fig. 19: Example of a diagnostic message in the Graphic Display Graphic Display Messages MID’s (Message ID’s or Description sources) Engine SRS (Airbag) Instrument Cab Controller Transmission PID’s (Parameter ID’s) Description...
  • Page 24 Group 38 Instrumentation, VNL, VNM Design and Function PPID’s (Proprietary Parameter Description ID’s) Buffered idle switch Pedal switches, supply Cruise control and retarder, supply switch Accelerator pedal and retarder, supply sensors Accelerator control 2 and primary tank, supply sensors Range inhibitor, status solenoid valve...
  • Page 25 Group 38 Instrumentation, VNL, VNM Design and Function Engine SID’s (Subsystem Description ID’s) Injector #1 Injector #2 Injector #3 Injector #4 Injector #5 Injector #6 Engine position sensor Timing sensor Ext. Engine protection sig. PSID’s (Proprietary Subsys- Description tem ID’s)
  • Page 26 Group 38 Instrumentation, VNL, VNM Design and Function FMI’s (Failure Modes) 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 respons...
  • Page 27 Group 38 Instrumentation, VNL, VNM Design and Function Cluster self-test mode • As an aid in troubleshooting the cluster, the cluster self- Display test - To help identify defects in the Graphic test mode provides the following tests: Display, the display will alternate between all dark...
  • Page 28 Group 38 Instrumentation, VNL, VNM Design and Function Set-up Mode the setting won’t be saved — the setting will remain in effect until the ignition is turned off and will return The Set-up mode allows the driver to choose between...
  • Page 29 (the Trip Fuel Meter value will also be reset). critical condition. Trip Fuel Meter Trip points for clusters to be used with Volvo engines are The Trip Fuel meter displays the amount of fuel used preset at the factory during End-of-Line programming.
  • Page 30 Group 38 Instrumentation, VNL, VNM Design and Function Center Section Tachometer The tachometer is an electrical aircore meter movement driven by signals from the J1587 data link. In the ab- sence of data link information, the gauge pointer will move to its minimum reading after a 3–5 second delay.
  • Page 31 Group 38 Instrumentation, VNL, VNM Design and Function Telltale Lamps, Center Section W3002562 Fig. 25: Left Turn Indicator Parking Brake Indicator 5th Wheel Lock Indicator Anti-Lock Brake System (Tractor) Indicator Wheel Differential Lock Indicator 10 Anti-Lock Brake System (Trailer) Indicator...
  • Page 32 Group 38 Instrumentation, VNL, VNM Design and Function Right Section Forward and Rear Drive Axle Temperature (optional) The forward and rear axle temperature gauges are elec- trical aircore meter movements. They are connected to temperature sender units mounted on the axle housings.
  • Page 33 Group 38 Instrumentation, VNL, VNM Design and Function Front and Rear Brake Air Pressure The air pressure gauges are mechanical gauges. They are attached to their air systems by a hose going into a quick-disconnect fitting on the rear of the gauge. The air hoses and quick-disconnects are color-coded to avoid wrong connections.
  • Page 34 Group 38 Instrumentation, VNL, VNM Design and Function Buzzer signals The buzzer is part of the cluster and has the following distinct signals: • Turn signal - Single short beep in time with the Turn Indicator telltales. • Clock reminder - A double beep every other second. This is activated by the alarm clock function in the Graphic Display and works whether the ignition is on or off.

  • Page 35: Connector Pinouts

    Group 38 Instrumentation, VNL, VNM Design and Function Connector Pinouts LX and LY Connectors W3000849 Fig. 33: Left Module, LX Connector Description Circuit No. Input Data Link + (J1587) mV reading Fuel Sensor 33-250 ohms Fuel Level (Jumper to Right Module)
  • Page 36 Ground during bulb test No Charge Warning Lamp Ground (Note 1) Stop Engine Warning Lamp (Caterpillar, Cummins Ground and Detroit Diesel engines only. Volvo is not hard- wired.) Caution Lamp Ground (Note 2) Engine Fluids Warning Lamp (Volvo and Cummins Ground...
  • Page 37 Group 38 Instrumentation, VNL, VNM Design and Function CY Connector Center Module, CY Connector Description Circuit Input ABS, Truck Ground Park Brake Ground Heated Mirror +12V Bulb Test + (Jumper IPJ1 from LY-3) Bulb Test - (Jumper IPJ2 from LY-4)
  • Page 38 Group 38 Instrumentation, VNL, VNM Design and Function RX Connector W3000847 Fig. 35: Right Module, RX Connector Description Circuit No. Input Illumination + 141-G 0-12 V Ground 0X-2 Ground Rear Axle Temperature (Front) Variable resistance (Note 1) Fuel Level (Jumper from LX-3, Left Module)

  • Page 39: Troubleshooting

    • T25 Torx head driver (cluster mounting screws). includes all telltale lamps, the speedometer, tachometer, • Telltale lamp removal tool (Volvo P/N 1608077) oil pressure gauge, coolant temperature gauge and • Digital multi-meter which can measure down to 5 Graphic Display unit. The pivot-down mounting feature of...

  • Page 40: Troubleshooting Notes

    Group 38 Instrumentation, VNL, VNM Troubleshooting Troubleshooting Notes For All Gauges: The gauge pointer can appear to be stuck out of range, either in the right or left lower corner. This may be caused by loss of power when the gauge pointer is past the halfway mark (to the right of center).

  • Page 41: Gauges, Troubleshooting

    Group 38 Instrumentation, VNL, VNM Troubleshooting Gauges, Troubleshooting backlighting is independent of the odometer and Graphic Display backlighting. CAUTION Testing the Cluster Backlighting To test the cluster backlighting, turn the dash lights on Before starting this procedure, see “General Work and adjust the dimmer control for maximum brightness.
  • Page 42 If none of the telltale bulbs light during the Bulb Test in the wiring harness. function, check for +12 volts between LY-3 and LY-4 during the Bulb Test function. If missing, replace the For more information, refer to the VNL, VNM Electrical cluster. Schematics.
  • Page 43 Group 38 Instrumentation, VNL, VNM Troubleshooting Pyrometer Gauge 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.
  • Page 44 Solution: The Pro-Link with the Volvo Card (see Tools the engine manufacturer’s service literature. Also re- section) can be used to check and correct configuration fer to the VNL, VNM Electrical Schematics for wiring errors. information. If the cluster does NOT have a Turbo gauge:...
  • Page 45 Note: Oil pressure gauge takes the place of the gauge location. Turbo gauge when the Turbo gauge is not used. Solution: The Pro-Link with the Volvo Card (see Tools section) can be used to check and correct configuration errors. If the cluster DOES have a Turbo gauge: Using the Pro-Link, go to Special Tests, and select the Turbo Gauge test.
  • Page 46 The coolant temperature gauge is an electrical aircore meter movement which receives its signal from the en- Using the Pro-link with the Volvo Card, check accu- gine via the J1587 data bus. In the absence of a data racy with the signal value going up to 170...
  • Page 47 Group 38 Instrumentation, VNL, VNM Troubleshooting W3002016 Fig. 50:...
  • Page 48 If a sensor problem is indicated, check the wiring from the sensor for opens or shorts, according to the engine manufac- turer’s service literature. Refer to the VNL, VNM Electrical Schematics for wiring information. Also see “Turbo Gauge Reads too High” page 47.
  • Page 49 (above the Turbo gauge), where it belongs. Note: Oil pressure gauge takes the place of the Turbo gauge when the Turbo gauge is not used. Solution: The Pro-Link with the Volvo Card (see Tools section) can be used to check and correct configuration errors.
  • Page 50 Inaccurate Gauge Reading Intermittent Function Using the Pro-link 9000 and the Volvo card scroll to • If this and other gauges on the J1587 data link ap- the instrument cluster menu.
  • Page 51 Group 38 Instrumentation, VNL, VNM Troubleshooting mph the speedometer should read between the 55 Note: For some instrument clusters, with an input and 58 mph marks (see figure). If there is a reading value of 30 mph, the gauge should read between 29 below 55 mph, or above 58 mph, the gauge is faulty.
  • Page 52 Group 38 Instrumentation, VNL, VNM Troubleshooting Odometer W3000720 Fig. 59: Speedometer/Odometer/Tachometer signal flow During normal operation, the odometer display remains odometer display to engine odometer data: the dis- on for 30 seconds after the ignition is switched off. To re-...
  • Page 53 1925 and 2075 to the engine manufacturer’s service literature. Also refer rpm (see figure). If readings outside 1925 and 2075 to the VNL, VNM Electrical Schematics for wiring infor- rpm are received, the gauge is faulty. mation.
  • Page 54 14. If not, and the rest of the cluster works, the wire from RX-14 is probably open. If the readings are off more than 10%, the sender unit should be checked. The sender is mounted on the axle. Refer to the VNL, VNM Electrical Schemat- ics for wiring information.
  • Page 55 Group 38 Instrumentation, VNL, VNM Troubleshooting Air Pressure Gauges W3000836 Fig. 64: Note: The LED connector wires are not polarity- sensitive. Inaccurate or erratic gauge readings are usually caused by dirt or other contamination in the gauge. The gauges and their warning LEDs can be tested as shown.
  • Page 56 If resistance is as shown in Table A, go to step • If resistance is not as shown in Table A, check the connectors and wiring from the LX connec- tor to the fuel level sender. Refer to the VNL,...
  • Page 57 Group 38 Instrumentation, VNL, VNM Troubleshooting VNM Electrical Schematics for wiring informa- tion.
  • Page 58 Group 38 Instrumentation, VNL, VNM Troubleshooting Turn the ignition ON and use a voltmeter to mea- a. If the pointer stays below “E” AND the sure the voltage between pins 2 and 4 on the RX pointer moves slightly during the gauge test, connector.

  • Page 59: Gauges, Troubleshooting (With Pro-Link)

    Note: The tachometer will move to the 600 RPM mark during Special Tests. In vehicles with a Volvo engine, it is nor- mal for an audible beeping to occur during certain Special Tests. The engine must not be running during any Special Tests, or the tests will not function.
  • Page 60 Group 38 Instrumentation, VNL, VNM Troubleshooting View EEPROM Reprogram EEPROM Clock Mode 12 or 24 hour mode Note: When the Reprogram mode is entered, the serial number of the MPSI tool in use is recorded in the instru- Turbo Gauge indicates whether the turbo gauge is in- ment cluster memory.

  • Page 61: Service Procedures

    Group 38 Instrumentation, VNL, VNM Service Procedures Service Procedures...

  • Page 62: Warranty Notice

    This is done using the Pro-link 9000 tool with the Volvo card. To reset either of these readings, follow the Pro-link menus to the Reprogram EEPROM menu, then select either the Odometer or Hourmeter Total.

  • Page 63: Bulb, Replacement

    • “Warranty Notice” page 60. Information about in- CAUTION strument clusters still under warranty. Use only the Volvo bulb removal tool, P/N 1089953, to Removal remove bulbs, or damage to the cluster may occur. Insert removal tool, P/N 1089953, onto Make certain the vehicle ignition is the bulb assembly.
  • Page 64 Group 38 Instrumentation, VNL, VNM Service Procedures 3811-03-02-01 Cut the tie straps fastening the wiring Instrument Cluster, Replace- harness to the back of the cluster for ment stress relief on the connectors. CAUTION Before starting this procedure, see “General Work Practices”...

  • Page 65: Instrument Cluster, Replacement

    Group 38 Instrumentation, VNL, VNM Service Procedures 3811-03-02-02 Right Module, Replacement CAUTION Before starting this procedure, see “General Work Practices” page 3 for general safety precautions when working with the instrument cluster. Failure to follow the safety precautions may result in instrument cluster damage.
  • Page 66 Group 38 Instrumentation, VNL, VNM Service Procedures Installation Lift out the Right Circuit Board assem- bly, with gauges. CAUTION To avoid damaging the gauge, do not push on the needle when installing the gauge. Pushing on the nee- dle can make the gauge inaccurate.
  • Page 67 Group 38 Instrumentation, VNL, VNM Service Procedures Install the Right Circuit Board assem- bly into the housing. Place the cover over the board assem- bly and secure with three machine screws. Install the cluster into the dash (see “Instrument Cluster, Replacement”...

  • Page 68: Center Module, Replacement

    Group 38 Instrumentation, VNL, VNM Service Procedures 3811-03-02-03 Additional Information Center Module, Replacement • “Warranty Notice” page 60. Information about in- strument clusters still under warranty. CAUTION Before starting this procedure, see “General Work Practices” page 3 for general safety precautions when working with the instrument cluster.
  • Page 69 Group 38 Instrumentation, VNL, VNM Service Procedures Removal CAUTION Note: Individual gauges in the center and left modules of the VN instrument cluster are not serviceable during the To prevent electrostatic discharge (ESD), which can warranty period. Attempts to remove...
  • Page 70 Group 38 Instrumentation, VNL, VNM Service Procedures Remove the Phillips screws at the top of the left rear cover, and the two at the bottom, then lift the left rear cover from the cluster. Remove the four Phillips cover screws.
  • Page 71 Group 38 Instrumentation, VNL, VNM Service Procedures Installation W3002500 Fig. 78: To reinstall the Center Module, line up Verify that all E1 pins are in connector connector E1 pins with connector E2 E2 holes, then use your thumb to fully holes on the Center Circuit Board, seat E2 onto the Left Circuit Board.
  • Page 73 Group 38 Instrumentation, VNL, VNM Service Procedures Tachometer, Speedometer and Additional Information Odometer, Replacement • “Warranty Notice” page 60. Information about in- strument clusters still under warranty. CAUTION Removal Before starting this procedure, see “General Work Practices” page 3 for general safety precautions when working with the instrument cluster.
  • Page 74 Group 38 Instrumentation, VNL, VNM Service Procedures W3002502 W3002503 Fig. 80: Fig. 81: When all five pins are inserted into the Center Circuit Board, seat the CAUTION tach/speedo gauge pins while guiding the tabs on the sides of the gauges To avoid damaging the gauges, do not pull on the into the notches on the housing.

  • Page 75: Left Gauge Module, Replacement

    Group 38 Instrumentation, VNL, VNM Service Procedures 3811-03-02-04 Left Gauge Module, Replace- ment CAUTION Before starting this procedure, see “General Work Practices” page 3 for general safety precautions when working with the instrument cluster. Failure to follow the safety precautions may result in instrument cluster damage.
  • Page 76 Group 38 Instrumentation, VNL, VNM Service Procedures Gauges and gauge blanks are held tightly by their pin sockets. To remove, grasp the side of the gauge face plate CAUTION with your thumb; place your 2nd and 3rd fingers underneath the face plate Do not bend the printed circuit board.
  • Page 77 If installing a gauge blank into the En- gine Oil Pressure or Turbo Boost Pressure gauges, use the Pro-Link 9000 with the VOLVO card to enable the gauge which is being added, or to disable the gauge which is being re- moved.
  • Page 79 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. From Volvo Trucks North America, Inc................Dept. 516 Service Publications ................
  • Page 81 Operation Numbers 3811-03-02-01 Instrument Cluster, Replacement ......62 3811-03-02-02 Right Module, Replacement ......63 3811-03-02-03 Center Module, Replacement .
  • Page 82 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-TSP106805/1 2.1998 © Volvo Trucks North America, Inc., 1998...

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