PV776 TSP23762 1

Service Manual
Trucks
Group
38
Instrumentation
VNL, VNM
PV776-TSP23762/1
Foreword
The descriptions and service procedures contained in this manual are based on design
and method studies up to June 1996.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary service
bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a
reference to an S.R.T. (Standard Repair Time).
Service procedures which do not include an operation number in the title are for general
information and no reference is made to an S.R.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could
occur.
Volvo GM Heavy Truck

Greensboro, NC USA
Order number: PV776-TSP23762/1
1996 Volvo GM Heavy Truck, Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in

retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of Volvo GM Heavy Truck.
Contents
General .................................................................................................... 3
General cautions ................................................................................... 3
Basic description ................................................................................... 4
Specifications ...................................................................................... 4
Tools ....................................................................................................... 7
Special tools .......................................................................................... 7
Special equipment ................................................................................. 8
Design and Function ........................................................................... 11
Gauges and indicators ........................................................................ 13
Connector pinouts ............................................................................... 34
Troubleshooting ...................................................................................
General service information ................................................................
Troubleshooting individual gauges ......................................................
Left section ........................................................................................
Center section ...................................................................................
Right section ......................................................................................
Troubleshooting with the MPSI Pro-Link 9000 and VOLVO Cartridge
39
39
40
42
46
48
52
Service Procedures .............................................................................

Updating the odometer reading after replacing the cluster ................
Cleaning the housing and front panel glass .......................................
Bulb replacement .................................................................................
Removal ............................................................................................
Installation .........................................................................................
Instrument cluster replacement ...........................................................
Removal ............................................................................................
Installation .........................................................................................
Gauge replacement, right circuit board gauges ..................................
Removal ............................................................................................
Installation .........................................................................................
Center module replacement ................................................................
Removal ............................................................................................
Installation .........................................................................................
Gauge replacement, left circuit board gauges ....................................
Removal ............................................................................................
Installation .........................................................................................
55
55
55
55
55
56
56
56
57
58
58
60
61
61
63
64
64
66
Group 38 Instrumentation, VNL, VNM
General
General
General cautions
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.
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.
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.
Human skin can hold more than 1000 volts of static
electricity. Although getting a static shock is annoying, it is
not dangerous because there is so little energy stored by
clothing. But when dealing with circuits designed to sense
differences smaller than 1 volt, electrostatic discharge
can be a subtle but destructive problem. Circuit boards
mounted in the instrument cluster or in modules mounted
elsewhere may not fail immediately after being hit with
a static discharge. Rather they may work for a while,
then fail for no apparent reason. The culprit then is often
the normal warming up and cooling down process of the
module, engine or cab interior.
Grounding straps and anti-static mats are available for
minimal cost from electronic supply stores. Grounding
straps consist of a wrist strap, a coiled extension wire
and an alligator clip. Be sure to purchase one with a long
enough extension wire to allow freedom of movement.
An anti-static wrist strap is available from Kent-Moore
(see Tools section of this manual). Call 1-800-3286657.
An anti-static mat is also available from KentMoore
(see Tools section of this manual).
General
Basic description
W3000787
This manual describes the 1996 AMETEK/Dixson Instrument Cluster for VN Series
vehicles and how to service it. For information about the vehicles Electronic Control
Units, wiring diagrams, sensors and other components, please refer to the service
manual for that component.
The cluster is available in 6 configurations, with either an mph or km/h speedometer.
The instrument cluster is divided into the following sections
Left Section - Contains a Coolant Temperature and an Oil Pressure gauge, and
optionally, a Pyrometer and a Turbo Boost gauge. A Graphic Display module at the
bottom provides additional information about the vehicle. Also contains four telltale
indicators: Engine Fluids, Caution, Stop and No Charge.
Center Section - Contains a tachometer, speedometer and odometer. Also

contains a buzzer, fourteen telltale indicators and a Master Warning indicator.
Telltales in this section are: Left and Right Turn Indicators, Fifth Wheel Lock, Wheel
Differential Lock, Interaxle Differential Lock, High Beam Indicator, SRS (Air Bag),
Parking Brake, Anti-Lock Brake System (ABS) for Tractor (and ABS for Trailer
for future use), Air Suspension, Bogie and Mirror Defroster.
Right Section - Contains a Fuel Level gauge, a Front Brake Air Pressure gauge,
and a Rear Brake Air Pressure gauge. It may also contain an optional Application
Air Pressure gauge, and a Forward Axle and a Rear Axle Temperature gauge. It
can also contain up to six telltale indicators. Standard telltales are Preheat, Traction
Control System and APADS (Air Conditioning Protection and Diagnostic System
for future use).
Note that all gauges and telltales may not be used in all vehicles.
Four push-buttons above the speedometer allow the driver to access and display
information in the Graphic Display.
Specifications
This instrument cluster is designed to operate with an input voltage of between +10 and
+18 volts.
General
Available configurations
W3000832
General
Available configurations (contd.)
W3000833
Tools
Tools
Special tools
The following special tools are required for work on the instrument cluster. The tools
can be ordered from Volvo GM Heavy Truck Corporation.
W3000642
1608077
Lamp removal tool
Tools
Special equipment
The following items are required for work on the instrument cluster. They can be ordered
as shown below.
W3000572
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 cluster at a workbench. Several different wrist straps are available from
Kent-Moore at 18003286657.
W2001014
Fluke 87 Digital Multi-meter (DMM)

Available from Kent-Moore (P/N J-39200)
at 18003286657.
W3000704
Type 8501 Static Dissipative Grounding Kit

Available from KentMoore (P/N J42444)
at 18003286657.
The kit shown includes both a wrist strap
and anti-static mat. Use both when working
on the instrument cluster at a workbench.
Tools
W3000752
MPSI Pro-Link 9000

The Pro-Link 90001 with the VOLVO cartridge
is available from Kent-Moore at
18003286657.
1
MPSI Pro-Link 9000

(Kent-Moore P/N J-385001)
VOLVO Cartridge, version 2.0

Power/Data Cable
Diagnostic Adaptor Cable

(Kent-Moore P/N J-3850060A)
Pro-Link is a registered trademark of MPSI.
10
Design and Function
Design and Function

Instrument cluster block diagram for Volvo engine
W3000864
11
Design and Function
Instrument cluster block diagram for Caterpillar, Cummins, Detroit Diesel

engines
W3000865
12
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 hightemperature thermocouple.
If the pyrometer thermocouple fails, the pointer will move

to one end of the dial or the other. A reading of 149 C

(300 F) or less indicates an open in the trucks wiring or

thermocouple, and a reading of 815 C (1500 F) or more
indicates a short.
W3000601
Engine Coolant Temperature

The coolant temperature gauge is an electrical aircore
meter movement which receives its signal from the engine
via the SAE J1587 data bus. In the absence of a data
signal, the gauge pointer will move to its minimum reading
after a 35 second delay.
Red Warning LED illuminates when coolant temperature
is too high for safe operation. The temperature which
activates this LED is engine-dependent.
W3000602
Turbo Boost Pressure (optional)

The turbo boost pressure gauge is an electrical aircore
meter movement driven by a signal from the J1587 data
link. In the absence of a data signal, the gauge pointer will
move to its minimum reading after a 35 second delay.
W3000604
13
Design and Function
Engine Oil Pressure

The engine oil pressure gauge is an electrical aircore
meter movement that receives its signal from a sender unit
mounted on the engine. For Caterpillar, Cummins and
Detroit Diesel engines, the sender unit supplies data to the
Engine ECU which sends engine oil pressure information
to the instrument cluster via the J1587 data link.
For the Volvo VE D12 engine, the sender supplies a signal
to the Data Concentrator Module which then broadcasts
engine oil pressure data to the cluster via the J1587 data
link.
In the absence of a data signal, the gauge pointer will
move to its minimum reading after a 35 second delay.
W3000983
Note: Engine oil operating pressure is engine dependent.

A Red Warning LED illuminates when engine oil pressure
is too low for safe operation. The pressure which activates
this LED is engine-dependent.
Telltale lamps. left section
W3000768
1
2
3
4
Engine Fluids lamp

Caution lamp
Stop lamp
No Charge lamp
Engine Fluids
Stop
Illuminates when engine oil pressure or coolant level

is too low, or when engine coolant temperature is too
high. Hard-wired to the Data Concentrator Module (Volvo
engine), or to the engine ECU (Cummins engine).
Illuminates to alert the driver that an engine problem has

been detected by the engine ECU, and that action may
be taken by the ECU to protect the engine. (for example,
engine oil pressure, low coolant level).
Note: The Engine Fluids lamp is not used in vehicles with

Caterpillar or Detroit Diesel engines.
No Charge
Caution
Illuminates to indicate a control system or component
malfunction (for example: throttle position sensor, boost
pressure sensor).
For the VE D12 engine only, it will also illuminate (solid)
during engine ECU programming. Also for the VE D12
only, the Caution lamp is always on for 35 seconds when
the key switch is turned to the Ignition position.
Note: This lamp replaces the Check Engine lamp in
earlier model vehicles.
14
Illuminates when a problem exists in the charging system.

A voltage output decrease of 12 volts from normal will
cause this lamp to illuminate dimly. As the voltage output
decreases more, the illumination goes from dim to bright.
Design and Function
Engine-related Warnings: Volvo VE D12

Conditions
Engine
Fluids Lamp
Caution
Lamp
Stop Lamp
Display
icon
/message
Gauge LED
Engine
Protection
(Note 5)
Low Coolant Level

(Source: switch, Data Concentrator)
On, Solid
On, Solid
Icon Blinking
N/A
Shutdown
Active
Low Oil Pressure, with Oil

Pressure <36.2 psi, and
>1000 RPM for 2 sec.
Blinking
Message on
Request
(Note 4)
On
Shutdown
Inactive

Pressure <9 psi (Source:
Data Concentrator)
Blinking
Message on
Request
(Note 4)
On
Shutdown
Inactive

Pressure <6 0.5 psi
(Source: Data Concentrator)
On, Solid
On, Solid
Message on
Request
(Note 4)
On
Shutdown
Active
High Coolant Temperature

(Source: Engine)
(Note 1)
Blinking
(Note 3)
Blinking
Message on
Request
(Note 4)
On
Engine Hp
Output
Derated
High Oil Temperature

(Source: Engine, Sender)
On, Solid
Icon On
N/A
N/A
Other Engine-Related
Fault Codes (Note 1)
Blinking
Message on
Request
(Note 4)
N/A
N/A
During Programming
(Note 2)
On, Solid
On, Solid
N/A
N/A
N/A
Yes
N/A
Yes
N/A
N/A
N/A
Audible Buzzer
Note: When Key switch = Ignition position:

Engine Fluids lamp is on.
Caution lamp is on solid for 35 seconds.
1
Lamp remains flashing even when the fault becomes

inactive. The key switch must be cycled to turn off
the lamp.
Ignition on, engine not running.
Source = Data Concentrator Module (DCM), when an

above normal operational range for coolant temperature condition is broadcast on the data bus.
Message on Request = Cluster Diagnostic Messages, which are displayed in the Graphic Display
Diagnostic Mode.
Engine Protection is not controlled by the instrument
cluster. It is a programmable parameter.
For more information, refer to the Electronic Control

System, VE D12 VOLVO manual.
Engine-related warnings, Caterpillar 3406E

and Detroit Diesel Series 60 11.1/12.7
Caution and Stop Lamp signals are sourced from the
Engine ECU (hard-wired). Caterpillar and Detroit Diesel
do not use the Engine Fluids lamp.
Refer to the engine manufacturers literature for information on the conditions which activate individual lamps in
the instrument cluster.
Engine-related warnings, Cummins M11/N14

The Engine Fluids, Caution and Stop Lamp signals are
sourced from the Engine ECU (hard-wired).
Refer to the engine manufacturers literature for information on the conditions which activate individual lamps in
the instrument cluster.
15
Design and Function
Graphic Display
The Graphic Display is located below the gauges in the
left section of the instrument cluster. It displays vehicle
system information not available from the other gauges,
and helps the driver obtain maximum efficiency from the
vehicle.
Standard displays include an alarm clock, voltmeter, engine hours, two resettable trip odometers, a fuel economy
display and diagnostic information. Optional displays include engine and transmission oil temperature gauges.
Displayed data can come from
adding coolant does not correct the problem, check

the coolant sensor for continuity between pins A and
B, then check the wiring.
Air filter restriction
The air filter restriction display and a buzzer will

sound ONLY during the first 10 seconds after ignition.
The air filter restriction sensor is a normally open
switch closed by approx. 25 Hg.
If this warning appears, check the air filter restriction

gauge at the air filter assembly to see that it has an
approximate reading of 25 Hg. If so, replace the filter
and reset the mechanical gauge at the air filter. If the
gauge is not reset, the warning will still appear in the
instrument cluster.
If the warning still appears after these steps, check

the air filter restriction gauge for continuity between
pins A and C. If there is continuity between pins A
and C replace the air filter restriction gauge.
the J1587 data link

external switches
external sensors.
The display can be customized to suit individual preferences. For example, its backlighting can be adjusted independently of gauge backlighting.
When the ignition is on and the vehicle is not moving, the
Graphic Display can also be used to help diagnose the
cluster and external problems.
If battery power is lost, the Graphic Display will default to
the clock display. When power is regained, the clock will
come on, flashing, and will need to be reset.
If the warning still appears after these steps, troubleshoot the air filter restriction gauge circuit.
Washer fluid low
The washer fluid low warning will be displayed when

the washer fluid drops below a predetermined level.
The washer fluid low warning is a normally open
switch located on the washer fluid pump assembly,
which is closed by a low washer fluid condition.
The warning activation has a 10 second delay to allow

for fluid slosh.
This warning may be cleared by pressing the instrument clusters Set button. The warning will reappear
each time the key is cycled off and on.
If adding washer fluid does not clear the warning,

check the washer fluid pump assembly for continuity
between connector pins B and C. If there is continuity,
replace the pump assembly. If the warning is still
displayed, troubleshoot the washer fluid pump circuit.
Automatically activated warnings
W3000709
Automatically Activated Telltale Warnings Appearing in the Graphic Display
Should a condition requiring attention occur, a telltale

warning message identifying that condition will override
the current display. For example, if the engine coolant
level drops below a predetermined point while the clock
is displayed, a low coolant display will replace the clock
display.
Gauge warnings:
If a gauge warning such as voltmeter, engine or transmission oil temperature occurs, the CAUTION lamp
will come on and the gauge warning will be displayed.
But if a telltale warning is already displayed, the Mode
button must be pressed to display the warning on the
Graphic Display screen.
Gauge warnings are activated when the input exceeds a pre-set trip point. The trip points are as follows, shown in order of priority:
Telltale warnings:
Low coolant
The low coolant warning display is activated by an

input from the low coolant sensor, and will stay on
until the problem is corrected.
Note that engine shutdown mode may be engaged by

a low coolant condition (this is an engine dependent
parameter).
16
The low coolant sensor is a normally open switch,

and is closed by a low coolant level. To clear the
low coolant display, check for proper coolant level. If
Note: Engine oil temperature trip point varies by

engine.

1) Engine oil temp

VE D12: 130 C (265 F)

2) Transmission oil temp 140 C (285 F)
3) Voltmeter
16 volts
Design and Function
Multiple warnings:
If more than one telltale warning message is activated, 2 or 3 warning icons may be displayed at the
same time. A multiple display appears as shown in
the illustration.
W3000848
1) Washer Fluid Low icon in the Primary display location

2) Low Coolant icon in the Secondary display
location
The icon on the left side is the primary icon during

multiple displays. If, as in the illustration, the washer
fluid low icon is in the primary position, it may be
cleared by pressing the Set button.
The text displayed above the icons is always that

of the icon in the primary position. If the icon is in
the right, or secondary position, it cannot be cleared.
Note that the low coolant icon cannot be cleared until
the problem is corrected.
Every 8 seconds the display will change, and the

primary and secondary icons will switch positions.
If a gauge warning occurs while a telltale warning

is displayed, the CAUTION lamp will illuminate. A
gauge warning will not automatically replace a telltale
warning. To view the gauge warning in the display,
the Mode button must be pressed.
For troubleshooting, the diagnostic mode may be entered

while any of these warnings are displayed.
17
Design and Function
Using the Graphic Display
W3000867
Graphic display modes
If the vehicle is in motion, reach around the steering

wheel with the right hand to access the control buttons
to avoid possible personal injury. Accessing the control
buttons through the steering wheel can result in injury
or death due to loss of vehicle control.
W3000639
Mode button - Pressing the Mode button moves from

one mode to another. For example, press MODE to
change from the Set-Up mode to the Gauge mode.
Up and Down buttons - Pressing the Up or Down

buttons scrolls to the next or to the previous available
function within a mode. For example, if the Trip 1
odometer is displayed, pressing Down scrolls to the
Trip 2 odometer, and pressing Up scrolls to the Alarm
Clock. The Up and Down buttons are also used to
change the displayed time and alarm.
Set button - If the current display contains a value

which can be changed using the Up and Down
buttons, the Set button enables the change and
selects the digit to be changed. The Set button also
resets the Trip Odometer 1 and Trip Odometer 2
readings to zero when pressed for 1 second.
To use the menu system:
18
Turn the ignition on.
Using the right hand, reach around the steering wheel

and press the Mode button to select the desired
mode.
When the desired mode appears, use the Up and

Down buttons to select the desired function in that
mode.
Note: The Diagnostic and Set-up Modes are not available

when the vehicle is in motion. If these modes are in use
and the vehicle reaches a speed of 5 mph, the Graphic
Display will automatically change to the clock display.
Design and Function
Multi-Function mode
The Multi-Function mode contains a clock, an alarm
clock, two independent trip odometers, and an engine
hourmeter.
d. Press the Set button a second time to select

the minutes digits. The minutes digits will flash
when selected.
Clock display
e. When the minutes digits flash, use the Up and

Down buttons to set the desired minute.
The clock displays the current time in either a 12-hour

format (12:00:00 am to 12:59:59 pm) or a 24-hour format
(00:00:00 to 23:59:59). The choice is made in the Set-Up
Menu.
1
f. To accept the displayed alarm time and exit

the set function, press the Set button a third time.
The alarm will automatically be enabled and the
Bell symbol will appear.
To display the clock:

a. Use the Mode button to select the MultiFunction mode.
Press and hold the Mode button. The next mode

display will appear when the reminder is set. The
clock display with a bell will appear on screen.
b. Use the Up or Down button to display the

time.
2
OR Select the Alarm Clock display as previously

described.
To change the time display:

a. When the clock time is displayed, press the
Set button to select the hours digits. The hours
digits will flash when selected.
To change the time format:

Use the Clock Mode function of the Set-Up
Menu.
Trip Odometer displays

Two independent trip odometers are available (Trip
Odometer 1 and Trip Odometer 2). Each one displays
the distance traveled since it was last reset.
1
The Alarm Clock function determines when the alarm

reminder sounds. Set the reminder time and enable the
alarm by using the Alarm Clock function.
To display the alarm clock:
To display a trip odometer:

Alarm clock display
To silence the reminder:

Press any of the four buttons while the reminder
is sounding.
d. When the minutes digits flash, use the Up and

Down buttons to set the desired minute.
e. To accept the displayed time and exit the set
time function, press the Set button a third time.
To disable the reminder tone:

When the bell symbol is displayed, press and
hold the Mode button until the next mode display
appears. The clock display will appear without
the bell symbol.
b. When the hours digits flash, use the Up and

Down buttons to set the desired hour.
c. Press the Set button a second time to select
the minutes digits. The minutes digits will flash
when selected.
To enable the reminder tone:
b. Use the Up and Down buttons to display either

TRIP ODOMETER 1 or TRIP ODOMETER 2.
2
To reset a trip odometer:
a. Display the trip odometer to be reset (1 or 2).
b. Use the Up or Down button to display ALARM.
b. Press and hold the Set button for 1 second.
To change the alarm time:

a. Display the alarm clock.
b. When the alarm time is displayed, press the
Set button to select the hours digits. The hours
digits will flash when selected.
c. When the hours digits flash, use the Up and
Down buttons to set the desired hour.
Hourmeter display
The hourmeter accumulates and displays the total time
the engine has been running. It is not resettable by the
driver. To display the hourmeter:
1
Use the Mode button to select the Multi-Function

mode.
Use the Down button to scroll to HOURMETER.
19
Design and Function
Diagnostics mode
The Diagnostics mode provides two functions:
Diagnostic Messages - Reports the status of various

vehicle sub-systems.
Cluster Self Test Mode - Contains several tests to

check the cluster.
The figure on the following page is an example of a

message indicating that a problem with the engine coolant
temperature has been detected. In this example, the fault
still exists, and has occurred five times.
To see diagnostic messages:

Diagnostic messages
Turn on the ignition. The engine may be started.

Diagnostic messages from all J1708/1587supported
vehicle systems are accessible.
Use the Mode button to display DIAGNOSTICS

MENU.
Use the Up and Down buttons to display DIAGNOSTIC MESSAGES.
When DIAGNOSTIC MESSAGES is displayed, press

the Set button. RECEIVING DATA, PLEASE WAIT
will be displayed while the systems on the J1587 data
link are polled.
When the first message appears, the Set button can

be pressed to toggle the display between the text
description and the received data. If the display
shows UNKNOWN in any line, press the Set button
to display the MID, PID or SID and FMI.
W3000851
Diagnostic message path
The vehicle contains one or more Electronic Control Units

(ECUs). Each ECU monitors or controls a particular
vehicle sub-system.
For example, an Engine ECU
monitors engine conditions, a Antilock Brake System
ECU monitors ABS conditions, and so on.
a. If the condition that caused the currently

displayed fault still exists, the cluster will display
ACTIVE.
The ECUs are connected to each other and to the cluster

by a pair of wires known as the SAE J1708/1587 data link.
The ECUs communicate with each other by sending and
receiving messages in a format specified by SAE J1587.
Note: SAE J1587 is an industry standard which defines
the format of electronic signals and information transmitted between truck and bus electronic components.
SAE J1708 defines the hardware and basic protocol (data
formatting) requirements for the truck and bus electronic
communications system.
The cluster can display active and inactive fault codes in
the Graphic Display. The message path from the J1587
data link to the Graphic Display is shown in the figure.
Each diagnostic message consists of a Message Identifier
(MID) code, a Sub-system Identifier (SID) or Parameter
Identifier (PID) code, and a Fault Mode Indicator (FMI)
code. An FMI describes the type of failure detected in
the subsystem identified by the PID or SID. The codes
are standardized and are listed in the SAE J1708/1587
Specification. A list of codes which may be displayed as
text messages is shown in the following section.
20
b. If the condition that caused the currently

displayed fault has gone away, the cluster will
display INACTIVE.
c. The number of times a fault has occurred will
be displayed when available. In some cases, a
short message may also be displayed.
6
Record all codes displayed.
To display the next stored fault, press the Down

button.
If the Graphic Display detects a complete failure of

the J1587 data link between the instrument cluster and
the other system modules, it will display DATA LINK
BROKEN. In this case, the actual wires used for the J1587
data link should be inspected for damage.
If the Graphic Display does not receive a response from
any of the individual modules on the J1587 data link, it will
display the name of the system and NOT RESPONDING.
Design and Function
W3000866
Example of a diagnostic message in the Graphic Display
Graphic display messages supported

MIDs (Message IDs or
sources)
Description
128
Engine
130
Transmission
136
ABS
140
Instrument
178
Data Conc (Note: VE D12 engine only)
232
SRS (Airbag)
Additional MIDs (text message will not be displayed)
MIDs (Message IDs or

sources)
Description
137
Brakes, Trailer #1
138
Brakes, Trailer #2
139
Brakes, Trailer #3
141
Trip Recorder
162
Vehicle Navigation Unit
166
Tires, Power Unit
171
Driver Information Center
172
Off-board Diagnostics #1
179
Data Logging Computer
181
Communication Unit - Satellite
191
Vehicle Location Unit
231
Communication unit - Satellite/GPS/cellular

21
PIDs (Parameter IDs)
22
Description
62
Retarder inh status
71
Idle shutdn status
84
Road speed
91
% Throttle pedal
100
Engine oil pressure
102
Boost pressure
105
Air inlet temperature
106
Air inlet pressure
108
Barometric pressure
110
Engine coolant temp
111
Coolant level
127
Transmission oil PSI
160
Main shaft speed
161
Input shaft speed
175
Engine oil temperature
177
Transmission oil temperature
190
Engine speed
191
Transm. output RPM
Common SIDs (Subsystem

IDs)
Description
233
Controller #2
236
Power contact device
237
Start enable solenoid
242
CC resume switch
243
CC set switch
244
CC enable switch
245
Clutch pedal switch
246
Brake pedal switch #1
247
Brake pedal switch #2
248
Proprietary data link
249
SAE J1922 data link
250
SAE J1708 data link (Note: J1708/J1587)
251
Power supply
252
Calibration module
253
Calibration memory
254
Controller #1
Design and Function
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.
Transmission SIDs
(Subsystem IDs)
Description
C1 Solenoid valve
C2 Solenoid valve
C3 Solenoid valve
C4 Solenoid valve
C5 Solenoid valve
C6 Solenoid valve
Lockup solenoid valve
16
Neutral start output
18
Shift selector #1
27
Lockup clutch PSI sw
28
Forward range PSI sw
29
Neutral range PSI sw
30
Reverse range PSI sw
Vehicle Navigation SIDs

(Subsystem IDs)
Design and Function
Description
Dead reckoning unit
Loran receiver
Global positioning system (GPS)
Integrated navigation unit
23
Brake SIDs (Subsystem IDs)
24
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
14
ABS relay, diagonal 1
15
ABS relay, diagonal 2
18
ABS, dif 1 - ASR valve
19
ABS, dif 2 - ASR valve
22
Speed signal input
23
Warning light bulb
24
ASR light bulb
31
Trailer brake slack out of adjustment, forward axle left
32
Forward axle right
33
Rear axle left
34
Rear axle right
35
Trailer brake slack out of adjustment, axle 1 left
36
Axle 1 right
37
Axle 2 left
38
Axle 2 right
39
Axle 3 left
40
Axle 3 right
Design and Function
FMIs (Failure Modes)
Design and Function
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
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, or by the data
concentrator when the engine shutdown output has been
activated.
25
Design and Function
Cluster self-test mode

As an aid in troubleshooting the cluster, the cluster selftest mode provides the following tests:
Note: While in the cluster self-test mode, the engine ECU

data link is disconnected. Therefore the gauges will not
function until the cluster is out of the self-test mode.
W3000719
Bulb test - Turns on all telltale indicators, and red

warning LEDs in the gauges which have them, for
ten seconds.
Note: The gauges in the instrument cluster are not
functional during the bulb test. The ignition key can
be cycled off and on to interrupt any test.
Gauge test - This causes the pointers in the

Tachometer, Speedometer, Oil PSI, Coolant Temperature, Fuel, and Turbo Boost gauges to sweep
from minimum scale to full scale and back, briefly
stopping at mid-scale each way. This occurs three
times. The pyrometer, axle temperature and air
pressure gauges are excluded from the self test.
Cycle the ignition key off and on after the gauge test
to return the gauges to normal function.
Note: Each time power is applied to the cluster, the
speedometer and tachometer pointers return to zero,
taking the shortest path (usually counter-clockwise).
If (during shipment, for example) the pointers are at
the high end of their scales, they will move clockwise
towards zero when power is applied, and will be
prevented from reaching zero by the gauge housing.
In this case, use the Gauge Test function to return
the tachometer and speedometer pointers counterclockwise to zero.
26
Display test - To help identify defects in the Graphic

Display, the display will alternate between all dark
and all light for about 10 seconds:
Buzzer test - Sounds each of the three buzzer

signals for 10 seconds each.
1
To access the Cluster Self Test:
Use the Mode button to display DIAGNOSTICS

MENU.
Press the Up or Down button to scroll to

CLUSTER SELF TEST MODE.
Press the Set button to activate the Cluster Self

Test mode.
Press the Up or Down button to display the desired test name (Bulb Test, Gauge Test, Display
Test, or Buzzer Test).
Press the Set button to begin the displayed test.

The test will end automatically.
Design and Function
Set-up mode
The Set-up mode allows the driver to choose between
English or metric units, between 12- or 24-hour time, and
to set the Graphic Display contrast, the Graphic Display
and odometer brightness, and (optionally) to set a fuel
economy target value.
Settings are retained when the ignition is off, and also
when the battery is disconnected. If battery power is lost
while in the Set-Up mode, the instrument cluster will go
back to its default values.
Units
The units function configures the cluster to display data
in the English or metric mode.
English - Distances are displayed in miles, temperatures are displayed in Fahrenheit degrees, and Fuel
Economy is displayed in miles per gallon.
Metric - Distances are displayed in kilometers, temperatures are displayed in Celsius degrees, and Fuel
Economy is displayed in liters per kilometer.
To configure the cluster for English or metric:

1
Use the Mode button to display SET UP MENU.
Press the Up or Down button to scroll to UNITS.
Use the Set button to toggle between ENGLISH and

METRIC.
Clock mode
The clock mode configures the clock to display 12-hour
(am/pm) or 24-hour time. To change the clock format:
1
Press the Down button to scroll to CLOCK MODE.
Use the Set button to toggle between the 12- and 24hour formats.
Contrast adjust function

This function adjusts the contrast of the Graphic Display.
To adjust the display contrast level, do the following:
1
Use the Down button to scroll to CONTRAST ADJUST.
Press the Set button.
Use the Up and Down buttons to increase or decrease the contrast.
When the contrast is at the desired level, press the

Set button. (If you do not press the Set button here,
the setting wont be saved the setting will remain

in effect until the ignition is turned off and will return
to its previous setting when the ignition is turned back
on.)
6
Press the Mode button to return to the SET-UP

MENU display.
Backlighting adjust function

This function allows the odometer and graphic display
backlighting (brightness) to be adjusted independently of
the gauge backlighting. To adjust the backlighting, do the
following:
1
Press the Down button to scroll to BACKLIGHTING

ADJUST.
Use the Up and Down buttons to increase or decrease the backlighting.
When the backlighting is at the desired level, press

the Set button. (Note: If you do not press the Set
button here, the setting wont be saved the setting
will remain in effect until the ignition is turned off and
will return to its previous setting when the ignition is
turned back on.)

MENU display.
Fuel economy target adjust function

This function allows a fuel economy target to be set. To
change the fuel economy target value, do the following:
1
Use the Mode button to display SET-UP MENU.
Press the Down button to scroll to FUEL ECONOMY

TARGET.
Use the Up and Down buttons to increase or decrease the desired value.
When the desired value is displayed, press the Set

button. (If you do not press the Set button here, the
setting wont be saved the setting will remain in
effect until the ignition is turned off and will return to
its previous setting when the ignition is turned back
on.)

MENU display.
27
Design and Function
Gauge mode
The Gauge mode provides additional gauge displays. A
voltage display is standard. Engine oil temperature and
transmission oil temperature displays are optional and are
enabled by End-of-Line programming. Gauge displays
contain a symbol and a value (such as volts or degrees),
and text messages when appropriate.
when a trip point is reached. These warnings will continue

until the ignition is turned off or until the condition causing
the warning no longer exists. The visual and audible
warnings will return if the condition that caused the
warning still exists when the ignition is turned back on.
The Engine Oil Temperature gauge in Volvo applications
uses an analog sensor.
In other applications, this
gauge receives its display data from the engine electronic
control unit. These trip points are set to the engine
manufacturers specifications.
W3000712
Gauge displays
Note: When a condition requiring attention occurs, the

symbol identifying that condition will automatically replace
the current gauge display.
To choose a gauge display:
Fuel Economy mode

The Fuel Economy mode allows the driver to see his fuel
economy during a trip. Information is updated continually
and is presented in the form of a bargraph. Average fuel
economy during the trip (AVG), and the fuel economy
under the current conditions (INST) can be seen at a
glance, along with the fuel economy target value (set
using the Set-Up menu).
Press the Mode button until a gauge display appears.
Use the Up and Down buttons to display the desired

gauge:
The Fuel Economy mode contains a Avg/Inst/Target

display and a Trip Fuel Meter display function. To select
one of these displays:
Voltmeter - This standard gauge display monitors the battery voltage. If the voltage exceeds
16 volts, TOO HIGH will be displayed.
Use the Mode button to select the Fuel Economy

display.
Engine Oil Temperature - The range of this

optional gauge display is 90 to 310 F. If the
temperature exceeds the trip point, TOO HIGH
will be displayed and the yellow Caution telltale
will light.
Use the Up and Down buttons to display the bargraph

or TRIP FUEL METER.
Avg/Inst/Target Display
Transmission Oil Temperature - This optional

gauge display monitors the transmission oil tem

perature. Its range is 90 to 310 F. If the temperature exceeds the trip point, HIGH will be displayed and the yellow Caution telltale will light.
Preset trip points for Graphic Display

gauges
Each of the gauges in the Graphic Display has a preset
trip point. A trip point represents a critical condition when
reached. The Engine Oil Temperature gauge display may

have a trip point of 270 F, for example. Should a trip point
be reached, the Graphic Display will automatically replace
the current gauge display (or any other display, for that
matter) with a symbol or message identifying the critical
condition.
W3000713
The Avg/Inst/Target Display shows the vehicles average,

instantaneous, and target fuel economy. The range is
0 to 99.9 miles per gallon, or 0 to 999 liters per 100
kilometers (selectable using the Set-Up menu). The data
is calculated by the microprocessor on the Left Circuit
Board using inputs from the J1587 data link. The AVG
value can be reset by pressing the Set button while in
this display (the Trip Fuel Meter value will also be reset).
Trip Fuel Meter
Trip points for clusters to be used with Volvo engines

are preset at the factory during End-of-Line programming.
When the cluster is installed with a Caterpillar, Cummins,
or Detroit Diesel engine, the trip points are sent via
the J1587 data link according to each manufacturers
specifications. Refer to the appropriate manual for these
trip points.
In some cases, the yellow Caution telltale or red Stop
telltale may also light, and the buzzer may also sound
28
The Trip Fuel meter displays the amount of fuel used

since the last time it was reset. Its range is from 0 to
9999 gallons or liters (driver selectable), and the data is
calculated by the microprocessor on the Left Circuit Board
using inputs from the J1587 data link. The Trip Fuel value
can be reset to zero by pressing the Set button while
in this display (the AVG fuel economy value will also be
reset).
Design and Function
Center section
Tachometer
The tachometer is an electrical aircore meter movement
driven by signals from the J1587 data link. In the absence
of data link information, the gauge pointer will move to its
minimum reading after a 35 second delay.
W3000843
Speedometer and odometer

The speedometer is an electrical aircore meter movement
driven by signals from the J1587 data link. In the absence
of data link information, the gauge pointer will move to
its minimum reading after a 35 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 or transmission ECU.
The Odometer is a Liquid Crystal Display (LCD) mounted
behind the speedometer dial. It has a full scale reading
of 999999.9. Odometer information is calculated from
road speed via the J1587 data link and is stored in the
clusters microprocessor. The odometer backlighting can
be adjusted independently of gauge backlighting.
W3000844
During normal operation, the odometer display goes blank

30 seconds after the ignition is switched off. To reactivate
the display, turn the ignition on, or the odometer display
can be reactivated by pressing any of the buttons.
In the absence of speedometer data, the odometer display
will not change and the speedometer pointer will remain
at zero.
29
Design and Function
Telltale lamps, center section
W3000840
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
SRS (Airbag) Indicator
8
9
10
11
12
13
14
Parking Brake Indicator

Anti-Lock Brake System (Tractor) Indicator
Anti-Lock Brake System (Trailer) Indicator
Air Suspension System Indicator
Bogie Lift Indicator
Mirror Defroster Indicator
Right Turn Indicator
Note that all gauges and telltales may not be used in all
vehicles.
Master Warning telltale

A red Master Warning telltale consisting of an exclamation
point (!) inside a triangle is located near the bottom and
midway between the tachometer and the speedometer. It
lights when the front or rear brake air pressure is too low
for safe operation (below 72 psi).
W3000638
30
Design and Function
Right section
Forward and rear drive axle temperature (optional)
The forward and rear axle temperature gauges are electrical aircore meter movements. They are connected to
temperature sender units mounted on the axle housings.
The higher the temperature, the lower the resistance of
the sender unit, and the farther the gauge pointer moves
to the right.
W3000984
Forward Axle Temperature Gauge
Fuel level
The fuel level gauge is an electrical aircore meter movement that receives its signal from a sensor in the fuel tank.
The fuel level sensor signal is input to the cluster microprocessor through the left module connector. In the microprocessor the signal is changed from a resistance to a
pulse width modulated signal. It is then sent to the right
module via jumper IPJ5. As the duty cycle of the signal
increases, the level shown on the gauge increases.
W3000814
Application air pressure (optional)

The application air pressure gauge is a mechanical gauge.
It is attached to the 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 quick-disconnects are color-coded to
avoid wrong connections.
W3000608
31
Design and Function
Front and rear brake air pressure

The air pressure gauges are mechanical gauges. They
are attached to their air systems by a hose going into
a quick-disconnect fitting on the rear of the gauge. The
air hoses and quick-disconnects are color-coded to avoid
wrong connections.
The front and rear brake air pressure gauges contain
mechanical contacts. When the air pressure drops below
a preset value, the contacts close, causing a warning
buzzer to sound and a red warning LED in the lower right
corner of the gauge to light. The Master Warning indicator
will also light.
W3000609
Front Brake Air Pressure Gauge
Telltale lamps, right section
W3000841
1
2
3
Pre-heat
Traction Control System
APADS (Air Conditioning Protection and Diagnostic System for future use)
Note that all gauges and telltales may not be used in all
vehicles.
32
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.
Warning signal - Two beeps every second. This is activated when any red telltale
except No Charge and Park Brake are on and the engine is running faster than 300
rpm (idle). The Warning signal will override all other signals.
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.
The clock reminder will override a Turn signal buzzer.
While in the cluster self test or diagnostic mode the buzzers do not sound.
33
Design and Function
Connector pinouts
LX and LY connectors
W3000849
Left Module, LX Connector

Pin
Description
Input
Data Link + (J1587)
400
mV reading
Fuel Sensor
183
33-250 ohms
Fuel Level (Jumper to Right Module)
IPJ5
Pulse width
modulated signal (5V)
Battery -
0X-1
Ground
10
Battery +
202
+12 V
11
Data Link - (J1587)
401
mV reading
12
Power Ground
0P-1
Ground
20
Illumination +
141-J
0-12 V
22
Ignition +
180
+12 V
Pins not listed are not used.
34
Circuit No.
Note: All resistance measurements must be made with

power removed from the circuit.
Design and Function
Left Module, LY Connector

Pin
Description
Circuit No.
Input
Air Filter Restriction Gauge
199
Ground (when
activated)
Bulb Test + (Output) (Jumper to Center Module)
IPJ1
+12V during bulb test
Bulb Test - (Output) (Jumper to Center Module)
IPJ2
Ground during bulb

test
No Charge Warning Lamp
14
Ground (Note 1)
Stop Engine Warning Lamp (Caterpillar, Cummins

and Detroit Diesel engines only. Volvo is not
hardwired.)
575
Ground
10
Caution Lamp
576
Ground (Note 2)
11
Engine Fluids Warning Lamp (Volvo and Cummins

engines only)
577
Ground
13
Pyrometer -
190
Ground
15
+ 5V Output (Reference Jumper to Right Module)
IPJ3
+5V
16
Return to Zero (Jumper to Right Module)
IPJ4
Ground
19
End Of Line Programming Enable
403A
Ground (used only

when programming)
23
Washer Fluid Level
387A
Ground (when
activated)
27
Engine Oil Temperature (Volvo engine only)
204
Sensor Input
28
Transmission Oil Temperature
314
Sensor Input
30
Pyrometer +
191
0-100 mV

All resistance measurements must be made with power
removed from the circuit.
Note 1: The No Charge Warning Lamp will begin to
illuminate dimly when the engine is running and the input
on this pin drops below 12 V. It will illuminate fully when
it drops below 8 V.
Note 2: The Caution lamp illuminates when engine RPM

is above 500, and there is a fault in the graphic display for
Engine Oil Temperature, Transmission Oil Temperature,
or Voltage. The Caution lamp will also illuminate if other
engine ECU fault codes instruct the lamp to illuminate.
35
Design and Function
CY connector
Center Module, CY Connector
W3000765
Pin
Description
Circuit
No.
ABS, Truck
779
Ground
Park Brake
420
Ground
Heated Mirror
702
+12V
Bulb Test + (from LY-3)
IPJ1
Bulb Test - (from LY-4)
IPJ2
High Beam
33
+12V
Right Turn Indicator
113
+12V
10
Interaxle Differential
Lock
422
+12V
11
Power Ground
0P-3
Ground
12
Interwheel Differential
Lock
426
Ground
13
Fifth Wheel Lock
424
Ground
14
Left Turn Indicator
112
+12V
15
Air Suspension
Pressure
431
Ground
18
Backlighting
19
Bulb Test + (to Right

Module)
IPJ6
20
Bulb Test - (to Right

Module)
IPJ7
22
Ignition +
180
+12V
24
SRS (Airbag) Warning
0X-3
Ground
(Needs
open
circuit to
turn on)
25
Master Warning (from

Right Module)
IPJ8
Ground
141-H
Input
0-12V

36
Design and Function
RX connector
W3000847
Right Module, RX Connector

Pin
Description
Illumination +
Circuit No.
Input
141-G
0-12 V
Ground
0X-2
Ground
Rear Axle Temperature (Front)
468
Variable resistance
(Note 1)
Fuel Level (Jumper from LX-3, Left Module)
IPJ5
Pulse width modulated signal
Master Warning output (Jumper to Center Module)
IPJ8
Ground
11
Power Ground
0P-4
Ground
12
+5V (Jumper from LY-15, Left Module)
IPJ3
+5 V
13
Rear Axle Temperature (Rear)
469
Variable resistance
(Note 1)
14
Ignition +
180
+12V
15
Return to Zero (Jumper from LY-16, Left Module)
IPJ4
Ground
18
Bulb Test + (Input) (Jumper from Center Module)
IPJ6
+12V during bulb test
19
Bulb Test - (Input) (Jumper from Center Module)
IPJ7
Ground during bulb

test
20
Engine Preheat (Volvo engine only)
361
Ground
21
Traction Control System

774-B (Bendix)
774-A (Wabco)
Ground
Note 1: Axle temperature measurements must be made

with the RX connector disconnected.
37
38
Troubleshooting
Troubleshooting
This chapter describes how to test the instrument cluster
and troubleshoot the cluster as a whole.
General service information

Many of the components can be tested without disturbing
the cluster by using the Cluster Self Test Mode function in
the Graphic Displays Diagnostics Menu. This includes all
telltale lamps, the speedometer, tachometer, oil pressure
gauge, coolant temperature gauge and Graphic Display
unit. The pivot-down mounting feature of the cluster
allows troubleshooting of input signals without removing
the cluster from the vehicle.
Tools and test equipment

For the procedures described in this chapter, you will need
the following tools:
T25 Torx head driver (cluster mounting screws).

Telltale lamp removal tool (Volvo P/N 1608077)
Digital multi-meter which can measure down to 5
millivolts
Hose connections to the air pressure gauges are quickdisconnect and the air hoses to them can be disconnected
and reconnected without tools.
Storing the cluster

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.
Never disconnect an air system component unless

all system pressure has been depleted. Failure to
deplete system pressure before disconnecting hoses
or components may result in them separating violently
and causing serious bodily injury.
The electrical gauges contain an oil that can start to

run out if the gauge is left upside down longer than
15 minutes. If the oil runs out, the gauge becomes
inaccurate. For this reason, always store clusters and
gauges face-up.
39
Troubleshooting
Troubleshooting individual gauges

Cluster backlighting
The 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. The cluster
backlighting is independent of the odometer and Graphic
Display backlighting.
Testing the cluster backlighting

To test the cluster backlighting, turn the dash lights on
and adjust the dimmer control for maximum brightness.
1
Left Section
pin LX-20
Center Section
pin CY-18
Right Section
pin RX-1
a. If present, replace the cluster.
If none of the backlights light, check for +12 volts at

the output of the dimmer control on the vehicle dash.
a. If present, replace the cluster.
If only the right, center or left section of the cluster

has no backlighting, check the input pin for +12 volts.
b. If not present, check the input to the control

and the fuse.
3
b. If not present, there could be a short in

the cluster. One at a time, unplug each cluster
connector and recheck for +12 volts. If present,
replace the cluster; if not, check the input to the
dimmer control and the fuse.
If only one bulb of a particular board is affected,

replace the lamp/socket assembly as described in
Service Procedures in this manual. If the problem
persists, replace the cluster.
W3000716
Cluster backlighting signal flow
Odometer and graphic display backlighting

Odometer and Graphic Display backlighting is independent of the rest of the cluster. Test the odometer and
Graphic Display backlighting as follows:
1
40
Use the Backlighting Adjust function in the SetUp Menu to set the odometer and Graphic Display
backlighting to maximum brightness.
If neither the Graphic Display nor the odometer

backlighting work, or if the backlighting will not dim,
replace the cluster.
Troubleshooting
Buzzer problems
The buzzer can be tested by performing the Buzzer Test
in the Cluster Self Test Mode of the Diagnostics Menu.
The buzzer is not serviceable. If it fails to sound, replace

the cluster.
Buzzer Signal
Turn signal beep (momentary beep)
Clock reminder (double beep every other second)
Warning signal (two beeps every second)
Telltale indicators
W3000986
Telltale bulb signal flow
Telltale indicators are lighted by bulbs positioned across

the bottom of the instrument cluster.
If the suspect bulb lights during the self test, the

problem is not in the cluster. Check the signal source
for individual telltale bulbs.
Test the telltale bulbs by using the Bulb Test function in

the Cluster Self Test Mode of the Diagnostics menu.
If the suspect bulb fails but other bulbs light during

the self test, replace the suspect bulb.
If none of the bulbs in the center section light during

the Bulb Test function, check for
+12 volts between CY-5 and CY-6,
or between CY-19 and CY-20.
If missing, there is an open wire in the wiring harness.
If none of the bulbs in the right section light during

the Bulb Test function, check for +12 volts between
RX-18 and RX-19. If missing, there is an open wire
in the wiring harness.
Testing the telltale bulbs
CAUTION
When probing connector terminals, do not insert
probes into the terminals. This will spread the terminals apart, causing permanent damage. Probe
the insertion side of the connector.
If none of the telltale bulbs light during the Bulb Test
function, check for +12 volts between LY-3 and LY-4
during the Bulb Test function. If missing, replace the
cluster.
For more information, refer to the VNL, VNM Electrical

Schematics.
41
Troubleshooting
Left section
Pyrometer gauge
2
CAUTION
W3000870
Pyrometer gauge signal flow
If the pyrometer thermocouple fails, the pointer will move

to one end of the dial or the other. A reading of 300
F or less indicates an open in the trucks wiring or

thermocouple, and a reading of 1500 F or more indicates
a short.

If the Pyrometer gauge fails to indicate within 100 F of a

known true value, check the thermocouple and wiring with
a digital voltmeter capable of reading down to 5 millivolts.
1
Make certain the vehicle ignition is OFF.
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.
CAUTION
Gain access to the back of the cluster. With the
ignition on, there should be 5 to 50 millivolts between
connector LY pins 30 and 13.
a. If the voltage is incorrect, replace the thermocouple or the wire to it.
b. If the voltage is correct, replace the cluster.
42
Troubleshooting
Engine oil pressure gauge
W3000869
Engine Oil Pressure gauge signal flow
In the absence of an engine oil pressure data signal, the

gauge pointer will move to its minimum reading after a
35 second delay.
If the pointers on all the gauges on the J1587 data bus
move to the minimum reading, there is a problem in the
data link circuit. Troubleshoot the 400/401 wiring and
connectors.
Incorrect gauge reading

If the gauge does not appear to indicate the correct engine
oil pressure, test it using the Gauge Test function in the
Cluster Self Test Mode of the Diagnostics Menu:
1
If the gauge pointer sweeps back and forth across the

full range, the meter movement and its associated circuitry in the cluster are working. Use the Diagnostic
Messages function of the Diagnostics Menu to check
for oil pressure related messages. Use the service
tool for the engine in your vehicle to compare any diagnostic messages shown in the instrument cluster.
If a sensor problem is indicated, check the wiring

from the sensor for opens or shorts, according to the
engine manufacturers service literature. Also refer
to the VNL, VNM Electrical Schematics for wiring
information.
If the pointer fails to sweep, and a sensor problem

has been ruled out replace the cluster.
Intermittent function
If this and other gauges on the J1587 data link appear

to twitch or function intermittently, check the 400/
401 circuit for a loose connection.
If this gauge only appears to function intermittently,

the data link could be overloaded with data from
ECUs in the vehicle system. In this case, check the
data link using the MPSI Pro-Link Snapshot function.
43
Troubleshooting
Engine coolant temperature gauge
W3000718
Coolant temperature gauge signal flow
The coolant temperature gauge is an electrical aircore

via the J1587 data bus. In the absence of a data signal,
the gauge pointer will move to its minimum reading after
a 35 second delay.

The gauge can be tested by activating the Cluster Self
Test Mode function of the Diagnostics Menu.
1

connectors.
a. Check for coolant-related messages using the

Diagnostic Messages function of the Diagnostics
Menu. Use the service tool for the engine in your
vehicle to compare any diagnostic messages
shown in the instrument cluster.
44

If the gauge pointer sweeps back and forth across

the full range, the gauge and its associated circuitry
in the cluster are working.
b. If a sensor problem is indicated, check

the wiring from the sensor for opens or shorts,
according to the engine manufacturers service
literature. Also refer to the VNL, VNM Electrical
Schematics for wiring information.
2
If the gauge pointer does not move during the self

test, and a sensor problem has been ruled out,
replace the cluster.
Troubleshooting
Turbo boost pressure gauge
W3000723
Turbo Boost Pressure gauge signal flow
The Turbo Boost Pressure gauge is an electrical aircore

via the J1587 data bus. In the absence of a data signal,
the gauge pointer will move to its minimum reading after
a 35 second delay. If Turbo Boost Pressure data is
missing during normal operating conditions, the Turbo
Boost Pressure gauge pointer will move to the low end
of the scale (zero pressure).
connectors.



To test the gauge:
1
Check for messages using the Diagnostic Messages

function of the Diagnostics Menu. Use the engine
service tool to compare any diagnostic messages
shown in the instrument cluster. If a sensor problem is indicated, check the wiring from the sensor for
opens or shorts, according to the engine manufacturers service literature. Also refer to the VNL, VNM
Electrical Schematics for wiring information.
Use the Gauge Test function in the Cluster Self Test

Mode of the Diagnostics Menu.
a. If the Turbo Boost Pressure gauge pointer
sweeps back and forth across its full range, its
meter movement and associated circuitry in the
cluster are working.
b. If the gauge pointer does not move during the
self test, and a sensor problem has been ruled
out, replace the cluster.
Graphic Display
Use the Display Test function in the Cluster Self Test
Mode of the Diagnostics Menu to test the graphic display.
If the display is defective, replace the instrument cluster.
During the Display Test, all pixels in the display will
alternate from dark to light 2 times.
W3000719
Check for missing pixels, and for pixels that are always
dark. If defective, replace the cluster.
45
Troubleshooting
Center section
Speedometer, odometer and tachometer
W3000720
Speedometer/Odometer/Tachometer signal flow
Speedometer
The speedometer gauge is an electrical aircore meter
movement which receives its signal from the engine via
the J1587 data bus. In the absence of a data signal, the
35 second delay.
connectors.



If the speedometer accuracy is off more than 10%,
check the calibration of the engine ECU. Compare the
results of the ECU calibration with readings obtained with
the diagnostic service tool recommended by the engine
manufacturer.
for example, pulses/mile = 501 rev/mi x 4.10 x 16

pulses/rev = 32866 pulses/mile.
Test the speedometer by using the Gauge Test function in
the Cluster Self Test Mode of the Diagnostics Menu. Use
the service tool for the engine in your vehicle to compare
any diagnostic messages shown in the instrument cluster.
If a sensor problem is indicated, check the wiring from
the sensor for opens or shorts, according to the engine
manufacturers service literature. Also refer to the VNL,
VNM Electrical Schematics for wiring information.
If the speedometer pointer sweeps back and forth across
its full range, its meter movement and associated circuitry
within the cluster are working. If the gauge pointer does
not move during the self test, and a sensor problem has
been ruled out, replace the cluster.
Odometer
During normal operation, the odometer display remains
on for 30 seconds after the ignition is switched off. To
reactivate the display, turn the ignition on.
In the absence of speedometer data, the odometer display
will not change and the speedometer pointer will remain
at zero.
Each engine manufacturer formats calibration differently.

For the Volvo engine only, the engine ECU calibrates the
speedometer with the following formula:
If there is a problem with the odometer but the

speedometer works, replace the cluster.
pulses/mile = (tire rev/mile) x (rear axle ratio) x (no.

of teeth on chopper wheel on transmission)
If the odometer is inaccurate, check the engine ECU

speed calibration. If correct, replace the cluster.
46
Troubleshooting
Tachometer
In the absence of data link information, the tachometer

35 second delay.
Test the tachometer by using the Gauge Test function in

the Cluster Self Test Mode function of the Diagnostics
Menu. Use the service tool for the engine in your
vehicle to compare any diagnostic messages shown in
the instrument cluster. If a sensor problem is indicated,
check the wiring from the sensor for opens or shorts,
according to the engine manufacturers service literature.
Also refer to the VNL, VNM Electrical Schematics for
wiring information.

connectors.


If the tachometer pointer sweeps back and forth across

its full range, its meter movement and associated circuitry
within the cluster are working. If the gauge pointer does
not move during the self test, and a sensor problem has
been ruled out, replace the cluster.
47
Troubleshooting
Right section
Axle temperature gauges (forward and rear)
Testing the axle temperature gauges
1
CAUTION
W3000715
Front and Rear Drive Axle Temperature gauge signal flow
Fault indications
A constant gauge reading of 90 F or less can be caused

by a defective sender unit or gauge, or an open wire
between the cluster and the sender unit.
CAUTION

A constant reading of 270 F or more can be caused by a

defective gauge or sender unit, or by a wire that is shorted
to ground between the gauge and the sender unit.

Inaccuracies greater than 10 F usually indicate a defective sender unit or gauge.
Gain access to the rear of the instrument cluster. Disconnect connector RX and measure the resistance
between harness pin 13 (Front Axle gauge) or pin 3
(Rear Axle gauge), and pin 11 (ground):
Axle Temp.

70 F

120 F

200 F
48
Expected Reading
1000 ohms 10%
430 ohms 10%
110 ohms 10%
If the resistance readings are correct, reconnect the

connectors and turn the key on. There should be
battery voltage between connector RX pins 11 and
14. If not, and the rest of the cluster works, the wire
from RX-14 is probably open.
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 Schematics
for wiring information.
Troubleshooting
Air pressure gauges

3
W3000836
Note: The LED connector wires are not polaritysensitive.
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.
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
W3000834
1) Rear Brake Pressure Air Line (Red)

2) Front Brake Pressure Air Line (Green)
3) Application Air Pressure Air Line (Black)
Air Gauge Test:

1
Drain the air pressure from both air systems.
Remove the air lines from the Front and Rear Brake
Air Pressure gauges.
2
4
Connect the air lines back into the opposite gauges,

start the engine and build the air pressure in the
systems.
Compare the sweep of both gauges to see if the

problem still exists, or if the problem is now in the
other gauge. If the problem is in the other gauge,
troubleshoot the air line for a kink or restriction.
If the problem still exists in the same gauge, replace

the cluster.
Air Gauge LED Test

1
To test the red warning LED in the Front or Rear

Brake Air Pressure gauge, pump the brake pedal
while the ignition is on (and engine is off) to lower
the system air pressure. When the pressure drops
below 60 psi, the LED must light. If not, check the
LED circuitry by using the Bulb Test function. If the
LED does not light during the Bulb Test, replace the
cluster.
Start the engine. When the air pressure rises above

70 10 psi, the LED should turn off. If not, replace
the cluster.
W3000842
Remove the two screws at the top of the instrument

cluster and lay the cluster face-down on the steering
column.
49
Troubleshooting
Fuel Level gauge
W3000873
Fuel level gauge signal flow
The Fuel Gauge is an electrical aircore meter movement

that receives its signal from a sensor in the fuel tank. This
signal is input to the microprocessor on the instrument
cluster, which drives the gauge.
Fuel Level
Expected Reading
(at sender and
LX-2 to LX-12)
If the fuel gauge is reading incorrectly, it can be tested

by activating the Cluster Self Test Mode function of the
Diagnostics Menu:
Empty tank
240 ohms 10%
1/4 tank
153 ohms 10%
1/2 tank
103 ohms 10%
3/4 tank
67 ohms 10%
Full tank
33 ohms 10%
If the pointer sweeps back and forth across its full

range during the cluster self test, the meter and its
associated circuitry in the cluster are working. Go to
step 1 below.
If the pointer does not sweep during the cluster
self test, the most likely cause is a defective Fuel
Level gauge, or a wiring problem in the harness. Go
to step 4.
If the pointer does not sweep during the cluster
self test AND the pointer:
falls below the empty mark
or constantly stays on the Full mark
or constantly stays on the 1/2 mark
Go to step 6.
If gauge failure is suspected, check for mechanical

failure of the fuel level sender. If the sender is in
good physical condition, disconnect the connector
and measure resistance at the fuel level sender.
The reading should be between 33 and 240 ohms
depending upon the fuel level in the tank (see Table
A).
50
Table A: Resistance Check
If resistance is as shown in Table A, reconnect

the sender connector and proceed to step 3.
If resistance is not as shown in Table A, replace

the fuel level sender.
CAUTION
CAUTION
Gain access to the back of the instrument cluster.
Disconnect connector LX and use an ohmmeter to
measure the resistance between pins 2 and 12 on
the harness connector (insertion side). The reading
should be between 33 and 240 ohms depending upon
the fuel level in the tank (see Table A for values).
If resistance is as shown in Table A, go to step

4.
If resistance is not as shown in Table A, check

the connectors and wiring from the LX connector
to the fuel level sender. Refer to the VNL, VNM
Electrical Schematics for wiring information.
Troubleshooting
Turn the ignition ON and use a voltmeter to measure

the voltage between pins 2 and 4 on the RX connector. Measurements should be as follows:
b. If the pointer stays above F AND does

not move during the cluster self test, there is
no signal on the +5V input to the cluster. Check
LY-15 and RX-12 for an open circuit.
Table B: Voltage Check
Fuel Level
Expected Reading
(RX-2 to RX-4
and RX-2 to LX-3)
Empty tank
0.19 volts 10%
1/4 tank
1.1 volts 10%
1/2 tank
2.3 volts 10%
3/4 tank
3.5 volts 10%
Full tank
4.7 volts 10%

W3000872
If voltage is as shown in Table B, replace the

cluster.
If voltage is not as shown in Table B, go to step

5.
c. If the pointer stays at the 1/2 mark AND the

pointer does not move during the cluster self
test, there is no signal on the fuel level input.
Check RX-4 for an open circuit.
Check voltage between RX-2 and LX-3.
If voltage is as shown in the Table B, check

the circuit, connector terminals and wiring from
RX4 to LX3, and replace components as
necessary.
If voltage is not as shown in Table B, replace the

instrument cluster.
If the pointer constantly stays on the 1/2 mark,

Full mark, or falls below the empty mark, the most
likely cause is a wiring problem.
a. If the pointer stays below E AND the
pointer moves slightly during the gauge test,
there is no signal on the ground input. Check
for an open circuit on RX-2.
Note that RX-2 is associated with the axle temperature circuit, so that gauge may be affected
also.
W3000814
W3000871
51
Troubleshooting
Troubleshooting with the MPSI Pro-Link 9000 and VOLVO

Cartridge
Special tests
The MPSI Pro-Link 90002 with the Volvo cartridge provides easy diagnosis of faults, with more information than
instrument cluster self-diagnostics.
The following tests can be performed with the Pro-Link 9000 and the Volvo cartridge, version 2.0 (see Tools for ordering
information).
Gauge tests
These gauges can be individually driven.
Speedometer: The speedometer gauge can be driven
in steps of 5 mph, from 080 mph.
Tachometer: The tachometer gauge can be driven in
steps of 100 RPM, from 02500 RPM.
Engine Oil Pressure: The engine oil pressure gauge
can be driven in steps of 15 psi, from 090 psi.
Engine Oil Temperature: The engine oil temperature

gauge can be driven in steps of 10 F, from 50 to 270

F.
Turbo boost: The turbo boost pressure gauge can be
driven in steps of 5 psi, from 030 psi.
Coolant temp.: The coolant temp gauge can be driven

in steps of 5 F, from 150 to 230 F.
Pro-Link is a registered trademark of MPSI.
52
Lamp circuitry tests

The following tests check the function of the telltale
lamp circuitry.
High Coolant Temperature
Low Engine Oil Pressure
High Engine Oil Temperature (Caution)
Low Coolant Level (Stop)
Troubleshooting
View EEPROM
Read functions
Clock Mode 12 or 24 hour mode
Operating Volts 12 or 24 volts
Turbo Gauge indicates whether the turbo gauge is
installed
Voltmeter indicates whether the voltmeter display is
enabled or disabled
Eng Oil Temp indicates whether the engine oil temperature display is enabled or disabled
Trans Temp indicates whether the transmission oil temp.

is enabled or disabled
Fuel Econ indicates whether the fuel economy feature is
enabled or disabled

Eng Oil F Src indicates the signal source for the engine
oil temperature from data bus or sensor (VE D12 engine)
Hourmeter This allows the hourmeter total to be checked.
Odometer This allows the odometer total to be checked.
Reprogram EEPROM
Read/write functions
Clock Mode set 12 or 24 hour mode
Operating Volts set 12 or 24 volts
Turbo Gauge enable or disable
Voltmeter enable or disable
Eng Oil Temp Allows checking of whether the engine oil
temperature gauge is enabled or disabled. Also allows
changing of the status from enabled to disabled, or viceversa.
Trans Temp Allows checking of whether the transmission
oil temperature gauge is enabled or disabled. Also allows
changing of the status from enabled to disabled, or viceversa.
Fuel Econ Allows checking of whether the fuel economy
gauge is enabled or disabled. Also allows changing of the
status from enabled to disabled, or vice-versa.
Eng Oil F Src Allows checking of whether the engine oil

temperature signal source is from the data bus (Caterpillar, Cummins, Detroit Diesel engines) or from a sensor
(Volvo engine). If installing a new cluster into a vehicle,
this variable will need to be set for the appropriate engine.
Password-protected read/write functions

The password for instrument cluster software, version 6.5
and above, use four dashes (- ) for the password.
Earlier versions of software used four zeros (0000). The
software version can be looked up in the engine ECU.
Hourmeter This allows the hourmeter total to be checked
and changed. It is used when installing a new instrument
cluster into a vehicle which already has miles on the
engine.
Odometer This allows the odometer total to be checked
and changed. It is used when installing a new instrument
cluster into a vehicle which already has miles on it.
53
54
Service Procedures
Service Procedures
Important: Individual gauges on the VN instrument
cluster are not serviceable. Attempts to service or
replace individual gauges during the warranty period
will void the cluster warranty. Instead, the whole unit
may be exchanged.
ONLY when a certified technician is repopulating a replacement instrument cluster may the cluster be opened
during the warranty period.
?????-?
Bulb replacement
Removal
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
CAUTION
2
To prevent electrostatic discharge (ESD), which can
damage the sensitive electronic components in the
instrument cluster, do the following:
Use a wrist grounding strap and an anti-static mat when
working on the instrument cluster.
Work in a clean environment.
Do not place the cluster on a metal table or any metal
surface while servicing.
Failure to do the above can result in permanent
damage to the printed circuit boards in the instrument
cluster.
W3000842
Updating the odometer reading

after replacing the cluster
The odometer and hourmeter values are stored in the
cluster. Whenever a new cluster is installed, these values
must be updated to reflect the mileage and engine hours
of the vehicle in which the cluster is installed. This is done
using the MPSI Pro-link 9000 tool with the Volvo cartridge,
version 2.0.
To reset either of these readings, follow the Pro-link
menus to the Reprogram EEPROM menu, then select
either the Odometer or Hourmeter Total. Change to the
appropriate total.
Note: Reprogramming the Odometer or Hourmeter is a
password-protected function.
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.
Cleaning the housing and front

panel glass
To clean the housing and front panel glass, use a soft,
non-abrasive cloth and a mild soap-and-water solution.
55
Service Procedures
?????-?
Instrument cluster replacement
Removal
1
Make certain the vehicle ignition is
OFF before beginning this procedure.
W3000642
CAUTION
1089953
Use only the Volvo bulb removal

tool, P/N 1089953, to remove bulbs,
or damage to the cluster may occur.
Insert removal tool, P/N 1089953, onto
the bulb assembly. Rotate 1/4 turn
and pull the bulb assembly out of the
socket.
Installation
1
Insert the new bulb assembly into the
removal tool, P/N 1089953. Insert the
assembly into cluster socket and rotate 1/4 turn.
2
Replace the instrument cluster in the
dash and tighten the 2 screws at the
top of the cluster. Torque to 2 0.3
Nm (17.5 2.5 in-lb).
1089953
W3000842
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 wraps fastening the wiring
harness to the back of the cluster for
stress relief on the connectors.
56
Service Procedures
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
Bleed all pressure from the vehicle air
system. Disconnect the electrical and
air connectors from the back of the
cluster, and remove the cluster from
the vehicle.
Installation
1
Connect electrical connectors and air
lines at the back of the instrument
cluster. For stress relief on the connectors, tie wrap the wiring to the back
of the instrument cluster.
2
Install the instrument cluster in dash
and tighten the 2 screws at the top of
the cluster. Torque to 2 0.3 Nm (17.5
2.5 in-lb).
57
?????-?
Gauge replacement, right circuit board gauges
Service Procedures

cluster are not serviceable. Attempts to service or
should be exchanged.
Removal
1
CAUTION
To prevent electrostatic discharge
(ESD), which can damage the sensitive electronic components in the
instrument cluster, use a wrist
grounding strap and an anti-static
mat when working on the instrument cluster. Failure to do so can
result in permanent damage to the
printed circuit boards in the instrument cluster. Do not place the
cluster on a metal table or any
metal surface while servicing.
Remove cluster from vehicle (see previous procedure). Place cluster on
anti-static mat. The anti-static mat
must be grounded to the nearest electrical outlet. When working at the
anti-static workbench, always keep a
wrist strap connected to the anti-static
mat.
58
W3000835
1) Gauge mounting screws do not remove

at this time
2) Top cover screw location
3) Bottom cover screw location
Right printed circuit board (PCB) with cover removed
Remove the Phillips screw at the top

of the right rear cover, and the two at
the bottom, then lift off the cover.
Note: Do not remove any of the three
Phillips screws in the board at this
time. They secure the air pressure
gauges to the board.
Service Procedures
Removing a gauge blank
3
Lift out the Right Circuit Board assembly, with gauges.
W3000990
Note: Early production models may have gauge

blanks as shown in the illustration. If replacing any
blank, use the newer gauge blank support assembly shown in the Installation procedure.
W3000989
CAUTION
When adding a gauge blank, remove

the gauge or gauge blank to be replaced.
To avoid damaging the gauge, do

not push on the needle when removing the gauge. Pushing on the
needle can make the gauge inaccurate.
Air pressure gauges only: These are
each secured by one Phillips screw.
Remove the screw, pull the gauge out
of the board and disconnect the 2-pin
LED connector.
Other gauges: Gauges are held
tightly by their pin sockets. To remove,
grasp the side of the gauge face plate
with your thumb; place your 2nd and
3rd fingers underneath the face plate
(see illustration). Carefully rock the
gauge from side to side while applying
upward pressure until the gauge pins
are free of the board sockets.
59
Service Procedures
Installation
3
Install the Right Circuit Board assembly into the housing.
CAUTION
4
Place the cover over the board assembly and secure with three machine
screws.

not push on the needle when installing the gauge. Pushing on the
5
Install the cluster into the dash (see
previous procedure).
Install the replacement gauge by

grasping the opposite corners of the
gauge face plate and pushing the
gauge pins into the socket onto the
circuit board. Do not push on the needle. (For gauge blanks, see the
following steps.) It is correctly installed
when its face plate is flush with the
other gauges face plates.
Air pressure gauges only: Connect
the 2-pin connector into the board (it is
not polarity-sensitive, so it can go in
either way) and secure the gauge to
the board with a self-tapping Phillips
screw.
6
If installing a gauge blank into the Engine Oil Pressure or Turbo Boost
Pressure gauges, use the MPSI ProLink 9000 with the VOLVO cartridge to
enable the gauge which is being
added, or to disable the gauge which
is being removed.
Adding gauge blanks

2
W3000820
1)
2)
3)
4)
Gauge Blank
Blank Support Assembly
Pins
Terminals
Install the new blank (1) into the cluster housing. Install the blank support
(2) in the PC board into the terminals
(4) where the gauge was removed.
60
Service Procedures
?????-?
Center module replacement
W3000739
1) Center Module screw locations
Removal
1
Important: Individual gauges on the
VN instrument cluster are not serviceable. Attempts to remove and
replace individual gauges during
the warranty period will void the
cluster warranty. Instead, the whole
unit should be exchanged. ONLY
when a certified technician is repopulating a replacement instrument cluster
may the cluster be opened during the
warranty period.
CAUTION
mat when working on the instrument
cluster. Failure to do so can result
in permanent damage to the cluster.
must be grounded to the nearest electrical outlet. When working at your
anti-static workbench, always keep
your wrist strap connected to the antistatic mat. Do not place the cluster on
a metal table or any metal surface
while servicing.
61
Service Procedures
3
Remove the Phillips screws at the top
of the left rear cover, and the two at
the bottom, then lift the left rear cover
from the cluster.
4
Remove the four Phillips cover screws.
5
W3000845
1) Connector E1
CAUTION
Do not bend the printed circuit
board. Bending the board can result in damage to the board or
components.
Grasp the top and bottom of connector
E1 (over the Left Circuit Board) with
your thumb and forefinger. Rock the
Center Module from top to bottom
while pulling up to unseat E1.
6
Remove the Center Module by lifting it
off of the cluster.
62
Service Procedures
Installation
W3000731
2
To reinstall the Center Module, line up
connector E1 pins with connector E2
holes on the Center Circuit Board,
then carefully seat E2 while lowering
the Center Module into the housing.
3
Verify that all E1 pins are in connector
E2 holes, then use your thumb to fully
seat E2 onto the Left Circuit Board.
W3000846
4
Secure the Center Module to the
housing with four machine screws.
1) Button extensions
Before reinstalling the Center Module,

make sure that all four plastic button
extensions are installed in the top of
the housing (the short ends stick out
the front of the housing).
63
Gauge replacement, left circuit

board gauges
Service Procedures

cluster are not serviceable. Attempts to remove and
may be exchanged.
Removal
1
CAUTION
mat when working on the instrument cluster. Failure to do so can
result in permanent damage to the
printed circuit boards in the instrument cluster.
must be grounded to the nearest electrical outlet. When working at the
anti-static workbench, always keep a
wrist strap connected to the anti-static
mat. Do not place the cluster on a
metal table or any metal surface while
servicing.
W3000734
1) Connector E2 (part of the center circuit

board)
2) Top cover screw location
3) Bottom cover screw location
4) Connector E4 to Graphic Display board underneath
Remove the Phillips screw at the top

of the left rear cover, and the two at
the bottom, then lift off the cover.
Note: Connector E2 is part of the
Center Circuit Board.
64
Service Procedures
Gauges are held tightly by their pin

sockets. To remove, grasp the side of
the gauge face plate with your thumb;
place your 2nd and 3rd fingers underneath the face plate (see illustration).
Carefully rock the gauge from side to
side while applying upward pressure
until the gauge pins are free of the
board sockets.
CAUTION
Do not bend the printed circuit
board. Bending the board can result in damage to the board or
components.
The Center Circuit Board connector
E2 is holding the Left Circuit Board assembly in at this point, so you will have
to remove the Center Module before
continuing (see previous procedure).
Removing a gauge blank

6
4
Carefully lift out the Left Circuit Board
assembly by lifting straight up. It is attached to the Graphic Display board
below at connector E4.
5
W3000990
Note: Early production models may have gauge

blanks like the above. If replacing a blank, use the
newer gauge blank support assembly shown in the
Installation procedure.
When adding a gauge blank, remove

the gauge or gauge blank to be replaced.
W3000991
CAUTION
not push on the needle when removing the gauge. Pushing on the
65
Service Procedures
Installation
CAUTION
not push on the needle when installing the gauge. Pushing on the
Install the replacement gauge by
grasping the opposite corners of the
gauge face plate and pushing the
gauge pins into the socket onto the
circuit board. Do not push on the needle. (For gauge blanks, see the
following steps.) It is correctly installed
when its face plate is flush with the
other gauges face plates.
W3000750
Important! Before installing the Left

Circuit Board assembly, check connector E4 pins and make sure they
are all perfectly straight and parallel to
each other.
Adding gauge blanks

4
Place the Left Circuit Board assembly
into the housing while lining up E4 pins
into the Graphic Display connector.
5
Install the Center Module, paying particular attention to connector E1 on the
Left Circuit Board assembly.
6
Install the left rear cover and secure it
with three machine screws.
W3000820
1)
2)
3)
4)
Gauge Blank
Blank Support Assembly
Pins
Terminals
Install the new blank (1) into the cluster housing. Install the blank support
(2) in the PC board into the terminals
(4) where the gauge was removed.
7
Install the cluster into the dash (see
previous procedure).
8
If installing a gauge blank into the Engine Oil Pressure or Turbo Boost
Pressure gauges, use the MPSI ProLink 9000 with the VOLVO cartridge to
enable the gauge which is being
added, or to disable the gauge which
is being removed.
9
Important: If the Left Circuit Board
has been replaced, update the odometer and hourmeter values to reflect the
vehicles actual mileage and engine
hours. This is done with the MPSI
Pro-Link 9000.
66
67
Volvo GM Heavy Truck

Volvo GM Heavy Truck Corporation 7825 National Service Road P.O. Box 26115 Greensboro, NC 27402-6115
Volvo GM Canada Heavy Truck Corp. 6490 Vipond Drive Mississauga, Ontario L5T 1W8
PV776-TSP23762/1 (7.95) 8.95

PV776 TSP23762 1

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Service Manual

Volvo GM Heavy Truck

Order number: PV776-TSP23762/1

1996 Volvo GM Heavy Truck, Greensboro, NC USA

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

Service Procedures .............................................................................

Group 38 Instrumentation, VNL, VNM

Preventing electrostatic discharge

Group 38 Instrumentation, VNL, VNM

Center Section - Contains a tachometer, speedometer and odometer. Also

Group 38 Instrumentation, VNL, VNM

Group 38 Instrumentation, VNL, VNM

Available configurations (contd.)

Group 38 Instrumentation, VNL, VNM

Lamp removal tool

Group 38 Instrumentation, VNL, VNM

ESD Wrist Strap

Fluke 87 Digital Multi-meter (DMM)

Type 8501 Static Dissipative Grounding Kit

Group 38 Instrumentation, VNL, VNM

MPSI Pro-Link 9000

MPSI Pro-Link 9000

VOLVO Cartridge, version 2.0

Diagnostic Adaptor Cable

Pro-Link is a registered trademark of MPSI.

Group 38 Instrumentation, VNL, VNM

Design and Function

Design and Function

Group 38 Instrumentation, VNL, VNM

Design and Function

Instrument cluster block diagram for Caterpillar, Cummins, Detroit Diesel

Group 38 Instrumentation, VNL, VNM

Design and Function

Gauges and indicators

Engine Coolant Temperature

Turbo Boost Pressure (optional)

Group 38 Instrumentation, VNL, VNM

Design and Function

Engine Oil Pressure

Note: Engine oil operating pressure is engine dependent.

Telltale lamps. left section

Engine Fluids lamp

Illuminates when engine oil pressure or coolant level

Illuminates to alert the driver that an engine problem has

Note: The Engine Fluids lamp is not used in vehicles with

Illuminates when a problem exists in the charging system.

Group 38 Instrumentation, VNL, VNM

Design and Function

Engine-related Warnings: Volvo VE D12

Low Coolant Level

Low Oil Pressure, with Oil

Low Oil Pressure, with Oil

Low Oil Pressure, with Oil

High Coolant Temperature

High Oil Temperature

Note: When Key switch = Ignition position:

Lamp remains flashing even when the fault becomes

Source = Data Concentrator Module (DCM), when an

For more information, refer to the Electronic Control