Volvo VNL User manual

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

Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to February1998.
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 ser-
vice 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 refer-
ence to an V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an V.S.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 oc-
cur.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP106805/1
©1998 VolvoTrucks North America, Inc., Greensboro,NC USA
All rights reserved. No part of this publication may be reproduced, stored in
retrieval system, or transmitted in any forms by any means, electronic, me-
chanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..
USA06444

Contents
General .................................................................................................... 3
General WorkPractices ........................................................................ 3
Basic Description ................................................................................... 4
Tools ........................................................................................................ 9
Special Tools ......................................................................................... 9
Special Equipment ............................................................................... 10
Design and Function ........................................................................... 11
Instrument Cluster ................................................................................. 11
Instrument Cluster Functional Diagram ............................................... 11
Gauges and Indicators ........................................................................ 13
Connector Pinouts ............................................................................... 33
Troubleshooting ................................................................................... 37
Instrumentation Troubleshooting ............................................................ 37
General Service Information ................................................................ 37
Troubleshooting Notes ......................................................................... 38
Gauges,Troubleshooting ..................................................................... 39
Gauges,Troubleshooting (with Pro-Link) ............................................ 57
Service Procedures ............................................................................. 59
Warranty Notice ................................................................................... 60
Odometer,Programming ..................................................................... 60
Housing and Front Panel Glass,Cleaning .......................................... 60
Bulb,Replacement .............................................................................. 61
Instrument Cluster,Replacement ........................................................ 62
Right Module,Replacement ................................................................ 63
Center Module,Replacement .............................................................. 66
Tachometer,Speedometer and Odometer,Replacement ................... 71
Left Gauge Module,Replacement ...................................................... 73
Feedback
Operation Numbers
1

2

Group 38 Instrumentation, VNL, VNM General
General
General Work Practices
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 prefer-
able to avoid welding on an assembled truck, but if
welding must be done on any structure on or in
contact with the vehicle, disconnect the electrical con-
nectors at the rear of the instrument cluster, all ECU’s
and the battery cables. When disconnecting the bat-
tery cables, disconnect any other ground cables
connected to the battery first, then the main battery
ground. Attach the welder ground cable as close to
the weld as possible.
Preventing electrostatic discharge
(ESD)
CAUTION
To prevent electrostatic discharge (ESD), which may
damage the sensitive electronic components in the in-
strument 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 in-
strument cluster, make sure the workbench has an
anti-static mat which is grounded to the nearest elec-
trical outlet when working on the instrument cluster.
Failure to use an anti-static mat may result in perma-
nent 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.
When dealing with circuits designed to sense differences
smaller than 1 volt, electrostatic discharge can be a sub-
tle 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 dis-
charge. Rather they may work for a while, then fail for no
apparent reason. The culprit then is often the normal
warming up and cooling down process of the module,
engine or cab interior.
Grounding straps and anti-static mats are available for
minimal cost from electronic supply stores. Grounding
straps consist of a wrist strap, a coiled extension wire
and an alligator clip. Be sure to purchase one with a long
enough extension wire to allow freedom of movement.
Anti-static wrist straps and mats are available from
Kent-Moore (see). Call 1-800-328-6657.
3

Group 38 Instrumentation, VNL, VNM General
Basic Description
T3009000
Fig. 1:
This information describes the 1996B AMETEK/Dixson Instrument Cluster for VN Se-
ries vehicles and how to service it. This instrument cluster went into production in
January 1998. It is distinguished from the earlier VN instrument cluster by the location
of the Mode/Set and Up/Down buttons on the stalk arm. The earlier model had these
buttons on the face of the cluster. For information about the vehicle’s Electronic Control
Units, wiring diagrams, sensors and other components, please refer to the service in-
formation or electrical schematic for that component.
The cluster is available in 7 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 con-
tains a buzzer, fourteen telltale indicators and a Master Warning indicator. Telltales
in this section are: Left and Right Turn Indicators, Fifth Wheel Lock, Wheel Differ-
ential 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, an optional Air Suspension gauge and a Forward Axle and a
Rear Axle Temperature gauge. It can also contain up to six telltale indicators.
Standard telltales are Traction Control System and A/C Diagnostic System (for fu-
ture use).
Note that all gauges and telltales may not be used in all vehicles.
Four push-buttons on the wiper/washer stalk allow the driver to access and display in-
formation in the Graphic Display.
Specifications
This instrument cluster is designed to operate with an input voltage of between +10
and +18 volts.
4

Group 38 Instrumentation, VNL, VNM General
Available Configurations
T3009001
Fig. 2:
5

Group 38 Instrumentation, VNL, VNM General
Available Configurations (contd.)
T3009002
Fig. 3:
6

Group 38 Instrumentation, VNL, VNM General
Available Configurations (contd.)
T3009303
Fig. 4:
7

8