pv776-tsp104956-1

Service Manual SupplementVolvo Trucks North America, Inc.Greensboro, NC USA

Date Group Supp. Page

12.97 38 03 1(21)

TrucksThis Service Bulletin is a supplement to Service Man-ual, Group 38 Instrumentation VNL, VNM.

InstrumentationGauge Replacement

VNM, VNL

Gauge Replacement

W3000787

This service bulletin provides the latest information regarding servicing and replace-ment of gauges on instrument clusters for the VNL, VNM series vehicles. Proceduresfor the replacement of these gauges apply only to VN Series instrument clusters thatare no longer under warranty protection.

While an instrument cluster is under warranty protection, ONLY the cluster gauges onthe right side are allowed to be removed and replaced. Attempts to remove andreplace individual gauges on the left and center modules during the warranty pe-riod will void the cluster warranty.

For additional information regarding VNL, VNM Instrumentation, refer to the followingpublications: PV776–TSP23762/1, Instrumentation VNL, VNM; PV776–TSP130751/1,Instrumentation Troubleshooting Supplementand PV776–TSP24947/1, Gauge Accu-racy & Troubleshooting.

PV776-TSP104956/1 USA04414

GeneralGeneral Cautions

CAUTION

When servicing or troubleshooting, do not leave thecluster face-down for more than 15 minutes, or dam-age to the gauges may occur. Gauge oil may run outof the front of the gauge faces and make the gaugesinaccurate.

CAUTION

Welding on trucks can damage the vehicle electricalsystem/components from the voltage and currentspikes that normally occur when welding. It is prefer-able to avoid welding on an assembled truck, but ifwelding must be done on any structure on or incontact with the vehicle, disconnect the electrical con-nectors at the rear of the instrument cluster.

Cleaning the Housing and FrontPanel GlassTo clean the housing and front panel glass, use a soft,non-abrasive cloth and a mild soap-and-water solution.

Preventing Electrostatic Discharge(ESD)

CAUTION

To prevent electrostatic discharge (ESD), which maydamage the sensitive electronic components in the in-strument cluster, a wrist grounding strap must beused when working on electronic equipment such asthe instrument cluster. Failure to use a wrist strap mayresult in permanent damage to the printed circuitboards in the instrument cluster. To use the wrist strapin a vehicle, attach the alligator clip to the nearestelectrical ground such as a metal mounting screw, aground terminal or preferably a ground stud.

CAUTION

To prevent electrostatic discharge (ESD), which maydamage the sensitive electronic components in the in-strument cluster, make sure the workbench has ananti-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 theinstrument cluster. When working at the anti-staticworkbench, always keep a wrist strap connected tothe anti-static mat.

Human skin can hold more than 1000 volts of staticelectricity. Although getting a static shock is annoying, itis not dangerous because there is so little energy storedby clothing. But when dealing with circuits designed tosense differences smaller than 1 volt, electrostatic dis-charge can be a subtle but destructive problem. Circuitboards mounted in the instrument cluster or in modulesmounted elsewhere may not fail immediately after beinghit with a static discharge. Rather they may work for awhile, then fail for no apparent reason. The culprit thenis often the normal warming up and cooling downprocess of the module, engine or cab interior.

Grounding straps and anti-static mats are available forminimal cost from electronic supply stores. Groundingstraps consist of a wrist strap, a coiled extension wireand an alligator clip. Be sure to purchase one with a longenough extension wire to allow freedom of movement.

An anti-static wrist strap is available from Kent-Moore (see Tools section of this supplement). Call1-800-328-6657.

An anti-static mat is also available from Kent–Moore(see Tools section of this supplement).

Volvo Trucks North America, Inc. Date Group Supp. Page

Service Manual Supplement 12.97 38 03 3(21)

ToolsSpecial equipment

The following items are required for work on the instrument cluster. They can be or-dered as shown below.

W3000572

ESD Wrist StrapUse a wrist strap when servicing the instru-ment cluster inside the vehicle. Use a wriststrap and anti-static mat when working onthe cluster at a workbench. Several differ-ent wrist straps are available fromKent-Moore at 1–800–328–6657.

W2001014

Fluke 87 Digital Multi-meter (DMM)Available from Kent-Moore (P/N J-39200)at 1–800–328–6657.

W3000704

Type 8501 Static Dissipative Grounding KitAvailable from Kent–Moore (P/N J–42444)at 1–800–328–6657.The kit shown includes both a wrist strapand anti-static mat. Use both when workingon the instrument cluster at a workbench.

W0001506

Pro-Link 9000The Pro-Link 90001 with the VOLVO PCMCIAcard is available from MPSI. Call 1–800–242–MPSI.

P/N 206040 Multi-Protocol Cartridge (MPC)

P/N 203031 PMCCIA (Application Card) for

1Pro-Link is a registered trademark of MPSI.

Volvo Engine

P/N 104004 Pro-Link 9000

P/N 404024 6–pin Deutsch Connector

P/N 501002 Power/Data Cable



Service ProceduresImportant: Attempts to service or replace individualgauges on the left and center modules during thewarranty period will void the cluster warranty. In-stead, the whole unit should be exchanged.ONLY when a trained technician is repopulating a re-placement instrument cluster may the cluster be openedduring the warranty period.

CAUTION

To prevent electrostatic discharge (ESD), which candamage the sensitive electronic components in the in-strument cluster, do the following:

Use a wrist grounding strap and an anti-static matwhen working on the instrument cluster.

Work in a clean environment.

Do not place the cluster on a metal table or any metalsurface while servicing.

Failure to do the above can result in permanent dam-age to the printed circuit boards in the instrumentcluster.

Odometer Setting (After Clus-ter Replacement)The odometer and hourmeter values are stored in thecluster. Whenever a new cluster is installed, these val-ues must be updated to reflect the mileage and enginehours of the vehicle in which the cluster is installed. Thisis done using the MPSI Pro-link 9000 tool with the Volvocard.

To reset either of these readings, follow the Pro-linkmenus to the Reprogram EEPROM menu, then selecteither the Odometer or Hourmeter Total. Change to theappropriate total.

Note: Reprogramming the Odometer or Hourmeter is apassword-protected function.

Instrument Cluster Light BulbReplacement

Removal1Make certain the vehicle ignition isOFF before beginning this procedure.

2

W3000842

CAUTION

When servicing or troubleshooting, do not leave thecluster face-down for more than 15 minutes, or dam-age to the gauges may occur. Gauge oil can run outthe front of the gauge faces and make the gauges in-accurate.

Adjust the steering column back wherepossible. Remove the two screws atthe top of the instrument cluster andlay the cluster face-down on the steer-ing column so that the bulbs areaccessible.

3

W3000642

CAUTION

Use only the Volvo bulb removal tool, P/N 1089953, toremove bulbs, or damage to the cluster may occur.

Insert removal tool, P/N 1089953, ontothe bulb assembly. Rotate 1/4 turn andpull the bulb assembly out of thesocket.

Installation1Insert the new bulb assembly into theremoval tool, P/N 1089953. Insert theassembly into cluster socket and ro-tate 1/4 turn.

Bulb RemovalToolP/N 1089953

2Replace the instrument cluster in thedash and tighten the 2 screws at thetop of the cluster. Torque to 2 ± 0.3Nm (17.5 ± 2.5 in-lb).

2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

Combined Instrument ClusterReplacement (Including Diag-nostics)

Removal1Make certain the vehicle ignition isOFF before beginning this procedure.

2

W3000842

CAUTION

When servicing or troubleshooting, do not leave thecluster face-down for more than 15 minutes, or dam-age to the gauges may occur. Gauge oil can run outthe front of the gauge faces and make the gauges in-accurate.

Adjust the steering column back wherepossible. Remove the two screws atthe top of the instrument cluster andlay the cluster face-down on the steer-ing column.

3Cut the tie wraps fastening the wiringharness to the back of the cluster forstress relief on the connectors.



4

Never disconnect an air system component unless allsystem pressure has been depleted. Failure to de-plete system pressure before disconnecting hoses orcomponents may result in them separating violentlyand causing serious bodily injury.

Bleed all pressure from the vehicle airsystem. Disconnect the electrical andair connectors from the back of thecluster, and remove the cluster fromthe vehicle.

Installation1Connect electrical connectors and airlines at the back of the instrumentcluster. For stress relief on the con-nectors, tie wrap the wiring to the backof the instrument cluster. Failure to tiewrap the wiring may cause intermittentelectrical connections.

2Install the instrument cluster in dashand tighten the 2 screws at the top ofthe cluster. Torque to 2 ± 0.3 Nm (17.5± 2.5 in-lb).

2 ± 0.3 Nm(17.5 ± 2.5 in-lb)

Cluster Gauge Replacement(Right Side)

Removal1

CAUTION

To prevent electrostatic discharge (ESD), which candamage the sensitive electronic components in the in-strument cluster, use a wrist grounding strap and ananti-static mat when working on the instrument clus-ter. Failure to do so can result in permanent damageto the printed circuit boards in the instrument cluster.Do not place the cluster on a metal table or any metalsurface while servicing.

Remove cluster from vehicle (see“Combined Instrument Cluster Re-placement (Including Diagnostics)”page 6). Place cluster on anti-staticmat. The anti-static mat must begrounded to the nearest electrical out-let. When working at the anti-staticworkbench, always keep a wrist strapconnected to the anti-static mat.

2

W3000835

1) Gauge mounting screws — do not removeat this time2) Top cover screw location3) Bottom cover screw location

Right printed circuit board (PCB)with cover removed

Remove the Phillips screw at the topof the right rear cover, and the two atthe bottom, then lift off the cover.

Note: Do not remove any of the threePhillips screws in the board at thistime. They secure the air pressuregauges to the board.

3Lift out the Right Circuit Board assem-bly, with gauges.

4

W3002493

CAUTION

To avoid damaging the gauge, do not push on theneedle when removing the gauge. Pushing on theneedle can make the gauge inaccurate.

Air pressure gauges only: These areeach secured by one Phillips screw.Remove the screw, pull the gauge outof the board and disconnect the 2-pinLED connector.Other gauges: Gauges are heldtightly by their pin sockets. To remove,grasp the side of the gauge face platewith your thumb; place your 2nd and3rd fingers underneath the face plate(see illustration). Carefully rock thegauge from side to side while applyingupward pressure until the gauge pinsare free of the board sockets.Gauge blanks: Remove the gaugeblank by pulling the blank support up-ward until the pins are free of theboard sockets, and lifting the blankfrom the face of the instrument cluster.

Note: Early production models mayhave gauge blanks held in place with ametal clip and a screw.



Removing a gauge blank

5

W3002511

Note: Early production models may have gaugeblanks as shown in the illustration. If replacing anyblank, use the newer gauge blank support assem-bly shown in the Installation procedure.

When adding a gauge blank, removethe gauge or gauge blank to be re-placed.

Installation1

CAUTION

To avoid damaging the gauge, do not push on theneedle when installing the gauge. Pushing on theneedle can make the gauge inaccurate.

Install the replacement gauge bygrasping the opposite corners of thegauge face plate and pushing thegauge pins into the socket onto thecircuit board. Do not push on theneedle. (For gauge blanks, see the fol-lowing steps.) It is correctly installedwhen its face plate is flush with theother gauges’ face plates.Air pressure gauges only: Connectthe 2-pin connector into the board (it isnot polarity-sensitive, so it can go ineither way) and secure the gauge tothe board with a self-tapping Phillipsscrew.

Adding gauge blanks

2

W3000820

Note: If replacing any blank, use the newer gaugeblank support assembly shown in theillustration.

1) Gauge Blank2) Blank Support Assembly3) Pins4) Terminals

Install the new blank (1) into the clus-ter housing. Install the blank support(2) in the PC board into the terminals(4) where the gauge was removed.

3If the right module contains one ormore gauge blanks: Remove allgauges except the Front and Rear AirPressure gauges. Place these gaugesinto their locations in the housing be-fore replacing the Right Circuit Boardassembly.

4Place the Right Circuit Board assem-bly into the housing, making sure allgauge pins are lined up with their ter-minals on the circuit board.

5Place the cover over the board assem-bly and secure with three machinescrews.

6Install the cluster into the dash (see“Combined Instrument Cluster Re-placement (Including Diagnostics)”page 6).

7Important: If installing a gauge blankinto the Engine Oil Pressure or TurboBoost Pressure gauges, use the Pro-Link 9000 with the VOLVO card toenable the gauge which is beingadded, or to disable the gauge whichis being removed.



Gauge Cluster Center Module Replacement

W3000739

1) Center Module screw locations

Removal1Important: Attempts to remove andreplace individual gauges on theleft and center modules during thewarranty period will void the clusterwarranty. Instead, the whole unitshould be exchanged. ONLY when atrained technician is repopulating a re-placement instrument cluster may thecluster be opened during the warrantyperiod.

2

CAUTION

To prevent electrostatic discharge (ESD), which candamage the sensitive electronic components in the in-strument cluster, use a wrist grounding strap and ananti-static mat when working on the instrument clus-ter. Failure to do so can result in permanent damageto the cluster.

Remove cluster from vehicle (see“Combined Instrument Cluster Re-placement (Including Diagnostics)”page 6). Place cluster on anti-staticmat. The anti-static mat must begrounded to the nearest electrical out-let. When working at your anti-staticworkbench, always keep your wriststrap connected to the anti-static mat.Do not place the cluster on a metaltable or any metal surface while ser-vicing.

3Remove the Phillips screws at the topof the left rear cover, and the two atthe bottom, then lift the left rear coverfrom the cluster.

4Remove the four Phillips cover screws.

5

W3000845

1) Connector E1

CAUTION

Do not bend the printed circuit board. Bending theboard can result in damage to the board or compo-nents.

Grasp the top and bottom of connectorE1 (over the Left Circuit Board) withyour thumb and forefinger. Rock theCenter Module from top to bottomwhile pulling up to unseat E1.

6Remove the Center Module by lifting itoff of the cluster.



Installation

W3000731

1

W3000846

1) Button extensions

Before reinstalling the Center Module,make sure that all four plastic buttonextensions are installed in the top ofthe housing (the short ends stick outthe front of the housing).

2To reinstall the Center Module, line upconnector E1 pins with connector E2holes on the Center Circuit Board,then carefully seat E2 while loweringthe Center Module into the housing.

3Verify that all E1 pins are in connectorE2 holes, then use your thumb to fullyseat E2 onto the Left Circuit Board.

4Secure the Center Module to thehousing with four machine screws.

5Reinstall the left rear cover, and se-cure it with the three Phillips screws.

Tachometer, Speedometer and Odometer Replacement

Removal

W3002517

1 Odometer Mounting Screws2 5–pin Connector

1Important: Attempts to remove andreplace individual gauges on theleft and center modules during thewarranty period will void the clusterwarranty. Instead, the whole unitshould be exchanged. ONLY when atrained technician is repopulating a re-placement instrument cluster may thecluster be opened during the warrantyperiod.

CAUTION

To prevent electrostatic discharge (ESD), which candamage the sensitive electronic components in the in-strument cluster, use a wrist grounding strap and ananti-static mat when working on the instrument clus-ter. Failure to do so can result in permanent damageto the printed circuit boards in the instrument cluster.Do not place the cluster on a metal table or any metalsurface while servicing.

Remove Center Module (see “GaugeCluster Center Module Replacement”page 11).

2

W3002502

CAUTION

To avoid damaging the gauges, do not pull on theneedle when removing the gauge assembly. Pullingon the needle can make the gauges inaccurate.

The gauge assembly is held tightly bypin sockets. To remove, grasp the bot-tom of the tach/speedo assembly withyour thumb; place your 2nd and 3rdfingers underneath the face plate atthe top edge of the gauge assembly.Carefully rock the assembly from topto bottom while applying upward pres-sure until the gauge pins are free ofthe board sockets.

3To remove the Odometer Display as-sembly, remove the two Phillipsscrews which secure it to the rear ofthe speedometer.



Installation1Reinstall the Odometer Display withthe two Phillips screws, attaching it tothe rear of the speedometer.

2

CAUTION

To avoid damaging the gauges, do not push on theneedle when installing the gauge assembly. Pushingon the needle can make the gauges inaccurate.

Reinstall the tach/speedo assembly bystarting the 5–pin connector into theholes in the Center Module.

3

W3002503

When all five pins are inserted into theCenter Circuit Board, seat thetach/speedo gauge pins while guidingthe tabs on the sides of the gaugesinto the notches on the housing. Thetach/speedo assembly is correctly in-stalled when it is flush with the rear ofthe Center Board.

4Reinstall the Center Module (see“Gauge Cluster Center Module Re-placement” page 11).

Gauge Cluster Circuit Board Replacement

W3000733

1 Center Module Rear Cover2 Rubber Bumpers3 Switch Board4 Retaining Tabs5 Phillips Screws6 Center Circuit Board

CAUTION

To prevent electrostatic discharge (ESD), which candamage the sensitive electronic components in the in-strument cluster, use a wrist grounding strap and ananti-static mat when working on the instrument clus-ter. Failure to do so can result in permanent damageto the cluster.

Removal

1Remove Center Module. See “GaugeCluster Center Module Replacement”page 11.

2Remove the tachometer andspeedometer. See “Tachometer,Speedometer and Odometer Replace-ment” page 14.

3Remove the two rubber bumpers at-tached to each end of the switchboard.

Note: Do not discard the rubberbumpers. These will be needed for re-placement.



4Remove the Phillips screw near thecenter of the Center Circuit Board, andthe Phillips screw at the center of theSwitch Board assembly.

5

CAUTION


Lift the bottom edge of the Center Cir-cuit Board, one inch from the rearcover. Pull the Center Circuit Boarddown to clear the two small retainingtabs at the top of the board. One ofthe tabs is between the Center CircuitBoard and the Switch Board.

6Lift the two boards up and out as anassembly.

Installation

1

CAUTION


Place the Center Circuit Board with at-tached Switch Board into the rearcover.

2Lift the bottom of the Center CircuitBoard away from the cover about twoinches.

3

W3002516

1 Switch Board2 Retaining Tabs3 Rear Center Module Cover4 Center Circuit Board

With the Switch Board seated, positionthe top edge of the Center CircuitBoard under the two plastic retainingtabs in the rear cover.

4Seat the Center Circuit Board into theconnector in the housing (the connec-tor may be a tight squeeze past thehousing). The board is fully connectedwhen the top edge is under the retain-ing tabs and the bottom is flush withthe bottom edge of the rear cover.

5Reinstall the Phillips screws at thecenter of the Circuit Board, and at theSwitch Board assembly.

6Reinstall the rubber bumpers overeach side of the Switch Board assem-bly.

7Reinstall the tachometer andspeedometer gauges. See“Tachometer, Speedometer andOdometer Replacement” page 14.

8Reinstall the Center Module. See“Gauge Cluster Center Module Re-placement” page 11.

Cluster Gauge Replacement(Left Side)Important: Attempts to remove and replace individ-ual gauges on the left and center modules duringthe warranty period will void the cluster warranty. In-stead, the whole unit may be exchanged.ONLY when a trained technician is repopulating a re-placement instrument cluster may the cluster be openedduring the warranty period.

Removal1

CAUTION

To prevent electrostatic discharge (ESD), which candamage the sensitive electronic components in the in-strument cluster, use a wrist grounding strap and ananti-static mat when working on the instrument clus-ter. Failure to do so can result in permanent damageto the printed circuit boards in the instrument cluster.

Remove cluster from vehicle (see“Combined Instrument Cluster Re-placement (Including Diagnostics)”page 6). Place cluster on anti-staticmat. The anti-static mat must begrounded to the nearest electrical out-let. When working at the anti-staticworkbench, always keep a wrist strapconnected to the anti-static mat. Donot place the cluster on a metal tableor any metal surface while servicing.

2

W3000734

1) Connector E2 (part of the center circuitboard)2) Top cover screw location3) Bottom cover screw location4) Connector E4 to Graphic Display board un-derneath

Remove the Phillips screw at the topof the left rear cover, and the two atthe bottom, then lift off the cover.

Note: Connector E2 is part of theCenter Circuit Board.



3

CAUTION


The Center Circuit Board connectorE2 is holding the Left Circuit Board as-sembly in at this point, so you will haveto remove the Center Module beforecontinuing (see “Gauge Cluster Cen-ter Module Replacement” page 11).

4Carefully lift out the Left Circuit Boardassembly by lifting straight up. It is at-tached to the Graphic Display boardbelow at connector E4.

5

W3000991

Fig. 1: Correct Gauge Removal

CAUTION

To avoid damaging the gauge, do not push on theneedle when removing the gauge. Pushing on theneedle can make the gauge inaccurate.

Gauges and gauge blanks are heldtightly by their pin sockets. To remove,grasp the side of the gauge face platewith your thumb; place your 2nd and3rd fingers underneath the face plate(see illustration). Carefully rock thegauge from side to side while applyingupward pressure until the gauge pinsare free of the board sockets.

Note: Early production models mayhave gauge blanks held in place with ametal clip and a screw.

Removing a gauge blank

6

W3002511

Note: Early production models may have gaugeblanks like the above. If replacing a blank, use thenewer gauge blank support assembly shown in theInstallation procedure.

When adding a gauge blank, removethe gauge or gauge blank to be re-placed.

Installation1

CAUTION

To avoid damaging the gauge, do not push on theneedle when installing the gauge. Pushing on theneedle can make the gauge inaccurate.

Install the replacement gauge bygrasping the opposite corners of thegauge face plate and pushing thegauge pins into the socket onto thecircuit board. Do not push on theneedle. (For gauge blanks, see the fol-lowing steps.) It is correctly installedwhen its face plate is flush with theother gauges’ face plates.

Adding gauge blanks

2

W3000820

Note: If replacing any blank, use the newer gaugeblank support assembly shown in theillustration.

1) Gauge Blank2) Blank Support Assembly3) Pins4) Terminals

Install the new blank (1) into the clus-ter housing. Install the blank support(2) in the PC board into the terminals(4) where the gauge was removed.

3

W3000750

Important! Before installing the LeftCircuit Board assembly, check connec-tor E4 pins and make sure they are allperfectly straight and parallel to eachother.

4If the left module contains one ormore gauge blanks: Remove allgauges from the left module. Placethese gauges into their locations in thehousing before replacing the left mod-ule.

5Place the Left Circuit Board assemblyinto the housing while lining up E4 pinsinto the Graphic Display connector.

6Install the Center Module, paying par-ticular attention to connector E1 on theLeft Circuit Board assembly.

7Install the left rear cover and secure itwith three machine screws.

8Install the cluster into the dash (see“Combined Instrument Cluster Re-placement (Including Diagnostics)”page 6).



9If installing a gauge blank into the En-gine Oil Pressure or Turbo BoostPressure gauges, use the Pro-Link9000 with the VOLVO card to enablethe gauge which is being added, or todisable the gauge which is being re-moved.

10Important: If the Left Circuit Boardhas been replaced, update the odome-ter and hourmeter values to reflect thevehicle’s actual mileage and enginehours. This is done with the Pro-Link9000.

pv776-tsp104956-1

Documents

cluster warranty

asthe instrument cluster

theinstrument cluster

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instrumentation vnl

warranty protection

ment of gauges