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Electrical General VN from 2/98 and VHD

1. Design and Function W3004342 Fig 82 Graphic Display Mode Set or Esc Select Switch Note Numbers inside parenthesis are circuit numbers Controls for the instrument cluster s graphic display window are located on the stalk switch to the right of the steering column The Esc and Select or mode and set buttons allow for different vehicle information to be displayed The up and down buttons at the end of the stalk are used to scroll through the various display menus The mode and set buttons were used until March 1999 Since then the Esc and select buttons have been used For more complete information on the graphic display switch including troubleshooting and service procedures see Paper Windshield Wiper System VN VHD publication number PV776 TSP143133 Impact Function Group 36 48 Graphic Display Switch Connector Pin Circuit Description No A 219 Common 12V Supply 219E SET Input C 219A ESCAPE Input 219F MODE Input 219D SELECT Input 219C UP Input H 219B DOWN Input Group 3 Electrical System VN amp VHD Design and Function Cruise Control Turn Signal and Headlamp Dimmer Switch Volvo Engines Only The controls for turn signals cruise control and highbeam lowbeam selection are on the stalk switch on the left hand side of the steering column The highbeam lowbeam switch works
2. GE Once the ashtray housing is removed the air switch panel can be removed from the dash Pull the air switch panel away from the dash and to the left to clear the tip inserts 4 Disconnect the 2 terminal connectors from the cigar lighter and the electrical LED connections on the switch being replaced Ces TRIN oe TS NN W3000656 121 Group 3 Electrical System VN amp VHD W3000657 W3000658 122 Service Procedures 5 ZN WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious personal injury Drain air pressure from vehicle system Mark each air line to keep correct arrangement Disconnect air lines at switch being replaced by pushing in on the ring and air line then pulling the air line out 6 To remove switch insert No 1 flat tip screwdriver into back of switch at top and bottom to release locking tabs Push switch out of the panel Installation 1 Install new air switch into the panel pushing the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel 2 Connect air lines to the switch making sure they are installed in the correct position Be sure to insert airline to line indicated 3 Connect electrical LED connections on s
3. W3002563 Note If a battery side fusible link becomes an open circuit power will not be supplied to the cab power stud on that circuit no continuity between the cab stud and starter solenoid 84 Group 3 Electrical System VN amp VHD T8006862 a W3002486 Service Procedures Removal 1 Turn the ignition key OFF and disconnect the negative and positive battery cables 2 Remove the five torx bolts attaching the splash guard along the left frame rail Remove the splash guard 3 Remove the cable mounting nut from the bulkhead pass through plate Since there are two fusible links check the continuity in the fusible link wire to make sure you are replacing the one that has melted After locating the correct one cut the wire as close as possible to the wiring harness conduit and tape to prevent future use 4 Loosen the bolt that goes through the battery cable clamping bracket Remove the cable from the clamp This will allow the cable to be removed from the solenoid 85 Group 3 Electrical System VN amp VHD W3002564 W3002565 86 Service Procedures 5 Remove the nut from the starter solenoid post where the fusible link main battery cable is attached The melted fusible link should be noticeable If not check continuity to find the faulty fusible link Cut the melted fusible link wire as close as possible to the wiring harness
4. Instrument Cluster MIDs 234 amp 140 SRS ECU MID 232 Engine ECU Terminating Diagnos MID 128 Resistor tic con nector SAE J1587 1708 Vehicle ECU MID 144 Transmission ECU MID 130 Control unit Expansion capability SAE J1939 ABS ECU MID 136 Terminating Resistor Group 3 Electrical System VN amp VHD SAE J1939 Control Data Link The system s control signals are sent via this link The J1939 link is very fast operating at 250 000 bits per second This operating speed allows the system to function more effectively and adapt quickly to changing conditions and vehicle requirements The link complies with SAE standards and consists of three twisted wires a green wire 407 a yellow wire 406 and a shield wire 408 The twisted wire set 40 turns per meter is used to protect the link from electrical interference Note The shield wire 408 may not be present in some vehicles Z N CAUTION No modifications or connections should be made to wires 406 yellow 407 green or 408 shielded These wires carry the high speed communications between the electronic systems in the vehicle Any modification connection to or damage to these wires can result in the failure of the vehicle s electronic systems Terminatin
5. W3002566 1 Fusible Link Removed 2 Engine Ground Stud Note location varies by engine 5 Remove the nut on the side of the engine block where the fusible link is connected and remove the fusible link from the vehicle Installation 1 Install the fusible link terminal and negative battery cable at the starter ground stud Install the nut and tighten to 30 5 3 5 Nm 270 30 in Ib 30 5 3 5 Nm 270 30 in lb W3002567 1 Ground Side Fusible Link 2 Starter Ground Stud 3 Engine Ground location varies by engine 89 Group 3 Electrical System VN amp VHD 90 Service Procedures 2 Install the new fusible link cable assembly at the engine block Tighten the nut to 19 4 Nm 168 35 in lb 19 4Nm 168 35 in Ib Install the battery cables into the clamping bracket Tighten the bolt on the clamping bracket to 17 3 Nm 150 27 in lb Connect the battery cables into the clamp bracket Tighten the bolt to 23 Nm 203 in lb 17 3 Nm 150 27 in lb 23 Nm 203 in lb 4 Connect the battery positive and negative cables connecting the positive cable first Torque nuts 24 4 Nm 212 35 in Ib Group 3 Electrical System VN amp VHD Service Procedures 3645 03 02 05 Central Door Lock Module Replacement Volvo Engines ws3002701 W3002704 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices befo
6. 81 Group 3 Electrical System VN amp VHD W3002867 s W3002868 W3002869 82 Service Procedures 3 Remove the faulty terminal from the connector as follows using the removal tool from kit J 42449 Note In each of these JAE connectors there are two rows of terminals and two rows of release holes The release holes are slightly larger than the ones containing terminals Insert the removal tool into the release hole above the terminal being removed It will take some pressure to make the terminal locks release J 42449 Installation 1 Cut the faulty terminal wire to the same length as the JAE terminal pigtail replacement 2 Strip the insulation back approximately 6 mm 1 4 in and install butt splice 3948725 or 3948726 to the wire 3948725 3948726 3 Crimp in the 18 20 anvil of crimper J 38125 8 from Repair Kit 3947553 Slightly pull the wire to ensure a correct crimp J 38125 8 Group 3 Electrical System VN amp VHD W3002870 Service Procedures 4 Using heat gun J 25070 or equivalent tool heat the splice to shrink the tubing until the adhesive is visible for a good moisture seal J 25070 5 Install the terminal into the correct connector cavity Pull back on the wire to make certain the terminal is locked into the connector Push the connector lock back into position 6 Connect the connector to the component and check for proper function Mini fuse Replacement
7. W3002525 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it 1 To replace mini fuses in the TEC use only the fuse puller tool provided with the vehicle 20378326 Removing the mini fuses with another device can possibly damage the TEC panel connections 20378326 83 Group 3 Electrical System VN amp VHD Service Procedures Relay Replacement wo0001918 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it 1 To replace relays use relay puller tool J 43244 This tool can be used on standard size or micro relays power relays DRL modules mini circuit breakers maxi fuses etc J 43244 3714 03 02 02 Fusible Link Replacement Battery Side You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it
8. 40 Group 3 Electrical System VN amp VHD Design and Function Engine Brake On Off W3000577 Fig 63 Switch Wire Insertion Side View W3000578 Fig 62 Switch W3000589 Fig 64 Internal Switch Logic Engine Brake Low Med High W3000579 Fig 65 Switch Fig 67 Internal Switch Logic W3000583 W3000577 Fig 66 Switch Wire Insertion Side View 41 Group 3 Electrical System VN amp VHD Design and Function Engine Brake Off Low High W3000577 Fig 69 Switch Wire Insertion Side View W3000578 Fig 68 Switch W3000597 Fig 70 Internal Switch Logic Power Take Off VHD Lift Axle Switches W3004363 Fig 73 Internal Switch Logic W3004415 Fig 71 Switch W3000577 Fig 72 Switch Wire Insertion Side View 42 Group 3 Electrical System VN amp VHD Pneumatic Switches W3000574 Design and Function W3000573 Fig 74 Switch Fig 75 Switch Wire Insertion Side View Switch Terminal Function A B C D Interaxle DLO To Cluster Telltale 12V Supply Ground 12V Illumination Control Lamp Fifth Wheel Slide To Cluster Telltale Not used Ground 12V Illumination Control Lamp Suspension Dump To Cluster Telltale Not used Ground 12V Illumination Control Lamp Interwheel DLO N A Not used Ground 12V Illumination Control 43 44 Group 3 Electrical System
9. 2 Z N CAUTION 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 Remove the two screws at the top of the instrument cluster and lay the cluster face down on the steering column if steering column is adjustable adjust as far back as possible before leaning the cluster out 3 To release the switch panel reach behind the panel and depress the top and bottom clips on the left side Group 3 Electrical System VN amp VHD Service Procedures 4 Pull the panel through the front of the dash pulling toward the driver s side to clear tip inserts W3000996 5 Once the switch panel is removed install the instrument cluster in the dash and tighten the 2 screws at the top of the cluster Tighten to 2 0 3 Nm 17 5 2 5 in lb 2 0 3Nm 17 5 2 5 in lb 6 Disconnect connector Remove switch from panel by inserting a No 1 screwdriver into the back of the switch at the top and bottom to release the locking tabs 7 Remove the switch through the front of the panel W3000682 127 Group 3 Electrical System VN amp VHD Service Procedures Installation 1 Install the new switch into the panel Push the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel Connect the electrical connector 2 Install
10. 22 1 4 4 in lb 2 5 0 5 Nm 22 1 4 4 in lb Group 3 Electrical System VN amp VHD Service Procedures 3341 03 02 01 Ignition Switch Replacement W8002166 Wws8002165 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal from Locking Housing 1 Turn the ignition key OFF 2 Remove the 2 clips at the bottom of the steering column cover 3 Adjust the steering column up and toward you where possible Remove the front steering column cover by removing the 3 torx bolts from the cover and sliding the rubber grommets off of the cover at the stalk switches 4 Adjust the steering column forward and up where possible Remove the 3 torx bolts from the rear column cover and remove cover 95 Group 3 Electrical System VN amp VHD W3001001 1 Locking Clips W3000743 1 Machine Screws 96 Service Procedures 5 Disconnect the ignition switch electrical connector by carefully depressing clips on each side of connector 6 Remove the 2 machine screws on the left and right side of the ignition switch and remove the switch from its housing Group 3 Electrical System VN amp VHD Service Procedures Installation into Locking Housing 1 Place switch
11. Electrical Center TEC The TEC is located in the center of the dash just above the engine cover VN models built after February 1998 have an updated electrical center Before 1988 some fuses and relays were located in the front TEC panel In vehicles built after that date all fuses and relays are located in the top TEC panel The VHD TEC center is very similar to VN but with some additional fuse and relay positions Vehicles built after February 1998 include accessory and ignition power relays Also the daytime running lights module and its relay are located on the single TEC panel All relays and the DRL module are designed for easy access and replacement Refer to the decal inside the TEC cover for vehicle s exact fuse locations and ratings Note that all fuses and relays may not be used in every vehicle The TEC panel includes all maxi fuses mini fuses relays and micro relays Maxi fuses are designed for larger amounts of current than regular fuses The micro ISO relays are smaller in size than conventional relays and the pin arrangement is different Mini fuses are also smaller in size but the current rating is the same as ATO size fuses 32 W3002492 Group 3 Electrical System VN amp VHD Additional TEC Components Volvo Engines Only Located in front of the fuse and relay panel is the Vehicle Electronic Control Unit or VECU standard with Volvo engines The VECU is accessible by removing the front TEC panel
12. For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 39 Smoke Detector Disable Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 114 Switch Switch Switch Switch Switch Switch Switch Switch Group 3 Electrical System VN amp VHD Service Procedures Switch Replacement Left Dash Switches W3000641 W3000689 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Z N CAUTION 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 Remove the two screws at the top of the instrument cluster and lay the cluster face down on the steering column adjust steering column back before leaning cluster out where possible 3 To release the switch panel reach behind the panel and depress the top and bottom clips on the right and left side of the panel 115 Group 3 Electrical System VN amp VHD Service Procedures 4 Pull the panel t
13. Fusible links are used to protect high current circuits against current overload when there is a short to ground The fusible link is a short length of wire that is smaller in gauge than the wire in the protected circuit In the event of an overload the fusible link will melt breaking the circuit and preventing damage to the electrical system If a fusible link does open special attention must be paid to finding and repairing the cause Fusible links are used in two locations two are at the starter motor on the positive side feeding the cab main power studs and one is from ground on the starter motor to engine ground The fusible links on the positive side are 10 gauge cables 120 mm 4 72 in in length On the ground side it is an 8 gauge cable Diodes Diodes are used on many of the vehicle s circuits to protect and isolate them from voltage surges which can occur when a circuit is turned off Diodes allow voltage to flow in one direction only like a one way check valve Circuit Breakers Circuit breakers are optional equipment SAE Type 2 modified reset circuit breakers are the only type of circuit breakers approved for use in VN VHD vehicles They may be used on accessory and ignition circuits only Circuit breakers protect a circuit from overload When an overload high current flow occurs in a circuit a bimetallic strip in the breaker is heated This opens its contact temporarily breaking the circuit When this bimetallic
14. 02 40 Engine Exhaust Brake Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03 02 41 Traction Control Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03 02 26 Heated Mirror Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03 02 42 Lift Axle Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03 02 43 Beacon Lamp Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 118 Group 3 Electrical System VN amp VHD Service Procedures Right Dash Auxiliary Sleeper Control Panel Switch Replacement You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it The same procedure is used to replace both right dash optional auxiliary and sleeper control panel switches The right dash switches may
15. 33 Back of Cab Lamp Switch Replacamenii siscicccisenanccrersuneiwidrnsenesesaanrdreusnnvendaeeaavesunroeamennicnamenenseauues 114 3646 039 02 24 Fan Switch Replacement ssirasaraia ei a a aiia 114 3646 09 0235 FTO Swich Replacgmeni ssssrirniriabnauiii ninii aa 114 3646 03 02 36 Bunk Overhead Lamp Switch Replacement sssesssessiessreesissesrnerrnesrnernnernnntnnnenrransrneenanennnennnenanennnnannnnna 114 3646 03 02 37 Headlamp Interrupt Switch Replacement cccccccccceeceeeeeeeceeeeeeneeeeseececseaeeeeesneeseeeaeeeseseeeeeseneeeeeees 114 3646 03 02 38 Snowplow Lamp Switch Replacement cccccccceeceeeeeeceeeeeeeeeeeeseneeseeeeesesneeeseseeeeeeeeneeseneeeeeseneeeeeees 114 3646 03 02 39 Smoke Detector Disable Switch Replacement eescesseesneresneeeseceeseeecsenecsaessenersseeeenaeeesenesseneneners 114 3646 03 02 29 Sleeper Control Panel Switch Replacement se seeessceeeceesereceenerseneeeeneeeneeeneeesseeecsanerseneneseeteneeenees 118 3546 0302 2272 Auxiliary SWiteh Ropata iisiiscciicevastcinicvacuvelsiiniansnisisineelavisieiroiaicisieini neni uae reinlcin oral eidiotees 118 3646 03 02 24 Marker Interrupt Switch ReplaCenieMt sseisssicssiiiedsarioizeieasncdiniedemnd aaa 118 3646 03 02 40 Engine Exhaust Brake Switch Replacement eseeeseceeeseeseneseenecesneeeseeeesaseseeeeanessanessneseneeeeeeeesaes 118 3646 03 02 41 Traction Control Switch REplaCOMent sisiissecssecacsnicescesseccivueeneen
16. EXPANSION BLOCKS RHS GROUND STUD 17 INTERIOR SIDE W3004400 Fig 24 Ignition Power Supply This simplified schematic should only be used to clarify the design features of the VHD ignition power supply circuit For detailed vehicle specific schematics see the VHD Electrical Schematics Group 37 27 Group 3 Electrical System VN amp VHD System Ground Design and Function Cab ground studs are located on the left and right side bulkhead on both the inside and outside Each stud has a unique identity number which is used for reference in the vehicle electrical schematics Torque for the ground studs is 10 1 5 Nm 7 4 1 1 ft lb The cab main ground stud is located on the driver s side at ground stud 6 The cab main ground stud is wired directly to the engine ground by a 4 gauge cable and is the ground path for all cab grounds W3004401 Fig 25 Ground Studs driver side engine compartment UD GND ST GND STUD 22 GND STUD 23 Fig 26 Ground Studs inside cab driver side W3000593 28 GND STUD 9 GND STUD pos gt W3004364 Fig 27 Ground Studs passenger side engine compartment GND STUD GND STUD 19 18 GND STUD W3002759 Fig 28 Ground Studs inside cab passenger side under heater unit Group 3 Electrical System VN amp VHD Design and Function e The engine groun
17. For the mirror switch align the tip of the housing with the indention in the switch The switch will push into the housing 2 Make certain the replaced switch is locked into the panel Connect the switch connectors and install the assembly into the door panel Group 3 Electrical System VN amp VHD Service Procedures 3838 03 02 02 Digital Clock Replacement Sleeper W8002730 VN420 610 660 Sleeper Control Panel W3000698 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 VN420 610 660 Remove the screws from the sleeper control panel and bezel Remove the panel and bezel VN770 Remove the screws from the sleeper control panel and remove 3 Disconnect the clock electrical connector Using a small flat tip screwdriver release the locking tabs at the top and bottom of the clock to remove the clock from the panel The clock will push out through the front of the panel 137 Group 3 Electrical System VN amp VHD 1 Clock W3001000 VN 420 610 660 Panel Tabs 138 Service Procedures Installation 1 Install the new clock assembly 1 into the control panel and connect the electrical connector Gently p
18. Nm 44 7 in lb 0 8 Nm 5 44 7 in lb Group 3 Electrical System VN amp VHD W8002166 Service Procedures 3 Push the steering column forward and up where possible Install the rear cover of the steering column by installing torx bolts and attaching rubber grommets at the stalk switches Tighten bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 4 Install the 2 clips on the bottom of the steering column cover 113 Group 3 Electrical System VN amp VHD Service Procedures 3646 03 02 11 Hazard Warning Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 33 Back of Cab Lamp Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 34 Fan Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 35 PTO Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 36 Bunk Overhead Lamp Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 37 Headlamp Interrupt Switch Replacement For a complete description of this procedure see Replacement Left Dash Switches page 115 3646 03 02 38 Snowplow Lamp Switch Replacement
19. Pin Circuit Description f as an No Pin Circuit Description No 71 itch AAU A 32L Output to DRL module low B 115 Left stop amp turn lamp feed beam left 116 Right stop amp turn lamp feed B 31L Dimmer switch power supply F 33L Headlamp high beam ground Turn Signal Connector 4 way left Pin Circuit Description D Not used No E 33F Flash to pass headlight 111 Turn signal switch feed interrupt contact B Not used F 33R Headlamp high beam ground 112B Left turn signal lamp amp indicator right feed 31R A Dimmer switch power supply D 113B Right turn signal lamp amp H 32R Output to DRL module low indicator feed beam right 51 Group 3 Electrical System VN amp VHD Design and Function Instrumentation Ave Asse bate W3004310 In January 1998 an updated instrument panel was introduced for the VN with a number of changes from panels included in earlier models These changes include the graphic display control buttons now located on the wiper washer switch The cluster is available in 7 configurations with either an mph or km h speedometer Particular variants depend on the options chosen for the vehicle For instrumentation design troubleshooting and service procedures see VN VHD service information in group 38 The instruments are divided into three groups On a truck with the standard instrument cluster the left hand instrument section contains gauges for coolant tempe
20. Schematic Note Relays are shown from insertion side view 86 86 CEJ 30 A 87 C 87 30 D 85 W3002794 Fig 7 Power Relay Pin Arrangement and Schematic 11 Group 3 Electrical System VN amp VHD Sensors and Senders Many electronic signals used by ECUs and the instrument cluster are supplied by sensors and senders A sensor or sender sends a signal to a control unit or to the microprocessor in the instrument cluster Sensors used in the vehicle system include the vehicle speed sensor the throttle position sensor and Anti lock Brake System ABS wheel speed sensors The vehicle speed sensor is mounted in the transmission and reads the movement of the teeth on the output shaft It is of an inductive type and sends a fluctuating sinusoidal signal to the engine ECU The fuel sender mounted in the fuel tank transmits the fuel level to the instrument cluster An Anti lock Brake System ABS wheel speed sensor is mounted in each monitored wheel As the wheel spins the sensor sends a fluctuating signal to the ABS ECU which the ECU interprets as wheel speed VN and VHD vehicles are equipped with combination sensors that can measure both pressure and temperature of certain engine functions The turbo boost temperature and pressure sensor for example measures both the temperature and the pressure of turbo boost air in the intake manifold A capacitive type sensor me
21. Switch Wire Insertion Side View Hazard Warning W3000579 Fig 47 Switch W3000577 Fig 48 Switch Wire Insertion Side View 38 Design and Function W3000676 Fig 46 Internal Switch Logic W3000585 Fig 49 Internal Switch Logic Group 3 Electrical System VN amp VHD Design and Function Back of Cab Lamp Heated Mirror Auxiliary Lamps Traction Control System Beacon Snow Plow Lights Smoke Detector Disable Bunk Overhead Light VN770 W3000579 W3000588 Fig 50 Switch Fig 52 Internal Switch Logic W3000577 Fig 51 Switch Wire Insertion Side View Power Take Off VN ot E l l I I ial ae See el J 4 3 4 W3000579 W3000587 Fig 53 Switch Fig 55 Internal Switch Logic a AB 2 py W3000577 Fig 54 Switch Wire Insertion Side View 39 Group 3 Electrical System VN amp VHD Design and Function Marker Interrupter Headlight Interrupter Switch W3000577 Fig 57 Switch Wire Insertion Side View W3000578 Fig 56 Switch W3000586 Fig 58 Internal Switch Logic Idle Diagnostic Cummins Only 9 T 1 Pe l Aw D gt 204 74 l DI Ye I Ey gt aes pent a eens penn eee eS J 7B 10 3 W3000579 W3000584 Fig 59 Switch Fig 61 Internal Switch Logic W3000577 Fig 60 Switch Wire Insertion Side View
22. VN amp VHD Design and Function Door Switches WON W3004338 Fig 76 Switches on Driver s Door Driver Side Window Switch Driver Side Mirror Switch Passenger Side Mirror Switch Passenger Side Window Switch The driver s door may include switches to control the horizontal and vertical positioning of both the left and right west coast mirrors The driver s door may also include window switches to control both the left and right windows The passenger side may only include a window switch to control the right window Group 3 Electrical System VN amp VHD Design and Function Sleeper Control Panel Switches There are two sleeper control panels One for the VN420 610 and 660 The other is for the VN770 only Both have controls for the bunk climate control system power outlets a digital alarm clock and light control switches The VN770 panel has an additional switch to control the 12 volt power supply to the left side tower cabinet power outlets and an optional remote TV speaker and headphone jack 3 4 4 30 TOE 5 W8002382 Fig 77 Bunk Control Panel VN421 610 660 2 3 4 5 6 7 Alarm Clock Timer Fan Speed Control 12V Power Outlet Optional Switches Interior Cab Light Switches Temperature Control Cigarette Lighter w3004366 Fig 78 Bunk Control Panel VN770 Alarm Clock Timer Fan Speed Control 12V Power Outlet Optional Switches Interior Cab Light S
23. Washer Switch _ SINGLE WIPE NORMAL WIPE FAST WIPE 77 INTERMITTENT WIPE W3004343 Fig 81 Wiper Washer Switch Note Numbers inside parenthesis are circuit numbers Controls for the windshield wiper washer are on the stalk Wiper washer Switch Connector on the right hand side of the steering column Pin Circuit Description Intermittent wipers are pre set to make a single sweep No every 10 seconds The interval can be set to between 1 and 10 seconds by moving the wiper stalk to the intermittent position then to off then to intermittent again when another sweep is desired 383 High Speed Wiper 387 12V Supply to Washer Motor A B C 384 C 12V Supply to Wiper Motor The intermittent wiper function is controlled differently depending on the engine variant On vehicles with Volvo E eee bow speed Wiper engines the Vehicle Electronic Control Unit VECU and 389 intermittent wiper relay are used On vehicles with other engines a wiper control module is used 12V Supply to Wiper Control E Module 385B 12V Supply to VECU For more complete information on the wiper washer system including troubleshooting and service procedures z Bee ee Control see Paper Windshield Wiper System VN VHD publication number PV776 TSP143133 Impact Function Group 36 47 Group 3 Electrical System VN amp VHD Graphic Display Switch
24. by pulling back on the stalk This switch includes a flash to pass feature It is possible to increase or decrease the engine speed by pressing the button at the end of the stalk Pressing the top of the button toward the sign will increase vehicle speed while pressing the lower part of the button the sign will decrease speed To return to the set speed move the switch on the stalk toward Resume The Cruise control switch may also be used to control engine speed on vehicles equipped with PTOs Cruise Control Connector Pin Circuit No Description A Engine Common Dependent C 562A Cruise control On E 563A Cruise control Set G 564A Cruise control Set H 565A Cruise control Resume W3002499 Fig 83 Cruise Control Switch Volvo Engines Only 564A 563A 565A 562A OG SE oH ac per S T RESUME ONT i Q224 SEF SET TOTO 1 l i i AJ I ENGINE DEPENDENT W3004386 Fig 84 Cruise Control Switch Logic Diagram Volvo Engines Only Note Numbers inside parenthesis are circuit numbers 49 Group 3 Electrical System VN amp VHD Design and Function Cruise Control Turn Signal and Headlamp Dimmer Switch Other Engines For these engines the controls for turn signals cruise control and highbeam lowbeam selection are on the stalk switch on the left hand side of the steering column The highbeam lowbeam switch works by pulling ba
25. conduit and tape to prevent future use Installation 1 Install the new fusible link by installing the eye terminal onto the bulkhead pass through stud Position the eye terminal with the wire down Tighten the pass through stud nut to 10 2 Nm 88 18 in lb Install the insulator cap 10 2Nm 88 18 in Ib 2 Route the new fusible link along the engine wiring harness Install the fusible link onto the starter solenoid stud along with the other terminals that were connected before Tighten the starter solenoid stud nut to 27 34 Nm 20 25 ft lb Tie strap the new fusible link to the engine harness making sure to trim the extra tie strap ends 27 34 Nm 20 25 ft lb Group 3 Electrical System VN amp VHD Service Procedures 3 Install the cable into the battery cable clamping bracket Tighten the bolt on the bracket to 17 3 Nm 150 27 in lb 17 3 Nm 150 27 in lb 4 Install the splash guard along the left frame rail with 5 torx bolts and tighten to 18 3 Nm 160 26 in lb 18 3 Nm 160 26 in lb 5 Z N CAUTION In vehicles with a Supplemental Restraint System SRS turn the ignition switch ON before connecting the battery Failure to do so may result in permanent damage to the instrument cluster or other electronic circuits on the vehicle Check for fault codes after repairs are complete Z N CAUTION If there are other ground cables to be connected to the battery such a
26. fog and driving and dimmer control Pneumatic Switches Pneumatic switches may include interaxle lock interwheel lock suspension level dump and sliding fifth wheel 36 Auxiliary Switches These switches are used for additional customer requested components Some vehicles may have other dash mounted equipment such as Road Relay or Autoshift mounted in the optional switch location tray VHD vehicles may have beacon lights and lift axle switches in this location Right Dash Switches The right dash switches may include marker light interrupt traction control heated mirror idle diagnostic and engine exhaust brake Optional switches are used for additional customer requested components Group 3 Electrical System VN amp VHD Switch Logic Diagrams Note Switches are illustrated from wire insertion side view Headlamp Parking Lamp Switch W3000575 Fig 38 Switch W3000576 Fig 39 Switch Wire Insertion Side View Heater AC Blower Motor Control W3000575 Fig 41 Switch W3000576 Fig 42 Switch Wire Insertion Side View Design and Function 31 3la 51 53a 52a 56 1 45 2o33 44 a6 d7 Js 30 30a 50a 50 W3000582 Fig 40 Internal Switch Logic 302A 155 1 p 1 P 1 a 150 150 Fig 43 Internal Switch Logic W3000688 37 Group 3 Electrical System VN amp VHD Dimmer Control Dash Illumination W3000685 Fig 44 Switch W3000686 Fig 45
27. include Marker Interrupt Engine Brake Traction Control or Heated Mirror Switches Optional or auxiliary switches are used for additional customer requested components such as lift axle or beacon lights and are located in the panel above the radio Removal 1 Turn the ignition key OFF 2 Insert a No 1 flat tip screwdriver into the bottom of the switch to release the locking tab 3 The switch will rock out at the bottom Pull the switch down from the top and out W3000645 119 Group 3 Electrical System VN amp VHD 120 W3000692 Service Procedures 4 Disconnect the electrical connector of the switch being removed Installation 1 Connect electrical connection on switch 2 Install the new switch pushing the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel Group 3 Electrical System VN amp VHD Service Procedures 3646 03 02 32 Pneumatic Switch Replacement You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the ashtray from the ashtray housing Remove the 2 screws from the ashtray housing and remove
28. into locking housing aligning slots on switch and housing shaft Holding switch in place start both screws before tightening Tighten to 1 7 0 5 Nm 15 4 in Ib W3000743 1 Machine Screws 2 Connect the ignition switch electrical connector 3 Pull steering column back and up where possible Install front cover by installing torx bolts Tighten to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 4 Adjust the steering column forward and up where possible Install the rear cover of the steering column by installing torx bolts and attaching rubber grommets at the stalk switches Tighten bolts to 5 0 8 Nm 44 7 in lb 0 8 Nm 5 44 7 in lb 97 Group 3 Electrical System VN amp VHD W8002166 Service Procedures 5 Replace the 2 clips on the bottom of the steering column cover 3341 03 02 02 Ignition Switch and Housing Replacement W8002166 98 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the 2 clips at the bottom of the steering column cover 3 Adjust the steering column up and toward you where possible Remove the front steering column cover by removing the 3 torx bolts from t
29. side door lock If the main supply is activated with one door locked and one unlocked both sides will be automatically unlocked to prevent the driver from accidentally being locked out The Central door lock module is located in the front TEC panel below the fuse and relay panel The door lock module is accessed by removing the front TEC panel cover Central Door Lock Module Connector Pin Circuit Number Description Input Characteristics Output 1 710 Battery supply voltage Unswitched battery supply 2 713R To passenger side motor unlock O Internally switched to GND or Unswitched Batt 3 713L To driver side motor unlock O Internally switched to GND or Unswitched Batt 4 714R To passenger side motor lock O Internally switched to GND or Unswitched Batt 5 714L To driver side motor lock O Internally switched to GND or Unswitched Batt 6 7 Not used 8 712 To passenger side switch Externally switched to GND or open 9 711 To driver side switch Externally switched to GND or open 10 11 12 13 Not used 14 15 16 0C C Battery ground Battery GND 56 Group 3 Electrical System VN amp VHD Smoke Detector VN sleeper cabs may be equipped with an optional smoke detector If equipped the smoke detector will be located on the sleeper headliner The smoke detector includes an alarm and indicator light test button The chart below gives the indicator la
30. through a splice to the Accessory Power Relay and to two Ignition Power Relays Power stud 2 may also supply battery power for Bodybuilder applications Design and Function lt PWR STUD 2 W3004399 Fig 16 Main Cab Electrical Power Studs driver side engine compartment 21 Group 3 Electrical System VN amp VHD Design and Function Battery Power Supply Schematic ACCESSORY POWER RELAY PR1 IGNITION POWER RELAY PR3 IGNITION SWITCH IGNITION POWER RELAY PR2 BODYBUILDER APPLICATIONS BUS BAR BUS BAR MAXI FUSES MAXI FUSES BATTERY BATTERIES STARTER BATTERY BATT MAXI FUSE BUS BAR FUSES TO BUS BUS BUS BATTERY BAR BAR BAR EXPANSION FUSES FUSES FUSES BLOCKS W3004347 Fig 17 Battery Power Supply This simplified schematic should only be used to clarify the design features of the VN VHD battery power supply circuit For detailed vehicle specific schematics see the VN or VHD Electrical Schematics Group 37 22 Group 3 Electrical System VN amp VHD Design and Function Accessory Power Supply e Constant battery power is supplied to the ignition switch and Accessory Power Relay See Battery Power Supply page 21 e When the ignition switch is switched to the ACCESSORY position the 195 wire energizes the Accessory Power Relay PR1 The relay supplies power to wire 195A for the bus bar for Accessory fuses e From the Accessory Power Relay PR1 wire OR R p
31. 03 02 01 TV Speaker Headphone Jack Replacement cccccsscsensenesseeesueeeceneenesenenseseeseneesneeenuesensennenerenien 139 3663 03 02 01 Smoke Detector Battery Replacement s ss cssessiessiessrrnnsrnnsrnasrnernertnnennsansnnnrtannnansnnennnnennneantnantnannnannnnnt 141 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 5600A Cancross Court Mississauga Ontario L5R 3E9 http Awww volvotrucks volvo com PV776 20 007111 1000 04 2004 Volvo Trucks North America Inc 2004
32. 6 W3003967 75 Group 3 Electrical System VN amp VHD Dielectric Grease The use of dielectric grease is recommended for certain non sealed plugs sockets and connectors that are exposed to the weather It reduces corrosion by providing protection against moisture and the elements Sealed connectors do not require dielectric grease Routing and Clipping Wiring should be secured as necessary to prevent rubbing against objects that may wear through the wiring insulation and cause circuit failures When securing wiring near connectors switches or sensors with cable ties leave some slack at the connector to prevent vibration from pulling the wiring out of the connector Z N CAUTION If a circuit must be added to the electrical system and will carry high currents or frequencies route it in a location AWAY from the J1587 data link wires 400 and 401 and the J1939 wires 406 407 and 408 to prevent mutual inductance from interfering with data link functions Z N CAUTION No modifications or connections should be made to wires 406 yellow 407 green or 408 shielded These wires carry the high speed communications between the electronic systems in the vehicle Any modification connection to or damage to these wires can result in the failure of the vehicle s electronic systems N CAUTION Wires 400 and 401 MUST NOT be cut or spliced for any connections These wires are used for the tra
33. C or diagnostic tool connected error codes can be read from all the control units This is important in fault tracing to carry out basic checks of all the vital parts of the vehicle s electronics Some programming can also be done via the diagnostic connector The standard diagnostic connector is a 6 pin Deutsch A newer 9 pin Deutsch version has been introduced on certain vehicle engine variants The new 9 pin connector connects to both the J1939 and J1587 1708 data links 16 Design and Function Communication Equipment Expansion capability Instrument Cluster MIDs 234 amp 140 SRS ECU MID 232 Engine ECU Terminating MID 128 Resistor Diagnostic connector SAE J1587 1708 Vehicle ECU MID 144 Transmission ECU MID 130 Control unit Expansion capability SAE J1939 Terminating ABS ECU MID 136 Resistor Group 3 Electrical System VN amp VHD Design and Function Starting and Charging System ALTERNATOR TOCAB PWR STUD 2 19 Dt a gt To caB ia PWR STUD 1 BODYBUILDER APPLICATIONS BATTERIES FUSIBLE FUSIBLE LINK LINK 1 14 TO OA INSTRUMENT CLUS TER 285A NGINE FUSIBLE FRAME RAIL GROUND LINK GROUND OVERCRANK GROUND PROTECTION SWITCH OR SHORTING JUMPER
34. ESSORY 12V FUSE J FUSE CITY AIR HORN pam HORN K AIR HORN I g gt SOLENOID l E SUPPLY AIR PRESSURE STEERING WHEEL STEERING WHEEL city KK PA air HORN 24 97 HORN CONTACT CONTACT CASE GROUNDED GROUND sw sea RHS GROUND STEERING STUD INTERIOR SIDE COLUMN W3004340 Fig 94 Horns Simplified Schematic Group 3 Electrical System VN amp VHD Design and Function TV Antenna and Speaker A TV Prep Kit including an antenna and coaxial cable is standard for the VN770 cab and optional in the 610 and 660 cabs The coaxial cable extends from the antenna in the headliner and runs behind the cabinets on the passenger side It should be connected to a television located in the cabinet on the passenger side The antenna is installed under the center headliner of the bunk area In the VN610 or 660 the antenna on is a ribbon type that is taped to the underside of the SMC roof panel in the bunk area In VN770 vehicles built after June 2000 the antenna is the same style as in the VN610 or 660 W3004004 Fig 95 VN610 660 770 TV Antenna 61 Group 3 Electrical System VN amp VHD Design and Function On 770 vehicles built before June 2000 the television antenna is a flexible grid type antenna and is integrated into the center bunk headliner See Fig 96 VN770 TV Antenna in vehicles built prior to June 2000 page 62 A coaxial cable extends from the antenna in the center bunk he
35. It gathers cab switch and sensor information and communicates with the engine ECU Many vehicle functions controlled by the combi relay on previous versions of Volvo engines are now controlled by the VECU For example the intermittent wiper function on these vehicles is now controlled by the VECU For more information on the windshield wiper function see Vehicle ECU page 55 in this manual The central door lock module is mounted to the left of the VECU The central door lock module is covered later in this manual See Central Door Lock Module page 56 Design and Function 33 Group 3 Electrical System VN amp VHD Fuse and Relay Positions VN Note Refer to the decal inside the TEC cover for vehicle s exact fuse descriptions and ratings B1 1 through B1 6 B2 2 through B2 4 PR1 PR2 PR3 Design and Function FL1 Flasher Unit PR2 Ignition Ignition Power Power Relay Relay Fig 35 Fuse and Relay Positions in the top TEC panel VN Ignition Expansion Blocks Battery Expansion Blocks Accessory Power Relay Ignition Power Relays One Accessory and two Ignition Power relays are used to transfer the heavy current load coming from the battery to the Ignition Accessory circuits These relays are located on the TEC tray for easy access and replacement 34 DRL Daytime Running Lamp Module W3002729 Group 3 Electrical System VN amp VHD Fuse and Relay Positions VHD
36. Note Refer to the decal inside the TEC cover for vehicle s exact fuse descriptions and ratings Design and Function PR2 PR3 IGNITION IGNITION POWER PR4 IGNITION POWER DRL DAYTIME RUNNING LAMP MODULE Fig 36 Fuse and Relay Positions in the top TEC panel VHD Bi 1 through B1 6 Battery and Ignition Expansion Blocks PR1 Accessory Power Relay PR2 PR3 PR4 R24 Ignition Power Relays One Accessory and four Ignition Power relays are used to transfer the heavy current load coming from the battery to the Ignition Accessory circuits These relays are located on the TEC tray for easy access and replacement PR4 is used in VHD bodybuilder applications W3004362 35 Group 3 Electrical System VN amp VHD Switches and Controls Dash Switches Design and Function W3004361 Fig 37 Dash Switches Left Dash Switches Driving Light Switches Pneumatic Switches Auxiliary Switches Right Dash Switches ahWwWND All dash mounted switches feature heavy duty terminals and locking mating connectors Rocker switches have illuminated legends with embedded LEDs to indicate ON or OFF status of electrical devices Left Dash Switches The left dash switches may include hazard 4 way flashers back of cab headlamp interrupt flash to pass snowplow light sleeper overhead light smoke detector disable or power take off Driving Light Switches Driving light switches include headlamp parking
37. Service Manual Trucks Group 300 500 Electrical General VN from 2 98 and VHD PV776 20 007111 WOiINO Foreword The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to April 2004 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 V S T Volvo Standard Times Service procedures which do not include an operation number in the title are for general information and no reference is made to an V S T Each section of this manual contains specific safety information and warnings which must be reviewed before performing any procedure If a printed copy of a procedure is made be sure to also make a printed copy of the safety information and warnings that relate to that procedure The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a situation handling or circumstance which should be observed Caution Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury
38. Switch Replacement scincdisiiisessisiieeesicidiovavedsicisieeridiciaes 95 Ignition Switch and Housing Replacement eee eeeeeeeeeeeseeeeeeees 98 Air H rn Contact Replatement is idiasvoisecisi isvenieisievnenniivicineeineeiiens 102 City Horn Contact Replacement soramea 107 Gily Horm RERISGEIIENY sminuonienu ne e 109 Air Horn Solenoid Replacement acceccssssseiaseaosieanscannennasscesnrooninenanes 110 Turn Signal CC Switch Assembly Replacement sessen 111 Hazard Warning Switch Replacement eeeeeeseeeseeeeneeeeeeeeeeeeeees 114 Back of Cab Lamp Switch Replacement eeeessseceresserereenerees 114 Fan Swich Replacement sorunca 114 PTO Switen REPS serron eiii 114 Bunk Overhead Lamp Switch Replacement sssessieeseesreesrsresrresrneee 114 Headlamp Interrupt Switch Replacement cceseeeeeeeeeeeeetees 114 Snowplow Lamp Switch Replacement eeceesseeeeeseeeeeneeeeeeees 114 Smoke Detector Disable Switch Replacement eee 114 Switch Replacement Left Dash Switches 00 0 0 eee eeeseeereeeseeeeeees 115 Marker Interrupt S Engine Exhaus E Operation Numbers Group 3 Electrical System VN amp VHD General General General Information ii ih ji ji j iil y W8002831 Fig 1 VN and VHD Models This information covers electrical features of VHD vehicles and VN vehicles built from February 1998 It includes information about major cab electrical compone
39. access to circuits in the main cab harness For connector pin outs see the wiring diagrams in VHD Electrical Schematics Group 37 2 Two identical harnesses for the center cab console one inside the cab and one that goes to the outside These have 31 pin Deutsch connectors on both ends with 14 wires installed in each These 14 wires can be used for any circuit the bodybuilder needs to install 63 Group 3 Electrical System VN amp VHD Design and Function Circuits in Bodybuilder Harness Circuit Description Circuit Description BAT A 25 amp fused battery circuit A118 PTO from Allison Transmission IGN X 15 amp fused ignition circuit IGN Y 15 amp fused ignition circuit A153 Auto Neutral from Allison Transmission IGN Z 15 amp fused ignition circuit A117 Auto Neutral from Allison Transmission 410 B Reverse circuit A314NO Auto Neutral from Allison Transmission 19 R terminal A314NC Auto Neutral from Allison Transmission OT C Ground A314CM Auto Neutral from Allison Transmission NEU Neutral signal from Allison A143 L Auto Neutral from Allison Transmission Tansinission A161 A Auto Neutral from Allison Transmission 573 Speed Control from Vehicle ECU A157 Aison mansmissib 573A PTO enable from Vehicle ECU A155 Alison Transmission 573B PTO enable from Vehicle ECU A166 Allison Transmission 573C PTO enable from Vehicle ECU A167 Allison Transmissi
40. adliner and runs behind the cabinets on the passenger side It is connected to a television located on the middle shelf of the cabinet on the passenger side The 770 also includes a remote TV speaker that is integrated into the sleeper control panel For replacement instructions see TV Speaker Headphone Jack Replacement page 139 Sy OSG 2010 J JED O A ai Wael MCCS W3004005 Fig 96 VN770 TV Antenna in vehicles built prior to June 2000 For more information on TV antenna troubleshooting and replacement see TV antenna information in Group 39 62 Group 3 Electrical System VN amp VHD Design and Function Bodybuilder Wiring W3004424 Fig 97 Bodybuilder Prep Kit Wiring A Bodybuilder Prep Kit is standard in VHD truck models and optional on tractors It consists of the harnesses shown 1 One jumper harness off the main cab harness It runs from the A pillar to the center of the cab It routes along the right side of the cab floor to the back of the cab then across to holes in the center of the cab where a console can be mounted The circuits provided are listed in Circuits in Bodybuilder Harness page 64 Either 2 or 4 connectors will be used at each end of this harness 4 with Allison transmissions and 2 with other transmissions This harness allows the bodybuilder easy
41. aker jack and secure the nut with a 1 2 inch socket 3 Connect the connectors 4 Turn on power to the TV Check the speaker for operation 5 Insert the sleeper control panel into the trim panel Install the six mounting screws Group 3 Electrical System VN amp VHD Service Procedures 3663 03 02 01 Smoke Detector Battery Replacement Removal You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it 1 To remove the smoke detector from the mounting base press the release tab up With the smoke detector removed the 9 volt battery can be replaced W8002732 2 To remove the mounting base remove the two mounting screws and disconnect the connector Installation 1 Connect the connector to the replacement mounting base and install with the two screws W8002734 141 Group 3 Electrical System VN amp VHD 142 Service Procedures 2 Check that a known good 9 volt battery is installed in the smoke detector Snap the smoke detector into the mounting base Be sure the release tab is locked into position 3 Test the smoke detector for proper operation by pressing the function button indicator light for 5 seconds If the battery is OK the alarm should sound as long as
42. an result in unexpected vehicle movement and can cause serious personal injury or death N CAUTION Never use the ohmmeter mode of the DMM ina powered circuit or as a substitute for a voltmeter or ammeter since damage to the instrument will result Use the ohmmeter mode only when power is removed from the circuit w2001014 Fig 101 Fluke 87 Digital Multimeter Available from Volvo P N 9510060 or Kent Moore J 39200 67 Group 3 Electrical System VN amp VHD Troubleshooting Troubleshooting Wiring and Connectors General Troubleshooting Procedures General Troubleshooting Procedures e Use Multimeter J 39200 or equivalent tool to perform tests The use of test lights is discouraged e When troubleshooting wiring and connectors use breakout boxes harnesses when available A list of various breakout boxes harnesses is included in Special Tools page 7 e Never pierce the wiring insulation with test probes e Do not pierce through seals on water resistant connectors e Never insert test probes into connectors The probes may spread the terminals and cause intermittent faults e f breakout boxes harnesses are not available contact the metal outer edges of connector terminals as necessary to take readings e Consult VN or VHD Series Electrical Schematics in Group 37 for vehicle specific wiring and connector information These schematics include pin out and vehicle location drawi
43. and tighten the 2 screws at the top of the cluster Tighten to 2 0 3 Nm 17 5 2 5 in Ib 2 0 3Nm 17 5 2 5 in lb 6 Use a rag and a pair of pliers to remove the rheostat knob Then disconnect the terminal connectors on the switch W3000812 130 Group 3 Electrical System VN amp VHD W3000798 W3000647 Service Procedures 7 Use the rheostat removal tool J 42395 to remove the shaft nut from the rheostat J 42395 Installation 1 Install the new rheostat into panel Install the nut on the rheostat shaft Connect the terminal connectors and install the knob 2 Install panel by inserting tips on right side and pushing the panel into position The clips will snap in place on the left side 131 Group 3 Electrical System VN amp VHD Service Procedures 3647 03 02 01 Cigar Lighter Replacement W3000649 W3000656 132 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the ashtray from the ashtray housing Remove the 2 screws from the ashtray housing and remove the housing 3 Once the ashtray housing is removed the air switch panel can b
44. assenger Side Window Switch wo 2 Disconnect all the mirror and window switches installed in the panel Mark the wire connectors to keep the arrangement correct W3000805 1 Mirror Switch Connector 2 Window Switch Connector 134 Group 3 Electrical System VN amp VHD W3000802 W3000803 Service Procedures 3 For the window switch insert the mirror window switch removal tool between the housing clip and the window switch When the tool is inserted push on the switch to clear the switch tabs from the clips Repeat on the opposite end and push the switch out 4 For the mirror switch insert the mirror window switch removal tool between the inner housing lip and the mirror switch When the tool is inserted push on the switch to clear the locking tab Then insert the removal tool between the outer lip and the mirror switch Keeping a steady pressure push the switch out of the housing 135 Group 3 Electrical System VN amp VHD pn W3000804 Switches on driver s side door 1 Location for Drivers Side Window Switch shown not installed 2 Driver Side Mirror Switch Passenger Side Mirror Switch 4 Passenger Side Window Switch wo 136 Service Procedures Installation 1 For the window switch the tabs are different sizes on each end so make certain the switch is aligned the correct way and push the switch into the housing
45. asures the pressure of the turbo boost and sends a signal to the Engine ECU which interprets this pressure and adjusts engine functions accordingly The sensor s temperature element is a thermistor type that creates a resistance from the temperature of the turbo boost air and also sends a signal to the engine ECU The combination engine oil temperature and pressure sensor functions identically but sends engine oil information first to the Engine ECU then to gauges on the instrument cluster via the Data Link wires 12 Design and Function W5000602 Fig 8 Anti lock Brake Wheel Speed Sensor Group 3 Electrical System VN amp VHD Data Link Communication General Communication between the different ECUs takes place via the two data links the J1939 control data link and the J1587 1708 information data link The diagram shows how the control units the diagnostic connector and the instrument cluster are connected in principle The instrument cluster the engine ECU and the diagnostic connector are always included in the system The system may include other control units depending on the vehicle type engine type and optional equipment An overview of data link communication follows For complete information on data link communications see Vehicle Electronics Design and Function Volvo publication number PV776 TSP 132163 Design and Function Communication Equipment Expansion capability
46. ck on the stalk This switch includes a falsh to pass feature It is possible to increase the engine speed with the button at the end of the stalk To return to the set speed move the switch on the stalk toward Resume The Cruise control switch may also be used to control engine speed on vehicles equipped with PTOs Cruise Control Connector Pin Circuit No Description A Engine Common Dependent B 562 Cruise control On 563 Cruise control Set D 565 Cruise control Resume 50 W3000807 Fig 85 Cruise Control Switch Caterpillar Cummins Detroit Diesel En gines Zz 5 lt 563 565 562 2 2 amp 4 __ B oe SET RESUME JON wy 5 o J S22 Ft i cond oO or I ENGINE DEPENDENT W3004385 Fig 86 Cruise Control Switch Logic Diagram Caterpillar Cummins Detroit Diesel Engines Note Numbers inside parenthesis are circuit numbers Group 3 Electrical System VN amp VHD TURN SIGNAL LEFT TURN SIGNAL RIGHT 112 B Fig 87 Turn Signal and High Low Beam Switch Logic Diagram 115 116 113B Note Numbers inside parenthesis are circuit numbers 32L 33L 31L 32R Design and Function HIGH LOW BEAM HIGH BEAM FLASH TO PASS 0 31R A W3004427 Turn Signal Connector 3 wa um Sig y Headlamp Dimmer Switch Connector
47. d is the common ground location on the vehicle The main cab ground frame rail ground and alternator ground all meet at the engine ground stud From this common termination point a fusible link then carries all vehicle return current to the negative battery cable at the ground stud on the starter motor e The fusible link is designed to protect the vehicle in the event of a short circuit in a high current component such as an alternator or positive battery cable Note that the fusible link cannot protect the starter since the starter has a direct cable connection to the batteries W3002567 Fig 29 Starter Motor 1 Ground Side Fusible Link 2 Starter Ground Stud 3 Engine Ground location varies by engine 29 Group 3 Electrical System VN amp VHD Design and Function System Ground Schematic B ALTERNATOR BATTERIES FUSIBLE LINK GRD STARTER FRAME ENGINE RAIL GROUND GROUND GROUNDS LHS GROUND STUD 6 ENGINE SIDE W3004345 Fig 30 System Ground Schematic This simplified schematic should only be used to clarify the design features of the VN VHD ground circuit For detailed vehicle specific schematics see the VN or VHD Electrical Schematics Group 37 30 Group 3 Electrical System VN amp VHD Design and Function Electrical Pass through for Cab Wiring The two main cab cable pass throughs are on the left and right sides of the bulkhead The pass throughs contain connectors which join
48. dash pulling toward the driver s side to clear tip inserts W3000996 5 Once the switch panel is removed install the instrument cluster in the dash and tighten the 2 screws at the top of the cluster Tighten to 2 0 3 Nm 17 5 2 5 in lb 0 3 Nm 5 2 17 5 2 5 in lb 6 Disconnect connector Remove switch from panel by pulling locking tabs away from switch with a No 1 screwdriver ryt Lee VC W3000646 124 Group 3 Electrical System VN amp VHD Service Procedures 7 Remove the switch through the front of the panel W3000682 Installation 1 Install the new switch into the panel Push the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel Connect the electrical connector 2 Install the panel by inserting tips on right side and pushing the panel into position The clips will snap in place on the left side i W3000647 125 Group 3 Electrical System VN amp VHD Service Procedures 3646 03 02 23 Fog Driving Lamp Switch Replacement W3000641 a oo A W3000650 126 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF
49. e VN or VHD Series Electrical Schematics Group 37 IGNITION POWER SMOKE DETECTOR Fig 91 Smoke Detector Simplified Schematic 58 SMOKE DETECTOR DISABLE SWITCH Design and Function SWITCH ILLUMINATION GROUND W3004348 Group 3 Electrical System VN amp VHD Horn Both city and air horns are standard equipment on VN VHD vehicles The air horns may be located on the roof inside the right frame rail near the radiator or on the left frame rail near the batteries The city horn is located at the left front of the vehicle near the radiator Both horns are operated by steering wheel controls The city horn operates by pressing buttons on either the left or right steering wheel spoke The air horn is electrically operated via a remote solenoid The air horn button is the one in the center of the steering wheel on non SRS equipped vehicles On SRS equipped vehicles the entire air bag module acts as the air horn button W8002736 Fig 92 Steering Wheel Without SRS 1 City Horn 2 Air Horn Design and Function W8002735 Fig 93 Steering Wheel With SRS 1 City Horn 2 Air Horn 59 Group 3 Electrical System VN amp VHD 60 Design and Function The simplified schematic below should only be used to clarify the design of the horns For detailed vehicle specific schematics see VN or VHD Series Electrical Schematics Group 37 an lt lt lt IGNITION 12 V ACC
50. e removed from the dash Pull the air switch panel away from the dash and to the left to clear the tip inserts 4 Disconnect the 2 terminal connectors at the cigar lighter Group 3 Electrical System VN amp VHD W3000696 Service Procedures 5 Push the lighter housing out of the panel enough to get a small flat tip screwdriver under the lip of the cigar lighter Remove the lighter from the LED housing and slide the housing out of the dash Installation 1 Install the LED housing back into the dash panel Make sure it s properly aligned with the molding Push the cigar lighter through the LED housing until it touches the LED Connect the terminal connectors 2 Install the panel back into the dash Install the ashtry housing with 2 torx screws and install the ashtray 133 Group 3 Electrical System VN amp VHD Service Procedures 3646 03 02 28 Window Power Mirror Switch Replacement You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Insert a No 1 screwdriver into the corner of the switch panel to remove it from the door panel W3000806 1 Location for Driver s Side Window Switch shown not installed 2 Driver Side Mirror Switch Passenger Side Mirror Switch 4 P
51. ectrical interference Z N CAUTION If a circuit must be added to the electrical system and will carry high currents or frequencies route it in a location AWAY from wires 400 and 401 to prevent mutual inductance from interfering with data link functions Z N CAUTION Wires 400 and 401 MUST NOT be cut or spliced for any connections These wires are used for the transmission of data for diagnostic messages and gauges Modifying this circuit can cause these functions to fail SAE J1922 Data Link For a short period of time some vehicles were produced which used the J1922 data link The J1922 data link was developed as an interim standard until the J1939 control data link was established The J1922 link operates on J1708 defined hardware and is used like a control link for communication between engine transmission and ABS ECUs The J1922 link consists of two wires 404 and 405 that are twisted around each other approx 30 turns per meter The twisted pair wires are to protect the link against electrical interference Design and Function Group 3 Electrical System VN amp VHD Diagnostic Connector W8001310 Fig 10 Diagnostic Connector The diagnostic connector is a round Deutsch connector located in the driver s side kick panel The diagnostic connector is connected to the J1587 1708 information link and gives the system a way to communicate with an external PC or diagnostic tool With a P
52. eessucsivennucnetsleeanniennieunceunnusonvcnmuenncaiues 118 3646 03 02 26 Heated Mirror Switch Replacement ccccciccccccscicccnccccscccesasssesanecnicerasesetanseraeecesanstiaiciaasacerasersetanearaeekens 118 3646 09 0242 Lith Axle Swich Replacement guisssorsisnunisisteinibialaiasehnlncetbtalomaeleiilamastslgiaiuhidam i 118 3646 03 02 43 Beacon Lamp Switch REPICOMER sn ccniesscsdnssnnnoanicnmnnneeannssnnvaeonierannennedhneskieaueedunedaae abdeedanedbndnkinraieunes 118 3646 03 02 32 Preumatit Switch Replacement iscciscisvcisreisasarisicierdaveidicisievalesvimeudeiaieisi oaniRieisUiaeeieinomeiaieinier 121 3646 03 02 06 Headlamp Parking Lamp Switch Replacement eesccescesesneeeseceesenecsenerenesnanereeneeenaeeeseeesseneeeners 123 3646 03 02 23 Foo Driving Lamp Switch Replacement siiicisiciisicierinasicinveasaciiericiseiieisi i i ii 126 3646 03 02 12 Dash Dimmer Control Switch Replacement csscceseeseceeseeeesenesseneneenenenenenneneneeeesonerseneneeeeesnenenaes 129 3647 039 02 01 Cigar Lighter Replaces merit ss ecesicisss et es sntceissedbnades asa raecanraisidinseaisraidaenadesiayndeaakersiarepinecngidasamebiardeantels 132 3646 03 02 28 Window Power Mirror Switch Replacement eee eeeeesseeeceeseeeceenersneeeeneeeneeeseeeesanecsanessnerereeesnetenees 134 3838 03 02 02 Digital Clock Replacement Sleeper cccccccccececceeeeeeceeeeeeeeeeeeeaeeeseaeeesesaeeesesaeeeseeeaneeseaeeeseenneeeeeees 137 3935
53. ery expansion blocks were designed for plug in harnesses or fuses only DO NOT plug ATO size fuses or circuit breakers into either expansion block These devices will short the power point to the ground bus N CAUTION Failure to properly install additional electrical components may adversely affect the operation of the vehicle including the engine electrical charging system truck body stereo system and the driver information systems Constant battery power is supplied to the ignition switch and Ignition Power Relays See Battery Power Supply page 21 When the ignition switch is turned to the ON position the 196 wires energize the Ignition Power Relay Coils The relay coils are grounded at ground stud 17 or 18 When energized Ignition Power Relay PR2 supplies power to a maxi fuse bus bar These maxi fuses in turn supply power to expansion block fuses The ignition power expansion block is used to supply power to optional electrical accessories When energized Ignition Power Relay PR3 supplies power to a maxi fuse bus bar These maxi fuses in turn supply power to ignition bus bar fuses When energized Ignition Power Relay PR4 supplies power through a maxi fuse to an expansion fuse block The wiring from these fuses supply a chassis harness connector for bodybuilder applications PR4 is used only on VHD vehicles When energized Ignition Power Relay R24 supplies power to a Start ignition splice pack
54. for various vehicle functions R24 is used only on VHD vehicles 25 Group 3 Electrical System VN amp VHD Design and Function Ignition Power Supply Schematic VN BUS BAR MAXI FUSES IGNITION IGNITION IGNITIONG IGNITION EX MAXI MAX BUS BAR 19 196R MAXI FUSES aoe IGNITION MAXI FUSE age Torrene IGNITION Sele ae POWER FUSE FUSE bo RELAY PR3 IGNITION SWITCH IGNITION POWER RELAY PR2 BATTERY POWER ORM OR N TO IGNITION PANEN EXPANSION BLOCKS RHS GROUND STUD 18 INTERIOR SIDE W3004360 Fig 23 Ignition Power Supply This simplified schematic should only be used to clarify the design features of the VN ignition power supply circuit For detailed vehicle specific schematics see the VN Electrical Schematics Group 37 26 Group 3 Electrical System VN amp VHD Design and Function Ignition Power Supply Schematic VHD OR S IGNITION IGNITION POWER MAXL RELAY PR4 RHS GROUND BUS STUD 18 INTERIOR SIDE BAR FUSES BATTERY POWER BUS BAR BODY 196A A MAXI FUSES BUILDER IGNITION CONNECTOR IGNITION hIGNITION H IGNITION MAXI MAXI MAXI FUSE BUS BAR FUSES RHS GROUND STUD 17 INTERIOR SIDE BUS BAR 196 196B MAXI FUSES CONTON IGNITION MAXI FUSE IGNITION h IGNITION IGNITION a POWER he Mie MSE RELAY PR3 IGNITION SWITCH IGNITION POWER RELAY PR2 BATTERY POWER OR M ORN IGNITION BATTERY
55. fuse in the fuse panel This could cause damage to the electrical system Troubleshooting ws3000491 W3003968 73 Group 3 Electrical System VN amp VHD High Resistance A high resistance condition in a circuit is often difficult to find Symptoms of high resistance include dim or flickering lamps or inoperative components since current decreases when resistance increases the components may not be receiving enough current to operate properly The first step in finding a high resistance problem should be a visual check of all connectors and wires in the circuit Possible cause of High Resistance e Achafed cable where one or more wires have been cut effectively reducing the diameter of the wire e An inadequate power or ground path due to corrosion loose terminals or fasteners e A terminal that is worn due to excessive cycling connecting disconnecting e An internal component fault Corrosion Corrosion in sockets and connectors is caused by acids and road salt reacting with the copper Connections exposed to concentrated splash spray and wheel wash should be sealed tightly Periodically check to see that all wiring connections are clean and tight Corrosion in wiring is due mainly to poor wire splicing or breaks in the wire insulation Wires should not be spliced by twisting them together and wrapping with tape Several hand crimped connectors are available on the market which will result in a
56. g Resistor Terminating resistors are wired into each end of the J1939 data link One is located near the ABS ECU and the other near the engine ECU On Volvo engines the terminating resistor at the engine ECU end is located inside the EECU Only two terminating resistors are used in a vehicle Never install three in one truck If more than two terminating resistors exist in the J1939 circuit damage to the ECU electronics can occur over time You can easily check to see if you have two resistors by measuring the resistance between circuits 406 and 407 with the ignition OFF The correct resistance is 6092 The purpose of these resistors is to prevent data link signal reflections They must remain connected for the system to function properly 14 Design and Function W3002905 Fig 9 J1939 Terminating Resistor Group 3 Electrical System VN amp VHD SAE J1587 1708 Information Data Link Information and diagnostic signals are sent via this link The link also functions as a backup should the J1939 control data link fail to function for any reason SAE J1708 is a standard that specifies hardware and a databus speed of 9600 bits per second SAE J1587 isa protocol that provides a standard method for exchanging information between microprocessors The J1587 link consists of two wires 400 and 401 that are twisted around each other approx 30 turns per meter The twisted pair wires are to protect the link against el
57. good joint or union but most do not provide a water tight seal Corrosion is also caused by terminals that are improperly fastened to the vehicle Excessive vibrations at the contact points will cause fretting corrosion Corroded wires should be replaced as needed Corroded terminals should be cleaned with wire brushes or scraped as needed to remove corrosion It s important to also check for corrosion in the wire if a terminal is corroded The wire can act like a wick and absorb moisture Additionally terminals may be cleaned with cleaning chemicals designed for electronic terminal cleaning and then blown dry with compressed air But there is a risk of forcing the moisture further into the terminal or cable After cleaning closely inspect the terminals to determine their serviceability Check for proper contact as outlined in Contact Problems page 75 Replace any connectors that are determined to be in less than serviceable condition 74 73009652 Troubleshooting Group 3 Electrical System VN amp VHD Contact Problems Loose or corroded connections are often the cause of intermittent faults Intermittent faults are usually difficult to find since the fault must be active at the time of troubleshooting to insure that the fault is corrected Wiggling the suspected wiring or connector while monitoring the circuit function or multimeter may be effective in helping to locate intermittent faults To check for proper con
58. he cover and sliding the rubber grommets off of the cover at the stalk switches Group 3 Electrical System VN amp VHD Service Procedures 4 Adjust the steering column forward and up where possible Remove the 3 torx bolts from the rear column cover and remove cover ws8002165 5 Disconnect the ignition switch electrical connector Remove the 2 allen bolts from the forward side of the ignition switch housing to remove switch and housing W3000746 1 Bolts 2 Switch and Housing Assembly 99 Group 3 Electrical System VN amp VHD Service Procedures Installation 1 Mount the switch and housing on the steering column with the 2 bolts Tighten to 24 4 Nm 18 3 ft lb 24 4Nm 18 3 ft lb W3000746 1 Bolts 2 Switch and Housing Assembly 2 Connect the ignition switch electrical connector 100 Group 3 Electrical System VN amp VHD W8002166 Service Procedures 3 Adjust the steering column forward and up where possible Install the rear cover of the steering column Torque bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 4 Adjust the steering column up and toward you where possible Install front cover by installing torx bolts and attaching rubber grommets at stalk switches Tighten bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 5 Replace the 2 clips on the bottom of the steering column covers 101 Group 3 Electrical System VN amp VHD Ser
59. hrough the front of the dash W3000660 5 Once the panel is removed install the instrument cluster in the dash and tighten the 2 screws at the top of the cluster Tighten to 2 0 3 Nm 17 5 2 5 in Ib 2 0 3 Nm 17 5 2 5 in lb 116 Group 3 Electrical System VN amp VHD W3000659 Service Procedures 6 Disconnect the electrical connector from the switch to be removed Insert a small flat tip screwdriver No 1 into the bottom of the switch to release the locking tab then remove the switch from the panel these switches are removed through the front of the panel Installation 1 Install the new switch pushing the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel Connect electrical connector and install panel back in dash 117 Group 3 Electrical System VN amp VHD Service Procedures 3646 03 02 29 Sleeper Control Panel Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03 02 22 Auxiliary Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03 02 24 Marker Interrupt Switch Replacement For a complete description of this procedure see Right Dash Auxiliary Sleeper Control Panel Switch Replacement page 119 3646 03
60. hting system including design and function troubleshooting and service procedures see the service information on lighting in Group 35 53 Group 3 Electrical System VN amp VHD Design and Function Supplemental Restraint System 54 Volvo vehicles may be equipped with a Supplemental Restraint System SRS The SRS is supplemental protection for use together with the safety belt The SRS is designed to reduce the risk of injury to the driver s face and upper body The system consists of an inflatable bag mounted in the center of the steering wheel and a control unit mounted on the bulkhead inside the cab A chemical based gas generator attached to the rear of the bag inflates the bag in the event of a collision Sensors in the control unit detect deceleration If the control unit detects a sufficiently violent deceleration collision the system is activated The gas generator activates and fills the bag with a harmless gas within a few hundredths of a second During a collision after the bag has been filled the gas flows out through two holes in the back of the bag These holes are large enough to let the airbag collapse slowly gently catching the driver The control unit also contains a standby power unit which can supply the system with power for a short time should the normal power supply be broken For more information on SRS see the VN VHD service information in Group 88 ws001291 Fig 88 SRS System Group 3 Elec
61. ies and operating electrical accessories through wire 8 An integral voltage regulator maintains operating voltage to a predetermined setting See Fig 11 Starting amp Charging Circuit Simplified Schematic page 17 20 Design and Function Group 3 Electrical System VN amp VHD Battery Power Supply Power is supplied from the batteries to the starter solenoid then from the starter solenoid battery post via wires 1A A and 1B A Note that each of these wires contains a fusible link Wire 1B feeds cab main power stud 1 and 1A feeds cab main power stud 2 N CAUTION The ignition and battery expansion blocks were designed for plug in harnesses or fuses only DO NOT plug ATO size fuses or circuit breakers into either expansion block These devices will short the power point to the ground bus Z N CAUTION Failure to properly install additional electrical components may adversely affect the operation of the vehicle including the engine electrical charging system truck body stereo system and the driver information systems e Power stud 1 feeds wires 1B and 1P which power maxi fuse bus bars These maxi fuses supply power to various fuses and possibly a battery expansion block Battery power is also supplied to the ignition switch through this circuit The battery power expansion block is used to supply power to optional electrical accessories e Power stud 2 feeds wire 1A which delivers power
62. ilure to de energize circuits may result in electronic equipment damage 1 Visually inspect the circuit 2 Disconnect the connectors at both ends of the wiring harness 3 Measure resistance using multimeter J 39200 or equivalent tool between the ends of the wire The expected value is lt 1 2 Readings of OL infinite resistance indicate an open circuit If an open circuit is detected disconnect and test progressively smaller lengths of the circuit until the faulty wiring is located 4 Test for intermittent faults by wiggling the connectors and or wiring while monitoring the meter Troubleshooting W3000489 T3009650 69 Group 3 Electrical System VN amp VHD Short Circuit The term short circuit is used to describe another type of condition which can develop in electrical circuits or units It refers to a circuit that is completed in the wrong way such as two bare wires touching each other so that the current bypasses part of the normal circuit If the short circuit is to a ground wire this can result in blown fuses open circuit breakers wiring or component overheat burned parts and insulation and of course non working components Hot smelly insulation is always a sign of trouble If the wire melts through there is no electrical path so the circuit then becomes open If the short circuit is to a power wire it can result in components operating at inappropriate times This occurs because
63. ina split plastic casing or braided tubing called a conduit This grouping of wires is called a harness Major wiring harnesses are joined by using multiple plug and receptacle connectors Each harness or wire must be held securely in place by clips or other holding devices to prevent chafing of the insulation Terminals used throughout the system are Deutsch Amp JAE KOSTAL and Packard Wiring Schematics The wiring schematics for VN VHD series vehicles are found in VN or VHD Series Electrical Schematics Group 37 These schematics are continuously updated to provide detailed vehicle specific wiring information Detailed instructions for schematic use is included in these binders The schematics feature Single circuit format Illustrated location of connectors on the vehicle Connector cavity circuit and function details Fuse numbers Wire numbers Splice details Vehicle variant details Simplified schematics are sometimes used in manuals and bulletins to help explain component design and function features or to clarify troubleshooting instructions These simplified schematics do not offer the level of detail needed for vehicle troubleshooting nor are they updated regularly Always use the schematics found in VN VHD Series Electrical Schematics Group 37 for the most current information 10 Design and Function Circuit Protection To protect wiring and equipment from overloads circuit protectors such as fu
64. l Door Lock Module Replacement Non Volvo Engines ws3002701 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the two bolts attaching the front cover of the TEC just above the ashtray Remove the front cover to gain access to both modules 3 Remove the ashtray from the ashtray housing Remove the 2 screws from the ashtray housing and remove the housing 93 Group 3 Electrical System VN amp VHD 94 1 Central Door Lock Module 2 Wiper Module W3002524 Service Procedures 4 Disconnect the module connector remove the mounting screws and remove the module Installation 1 Install the new module in the same location where the old module was installed Bolt the module in place with 2 torx bolts Tighten to 4 0 0 5 Nm 35 4 in lb Connect the module electrical connector 4 0 0 5 Nm 35 4 in lb 2 Check the new module for correct operation of the system 3 Install the ashtray housing using the two mounting screws Tighten the screws to 1 5 0 25 Nm 13 3 2 2 in lb Install the ashtray 1 0 25 Nm 1 5 3 3 2 2 in lb 4 Install the front TEC cover Tighten the bolts to 2 5 0 5 Nm
65. mp and alarm operation for the conditions listed Operation Indicator Lamp Alarm Mode Normal Flashes every 45 Silent seconds Alarm Active Flashes continuously Pulsating Low Battery Flashes every 45 Beeps every Warning seconds 45 seconds Timer Mode Flashes every 10 Silent seconds A 9 volt battery powers the smoke detector The low battery indicator should sound approximately one month before the battery is depleted To test the battery press and hold the test button for approximately 5 seconds If the battery is OK the alarm will sound as long as the test button is pressed Always test the alarm for proper operation after the battery has been replaced Design and Function ws002731 Fig 90 Smoke Detector Indicator Lamp Test Button 57 Group 3 Electrical System VN amp VHD The smoke detector alarm may be erroneously activated by cigarette smoke dust exhaust fumes etc In these cases the alarm may be temporarily silenced by pressing the test button or the disable switch on the left side of the dash This initiates the timer mode in which the alarm is silenced for 10 minutes then goes back to normal operation The timer mode can be initiated with the smoke detector in normal operation mode or after the alarm has been activated The simplified schematic below should only be used to clarify the design of the smoke detector For detailed vehicle specific schematics se
66. n power to energize the starter relay coil is supplied on wire number 284 The starter relay coil is grounded through the overcrank protection switch or a shorting jumper The overcrank protection OCP switch is located inside the starter This switch is optional Where the OCP switch is not used a shorting jumper is used to complete the starter relay coil ground circuit The OCP switch is designed to open and prevent the starter from turning if the starter becomes excessively hot It should reset when the starter cools sufficiently When the starter relay energizes a connection is made from the starter solenoid BATT terminal wire 285A to the starter solenoid SW terminal wire 285 When the solenoid pulls in a connection is made internally in the solenoid that connects the battery terminal to the motor terminal Then the starter begins to crank the engine See Fig 11 Starting amp Charging Circuit Simplified Schematic page 17 Design and Function W3004339 Fig 14 Overcrank Protection OCP Switch Fig 15 Starter Relay W3003757 Group 3 Electrical System VN amp VHD Charging Circuit With the engine running AC voltage is initially generated in the alternator s stator windings by passing magnetic fields from the rotor Diodes in the rectifier bridge change the AC voltage to DC voltage at the alternator B terminal As the alternator speed increases current is provided for charging the batter
67. ng nut 5 Connect the electrical connector and check horn operation 109 Group 3 Electrical System VN amp VHD 110 Service Procedures 3621 03 02 02 Air Horn Solenoid Replacement wo0001908 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Note The air horn solenoid may be located inside the right front frame rail near the radiator or inside the left frame rail near the drivers seat 1 Turn the ignition key OFF 2 Disconnect the electrical connector 3 AN WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious personal injury Bleed all air from the vehicle air brake system Use tool J 42189 to remove the two air lines from the solenoid Note It may be easier to remove the solenoid from its mounting location before removing the air lines 4 Remove the mounting bolts and remove the solenoid from the vehicle 5 Position the replacement solenoid in its mounting location and secure with mounting bolts 6 Connect the air lines and electrical connector Check horn operation Group 3 Elect
68. ngs for connectors Visual Inspection Before beginning electrical checks visually inspect the wiring and connectors e Inspect for corrosion in wiring or connectors See Corrosion page 74 e Check that terminal pins are not bent or damaged locked into their connectors and properly crimped e Check that the terminal pins make good mechanical contact with their mating pin See Contact Problems page 75 e To help locate intermittent faults wiggle the wire and connector while testing 73009648 68 Group 3 Electrical System VN amp VHD Open Circuit Whenever there is a complete break or interruption in the normal current path such as a break in wiring from the source of power to the electrical unit or within the unit itself current will not flow In a circuit current normally travels through the wires or cables to switches and electrical unit s such as the starter solenoid and cranking motor through another wire to ground and back to the source A break anywhere along this route results in an open circuit and the complete loss of power An ammeter will not register at all because there cannot be current flow through an open circuit A voltmeter depending on where it is placed in relation to the open circuit may or may not give a reading Checks N CAUTION Possible damage to electric electronic components Turn the vehicle OFF before connecting or disconnecting electrical components Fa
69. ning TIN sororaysiknasani eaii REEE 53 Supplemental Restraint Sys emi seiisisinniniecdieiessistersaleiaisiednneaseaions 54 VOO ECU paiia aa cietaiaes 55 Central Dogi Lock GGUS siveasrcaitesrnecicensdsonrasseanniaiteatacandeaednmateasninwae 56 oma NUE ranira iaa tap iaeatsted ceca Soc 57 Hari socaiecagucaumeoledayeenibil elowealeuainshnladainbadenaselstakadantolaselale bisa euanmeanam 59 TY Antenna and Speaker iso ccssticcstcscsctrsttcidienssaisinicies nianna aia 61 BPodyouldor VANGO inasai 63 TRCUDIESHIGOUNG 4 5 cin ei inde 67 Electrical System Troubleshooting eeccessceeneeeeneeeeeeeeeenersenereerens 67 EI SCIGal SU StS der E 67 Troubleshooting Using a Digital Multimeter ececceeeeeeeeeeeeeeeeeee 67 Troubleshooting Wiring and Connectors ccecceeeeeeeeeeeeeeeeeeteeeetees 68 S rvic PROCCMUNCS occcoieisisicuiiian ikiiki 79 Engine ECU Terminal Replacement cesseeseseseresesrereenereenerenees 79 JAE Terminal Replacement cescsicciecscsctcscstiescessssssinicrsieeesesereiniantenesecens 81 Minkiuse Roplatemeni sinisini 83 Relay Feplacemeni ncnreiorroce nE en NSA 84 Fusible Link Replacement Battery Side 0 0 eee eeeneeereeeerereeeeeesees 84 Fusible Link Replacement Ground Cable cc ecceeeseeeeeeeees 88 Central Door Lock Module Replacement esesessseeereeseereeeerees 91 Central Door Lock Module Replacement eseseeseseeereeserereenerees 93 Ignition
70. nsmission of data for diagnostic messages and gauges Modifying this circuit can cause these functions to fail 76 Troubleshooting T3009653 ite Afi T3009651 Group 3 Electrical System VN amp VHD Switch Troubleshooting Checking the continuity between pin or cavity positions in various operating positions may help troubleshoot switches The switch detail information in Switch Logic Diagrams page 37 or in the electrical schematics may be used as a guide when checking for proper switch operation Troubleshooting information on specific switches may also be found in various service information that deals with specific components or systems Electronic Control Unit ECU Troubleshooting Generally there is no actual testing of electronic control units or electronic modules Electronic control unit module connector wire input or output may be tested but caution must be used not to introduce problems where none exist Simple troubleshooting of such things as power and ground supply or sensor continuity may be attempted with the ECU disconnected If tests exist for an ECU the details of those tests will be covered in the service procedures for that ECU Troubleshooting 77 78 Group 3 Electrical System VN amp VHD Service Procedures Service Procedures Engine ECU Terminal Replacement 2636 72012121 You must read and understand the precautions and guidelines in Service Informati
71. nt Moore J 42395 Rheostat Removal Tool Kent Moore 20378326 Fuse Puller Tool Volvo J 42396 Window Mirror Switch Removal Tool Kent Moore J 38125 8 Packard Crimper Kent Moore J 43244 Relay Puller Tool Kent Moore Group 3 Electrical System VN amp VHD Design and Function Electrical General Typical Circuit Components page 10 Data Link Communication page 13 Starting and Charging System page 17 Fuse and Relay Locations page 32 Switches and Controls page 36 Instrumentation page 52 Lighting System page 53 Supplemental Restraint System page 54 Vehicle ECU page 55 Central Door Lock Module page 56 Smoke Detector page 57 Horn page 59 Bodybuilder Wiring page 63 Design and Function Group 3 Electrical System VN amp VHD Typical Circuit Components Wiring Harnesses Wires amp Connectors Each circuit uses a wire of a specific size based on the current demands for that circuit The circuit number is stamped into the insulation every 76 mm 3 in This aids in proper connections and simplifies circuit tracing Black numbered wires are fused powered circuits White wires are ground Red wires are hot at all times and protected by fusible links Multi colored wire harnesses may be used as interfaces to some components the definition of those multi colored wires varies by component Some wires are grouped together and encased
72. nts circuit types controls connectors and the tools commonly used for maintenance For vehicle specific electrical wiring refer to the VN and VHD electrical schematics in Group 37 Group 3 Electrical System VN amp VHD Tools Tools Special Tools The following special tools may be needed when troubleshooting wiring and connectors The tools can be ordered from Kent Moore 800 328 6657 or Volvo as indicated 999 8534 wo0001767 Fig 2 Special Tools J 42472 2 pin Breakout Harness Kent Moore 9998551 60 pin Breakout Box Volvo J 41133 5 pin Breakout Harness Kent Moore J 43340 Overlay for 60 pin Breakout Box J 43147 2 pin Breakout Harness Kent Moore ene Meare J 42449 JAE Terminal Removal and Probe Kit 9998534 4 pin Breakout Harness Volvo Kent Moore J 43233 36 pin Jumper Harness Kent Moore 3949522 VN Cab Terminal Kit Volvo J 43234 Adapter Kent Moore 3949523 VN Chassis Terminal Kit Volvo TEE aiv Breakout Box KentiMootey 3947553 D12 Engine Harness Terminals Volvo Group 3 Electrical System VN amp VHD Tools Special Equipment The following items can be ordered from the vendors listed 20378326 CANNY SANN TND A we a BT 8639 B J 38125 8 wo0001909 Fig 3 Special Equipment J 25070 Heat Gun Kent Moore J 42189 Air Line Removal Tool Kent Moore J 39200 Fluke 87 Digital Multimeter Kent Moore BT 8639 B Anti Static Wrist Strap Ke
73. o the connector until it locks Pull on the wire gently to insure the terminal is locked Install the terminal locking plate in the connector 7 Tape the wire harness and conduit from where the tape was removed 8 Install the tie strap fastening the wire harness to the connector housing Install the screws for the connector housing and clamp 9 Insert the connector back into the control unit and lock the clamp Group 3 Electrical System VN amp VHD Service Procedures JAE Terminal Replacement W3002865 W3002866 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it JAE connectors are used on the Vehicle ECU VECU and on the instrument cluster To replace faulty terminals in these connectors use the butt splice connectors listed below available from Volvo e 3948725 for black numbered wires e 3978726 for ground wires Special tools 3949522 J 42449 J 38125 8 J 25070 Removal 1 Disconnect the JAE connector with the faulty terminal from the component 2 Carefully pry open the lock on the male portion of the connector using a small flat screwdriver Note The lock is not easy to see To open the lock pry just under the top ledge of the connector see figure
74. on A312NC PTO from Allison Transmission A177 Alison Tranemiseion A312NO PTO from Allison Transmission A178 Allison Transmission A312CM PTO from Allison Transmission 64 Group 3 Electrical System VN amp VHD Bodybuilder Lighting Junction Box Design and Function W3004413 Fig 98 Bodybuilder Junction Box and Trailer Receptacle End of Frame Installation A junction box at the back of the cab is also standard in VHD models It is usually mounted on the left side under the cab It may optionally be located at the end of the frame or a trailer receptacle may be installed The junction box contains the same 7 wires for rear circuits as the trailer receptacle The Volvo circuit numbers for the standard wire colors are listed below 12 3 4 5 6 7 W3004412 Fig 99 Bodybuilder Junction Box Inside View Color Circuit Description 1 White OT Ground 2 Black 53 ICC Trailer Marker 3 Yellow 112 LH Turn Signal Light 4 Red 72 Stop Lights 5 Green 113 RH Turn Signal Light 6 Brown 51 Trailer Marker and Tail Lamps 7 Blue Aux Auxiliary 12V ignition power 65 Group 3 Electrical System VN amp VHD Bodybuilder Option Connectors Four bodybuilder option connectors are in the cab and engine harnesses These wires provide a pass through for add on wiring from the engine compartment to inside the cab They are single wires with plugged connectors circuit numbe
75. on group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Note The tools used in this procedure can be found in repair kit 3947553 Special tools 9512636 9998482 1078054 1 Remove the screws for the connector housing locking clamp and the connector housing Cut the tie strap fastening the wiring harness to the connector housing Remove the terminal locking plate from the connector Remove the faulty terminal from the connector using tool 9512636 from VE D12 Engine Kit 3947553 9512636 3 Remove the tape from the wiring harness and conduit Cut the wire that has the faulty terminal to the correct length for proper installation 79 Group 3 Electrical System VN amp VHD ad ea EE ee I a 72011829 ACIS 72011830 80 Service Procedures Strip the insulator back on the end and crimp the replacement terminal splice 1078054 from VE D12 Engine Kit 3947553 Crimp the butt splice connector housing crimpers 3947557 Packard crimpers 12085115 in the 18 20 anvil Pull gently on the connection to check for a proper crimp 1078054 3947557 5 Use heat gun J 25070 or equivalent tool on the butt splice insulator until the insulator shrinks around the wire and sealant is visible to ensure the connection is sealed J 25070 6 Insert the terminal int
76. or damage to property Warning Indicates a potentially hazardous situation which if not avoided could result in death serious injury or major damage to property Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Volvo Trucks North America Inc Greensboro NC USA Order number PV776 20 007111 Repl This Service Manual replaces Service Manual Electrical General VN from 2 98 and VHD 08 2000 publication number PV776 TSP145645 2004 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc USA15172 Contents RAG GGN sesioa aaa aaa 5 Gonera Nonn ANO i s 5 Ee A A AEE EEA AE AA A T PA T E AEE A EA 7 Spoel TOIS aian S 7 Spaca EGUDMONI sorisa eE 8 Design and FUNCTION ssccogincariaieena anes 9 Elesmica General isre oie incinineit minnie isan O 9 EE E E E A beanies aladaMtalieiad 10 Typical Circuit GOMPONGMIS s cccccctsctsiceasstcesenssnteicresseneesscassiananseeesciens 10 Data Link Comimm nitalloh sssusa 13 Staring and Charging System sissxismasiiisiasiiei inanin 17 Fuse and Relay Locations ssssisiiisessinsnirinpi 32 PIL MSS and SONGS sararins inii a a A 36 MeRUMEM OGON acien ea 52 Gia
77. power that normally should be supplied by one component switch or circuit is bypassed by the short circuit and power is supplied by a different switch or circuit 70 Troubleshooting W3000490 Short circuit to ground 2H II W3002836 Short circuit to power wire Group 3 Electrical System VN amp VHD Troubleshooting Checks Short circuit to ground 1 Visually inspect the circuit 2 Turn ignition key to ON or ACCESSORY as necessary 3 Activate the suspect circuit and check if the fuse blows or if there is excessive current draw 4 Z N CAUTION Possible damage to electric electronic components Turn the vehicle OFF before connecting or w3003970 disconnecting electrical components Failure to de energize circuits may result in electronic equipment damage Turn the ignition key to OFF Disconnect the connectors at both ends of the wiring harness 5 Measure resistance using multimeter J 39200 or equivalent tool between the end of the wire and ground The expected value is OL infinite resistance Low resistance readings may indicate a circuit shorted to ground If a short circuit is detected disconnect and test progressively smaller lengths of the circuit until the faulty wiring is located 6 Test for intermittent faults by wiggling the connectors and or wiring while monitoring the meter Z N CAUTION Do not check a short circuit by using a jump
78. procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the city horn buttons by inserting a small flat tip screwdriver No 1 under each of the 2 horn buttons as shown Gently pry up on the button and remove 3 Remove the contact strip under the button 107 Group 3 Electrical System VN amp VHD 108 W3000793 Service Procedures Installation 1 Install the city horn buttons by first installing the contact strip Then insert the button toward the inside of the steering wheel making certain the dowel is aligned with the hole in the steering wheel Push the button into place Group 3 Electrical System VN amp VHD Service Procedures 3621 03 02 03 City Horn Replacement You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Note The city horn is generally located on the left side in front of the radiator on the VHD and inside the left front frame rail on the VN 1 Turn the ignition key OFF 2 Disconnect the electrical connector 3 Remove the mounting nut securing the horn to the bracket Remove the horn from the vehicle 4 Position the replacement horn in the mounting bracket Secure with the mounti
79. rature and oil pressure as well as the graphic display and indicator lamps Optional pyrometer and turbo gauges may be installed The Info and Stop warning lamps are on this side and are used to warn of engine cautions and engine shutdowns The other lamps are for low engine fluid and preheater The center group is always the same regardless of which options are installed on the vehicle The center instrument group contains in addition to a number of indicator and warning lamps the tachometer and speedometer odometer The right hand instrument section contains the fuel and brake pressure gauges and the remainder of the warning lamps Axle temperature and air pressure gauges may be installed Note that all gauges and telltales may not be used in all vehicles 52 Group 3 Electrical System VN amp VHD Design and Function Lighting System The lighting system of the VN VHD series may incorporate different design lamp assemblies for each vehicle type The headlights on the VN use replaceable halogen bulbs that fit into a reflector housing The VHD uses the more traditional sealed beam bulbs Daytime running lights turn the low beam headlights on whenever the ignition switch is on and the park brake is released Fog and driving lights are available When switched on these lights will alternate between fog lights with the headlamp low beams on and driving lights with the headlamp high beams on For more information on the lig
80. re performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the two bolts attaching the front cover of the TEC just above the ashtray Remove the front cover to gain access to the central door lock module 3 Remove the ashtray from the ashtray housing Remove the 2 screws from the ashtray housing and remove the housing 4 Clip the wire ties along the top of the Vehicle ECU to free the harness Unplug the connector to the Central Door Lock Module Remove the mounting screws and remove the module 91 Group 3 Electrical System VN amp VHD 92 Service Procedures Installation 1 Install the new module in the same location where the old module was installed Bolt the module in place with 2 torx bolts Tighten to 4 0 0 5 Nm 85 4 in lb 4 0 0 5 Nm 35 4 in lb 2 Reconnect the module electrical connector Install wire ties to the VECU harness Remove any excess wire tie 3 Install the ashtray housing using the two mounting screws Tighten the screws to 1 5 0 25 Nm 13 3 2 2 in lb Install the ashtray 1 5 0 25 Nm 13 3 2 2 in lb 4 Install the front TEC cover Tighten the bolts to 2 5 0 5 Nm 22 1 4 4 in lIb 2 5 0 5 Nm 22 1 4 4 in lb Group 3 Electrical System VN amp VHD Service Procedures 3645 03 02 05 Centra
81. rical System VN amp VHD Service Procedures 3643 03 02 01 Turn Signal CC Switch Assembly Replacement W8002166 W3000653 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Remove the 2 clips at the bottom of the steering column cover 3 Adjust the steering column up and toward you where possible Remove the front steering column cover by removing the 3 torx bolts from the cover and sliding the rubber grommets off of the cover 111 Group 3 Electrical System VN amp VHD ws002165 W3000643 112 Service Procedures 4 Push the steering column forward and up where possible Remove the 3 torx bolts from the rear column cover and remove cover 5 Disconnect all electrical connections for turn signals cruise and headlamp dimmer switch Remove the 2 torx bolts on the sides of the switch and remove switch Installation 1 Mount the switch assembly to steering column with the 2 bolts and connect all electrical connectors Tighten bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in Ib 2 Pull steering column back and up where possible Install front cover by installing torx bolts Tighten bolts to 5 0 8
82. rovides a ground connection to the Ignition Power Relay Coil PR2 From the Ignition Power Relay PR2 wire OR N provides a ground to the Ignition Power Relay Coil PR3 From this Ignition Power Relay the ground connection OR M goes to a passenger side interior ground stud number 18 in W3004398 Fig 18 Accessory Power Relay PR1 GND STUD GND STUD 18 GND STUD W3002759 Fig 19 Ground Studs inside cab passenger side under heater unit 23 Group 3 Electrical System VN amp VHD Design and Function Accessory Power Supply Schematic 195 195 A BUS BAR ACCESSORY FUSES ACCESSORY RELAY PR1 BATTERY POWER eee IGNITION L R Ta OR R POWER RELAY PR3 IGNITION SWITCH OR N IGNITION POWER RELAY PR2 BATTERY L POWER OR M STUD 18 INTERIOR SIDE W3004346 Fig 20 Accessory Power Supply This simplified schematic should only be used to clarify the design features of the VN VHD accessory power supply circuit For detailed vehicle specific schematics see the VN or VHD Electrical Schematics Group 37 24 Group 3 Electrical System VN amp VHD Ignition Power Supply W3004397 Fig 21 Ignition Power Relays 1 PR2 2 PR3 3 PR4 4 R24 GND STUD GND STUD GND STUD W3002759 Fig 22 Ground Studs inside cab passenger side under heater unit Design and Function N CAUTION The ignition and batt
83. rs 999A 999B 999C 999D They are located near the engine pass through on the engine side and inside the dash on the cab side For more information see Bodybuilder service information in Group 9 66 Design and Function W3004414 Fig 100 Option Connectors Driver Side Engine Compartment Group 3 Electrical System VN amp VHD Troubleshooting Troubleshooting Electrical System Troubleshooting e Troubleshooting Using a Digital Multimeter page 67 e Troubleshooting Wiring and Connectors page 68 e Switch Troubleshooting page 77 e Electronic Control Unit ECU Troubleshooting page 77 Electrical System Troubleshooting Using a Digital Multimeter A Digital Multimeter DMM is one of the most important tools available for electrical troubleshooting A multimeter such as a Fluke 87 is recommended for troubleshooting It provides diagnostic capabilities such as current amperage resistance and voltage tests as well as specialized features for automotive troubleshooting Always consult the DMM manufacturer instructions for the proper use of the meter before beginning testing Before using the DMM to measure resistance check its calibration by touching the leads together If there is a reading other than zero subtract it from measurements made with the DMM Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so c
84. s engine ECU satellite system etc connect the battery ground cable first then connect those grounds Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always reconnect the main battery ground first Connect the battery positive and negative cables connecting the positive cable first Tighten nuts to 24 4 Nm 212 35 in Ib 87 Group 3 Electrical System VN amp VHD Service Procedures 3714 03 02 01 Fusible Link Replacement Ground Cable W3002567 1 Ground Side Fusible Link 2 Starter Ground Stud 3 Engine Ground location varies by engine T8006862 88 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 To verify ground fusible link failure check for a visible break in the fusible link 1 2 Turn the ignition key OFF and disconnect the negative and positive battery cables 3 Loosen the bolt on the battery cable clamping bracket This will allow the negative battery cable to be removed Group 3 Electrical System VN amp VHD Service Procedures 4 Remove the nut from the ground stud at the starter solenoid and remove the fusible link terminal from the starter
85. s part of the normal circuit In this instance the current flows directly to ground This may be caused by a wire touching ground or part of the circuit within a unit coming in contact with the frame or housing of the unit A grounded circuit may also be caused by deposits of oil dirt and moisture around connections or terminals Checks 1 Visually inspect the circuit 2 Turn ignition key to ON or ACCESSORY as necessary 3 Activate the suspect circuit and check if the fuse blows or for excessive current draw 4 Z N CAUTION Possible damage to electric electronic components Turn the vehicle OFF before connecting or disconnecting electrical components Failure to de energize circuits may result in electronic equipment damage Turn the ignition key to OFF Disconnect the connectors at both ends of the wiring harness 5 Measure resistance using multimeter J 39200 or equivalent tool between the end of the wire and ground The expected value is OL infinite resistance Low resistance readings may indicate a grounded circuit If a grounded circuit is detected disconnect and test progressively smaller lengths of the circuit until the faulty wiring is located 6 Test for intermittent faults by wiggling the connectors and or wiring while monitoring the meter Z N CAUTION Do not check a short circuit by using a jump wire across the fuse terminals or by installing an oversized
86. ses are used Circuit breakers and fusible links are also used Z N CAUTION Failure to use proper circuit protection devices in the vehicle can result in damage to the vehicle and its components Replace blown fuses only with fuses of the same rating Replace fusible links only with proper replacement parts of the exact gauge and length Failure to use proper circuit protection could overload the circuit causing severe damage to the vehicle Fuses W3000484 Fig 4 Blade type Fuses 1 Good fuse 2 Blown fuse The most common protector in the vehicle circuit is a fuse A fuse consists of a fine wire or strip of metal inside a glass tube or more commonly in a plastic housing The strip melts and interrupts the flow of current in the circuit when there is an overload caused by an unwanted short or ground The fuse is designed to melt before the wiring or electrical components in a circuit can be damaged Naturally the cause must be located or the new fuse will also blow Since different circuits handle different amounts of current fuses of various ratings are used Be sure to replace a blown fuse with a fuse of the same rating The VN VHD vehicles use maxi fuses which are designed for a larger amount of current than a regular fuse Mini fuses are also used They are smaller in size but their current ratings are the same as ATO blade type fuses Group 3 Electrical System VN amp VHD Fusible Links
87. strip cools down it remakes the contact Type 2 circuit breakers are opened by current overload and remain open as long as the power is on A Type 2 circuit breaker keeps the bimetallic strip hot after tripping by diverting a small amount of current through a small coil of resistance wire If power to the circuit breaker is switched off long enough for the bimetallic strip and resistance wire to cool down the breaker will automatically reset When any circuit breaker trips it should be viewed as an indication of a possible fault in the circuit Every effort should be made to identify and correct the fault if one exists Design and Function Switches and Relays Circuit controls are switches or relays Switches are usually at the beginning of a circuit but can be used to control a ground path For example the switch controlling the headlights is at the power end of the circuit while the door switch controlling the dome light completes the circuit to ground Relays are remotely controlled switches They use a low current signal through a coil to control larger currents conducted through their contacts VN Series vehicle circuits also include micro relays The micro relay is smaller in size than a conventional relay and the pin arrangement is different see illustration 86 30 87A E 87 C D 87A 87 85 85 W3000777 Fig 5 Relay Pin Arrangement and Schematic 86 87A 85 W3000778 Fig 6 Micro relay Pin Arrangement and
88. tact on terminal pins begin by visually inspecting the connector For the Volvo engine ECU connector pins use gauge 9998482 found in kit 3947553 to check for proper contact e Insert the gauge into the terminal e Move the gauge in and out of the terminal to check that the terminal has proper clamping force on the gauge If the terminal does not have any clamping force is weak or loose the terminal must be replaced To replace the terminal see Engine ECU Terminal Replacement page 79 For the JAE connector pins used on Vehicle ECUs and the instrument cluster use tool J 42449 1 found in kit J 42449 to check for proper contact e Insert the gauge into the terminal e Move the gauge in and out of the terminal to check that the terminal has proper clamping force on the gauge If the terminal does not have any clamping force is weak or loose the terminal must be replaced To replace the terminal see JAE Terminal Replacement page 81 For other types of terminal pins or connectors use a new mating terminal of the correct type to check for proper contact Several types of terminals can be found in kits 3947553 3949522 and 3949523 If the terminal does not have any clamping force is weak or loose the terminal must be replaced Note Excessive use of the test gauge will degrade the clamping force of the mating terminal and may cause additional intermittent faults Troubleshooting W3003965 W300396
89. the button is pressed Operation Numbers of 14 03 02 02 Fusible Link Replacemant Battery Side ssiscsccicietsaneaiscsrnectediniasnenlansshisigiiaebubalneamoniniaieenlnosnialainiedbinleien 84 3714 03 02 01 Fusible Link Replacement Ground Cable ssori aeaio ERE EENAA 88 3645 03 02 05 Central Door Lock Module Replacement ciicisiiscisseisiersciscisicinvessveineisieiaveiveiaternneisieisiesavernrsieeiieettiointe 91 3645 03 02 05 Central Door Lock Module Replacement sscccsccessereseseeeenecsenersenenesensnneneeeesnonessonensnnensnenenneeeneners 93 3341 03 02 01 Ignition SWwilen Replacement sucrina niente shied aides aa i 95 3341 03 02 02 Ignition Switch and Housing Replacement x isccsminnsossssaseensnsascannensmesunecnncmnmonseanmeniinndaneshionuernstesaxetmenstedaneds 98 3623 03 0202 Air Hori Contech ReplacemMeni oruinn ea O A aaa EEE Ea EE OE 102 3623 03 02 04 City Hori Contact REpiacemenl nsnivisnicinicidiarsiinnn a N E 107 3021 09 0203 Giy Horn EP IES IU sacru E O E eomeeN eae 109 3621 03 02 02 Air Horn Solenoid Repla emei o iscdiisccvicrinioineunscisicinencorneimaiiecineinvornetinteinvaievoreeieeniaieiamenancinielviai 110 3643 03 02 01 Turn Signal CC Switch Assembly Replacement ssessssssnessnesrnennernnrsnnrrnnrrnnsrnnsnnnsnnrnnnennnennrrnanrnannnenneena 111 3646 03 02 11 Hazard Warning Switch Replacement s sssesseessresssrnnsrnasrnasrnnsnnesnnesnnranrnannnansnnnsnnnnnnnnnnnaannnantaannnan nnana 114 3646 03 02
90. the contact out from the horn button area Group 3 Electrical System VN amp VHD W3000792 Service Procedures Installation 1 Insert the wire through the hole in the steering wheel where the old contact was Align with the tab on the contact housing 2 Install the horn contact ring onto the steering shaft The ring should slide down over the shaft Route the wires as they originally were and connect the electrical connector 3 Adjust the steering shaft forward and up where possible Install the rear cover of the steering column Tighten the 3 bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 4 Install the 2 clips on the bottom of the steering column covers and slide the rubber grommets onto the stalk switches 105 Group 3 Electrical System VN amp VHD 106 W3000790 Service Procedures 5 Install the steering wheel onto the shaft lining up the marks Install a new bolt and tighten to 85 Nm 62 7 ft lb 85 Nm 62 7 ft lb Install the air horn button by connecting wire connectors and pushing the button into the steering wheel Group 3 Electrical System VN amp VHD Service Procedures 3623 03 02 04 City Horn Contact Replacement W3000782 W3000793 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this
91. the inner and outer cable harnesses The passenger side pass through contains wiring for chassis mounted components The driver s side pass through contains wiring for components mounted under the hood Both pass throughs consist of a protective outer housing and an attachment plate which holds the connectors in position The pass through covers can be opened from the outside The cab main power studs are located at the left hand side pass through Torque for the main power studs is 10 2 Nm 7 4 1 5 ft lb W3004365 Fig 32 Cab Electrical Pass Through passenger side The Bodybuilder pass through may be installed in VHD engine compartment models It is present only if the Bodybuilder prep kit has been installed It is located in the center of the cab floor between the seats in the center console mounting plate 1N Dy KD RE eK W3004417 Fig 31 Bodybuilder Pass through in Center of Cab Floor 1 Bodybuilder Harness from A pillar W3004402 2 Bodybuilder Pass through Wiring Fig 33 Main Cab Electrical Pass Through driver side engine compartment 1 Pass through for main cab wiring 2 Pass through for Allison transmission wiring if equipped VHD model only 31 Group 3 Electrical System VN amp VHD Fuse and Relay Locations Design and Function Fig 34 TEC in Center Dash The vehicle s instrumentation gauges and other electrically controlled parts are wired through the Truck
92. the panel by inserting tips on right side and pushing the panel into position The clips will snap in place on the left side i W3000647 128 Group 3 Electrical System VN amp VHD Service Procedures 3646 03 02 12 Dash Dimmer Control Switch Replacement W3000641 a cs A W3000650 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 Z N CAUTION 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 Remove the two screws at the top of the instrument cluster and lay the cluster face down on the steering column if steering column is adjustable adjust as far back as possible before leaning cluster out 3 To release the dimmer switch panel reach behind the panel and depress the top and bottom clips on the left side 129 Group 3 Electrical System VN amp VHD Service Procedures 4 Pull the panel through the front of the dash pulling toward the driver s side to clear tip inserts W3000996 5 Once the panel is removed install instrument cluster back in its original position
93. trical System VN amp VHD Design and Function Vehicle ECU W2002673 Fig 89 VECU Vehicles with Volvo engines built after February 1998 are equipped with a Vehicle Electronic Control Unit VECU located under the fuse and relay panel The VECU is accessible by removing the front TEC panel The VECU receives inputs and generates output signals for functions associated with cab devices It also converts information into digital data to be broadcast over the J1708 J1587 Information Data Link and the J1939 Control Data Link Note the VECU may also be referred to as the Cab Controller on the graphics display of the instrument cluster and in some other Volvo publications Each VECU is programmed with a specific vehicle dataset according to what the customer has ordered for that vehicle This dataset is stored in the VECU memory making the VECU unique to each vehicle For this reason it is not possible to swap a suspected faulty VECU with one from another vehicle without reprogramming the replacement VECU For more information on the design and troubleshooting of the VECU see Paper Vehicle Electronic Control Unit MID 144 PV776 TSP29763 1 Impact Function Group 364 Info Type Description 55 Group 3 Electrical System VN amp VHD Design and Function Central Door Lock Module W3000553 Central door locks are an optional feature The central locking can be activated from either the passenger or driver
94. ull on the clock to make certain it is locked in the panel 2 VN 420 610 660 Loosely install the control panel and vent bezel The right side panel tabs must fit into the bezel slots Secure with screws VN770 Install the sleeper control panel and secure with screws Group 3 Electrical System VN amp VHD Service Procedures 3935 03 02 01 TV Speaker Headphone Jack Replacement W3004368 Sleeper Control Panel Rear View 2 3 4 Speaker Mounting Screws TV Speaker Connector TV Harness Connector TV Jack You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF Turn off the power to the TV 2 Remove the six screws from the sleeper control panel Pull the panel cover away from the bunk wall 3 Disconnect the TV speaker and harness connector 4 Remove the two mounting screws for the TV speaker Remove the TV speaker 5 To remove the TV speaker jack remove the nut on the front with a 1 2 inch socket and remove the jack Installation 1 Install the replacement TV speaker into the control panel with the two mounting screws 139 Group 3 Electrical System VN amp VHD 140 Service Procedures 2 Install the replacement spe
95. vice Procedures 3623 03 02 02 Air Horn Contact Replacement without SRS Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Removal Air Horn Button and Horn Contact 1 Turn the ignition key OFF 2 Remove the horn button for the air horn center of steering wheel using a No 1 flat tip screwdriver Place the screwdriver between the horn button and steering wheel and gently pry up on the button W3000789 102 Group 3 Electrical System VN amp VHD Service Procedures 3 Remove the wire connectors from the underneath side of the button Ww3000790 4 Remove the bolt from the steering wheel Pull the steering wheel from the steering shaft ws3000791 1 Horn Contacts 2 Contact Assembly 5 Remove the 2 clips at the bottom of the steering column cover Slide the rubber grommets off of the cover at the stalk switches 6 Adjust the steering column up and toward you where possible Remove the 3 torx bolts from the rear column cover and remove cover 103 104 Group 3 Electrical System VN amp VHD W3000792 Service Procedures 7 Disconnect the connector for the horn contact Remove the contact assembly from the steering shaft 8 Remove the contact in the steering wheel with a No 1 flat tip screwdriver Push
96. w o OCP ONLY TO IGN SWITCH lt __ 284 STARTER RELAY 990 W3004350 Fig 11 Starting amp Charging Circuit Simplified Schematic This simplified schematic should only be used to clarify the design features of the VN VHD starting and charging circuit For detailed vehicle specific schematics see the VN or VHD Electrical Schematics Group 37 17 Group 3 Electrical System VN amp VHD Batteries Design and Function W3004394 Fig 12 Typical Battery Box Locations VN VHD generally will use groups of three or four 12 volt batteries All batteries are wired in series with the battery cables going directly to the starter There are no frame rail grounds that go directly to the battery set Battery box locations vary per application The VN series and some VHD models have the battery box on the left frame rail under the cab steps As an option some vehicles may have a master battery disconnect switch main switch The switch will be mounted on or near the battery box in all applications The battery disconnect switch can be used to cut all positive battery power to the vehicle Note The battery disconnect switch should not be used as a substitute for removing battery cables to prevent damage to the vehicle when welding 18 W3004404 Fig 13 Battery Disconnect Switch Group 3 Electrical System VN amp VHD Starting Circuit When the ignition switch is turned to the START positio
97. wire across the fuse terminals or by installing an oversized fuse in the fuse panel This could cause damage to the electrical system 71 Group 3 Electrical System VN amp VHD Checks Short circuit to power 1 Visually inspect the circuit 2 Turn ignition key to ON or ACCESSORY as necessary 3 Activate the suspect circuit and check to see if another inappropriate circuit operates at the same time 4 Z N CAUTION Possible damage to electric electronic components Turn the vehicle OFF before connecting or disconnecting electrical components Failure to de energize circuits may result in electronic equipment damage Turn the ignition key to OFF Disconnect the connectors at both ends of the wiring harness of each affected circuit 5 Measure resistance using multimeter J 39200 or equivalent tool between the ends of the wires of each affected circuit The expected value is OL infinite resistance Low resistance readings may indicate the circuit shorted together If a short circuit is detected disconnect and test progressively smaller lengths of the circuit until the faulty wiring is located 6 Test for intermittent faults by wiggling the connectors and or wiring while monitoring the meter 72 Troubleshooting W3003969 Group 3 Electrical System VN amp VHD Grounded Circuit A grounded circuit is similar to a short circuit in that the current bypasse
98. witch and both cigar lighter connectors Group 3 Electrical System VN amp VHD Service Procedures 4 Align and install switch panel in dash 5 Install ashtray housing with the 2 mounting screws and place ashtray in housing Tighten screws to 0 4 0 1 Nm 3 5 1 in Ib 0 4 0 1 Nm 3 5 1 in lb 3646 03 02 06 Headlamp Parking Lamp Switch Replacement W3000641 You must read and understand the precautions and guidelines in Service Information group 30 General Safety Practices before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Removal 1 Turn the ignition key OFF 2 N CAUTION 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 Remove the two screws at the top of the instrument cluster and lay the cluster face down on the steering column if steering column is adjustable adjust as far back as possible before leaning the cluster out 123 Group 3 Electrical System VN amp VHD Service Procedures 3 To release the switch panel reach behind the panel and 37 depress the top and bottom clips on the left side ba yy AA ee Le ee aS ee ate oe oe A lA d D e M SAN Aa W3000650 4 Pull the panel through the front of the
99. witches Temperature Control Cigarette Lighter 12V Power Switch to Left Tower Cabinet Headphone Jack OANDOaABRWND 45 Group 3 Electrical System VN amp VHD Design and Function Ignition Switch ENGINE DEPENDENT ay a a DR ii x 4 a Slo re er i DR dso B 2 0 t ace O i a ioe AST 1 hs o gt I D E ea N I x 1 co O i Sea be ede SP x S O rer ae Z Ll B o aka 243 W3000687 Fig 79 Ignition Switch Connector Detail W3004344 Fig 80 Ignition Switch Logic Diagram Note Numbers inside parenthesis are circuit numbers The ignition switch is mounted in the key lock assembly It is a single switch of a double contact design there is no separate start button The chart below gives the pin and circuit description Note The ignition switch and door locks use the same laser cut key Laser cut keys require special key cutting equipment that most locksmiths will not have Replacement keys can be ordered from Volvo by key code Pin Circuit No Description R 195 To accessory power relay coil B 243 12V Battery supply 50 284 Starter relay feed P Not used 30 243A 12V Battery supply 19 Engine dependent VOLVO Preheat request VOLVO 245 Detroit Diesel Shutdown override relay feed Detroit Diesel 591 15 196 To ignition power relay coil DR 196DR Ignition feed 46 Group 3 Electrical System VN amp VHD Design and Function Stalk Switches Wiper

Electrical General VN from 2/98 and VHD

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