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Starting and Charging - VN,VHD - Heavy Haulers RV Resource Guide

1. 4 Set the volt switch to the INTERNAL VOLTS posi tion Connect the clamps from the tester to the positive and negative A amp B battery jumper stud posts 2 Zero the ammeter if neccessary 3 Clamp the inductive amp probe around the output cable from the B post X at the alternator Be sure that the inductive amp probe is pointing the proper direction 4 Turn the ignition key to ON and note the amps 38 draw FUSIBLE STARTER LINK 5 W3004738 Start the engine and run at high idle Note Engine speed must be above approximately 1700 RPM to achieve maximum alternator output While observing the volt and amp gauges on the meter adjust the load knob to obtain maximum al ternator output Use caution not to go below 12 volts when applying the load Also note the red STATOR DIODE LED If the LED glows steady red it indi cates that a diode or the stator is faulty Note the maximum alternator output observe in step 6 Add the current draw obtained in step 4 This is the total alternator output which should be a mini mum of 85 percent of the rated alternator output Note The rated alternator output can be found on the alternator identification tag Group 33 Starting and Charging VN VHD Troubleshooting Starting and Charging System with The Accuracy Plus Tester The J 44700 Accuracy Plus Tester will test the starting and charging system for the following e Battery open c
2. connected Disconnect the main battery ground last 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 in the vehicle This applies only to vehicles with SRS and Cummins or Detroit Diesel engines Check for fault codes after repairs are complete 47 Group 33 Starting and Charging VN VHD Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as the ECU s satellite systems etc 3 Disconnect the main ground cable s at the batteries 4 Disconnect the positive cable s at the batteries 5 Remove the battery nuts on all battery connections and remove all cables and wiring 6 Clean any battery post or cable termi nals as necessary Installation 7 Replace the defective battery inter connecting cable s 8 Install all battery cables and wiring connections removed in step five 5 Install the battery nuts hand tighten securing the cables wiring 9 Connect the positive cable s and pos itive wi
3. flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounas first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last 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 in the vehicle This applies only to vehicles with SRS and Cummins or Detroit Diesel engines Check for fault codes after repairs are complete 44 Service Procedures Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Note Some applications will require the removal of air fairings battery box covers or other components to ac cess the batteries Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from electri cal equipment connected directly to the batteries such as ECU s satellite systems etc 3 Disconnect the main ground cable s at the batteries 4 Disconnect the
4. ies in the other vehicle This is so the cranking current is carried through the proper starter wiring To access the batteries on a vehicle equipped with side fairings open the fairing access cover Jumper Studs which are longer and made of brass are factory installed on one battery positive and negative post These jumper studs are designed to accept the jumper cable claws Connect the jumper cables to the positive or hot terminal first and the ground terminal last When discon necting the cables disconnect the ground terminal first Connect the jumper cable clamps to the discharged bat tery first and to the booster battery last Avoid creating sparks by making all connections quickly and firmly Do not permit the vehicles to touch each other when jump starting 43 Group 33 Starting and Charging VN VHD 3111 03 02 02 Battery Replacement One or Two AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open
5. 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 within the vehicle This applies only to vehi cles with SRS and a Cummins or Detroit Diesel engine Always check for fault codes after repairs are completed If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Service Procedures Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Note In some installations the replacement of the starter may be aided by the removal of additional com ponents or wiring not referenced in this manual or affected by alternate battery cable routing due to alter nate battery mounting locations Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the main battery ground cable s 4 Remove t
6. 47 Battery Cables Removal and Installation 2 41 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http Awww volvotrucks volvo com PV776 TSP146025 0000 01 2001 Volvo Trucks North America Inc 2001
7. ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Service Procedures W3004732 See removal and installation procedures following this illustration for explanation of numbers 1 to 6 shown in above illustration Note In some installations the replacement of the starter may be aided by the removal of additional com ponents or wiring not referenced in this manual or affected by alternate battery cable routing due to alter nate battery mounting locations Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as the ECU s satellite systems etc 3 Disconnect the main battery ground cable s 4 Remove the splash shield 5 Remove the inner fender assembly 49 Group 33 Starting and Charging VN VHD 6 Loosen or remove the battery cable mounting support brackets if needed to allow enough slack for removal of the battery cable terminals at the sta
8. Telltale Lamp page Lamp Op age Lamp Off 37 eration Positive ON Engine Output Terminal X lt 0 5 total A C On Excessive resistance in positive Cables Running Batt Terminal A voltage drop Blower Motor cables Check measuring points positive and on High X H and A H to help isolate negative volt Headlamps on problem cable connectors age drops Bright combined Ground Ca ON Engine Ground Terminal Y lt 0 5 total A C On Excessive resistance in nega bles Running Batt Terminal B voltage drop Blower Motor tive cables Check measuring positive and on High points Y Q Y1 Q Q I and l B to negative volt Headlamps on help isolate problem cable con age drops Bright nectors combined 36 Group 33 Starting and Charging VN VHD Troubleshooting Charging Indica tor Telltale Lamp When the ignition key is turned ON the Charging Indi cator telltale lamp will momentarily illuminate for a bulb test The lamp will remain on until the engine is started With the engine running and the alternator properly charging the wire at the indicator light terminal from the instrument cluster and the indicator light terminal on the alternator Z should be at approximately the same volt age With the voltages equal the Charging telltale light should go out To clarify the procedures below refer to Troubleshooting Simplified Schematics Charging System page 34 e Instrument cl
9. addi tional preheat is desired after the timed preheat period The preheat relay s coil is supplied ignition power via a fuse in the Truck Electrical Center TEC panel The re lay s is energized when a ground is supplied by the EECU When the relay s is energized an internal con nection is made that connects the preheater element power supply from the alternator cable to the fuse that connects to the preheat element s The preheat ele ment s are case grounded A sense circuit s provides information to the EECU to confirm that the preheat circuit is intact If the EECU de termines that the circuit is not intact a fault code s will be generated For simplified schematic see Starting and Charging Design and Function W3004558 1 Solenoid 2 Shift Lever Housing 3 Nose Housing 4 Pinion 5 Overcrank Protection Input Switch page 3 Group 33 Starting and Charging VN VHD Design and Function Preheater Assembly Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to avoid severe burns The preheater assembly on a D7 engine is standard with one relay element and fuse The preheater assembly on a D12 engine is optional with two relays elements and fuses W3004559 1 Relay 2 Element 3 Fuse Assembly Group 33 Starting and Charging VN VHD Charging System Charging Circ
10. decreased current flow to the starter Due to the high current flow demands of the starting circuit voltage drop tests are more effective than ohm meter tests in determining if excessive resistance exists in the cable assemblies 1 Check for 12 4V at the battery cable terminals A1 8 B1 to the starter motor If 12 4 V is not present or if a weak battery s is suspected see Battery Trou bleshooting page 17 for battery testing information 2 Test complies with SAE J541 10 96 or 0 1 volts per 100 amps current draw Specification assumes a typical 700 amps starting current draw Troubleshooting 3 Confirm that the cables between batteries are clean tight and in proper working order 4 Remove engine ECU fuses located in the battery box to prevent the engine from running during the tests Use the digital multimeter J 39200 or equivalent tool to perform the test in the table below The measuring points referenced in the tables as A B C etc correspond to measuring points that are illustrated in the simplified schematics and drawing See Troubleshooting Simpli fied Schematic Starting System page 23 Note Due to battery mounting locations some vehicles will have dual positive and negative cables This test as sumes that both cables are connected Note Test complies with SAE J541 10 96 of 0 1 volts per 100 amp current draw Specification assumes a maximum of 700 amps starting current draw and normal circuit
11. housing can be rotated to clock the solenoid to accommodate various engine mounting locations A positive engagement shift mecha nism moves the pinion into mesh with the engine flywheel ring gear prior to cranking to minimize gear tooth damage An optional overcrank protection OCP switch protects the starter in adverse starting conditions such as cold weather starting or operator misuse The OCP switch is a temperature sensitive circuit breaker that prevents overcrank heat damage by opening the starter relay ground then automatically resetting when the starter has cooled sufficiently Preheat System Preheat Circuit Vehicles equipped with Volvo engines may be equipped with intake air preheaters to assist in cold weather start ing Preheating is standard on the D7 engine with one pre heat relay element and optional on the D12 engine with two preheat relays elements In normal operation the ignition switch is turned to the preheat position then released back to the On position The Vehicle Electronic Control Unit VECU rec ognizes the preheat request and sends the request to the Engine Electronic Control Unit EECU via the J 1939 Control Data Link The EECU will supply a ground to the preheat relay s and the preheater will begin to operate Based on engine temperature the EECU will time the in terval for preheater operation The operator may also hold the ignition switch in the preheat position if
12. lb I TERMINAL 2 3 0 5 Nm 20 5 in lb R TERMINAL 2 3 0 5 Nm 20 5 in lb 14 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition switch to the ON po sition If not leave the ignition switch in the OFF position 15 Connect the main ground cable s Turn ignition switch back to OFF if necessary 16 Connect ground wiring from the elec trical equipment connected directly to the batteries 17 Tighten all battery cable connections 13 20 Nm Torque 10 15 ft lb 13 20 Nm 10 15 ft lb Service Procedures 3211 03 02 04 Alternator Replacement Fixed Mount AN DANGER 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last In vehicles with a Supplemental Restraint
13. may damage vehicle electronics An internal voltage regulator limits the charging voltage from 13 8 to 14 2 volts Volvo VN VHD vehicles currently are equipped with one of three different Delco Remy alternators e 338 The 33S alternator is a brushless design for longer operating life It is the standard alternator used in most applications It is available with 110 and 135 amp output ratings e 228l The 2281 alternator is a smaller standard brush type alternator It is available with 100 130 and 145 amp output ratings e 34SI The 34SI alternator is internally identical to the 338 The major difference is that the housing has a fourth mounting lug to withstand higher vibra tion applications The 34Sl is currently only used in VN vehicles equipped with Detroit Diesel engines 16 B DU Design and Function W3004561 Group 33 Starting and Charging VN VHD Troubleshooting Troubleshooting Battery Troubleshooting AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion Important lf contacted with sulfuric acid flush immediately with water and get medical attention Batteries ma
14. preheating If any of the following fault codes is present refer to Service Fault Tracing Information Information Diagnostics Binder IMPACT Function Group 0 Information Type Diagnostics e MID 128 PID 45 preheating e MID 128 SID 70 preheating element 1 e MID 128 SID 71 preheating element 2 Group Number 030 600 W0001632 Troubleshooting 29 Group 33 Starting and Charging VN VHD Troubleshooting Troubleshooting Simplified Schematic D7 Preheater The simplified schematic and Illustration below should clarify the procedures in Troubleshooting Preheater with Digital Multimeter page 32 For detailed vehicle specific schematics refer to Function Group 370 Service Manual Electrical Schematics VN VHD Information Type Schematics VEHICLE ECU Y ON IGNITION SWITCH ENGINE PRE HEATER ELEMENT FUSE F61 SB GROUND ENGINE BLOCK W3003776 Wire color codes in schematic SB Solid Black BL R Blue Red R Red RW Red White Y Yellow GN Green W3003778 A B C and D are measuring points See Troubleshooting Preheater with Digital Multimeter page 32 for more information 30 Group 33 Starting and Charging VN VHD Troubleshooting Troubleshooting Simplified Schematic D12 Preheater The simplified schematic and Illustration below should clarify the procedures in Troubleshooting Preheater with Digital Multimeter page 32 For detailed vehi
15. temperature of 20 C 68 F Function Key Position Measuring Point Approximate Note Possible Cause if ex Value pected value not correct Positive Start Battery positive lt 0 7 V drop See Starter cranking Positive battery cable or Cable post A1 Starter Note 2 above engine connectors BATT post H Negative Start Battery negative lt 0 7 V drop See Starter cranking Negative battery cable or cable post B1 Ground Note 2 above engine connectors post at starter 1 Positive Start Individual Battery lt 0 1 V drop Starter cranking Positive battery intercon Inter Positive Post between any termi engine nect cable or connections Connect A1 A2 A2 A3 nals Cables etc Negative Start Individual Battery lt 0 1 V drop Starter cranking Negative battery intercon Inter Negative Post between any termi engine nect cable or connections Connect B1 B2 B2 B3 nals Cables etc 25 Group 33 Starting and Charging VN VHD Troubleshooting Ignition Switch Starter Relay Circuit With Digital Multimeter When the start position is selected at the ignition switch 12 volts are supplied to the starter relay coil If the starter relay coil is properly grounded either directly or through the overcrank protection switch the starter re lay will energize and close the contacts between the common and normally open terminals This creates a connection betwe
16. the main battery ground cable s 4 Remove the right inner fender assem bly 5 Remove the positive and negative ca bles and switch terminal wire from the starter Disconnect the overcrank protection switch if equipped Note the cable wiring position for installa tion 6 Remove the battery cable support bracket which is below the starter and pull the cables away from the starter area cables under starter routing 7 Bleed all pressure from the vehicle air system Disconnect the Exhaust Pres sure Governor EPG solenoid connector Note their position for in stallation then disconnect the EPG solenoid and regulator air lines Re move the EPG solenoid regulator assembly for the engine 8 Remove the starter mounting nuts and remove the starter from the vehicle 52 Service Procedures Installation 9 Compare the orientation of the nose housing on the old starter to the re placement starter If necessary remove the nose housing on the re placement starter and clock it to the position of the old starter Nose housing bolt torque 18 23 Nm 13 17 ft lb 10 Install the replacement starter and se cure the mounting nuts Torque 85 15 Nm 63 6 5 ft lb 11 Install the EPG solenoid regulator as sembly Install the EPG solenoid and regulator air lines Engage the EPG solenoid connector 12 Install the battery cable support bracket below the starter 13 Install al
17. 3745 Starter Motor H I J and K are measuring points For details see Troubleshooting Battery Starter Cables With Digital Multimeter page 25 T IWITHOUT IOVERCRANK PROTECTION SWITCH LT JOVERCRANK Ee PROTECTION FIGNITION SWITCH Es BT W3003744 Starter Relay Switch The connector is illustrated from the relay insertion side C 86 12V from Ignition Switch D 85 Coil Ground E 87 12V to Starter Solenoid F 30 12V Supply 23 Group 33 Starting and Charging VN VHD Troubleshooting Ignition Switch with VCADS Pro Tool The VCADS Pro Tool is a Windows 95 based PC tool that can be used to perform some ignition switch testing The following is a brief description of tests that are cur rently available Test number 3340 08 02 01 Ignition Switch test Indicators on the VCADS Pro Screen will illuminate green when the ignition key is turned to the Start position For detailed information about the VCADS Pro Tool op eration see refer to Service VCADS Pro User s Manual Manual Group Number 030 600 24 Troubleshooting Note This test only applies to vehicles with a Vehicle ECU Volvo engines W0001632 Group 33 Starting and Charging VN VHD Troubleshooting Battery Starter Cables With Digital Multimeter The starter is supplied power and ground through cables connected directly to the batteries Excessive resistance in the cables or connectors will cause
18. 4556 Group 33 Starting and Charging VN VHD Starting System Starting Circuit When the ignition switch is turned to the START posi tion power to energize the starter relay coil is supplied on wire number 284 The starter relay coil is grounded through the overcrank protection switch OCP or a shorting jumper The OCP switch is located inside the starter This switch is optional Where the OCP switch is not used a short ing jumper is used to complete the starter relay coil ground circuit When the starter relay is energized 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 inter nally in the solenoid which connects the battery terminal to the motor terminal then the starter begins to crank the engine For more details see schematic in Starting and Charg ing page 3 12 Design and Function overcrank protection OCP input switch Starter Relay W3003757 W3004339 Group 33 Starting and Charging VN VHD Starter Volvo VN VHD vehicles are equipped with Delco Remy 42MT starters for most applications If the vehicle is equipped with a Volvo D7 engine it will be equipped with a Delco Remy 37MT starter These starters sometimes referred to as starting motors have a shift lever and so lenoid housing that is totally enclosed to protect them from the elements The nose
19. D Battery Tester or equivalent elec tronic testers and should be used as a general guide for performing electronic battery testing Read and follow the test instructions supplied with the electronic test equipment used to perform battery testing 1 Batteries must be tested individually Remove battery cables as described in Battery Cables Re moval and Installation page 41 2 Visually inspect the battery for corroded terminals damage or a clear built in hydrometer eye if equipped Clean the terminals if needed Replace damaged batteries or batteries with clear hydrome ter eyes indicates electrolyte loss W0001836 J 44700 Accuracy Plus HD Battery Tester 3 To operate the Accuracy Plus tester connect the positive and negative tester leads to the battery stud posts Select the Battery Test and follow the on screen prompts until the test is complete Test re sults will appear on screen 21 Group 33 Starting and Charging VN VHD Troubleshooting Starting System Troubleshooting HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine an or fluids can cause burns Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or AN DANGER 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 persona
20. ER 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounas first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last 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 in the vehicle This applies only to vehicles with SRS and Cummins or Detroit Diesel engines Check for fault codes after repairs are complete 62 Service Procedures Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Note In some installations the replacement of the alter nator may be aided by the removal of splash shields Removal 1
21. Note The open circuit voltage must be at least 12 4 volts after the surface charge has been removed to con tinue battery testing Troubleshooting Group 33 Starting and Charging VN VHD Load Testing Batteries 7 The BVA 34 System Analyzer is a digital carbon pile battery load tester and starting charging system ana lyzer It is portable and designed for use in the heavy truck market The test that follows may be performed with the BVA 34 System Analyzer or equivalent carbon pile type tester and should be used as a general guide for performing a battery load test Read and follow the test instructions supplied with the tester used to perform battery testing 1 Batteries must be tested individually Remove battery cables as described in Battery Cables Re moval and Installation page 41 2 Visually inspect the battery for corroded terminals damage or a clear built in hydrometer eye if equipped Clean the terminals if needed Replace damaged batteries or batteries with clear hydrome ter eyes indicates electrolyte loss 3 Screw the brass jumper studs onto the positive and negative terminal before connecting the tester Do not connect the tester leads directly to the bat tery terminal post ARROW ON PROBE SHOULD FLOW FOR CORRECT POLARITY W3004563 Connect the BVA 34 System Analyzer or equivalent tool to the battery as shown Set the voltmeter to the INTERNAL setting Zero the ammeter 5 Chec
22. Service Manual Trucks Group 330 500 Starting and Charging VN VHD PV776 TSP146025 WOIVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to March 2001 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur Volvo Trucks North America Inc Greensboro NC
23. 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 in the vehicle This applies only to vehicles with SRS and Cummins or Detroit Diesel engines Check for fault codes after repairs are complete 63 Group 33 Starting and Charging VN VHD Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Note In some installations the replacement of the alter nator may be aided by the removal of splash shields Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect the ground wiring electrical equipment connected directly to the batteries such as ECU s satellite sys tems etc 3 Disconnect the main ground cable s 4 Disconnect all alternator wiring Note wire positions to aid in installation 5 Use fan belt tensioner tool J 44392 or equivalent tool to release the pres sure from the automatic belt tensioner and remove the belt from the alterna tor pulley 6 Remove the alternator mounting bolts and remove the alternator from the ve hicle Installation 7 If necessary remove the pulley from 109 11 Nm the alternator and install it on the re 80 8 ft lb placement alternator Torq
24. Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the main ground cable s 4 Disconnect all alternator wiring Note wire positions to aid in installation 5 Loosen the alternator mounting bolts 6 Loosen the tensioner bolt as needed and remove the belt from the pulley 7 Remove the alternator mounting bolts and remove the alternator from the ve hicle Installation 8 If necessary remove the pulley from 109 11 Nm the alternator and install it on the re 80 8 ft lb placement alternator Torque 109 11 Nm 80 8 ft lb 9 Install the replacement alternator and tensioner Leave bolts loose enough to adjust belt tension Group 33 Starting and Charging VN VHD 10 Adjust the tensioner as needed to achieve a belt tension of 111 Nm 150 ft lb for a new belt or 73 Nm 100 ft lb for a used belt Use Belt Tension Gauge J 23600 B or equivalent tool to check tension 11 Tighten the alternator adjustment 48 8 Nm mounting bolt 34 6 ft lb Torque 48 8 Nm 34 6 ft lb 12 Tighten the alternator pivot mounting 88 7 Nm bolt 65 5 ft lb Torque 88 7 Nm 65 5 ft lb 13 Connect all alternator wiring Torque BATTERY TERMINAL 6 5 0 5 Nm 58 5 in lb GROUND TERMINAL 6 2 0 5 Nm 55 5 in
25. USA Order number PV776 TSP146025 O 2001 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents OMC oe reser tee eet nicer reer era eran error ree mtr 3 glaring and Gig Sie ho RR DR RS A FAR 3 TOOS Lei eli a tea iS 5 senal TOS acia 5 Design and FUNCI N siii ciaci n 9 Starting and Charging System Indicator Lights ooooonoccccnnncccinnnccinncoo 9 AMEN upa ae O RR RR RR needa 9 fia A RS 10 Reseno CABO in 10 Open Creul VOUS ai 10 Panerys LOCA noi 10 Battery CADSES tiara 11 Battery Disconnect SUCIO ii 11 Sana a 2 a eee an AO N acre ner T 12 AI AR Aa a A RNA NR RR OR 12 A OUR liens 13 PINO oroe nai 13 PRENSA o e ee tos li a 13 Preheater ASSIM cappinnepirojatoasooisieINOUAUE ANG AS Naa SR 14 CHAINS USO SAR 15 CATIA Jo DRA ERR PR ERROR SERENA ida 15 A Ca AS oR Cc er rn Cee CR a Cac RN 16 TROMBIOSHOONING aiii 17 Battery Toubleshooting susi aia 17 Baten Stale Oi Charge oia ARAS 18 Battery Surface Charge Removal nnie 19 Load Testing Bates sas snes os 20 Electronic Battery ISSIMO pri 21 Starting System TraublesAOO NO siii 22 Troubleshooting Simplified Schematic Starting System 23 Troubleshooting Ignition Switch
26. VHD Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Before you start the replacement of the battery to starter cable s visually inspect the existing cables Note the lo cation of all routing support clips brackets and cable ties If any area is visibly distressed take appropriate cor rective actions to prevent damage to the replacement cable s The following installation points should be ob served always when replacing battery to starter cables e Cables should be supported at no less than 600 mm 24 in intervals with non conductive compres sion clips e Cables must be supported as close as possible to all cable bends e Cable ties may be used as needed to prevent rela tive movement between cables e Strain relief should be provided at terminals to pre vent terminal breakage e Route cables to avoid sharp edges or abrasive ar eas e Edges that cables pass through must be bushed with suitable grommets e Cables must not be routed within 130 mm 5 in of engine exhaust components or other sources of in tense heat e Cables should not be located in areas that experi ence routine exposure to diesel fuel hydraulic fluid or oil Note Some applications will require removal of air fair ings battery box covers or other com
27. age falling below 7 2 volts This rating is useful in determining the battery s ability to start an engine in cold weather conditions The cold cranking amp rating is determined by the amount of plate surface area in each cell Reserve Capacity The Reserve Capacity is the number of minutes that a battery can sustain a 25 Amp load at 27 C 80 F until the post voltage drops to 10 5 volts This rating is useful in determining the battery s ability to supply operating power in the event of a vehicle charging sys tem failure The reserve capacity is determined by the amount of active plate material in each cell Open Circuit Voltage The Open Circuit Voltage is the voltage at the battery post with no loads applied Battery Locations Battery box locations vary per application The stan dard mounting location 1 is on the left frame rail under the cab steps This is the mounting location for all VN and some VHD vehicles Depending on the equipment ordered there are three optional battery box mounting locations for the VHD vehicle See illus tration for locations 2 3 and 4 W3004555 10 Group 33 Starting and Charging VN VHD Battery Cables All copper 3 0 battery cables 1 are used on VN VHD vehicles Single cables are used if the batteries are mounted in the standard location If the batteries are mounted in optional locations dual cables are used to prevent excessive voltage drop due to cable lengt
28. amage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to avoid severe burns Group 33 Starting and Charging VN VHD Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from electri cal equipment connected directly to the batteries such as ECU s satellite systems etc 3 Disconnect the battery main ground cable s 4 Remove the power cable fuse and wiring from relays Note position for re assembly 5 Remove the support bracket wiring harness clamp bolts VN or fan ring support bracket VHD 6 Remove the charge air pipe hose clamp 7 Remove the charge air pip ing preheater mounting bolts and remove the charge air piping from the vehicle 8 Remove the preheater element block from the intake manifold Tap the relay mounting bracket off the element block 9 Remove the relay s from the mount ing bracket Installation 10 Install the replacement relay s onto the bracket and secure 11 Clean the gasket surfaces Service Procedures 12 Tap the relay mounting bracket onto the element block 13 Install the pr
29. attery pack performs four basic functions 1 It supplies energy for starting the engine 2 It supplies energy to operate all the vehicles electri cal systems and accessories 3 It acts as a voltage stabilizer for the electrical sys tem 4 It supplies additional energy to operate the electrical system during peak demands for instance when the alternator is already at maximum output The battery case 1 is made of a strong lightweight ma terial commonly polypropylene to withstand shock and vibration The cover is vented to allow chemical gases to escape Each battery cell 2 is constructed of positive and negative plates 3 that are insulated from each other by a porous separator 4 Plate straps 5 connect the positive and negative plates and provide a means of interconnecting the cells The cell is immersed in an electrolyte solution of sulfuric acid and water The electri cal energy is produced in the battery by the chemical reaction of the active materials that comprise the positive and negative plates and the electrolyte Each cell will produce approximately 2 1 volts The six cells that com prise the battery are connected in series to deliver approximately 12 6 volts at the battery post 6 W3004553 Group 33 Starting and Charging VN VHD Design and Function Cold Cranking Amps The Cold Cranking Amps rating is the amount of am perage load that can be maintained at 18 C 0 F without the post volt
30. batteries the state of charge is determined by a built in hydrome ter or an open circuit voltage test The battery may have a special temperature compen sated hydrometer built into the cover to show at a glance the battery s state of charge The hydrometer has a green ball within a cage which is attached to a clear plastic rod The green ball will float at a predetermined specific gravity of the electrolyte that represents about 65 state of charge When the green ball floats it rises within the cage and positions itself under the rod Visually a green dot then shows in the center of the hy drometer The built in hydrometer provides a guide for battery testing and charging In testing the green dot means the battery is charged enough for testing If the green dot is not visible it means the battery must be charged before the test pro cedure is performed In charging the appearance of the green dot means that the battery is sufficiently charged The hydrometer on some batteries may be clear or light yellow This means the fluid level is below the bottom of the rod and attached cage This may have been caused by excessive or prolonged charging a broken case ex cessive tipping or normal battery wear out If a battery displays a clear eye it must be replaced Do not attempt to charge test or jump start the bat tery Note The built in hydrometer only monitors one battery cell Low state of charge in other cells will not be i
31. cedures in Troubleshooting Charging System with Digital Multimeter page 35 For detailed vehicle specific schematics refer to Service Electrical Schematics VN VHD Manual IMPACT Function Group 370 Information Type Schematics ALTERNATOR 19 BODYBUILDER APPLICATIONS Pies UU A Q FUSIBLE STARTER LINK Ww2nn4729 W3004567 H and Q are measuring points for more informa tion see page 37 W3004566 X Output Terminal B Y Ground Terminal B WwW Relay Terminal Z Indicator Light Terminal Y 1 Ground Terminal B 34SI only 34 Group 33 Starting and Charging VN VHD Troubleshooting Charging System with Digital Multimeter One or more of the following conditions will generally in dicate charging systems problems e Undercharged or overcharged batteries e Charging indicator telltale lamp on with the engine running e Charging indicator telltale lamp off with the ignition switch on and the engine not running e The voltmeter in the graphic display showing a charging rate outside the normal range e Incorrect or no operation of accessories connected to the Relay terminal Troubleshooting e Short life of light bulbs or other electrical compo nents due to unusually high system voltage Prior to troubleshooting visually check the cables and connections for obvious problems Check the drive belt tension and adjust if necessary Use the digital multimeter J 39200 o
32. cle specific schematics refer to Function Group 370 Service Manual Electrical Schematics VN VHD Information Type Schematics VEHICLE ECU Y ON IGNITION SWITCH BL R ENGINE de PRE HEATER CONN H Eoonn BL R GROUND ENGINE BLOCK W3003777 Wire color codes in Schematic SB Solid Black BL R Blue Red RW Red White Y Yellow GN Green W3003779 A B C and D are measuring points See Troubleshooting Preheater with Digital Multimeter page 32 for more information 1 Relay 1 2 Relay 2 31 Group 33 Starting and Charging VN VHD Troubleshooting Preheater with Digital Multimeter Use digital Multimeter J 39200 or equivalent tool to perform the test in the table below The measuring points refer enced in the table as A B C etc correspond to measuring points that are illustrated in the preheat simplified schematics and drawings in Troubleshooting Simplified Schematic D7 Preheater page 30 and Troubleshooting Simplified Schematic D12 Preheater page 31 Troubleshooting These measuring points should not be confused with the wire color codes that are listed beside each schematic Each preheat relay fuse and element must be checked independently on D12 engines ments connection E to al ternate ground clicked in ele ments should produce heat Function Key Measuring Points Expected Note Possible Cau
33. d connected Disconnect the main battery ground last Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to Service Procedures 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the battery main ground cable s 4 Remove the power cable fuse and wiring from relay Note position for re assembly 5 Remove the relay from its mounting and remove from the vehicle Installation 6 Install the replacement relay and se cure 7 Install the power cable fuse and wiring to the relay and secure 8 Install the main ground cable s 9 Install ground wiring from the electrical equipment connected directly to the batteries de energize circuits may result in permanent damage 10 to electronic components Secure with the battery terminal nut s 3 7 5 7 Nm Torque 10 15 ft lb 3 7 5 7 Nm 10 15 ft lb Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to avoid severe burns Removal 1 Turn the ignition key to the OFF posi tion 58 Group 33 Starting and Charging VN VHD 3331 03 02 01 Preheater Element Replace ment D12B or D12C Engine AN DANGER Before working
34. detailed vehicle specific schematics refer to Service Electrical Schematics VN VHD Manual IMPACT Function Group 370 Information Type Schematics Group 33 Starting and Charging VN VHD Tools Tools Special Tools The tools referenced in this manual are listed below They can be obtained by contacting your local Volvo Trucks parts dealer Kent Moore at 1 800 328 6657 or you may call a local listed tool vendor Note For VCADS Pro tooling refer to Service VCADS Pro User s Manual Manual Group Number 030 600 Battery tester kit Includes Tester J 44700 and Printer 238598 available from Kent Moore telephone 800 328 6657 J 44701 W0001836 Fluke 87 digital multimeter available from Volvo or Kent Moore telephone 800 328 6657 J 39200 W2001014 Group 33 Starting and Charging VN VHD Relay puller tool available from Kent Moore telephone 800 328 6657 J 43244 VCADS Pro For VCADS Pro tooling refer to Service VCADS Pro User s Manual Manual Group Number 030 600 Fan Belt Tensioner Tool available from Volvo or Kent Moore telephone 800 328 6657 J 44392 BT 33 73F Belt Tension Gauge available from Kent Moore telephone 800 328 6657 J 23600 B W0001917 W0001632 W0001817 W0001844 Tools Group 33 Starting and Charging VN VHD BVA 34 System Analyzer The BVA 34 System Analyzer is a digital carbon pile battery load tester and starting chargin
35. eheater element block with new gaskets and the charge air piping to the intake manifold 14 Secure with mounting bolts Torque 24 4 Nm 18 3 ft lb 15 Install and secure the charge air pipe hose clamp 16 Install the support bracket wiring har ness clamp bolts VN or fan ring support bracket VHD and secure 17 Install the power cable fuse and wiring to the relays and secure 18 Install the main ground cable s 19 Install ground wiring from the electrical equipment connected directly to the batteries 20 Secure with the battery terminal nut s Torque 3 7 5 7Nm 10 15 ft lb 24 4 Nm 18 3 ft lb 3 7 5 7Nm 10 15 ft lb 57 Group 33 Starting and Charging VN VHD 3331 03 02 03 Preheater Relay Replacement D7C Engine AN DANGER 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounas first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery groun
36. el Alternator Re Feedback Operation Numbers Group 33 Starting and Charging VN VHD General General Starting and Charging The starting and charging system on the VN VHD series vehicles is comprised of batteries the starter alternator and all the connecting wiring cables and switches Vehicles equipped with Volvo engines may also have preheaters in stalled in the intake manifold to assist starting For maximum efficiency all parts of the system must function properly Note The information in this manual pertains specifically to the Volvo VN VHD series vehicles For more general information on the starting and charging system including test refer to Vendor Diagnostic Procedures For Heavy Duty Electrical Systems Information Delco Remy DRA DP1029 PREHEAT RELAY1 PREHEAT FUSE PREHEATER TO CAB at VV E PWA abia STUD 2 TO CAB 1A FP PWR PREHEAT IB STUD 1 BODYBUILDER RELAY APPLICATIONS IGN GROUND SENSE FUSIBLE FUSIBLE SENSE LINK LINK y 285A TO TOEECU INSTRUMENT CLUSTER ENGINE GROUND O FRAME FUSIBLE RAIL Li LINK GROUND CAB OVERCRANK PROTECTION SWITCH OR SHORTING JUMPER w o OCP ONLY GROUND STARTER RELAY TO IGN SWITCH lt 284 990 W3004734 Starting and Charging Circuit Simplified Schematic This simplified schematic should only be used to clarify the design features of the VN VHD starting and charging cir cuit For
37. elays Note position for re assembly 5 Remove the support bracket wiring harness clamp bolts 6 VN only or fan ring support bracket 5 VHD only 59 Group 33 Starting and Charging VN VHD 6 Remove the charge air pipe hose clamp 7 Remove the charge air piping pre heater mounting bolts 3 and remove the charge air piping 4 from the vehi cle 8 Remove the preheater element block 1 from the intake manifold Tap the relay mounting bracket off the element block 9 Clean the gasket surfaces Installation 10 Tap the relay mounting bracket onto the replacement element block 11 Install the preheater element block 24 4 Nm with new gaskets 2 and the charge 18 3 ft lb air piping to the intake manifold Se cure with mounting bolts Torque 24 4 Nm 18 3 ft lb 12 Install and secure the charge air pipe hose clamp 13 Install the support bracket wiring har ness clamp bolts VN or fan ring support bracket VHD and secure 14 Install the power cable fuse and wiring to the relays and secure 15 Install the main ground cable s 16 Install ground wiring from the electrical equipment connected directly to the batteries 60 Service Procedures 17 Secure with the battery terminal nut s 3 7 5 7 Nm Torque 10 15 ft lb 3 7 5 7 Nm 10 15 ft lb 3331 03 02 01 Preheater Element Replace ment D7C Engine AN DANGER Before working on a vehic
38. en the battery that con nects to the common terminal and the starter solenoid switch feed that connects to the normally open termi nal With this connection made 12 volts are supplied to the starter solenoid which engages and the starter mo tor begins to crank the engine The overcrank protection 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 Troubleshooting 1 Check for 12 4V at the battery cable terminals A1 amp B1 to the starter motor If 12 4 V is not present or if a weak battery s is suspected see Battery Trou bleshooting page 17 for battery testing information 2 Confirm that the cables between batteries are clean tight and in proper working order 3 Remove the engine ECU fuses located in the bat tery box to prevent the engine from running during the tests 4 Unplug the starter relay from the connector Use digital multimeter J 39200 or equivalent tool to per form the test in the table below The measuring points referenced in the tables as A B C etc correspond to measuring points that are illustrated in the starting sys tem simplified schematics and drawing See Troubleshooting Simplified Schematic Starting System page 23 Function Key Measuring Point Expected Position Value Note Possible Cause if expected value not cor rect Start signal to Start
39. ent connected directly to the batteries 14 Secure all battery terminal nuts 3 7 5 7 Nm Battery terminal torque 10 15 ft lb 3 7 5 7 Nm 10 15 ft lb Ground Cables Many service operations require the removal of the bat tery ground negative cables as a safety measure If the battery ground cable s and wiring are not removed and installed in the proper order damage to sensitive elec tronic equipment may occur To properly remove and install the battery ground cables and wiring proceed as follows Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect the ground wiring from electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 42 Service Procedures 3 Disconnect the main ground cable s 4 Perform service operations as needed Installation 5 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition switch to the ON po sition If not leave the ignition switch in the OFF position 6 Connect the main ground cable s Turn the ignition switch back to OFF if necessary 7 Connect ground wiring from the elec trical equipment connected directly to the batteries 8 Secure all battery terminal nuts Bat 13 20 Nm tery terminal torque 10 15 ft lb 13 20 Nm 10 15 ft lb Group 33 Starting and Charging VN VHD Ba
40. g system ana lyzer It is portable and designed for use in the heavy truck market Optional tester stand part number ES 2 is also available For more information contact Auto Meter telephone 435 283 4142 or visit their web site at www autometer com Stator DICDE CHECK LOAD ON O TIMER O stant O o NO an VALVZE W3004737 Tools Group 33 Starting and Charging VN VHD Design and Function Design and Function Starting and Charging System Indicator Lights When the ignition key is turned ON the Charging Indi cator telltale lamp 1 will momentarily illuminate for a bulb test The lamp will remain on until the engine is started With the engine running and the alternator prop erly charging the Charging telltale light should go off 900 300 1 21500 170 210 The instrument cluster left module is equipped with a ESA graphics display 2 that includes a voltmeter function With the voltmeter function active the display will show a battery icon and display the battery charging voltage If the battery charging voltage exceeds 17 volts the yel low INFO lamp 3 will illuminate and the graphic display will show the voltage reading with the text mes E TOO sage TOO HIGH 17 9 T3008832 Battery The battery is an electrochemical device for converting chemical energy into electrical energy The battery or b
41. greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America Inc 0 han eeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeetesteeeesseeeeeeeees Dept 516 Service Publications mmcccnnnnnnnnnnnnn nn nn nn r nn nr nn nr rra rn narran nr nn n narran nana nana 7900 National Service Road cnc PO Box 26115 00 RC nab be deheuele den a debs deeevahlacl deh ctlice desseeh Pence Greensboro NC 27402 6115 0 ianaeetttetceeeeeeccceneeeeeecccaaeeeeeeeeseeseaeeeeecsestaeeeeeeeess USA Fax 336 393 3170 Comments proposals 3111 03 02 02 3211 03 02 03 3211 03 02 04 3311 03 02 01 3331 03 02 01 3331 03 02 02 3331 03 02 03 3714 03 02 03 3714 03 02 04 3714 19 03 01 Operation Numbers Battery Replacement One or Two 050 2 eee eee 44 Alternator Replacement Adjustable Mount 62 Alternator Replacement Fixed Mount 22 224 63 Starter Motor Replacement 2202 49 51 53 Preheater Element Replacement 0 e 59 60 Preheater Fuse Replacement s au ms ua mp a pm de aa a a 55 Preheater Relay Replacement a a oa a a a a a e 56 58 Battery Cables to Starter Replacement aooo a a a 45 Battery Inter connection Cables Replacement 2
42. h Bat tery inter connection cables 2 are 2 0 size Some applications may use interconnection bars instead of ca bles All battery cables are sealed with polyvinyl chloride PVC insulation to resist abrasion and the elements The battery cable terminals are secured to the batteries with either stainless steel terminal nuts 3 or brass jumper studs 4 Some applications may be equipped with insulated terminal nuts that are made of plastic with a brass insert Protective covers 6 are installed on all uninsulated battery cable terminal nuts studs Mounting brackets 5 support and secure the battery cables at ap proximately 300 mm 12 in to 600 mm 24 in intervals to avoid damage from abrasion vibration heat and strain Ideally battery sets should be connected to the bat tery starter cables in a diagonal pattern 1 rather than both cables being connected to one battery at the end of the set 2 The diagonal connection will help assure that all batteries in the set are cycled at the same rate ex tending service life Battery Disconnect Switch 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 should not be used as a substitute for removing battery cables to prevent damage to the vehicle when welding m Design and Function B B B W3004557 W3004404 W300
43. he left splash shield 5 Remove the left inner fender assembly 6 Loosen or remove the battery cable mounting support brackets and cable dividers if equipped as needed to al low enough slack for removal of the battery cable terminals at the starter Cut any cable ties as needed 7 Remove the positive and negative ca bles and switch terminal wire from the starter Disconnect the overcrank protection switch if equipped Note the cable wiring position for installa tion 8 Remove any wiring harness support clamps and brackets as needed to ac cess the starter mounting bolts and allow removal of the starter 53 Group 33 Starting and Charging VN VHD 9 Remove the starter mounting bolts and remove the starter and spacer if equipped from the vehicle Installation 10 Compare the orientation of the nose 9 5 12 5 Nm housing on the old starter to the re 13 17 ft lb placement starter If necessary remove the nose housing on the re placement starter and clock it to the position of the old starter Nose housing bolt torque 9 5 12 5 Nm 13 17 ft lb 11 Install the replacement starter and 176 25 Nm spacer if equipped and secure the 130 18 ft lb mounting bolts Torque 176 25 Nm 130 18 ft lb 12 Install any wiring harness support clamps and brackets removed to ac cess the starter mounting bolts 13 Install all starter wiring and cables 30 5 3 5 Nm Batter
44. he risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries Service Procedures If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components NJ O q WO ND 3 1 W3004733 Starter D7C Engine Dual Battery Cables shown Positive cables Negative cables Switch terminal overcrank protection connector with jumper Cable support bracket EPG solenoid EPG regulator 51 Group 33 Starting and Charging VN VHD Note In some installations replacement of the starter may be aided by removal of additional components or wiring not referenced in this manual or affected by alter nate battery cable routing due to alternate battery mounting locations Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from electri cal equipment connected directly to the batteries such as ECU s satellite systems etc 3 Disconnect
45. ified Schematic Starting System page 23 Positive battery cable or con nectors See Troubleshooting Battery Starter Cables With Digital Multimeter page 25 Negative battery cable or con nectors See Troubleshooting Battery Starter Cables With Digital Multimeter page 25 Starter should crank with terminal en ergized Starter relay Connectors or wiring faults in starter relay ignition switch cir cuit See Troubleshooting Ignition Switch Starter Relay Circuit With Digital Multimeter page 26 1 Check that the engine can be manually turned with a reasonable amount of effort to eliminate the possi bility of a mechanical engine fault 2 Check the starting system with the engine at operat ing temperature Extreme cold will make the engine more difficult to turn and will reduce the batteries output 3 Perform the test Troubleshooting Battery Starter Cables With Digital Multimeter page 25 27 Group 33 Starting and Charging VN VHD Preheat System Troubleshoot ing AN DANGER 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 in jury or death Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to to avoid severe bu
46. ircuit voltage e Cranking voltage e Charging voltage e Regulator voltage e Diode condition To operate the Accuracy Plus tester connect the positive and negative tester leads to the battery jumper stud posts Select the System Test and follow the on screen prompts until the tests are complete The test results may be printed if desired with the optional printer number 238598 Both the J 44700 Accuracy Plus tester and the 238598 printer are available in kit part number J 44701 See the tools section of this manual for more information Note Enter the combined CCA rating of all batteries when prompted Note If the results of this test indicate a faulty battery the batteries must be disconnected and tested individu ally See section Battery Troubleshooting page 17 Troubleshooting J 44700 Accuracy Plus HD Battery Tester W0001836 39 40 Group 33 Starting and Charging VN VHD Service Procedures Service Procedures 3714 19 03 01 Battery Cables Removal and Installation AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with wate
47. ive fuse assembly s 5 Remove the wiring support and fuse Installation 6 If the defective fuse assembly is the long fuse assembly on the D12 en gine remove the screw securing the fuse to the support Install the replace ment fuse onto the support and secure with the screw 7 Install the replacement fuse with sup port and wiring onto the mounting terminals and secure 8 Install the main ground cable s 9 Install ground wiring from the electrical equipment directly to the batteries 10 Secure with the battery terminal nut s 3 7 5 7 Nm Torque 10 15 ft lb 3 7 5 7 Nm 10 15 ft lb 56 Service Procedures 3331 03 02 03 Preheater Relay Replacement Volvo D12B or D12C Engine AN DANGER 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Possible d
48. k the battery open circuit voltage The reading must be between 12 40 and 12 66 volts to proceed If not see Battery State of Charge page 18 6 Adjust the load control knob to equal one half the battery s Cold Cranking Amp CCA rating The bat tery CCA specification can be found on the battery label Maintain the load for 15 seconds then note the battery voltage with load applied 20 Troubleshooting POINT IN DIRECTION OF CURRENT ESTIMATED MINIMUM REQUIRED ELECTROLYTE VOLTAGE UNDER 15 TERMPERATURE SECOND LOAD 70 F 21 C and above 9 6 60 F 16 C 9 5 50 F 10 C 9 4 40 F 4 C 9 3 30 F 1 C 9 1 20 F 7 C 8 9 10 F 12 C 8 7 0 F 18 C 8 5 Compare the voltage reading obtained to the tem perature compensated chart above If the battery does not meet or exceed the minimum voltage re quired replace the battery Group 33 Starting and Charging VN VHD Troubleshooting Electronic Battery Testing The J 44700 Accuracy Plus HD Battery Tester is a hand held electronic battery diagnostic tester The tester ap plies variable loads to the battery and measures the battery s response Results are then displayed and may be printed if desired with the optional printer number 238598 Both the J 4477 Accuracy Plus tester and the 238598 printer are available in kit part number J 44701 The test that follows may be performed with the J 44770 Accuracy Plus H
49. l in jury or death Always wear eye protection when working around bat connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components teries to prevent the risk of injury due to contact with sulfuric acid or an explosion Important If contacted with sulfuric acid flush immediately with water and get medical attention Never use the ohmmeter mode of the DMM in a pow ered circuit or as a substitute for a voltmeter or ammeter since this will result in damage to the instru ment Use the ohmmeter mode only when power is removed from the circuit Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries 22 Group 33 Starting and Charging VN VHD Troubleshooting Simplified Schematic Starting System Troubleshooting The simplified schematic and illustration below should be used to clarify the troubleshooting procedures in Troubleshooting Battery Starter Cables With Digital Multimeter page 25 Troubleshooting Ignition Switch Starter Relay Circuit With Digital Multimeter page 26 and Troubleshooting Starter with Digital Multimeter page 27 For de tailed vehicle specific schematics refer to Service Electrical Schematics VN VHD Manual IMPACT Function Group 370 Information Type Schematics BATTERIES W300
50. l starter wiring and cables Battery cable terminals torque 30 5 3 5 Nm 22 5 2 5 ft lb switch terminal torque 2 6 0 8 Nm 23 7 in lb Secure wiring with cable ties as needed 14 Install the right inner fender assembly 15 Install the main ground cable s onto the battery ground terminal 16 Install ground wiring from the electrical equipment connected directly to the batteries onto the battery ground ter minal 17 Tighten all battery cable connections Torque 13 20 Nm 10 15 ft lb 18 23 Nm 13 17 ft lb 85 9 Nm 63 6 5 ft lb 30 5 3 5 Nm 22 5 2 5 ft lb 2 6 08 Nm 23 7 in lb 13 20 Nm 10 15 ft lb Group 33 Starting and Charging VN VHD 3311 03 02 01 Starter Motor Replacement Cummins or Detroit Diesel Engine AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fulids can cause burns In vehicles with a Supplemental Restraint System SRS
51. le 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to avoid severe burns Group 33 Starting and Charging VN VHD Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the battery main ground cable s 4 Remove the power cable fuse and wiring from relay No
52. luminated Disconnect the wire at the indicator light terminal Z Use a jumper wire to ground the removed indicator light wire The Charg ing telltale should illuminate If not check for an open circuit between the alternator and the instru ment cluster If an open circuit is indicated refer to Service Electrical Schematics VN VHD Manual IMPACT Function Group 370 Information Type Schematics Alternator check With the engine running and the alternator properly charging remove the wire at the indicator light terminal The indicator light terminal on the alternator Z should be at approximately charging voltage If not the alternator is probably defective 37 Group 33 Starting and Charging VN VHD Troubleshooting Alternator Output Test with BVA 34 Tester Troubleshooting Before beginning the alternator output test visually check the cables and connections for obvious problems Check the drive belt tension and adjust if necessary ARROW ON PROBE SHOULD POINT IN DIRECTION OF CURRENT FLOW FOR CORRECT POLARITY Use BVA 34 System Analyzer or equivalent tool to per form the test below Read and follow the directions with the test equipment used The test outlines below should be used as a general guide for performing an alternator output test The measuring points referenced in the text as A B X etc correspond to measuring points that are illustrated in the alternator output test simplified schematics above
53. ndi cated by the built in hydrometer The battery state of charge may also be checked by reading the open circuit voltage To check connect a voltmeter to the positive and negative battery post If the reading is below 12 40 volts the battery is too low for proper testing and must be recharged If the reading is above 12 66 volts the surface charge must be removed before testing See Battery Surface Charge Removal page 19 18 State of charge 65 or above Below 65 state of charge Low electrolyte level Troubleshooting W3004562 Group 33 Starting and Charging VN VHD Battery Surface Charge Removal When a battery is charged very small hydrogen gas bubbles form on the surface of the battery plates caus ing what is known as surface charge When a voltmeter is connected to the battery post it may give a false read ing if the surface charge is not removed Before testing a battery the surface charge must be re moved by one of the following methods e Turn on the headlights for 2 3 minutes Then allow the battery to stabilize for 1 minute before testing e Remove the Engine ECU fuse in the battery box to prevent the engine from starting Start the engine for 5 10 seconds Then allow the battery to stabilize for 1 minute before testing e Use BVA 34 System Analyzer or equivalent tool to load the battery to 300 amps for 5 10 seconds Then allow the battery to stabilize for 1 minute be fore testing
54. nt fault 32 Group 33 Starting and Charging VN VHD Charging System Troubleshooting AN DANGER 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 in jury or death Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Troubleshooting Never use the ohmmeter mode of the DMM in a pow ered circuit or as a substitute for a voltmeter or ammeter since this will damage the instrument Use the ohmmeter mode only when power is removed from the circuit If contacted with sulfuric acid flush immediately with water and get medical attention Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion Important If contacted with sulfuric acid flush immediately with water and get medical attention HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns 33 Group 33 Starting and Charging VN VHD Troubleshooting Troubleshooting Simplified Schematics Charging System The simplified schematic and illustration below should be used to clarify the pro
55. o the SW terminal via the starter relay When the starter solenoid engages a connection is made in ternally in the solenoid that connects the battery and motor terminals and the starter cranks the engine 1 Check for 12 4V at the battery cable terminals A1 8 B1 to the starter motor If 12 4 V is not present or if a weak battery s is suspected see Battery Trou bleshooting page 17 for battery testing information Power supply Starter Batt from batter post H al ies ternate ground Ground from batteries Ground post at starter 1 alternate ground Starter SW terminal G Start signal from starter relay alternate ground e fall the measurements are correct and the starter will not engage the starter is probably defective e fall the measurements are correct and the starter engages but will not crank or the engine cranks slowly perform the following checks before replacing starter Troubleshooting 2 Confirm that the cables between batteries are clean tight and in proper working order 3 Remove the engine ECU fuses located in the battery box to prevent the engine from running during tests Use a digital multimeter J 39200 or equivalent tool to perform the test in the table below The measuring points referenced in the tables as A B C etc corre spond to measuring points that are illustrated in the starting system simplified schematics and drawing See Troubleshooting Simpl
56. 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounas first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Service Procedures Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to avoid severe burns W3004730 Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from electri cal equipment connected directly to the batteries such as ECU s satellite systems etc 3 Disconnect the battery main ground cable s 4 Remove the power cable fuses and wiring from r
57. physical damage The support is also used as a path for current flow and a Batteries may contain explosive gases To help mini connection point 3 for the fuse on the long fuse assem mize the risks of explosion avoid sparks or open bly used in the D12 engines flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Use caution when working around the preheat elements When active the elements will heat to ap proximately 705 C 1300 F Allow sufficient time for the elements to cool to avoid severe burns 55 Group 33 Starting and Charging VN VHD Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the battery main ground cable s 4 Remove the nuts securing the defec t
58. ponents to access the battery cables Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect ground wiring from the electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the main ground cable s at the batteries 46 Service Procedures 4 Disconnect the positive cable s at the batteries 5 Remove all support clips brackets and cut cable ties 6 Disconnect the battery cables at the starter Note the wire positions to aid in installation 7 Remove the defective cable s Installation 8 Position the replacement cable s in the proper routing position Be sure the cable will connect to the starter and batteries when all the support clips are secure 9 Install the battery cables and wiring at the starter Torque 30 5 3 5 Nm 22 5 2 5 ft lb 30 5 3 5 Nm 22 5 2 5 ft lb 10 Install the cables into the support clips and secure beginning at the starter and working toward the battery Ob serve the installation points as noted above Support Clip Torque 18 2 Nm 13 1 5 ft lb Secure with cable ties as needed 18 2 Nm 13 1 5 ft lb 11 Connect the positive cable s and any positive wiring from electrical equip ment connected directly to the batteries 12 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition
59. positive cable s at the batteries 5 Remove the battery nuts on all battery connections and remove all cables and wiring 6 Loosen the battery hold down clamp nuts enough to allow removal of the hold down clamp assembly 7 Remove the defective battery s 8 Clean any battery post or cable termi nals as necessary Installation 9 Install the replacement battery s Ob serve that the battery positive and negative posts are oriented properly when installed Group 33 Starting and Charging VN VHD 10 Install the battery hold down clamp 24 4 Nm Torque 18 3 ft lb 24 4 Nm 18 3 ft lb 11 Install all battery cables and wiring connections removed in steps 5 Install the battery nuts hand tighten secur ing those cables wiring 12 Connect the positive cables s and any positive wiring from electrical equip ment connected directly to the batteries 13 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition switch to ON posi tion If not leave the ignition switch in the OFF position 14 Connect the main ground cable s Turn ignition switch back to OFF if necessary 15 Connect ground wiring from electrical equipment connected directly to the batteries 16 Tighten all battery cable connections 13 20 Nm Torque 10 15 ft lb 13 20 Nm 10 15 ft lb Service Procedure
60. r Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last 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 within the vehicle This applies only to vehi cles with SRS and Cummins or Detroit Diesel engine Always check for fault codes after repairs are com pleted Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components All Cables Volvo VN VHD vehicles are equipped with 2 3 or 4 bat teries depending on the engine and options ordered The batteries are connected together in parallel with battery interconnecting cables The batteries cannot be tested or serviced as a set but must be tested or ser viced individually To te
61. r equivalent tool to perform the test in the following table The measuring points referenced in the table as X Y Z etc correspond to measuring points that are illustrated in the charging system simplified schematics and drawings See Troubleshooting Simplified Schematics Charging Sys tem page 34 35 Group 33 Starting and Charging VN VHD Troubleshooting Funtion Key Posi Measuring Point Expected Note Possible Cause if expected tion Value valve not correct Alternator ON Engine Output Terminal X 13 8 14 2 V Accessories 1 Power circuit from battery Charging Running Ground Terminal Y Off res be Voltage or Ground Terminal 2 Ground circuit from battery Ya 3 Alternator belt loose missing 4 Alternator failure Charging ON Engine Batt Terminal 13 8 14 2 V Accessories If alternator charging voltage Voltage at Running A Batt Terminal Off Reading OK probable power or ground Batteries B may be slightly cable fault less than at alternator Relay Ter ON Engine Relay Terminal W Approx 1 2 Accessories 1 Probable alternator failure minal Running Ground Terminal Y Charging Volt Off Signal age 2 Check for broken or loose no 19 ire at the alternator terminal Ins Cluster ON Engine Ind Light Terminal Approx Accessories See Troubleshooting Charging Indicator Running Z Terminal Y Charging Volt Off Indicator Indicator
62. ring from the electrical equipment connected directly to the batteries 48 Service Procedures 10 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition switch to the ON po sition If not leave the ignition switch in the OFF position 11 Connect the main ground cable s Turn the ignition switch back to OFF if necessary 12 Connect ground wiring from the elec trical equipment connected directly to the batteries 13 Tighten all battery cable connections 13 20 Nm Torque 10 15 ft lb 13 20 Nm 10 15 ft lb Group 33 Starting and Charging VN VHD 3311 03 02 01 Starter Motor Replacement Volvo D12B or D12C Engine AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine
63. rns Do not keep the ignition key in the preheating position longer than approx 15 seconds Allow the starting heater to cool between each activation or damage to the preheater can occur 28 Troubleshooting Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Never use the ohmmeter mode of the DMM in a pow ered 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 Group 33 Starting and Charging VN VHD Troubleshooting Preheater with VCADS Pro Tool The VCADS Pro tool is a Windows 95 based PC tool that can be used to perform some preheater testing The following is a brief description of tests that are currently available Test number 3330 08 02 01 preheat test Indicators on the VCADS Pro screen will illuminate green when the ignition key is turned to the preheat po sition and when the preheat relay 1 and or 2 is activated The VCADS Pro Tool also displays the engine coolant temperature For detailed information about the VCADS Pro Tool op eration refer to Service VCADS Pro User s Manual Manual Troubleshooting Preheater with Fault Codes Check for stored fault codes when beginning trou bleshooting procedures for
64. rter 7 Remove the positive 1 and negative 2 cables wiring and switch terminal 3 wire from the starter Disconnect the overcrank protection switch 4 if equipped Note the cable wiring posi tion for installation 8 Remove the engine ground terminal connector 5 9 Disconnect the engine wiring harness connector 6 Remove the engine wiring harness support clamp and pull the harness away from the starter area 10 Remove the starter mounting bolts and remove the starter from the vehicle Installation 11 Compare the orientation of the nose housing on the old starter to the re placement starter If necessary remove the nose housing on the re placement starter and clock it to the position of the old starter Nose housing bolt torque 10 13 Nm 13 17 ft lb 12 Install the replacement starter and se cure the mounting bolts Torque 85 9 Nm 63 6 5 ft lb 13 Position the engine wiring harness and engage the connector 6 Install the engine wiring harness support clamp 50 10 13Nm 13 17 ft lb 85 9 Nm 63 6 5 ft lb Service Procedures 14 Install the engine ground cables 5 and secure Torque 48 8 Nm 35 6 ft lb 15 Install all starter wiring and cables Battery cable terminals 1 amp 2 torque 30 5 3 5 Nm 22 5 2 5 ft lb Switch terminal 3 torque 2 6 0 8 Nm 23 7 in lb 16 Secure the battery cables in
65. s 3714 03 02 03 Battery Cables to Starter Re placement AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last 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 in the vehicle This applies only to vehicles with SRS and Cummins or Detroit Diesel engines Check for fault codes after repairs are complete 45 Group 33 Starting and Charging VN
66. se if ex Position Value pected value not correct Power Supply to On Relay coil positive 12V Fuse connectors or Relay Coil connector A to alter wiring fault in power nate ground supply circuit Ground to Relay Off Control Wire B to al 180 kQ 20 Disconnect Connectors or wiring Coil ternate ground control wire at fault in ground circuit relay through EECU Control Signal Preheat Control Wire B to al lt 1V Relay s click in 1 Connectors or ternate ground wiring fault in ground circuit through EECU 2 Preheat relay s Relay Coil Func On Control Wire B to al Relay s click If values above are tion Test ternate ground in correct probably relay fault Power Supply Off Relay Common C 12V Connectors or wiring for Pre heater terminal to alternate fault in power supply Elements ground circuit from alternator Ground through Off Relay NO D termi lt 10 1 Preheater fuse Preheater Ele nal to alternate ground ments 2 Preheater ele ment Relay Function Preheat Relay NO D termi 9V 12V Relay s click in If power supply for pre Test nal to alternate ground heater elements correct probable relay fault Preheat Fuses Preheat Preheat element 9V 12V Relay s click in If relay function cor connection E to al rect probable pre heat ternate ground fuse fault Preheater Ele Preheat Preheat element 9V 12V With relay s If values above correct probable pre heater el eme
67. st or service the batteries all battery cables and wiring connected directly to the batteries must be re moved lf the battery cables and wiring are not removed and installed in the proper order damage to sensitive electronic equipment may occur To properly remove and install the battery cables proceed as follows Removal 1 Turn the ignition key to the OFF posi tion 2 Disconnect the ground wiring from electrical equipment connected directly to the batteries such as ECU s satel lite systems etc 3 Disconnect the main ground cable s 4 Disconnect the positive wiring from the electrical equipment connected directly to the batteries 5 Disconnect the main positive cables s 6 Disconnect the battery interconnecting cables 7 Perform battery test or service as needed 41 Group 33 Starting and Charging VN VHD Installation 8 Connect the battery interconnection cables 9 Connect the main positive cable s 10 Connect the positive wiring from the electrical equipment connected directly to the batteries 11 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition switch to the ON po sition If not leave the ignition switch in the OFF position 12 Connect the main ground cable s Turn the ignition switch back to OFF if necessary 13 Connect ground wiring from the elec trical equipm
68. starter relay Ignition switch ter 12V minal at the starter relay C alternate 1 Power supply to igni tion switch ground 2 Connectors wiring fault in circuit from ig nition switch to starter relay 3 Ignition switch Ground to Off Ground terminal lt 19 1 Connectors wiring starter relay at starter relay fault in ground circuit D alternate from starter relay ground 2 Overcrank protection switch open if equipped Battery signal Off to starter relay Battery terminal at 12V starter relay F alternate ground 1 Power supply to starter batt post 2 Connectors wiring fault in circuit from starter batt post to starter relay Start signal to Start SW terminal at 12V Reinstall 1 Connectors or wiring starter sole starter solenoid relay to con faults in starter re noid G alternate nector lay starter solenoid ground Starter relay circuit should click when 2 If values in previous energized test OK probably starter relay failure Overcrank Off OCP Switch con lt 19 Not 1 Starter overheated Protection nector K J equipped on E OCP Switch all engines 2 OCP Switch failure 26 Group 33 Starting and Charging VN VHD Troubleshooting Starter with Digital Multimeter The starter motor solenoid is supplied power and ground through cables connected directly to the batteries The starter solenoid is engaged when a 12 volt signal is de livered t
69. switch to the ON po sition If not leave the ignition switch in the OFF position Group 33 Starting and Charging VN VHD 13 Connect the main ground cable s Turn ignition switch back to OFF if necessary 14 Connect ground wiring from the elec trical equipment connected directly to the batteries 15 Tighten all battery cable connections 13 20Nm Torque 10 15 ft lb 13 20 Nm 10 15 ft lb Service Procedures 3714 03 02 04 Battery Inter connection Ca bles Replacement AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground
70. te position for re assembly 5 Remove the relay from its mounting and remove from the vehicle 6 Remove the charge air pipe hose clamp 7 Remove the charge air piping mount ing bolts at the fan ring and preheater and remove the vehicle 8 Remove the ground wire from the pre heater element book 9 Remove the preheater element block from the intake manifold 10 Clean the gasket surfaces Installation 11 Install new gasket between intake manifold and replacement preheater element block Install the preheater el ement block Install new gasket on the intake side of the preheater element block Service Procedures 12 Install the ground wire from the pre heater element block 13 Install the charge air piping Secure the mounting bolts at the preheat ele ment block Torque 24 4 Nm 18 3 ft lb secure the mounting bolts at the fan ring 14 Install and secure the charge air pipe hose clamp 15 Install the relay and secure 16 Install the power cable fuse and wiring to the relay and secure 17 Install the main ground cable s 18 Install ground wiring from electrical equipment connected directly to the batteries 19 Secure with the battery terminal nut s Torque 3 7 5 7 Nm 10 15 ft lb 24 4Nm 18 3 ft lb 3 7 5 7 Nm 10 15 ft lb 61 Group 33 Starting and Charging VN VHD 3211 03 02 03 Alternator Replacement Ad justable Mount AN DANG
71. the mounting support brackets 17 Install the inner fender assembly 18 Install the splash shield 19 Install the main ground cable s 20 Install ground wiring from the electrical equipment connected directly to the batteries 21 Secure with the battery terminal nut s Torque 3 7 5 7 Nm 10 15 ft lb 48 8 Nm 35 6 ft lb 30 5 3 5 Nm 22 5 2 5 ft lb 2 6 0 8 Nm 23 7 in lb 3 7 5 7 Nm 10 15 ft lb Group 33 Starting and Charging VN VHD 3311 03 02 01 Starter Motor Replacement Volvo D7C Engine AN DANGER 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 in jury or death Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention Never disconnect an air system component unless all system pressure has been depleted Failure to de plete system pressure before disconnecting hoses or components may result in them separating violently causing serious eye and or body injury HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns Batteries may contain explosive gases To help mini mize t
72. ttery Jump Starting AN DANGER 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 in jury or death Do not use a Hot Shot type starting cart as most use extremely high voltages Use of Hot Shot device to jump start the vehicle will seriously damage the ECU s and other electrical equipment Do not attempt to jump start a vehicle equipped with Delco Maintenance Free batteries if the test indicator light is yellow Replace the battery instead Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion If contacted with sulfuric acid flush immediately with water and get medical at tention Batteries may contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries Service Procedures W3002432 If the vehicle needs to be jump started use starting bat teries DO NOT use battery chargers with boosting capability These utilize a high voltage that will cause damage to the vehicle electrical and electronic compo nents When jumping batteries to start an engine it is important that the jumper cables are connected directly from one set of batteries in one vehicle to the other set of batter
73. ue 109 11 Nm 80 8 ft lb 8 Install the replacement alternator and 88 Nm tighten the mounting bolts 65 5 ft lb Torque 88 7 Nm 65 5 ft lb 64 Service Procedures 9 Use fan belt tensioner tool J 44392 or equivalent tool to release the pres sure from the automatic belt tensioner and install the belt onto the alternator pulley 10 Connect all alternator wiring Torque BATTERY TERMINAL 6 5 0 5 Nm 58 5 in lb GROUND TERMINAL 6 2 0 5 Nm 55 5 in lb I TERMINAL 2 3 0 5 Nm 20 5 in lb R TERMINAL 2 3 0 5 Nm 20 5 in lb 11 If the vehicle is equipped with a Sup plemental Restraint System SRS and a Cummins or Detroit Diesel engine turn the ignition switch to the ON po sition If not leave the ignition in the OFF position 12 Connect the main ground cable s Turn ignition switch back to OFF if necessary 13 Connect ground wiring from the elec trical equipment connected directly to the batteries 14 Tighten all battery cable connections 3 7 5 7 Nm Torque 10 15 ft lb 3 7 5 7 Nm 10 15 ft lb Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of our literature your opinions and experience when using this manual would be
74. uit With the engine running DC voltage is generated at the alternator output B terminal and supplied to the vehi cles electrical system through wire no 8 The alternator is grounded by a wire from the ground terminal B on the alternator case to the engine ground terminal A fusible link in the ground circuit is designed to protect the vehicle electrical system if a short in the alternator alter nator cable or battery cable occurs A wire from the alternator indicator light terminal to the instrument cluster sends a signal to indicate that the alternator is not charging Vehicles with body builder ap plications may also have a wire from the alternator relay terminal to provide engine speed information for PTO op eration Also see Starting and Charging Simplified Schematic in Starting and Charging page 3 GRONA Design and Function W3004731 Output Terminal B Ground Terminal B Relay Terminal Indicator Light Terminal Ground Terminal B 34S only Group 33 Starting and Charging VN VHD Alternator The alternator converts the mechanical energy supplied by the engine via drive belts into electrical energy that is used to recharge the batteries and operate the electrical devices on the vehicle The alternator produces alternat ing current AC which is converted to direct current DC by the diodes in the rectifier bridge The rectifier bridge also has design features to clamp voltage spikes that
75. uster and bulb check Test the Charging Indicator telltale lamps ability to function by running the Bulb Test from the instrument cluster self test menu Use the graphic display control buttons to ac cess the System Diagnostics menu select Cluster Self Test then Bulb Test With the bulb test active all the telltale and LED indicator lamps including the Charging telltale will illuminate for approximately 5 seconds With the bulb test active the charging indi cator wiring is ignored and the test is operated by the instrument cluster internal electronics If the indi cator does not illuminate properly refer to Service Instrumentation VN from 3 99 Manual VHD IMPACT Function Group 381 Information Type Diagnostics Instrument Cluster Tests e Wiring check grounded circuit With the ignition key ON and the engine not running the Charging Troubleshooting telltale should be illuminated Disconnect the wire at the indicator light terminal Z The Charging telltale should go off If not check for a grounded circuit be tween the alternator and instrument cluster If a grounded circuit is indicated refer to manual below for detailed vehicle specific schematics Service Electrical Schematics VN VHD Manual IMPACT Function Group 370 Information Type Schematics Wiring check open circuit With the ignition key ON and the engine not running the Charging tell tale should be il
76. with VCADS Pro Tool 24 Troubleshooting Battery Starter Cables With Digital Multimeter 25 Troubleshooting Ignition Switch Starter Relay Circuit With Digital A Sess ctcs2i at bescg SA RD E ER saeco ms CR RR 26 Troubleshooting Starter with Digital Multimeter eee 27 Preheat System Troubleshooting 28 Troubleshooting Preheater with VCADS Pro Tool 29 Troubleshooting Preheater with Fault Codes c eecceeeeeeeeeeeees 29 Troubleshooting Simplified Schematic D7 Preheater 30 Troubleshooting Simplified Schematic D12 Preheater ol Troubleshooting Preheater with Digital Multimeter se Charging System Troubleshooting 33 Troubleshooting Simplified Schematics Charging System 34 Troubleshooting Charging System with Digital Multimeter 35 Troubleshooting Charging Indicator Telltale Lamp 37 Troubleshooting Alternator Output Test with BVA 34 Tester 38 Troubleshooting Starting and Charging System with The Accu taty Plus TESIS wecsrtsccssncstiurisneanaclenedzectaeareeninasendosnemmnsgurenecsvetmaqueaians 39 DEVICE PIOCEOUTES cin 41 Battery Cables Removal and Installation ii 41 DADO arana 41 Ground Cable Battery Jump St or DiZG ncassediside lide ne alias y Replacement gine Alternator R
77. y cable terminals torque 22 5 2 5 ft lb 30 5 3 5 Nm 2 6 0 8 Nm 22 5 2 5 ft lb 23 7 in lb switch terminal torque 2 6 0 8 Nm 23 7 in lb 14 Secure the battery cables in the mounting support brackets and cable dividers Secure with cable ties as needed 15 Install the inner fender assembly 16 Install the splash shield 17 If the vehicle is equipped with a Sup plemental Restraint System SRS turn the ignition switch to the ON po sition If not leave the ignition switch in the OFF position 54 Service Procedures 18 Install the main ground cable s Turn ignition switch back to OFF if neces sary 19 Install ground wiring from electrical equipment connected directly to the batteries 20 Secure with the battery terminal nuts 3 7 5 7Nm Torque 10 15 ft lb 3 7 5 7 Nm 10 15 ft lb Group 33 Starting and Charging VN VHD Service Procedures 3331 03 02 02 Preheater Fuse Replacement AN DANGER 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 in jury or death HOT ENGINE Keep clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns W3004715 The preheat fuse assembly includes a support 1 de N WARNING signed to protect the fuse 2 from
78. y contain explosive gases To help mini mize the risks of explosion avoid sparks or open flames near batteries Do not smoke when servicing batteries If there are other ground cables connected to the bat tery such as engine ECU s satellite system etc disconnect those grounds first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are con nected disconnected without the main battery ground connected Disconnect the main battery ground last 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 within the vehicle This applies only to vehi cles with SRS and a Cummins or Detroit Diesel engine Always check for fault codes after repairs are completed Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components Failure to de energize circuits may result in permanent damage to electronic components Group 33 Starting and Charging VN VHD Battery State of Charge The battery state of charge must be determined before battery testing Battery hydrometers that measured bat tery acid specific gravity were used to determine the state of charge in earlier battery designs with removable filler caps In current maintenance free design

Starting and Charging - VN,VHD - Heavy Haulers RV Resource Guide

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