Service Manual Trucks - Heavyhhrvresource.com/VolvoDocs/30-37/PV776-TSP146025.pdf · The tools referenced in this manual are listed below. They can be obtained by contacting your

Service ManualTrucks

Group 330–500

Starting and Charging

VN, VHD

PV776-TSP146025

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 producedafter 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 ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave 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 theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP146025

© 2001 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral .................................................................................................... 3

Starting and Charging ........................................................................... 3

Tools ........................................................................................................ 5Special Tools ......................................................................................... 5

Design and Function ............................................................................. 9Starting and Charging System Indicator Lights .................................... 9Battery ................................................................................................... 9

Cold Cranking Amps ....................................................................... 10Reserve Capacity ............................................................................ 10Open Circuit Voltage ....................................................................... 10

Battery Locations .............................................................................. 10Battery Cables ................................................................................... 11Battery Disconnect Switch ................................................................ 11

Starting System ................................................................................... 12Starting Circuit ................................................................................... 12Starter ................................................................................................ 13

Preheat System ................................................................................... 13Preheat Circuit ................................................................................... 13Preheater Assembly .......................................................................... 14

Charging System ................................................................................. 15Charging Circuit ................................................................................. 15Alternator ........................................................................................... 16

Troubleshooting ................................................................................... 17Battery Troubleshooting ....................................................................... 17

Battery State of Charge .................................................................... 18Battery Surface Charge Removal ..................................................... 19Load Testing Batteries ....................................................................... 20Electronic Battery Testing .................................................................. 21

Starting System Troubleshooting ......................................................... 22Troubleshooting Simplified Schematic, Starting System ................... 23Troubleshooting Ignition Switch with VCADS Pro Tool ..................... 24Troubleshooting Battery/Starter Cables With Digital Multimeter ....... 25Troubleshooting Ignition Switch/Starter Relay Circuit With DigitalMultimeter .......................................................................................... 26Troubleshooting Starter with Digital Multimeter ................................ 27

Preheat System Troubleshooting ........................................................ 28Troubleshooting Preheater with VCADS Pro Tool ............................. 29Troubleshooting Preheater with Fault Codes .................................... 29Troubleshooting Simplified Schematic, D7 Preheater ....................... 30Troubleshooting Simplified Schematic, D12 Preheater ..................... 31Troubleshooting Preheater with Digital Multimeter ............................ 32

Charging System Troubleshooting ...................................................... 33Troubleshooting Simplified Schematics, Charging System ............... 34Troubleshooting Charging System with Digital Multimeter ................ 35Troubleshooting Charging Indicator (Telltale) Lamp .......................... 37Troubleshooting — Alternator Output Test with BVA-34 Tester ........ 38Troubleshooting Starting and Charging System with The Accu-racy Plus Tester ................................................................................. 39

Service Procedures ............................................................................. 41Battery Cables, Removal and Installation ........................................... 41

All Cables .......................................................................................... 41

1

Ground Cables .................................................................................. 42Battery Jump Starting .......................................................................... 43Battery, Replacement (One or Two) .................................................... 44Battery Cables to Starter, Replacement ............................................. 45Battery Inter-connection Cables, Replacement ................................... 47Starter Motor, Replacement ................................................................ 49

Volvo D12B or D12C Engine ............................................................. 49Starter Motor, Replacement ................................................................ 51

Volvo D7C Engine ............................................................................. 51Starter Motor, Replacement ................................................................ 53

Cummins or Detroit Diesel Engine .................................................... 53Preheater Fuse, Replacement ............................................................ 55Preheater Relay, Replacement ............................................................ 56

Volvo D12B or D12C Engine ............................................................. 56Preheater Relay, Replacement ............................................................ 58

D7C Engine ....................................................................................... 58Preheater Element, Replacement ....................................................... 59

D12B or D12C Engine ...................................................................... 59Preheater Element, Replacement ....................................................... 60

D7C Engine ....................................................................................... 60Alternator, Replacement (Adjustable Mount) ...................................... 62Alternator, Replacement (Fixed Mount) .............................................. 63

Feedback

Operation Numbers

2

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 andall 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:

VendorInformation

Diagnostic Procedures For Heavy Duty Electrical Systems

Delco Remy DRA/DP1029

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 detailed vehicle-specific schematics, refer to:

ServiceManual

Electrical Schematics VN, VHD

IMPACT Function Group: 370Information Type: Schematics

3

4

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 partsdealer, Kent-Moore at 1–800–328–6657, or you may call a local listed tool vendor.

Note: For VCADS Pro tooling refer to:

ServiceManual

VCADS Pro User’s ManualGroup Number 030–600

Battery tester kit. Includes: Tester J-44700 and Printer238598, 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

5


Relay puller tool, available from Kent-Moore (telephone:800–328–6657).

J-43244

W0001917

VCADS ProFor VCADS Pro tooling refer to:

ServiceManual


W0001632

Fan Belt Tensioner Tool, available from Volvo or Kent-Moore (telephone: 800–328–6657).

J-44392

W0001817

(BT-33–73F) Belt Tension Gauge, available from Kent-Moore (telephone: 800–328–6657).

J-23600–B

W0001844

6


BVA-34 System AnalyzerThe 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 heavytruck market. Optional tester stand, part number ES-2, isalso available . For more information contact Auto-Meter® (telephone: 435–283–4142) or visit their web siteat www.autometer.com.

W3004737

7

8

Group 33 Starting and Charging VN, VHD Design and Function

Design and Function

Starting and Charging System Indicator LightsWhen the ignition key is turned “ON,” the Charging Indi-cator (telltale) lamp (1) will momentarily illuminate for abulb test. The lamp will remain on until the engine isstarted. With the engine running and the alternator prop-erly charging, the Charging telltale light should go off.

The instrument cluster left module is equipped with agraphics display (2) that includes a voltmeter function.With the voltmeter function active, the display will show abattery icon and display the battery/charging voltage.

W3004552

If the battery/charging voltage exceeds 17 volts, the yel-low “INFO” lamp (3) will illuminate and the graphicdisplay will show the voltage reading with the text mes-sage “TOO HIGH.”

T3008832

TOO HIGH17.9 V

BatteryThe battery is an electrochemical device for convertingchemical energy into electrical energy. The battery, orbattery 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 electricalsystem during peak demands, for instance, whenthe alternator is already at maximum output.

The battery case (1) is made of a strong, lightweight ma-terial, commonly polypropylene, to withstand shock andvibration. The cover is vented to allow chemical gases toescape. Each battery cell (2) is constructed of positiveand negative plates (3) that are insulated from eachother by a porous separator (4). Plate straps (5) connectthe positive and negative plates and provide a means ofinterconnecting the cells. The cell is immersed in anelectrolyte solution of sulfuric acid and water. The electri-cal energy is produced in the battery by the chemicalreaction of the active materials that comprise the positiveand negative plates and the electrolyte. Each cell willproduce approximately 2.1 volts. The six cells that com-prise the battery are connected in series to deliverapproximately 12.6 volts at the battery post (6).

W3004553

9


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 voltage falling below 7.2 volts. Thisrating is useful in determining the battery’s ability tostart an engine in cold weather conditions. The coldcranking amp rating is determined by the amount ofplate surface area in each cell.

Reserve Capacity

The “Reserve Capacity” is the number of minutes thata battery can sustain a 25 Amp load at 27�C (80�F)until the post voltage drops to 10.5 volts. This rating isuseful in determining the battery’s ability to supplyoperating power in the event of a vehicle charging sys-tem failure. The reserve capacity is determined by theamount of active plate material in each cell.

Open Circuit VoltageThe “Open Circuit Voltage” is the voltage at the batterypost with no loads applied.

Battery LocationsBattery box locations vary per application. The stan-dard mounting location (1) is on the left frame railunder the cab steps. This is the mounting location forall VN and some VHD vehicles. Depending on theequipment ordered, there are three optional batterybox mounting locations for the VHD vehicle. See illus-tration for locations: (2), (3) and (4).

W3004555

10


Battery CablesAll copper, 3/0 battery cables (1) are used on VN/VHDvehicles. Single cables are used if the batteries aremounted in the standard location. If the batteries aremounted in optional locations, dual cables are used toprevent excessive voltage drop due to cable length. Bat-tery inter-connection cables (2) are 2/0 size. Someapplications 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 batterieswith either stainless steel terminal nuts (3) or brassjumper studs (4). Some applications may be equippedwith insulated terminal nuts that are made of plastic witha brass insert. Protective covers (6) are installed on alluninsulated battery cable terminal nuts/studs. Mountingbrackets (5) support and secure the battery cables at ap-proximately 300 mm (12 in.) to 600 mm (24 in.) intervalsto avoid damage from abrasion, vibration, heat andstrain.

Ideally, battery sets should be connected to the bat-tery/starter cables in a diagonal pattern (1) rather thanboth cables being connected to one battery at the end ofthe set (2). The diagonal connection will help assure thatall batteries in the set are cycled at the same rate, ex-tending service life.

W3004556

W3004557

Battery Disconnect SwitchAs an option, some vehicles may have a master batterydisconnect switch (main switch). The switch will bemounted on or near the battery box in all applications.The battery disconnect switch should not be used as asubstitute for removing battery cables to prevent damageto the vehicle when welding.

W3004404

11


Starting System

Starting CircuitWhen the ignition switch is turned to the “START” posi-tion, power to energize the starter relay coil is suppliedon wire number 284. The starter relay coil is groundedthrough the overcrank protection switch (OCP) or ashorting jumper.

The OCP switch is located inside the starter. This switchis optional. Where the OCP switch is not used, a short-ing jumper is used to complete the starter relay coilground circuit.

W3004339

overcrank protection (OCP) input switch.

When the starter relay is energized, a connection ismade from the starter solenoid BATT terminal (wire285A) 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 terminalto the motor terminal, then the starter begins to crankthe engine.

For more details see schematic in “Starting and Charg-ing” page 3.

W3003757

Starter Relay.

12


StarterVolvo VN/VHD vehicles are equipped with Delco Remy-42MT starters for most applications. If the vehicle isequipped with a Volvo D7 engine, it will be equipped witha Delco-Remy 37MT starter. These starters, sometimesreferred to as starting motors, have a shift lever and so-lenoid housing that is totally enclosed to protect themfrom the elements. The nose housing can be rotated to“clock” the solenoid to accommodate various enginemounting locations. A positive engagement shift mecha-nism moves the pinion into mesh with the engineflywheel ring gear prior to cranking to minimize geartooth damage. An optional overcrank protection (OCP)switch protects the starter in adverse starting conditions,such as cold weather starting or operator misuse. TheOCP switch is a temperature sensitive circuit breakerthat prevents overcrank heat damage by opening thestarter relay ground, then automatically resetting whenthe starter has cooled sufficiently.

W3004558

1 Solenoid2 Shift Lever Housing3 Nose Housing4 Pinion5 Overcrank Protection Input Switch

Preheat System

Preheat CircuitVehicles equipped with Volvo engines may be equippedwith 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 withtwo 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 theEngine Electronic Control Unit (EECU), via the J-1939Control Data Link. The EECU will supply a ground to thepreheat 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 alsohold the ignition switch in the “preheat” position if addi-tional preheat is desired after the timed preheat period.

The preheat relay(s) coil is supplied ignition power via afuse in the Truck Electrical Center (TEC) panel. The re-lay(s) is energized when a ground is supplied by theEECU. When the relay(s) is energized, an internal con-nection is made that connects the preheater elementpower supply from the alternator cable to the fuse thatconnects to the preheat element(s). The preheat ele-ment(s) are case grounded.

A “sense” circuit(s) provides information to the EECU toconfirm that the preheat circuit is intact. If the EECU de-termines that the circuit is not intact, a fault code(s) willbe generated.

For simplified schematic see: “Starting and Charging”

page 3.

13


Preheater Assembly

WARNING

Use caution when working around the preheatelements. When active, the elements will heat to ap-proximately 705�C (1300�F). Allow sufficient time forthe elements to cool to avoid severe burns.

The preheater assembly on a D7 engine is standard withone relay element and fuse. The preheater assembly ona D12 engine is optional with two relays, elements andfuses.

W3004559

1 Relay2 Element3 Fuse Assembly

14


Charging System

Charging CircuitWith the engine running, DC voltage is generated at thealternator output (B+) terminal and supplied to the vehi-cles electrical system through wire no. 8. The alternatoris grounded by a wire from the ground terminal (B-) onthe alternator case to the engine ground terminal. Afusible link in the ground circuit is designed to protect thevehicle electrical system if a short in the alternator, alter-nator cable or battery cable occurs.

A wire from the alternator indicator light terminal to theinstrument cluster sends a signal to indicate that thealternator is not charging. Vehicles with body builder ap-plications may also have a wire from the alternator relayterminal to provide engine speed information for PTO op-eration. Also see Starting and Charging SimplifiedSchematic in “Starting and Charging” page 3.

W3004731

1 Output Terminal (B+)2 Ground Terminal (B-)3 Relay Terminal4 Indicator Light Terminal5 Ground Terminal (B-) 34SI only

15


AlternatorThe alternator converts the mechanical energy suppliedby the engine via drive belts into electrical energy that isused to recharge the batteries and operate the electricaldevices 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 rectifierbridge also has design features to “clamp” voltage spikesthat may damage vehicle electronics. An internal voltageregulator limits the charging voltage from 13.8 to 14.2volts. Volvo VN/VHD vehicles currently are equipped withone of three different Delco Remy alternators:

• 33SI — The 33SI alternator is a brushless designfor longer operating life. It is the standard alternatorused in most applications. It is available with 110and 135 amp output ratings.

• 22SI — The 22SI alternator is a smaller, standardbrush type alternator. It is available with 100, 130and 145 amp output ratings.

• 34SI — The 34SI alternator is internally identical tothe 33SI. The major difference is that the housinghas a fourth mounting lug to withstand higher vibra-tion applications. The 34SI is currently only used inVN vehicles equipped with Detroit Diesel engines.

W3004561

16

Group 33 Starting and Charging VN, VHD Troubleshooting

TroubleshootingBattery Troubleshooting

Before working on a vehicle, set the parking brakes,place the transmission in neutral, and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

WARNING

Always wear eye protection when working around bat-teries to prevent the risk of injury due to contact withsulfuric acid or an explosion. (Important: If contactedwith sulfuric acid, flush immediately with water andget medical attention).

WARNING

Batteries may contain explosive gases. To help mini-mize the risks of explosion, avoid sparks or openflames near batteries. Do not smoke when servicingbatteries.

CAUTION

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 mainbattery ground cable. Electronic modules may bedamaged when additional grounds are con-nected/disconnected without the main battery groundconnected. Disconnect the main battery ground last.

CAUTION

In vehicles with a Supplemental Restraint System(SRS), turn the ignition switch ON before connectingthe battery. Failure to do so may result in permanentdamage to the instrument cluster or other electroniccircuits within the vehicle. (This applies only to vehi-cles with SRS and a Cummins or Detroit Dieselengine.) Always check for fault codes after repairs arecompleted.

CAUTION

Possible damage to electronic components. Turn thevehicle ignition switch OFF before disconnecting orconnecting any electronic components. Failure tode-energize circuits may result in permanent damageto electronic components.

17


Battery State of ChargeThe battery state of charge must be determined beforebattery testing. Battery hydrometers that measured bat-tery acid specific gravity were used to determine thestate of charge in earlier battery designs with removablefiller caps. In current “maintenance free” design batteriesthe 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 glancethe battery’s state-of-charge. The hydrometer has agreen ball within a cage which is attached to a clear,plastic rod. The green ball will float at a predeterminedspecific gravity of the electrolyte that represents about65% state-of-charge. When the green ball floats, it riseswithin 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 forbattery testing and charging.

In testing, the green dot means the battery is chargedenough for testing. If the green dot is not visible, itmeans the battery must be charged before the test pro-cedure is performed.

In charging, the appearance of the green dot means thatthe battery is sufficiently charged.

The hydrometer on some batteries may be clear or lightyellow. This means the fluid level is below the bottom ofthe rod and attached cage. This may have been causedby 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 batterycell. Low state of charge in other cells will not be indi-cated by the built-in hydrometer.

The battery state of charge may also be checked byreading the open circuit voltage. To check, connect avoltmeter to the positive and negative battery post. If thereading is below 12.40 volts, the battery is too low forproper testing and must be recharged. If the reading isabove 12.66 volts, the surface charge must be removedbefore testing. See: “Battery Surface Charge Removal”page 19.

W3004562

1. State of charge 65% or above2. Below 65% state of charge3. Low electrolyte level

18


Battery Surface Charge RemovalWhen a battery is charged, very small hydrogen gasbubbles form on the surface of the battery plates, caus-ing what is known as “surface charge.” When a voltmeteris 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:

• Turn on the headlights for 2–3 minutes. Then allowthe battery to stabilize for 1 minute before testing.

• Remove the Engine ECU fuse in the battery box toprevent the engine from starting. Start the enginefor 5–10 seconds. Then allow the battery to stabilizefor 1 minute before testing.

• Use BVA-34 System Analyzer or equivalent tool toload the battery to 300 amps for 5–10 seconds.Then allow the battery to stabilize for 1 minute be-fore testing.

Note: The open circuit voltage must be at least 12.4volts after the surface charge has been removed to con-tinue battery testing.

19


Load Testing BatteriesThe 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 heavytruck market. The test that follows may be performedwith the BVA-34 System Analyzer, or equivalent carbonpile type tester, and should be used as a general guidefor performing a battery load test. Read and follow thetest instructions supplied with the tester used to performbattery testing.

1 Batteries must be tested individually. Removebattery 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, ifequipped. Clean the terminals if needed. Replacedamaged batteries or batteries with clear hydrome-ter eyes (indicates electrolyte loss).

3 Screw the brass “jumper studs” onto the positiveand negative terminal before connecting the tester.Do not connect the tester leads directly to the bat-tery terminal post.

4

W3004563

Connect the BVA-34 System Analyzer (or equivalenttool) to the battery as shown. Set the voltmeter tothe “INTERNAL” setting. Zero the ammeter.

5 Check the battery open circuit voltage. The readingmust 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 thebattery’s Cold Cranking Amp (CCA) rating. The bat-tery CCA specification can be found on the batterylabel. Maintain the load for 15 seconds then notethe battery voltage (with load applied).

7

ESTIMATEDELECTROLYTETERMPERATURE

MINIMUM REQUIREDVOLTAGE UNDER 15SECOND 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 batterydoes not meet or exceed the minimum voltage re-quired, replace the battery.

20


Electronic Battery TestingThe J-44700 Accuracy Plus HD Battery Tester is a handheld electronic battery diagnostic tester. The tester ap-plies variable loads to the battery and measures thebattery’s response. Results are then displayed and maybe printed if desired with the optional printer number238598. Both the J-4477 Accuracy Plus tester and the238598 printer are available in kit part number J-44701.

The test that follows may be performed with the J-44770Accuracy Plus HD Battery Tester, or equivalent elec-tronic testers, and should be used as a general guide forperforming electronic battery testing. Read and followthe test instructions supplied with the electronic testequipment used to perform battery testing.

1 Batteries must be tested individually. Removebattery 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 ifequipped. Clean the terminals if needed. Replacedamaged batteries or batteries with clear hydrome-ter eyes (indicates electrolyte loss).

3 To operate the Accuracy Plus tester, connect thepositive and negative tester leads to the battery studposts. Select the “Battery Test” and follow the onscreen prompts until the test is complete. Test re-sults will appear on screen.

W0001836

J-44700 Accuracy Plus HD Battery Tester.

21


Starting SystemTroubleshooting


WARNING


WARNING


WARNING

HOT ENGINE! Keep clear of all moving parts or hotengine parts and/or fluids. A hot engine an/or fluidscan cause burns.

CAUTION


CAUTION

Never use the ohmmeter mode of the DMM in a pow-ered circuit, or as a substitute for a voltmeter orammeter, since this will result in damage to the instru-ment. Use the ohmmeter mode only when power isremoved from the circuit.

22


Troubleshooting SimplifiedSchematic, Starting SystemThe 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/StarterRelay Circuit With Digital Multimeter” page 26 and “Troubleshooting Starter with Digital Multimeter” page 27. For de-tailed, vehicle-specific schematics refer to:

ServiceManual



W3004564

W3003745

StarterMotor

H, I, J and K are measuring points. For details see“Troubleshooting Battery/Starter Cables With DigitalMultimeter” page 25.

W3003744

StarterRelaySwitch

The connector is illustrated from the relay insertion side.

C=86 12V from Ignition SwitchD=85 Coil GroundE=87 12V to Starter SolenoidF=30 12V Supply

23


Troubleshooting Ignition Switchwith VCADS Pro ToolThe VCADS Pro Tool is a Windows 95 based PC toolthat 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 greenwhen the ignition key is turned to the “Start” position.

For detailed information about the VCADS Pro Tool op-eration see refer to:

ServiceManual


Note: This test only applies to vehicles with a VehicleECU (Volvo engines).

W0001632

24


Troubleshooting Battery/StarterCables With Digital MultimeterThe starter is supplied power and ground through cablesconnected directly to the batteries. Excessive resistancein the cables or connectors will cause decreased currentflow to the starter.

Due to the high current flow demands of the startingcircuit, voltage drop tests are more effective than ohm-meter tests in determining if excessive resistance existsin the cable assemblies.

1 Check for 12.4V at the battery cable terminals (A1 &B1) to the starter motor. If 12.4 V is not present or ifa 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 voltsper 100 amps current draw. Specification assumes atypical 700 amps starting current draw.

3 Confirm that the cables between batteries are clean,tight and in proper working order.

4 Remove engine ECU fuses, located in the batterybox, to prevent the engine from running during thetests.

Use the digital multimeter J-39200 or equivalent tool toperform the test in the table below. The measuringpoints referenced in the tables as A,B,C etc. correspondto measuring points that are illustrated in the simplifiedschematics and drawing. See: “Troubleshooting Simpli-fied Schematic, Starting System” page 23.

Note: Due to battery mounting locations some vehicleswill 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 voltsper 100 amp current draw. Specification assumes amaximum of 700 amps starting current draw and normalcircuit temperature of 20�C (68� F).

Function Key Position Measuring Point ApproximateValue

Note Possible Cause (if ex-pected value not correct)

PositiveCable

Start Battery positive-post (A1)/Starter"BATT" post (H)

<0.7 V drop. SeeNote 2 above.

Starter crankingengine

Positive battery cable orconnectors

Negativecable

Start Battery negativepost (B1)/Groundpost at starter (I)

<0.7 V drop. SeeNote 2 above.


Negative battery cable orconnectors

PositiveInter-ConnectCables

Start Individual BatteryPositive PostA1/A2; A2/A3;etc.

<0.1 V dropbetween any termi-nals


Positive battery intercon-nect cable or connections

NegativeInter-ConnectCables

Start Individual BatteryNegative PostB1/B2;B2/B3;etc.

<0.1 V dropbetween any termi-nals


Negative battery intercon-nect cable or connections

25


Troubleshooting IgnitionSwitch/Starter Relay Circuit WithDigital MultimeterWhen the “start” position is selected at the ignitionswitch, 12 volts are supplied to the starter relay coil. Ifthe starter relay coil is properly grounded, either directlyor 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 between the battery that con-nects to the “common” terminal, and the starter solenoidswitch feed, that connects to the “normally open” termi-nal. With this connection made, 12 volts are supplied tothe starter solenoid, which engages, and the starter mo-tor begins to crank the engine.

The overcrank protection switch is designed to open andprevent the starter from turning if the starter becomesexcessively hot. It should reset when the starter coolssufficiently.


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 duringthe 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 pointsreferenced in the tables as A,B,C, etc. correspond tomeasuring points that are illustrated in the starting sys-tem simplified schematics and drawing. See“Troubleshooting Simplified Schematic, Starting System”page 23.

Function KeyPosition

Measuring Point ExpectedValue

Note Possible Cause (ifexpected value not cor-rect)

Start signal tostarter relay

Start Ignition switch ter-minal at the starterrelay (C)/alternateground

12V 1 Power supply to igni-tion switch

2 Connectors/ wiringfault in circuit from ig-nition switch to starterrelay

3 Ignition switch

Ground tostarter relay

Off Ground terminalat starter relay(D)/alternateground

<1 1 Connectors/ wiringfault in ground circuitfrom starter relay

2 Overcrank protectionswitch open (ifequipped)

Battery signalto starter relay

Off Battery terminal atstarter relay(F)/alternateground

12V 1 Power supply tostarter "batt" post

2 Connectors/ wiringfault in circuit fromstarter "batt" post tostarter relay

Start signal tostarter sole-noid

Start SW terminal atstarter solenoid(G)/alternateground

12V Reinstallrelay to con-nector.Starter relayshould"click" whenenergized.

1 Connectors or wiringfaults in starter re-lay/starter solenoidcircuit

2 If values in previoustest OK, probablystarter relay failure

OvercrankProtection(OCP) Switch

Off OCP Switch con-nector (K/J)

<1 Notequipped onall engines

1 Starter overheated

2 OCP Switch failure

26


Troubleshooting Starter withDigital MultimeterThe starter motor/solenoid is supplied power and groundthrough cables connected directly to the batteries. Thestarter solenoid is engaged when a 12 volt signal is de-livered to the “SW” terminal via the starter relay. Whenthe starter solenoid engages, a connection is made in-ternally in the solenoid that connects the battery andmotor terminals and the starter cranks the engine.


2 Confirm that the cables between batteries are cleantight and in proper working order.

3 Remove the engine ECU fuses located in the batterybox to prevent the engine from running during tests.

Use a digital multimeter J-39200 or equivalent tool toperform the test in the table below. The measuringpoints referenced in the tables as A, B, C etc. corre-spond to measuring points that are illustrated in thestarting system simplified schematics and drawing. See:“Troubleshooting Simplified Schematic, Starting System”page 23.

Function Key Position MeasuringPoint

ExpectedValue

Note Possible Cause (if expectedvalue not correct)

Power supplyfrom batter-ies

Off Starter "Batt"post (H) / al-ternateground

12V 1 Positive battery cable or con-nectors. See: “TroubleshootingBattery/Starter Cables WithDigital Multimeter” page 25.

Ground frombatteries

Off Ground postat starter (I) /alternateground

<1 1 Negative battery cable or con-nectors. See: “TroubleshootingBattery/Starter Cables WithDigital Multimeter” page 25.

Start signalfrom starterrelay.

Start Starter "SW"terminal (G)/alternateground

12V Startershouldcrank withterminal en-ergized

1 Starter relay.

2 Connectors or wiring faults instarter relay/ignition switch cir-cuit. See: “TroubleshootingIgnition Switch/Starter RelayCircuit With Digital Multimeter”page 26.

• If all the measurements are correct and the starterwill not engage, the starter is probably defective.

• If all the measurements are correct and the starterengages, but will not crank or the engine cranksslowly, perform the following checks before replacingstarter:

1 Check that the engine can be manually turned witha 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 enginemore difficult to turn and will reduce the batteriesoutput.

3 Perform the test “Troubleshooting Battery/StarterCables With Digital Multimeter” page 25.

27


Preheat System Troubleshoot-ing


CAUTION

Use caution when working around the preheatelements. When active, the elements will heat to ap-proximately 705�C (1300�F). Allow sufficient time forthe elements to cool to to avoid severe burns.

CAUTION

Do not keep the ignition key in the preheating positionlonger than approx. 15 seconds. Allow the startingheater to cool between each activation or damage tothe preheater can occur.

CAUTION


CAUTION

Never use the ohmmeter mode of the DMM in a pow-ered circuit, or as a substitute for a voltmeter orammeter, since damage to the instrument will result.Use the ohmmeter mode only when power is removedfrom the circuit.

28


Troubleshooting Preheater withVCADS Pro ToolThe VCADS Pro tool is a Windows 95 based PC toolthat can be used to perform some preheater testing. Thefollowing is a brief description of tests that are currentlyavailable.

Test number — 3330–08–02–01, preheat test.

Indicators on the VCADS Pro screen will illuminategreen 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 coolanttemperature.

For detailed information about the VCADS Pro Tool op-eration, refer to:

ServiceManual

VCADS Pro User’s Manual

Group Number 030–600

W0001632

Troubleshooting Preheater withFault CodesCheck for stored fault codes when beginning trou-bleshooting procedures for preheating. If any of thefollowing fault codes is present, refer to:

ServiceInformation

Fault Tracing InformationDiagnostics Binder

IMPACT Function Group: 0Information Type: Diagnostics

• MID 128 — PID 45, preheating

• MID 128 — SID 70, preheating element 1

• MID 128 — SID 71, preheating element 2

29


Troubleshooting SimplifiedSchematic, D7 PreheaterThe simplified schematic and lllustration below should clarify the procedures in “Troubleshooting Preheater with DigitalMultimeter” page 32. For detailed, vehicle-specific schematics refer to Function Group 370, Service Manual: ElectricalSchematics VN, VHD. Information Type: Schematics.

W3003776

Wire color codes in schematic:SB Solid BlackBL/R Blue/RedR RedR/W Red/WhiteY YellowGN Green

W3003778

A, B, C and D are measuring points. See:“Troubleshooting Preheater with Digital Multimeter” page32 for more information.

30


Troubleshooting SimplifiedSchematic, D12 PreheaterThe simplified schematic and lllustration below should clarify the procedures in “Troubleshooting Preheater with DigitalMultimeter” page 32. For detailed, vehicle-specific schematics refer to Function Group 370, Service Manual: ElectricalSchematics VN, VHD. Information Type: Schematics.

W3003777

Wire color codes in Schematic:SB Solid BlackBL/R Blue/RedR/W Red/WhiteY YellowGN Green

W3003779

A, B, C and D are measuring points. See:“Troubleshooting Preheater with Digital Multimeter” page32 for more information. 1: Relay 1, 2: Relay 2.

31


Troubleshooting Preheater withDigital MultimeterUse 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 simplifiedschematics and drawings in “Troubleshooting Simplified Schematic, D7 Preheater” page 30 and “TroubleshootingSimplified Schematic, D12 Preheater” page 31.

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.

Function KeyPosition

Measuring Points ExpectedValue

Note Possible Cause (if ex-pected value notcorrect)

Power Supply toRelay Coil

On Relay coil positiveconnector (A) to alter-nate ground.

12V Fuse, connectors orwiring fault in powersupply circuit.

Ground to RelayCoil

Off Control Wire (B) to al-ternate ground

180 k ± 20% Disconnectcontrol wire atrelay

Connectors or wiringfault in ground circuitthrough EECU.

Control Signal Preheat Control Wire (B) to al-ternate ground

<1V Relay(s) click in 1 Connectors orwiring fault inground circuitthrough EECU

2 Preheat relay(s).

Relay Coil Func-tion Test

On Control Wire (B) to al-ternate ground

Relay(s) clickin

If values above arecorrect probably relayfault.

Power Supplyfor Pre-heaterElements

Off Relay "Common" (C)terminal to alternateground

12V Connectors or wiringfault in power supplycircuit from alternator.

Ground throughPreheater Ele-ments

Off Relay "NO" (D) termi-nal to alternate ground

<1 1 Preheater fuse.

2 Preheater ele-ment.

Relay FunctionTest

Preheat Relay "NO" (D) termi-nal to alternate ground

9V - 12V Relay(s) click in If power supply for pre-heater elementscorrect, probable relayfault.

Preheat Fuses Preheat Preheat elementconnection (E) to al-ternate ground

9V - 12V Relay(s) click in If relay function cor-rect, probable pre-heatfuse fault

Preheater Ele-ments

Preheat Preheat elementconnection (E) to al-ternate ground

9V - 12V With relay(s)clicked in ele-ments shouldproduce heat

If values above correct,probable pre-heater el-ement fault

32


Charging SystemTroubleshooting


CAUTION


CAUTION

Never use the ohmmeter mode of the DMM in a pow-ered circuit or as a substitute for a voltmeter orammeter, since this will damage the instrument. Usethe ohmmeter mode only when power is removedfrom the circuit. (If contacted with sulfuric acid, flushimmediately with water and get medical attention).

WARNING


WARNING

HOT ENGINE! Keep clear of all moving parts or hotengine parts and/or fluids. A hot engine and/or fluidscan cause burns.

33


Troubleshooting SimplifiedSchematics, Charging SystemThe simplified schematic and illustration below should be used to clarify the procedures in “Troubleshooting ChargingSystem with Digital Multimeter” page 35. For detailed, vehicle-specific schematics refer to:

ServiceManual

Electrical Schematics VN/VHD

IMPACT Function Group: 370Information Type: Schematics.

W3004739

W3004567

H, I and Q are measuring points, for more informa-tion see page 37.

W3004566

X Output Terminal (B+)Y Ground Terminal (B-)W Relay TerminalZ Indicator Light TerminalY(1) Ground Terminal (B-) 34SI only

34


Troubleshooting Charging Systemwith Digital MultimeterOne or more of the following conditions will generally in-dicate charging systems problems:

• Undercharged or overcharged batteries.

• Charging indicator telltale lamp “on” with the enginerunning.

• Charging indicator telltale lamp “off” with the ignitionswitch on and the engine not running.

• The voltmeter in the graphic display showing acharging rate outside the normal range.

• Incorrect or no operation of accessories connectedto the “Relay” terminal.

• Short life of light bulbs or other electrical compo-nents due to unusually high system voltage.

Prior to troubleshooting, visually check the cables andconnections for obvious problems. Check the drive belttension and adjust if necessary.

Use the digital multimeter J-39200 or equivalent tool toperform the test in the following table. The measuringpoints referenced in the table as X, Y, Z, etc. correspondto measuring points that are illustrated in the chargingsystem simplified schematics and drawings. See:“Troubleshooting Simplified Schematics, Charging Sys-tem” page 34.

35


Funtion Key Posi-tion

Measuring Point ExpectedValue

Note Possible Cause (if expectedvalve not correct

AlternatorChargingVoltage

ON/ EngineRunning

Output Terminal (X)/Ground Terminal Yor Ground TerminalY(1)

13.8 - 14.2 V AccessoriesOff

1 Power circuit from battery

2 Ground circuit from battery

3 Alternator beltloose/missing

4 Alternator failure

ChargingVoltage atBatteries

ON/ EngineRunning

Batt (+) Terminal(A)/ Batt (-) Terminal(B)

13.8 - 14.2 V AccessoriesOff. Readingmay be slightlyless than atalternator.

If alternator charging voltageOK, probable power or groundcable fault.

Relay Ter-minalSignal

ON/ EngineRunning

Relay Terminal (W)/Ground Terminal (Y)

Approx. 1/2Charging Volt-age

AccessoriesOff.

1 Probable alternator failure.

2 Check for broken or looseno. 19 ire at the alternatorterminal.

Ins. ClusterIndicatorLamp Op-eration

ON/ EngineRunning

Ind. Light Terminal(Z)/ Terminal (Y)

Approx.Charging Volt-age

AccessoriesOff. IndicatorLamp Off.

See: “Troubleshooting ChargingIndicator (Telltale) Lamp” page37.

PositiveCables

ON/ EngineRunning

Output Terminal (X)/Batt + Terminal (A)

<0.5 totalvoltage drop= positive andnegative volt-age dropscombined

A/C On,Blower Motoron High,Headlamps onBright

Excessive resistance in positivecables. Check measuring pointsX/H and A/H to help isolateproblem cable/ connectors.

Ground Ca-bles

ON/ EngineRunning

Ground Terminal (Y)Batt - Terminal (B)

<0.5 totalvoltage drop= positive andnegative volt-age dropscombined

A/C On,Blower Motoron High,Headlamps onBright

Excessive resistance in nega-tive cables. Check measuringpoints Y/Q, Y1/Q, Q/I and I/B tohelp isolate problem cable/ con-nectors.

36


Troubleshooting Charging Indica-tor (Telltale) LampWhen the ignition key is turned “ON”, the Charging Indi-cator (telltale) lamp will momentarily illuminate for a bulbtest. The lamp will remain on until the engine is started.With the engine running and the alternator properlycharging, the wire at the indicator light terminal from theinstrument cluster and the indicator light terminal on thealternator (Z) should be at approximately the same volt-age. With the voltages equal, the Charging telltale lightshould go out.

To clarify the procedures below refer to: “TroubleshootingSimplified Schematics, Charging System” page 34.

• Instrument cluster and bulb check: Test the ChargingIndicator (telltale) lamps ability to function by runningthe “Bulb Test” from the instrument cluster self testmenu. Use the graphic display control buttons to ac-cess the “System Diagnostics” menu, select “ClusterSelf Test,” then “Bulb Test.” With the bulb test active,all the telltale and LED indicator lamps, including theCharging telltale, will illuminate for approximately 5seconds. With the bulb test active, the charging indi-cator wiring is ignored and the test is operated bythe instrument cluster internal electronics. If the indi-cator does not illuminate properly, refer to:

ServiceManual

Instrumentation, VN from 3/99,VHD

IMPACT Function Group: 381Information Type: Diagnostics”Instrument Cluster Tests”

• Wiring check — grounded circuit: With the ignitionkey “ON” and the engine not running, the Charging

telltale should be illuminated. Disconnect the wire atthe indicator light terminal (Z). The Charging telltaleshould go off. If not, check for a grounded circuit be-tween the alternator and instrument cluster. If agrounded circuit is indicated, refer to manual belowfor detailed vehicle-specific schematics:

ServiceManual



• Wiring check — open circuit: With the ignition key“ON” and the engine not running, the Charging tell-tale should be illuminated. Disconnect the wire atthe indicator light terminal (Z). Use a jumper wire toground the removed indicator light wire. The Charg-ing telltale should illuminate. If not, check for anopen circuit between the alternator and the instru-ment cluster. If an open circuit is indicated, refer to:

ServiceManual



• Alternator check: With the engine running and thealternator properly charging, remove the wire at theindicator light terminal. The indicator light terminalon the alternator (Z) should be at approximatelycharging voltage. If not, the alternator is probablydefective.

37


Troubleshooting — AlternatorOutput Test with BVA-34 TesterBefore beginning the alternator output test, visually check the cables and connections for obvious problems. Check thedrive belt tension and adjust if necessary.

W3004738

Use BVA-34 System Analyzer or equivalent tool to per-form the test below. Read and follow the directions withthe test equipment used. The test outlines below shouldbe used as a general guide for performing an alternatoroutput test. The measuring points referenced in the textas A, B, X etc. correspond to measuring points that areillustrated in the alternator output test simplifiedschematics above.

1 Set the volt switch to the “INTERNAL VOLTS” posi-tion. Connect the clamps from the tester to thepositive and negative (A& B) battery jumper studposts.

2 “Zero” the ammeter if neccessary.

3 Clamp the inductive amp probe around the outputcable from the B+ post (X) at the alternator. Be surethat the inductive amp probe is pointing the properdirection.

4 Turn the ignition key to “ON” and note the ampsdraw.

5 Start the engine and run at high idle.

Note: Engine speed must be above approximately1700 RPM to achieve maximum alternator output.

6 While observing the volt and amp gauges on themeter, adjust the load knob to obtain maximum al-ternator output. Use caution not to go below 12 voltswhen applying the load. Also note the red “STATORDIODE” LED. If the LED glows steady red, it indi-cates that a diode or the stator is faulty.

7 Note the maximum alternator output (observe in step6). Add the current draw obtained in step 4. This isthe 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 onthe alternator identification tag.

38


Troubleshooting Starting andCharging System with TheAccuracy Plus Tester

The J-44700 Accuracy Plus Tester will test the startingand charging system for the following:

• Battery open circuit voltage

• Cranking voltage

• Charging voltage

• Regulator voltage

• Diode condition

To operate the Accuracy Plus tester, connect the positiveand negative tester leads to the battery jumper studposts. Select the “System Test” and follow the on screenprompts until the tests are complete. The test resultsmay be printed if desired with the optional printer number238598. Both the J-44700 Accuracy Plus tester and the238598 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 batterieswhen 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.

W0001836

J-44700 Accuracy Plus HD Battery Tester.

39

40

Group 33 Starting and Charging VN, VHD Service Procedures

Service Procedures3714-19-03-01Battery Cables, Removal andInstallation


WARNING

Always wear eye protection when working around bat-teries to prevent the risk of injury due to contact withsulfuric acid or an explosion (If contacted with sulfuricacid, flush immediately with water).

WARNING


CAUTION


CAUTION

In vehicles with a Supplemental Restraint System(SRS), turn the ignition switch ON before connectingthe battery. Failure to do so may result in permanentdamage to the instrument cluster or other electroniccircuits 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.

CAUTION


All CablesVolvo 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, withbattery interconnecting cables. The batteries cannot betested or serviced as a set, but must be tested or ser-viced individually.

To test or service the batteries, all battery cables andwiring connected directly to the batteries must be re-moved. If the battery cables and wiring are not removedand installed in the proper order, damage to sensitiveelectronic equipment may occur. To properly remove andinstall the battery cables, proceed as follows:

Removal

1Turn the ignition key to the “OFF” posi-tion.

2Disconnect the ground wiring fromelectrical equipment connected directlyto the batteries, such as ECU’s, satel-lite systems, etc.

3Disconnect the main ground cable(s).

4Disconnect the positive wiring from theelectrical equipment connected directlyto the batteries.

5Disconnect the main positive cables(s).

6Disconnect the battery interconnectingcables.

7Perform battery test or service asneeded.

41


Installation

8Connect the battery interconnectioncables.

9Connect the main positive cable(s).

10Connect the positive wiring from theelectrical equipment connected directlyto the batteries.

11If the vehicle is equipped with a Sup-plemental Restraint System (SRS) anda Cummins or Detroit Diesel engine,turn the ignition switch to the “ON” po-sition. If not, leave the ignition switchin the “OFF” position.

12Connect the main ground cable(s).Turn the ignition switch back to “OFF”if necessary.

13Connect ground wiring from the elec-trical equipment connected directly tothe batteries.

14Secure all battery terminal nuts.Battery terminal torque =3.7 ± 5.7 Nm(10 –15 ft-lb)

3.7 ± 5.7 Nm(10 –15 ft-lb)

Ground CablesMany service operations require the removal of the bat-tery ground (negative) cables as a safety measure. If thebattery ground cable(s) and wiring are not removed andinstalled in the proper order, damage to sensitive elec-tronic equipment may occur. To properly remove andinstall the battery ground cables and wiring, proceed asfollows:

Removal


2Disconnect the ground wiring fromelectrical equipment connected directlyto the batteries, such as ECU’s, satel-lite systems, etc.


4Perform service operations as needed.

Installation




8Secure all battery terminal nuts. Bat-tery terminal torque =13 ± 20 Nm(10 –15 ft-lb)

13 ± 20 Nm(10 –15 ft-lb)

42


Battery Jump Starting


CAUTION

Do not use a “Hot Shot” type starting cart, as mostuse extremely high voltages. Use of “Hot Shot” deviceto jump start the vehicle will seriously damage theECU’s and other electrical equipment.

CAUTION

Do not attempt to jump-start a vehicle equipped withDelco Maintenance Free batteries, if the test indicatorlight is yellow. Replace the battery instead.

WARNING

Always wear eye protection when working around bat-teries to prevent the risk of injury due to contact withsulfuric acid or an explosion (If contacted with sulfuricacid, flush immediately with water and get medical at-tention).

WARNING


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 causedamage to the vehicle electrical and electronic compo-nents.

When jumping batteries to start an engine, it is importantthat the jumper cables are connected directly from oneset of batteries in one vehicle to the other set of batter-ies in the other vehicle. This is so the cranking current iscarried through the proper starter wiring.

To access the batteries on a vehicle equipped with sidefairings, open the fairing access cover. “Jumper Studs”,which are longer and made of brass, are factory installedon one battery positive and negative post. These jumperstuds 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 creatingsparks by making all connections quickly and firmly. Donot permit the vehicles to touch each other when jumpstarting.

43


3111-03-02-02Battery, Replacement (One orTwo)


WARNING


WARNING


CAUTION


CAUTION

In vehicles with a Supplemental Restraint System(SRS), turn the ignition switch ON before connectingthe battery. Failure to do so may result in permanentdamage to the instrument cluster or other electroniccircuits in the vehicle. This applies only to vehicleswith SRS and Cummins or Detroit Diesel engines.Check for fault codes after repairs are complete.

CAUTION


Note: Some applications will require the removal of airfairings, battery box covers, or other components to ac-cess the batteries.

Removal


2Disconnect ground wiring from electri-cal equipment connected directly tothe batteries, such as ECU’s, satellitesystems, etc.

3Disconnect the main ground cable(s)at the batteries.

4Disconnect the positive cable(s) at thebatteries.

5Remove the battery nuts on all batteryconnections and remove all cablesand wiring.

6Loosen the battery hold down clampnuts enough to allow removal of thehold down clamp assembly.

7Remove the defective battery(s).

8Clean any battery post or cable termi-nals as necessary.

Installation

9Install the replacement battery(s). Ob-serve that the battery positive andnegative posts are oriented properlywhen installed.

44


10Install the battery hold down clamp.Torque =24 ± 4 Nm(18 ± 3 ft-lb)

24 ± 4 Nm(18 ± 3 ft-lb)

11Install all battery cables and wiringconnections removed in steps 5. Installthe battery nuts (hand tighten) secur-ing those cables/wiring.

12Connect the positive cables(s) and anypositive wiring from electrical equip-ment connected directly to thebatteries.

13If the vehicle is equipped with a Sup-plemental Restraint System (SRS) anda Cummins or Detroit Diesel engine,turn the ignition switch to “ON” posi-tion. If not, leave the ignition switch inthe “OFF” position.

14Connect the main ground cable(s).Turn ignition switch back to “OFF” ifnecessary.

15Connect ground wiring from electricalequipment connected directly to thebatteries.

16Tighten all battery cable connections.Torque =13 ± 20 Nm(10 –15 ft-lb)

13 ± 20 Nm(10 –15 ft-lb)

3714-03-02-03Battery Cables to Starter, Re-placement


WARNING


WARNING


CAUTION


CAUTION


45


CAUTION


Before you start the replacement of the battery to startercable(s), visually inspect the existing cables. Note the lo-cation of all routing, support clips (brackets), and cableties. If any area is visibly distressed take appropriate cor-rective actions to prevent damage to the replacementcable(s). The following installation points should be ob-served always when replacing battery to starter cables.

• Cables should be supported at no less than 600mm (24 in.) intervals with non-conductive compres-sion clips.

• Cables must be supported as close as possible toall cable bends.

• Cable ties may be used as needed to prevent rela-tive movement between cables.

• Strain relief should be provided at terminals to pre-vent terminal breakage.

• Route cables to avoid sharp edges or abrasive ar-eas.

• Edges that cables pass through must be bushedwith suitable grommets.

• Cables must not be routed within 130 mm (5 in.) ofengine exhaust components or other sources of in-tense heat.

• 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 components to accessthe battery cables.

Removal


2Disconnect ground wiring from theelectrical equipment connected directlyto the batteries, such as ECU’s, satel-lite systems, etc.



5Remove all support clips (brackets)and cut cable ties.

6Disconnect the battery cables at thestarter. Note the wire positions to aidin installation.

7Remove the defective cable(s).

Installation

8Position the replacement cable(s) inthe proper routing position. Be surethe cable will connect to the starterand batteries when all the supportclips are secure.

9Install the battery cables and wiring atthe starter. Torque =30.5 ± 3.5 Nm(22.5 ± 2.5 ft-lb)

30.5 ± 3.5 Nm(22.5 ± 2.5 ft-lb)

10Install the cables into the support clipsand secure beginning at the starterand working toward the battery. Ob-serve the installation points as notedabove. 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)

11Connect the positive cable(s) and anypositive wiring from electrical equip-ment connected directly to thebatteries.


46





13 ± 20Nm(10 –15 ft-lb)

3714-03-02-04Battery Inter-connection Ca-bles, Replacement


WARNING


WARNING


CAUTION


CAUTION


47


CAUTION


Removal


2Disconnect ground wiring from theelectrical equipment connected directlyto the batteries, such as the ECU’s,satellite systems, etc.



5Remove the battery nuts on all batteryconnections and remove all cablesand wiring.

6Clean any battery post or cable termi-nals as necessary.

Installation

7Replace the defective battery inter-connecting cable(s).

8Install all battery cables and wiringconnections removed in step five (5).Install the battery nuts (hand tighten)securing the cables/wiring.

9Connect the positive cable(s) and pos-itive wiring from the electricalequipment connected directly to thebatteries.





13 ± 20 Nm(10 –15 ft-lb)

48


3311-03-02-01Starter Motor, Replacement

Volvo D12B or D12C Engine


WARNING


WARNING


CAUTION


CAUTION


W3004732

See removal and installation procedures followingthis illustration, for explanation of numbers 1 to 6shown in above illustration.

Note: In some installations, the replacement of thestarter may be aided by the removal of additional com-ponents or wiring not referenced in this manual, oraffected by alternate battery cable routing due to alter-nate battery mounting locations.

Removal


2Disconnect ground wiring from theelectrical equipment connected directlyto the batteries, such as the ECU’s,satellite systems, etc.

3Disconnect the main battery groundcable(s).

4Remove the splash shield.

5Remove the inner fender assembly.

49


6Loosen or remove the battery cablemounting support brackets, if neededto allow enough slack for removal ofthe battery cable terminals at thestarter.

7Remove the positive (1) and negative(2) cables/wiring and “switch” terminal(3) wire from the starter. Disconnectthe overcrank protection switch (4) (ifequipped). Note the cable/wiring posi-tion for installation.

8Remove the engine ground terminalconnector (5).

9Disconnect the engine wiring harnessconnector (6). Remove the enginewiring harness support clamp and pullthe harness away from the starterarea.

10Remove the starter mounting bolts andremove the starter from the vehicle.

Installation

11Compare the orientation of the nosehousing on the old starter to the re-placement starter. If necessary,remove the nose housing on the re-placement starter and “clock” it to theposition of the old starter.Nose housing bolt torque =10 ± 13 Nm(13 – 17 ft-lb)

10 ± 13 Nm(13 – 17 ft-lb)

12Install the replacement starter and se-cure the mounting bolts.Torque =85 ± 9 Nm(63 ± 6.5 ft-lb)

85 ± 9 Nm(63 ± 6.5 ft-lb)

13Position the engine wiring harness andengage the connector (6). Install theengine wiring harness support clamp.

14Install the engine ground cables (5)and secure.Torque =48 ± 8 Nm(35 ± 6 ft-lb)

48 ± 8 Nm(35 ± 6 ft-lb)

15Install all starter wiring and cables.(Battery cable terminals (1 & 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)

30.5 ± 3.5 Nm(22.5 ± 2.5 ft-lb)2.6 ± 0.8 Nm.(23 ± 7 in-lb)

16Secure the battery cables in themounting support brackets.

17Install the inner fender assembly.

18Install the splash shield.

19Install the main ground cable(s).

20Install ground wiring from the electricalequipment connected directly to thebatteries.

21Secure with the battery terminal nut(s).Torque =3.7 ± 5.7 Nm(10 –15 ft-lb)

3.7 ± 5.7 Nm(10 –15 ft-lb)

50



Volvo D7C Engine


WARNING

Always wear eye protection when working around bat-teries to prevent the risk of injury due to contact withsulfuric acid or an explosion. (If contacted with sulfuricacid, flush immediately with water and get medical at-tention).

WARNING

Never disconnect an air system component unless allsystem pressure has been depleted. Failure to de-plete system pressure before disconnecting hoses orcomponents may result in them separating violently,causing serious eye and/or body injury.

WARNING


WARNING


CAUTION


CAUTION


W3004733

Starter D7C EngineDual Battery Cables shown.

1 Positive cables

2 Negative cables

3 Switch terminal

4 overcrank protection connector (with jumper)

5 Cable support bracket

6 EPG solenoid

7 EPG regulator

51


Note: In some installations, replacement of the startermay be aided by removal of additional components orwiring not referenced in this manual, or affected by alter-nate battery cable routing due to alternate batterymounting locations.

Removal




4Remove the right inner fender assem-bly.

5Remove the positive and negative ca-bles and “switch” terminal wire fromthe starter. Disconnect the overcrankprotection switch (if equipped). Notethe cable/wiring position for installa-tion.

6Remove the battery cable supportbracket which is below the starter andpull the cables away from the starterarea (cables under starter routing).

7Bleed all pressure from the vehicle airsystem. Disconnect the Exhaust Pres-sure Governor (EPG) solenoidconnector. Note their position for in-stallation, then disconnect the EPGsolenoid and regulator air lines. Re-move the EPG solenoid/regulatorassembly for the engine.

8Remove the starter mounting nuts andremove the starter from the vehicle.

Installation

9Compare the orientation of the nosehousing on the old starter to the re-placement starter. If necessary,remove the nose housing on the re-placement starter and “clock” it to theposition of the old starter.Nose housing bolt torque =18 ± 23 Nm (13 – 17 ft-lb)

18 ± 23 Nm(13 – 17 ft-lb)

10Install the replacement starter and se-cure the mounting nuts.Torque = 85 ± 15 Nm(63 ± 6.5 ft-lb)

85 ± 9 Nm(63 ± 6.5 ft-lb)

11Install the EPG solenoid/regulator as-sembly. Install the EPG solenoid andregulator air lines. Engage the EPGsolenoid connector.

12Install the battery cable supportbracket below the starter.

13Install all 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 cableties as needed.

30.5 ± 3.5 Nm(22.5 ± 2.5 ft-lb)2.6 ± .08 Nm(23 ± 7 in-lb)

14Install the right inner fender assembly.

15Install the main ground cable(s) ontothe battery ground terminal.

16Install ground wiring from the electricalequipment connected directly to thebatteries onto the battery ground ter-minal.


13 ± 20 Nm(10 –15 ft-lb)

52



Cummins or Detroit DieselEngine


WARNING


WARNING

HOT ENGINE! Keep clear of all moving parts or hotengine parts and/or fluids. A hot engine and/or fulidscan cause burns.

CAUTION

In vehicles with a Supplemental Restraint System(SRS), turn the ignition switch ON before connectingthe battery. Failure to do so may result in permanentdamage to the instrument cluster or other electroniccircuits within the vehicle. (This applies only to vehi-cles with SRS and a Cummins or Detroit Dieselengine.) Always check for fault codes after repairs arecompleted.

CAUTION

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 mainbattery ground cable. Electronic modules may bedamaged when additional grounds are con-nected/disconnected without the main battery groundconnected. Disconnect the main battery ground last.

CAUTION


Note: In some installations, the replacement of thestarter may be aided by the removal of additional com-ponents or wiring not referenced in this manual, oraffected by alternate battery cable routing due to alter-nate battery mounting locations.

Removal




4Remove the left splash shield.

5Remove the left inner fender assembly.

6Loosen or remove the battery cablemounting support brackets and cabledividers (if equipped) as needed to al-low enough slack for removal of thebattery cable terminals at the starter.Cut any cable ties as needed.

7Remove the positive and negative ca-bles and “switch” terminal wire fromthe starter. Disconnect the overcrankprotection switch (if equipped). Notethe cable/wiring position for installa-tion.

8Remove any wiring harness supportclamps and brackets as needed to ac-cess the starter mounting bolts andallow removal of the starter.

53


9Remove the starter mounting boltsand remove the starter and spacer(if equipped) from the vehicle.

Installation

10Compare the orientation of the nosehousing on the old starter to the re-placement starter. If necessary,remove the nose housing on the re-placement starter and “clock” it to theposition of the old starter.Nose housing bolt torque =9.5 ± 12.5 Nm(13 –17 ft-lb)

9.5 ± 12.5 Nm(13 –17 ft-lb)

11Install the replacement starter andspacer (if equipped) and secure themounting bolts. Torque =176 ± 25 Nm(130 ± 18 ft-lb)

176 ± 25 Nm(130 ± 18 ft-lb)

12Install any wiring harness supportclamps and brackets removed to ac-cess the starter mounting bolts.

13Install all 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)

30.5 ± 3.5 Nm(22.5 ± 2.5 ft-lb)2.6 ± 0.8 Nm(23 ± 7 in-lb)

14Secure the battery cables in themounting support brackets and cabledividers. Secure with cable ties asneeded.

15Install the inner fender assembly.

16Install the splash shield.

17If 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 switchin the “OFF” position.

18Install the main ground cable(s). Turnignition switch back to “OFF” if neces-sary.

19Install ground wiring from electricalequipment connected directly to thebatteries.

20Secure with the battery terminal nuts.Torque =3.7 ± 5.7 Nm(10 –15 ft-lb)

3.7 ± 5.7 Nm(10 –15 ft-lb)

54


3331-03-02-02Preheater Fuse, Replacement


WARNING


WARNING


CAUTION

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 mainbattery ground cable. Electronic modules may bedamaged when additional grounds are con-nected/disconnected without the main battery groundconnected. Disconnect the main battery ground last.

CAUTION


CAUTION

Use caution when working around the preheatelements. When active, the elements will heat to ap-proximately (705�C) 1300�F. Allow sufficient time forthe elements to cool to avoid severe burns.

W3004715

The preheat fuse assembly includes a support (1) de-signed to protect the fuse (2) from physical damage. Thesupport is also used as a path for current flow and aconnection point (3) for the fuse on the long fuse assem-bly used in the D12 engines.

55


Removal



3Disconnect the battery main groundcable(s).

4Remove the nuts securing the defec-tive fuse assembly(s).

5Remove the wiring, support and fuse.

Installation

6If the defective fuse assembly is thelong fuse assembly on the D12 en-gine, remove the screw securing thefuse to the support. Install the replace-ment fuse onto the support andsecure with the screw.

7Install the replacement fuse, with sup-port and wiring, onto the mountingterminals and secure.


9Install ground wiring from the electricalequipment directly to the batteries.

10Secure with the battery terminal nut(s).Torque =3.7 ± 5.7 Nm(10 – 15 ft-lb)

3.7 ± 5.7 Nm(10 – 15 ft-lb)

3331-03-02-03Preheater Relay, Replacement

Volvo D12B or D12C Engine


WARNING


CAUTION


CAUTION


CAUTION


56


Removal




4Remove the power cable, fuse, andwiring from relays. Note position for re-assembly.

5Remove the support bracket/wiringharness clamp bolts (VN) or fan ringsupport bracket (VHD).

6Remove the charge air pipe hoseclamp.

7Remove the charge air pip-ing/preheater mounting bolts andremove the charge air piping from thevehicle.

8Remove the preheater element blockfrom the intake manifold. Tap the relaymounting bracket off the elementblock.

9Remove the relay(s) from the mount-ing bracket.

Installation

10Install the replacement relay(s) ontothe bracket and secure.

11Clean the gasket surfaces.

12Tap the relay mounting bracket ontothe element block.

13Install the preheater element block,with new gaskets, and the charge airpiping to the intake manifold.

14Secure with mounting bolts.Torque =24 ± 4 Nm(18 ± 3 ft-lb)

24 ± 4 Nm(18 ± 3 ft-lb)

15Install and secure the charge air pipehose clamp.

16Install the support bracket/wiring har-ness clamp bolts (VN) or fan ringsupport bracket (VHD) and secure.

17Install the power cable, fuse, andwiring to the relays and secure.



20Secure with the battery terminal nut(s).Torque =3.7 ± 5.7Nm(10 –15 ft-lb)

3.7 ± 5.7Nm(10 –15 ft-lb)

57


3331-03-02-03Preheater Relay, Replacement

D7C Engine


WARNING

HOT ENGINE! Keep clear of all moving parts or hotengine parts and/or fluids. A hot engine and /or fluidscan cause burns.

CAUTION


CAUTION


CAUTION


Removal




4Remove the power cable, fuse, andwiring from relay. Note position for re-assembly.

5Remove the relay from its mountingand remove from the vehicle.

Installation

6Install the replacement relay and se-cure.

7Install the power cable, fuse andwiring to the relay and secure.



10Secure with the battery terminal nut(s)Torque =3.7 ± 5.7 Nm(10 –15 ft-lb)

3.7 ± 5.7 Nm(10 –15 ft-lb)

58


3331-03-02-01Preheater Element, Replace-ment

D12B or D12C Engine


WARNING


CAUTION


CAUTION


CAUTION

Use caution when working around the preheatelements. When active, the elements will heat to ap-proximately 705�C (1300�F.). Allow sufficient time forthe elements to cool to avoid severe burns.

W3004730

Removal




4Remove the power cable, fuses, andwiring from relays. Note position for re-assembly.

5Remove the support bracket/wiringharness clamp bolts (6, VN only) orfan ring support bracket (5, VHD only).

59



7Remove the charge air piping / pre-heater mounting bolts (3) and removethe charge air piping (4) from the vehi-cle.

8Remove the preheater element block(1) from the intake manifold. Tap therelay mounting bracket off the elementblock.


Installation

10Tap the relay mounting bracket ontothe replacement element block.

11Install the preheater element block,with new gaskets (2), and the chargeair piping to the intake manifold. Se-cure with mounting bolts.Torque =24 ± 4 Nm(18 ± 3 ft-lb)

24 ± 4 Nm(18 ± 3 ft-lb)


13Install the support bracket/wiring har-ness clamp bolts (VN) or fan ringsupport bracket (VHD) and secure.

14Install the power cable, fuse andwiring to the relays and secure.




3.7 ± 5.7 Nm(10 –15 ft-lb)

3331-03-02-01Preheater Element, Replace-ment

D7C Engine


WARNING


CAUTION


CAUTION


CAUTION

Use caution when working around the preheatelements. When active, the elements will heat to ap-proximately 705�C (1300�F.). Allow sufficient time forthe elements to cool to avoid severe burns.

60


Removal


2Disconnect ground wiring from theelectrical equipment connected directlyto the batteries, such as ECU’s, satel-lite systems etc.


4Remove the power cable, fuse andwiring from relay. Note position for re-assembly.

5Remove the relay from its mountingand remove from the vehicle.


7Remove the charge air piping mount-ing bolts at the fan ring and preheaterand remove the vehicle.

8Remove the ground wire from the pre-heater element book.

9Remove the preheater element blockfrom the intake manifold.


Installation

11Install new gasket between intakemanifold and replacement preheaterelement block. Install the preheater el-ement block. Install new gasket on theintake side of the preheater elementblock.

12Install the ground wire from the pre-heater element block.

13Install the charge air piping. Securethe mounting bolts at the preheat ele-ment block.Torque =24 ± 4 Nm(18 ± 3 ft-lb)secure the mounting bolts at the fanring.

24 ± 4 Nm(18 ± 3 ft-lb)


15Install the relay and secure.

16Install the power cable, fuse andwiring to the relay and secure.


18Install ground wiring from electricalequipment connected directly to thebatteries.


3.7 ± 5.7 Nm(10 –15 ft-lb)

61


3211-03-02-03Alternator, Replacement (Ad-justable Mount)


WARNING


CAUTION


CAUTION


CAUTION


Note: In some installations, the replacement of the alter-nator may be aided by the removal of splash shields.

Removal




4Disconnect all alternator wiring. Notewire positions to aid in installation.

5Loosen the alternator mounting bolts.

6Loosen the tensioner bolt as neededand remove the belt from the pulley.

7Remove the alternator mounting boltsand remove the alternator from the ve-hicle.

Installation

8If necessary, remove the pulley fromthe alternator and install it on the re-placement alternator. Torque =109 ± 11 Nm(80 ± 8 ft-lb)

109 ± 11 Nm(80 ± 8 ft-lb)

9Install the replacement alternator andtensioner. Leave bolts loose enough toadjust belt tension.

62


10Adjust the tensioner as needed toachieve a belt tension of 111 Nm (150ft-lb) for a new belt or 73 Nm (100 ft-lb) for a used belt. Use Belt TensionGauge J-23600–B, or equivalent tool,to check tension.

11Tighten the alternator adjustmentmounting bolt.Torque =48 ± 8 Nm(34 ± 6 ft-lb)

48 ± 8 Nm(34 ± 6 ft-lb)

12Tighten the alternator pivot mountingbolt.Torque =88 ± 7 Nm(65 ± 5 ft-lb)

88 ± 7 Nm(65 ± 5 ft-lb)

13Connect 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)



16Connect ground wiring from the elec-trical equipment connected directly tothe batteries


13 ± 20 Nm(10 –15 ft-lb)

3211-03-02-04Alternator, Replacement (FixedMount)


WARNING


CAUTION


CAUTION


63


CAUTION


Note: In some installations, the replacement of the alter-nator may be aided by the removal of splash shields.

Removal


2Disconnect the ground wiring electricalequipment connected directly to thebatteries, such as ECU’s, satellite sys-tems, etc.


4Disconnect all alternator wiring. Notewire positions to aid in installation.

5Use fan belt tensioner tool J-44392, orequivalent tool, to release the pres-sure from the automatic belt tensionerand remove the belt from the alterna-tor pulley.

6Remove the alternator mounting boltsand remove the alternator from the ve-hicle.

Installation

7If necessary, remove the pulley fromthe alternator and install it on the re-placement alternator. Torque =109 ± 11 Nm(80 ± 8 ft-lb)

109 ± 11 Nm(80 ± 8 ft-lb)

8Install the replacement alternator andtighten the mounting bolts.Torque =88 ± 7 Nm(65 ± 5 ft-lb)

88 ± Nm(65 ± 5 ft-lb)

9Use fan belt tensioner tool J-44392, orequivalent tool, to release the pres-sure from the automatic belt tensionerand install the belt onto the alternatorpulley.

10Connect 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)

11If the vehicle is equipped with a Sup-plemental Restraint System (SRS) anda Cummins or Detroit Diesel engine,turn the ignition switch to the “ON” po-sition. If not, leave the ignition in the“OFF” position.



14Tighten all battery cable connections.Torque =3.7 ± 5.7 Nm(10 –15 ft-lb)

3.7 ± 5.7 Nm(10 –15 ft-lb)

64

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7900 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

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Concerns Service Manual: ...............................................................................................................................

Operation Numbers

3111-03-02-02 Battery, Replacement (One or Two) . . . . . . . . . . . . . . . . . . . . . . . 443211-03-02-03 Alternator, Replacement (Adjustable Mount) . . . . . . . . . . . . . . . . . . . 623211-03-02-04 Alternator, Replacement (Fixed Mount) . . . . . . . . . . . . . . . . . . . . . . 633311-03-02-01 Starter Motor, Replacement . . . . . . . . . . . . . . . . . . . . . . . 49, 51, 533331-03-02-01 Preheater Element, Replacement . . . . . . . . . . . . . . . . . . . . . . 59, 603331-03-02-02 Preheater Fuse, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 553331-03-02-03 Preheater Relay, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 56, 583714-03-02-03 Battery Cables to Starter, Replacement . . . . . . . . . . . . . . . . . . . . . 453714-03-02-04 Battery Inter-connection Cables, Replacement . . . . . . . . . . . . . . . . . . 473714-19-03-01 Battery Cables, Removal and Installation . . . . . . . . . . . . . . . . . . . . . 41

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://www.volvotrucks.volvo.com

PV776-TSP146025 (0000) 01.2001 © Volvo Trucks North America, Inc., 2001

Documents

Service Manual Trucks - Heavyhhrvresource.com/VolvoDocs/30-37/PV776-TSP146025.pdf · The tools referenced in this manual are listed below. They can be obtained by contacting your