Volvo VN 2002 Service Manual
  1. Manuals
  2. Brands
  3. Volvo Manuals
  4. Trucks
  5. VN 2002
  6. Service manual
Volvo VN 2002 Service Manual

Volvo VN 2002 Service Manual

Hide thumbs Also See for VN 2002:
Table of Contents

Advertisement

Quick Links

Download this manual
Service Manual
Trucks
33
Group
Starting and Charging
VN, VHD VERSION2
PV776-TSP177230

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the VN 2002 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Volvo VN 2002

Summary of Contents for Volvo VN 2002

  • Page 1 Service Manual Trucks Group Starting and Charging VN, VHD VERSION2 PV776-TSP177230...
  • Page 3 Greensboro, NC USA Order number: PV776-TSP177230 © 2002 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..

  • Page 5: Table Of Contents

    Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Delco 42MT Starter ............24 Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Volvo Gear-reduction Starter .......... 27 Troubleshooting Starter with Digital Multimeter ........ 29 Preheat System Troubleshooting ............31 Troubleshooting Preheater with VCADS Pro Tool ......32 Troubleshooting Preheater with Fault Codes ........
  • Page 6 Battery, Replacement (One or Two) ............ 47 Battery Cables to Starter, Replacement ..........48 Battery Inter-connection Cables, Replacement ........50 Starter Motor, Replacement ..............51 Volvo D12D Engine ................51 Starter Motor, Replacement ..............53 Cummins ISX/ISL/ISC Engine ............53 Preheater Relay, Replacement ............

  • Page 7: General

    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.

  • Page 9: Tools

    Group 33 Starting and Charging Tools Tools Special Tools For ordering instructions, see special tools information in group 08. J-44701 Battery tester kit. Includes: Tester J-44700 and Printer 238598 W0001836 J-39200 Fluke 87 digital multimeter W2001014 J-43244 Relay puller tool W0001917...
  • Page 10 Group 33 Starting and Charging Tools VCADS Pro W0001632 J-44392 Fan Belt Tensioner Tool W0001817 J-23600–B (BT-33–73F) Belt Tension Gauge W0001844 BVA-34 System Analyzer The BVA-34 System Analyzer is a digital, carbon pile, battery load tester and starting/charging system ana- lyzer.

  • Page 11: Design And Function

    Group 33 Starting and Charging Design and Function Design and Function Starting and Charging System Indicator Lights When the ignition key is turned “ON,” the Charging Indi- voltmeter function active, the display shows a battery cator (telltale) lamp will illuminate for a bulb test. The icon and the battery/charging voltage.

  • Page 12: Cold Cranking Amps

    Group 33 Starting and Charging Design and Function Cold Cranking Amps The “Cold Cranking Amps” rating is the amount of am- peres (amps) that can be maintained for 30 seconds at –18 C (0 F) without the post voltage falling below 7.2V.

  • Page 13: Battery Cables

    Group 33 Starting and Charging Design and Function 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 length.

  • Page 14: Starting System

    (OCP) or a the engine. shorting jumper. For more details see schematic in “Starting and Charg- Note: The OCP switch is not avaliable on the Volvo Gear ing” page 3. Reduction Starter. The OCP switch is located inside the starter. This switch is optional.

  • Page 15: Starter

    42MT or Volvo Gear-reduction starters for most (OCP) switch protects the starter in adverse starting applications. If the vehicle is equipped with a Volvo D12 conditions, such as cold weather starting or operator engine, it will be equipped with a Volvo Gear-reduction misuse.

  • Page 16: Preheat System

    EECU. When the relays are energized, an internal con- The preheat system used on the Volvo engine consists nection is made that connects the preheater element of two preheat relays and two heating elements.

  • Page 17: Charging System

    Group 33 Starting and Charging Design and Function Charging System Charging Circuit With the engine running, DC voltage is generated at the alternator output (B+) terminal and supplied to the vehi- cle’s 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.

  • Page 18: Alternator

    13.8 to devices on the vehicle. The alternator produces alternat- 14.2 volts. The Volvo VN/VHD vehicles are currently ing current (AC), which is converted to direct current equipped with one of the three following Delco Remy al- (DC) by the diodes in the rectifier bridge.

  • Page 19: Troubleshooting

    Group 33 Starting and Charging Troubleshooting Troubleshooting Battery Troubleshooting Battery Surface Charge Removal When a battery is charged, very small hydrogen gas You must read and understand the precautions and bubbles form on the surface of the battery plates, caus- guidelines in Service Information, group 30, "General ing what is known as “surface charge.”...

  • Page 20: Load Testing Batteries

    Group 33 Starting and Charging Troubleshooting Load Testing Batteries The BVA-34 System Analyzer is a digital, carbon pile, ESTIMATED MINIMUM REQUIRED battery load tester and starting/charging system ana- ELECTROLYTE VOLTAGE UNDER 15 lyzer. It is portable and designed for use in the heavy TERMPERATURE SECOND LOAD truck market.

  • Page 21: Electronic Battery Testing

    Group 33 Starting and Charging 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.

  • Page 22: Starting System Troubleshooting

    Group 33 Starting and Charging Troubleshooting Starting System CAUTION Troubleshooting Never use the ohmmeter mode of the DMM in a pow- You must read and understand the precautions and ered circuit, or as a substitute for a voltmeter or guidelines in Service Information, group 30, "General ammeter, since this will result in damage to the instru- Safety Practices", before performing this procedure.

  • Page 23: Troubleshooting Simplified Schematic, Delco 42Mt Starting System

    Group 33 Starting and Charging Troubleshooting Troubleshooting Simplified timeter” page 22, “Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Schematic, Delco 42MT Starting Delco 42MT Starter” page 24, and “Troubleshooting System Starter with Digital Multimeter” page 29. For detailed, vehicle-specific schematics refer to the "VN, VHD VER- The simplified schematic and illustration below should be SION2 Electrical Schematics"...

  • Page 24: Troubleshooting Simplified Schematic, Volvo Gear-Reduction Starting System

    Group 33 Starting and Charging Troubleshooting Troubleshooting Simplified timeter” page 22, “Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Volvo Schematic, Volvo Gear-reduction Gear-reduction Starter” page 27, and “Troubleshooting Starting System Starter with Digital Multimeter” page 29. For detailed, vehicle-specific schematics refer to the "VN, VHD VER- The simplified schematic and illustration below should be...

  • Page 25: Troubleshooting Ignition Switch With Vcads Pro Tool

    “Start” position. For detailed information about the VCADS Pro Tool op- W0001632 eration refer to the “VCADS Pro User’s Manual” in group 030–600. Note: This test only applies to vehicles with a Vehicle ECU (Volvo engines).

  • Page 26: Troubleshooting Battery/Starter Cables With Digital Multimeter

    Schematic, Delco 42MT Starting System” page 19 or cable assemblies. “Troubleshooting Simplified Schematic, Volvo Check for 12.4V across the positive and negative Gear-reduction Starting System” page 20. battery cable terminals that go to the starter motor.
  • Page 27 Group 33 Starting and Charging Troubleshooting W3005384 Fig. 10: Gear Reduction Starter W3003745 Fig. 9: Delco 42 MT Starter Motor Function Key Position Measuring Point Approximate Note Possible Cause (if ex- Value pected value not correct) Positive Start Battery positive <0.7 V drop.

  • Page 28: Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Delco 42Mt Starter

    Group 33 Starting and Charging Troubleshooting Troubleshooting Ignition Check for 12.4V at the battery cable terminals to the starter motor. If 12.4 V is not present or if a weak Switch/Starter Relay Circuit With battery(s) is suspected, see: “Battery Troubleshoot- Digital Multimeter, Delco 42MT ing”...
  • Page 29 Group 33 Starting and Charging Troubleshooting W3003744 Starter W3005302 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 Function Measuring Point Expected Note Possible Cause (if Position...
  • Page 30 Group 33 Starting and Charging Troubleshooting Function Measuring Point Expected Note Possible Cause (if Position Value expected value not cor- rect) Start SW terminal at Reinstall Connectors or wiring Start signal to starter sole- starter solenoid relay to con- faults in starter re- (G)/alternate nector.

  • Page 31: Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Volvo Gear-Reduction Starter

    • The Volvo Gear-reduction starter is equipped with a more than 30 continuous seconds. If the starter is starter-mounted relay in addition to the cowl- operated for more than 30 continuous seconds, wait mounted starter relay.
  • Page 32 Group 33 Starting and Charging Troubleshooting Function Measuring Point Expected Note Possible Cause (if Position Value expected value not cor- rect) Start Ignition switch ter- Reinstall Power supply to igni- Start signal to cowl mounted minal at cowl relay to con- tion switch mounted relay nector.

  • Page 33: Troubleshooting Starter With Digital Multimeter

    For a view of the schematic see “Troubleshooting Simplified Schematic, Delco 42MT Starting System” Check for 12.4V at the battery cable terminals that page 19 or “Troubleshooting Simplified Schematic, Volvo are connected to the starter motor. If 12.4 V is not Gear-reduction Starting System” page 20.
  • Page 34 Circuit With Digital Multimeter, Delco 42MT Starter” page 24 or “Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter, Volvo Gear-reduction Starter” page • If all the measurements are correct and the starter Check that the engine can be manually turned with will not engage, the starter is probably defective.

  • Page 35: Preheat System Troubleshooting

    Group 33 Starting and Charging Troubleshooting Preheat System Troubleshoot- CAUTION Do not keep the ignition key in the preheating position You must read and understand the precautions and longer than approx. 15 seconds. Allow the starting guidelines in Service Information, group 30, "General heater to cool between each activation or damage to Safety Practices", before performing this procedure.

  • Page 36: Troubleshooting Preheater With Vcads Pro Tool

    Group 33 Starting and Charging Troubleshooting 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.

  • Page 37: Troubleshooting Simplified Schematic, D12 Preheater

    Group 33 Starting and Charging Troubleshooting Troubleshooting Simplified Schematic, D12 Preheater The simplified schematic and illustration below should clarify the procedures in “Troubleshooting Preheater with Digital Multimeter” page 34. For detailed, vehicle-specific schematics refer to “Electrical Schematics VN, VHD” in function group 37.

  • Page 38: Troubleshooting Preheater With Digital Multimeter

    Group 33 Starting and Charging Troubleshooting 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 C1, P, C2, etc. correspond to measuring points that are illustrated in the preheat simplified schematics and drawings in “Troubleshooting Simplified Schematic, D12 Preheater”...
  • Page 39 Group 33 Starting and Charging Troubleshooting Function Measuring Points Expected Note Possible Cause (if ex- Position Value pected value not correct) Preheat Control Wires (G1 and <1V Relay(s) click in 1 Connectors or Control Signal G2) to alternate wiring fault in ground ground circuit through EECM...

  • Page 40: Charging System Troubleshooting

    Group 33 Starting and Charging Troubleshooting Charging System Troubleshooting You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices", before performing this procedure. If you are not properly trained and certified in this pro- cedure, ask your supervisor for training before you perform it.

  • Page 41: Troubleshooting Simplified Schematics, Charging System

    Group 33 Starting and Charging Troubleshooting Troubleshooting Simplified ing System with Digital Multimeter” page 38. For detailed, vehicle-specific schematics refer to "VN, VHD Schematics, Charging System VERSION2 Electrical Schematics” in Function Group 37. The simplified schematic and illustration below should be used to clarify the procedures in “Troubleshooting Charg- W3005299 Fig.

  • Page 42: Troubleshooting Charging System With Digital Multimeter

    Group 33 Starting and Charging Troubleshooting • Short life of light bulbs or other electrical compo- Troubleshooting Charging System nents due to unusually high system voltage. with Digital Multimeter Prior to troubleshooting, visually check the cables and connections for obvious problems. Check the drive belt One or more of the following conditions will generally in- tension and adjust if necessary.
  • Page 43 Group 33 Starting and Charging Troubleshooting W3004566 Output Terminal (B+) Ground Terminal (B-) W3005299 Relay Terminal Fig. 15: Schematic shown with Delco starter (others Indicator Light Terminal similar) Y(1) Ground Terminal (B-) 34SI only Function Key Posi- Measuring Point Expected Note Possible Cause (if expected tion...
  • Page 44 Group 33 Starting and Charging Troubleshooting Function Key Posi- Measuring Point Expected Note Possible Cause (if expected tion Value valve not correct Positive ON/ Engine Output Terminal (X)/ <0.5 total A/C On, Excessive resistance in positive Cables Running Batt + Terminal (A) voltage drop Blower Motor cables.

  • Page 45: Troubleshooting Charging Indicator (Telltale) Lamp

    Group 33 Starting and Charging Troubleshooting Troubleshooting Charging Indica- tor (Telltale) Lamp When the ignition key is turned “ON”, the Charging Indi- cator (telltale) LED will illuminate for a circuit test. The LED 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...

  • Page 46: Troubleshooting - Alternator Output Test With Bva-34 Tester

    Group 33 Starting and Charging Troubleshooting Troubleshooting — Alternator Output Test with BVA-34 Tester Before beginning the alternator output test, visually check the cables and connections for obvious problems. Check the drive belt tension and adjust if necessary. W3005657 Use BVA-34 System Analyzer or equivalent tool to per- Start the engine and run at high idle.

  • Page 47: Troubleshooting Starting And Charging System With The Accu- Racy Plus Tester

    Group 33 Starting and Charging Troubleshooting Troubleshooting Starting and Charging System with The Accu- racy Plus Tester The J-44700 Accuracy Plus Tester will test the starting and charging system for the following: • Battery open circuit voltage • Cranking voltage •...

  • Page 49: Service Procedures

    Perform battery test or service as needed. All Cables Volvo VN/VHD vehicles are equipped with 2, 3 or 4 bat- Installation teries depending on the engine and options ordered. The batteries are connected together, in parallel, with battery interconnecting cables. The batteries cannot be...

  • Page 50: Ground Cables

    Group 33 Starting and Charging Service Procedures Ground Cables Battery Jump Starting Many service operations require the removal of the bat- You must read and understand the precautions and tery ground (negative) cables as a safety measure. If the guidelines in Service Information, group 30, "General battery ground cable(s) and wiring are not removed and Safety Practices", before performing this procedure.

  • Page 51: Battery, Replacement (One Or Two)

    Group 33 Starting and Charging Service Procedures 3111-03-02-02 To access the batteries on a vehicle equipped with side fairings, open the fairing access cover. “Jumper Studs”, Battery, Replacement (One or which are longer and made of brass, are factory installed on one battery positive and negative post.

  • Page 52: Battery Cables To Starter, Replacement

    Group 33 Starting and Charging Service Procedures 3714-03-02-03 Installation Battery Cables to Starter, Re- Install the replacement battery(s). Ob- placement serve that the battery positive and negative posts are oriented properly You must read and understand the precautions and when installed. guidelines in Service Information, group 30, "General Safety Practices", before performing this procedure.
  • Page 53 Group 33 Starting and Charging Service Procedures Installation Disconnect the main ground cable(s) at the batteries. Position the replacement cable(s) in the proper routing position. Be sure the cable will connect to the starter Disconnect the positive cable(s) at the and batteries when all the support batteries.

  • Page 54: Battery Inter-Connection Cables, Replacement

    Group 33 Starting and Charging Service Procedures 3714-03-02-04 Installation Battery Inter-connection Ca- Replace the defective battery inter- bles, Replacement connecting cable(s). You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices", before performing this procedure. If Install all battery cables and wiring you are not properly trained and certified in this pro- connections removed in step five.

  • Page 55: Starter Motor, Replacement

    Group 33 Starting and Charging Service Procedures 3311-03-02-01 Note: The Volvo Gear-reduction Starter can only be re- placed with another Volvo Gear-reduction Starter. Starter Motor, Replacement Note: In some installations, replacing the starter is aided You must read and understand the precautions and by removing additional components or wiring not refer- guidelines in Service Information, group 30, "General...
  • Page 56 Group 33 Starting and Charging Service Procedures Installation Secure the battery cables in the mounting support brackets. On 42MT starter installations compare 18 – 23 Nm the orientation of the nose housing on (13 – 17 ft-lb) the old starter to the replacement starter.

  • Page 57: Starter Motor, Replacement

    Group 33 Starting and Charging Service Procedures 3311-03-02-01 Remove any wiring harness support Starter Motor, Replacement clamps and brackets as needed to ac- cess the starter mounting bolts and You must read and understand the precautions and allow removal of the starter. guidelines in Service Information, group 30, "General Safety Practices", before performing this procedure.

  • Page 58: Preheater Relay, Replacement

    Turn ignition switch back to “OFF” if perform it. necessary. Install the main ground ca- Volvo D12D Engine ble(s). CAUTION Install ground wiring from electrical equipment connected directly to the Use caution when working around the preheat batteries.

  • Page 59: Preheater Element, Replacement

    Connect and secure the power cable cedure, ask your supervisor for training before you and wiring to the replacement relay. perform it. Volvo D12D Engine Connect the main ground cable(s). WARNING Connect any ground wiring from elec- HOT ENGINE! Keep clear of all moving parts or hot trical equipment removed from the engine parts and/or fluids.
  • Page 60 Group 33 Starting and Charging Service Procedures Installation Disconnect the ground wiring from electrical equipment connected directly Using new gaskets install the pre- 24 ± 4 Nm to the batteries, such as ECU’s, satel- heater element block between the (18 ± 3 ft-lb) lite systems, etc.

  • Page 61: Alternator, Replacement (Adjustable Mount)

    Group 33 Starting and Charging Service Procedures 3211-03-02-03 Disconnect all alternator wiring. Note Alternator, Replacement (Ad- wire positions to aid in installation. justable Mount) You must read and understand the precautions and Loosen the alternator mounting bolts. guidelines in Service Information, group 30, "General Safety Practices", before performing this procedure.

  • Page 62: Alternator, Replacement (Fixed Mount)

    Group 33 Starting and Charging Service Procedures 3211-03-02-04 Connect all alternator wiring. Torque = Alternator, Replacement (Fixed Mount) BATTERY TERMINAL 6.5 ± 0.5 Nm (58 ± 5 in-lb) GROUND TERMINAL 6.2 ± 0.5 Nm (55 ± 5 in-lb) You must read and understand the precautions and guidelines in Service Information, group 30, "General "I"...
  • Page 63 Group 33 Starting and Charging Service Procedures Remove the two mounting bolts and Install the two mounting bolts and se- remove the belt tensioner from the cure the belt tensioner to the front of front of the engine. the engine. Loosen the air compressor main dis- Use fan belt tensioner tool J-44392, or charge line isolator bracket mounting...

  • Page 64: Alternator, Replacement (Pad Mount)

    Group 33 Starting and Charging Service Procedures 3211-03-02-05 Install the replacement alternator and 58 – 73 Nm Alternator, Replacement (Pad tighten the four mounting bolts. Torque (43 – 54 ft-lb) Mount) 58 – 73 Nm You must read and understand the precautions and (43 –...
  • Page 65 Operation Numbers 3111-03-02-02 Battery, Replacement (One or Two) ..... . . 47 3211-03-02-03 Alternator, Replacement (Adjustable Mount) ....57 3211-03-02-04 Alternator, Replacement (Fixed Mount) .
  • Page 68 Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com PV776-TSP177230 () 11.2002 © Volvo Trucks North America, Inc., 2002...

This manual is also suitable for:

Vhd 2002

Table of Contents