Volvo VN Series Service Manual
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Volvo VN Series Service Manual

Volvo VN Series Service Manual

Group 330–500 starting and charging
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Service Manual
Trucks
330–500
Group
Starting and Charging
VN, VHD
PV776-TSP146025

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Summary of Contents for Volvo VN Series

  • Page 1 Service Manual Trucks 330–500 Group Starting and Charging VN, VHD PV776-TSP146025...
  • Page 3 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 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

    Contents General ....................3 Starting and Charging ................3 Tools ......................5 Special Tools ..................5 Design and Function ................9 Starting and Charging System Indicator Lights ........9 Battery ....................9 Cold Cranking Amps ............... 10 Reserve Capacity ................10 Open Circuit Voltage ...............
  • Page 6 Battery Cables to Starter, Replacement ..........45 Battery Inter-connection Cables, Replacement ........47 Starter Motor, Replacement ..............49 Volvo D12B or D12C Engine ............. 49 Starter Motor, Replacement ..............51 Volvo D7C Engine ................51 Starter Motor, Replacement ..............53 Cummins or Detroit Diesel Engine ............

  • 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

    Tools Special Tools The tools referenced in this manual are listed below. They can be obtained by contacting your local Volvo Trucks parts dealer, Kent-Moore at 1–800–328–6657, or you may call a local listed tool vendor. Note: For VCADS Pro tooling refer to: Service VCADS Pro User’s Manual...
  • Page 10 For VCADS Pro tooling refer to: Service VCADS Pro User’s Manual Manual Group Number 030–600 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).
  • Page 11 Group 33 Starting and Charging VN, VHD Tools BVA-34 System Analyzer The BVA-34 System Analyzer is a digital, carbon pile, battery load tester and starting/charging system ana- lyzer. It is portable and designed for use in the heavy truck market. Optional tester stand, part number ES-2, is also available .

  • Page 13: Design And Function

    Group 33 Starting and Charging VN, VHD Design and Function Design and Function Starting and Charging System Indicator Lights When the ignition key is turned “ON,” the Charging Indi- cator (telltale) lamp (1) will momentarily illuminate for a bulb test. The lamp will remain on until the engine is started.

  • Page 14: Cold Cranking Amps

    Group 33 Starting and Charging VN, VHD Design and Function Cold Cranking Amps The “Cold Cranking Amps” rating is the amount of am- perage load that can be maintained at –18 C (0 without the post voltage falling below 7.2 volts. This rating is useful in determining the battery’s ability to start an engine in cold weather conditions.

  • Page 15: Battery Cables

    Group 33 Starting and Charging VN, VHD 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 16: Starting System

    Group 33 Starting and Charging VN, VHD Design and Function Starting System Starting Circuit When the ignition switch is turned to the “START” posi- tion, power to energize the starter relay coil is supplied on wire number 284. The starter relay coil is grounded through the overcrank protection switch (OCP) or a shorting jumper.

  • Page 17: Starter

    Volvo VN/VHD vehicles are equipped with Delco Remy- 42MT starters for most applications. If the vehicle is equipped with a Volvo D7 engine, it will be equipped with a Delco-Remy 37MT starter. These starters, sometimes referred to as starting motors, have a shift lever and so- lenoid housing that is totally enclosed to protect them from the elements.

  • Page 18: Preheater Assembly

    Group 33 Starting and Charging VN, VHD Design and Function Preheater Assembly WARNING Use caution when working around the preheat elements. When active, the elements will heat to ap- proximately 705 C (1300 F). Allow sufficient time for the elements to cool to avoid severe burns. The preheater assembly on a D7 engine is standard with one relay element and fuse.

  • Page 19: Charging System

    Group 33 Starting and Charging VN, VHD 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- cles electrical system through wire no. 8. The alternator is grounded by a wire from the ground terminal (B-) on the alternator case to the engine ground terminal.

  • Page 20: Alternator

    “clamp” voltage spikes that may damage vehicle electronics. An internal voltage regulator limits the charging voltage from 13.8 to 14.2 volts. Volvo VN/VHD vehicles currently are equipped with one of three different Delco Remy alternators: •...

  • Page 21: Troubleshooting

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Battery Troubleshooting 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 main Before working on a vehicle, set the parking brakes, battery ground cable.

  • Page 22: Battery State Of Charge

    Group 33 Starting and Charging VN, VHD Troubleshooting Battery State of Charge The battery state of charge must be determined before battery testing. Battery hydrometers that measured bat- tery acid specific gravity were used to determine the state of charge in earlier battery designs with removable filler caps.

  • Page 23: Battery Surface Charge Removal

    Group 33 Starting and Charging VN, VHD Troubleshooting Battery Surface Charge Removal When a battery is charged, very small hydrogen gas bubbles form on the surface of the battery plates, caus- ing what is known as “surface charge.” When a voltmeter is connected to the battery post, it may give a false read- ing if the surface charge is not removed.

  • Page 24: Load Testing Batteries

    Group 33 Starting and Charging VN, VHD 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 25: Electronic Battery Testing

    Group 33 Starting and Charging VN, VHD Troubleshooting Electronic Battery Testing The J-44700 Accuracy Plus HD Battery Tester is a hand held electronic battery diagnostic tester. The tester ap- plies variable loads to the battery and measures the battery’s response. Results are then displayed and may be printed if desired with the optional printer number 238598.

  • Page 26: Starting System Troubleshooting

    Group 33 Starting and Charging VN, VHD Troubleshooting Starting System WARNING Troubleshooting HOT ENGINE! Keep clear of all moving parts or hot engine parts and/or fluids. A hot engine an/or fluids can cause burns. Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels.

  • Page 27: Troubleshooting Simplified Schematic, Starting System

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Simplified Schematic, Starting System The simplified schematic and illustration below should be used to clarify the troubleshooting procedures in “Troubleshooting Battery/Starter Cables With Digital Multimeter” page 25 , “Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter”...

  • Page 28: Troubleshooting Ignition Switch With Vcads Pro Tool

    Troubleshooting Troubleshooting Ignition Switch Note: This test only applies to vehicles with a Vehicle ECU (Volvo engines). with VCADS Pro Tool The VCADS Pro Tool is a Windows 95 based PC tool that can be used to perform some ignition switch testing.

  • Page 29: Troubleshooting Battery/Starter Cables With Digital Multimeter

    Group 33 Starting and Charging VN, VHD Troubleshooting Confirm that the cables between batteries are clean, Troubleshooting Battery/Starter tight and in proper working order. Cables With Digital Multimeter Remove engine ECU fuses, located in the battery box, to prevent the engine from running during the The starter is supplied power and ground through cables tests.

  • Page 30: Troubleshooting Ignition Switch/Starter Relay Circuit With Digital Multimeter

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Ignition Check for 12.4V at the battery cable terminals (A1 & B1) to the starter motor. If 12.4 V is not present or if Switch/Starter Relay Circuit With a weak battery(s) is suspected, see: “Battery Trou- Digital Multimeter bleshooting”...

  • Page 31: Troubleshooting Starter With Digital Multimeter

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Starter with Confirm that the cables between batteries are clean tight and in proper working order. Digital Multimeter Remove the engine ECU fuses located in the battery The starter motor/solenoid is supplied power and ground box to prevent the engine from running during tests.

  • Page 32: Preheat System Troubleshooting

    Group 33 Starting and Charging VN, VHD Troubleshooting Preheat System Troubleshoot- CAUTION Possible damage to electronic components. Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components. Failure to de-energize circuits may result in permanent damage Before working on a vehicle, set the parking brakes, to electronic components.

  • Page 33: Troubleshooting Preheater With Vcads Pro Tool

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Preheater with Group Number 030–600 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 34: Troubleshooting Simplified Schematic, D7 Preheater

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Simplified Schematic, D7 Preheater The simplified schematic and lllustration below should clarify the procedures in “Troubleshooting Preheater with Digital Multimeter” page 32. For detailed, vehicle-specific schematics refer to Function Group 370, Service Manual: Electrical Schematics VN, VHD.

  • Page 35: Troubleshooting Simplified Schematic, D12 Preheater

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Simplified Schematic, D12 Preheater The simplified schematic and lllustration below should clarify the procedures in “Troubleshooting Preheater with Digital Multimeter” page 32. For detailed, vehicle-specific schematics refer to Function Group 370, Service Manual: Electrical Schematics VN, VHD.

  • Page 36: Troubleshooting Preheater With Digital Multimeter

    Group 33 Starting and Charging VN, VHD 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 A, B, C, etc. correspond to measuring points that are illustrated in the preheat simplified schematics and drawings in “Troubleshooting Simplified Schematic, D7 Preheater”...

  • Page 37: Charging System Troubleshooting

    Group 33 Starting and Charging VN, VHD Troubleshooting Charging System CAUTION Troubleshooting Never use the ohmmeter mode of the DMM in a pow- ered circuit or as a substitute for a voltmeter or ammeter, since this will damage the instrument. Use the ohmmeter mode only when power is removed Before working on a vehicle, set the parking brakes, from the circuit.

  • Page 38: Troubleshooting Simplified Schematics, Charging System

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Simplified Schematics, Charging System The simplified schematic and illustration below should be used to clarify the procedures in “Troubleshooting Charging System with Digital Multimeter” page 35. For detailed, vehicle-specific schematics refer to: Service Electrical Schematics VN/VHD Manual...

  • Page 39: Troubleshooting Charging System With Digital Multimeter

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Charging System • Short life of light bulbs or other electrical compo- nents due to unusually high system voltage. with Digital Multimeter Prior to troubleshooting, visually check the cables and One or more of the following conditions will generally in- connections for obvious problems.
  • Page 40 Group 33 Starting and Charging VN, VHD Troubleshooting Funtion Key Posi- Measuring Point Expected Note Possible Cause (if expected tion Value valve not correct Alternator ON/ Engine Output Terminal (X)/ 13.8 - 14.2 V Accessories Power circuit from battery Charging Running Ground Terminal Y Ground circuit from battery...

  • Page 41: Troubleshooting Charging Indicator (Telltale) Lamp

    Group 33 Starting and Charging VN, VHD Troubleshooting Troubleshooting Charging Indica- telltale should be illuminated. Disconnect the wire at the indicator light terminal (Z). The Charging telltale tor (Telltale) Lamp should go off. If not, check for a grounded circuit be- tween the alternator and instrument cluster.

  • Page 42: Troubleshooting - Alternator Output Test With Bva-34 Tester

    Group 33 Starting and Charging VN, VHD 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. W3004738 Use BVA-34 System Analyzer or equivalent tool to per- Start the engine and run at high idle.

  • Page 43: Troubleshooting Starting And Charging System With The Accuracy Plus Tester

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

  • Page 45: Service Procedures

    Failure to do so can result in unexpected Volvo VN/VHD vehicles are equipped with 2, 3 or 4 bat- teries depending on the engine and options ordered. vehicle movement and can cause serious personal in- The batteries are connected together, in parallel, with jury or death.

  • Page 46: Ground Cables

    Group 33 Starting and Charging VN, VHD Service Procedures Installation Disconnect the main ground cable(s). Connect the battery interconnection cables. Perform service operations as needed. Connect the main positive cable(s). Installation If the vehicle is equipped with a Sup- Connect the positive wiring from the plemental Restraint System (SRS) and electrical equipment connected directly a Cummins or Detroit Diesel engine,...

  • Page 47: Battery Jump Starting

    Group 33 Starting and Charging VN, VHD Service Procedures Battery Jump Starting Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in- jury or death.

  • Page 48: Battery, Replacement (One Or Two)

    Group 33 Starting and Charging VN, VHD Service Procedures 3111-03-02-02 CAUTION Battery, Replacement (One or Two) Possible damage to electronic components. Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components. Failure to de-energize circuits may result in permanent damage to electronic components.

  • Page 49: Battery Cables To Starter, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3714-03-02-03 Install the battery hold down clamp. 24 ± 4 Nm Battery Cables to Starter, Re- Torque = (18 ± 3 ft-lb) placement 24 ± 4 Nm (18 ± 3 ft-lb) Install all battery cables and wiring connections removed in steps 5.
  • Page 50 Group 33 Starting and Charging VN, VHD Service Procedures CAUTION Disconnect the positive cable(s) at the batteries. Possible damage to electronic components. Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components. Failure to Remove all support clips (brackets) de-energize circuits may result in permanent damage and cut cable ties.

  • Page 51: Battery Inter-Connection Cables, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3714-03-02-04 Connect the main ground cable(s). Battery Inter-connection Ca- Turn ignition switch back to “OFF” if necessary. bles, Replacement Connect ground wiring from the elec- trical equipment connected directly to the batteries. Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels.
  • Page 52 Group 33 Starting and Charging VN, VHD Service Procedures CAUTION If the vehicle is equipped with a Sup- plemental Restraint System (SRS) and a Cummins or Detroit Diesel engine, Possible damage to electronic components. Turn the turn the ignition switch to the “ON” po- vehicle ignition switch OFF before disconnecting or sition.

  • Page 53: Starter Motor, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3311-03-02-01 Starter Motor, Replacement Volvo D12B or D12C Engine Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in- jury or death.
  • Page 54 Group 33 Starting and Charging VN, VHD Service Procedures Loosen or remove the battery cable Install the engine ground cables (5) 48 ± 8 Nm mounting support brackets, if needed and secure. (35 ± 6 ft-lb) to allow enough slack for removal of Torque = the battery cable terminals at the 48 ±...

  • Page 55: Starter Motor, Replacement

    CAUTION Starter Motor, Replacement If there are other ground cables connected to the bat- Volvo D7C Engine tery (such as engine ECU’s, satellite system, etc.), disconnect those grounds first, then remove the main battery ground cable. Electronic modules may be...
  • Page 56 Group 33 Starting and Charging VN, VHD Service Procedures Installation Note: In some installations, replacement of the starter may be aided by removal of additional components or wiring not referenced in this manual, or affected by alter- Compare the orientation of the nose 18 ±...

  • Page 57: Starter Motor, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3311-03-02-01 CAUTION Starter Motor, Replacement Possible damage to electronic components. Turn the Cummins or Detroit Diesel vehicle ignition switch OFF before disconnecting or connecting any electronic components. Failure to Engine de-energize circuits may result in permanent damage to electronic components.
  • Page 58 Group 33 Starting and Charging VN, VHD Service Procedures Remove the starter mounting bolts Install the main ground cable(s). Turn and remove the starter and spacer ignition switch back to “OFF” if neces- (if equipped) from the vehicle. sary. Installation Install ground wiring from electrical equipment connected directly to the Compare the orientation of the nose...

  • Page 59: Preheater Fuse, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3331-03-02-02 Preheater Fuse, Replacement Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in- jury or death.

  • Page 60: Preheater Relay, Replacement

    Removal Preheater Relay, Replacement Turn the ignition key to the “OFF” posi- tion. Volvo D12B or D12C Engine Disconnect ground wiring from the electrical equipment connected directly Before working on a vehicle, set the parking brakes, to the batteries, such as ECU’s, satel- place the transmission in neutral, and block the lite systems, etc.
  • Page 61 Group 33 Starting and Charging VN, VHD Service Procedures Removal Tap the relay mounting bracket onto the element block. Turn the ignition key to the “OFF” posi- tion. Install the preheater element block, with new gaskets, and the charge air Disconnect ground wiring from electri- piping to the intake manifold.

  • Page 62: Preheater Relay, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3331-03-02-03 Disconnect ground wiring from the Preheater Relay, Replacement electrical equipment connected directly to the batteries, such as ECU’s, satel- D7C Engine lite systems, etc. Disconnect the battery main ground cable(s). Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels.

  • Page 63: Preheater Element, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures 3331-03-02-01 CAUTION Preheater Element, Replace- ment Use caution when working around the preheat elements. When active, the elements will heat to ap- proximately 705 C (1300 F.). Allow sufficient time for D12B or D12C Engine the elements to cool to avoid severe burns.

  • Page 64: Preheater Element, Replacement

    Group 33 Starting and Charging VN, VHD Service Procedures Remove the charge air pipe hose Secure with the battery terminal nut(s). 3.7 ± 5.7 Nm clamp. Torque = (10 –15 ft-lb) 3.7 ± 5.7 Nm (10 –15 ft-lb) Remove the charge air piping / pre- heater mounting bolts (3) and remove 3331-03-02-01 the charge air piping (4) from the vehi-...
  • Page 65 Group 33 Starting and Charging VN, VHD Service Procedures Removal Install the ground wire from the pre- heater element block. Turn the ignition key to the “OFF” posi- tion. Install the charge air piping. Secure 24 ± 4 Nm the mounting bolts at the preheat ele- (18 ±...

  • Page 66: Alternator, Replacement (Adjustable Mount)

    Group 33 Starting and Charging VN, VHD Service Procedures 3211-03-02-03 CAUTION Alternator, Replacement (Ad- justable Mount) Possible damage to electronic components. Turn the vehicle ignition switch OFF before disconnecting or connecting any electronic components. Failure to de-energize circuits may result in permanent damage to electronic components.

  • Page 67: Alternator, Replacement (Fixed Mount)

    Group 33 Starting and Charging VN, VHD Service Procedures 3211-03-02-04 Adjust the tensioner as needed to Alternator, Replacement (Fixed achieve a belt tension of 111 Nm (150 Mount) ft-lb) for a new belt or 73 Nm (100 ft- lb) for a used belt. Use Belt Tension Gauge J-23600–B, or equivalent tool, to check tension.
  • Page 68 Group 33 Starting and Charging VN, VHD Service Procedures CAUTION Use fan belt tensioner tool J-44392, or equivalent tool, to release the pres- sure from the automatic belt tensioner Possible damage to electronic components. Turn the and install the belt onto the alternator vehicle ignition switch OFF before disconnecting or pulley.
  • Page 69 If you have any comments or suggestions, make a copy of this page, write down your comments and send them to us, either via telefax or mailing directly to the address listed below. From Volvo Trucks North America, Inc................Dept. 516 Service Publications ................
  • Page 70 Operation Numbers 3111-03-02-02 Battery, Replacement (One or Two) ..... . . 44 3211-03-02-03 Alternator, Replacement (Adjustable Mount) ....62 3211-03-02-04 Alternator, Replacement (Fixed Mount) .
  • Page 72 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...

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