Volvo VN 2002 User manual

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

Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to November 2002.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary ser-
vice bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a refer-
ence to an V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an V.S.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could oc-
cur.
Volvo Trucks North America, Inc.
Greensboro, NC 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..
USA12175

Contents
General....................................................................................................3
StartingandCharging...........................................................................3
Tools........................................................................................................5
SpecialTools.........................................................................................5
DesignandFunction.............................................................................7
StartingandChargingSystemIndicatorLights....................................7
Battery...................................................................................................7
ColdCrankingAmps.........................................................................8
ReserveCapacity..............................................................................8
OpenCircuitVoltage.........................................................................8
BatteryLocations................................................................................8
BatteryCables.....................................................................................9
BatteryDisconnectSwitch..................................................................9
StartingSystem...................................................................................10
StartingCircuit...................................................................................10
Starter................................................................................................11
PreheatSystem...................................................................................12
PreheatCircuit...................................................................................12
PreheaterAssembly..........................................................................12
ChargingSystem.................................................................................13
ChargingCircuit.................................................................................13
Alternator...........................................................................................14
Troubleshooting...................................................................................15
BatteryTroubleshooting.......................................................................15
BatteryStateofCharge....................................................................15
BatterySurfaceChargeRemoval.....................................................15
LoadTestingBatteries.......................................................................16
ElectronicBatteryTesting..................................................................17
StartingSystemTroubleshooting.........................................................18
TroubleshootingSimplifiedSchematic,Delco42MTStartingSys-
tem.....................................................................................................19
TroubleshootingSimplifiedSchematic,VolvoGear-reduction
StartingSystem.................................................................................20
TroubleshootingIgnitionSwitchwithVCADSProTool.....................21
TroubleshootingBattery/StarterCablesWithDigitalMultimeter.......22
TroubleshootingIgnitionSwitch/StarterRelayCircuitWithDigital
Multimeter,Delco42MTStarter........................................................24
TroubleshootingIgnitionSwitch/StarterRelayCircuitWithDigital
Multimeter,VolvoGear-reductionStarter..........................................27
TroubleshootingStarterwithDigitalMultimeter................................29
PreheatSystemTroubleshooting........................................................31
TroubleshootingPreheaterwithVCADSProTool.............................32
TroubleshootingPreheaterwithFaultCodes....................................32
TroubleshootingSimplifiedSchematic,D12Preheater.....................33
TroubleshootingPreheaterwithDigitalMultimeter............................34
ChargingSystemTroubleshooting......................................................36
TroubleshootingSimplifiedSchematics,ChargingSystem...............37
TroubleshootingChargingSystemwithDigitalMultimeter................38
TroubleshootingChargingIndicator(Telltale)Lamp..........................41
Troubleshooting—AlternatorOutputTestwithBVA-34Tester........42
TroubleshootingStartingandChargingSystemwithTheAccu-
racyPlusTester.................................................................................43 1