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

ServiceProcedures.............................................................................45
BatteryCables,RemovalandInstallation...........................................45
AllCables..........................................................................................45
GroundCables..................................................................................46
BatteryJumpStarting..........................................................................46
Battery,Replacement(OneorTwo)....................................................47
BatteryCablestoStarter,Replacement.............................................48
BatteryInter-connectionCables,Replacement...................................50
StarterMotor,Replacement................................................................51
VolvoD12DEngine...........................................................................51
StarterMotor,Replacement................................................................53
CumminsISX/ISL/ISCEngine.........................................................53
PreheaterRelay,Replacement............................................................54
VolvoD12DEngine...........................................................................54
PreheaterElement,Replacement.......................................................55
VolvoD12DEngine...........................................................................55
Alternator,Replacement(AdjustableMount)......................................57
Alternator,Replacement(FixedMount)..............................................58
Alternator,Replacement(PadMount).................................................60
Operation Numbers
2

Group 33 Starting and Charging General
General
Starting and Charging
The starting and charging system on the VN/VHD series vehicles is comprised of batteries, the starter, alternator and
all the connecting wiring, cables and switches. Vehicles equipped with Volvo engines may also have preheaters in-
stalled in the intake manifold to assist starting. For maximum efficiency, all parts of the system must function properly.
Note: The information in this manual pertains specifically to the Volvo VN/VHD series vehicles.
For more general information on the starting and charging system, including test, refer to vendor information
“Diagnostic Procedures For Heavy Duty Electrical Systems” in Delco Remy DRA/DP1029.
W3005303
Starting and Charging Circuit, Simplified Schematic
This simplified schematic should only be used to clarify the design features of the cir-
cuit. For detailed vehicle-specific schematics, refer to "VN, VHD VERSION2 Electrical
Schematics” in Function Group 37.
3

4

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
5

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. It is portable and designed for use in the heavy
truck market. Optional tester stand, part number ES-2, is
also available . For more information contact Auto-
Meter®(telephone: [phone]) or visit their web site
at www.autometer.com.
W3004737
6

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-
cator (telltale) lamp will illuminate for a bulb test. The
lamp will remain on until the engine is started. With the
engine running and the alternator properly charging, the
Charging telltale light should go off.
The instrument cluster module is equipped with a graph-
ics display that includes a voltmeter function. With the
voltmeter function active, the display shows a battery
icon and the battery/charging voltage.
T3014509
Battery
The battery is an electrochemical device for converting
chemical energy into electrical energy. The battery, or
battery pack, performs four basic functions:
1 It supplies energy for starting the engine.
2 It supplies energy to operate the electrical systems
and accessories, when the engine is off.
3 It acts as a voltage stabilizer for the electrical sys-
tem.
4 It supplies additional energy to operate the electrical
system during peak demands, for instance, when
the alternator is already at maximum output with the
engine running.
The battery case (1) is made of a strong, lightweight ma-
terial, commonly polypropylene, to withstand shock and
vibration. The cover is vented to allow chemical gases to
escape. Each battery cell (2) is constructed of positive
and negative plates (3) that are insulated from each
other by a porous separator (4). Plate straps (5) connect
the positive and negative plates and provide a means of
interconnecting the cells. The cell is immersed in an
electrolyte solution of sulfuric acid and water. The electri-
cal energy is produced in the battery by the chemical
reaction of the active materials that comprise the positive
and negative plates and the electrolyte. Each cell will
produce approximately 2.1 volts. The six cells that com-
prise the battery are connected in series to deliver
approximately 12.6 volts at the battery post (6).
W3004556
1Battery Case
2Battery Cell
3Battery Plates
4Separator
5Plate Straps
6Post
7

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. This rating is useful in determining the battery’s
ability to start an engine in cold weather conditions.
The cold cranking amp rating is determined by the
amount of plate surface area in each cell.
Reserve Capacity
The “Reserve Capacity” is the number of minutes that
a battery can sustain a 25 Amp load at 27

C (80

F)
until the post voltage drops to 10.5 volts. This rating is
useful in determining the battery’s ability to supply
operating power in the event of a vehicle charging sys-
tem failure. The reserve capacity is determined by the
amount of active plate material in each cell.
Open Circuit Voltage
The “Open Circuit Voltage” is the voltage at the battery
post with no loads applied.
Battery Locations
Battery box locations vary per application. The stan-
dard mounting location (1) is on the left frame rail
under the cab steps (behind folding fairing VNL). This
is the mounting location for all VN and some VHD ve-
hicles.
Depending on the equipment ordered, there are three
optional battery box mounting locations for the VHD
vehicle. See illustration for locations: (2), (3) and (4).
W3004555
8

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. Bat-
tery inter-connection cables (2) are 2/0 size. Some
applications may use interconnection bars instead of ca-
bles. All battery cables are sealed with polyvinyl chloride
(PVC) insulation to resist abrasion and the elements.
The battery cable terminals are secured to the batteries
with either stainless steel terminal nuts (3) or brass
jumper studs (4). Some applications may be equipped
with insulated terminal nuts that are made of plastic with
a brass insert. Protective covers (6) are installed on all
uninsulated battery cable terminal nuts/studs. Mounting
brackets (5) support and secure the battery cables at ap-
proximately 300 mm (12 in.) to 600 mm (24 in.) intervals
to avoid damage from abrasion, vibration, heat and
strain.
Ideally, battery sets should be connected to the bat-
tery/starter cables in a diagonal pattern (1) rather than
both cables being connected to one battery at the end of
the set (2). The diagonal connection will help assure that
all batteries in the set are cycled at the same rate, ex-
tending service life.
W3004556
W3004557
Battery Disconnect Switch
As an option, some vehicles may have a master battery
disconnect switch (main switch). The switch will be
mounted on or near the battery box in all applications.
The battery disconnect switch should not be used as a
substitute for removing battery cables to prevent damage
to the vehicle when welding or making repairs.
W3005317
9

Group 33 Starting and Charging Design and Function
Starting System
Starting Circuit
Note: The Volvo Gear Reduction Starter is equipped
with a starter mounted relay in addition to a cowl
mounted relay.
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.
Note: The OCP switch is not avaliable on the Volvo Gear
Reduction Starter.
The OCP switch is located inside the starter. This switch
is optional. Where the OCP switch is not used, a short-
ing jumper is used to complete the coil’s ground circuit.
W3004339
Fig. 1: 42 MT Starter
overcrank protection (OCP) input switch.
W3005337
Fig. 2: Gear Reducton Starter
1Positive Cable Stud
2Starter Solenoid
3Starter Relay
4Mounting Bolt
5Ground Stud
When the starter relay is energized, a connection is
made from the starter solenoid BATT terminal (wire
285A) to the starter solenoid SW terminal (wire 285).
When the solenoid pulls in, a connection is made inter-
nally in the solenoid, which connects the battery terminal
to the motor terminal, then the starter begins to crank
the engine.
For more details see schematic in “Starting and Charg-
ing” page 3.
W3003757
Cowl Mounted Starter Relay.
10

Group 33 Starting and Charging Design and Function
Starter
Volvo VN/VHD vehicles are equipped with Delco Remy-
42MT or Volvo Gear-reduction starters for most
applications. If the vehicle is equipped with a Volvo D12
engine, it will be equipped with a Volvo Gear-reduction
starter. Both starters, sometimes referred to as starting
motors, have a shift lever and solenoid housing that is
totally enclosed to protect them from the elements. The
nose housing (Delco starters only) can be rotated to
“clock” the solenoid to accommodate various engine
mounting locations. A positive engagement shift mecha-
nism moves the pinion into mesh with the engine
flywheel ring gear prior to cranking to minimize gear
tooth damage. On vehicles equipped with the Delco
Remy-42MT starter an optional overcrank protection
(OCP) switch protects the starter in adverse starting
conditions, such as cold weather starting or operator
misuse. The OCP switch is a temperature sensitive cir-
cuit breaker that prevents overcrank heat damage by
opening the starter relay ground, then automatically re-
setting when the starter has cooled sufficiently. The
Volvo Gear-reduction starter is not equipped with an in-
ternal overcrank protection feature. To prevent starter
overheating, the engine must not be cranked for more
than 30 continuous seconds. If the starter is operated for
more than 30 continuous seconds, there must be a 10
minuite wait before attempting to start the vehicle again.
W3004558
Fig. 3: Delco Remy 42MT Starter
1 Solenoid
2 Shift Lever Housing
3 Nose Housing
4 Pinion
5 Overcrank Protection Input Connector
W3005300
Fig. 4: Volvo Gear Reduction Starter
1 Solenoid
2 Heavy Duty Relay
3 Pinion
11

Group 33 Starting and Charging Design and Function
Preheat System
Preheat Circuit
Vehicles equipped with Volvo engines may be equipped
with intake air preheaters to assist in cold weather start-
ing.
The preheat system used on the Volvo engine consists
of two preheat relays and two heating elements.
In normal operation, the ignition switch is turned to the
“preheat” position then released back to the “On”
position. The Vehicle Electronic Control Unit (VECU) rec-
ognizes the preheat request and sends the request to the
Engine Electronic Control Unit (EECU), via the J-1939
Control Data Link. The EECU will supply a ground to the
preheat relay(s), and the preheater will begin to operate.
Based on engine temperature, the EECU will time the in-
terval for preheater operation. The operator may also
hold the ignition switch in the “preheat” position if addi-
tional preheat is desired after the timed preheat period.
The preheat relay coils are supplied Battery power via a
fuse in the Truck Electrical Center (TEC) panel. The re-
lays are energized when a ground is supplied by the
EECU. When the relays are energized, an internal con-
nection is made that connects the preheater element
power supply from the alternator cable to the preheat
elements. The preheat elements are grounded to the en-
gine block, below and slightly to the rear of the alternator.
A “sense” circuit(s) provides information to the EECU to
confirm that the preheat circuit is intact. If the EECU de-
termines that the circuit is not intact, a fault code(s) will
be generated.
For simplified schematic see: “Starting and Charging”
page 3.
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.
W3005576
1Element
12

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. A
fusible link in the ground circuit is designed to protect the
vehicle electrical system if a short in the alternator, alter-
nator cable or battery cable occurs.
A wire from the alternator indicator “I” light terminal to
the instrument cluster sends a signal to indicate that the
alternator is not charging. Vehicles with body builder ap-
plications may also have a wire from the alternator relay
“R” terminal to provide engine speed information for PTO
operation. For a simplified schematic see “Starting and
Charging” page 3.
W3004731
1 Output Terminal (B+)
2 Ground Terminal (B-)
3 Relay Terminal “R”
4 Indicator Light Terminal “I”
5 Ground Terminal (B-) 34SI only
13

Group 33 Starting and Charging Design and Function
Alternator
The alternator converts the mechanical energy supplied
by the engine via drive belts into electrical energy that is
used to recharge the batteries and operate the electrical
devices on the vehicle. The alternator produces alternat-
ing current (AC), which is converted to direct current
(DC) by the diodes in the rectifier bridge. The rectifier
bridge also has design features to “clamp” voltage
spikes that may damage vehicle electronics. An internal
voltage regulator limits the charging voltage from 13.8 to
14.2 volts. The Volvo VN/VHD vehicles are currently
equipped with one of the three following Delco Remy al-
ternators using several mounting configurations:
The 22SI spool mount alternator is a smaller, standard
brush type alternator. It is available with 100, 130 and
145 amp output ratings.
W3005347
Fig. 5: Spool Mount
The 22SI pad mount alternator is internally identical to
the 22SI spool mount. The major difference is the hous-
ing. The pad mount design uses four bolts into an
engine block mounting bracket for stability and viabration
resistance.
W3005318
Fig. 6: Pad Mount
33SI Spool Mount — The 33SI spool mount alternator is
a brushless design for longer operating life. It is the stan-
dard alternator used in most applications. It is available
with 110 and 135 amp output ratings.
W3005341
Fig. 7: Spool Mount
The 34SI pad mount alternator is internally identical to
the 33SI spool mount. The major difference is the hous-
ing. The pad mount design uses four bolts into an
engine block mounting bracket for stability and viabration
resistance.
W3005349
Fig. 8: Pad Mount
14

Group 33 Starting and Charging Troubleshooting
Troubleshooting
Battery 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.
Battery State of Charge
The battery state of charge must be determined before
battery testing. Battery hydrometers that measured bat-
tery acid specific gravity were used to determine the
state of charge in earlier battery designs with removable
filler caps. In current “maintenance free” design batteries
the state of charge is determined by either a built-in hy-
drometer or an open circuit voltage test.
If a battery with built in hydrometer displays a clear
eye, it must be replaced. Do not attempt to charge,
test or jump start the battery.
Note: The built-in hydrometer only monitors one battery
cell. 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 by
reading the open circuit voltage. To check, connect a
voltmeter to the positive and negative battery post. If the
reading is below 12.40 volts, the battery is too low for
proper testing and must be recharged before testing. If
the reading is above 12.66 volts, the surface charge
must be removed before testing. See: “Battery Surface
Charge Removal” page 15.
Battery Surface Charge Removal
When a battery is charged, very small hydrogen gas
bubbles form on the surface of the battery plates, caus-
ing what is known as “surface charge.” When a voltmeter
is connected to the battery post, it may give a false read-
ing if the surface charge is not removed.
Before testing a battery, the surface charge must be re-
moved by one of the following methods:
•Turn on the headlights for 2–3 minutes. Then allow
the battery to stabilize for 1 minute before testing.
•Remove the Engine ECU fuse in the battery box to
prevent the engine from starting. Crank the engine
for 5–10 seconds. Then allow the battery to stabilize
for 1 minute before testing.
•Use BVA-34 System Analyzer or equivalent tool to
load the battery to 300 amps for 5–10 seconds.
Then allow the battery to stabilize for 1 minute be-
fore testing.
Note: The open circuit voltage must be at least 12.4
volts after the surface charge has been removed to con-
tinue battery testing.
15

Group 33 Starting and Charging Troubleshooting
Load Testing Batteries
The BVA-34 System Analyzer is a digital, carbon pile,
battery load tester and starting/charging system ana-
lyzer. It is portable and designed for use in the heavy
truck market. The test that follows may be performed
with the BVA-34 System Analyzer, or equivalent carbon
pile type tester, and should be used as a general guide
for performing a battery load test. Read and follow the
test instructions supplied with the tester used to perform
battery testing.
1 Batteries must be tested individually. Remove
battery cables as described in “Battery Cables, Re-
moval and Installation” page 45.
2 Visually inspect the battery for corroded terminals,
damage or a clear built-in hydrometer eye, if
equipped. Clean the terminals if needed. Replace
damaged batteries or batteries with clear hydrome-
ter eyes (indicates electrolyte loss).
3 Screw the brass “jumper studs” onto the positive
and negative terminal before connecting the tester.
Do not connect the tester leads directly to the bat-
tery terminal post.
4
W3004563
Connect the BVA-34 System Analyzer (or equivalent
tool) to the battery as shown. Set the voltmeter to
the “INTERNAL” setting. Zero the ammeter.
5 Check the battery open circuit voltage. The reading
must be between 12.40 and 12.66 volts to proceed.
If not, see “Battery State of Charge” page 15.
6 Adjust the load control knob to equal one half the
battery’s Cold Cranking Amp (CCA) rating. The bat-
tery CCA specification can be found on the battery
label. Maintain the load for 15 seconds then note
the battery voltage (with load applied).
7
ESTIMATED
ELECTROLYTE
TERMPERATURE
MINIMUM REQUIRED
VOLTAGE UNDER 15
SECOND LOAD
70

F (21

C) and above 9.6
60

F (16

C) 9.5
50

F (10

C) 9.4
40

F(4

C) 9.3
30

F (-1

C) 9.1
20

F (-7

C) 8.9
10

F (-12

C) 8.7
0

F (-18

C) 8.5
Compare the voltage reading obtained to the tem-
perature compensated chart above. If the battery
does not meet or exceed the minimum voltage re-
quired, replace the battery.
16