Volvo VN User manual

Service Manual
Trucks
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 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 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 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-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..

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
ReserveCapacity ............................................................................ 10
Open Circuit Voltage ....................................................................... 10
BatteryLocations .............................................................................. 10
BatteryCables ................................................................................... 11
BatteryDisconnect Switch ................................................................ 11
Starting System ................................................................................... 12
Starting Circuit ................................................................................... 12
Starter ................................................................................................ 13
Preheat System ................................................................................... 13
Preheat Circuit ................................................................................... 13
Preheater Assembly .......................................................................... 14
Charging System ................................................................................. 15
Charging Circuit ................................................................................. 15
Alternator ........................................................................................... 16
Troubleshooting ................................................................................... 17
BatteryTroubleshooting ....................................................................... 17
BatteryState of Charge .................................................................... 18
BatterySurface Charge Removal ..................................................... 19
Load Testing Batteries ....................................................................... 20
Electronic BatteryTesting .................................................................. 21
Starting System Troubleshooting ......................................................... 22
Troubleshooting Simplified Schematic,Starting System ................... 23
Troubleshooting Ignition Switch with VCADS Pro Tool ..................... 24
Troubleshooting Battery/Starter Cables With Digital Multimeter ....... 25
Troubleshooting Ignition Switch/Starter RelayCircuit With Digital
Multimeter .......................................................................................... 26
Troubleshooting Starter with Digital Multimeter ................................ 27
Preheat System Troubleshooting ........................................................ 28
Troubleshooting Preheater with VCADS Pro Tool ............................. 29
Troubleshooting Preheater with Fault Codes .................................... 29
Troubleshooting Simplified Schematic,D7 Preheater ....................... 30
Troubleshooting Simplified Schematic,D12 Preheater ..................... 31
Troubleshooting Preheater with Digital Multimeter ............................ 32
Charging System Troubleshooting ...................................................... 33
Troubleshooting Simplified Schematics,Charging System ............... 34
Troubleshooting Charging System with Digital Multimeter ................ 35
Troubleshooting Charging Indicator (Telltale) Lamp .......................... 37
Troubleshooting —Alternator Output Test with BVA-34 Tester ........ 38
Troubleshooting Starting and Charging System with The Accu-
racy Plus Tester ................................................................................. 39
Service Procedures ............................................................................. 41
BatteryCables,Removal and Installation ........................................... 41
All Cables .......................................................................................... 41 1

Ground Cables .................................................................................. 42
BatteryJump Starting .......................................................................... 43
Battery,Replacement (One or Two) .................................................... 44
BatteryCables to Starter,Replacement ............................................. 45
BatteryInter-connection Cables,Replacement ................................... 47
Starter Motor,Replacement ................................................................ 49
VolvoD12B or D12C Engine ............................................................. 49
Starter Motor,Replacement ................................................................ 51
VolvoD7C Engine ............................................................................. 51
Starter Motor,Replacement ................................................................ 53
Cummins or Detroit Diesel Engine .................................................... 53
Preheater Fuse,Replacement ............................................................ 55
Preheater Relay,Replacement ............................................................ 56
VolvoD12B or D12C Engine ............................................................. 56
Preheater Relay,Replacement ............................................................ 58
D7C Engine ....................................................................................... 58
Preheater Element, Replacement ....................................................... 59
D12B or D12C Engine ...................................................................... 59
Preheater Element, Replacement ....................................................... 60
D7C Engine ....................................................................................... 60
Alternator,Replacement (Adjustable Mount) ...................................... 62
Alternator,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 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
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:
Service
Manual Electrical Schematics VN, VHD
IMPACT Function Group: 370
Information 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 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
Manual VCADS Pro User’s Manual Group Number 030–600
Battery tester kit. Includes: Tester J-44700 and Printer
238598, available from Kent-Moore (telephone: 800–
328–6657).
J-44701
W0001836
Fluke 87 digital multimeter, available from Volvo or Kent-
Moore (telephone: [phone]).
J-39200
W2001014
5

Group 33 Starting and Charging VN, VHD Tools
Relay puller tool, available from Kent-Moore (telephone:
800–328–6657).
J-43244
W0001917
VCADS Pro
For VCADS Pro tooling refer to:
Service
Manual VCADS Pro User’s Manual Group Number 030–600
W0001632
Fan Belt Tensioner Tool, available from Volvo or Kent-
Moore (telephone: [phone]).
J-44392
W0001817
(BT-33–73F) Belt Tension Gauge, available from Kent-
Moore (telephone: [phone]).
J-23600–B
W0001844
6