D

Service Manual Trucks

PV776-20032392

Foreword

The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to October 2005. 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 service 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 reference to an V.S.T. (Volvo Standard Times). Service procedures which do not include an operation number in the title are for general information and no reference is made to an V.S.T. Each section of this manual contains specific safety information and warnings which must be reviewed before performing any procedure. If a printed copy of a procedure is made, be sure to also make a printed copy of the safety information and warnings that relate to that procedure. 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 occur.

Volvo Trucks North America, Inc.

Order number: 20032392

2005 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, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..
USA17732.ihval

Contents

Illustrations ........................................................................................... 3 Illustration Index, Wiring Harnesses ...................................................... 3

Group 37

Illustrations

Illustrations
Note: For further information, concerning Electrical Schematics, refer to the current schematics documentation in Group 37. Number Cab Interior Description

Illustration Index, Wiring Harnesses

D
Page Fuse and Relay Center, Main Cab Harness page 6 Fuse and Relay Center, Main Cab Harness 2 page 7 Aux. Switch Overlay page 8 Cab Wiring Passthrough page 9 Modules page 10 ABS Overlay page 11 ECS ECU Overlay page 12 Dash Switches, VN page 13 Dash Switches, VHD page 14 Dash Harness and Cab Wiring Passthrough page 15 Dash Harness, Mobile Max page 16 Dash Harness, Qualcomm page 17 Dash Harness, Snow Plow/ Beacon Lights Option page 18 Front Overhead Shelf/CB Power Harness page 19 Radio Harness page 20 Steering Column Harness, Including Stalk Switches page 21 Cab Floor Harnesses, Front page 22 Sleeper Control Panel (LECM) page 36 Rear Cab Harness, VN430 page 23 Rear Cab Harness, VN630 page 24 Rear Cab Harness, VN670 page 25 Rear Cab Harness, VN780 page 26 Rear Cab, Lower Wall Harness, VN780 page 27 Rear Cab Valance Harness, VN780 page 28 Rear Cab Harness, Back of Cab Lights (HDI/HDO Variant) page 29 Rear Cab Harness, Back of Cab Lights (LDI/LDO Variant) page 30 Rear Cab Harness, Fifth Wheel Light page 31 Rear Cab Harness, Fifth Wheel Light page 32 Rear Cab Harness, Fifth Wheel Light and Rear Speakers (Daycab) page 33 3

Fuse and Relay Center, Main Cab Harness Fuse and Relay Center, Main Cab Harness 2 Auxiliary Switch Cab Wiring Passthrough Modules ABS Overlay ECS ECU Overlay Dash Switches, VN Dash Switches, VHD Dash Harness and Cab Wiring Passthrough Dash Harness, Mobile Max Dash Harness, Qualcomm Dash Harness, Snowplow Lights Dash Overhead Shelf Harness and CB Power Radio Harness Steering Column Harness Cab Floor Harnesses, Front Sleeper Control Panel Rear Cab Harness, VN430 Rear Cab Harness, VN630 Rear Cab Harness, VN670 Rear Cab Harness, VN780 Rear Cab, Lower Wall Harness, VN780 Rear Cab Valance Harness, VN780 Rear Cab Harness, Back of Cab Lights (HDI/HDO) Rear Cab Harness, Back of Cab Lights (LDI/LDO) Rear Cab Harness, Fifth Wheel Light Rear Cab Harness, Fifth Wheel Light Rear Cab Harness, Fifth Wheel Light and Speakers (Daycab)

Group 37

Illustrations

Number

Description

Rear Cab Harness, Dual Fifth Wheel Light and Rear Speakers (Daycab) Rear Cab Harness, Overhead Lights and Rear Speaker Detail Volvo Link Doors, Cab Exterior and Lighting Door Harness Power Mirrors Side Markers Roof Sign Harness Marker Lamps, Overhead

D
Page D12D page 56

Rear Cab Harness, Dual Fifth Wheel Light and Rear Speakers (Daycab) page 34 Rear Cab Harness, Overhead Lights and Rear Speaker Detail page 35 Volvo Link Harness and Antennas page 37

Door Harness page 40 Side Mirrors page 41 Side Markers page 42 Roof Sign Harness page 43 Overhead Marker Lights page 44 Sunvisor Harness (Daycab, VN430 and 630) page 45 Sunvisor Harness (VN670 and 780) page 46 Trailer Cable Connections page 47 Headlight Harness, VHD page 49 Headlight Harness, VNM page 50 Headlight Harness, VNL page 51 Fog and Driving Lights, VHD page 52 Fog and Driving Lights, VNL and VNM page 53 Tail lights page 54

Marker Lamps, Sunvisor (Daycab, VN430, VN630) Marker Lamps, Sunvisor (VN670, VN780) Trailer Cable Harness Headlight Harness, VHD Headlight Harness, VNM Headlight Harness, VNL Fog and Driving Lights, VHD Harness Fog and Driving Lights, VNL and VNM Harness Tail Lights Harness Engine Compartment Alternator Engine, Volvo D12D Engine, Cummins ISX Transmission Allison HD Transmission, VHD (BBOX-LF) Eaton Autoshift II Transmission Meritor Lightning Transmission Meritor Transmission Fuller Transmission Chassis Washer Reservoir Washer Fill Horn Fuel Sensor Diff Lock / Axle Temperature Harness Central Tire Inflation ECU Ambient Temperature Sensor Tempastart Pyrometer Sensor Chassis Harness 4

Alternator (typical view) page 55

Engine, Cummins ISX page 59

Allison HD Transmission, VHD (BBOX-LF) page 60 Eaton Autoshift II Transmission page 61 Eaton Lightning/Eaton Ultrashift II Transmission page 62 Meritor Transmission page 63 Eaton Fuller Transmission page 64

Washer Reservoir, VN page 65 Washer Reservoir, VHD page 66 Horn page 67 Fuel Level Sensor page 68 Differential Lock/Axle Temperature page 69 Central Tire Inflation System page 70 Ambient Temperature Sensor page 71 Temp A Start page 72 Pyrometer Sensor page 73 Chassis Harness page 74

Group 37

Illustrations

Number

Description VORAD Antennas Inverter Harness Bobybuilder Box ICON System

D
Page

VORAD Antennas page 75 Inverter page 77 Bodybuilder Box, VHD page 48 ICON page 76

Group 37

Illustrations

Fuse and Relay Center, Main Cab Harness

D
W3006891

Group 37

Illustrations

Fuse and Relay Center, Main Cab Harness 2

D
W3006904

Group 37

Illustrations

Aux. Switch Overlay

D
W3006890

Group 37

Illustrations

Cab Wiring Passthrough

D
W3006892

Group 37

Illustrations

Modules

D
W3006905

10

Group 37

Illustrations

ABS Overlay

D
W3006884

11

Group 37

Illustrations

ECS ECU Overlay

D
W3006885

12

Group 37

Illustrations

Dash Switches, VN

D
W3006718

13

Group 37

Illustrations

Dash Switches, VHD

D
W3006719

14

Group 37

Illustrations

Dash Harness and Cab Wiring Passthrough

D
W3005946

15

Group 37

Illustrations

Dash Harness, Mobile Max

D
W3006886

16

Group 37

Illustrations

Dash Harness, Qualcomm

D
W3006887

17

Group 37

Illustrations

Dash Harness, Snow Plow/ Beacon Lights Option

W3006379

18

Group 37

Illustrations

Front Overhead Shelf/CB Power Harness

W3005899

19

Group 37

Illustrations

Radio Harness

W3006717

20

Group 37

Illustrations

Steering Column Harness, Including Stalk Switches

D
W3006722

21

Group 37

Illustrations

Cab Floor Harnesses, Front

D
W3005950

22

Group 37

Illustrations

Rear Cab Harness, VN430

D
W3005902

23

Group 37

Illustrations

Rear Cab Harness, VN630

D
W3005896

24

Group 37

Illustrations

Rear Cab Harness, VN670

W3005887

25

Group 37

Illustrations

Rear Cab Harness, VN780

W3005889

26

Group 37

Illustrations

Rear Cab, Lower Wall Harness, VN780

D
W3005888

27

Group 37

Illustrations

Rear Cab Valance Harness, VN780

W3005936

28

Group 37

Illustrations

Rear Cab Harness, Back of Cab Lights (HDI/HDO Variant)

W3005905

29

Group 37

Illustrations

Rear Cab Harness, Back of Cab Lights (LDI/LDO Variant)

W3005903

30

Group 37

Illustrations

Rear Cab Harness, Fifth Wheel Light

D
W3005906

31

Group 37

Illustrations

Rear Cab Harness, Fifth Wheel Light

W3005904

32

Group 37

Illustrations

Rear Cab Harness, Fifth Wheel Light and Rear Speakers (Daycab)

W3005895

33

Group 37

Illustrations

Rear Cab Harness, Dual Fifth Wheel Light and Rear Speakers (Daycab)

W3005897

34

Group 37

Illustrations

Rear Cab Harness, Overhead Lights and Rear Speaker Detail

W3005939

35

Group 37

Illustrations

Sleeper Control Panel (LECM)

D
W3005951

36

Group 37

Illustrations

Volvo Link Harness and Antennas

Volvo Link Harness and Antennas, Day Cab

W3006516

37

Group 37

Illustrations

Volvo Link Harness and Antennas, 630 Sleeper Cab

W3006396

38

Group 37

Illustrations

Volvo Link Harness and Antennas, 670/780 Sleeper Cab

W3006397

39

Group 37

Illustrations

Door Harness

W3005921

40

Group 37

Illustrations

Side Mirrors

W3006633

41

Group 37

Illustrations

Side Markers

W3005928

42

Group 37

Illustrations

Roof Sign Harness

W3005923

43

Group 37

Illustrations

Overhead Marker Lights

W3005924

44

Group 37

Illustrations

Sunvisor Harness (Daycab, VN430 and 630)

W3005925

45

Group 37

Illustrations

Sunvisor Harness (VN670 and 780)

W3005929

46

Group 37

Illustrations

Trailer Cable Connections

W3006893

47

Group 37

Illustrations

Bodybuilder Box, VHD

W3006894

48

Group 37

Illustrations

Headlight Harness, VHD

W3005918

49

Group 37

Illustrations

Headlight Harness, VNM

W3006895

50

Group 37

Illustrations

Headlight Harness, VNL

W3006896

51

Group 37

Illustrations

Fog and Driving Lights, VHD

W3005952

52

Group 37

Illustrations

Fog and Driving Lights, VNL and VNM

W3005933

53

Group 37

Illustrations

Tail lights

W3006897

54

Group 37

Illustrations

Alternator (typical view)

D
W3005908

55

Group 37

Illustrations

D12D

W3006510

56

Group 37

Illustrations

D12D (Continued)

W3006513

57

Group 37

Illustrations

D16D

W3006882

58

Group 37

Illustrations

Engine, Cummins ISX

W3006509

59

Group 37

Illustrations

Allison HD Transmission, VHD (BBOX-LF)

D
W3006626

60

Group 37

Illustrations

Eaton Autoshift II Transmission

W3005890

61

Group 37

Illustrations

Eaton Lightning/Eaton Ultrashift II Transmission

W3005891

62

Group 37

Illustrations

Meritor Transmission

W3005892

63

Group 37

Illustrations

Eaton Fuller Transmission

W3005893

64

Group 37

Illustrations

Washer Reservoir, VN

D
W3006898

65

Group 37

Illustrations

Washer Reservoir, VHD

W3005910

66

Group 37

Illustrations

Horn

67

Group 37

Illustrations

Fuel Level Sensor

W3005909

68

Group 37

Illustrations

Differential Lock/Axle Temperature

W3005919

69

Group 37

Illustrations

Central Tire Inflation System

W3005930

70

Group 37

Illustrations

Ambient Temperature Sensor

W3006899

71

Group 37

Illustrations

Temp A Start

D
W3006906

72

Group 37

Illustrations

Pyrometer Sensor

W3006515

73

Group 37

Illustrations

Chassis Harness

D
W3006903

74

Group 37

Illustrations

VORAD Antennas

D
W3006907

75

Group 37

Illustrations

ICON

W3006733

76

Group 37

Illustrations

Inverter

W2004614

77

Volvo Trucks North America, Inc.

Volvo Trucks Canada, Ltd.

PV776-20032392 (1000) 10.2005 Volvo Trucks North America, Inc., 2005