service bulletin volvo trucks north america, inc. trucks 019383.pdfvolvo trucks north america, inc....

Service BulletinVolvo Trucks North America, Inc.Greensboro, NC USA

Date Group No. Page

12.2004 083 01 1(22)

TrucksThis Service Bulletin replaces Service Bulletin 083–01,“Special Tools, Group 3 Electrical Systems andInstrumentation VN, VHD VERSION2” (07.2004),publication no. PV776–20 012524 Special Tools, Group 3

Electrical Systems andInstrumentation

VN,VHD VERSION2From build date 11.2002

Special Tools, Group 3

Electrical Systems and Instrumentation

Updates to this Service Bulletin are indicated with a change bar.

“9813194, Adapter” page 3

“9990008, Set of Test Pins” page 3



“9990062, Extension Cable” page 5

“9990137, Interface Adapter Cable” page 5

“9990151, Breakout Harness” page 6


“9998534, 4-Pin Breakout Harness” page 7

“9998567, Breakout Harness” page 7



“9998699, 62 Pin Breakout Box” page 9

“9990135, Antenna Breakout Box” page 9

“85104354, Alligator Clip Kit” page 10

“85104355, Headlamp Bulb Cover Removal Tool” page 10

“85104357, Headlamp Aiming Kit” page 11

“85104406, Overlay” page 12






“85107792, TESlite Enhanced Volmeter Leads” page 15

“BVA-34, System Analyzer” page 15

PV776-20 019383 USA16263

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 12.2004 083 01 2(22)

“J38582-3, Terminal Remover” page 16

“J38751-301, DIN Terminal Remover” page 16

“J39200, Fluke 87 Multimeter” page 17

“J39916-A, Audio Diagnostic Kit” page 17

“J42018, DIN Terminal Remover” page 18

“J42449, Terminal Tool Kit, JAE Connectors” page 18

“J43052, DIN Terminal Remover” page 19

“J43143, Tie Strap Tensioner” page 19

“J43244, Relay Puller” page 20

“J44567, Probe Adapter Set” page 20

“J44701, Battery Tester Kit” page 21

“J46407, Auxiliary Valve Breakout Harness” page 21

“J47287, Adapter” page 22



Tools9813194, Adapter

T4015499

Order number: 9813194

Qty. per operation: 1

Used with:

“9998699, 62 Pin Breakout Box” page 9“85104407, Overlay” page 12

Variant / Component: VN, VHD VERSION2

Tool Class: 1

Essential Tool: Yes

9813194 Adapter (Break Out Harness) is used tointerface the Steering Wheel Module (SWM), LampControl Panel (LCP) and VECU PA Connector.

This tool can be ordered from Volvo.

9990008, Set of Test Pins

W3004992



Used with:


Variant / Component: VN, VHD VERSION2

Tool class: 1

Essential tool: Yes

The 9990008 set of test pins are designed to accessvarious connector types used in vehicle wiring. Thepins test various connector types with a reducedchance of damage to sockets and pins in the connector.These test pins may also be used as a gauge to helpdetermine if individual connector pins/sockets havesufficient clamping force to provide stable connections.

The test leads included are compatible with theKent Moore J39200 Fluke 87 Multimeter for circuitmeasurements.




9990020, Adapter

T0010644



Used with:


Variant / component: VN, VHD VERSION2

Tool class: 1

Essential tool: Yes

9990020 Adapter (Break Out Harness) is used totroubleshoot the Central Locking Module and CruiseControl Switches.


9990025, Adapter

T0010655



Used with:



Tool class: 1

Essential tool: Yes

9990025 Adapter (Break Out Harness) is used totroubleshoot the Lighting Control Module (LCM) andElectronic Climate Control (ECC) module.




9990062, Extension Cable

T0010359



Used with:

“9998699, 62 Pin Breakout Box” page 9


Tool class: 1

Essential tool: Yes


9990137, Interface Adapter Cable

W0001694



Used with:

VCADS Pro and“9998534, 4-Pin Breakout Harness” page 7


Tool class: 1

Essential tool: Yes

9990137 is used with 9998555 to connect the vehicleelectronic system with VCADS Pro.




9990151, Breakout Harness

W0002138



Used with: N/A

Variant / component: VN, VHD VERSION2 w/Eaton Transmission

Tool class: 1

Essential tool: Yes

9990151 is used to troubleshoot the vehicle speedsensor and wiring.


9998533, Adapter

T0008353



Used with:



Tool class: 1

Essential tool: Yes

9998533 Adapter is used to troubleshoot the VECU PBconnector and Instrument Cluster.




9998534, 4-Pin Breakout Harness

W0001692



Used with:

VCADS Pro and“9990137, Interface Adapter Cable” page 5


Tool class: 1

Essential tool: Yes

9998555 is used for communication between thevehicle electronic system and VCADS Pro.


9998567, Breakout Harness

T0008563



Used with: N/A


Tool class: 1

Essential tool: Yes

9998567 Break Out Harness is used to access 7 PinDIN connectors.




9998596, Adapter

T0010668



Used with:



Tool class: 1

Essential tool: Yes

9998596 Adapter is used to troubleshoot the ElectronicClimate Control (ECC) system.

Note: Adapter 9998596 should be equipped with5 break out connectors. Early production adapterswere equipped with 4 break out connectors and wereused with overlay 85104408. Early production adaptersand overlay 85104408 should be scrapped.


9998604, Adapter

T3011702



Used with:



Tool class: 1

Essential tool: Yes

9998604 Adapter is used to troubleshoot the SteeringWheel Buttons and Contact Reel.




9998699, 62 Pin Breakout Box

T0010202


Qty. per operation: 1 or 2

Used with:

Various Adapters and Overlays


Tool class: 1

Essential tool: Yes

9998699 62 Pin Break Out Box is used to troubleshootelectrical components and wiring.

Note: 9998699 62 Pin Break Out Box has a maximumcurrent carrying capacity of 3 amps.


9990135, Antenna Breakout Box

W3005860



Used with: N/A


Tool class: 1

Essential tool: Yes

This tool is used to help with troubleshooting Volvo LinkAntenna systems.




85104354, Alligator Clip Kit

W0002121


Qty. per operation: 1 Set

Used with:



Tool class: 1

Essential tool: Yes

85104354 Alligator Clip Kit contains a positive clip (red)and negative clip (black) that are compatible with theJ39200 Fluke 87 Multimeter test leads and other testleads that accept ’banana jack’ connectors.


85104355, Headlamp Bulb Cover Removal Tool

W0002157



Used with: N/A

Variant / component: VNL VERSION2

Tool class: 1

Essential tool: Yes

85104355 Headlamp Bulb Cover Removal Tool is usedto aid in the removal of the headlamp bulb cover onProjection Beam Headlamps.

Note: Early model VNL VERSION2 headlamp bulbcovers are removed by turning clockwise. Latermodel bulb covers are removed in the normalcounter-clockwise direction.




85104357, Headlamp Aiming Kit

W0002134



Used with: N/A

Variant / component: VNL VERSION2

Tool class: 1

Essential tool: Yes

85104357 Headlamp Aiming Kit is used to accuratelyaim the Projection Beam Headlamps.

Note: Some local laws may require the use ofelectronic optical aiming equipment. If required followthe aiming procedures as instructed in the aimingequipment supplier’s instructions.




85104406, Overlay

W0002125



Used with:

“9998699, 62 Pin Breakout Box” page 9“9998533, Adapter” page 6


Tool class: 1

Essential tool: Yes

85104406 Overlay is used to troubleshoot the VECUPB connector and instrument cluster.


85104407, Overlay

W0002127



Used with:



Tool class: 1

Essential tool: Yes

85104407 Overlay is used to troubleshoot the SteeringWheel Module (SWM), Lamp Control Panel (LCP) andVECU PA connector.




85105675, Overlay

W3005966



Used with:



Tool class: 1

Essential tool: Yes

85105675 Overlay is used to troubleshoot the ElectronicClimate Control (ECC) system.

Note: Overlay 85105675 supercedes overlay85104408. Overlay 85104408 was used with earlyproduction adapter 9998596 equipped with 4 breakout connectors. Current adapter 9998596 should beequipped with 5 break out connectors. Discard of earlyproduction adapter and overlay 85104408.


85104409, Overlay

W0002129



Used with:



Tool class: 1

Essential tool: Yes

85104409 Overlay is used to troubleshoot the SteeringWheel Buttons and Contact Reel.




85104410, Overlay

W0002130



Used with:



Tool class: 1

Essential tool: Yes

85104410 Overlay is used to troubleshoot the LightingControl Module (LCM) and Electronic Climate ControlModule (ECC).


85104411, Overlay

W0002126



Used with:



Tool class: 1

Essential tool: Yes

85104411 Overlay is used to troubleshoot the CentralLocking Module and Cruise Control Switches.




85107792, TESlite Enhanced Volmeter Leads

W7001326


Description TESlite1 EnhancedVoltmeter Leads


Used with:



Tool class: 1

Essential tool: Yes

Tool 85107792, is designed to find corrosion or poorconnections by applying a load to a circuit. Detailedinstructions, cautions and warnings on the tool useare included with the tool and are also available at theTESlite web site: www.teslite.com.

Note: This tool is designed for use on analog voltagecircuts only.


BVA-34, System Analyzer

W3004737

Order number: BVA-34


Used with:

ES-2 (Stand)


Tool class: 2

Essential tool: No

The BVA-34 System Analyzer is a digital, carbonpile, battery load tester and starting/charging systemanalyzer. It is portable and designed for use in theheavy truck market. Optional tester stand, part numberES-2, is also available.

For more information contact AutoMeter® at (435)283–4142 or visit their web site at www.autometer.com.

1TESlite is a registered trademark of Sullivan Training Systems.



J38582-3, Terminal Remover

W3003475

Order number: J38582-3


Used with: N/A


Tool class: 1

Essential tool: No

J38582-3 is necessary for removing the wiring terminalsfrom the diagnostic connector.

This tool can be ordered from Kent-Moore at800–328–6657. The Deutsch part number is 114010.

J38751-301, DIN Terminal Remover

W0001541

Order number: J38751-301


Used with: N/A


Tool class: 1

Essential tool: Yes

DIN Terminal Remover for Small Terminals

This tool can be ordered from Volvo by adding the prefix’KEM’ to the tool number or directly from Kent-Moore at800–328–6657.



J39200, Fluke 87 Multimeter

W2001014

Order number: J39200


Used with: Various test components

Variant / component: VN,VHD VERSION2

Tool class: 1

Essential tool: Yes


J39916-A, Audio Diagnostic Kit

W0001682

Order number: J39916-A


Used with: N/A


Tool class: 2

Essential tool: No

J39916–A CD and Cassette Audio Diagnostic Kitcan be used to diagnose audio problems in anyaudio system with a cd or cassette player. The kitincludes various high, medium, and low combinationfrequencies, testing devices for motor speed andspeaker rattle, in addition to a cassette deck cleaner kit.




J42018, DIN Terminal Remover

W0001620



Used with: N/A


Tool class: 1

Essential tool: Yes

Please make note that the GM tool numbers are listedon the tool.


J42449, Terminal Tool Kit, JAE Connectors

W0001430


Qty. per operation: 1 kit

Used with:


Variant/ component: VN, VHD VERSION2

Tool class: 1

Essential tool: Yes

J42449 is used to probe the instrument cluster JAEconnectors. They can also be used on other JAE typeconnectors.


J42449 Terminal Tool Kit contains two female and twomale test probes. Individual tool numbers are:

P/N Description Qty.

J42449–11 Male Test

Probes2

J42449–2Female Test

Probes2

J42449–10TerminalRemover

1



J43052, DIN Terminal Remover

W0001546



Used with: N/A


Tool class: 1

Essential tool: Yes


J43143, Tie Strap Tensioner

W0001560



Used with: N/A


Tool class: 2

Essential tool: No

Used for tie straps to set a predetermined torque toprevent over or under tightening. After the correcttorque is reached, the tie strap is cut clean to prevent ajagged edge. Used on wire harnesses, airlines, heaterhoses, etc.




J43244, Relay Puller

W0001917



Used with: N/A


Tool class: 1

Essential tool: Yes

J43244 is used to remove standard size or micro-relays,power relays, DRL modules, mini-circuit breakers,maxi-fuses, and most types of square or rectangularstyle electrical components.


J44567, Probe Adapter Set


Qty. per operation: 1 set (1 red, 1 black)

Used with:



Tool class: 1

Essential tool: Yes

J44567 is used for connecting J39200 to makeelectrical measurements from breakout box pin outlocations. These adapters provide a reliable contactsurface for a correct multimeter reading.




J44701, Battery Tester Kit

W0001836



Used with: N/A


Tool class: 2

Essential tool: No

The Accuracy Plus™ battery tester is a comprehensivehand held battery / starting / charging electrical systemtester. It has capability of printing test results with theincluded Hewlett Packard infrared printer. The J44701kit includes tester, J44700, and printer, 238598. Thetester or printer may be ordered as separate tools ifdesired.

Tool J44700, the complete kit J44701 or printer238598 must be ordered directly from Kent Moore at800–328–6657.

J46407, Auxiliary Valve Breakout Harness

W0002137



Used with: N/A

Variant / Component VN,VHD VERSION2

Tool class: 1

Essential tool: Yes

J46407 is used to interface the electrical connector tothe air-operated auxiliary valve manifold.




J47287, Adapter

W7001332



Used with:


Variant / Component VN,VHD VERSION2

Tool class: 1

Essential tool: Yes

This tool is used with the Fluke 87 multimeter to checkpressure transducers on the instrument cluster andElectronically Controlled Suspension (ECS) system.


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