Superstructure Instructions Electricity and Air

Superstructure instructions
Volvo Truck Corporation

Göteborg, Sweden Electricity and air
Vehicle type Date Chapter Page
Contents FM, FH, NH 10.00 4.0 1(2)
Date Revised
Contents 4.0
Electrical installations, general 4.10 10.00 x
Fuses and cables
Shielding from electromagnetic interference
Tachograph 4.20 10.00 x
Connection, general
Connection of extra equipment 4.30 10.00 x
Connection of prepared equipment
Connection of non-prepared equipment
Engaging power take–off
Trailer connection 4.40 10.00 x
Introduction
Joining, cable routing and repairs 4.50 10.00 x
Joining
Cable installation
Repair
Switch 4.60
Switches and symbol lenses
Brakes 4.70
Safety measures
Joining
Clamping
Connection of trailers
Pneumatic equipment 4.80
Connection
Vehicle electronics 4.90 10.00 x
Introduction
Engine related functions
Gearbox related functions
Other functions
TSP146843
ENG08919 English
Printed in Sweden
Page 2
Drawings 4.100 10.00 x

Pin location in tachograph connector
Location of switches
Vehicle type Date Section Page
Electrical installations, general FM, FH, NH 10.00 4.10 1(7)
Electrical installations, general

Faulty electrical installation can cause fires. Please ask
skilled personnel to do the necessary work on the elec-
trical system. Take the measures and follow the advice
given below, to get a reliable and safe installation.
Fuses and cables

Use the correct fuses and cables. Install electric cables
in a correct manner. Faulty installation can lead to over-
loading, short circuiting and fire.
T9006206
Fuses
The fuses which the truck is delivered with must not be Rec. mini-
replaced by fuses with higher rated amperage. This also Volvo part Fuse mum
applies to fuses for auxiliary equipment. Fuse (A)
no. colour conductor
area (mm2)
When you dimension auxiliary equipment, please re-
member that the load on fuses must not account to 3 981405 Violet 0.5
more than 80% of their rated amperage.
5 969160 Beige 0.75
New fuses for auxiliary equipment must not be connected
to cables which are narrower than in the table below. 7.5 980555 Brown 0.75
10 969161 Red 1.5
15 969162 Blue 1.5
20 978999 Yellow 2.5
25 969163 Natural 2.5
30 969164 Green 4.0
Page 2
Conductors
Extra cables and cable harnesses must be installed cor-
rectly. Remember the following:
• Use the correct cable length. Excessive length in-

creases the risk of chafing. Cables which are too
short risk being torn apart because of movement
between driveline, chassis and cab.
• Clamp cables securely, preferably alongside existing

cable harnesses, to avoid abrasion damage to ca-
bles. Use 8 mm wide tie wraps and install them with
200-400 mm spacing.

• Do not clamp cables to hot surfaces (>100 C) and
sharp edges. Examples of hot surfaces are fuel
pipes, compressed air and servo pipes. Sheet metal
edges, screws and nuts are examples of sharp
edges.
• Sensor and breaker connection cables on

Geartronic transmissions must not be used for an-
choring extra cables.
• Do not install cables where they could catch in, or

chafe against moving components.
• Use a protective sheath for cables outside the cab.
• Use grommets at all hole transitions.

Superstructure instructions Electricity and air
Cable too long
T9007081
Correctly clamped
T9007082
Cable too short
T9007083
Page 4
Correct clamping
• Cables which are too long should be clamped
together to form a single coil with free ends. The ca-
bles are thus still there and can be re-used as
necessary.
T9007077
Faulty clamping
T9007078
Clamping of cables to solenoid valves and cable joints

• When cables are clamped to components, a loop
should be formed. The loop allows components to
be changed and stops water from being led into the
component via the cable. Make sure that the strip
clamp ends up on the protective sheath of the cable.
The exception is cables with a corrugated sheath,
the so-called ”Schlemmer hoses”.
T9007079
Clamping of cables to solenoid valve
T9007080
Clamping of cable joints

Clamping of cables with a corrugated sheath

• Clamping of cables with a corrugated sheath, the
so-called ”Schlemmer hoses” shall be done as in
the illustrations below.
T9007075
T9007076
Tightening of solenoid valves

• Torque solenoid valves correctly. Use a counterhold
to tighten their top connector as in the illustration
below. Torque the upper nipples to 20 ± 1 Nm and
the other ones to 15 ± 1 Nm.
T9007084
Page 6
Shielding from electromagnetic interference

When components are installed, it is important that they
do not interfere with or affect the vehicle’s electronics.
The vehicles are equipped with suppressed electrical

and electronic components.
Connections must only be made to the special terminals

provided, to retain all functions in the electronic system.
Auxiliary equipment installed must be provided with sur-

pressors, please refer to the adjacent illustrations. It is
particularly important that all inductive loads such as re-
lays, solenoid valves and other solenoids are
suppressed.
T3009410
Solenoid valve
Electric motors, irrespective of size, must have suppres-

sion capacitors fitted, to reduce the risk of radio
interference. The size and type depends on the design
of the electric motor.
Volvo supplies a suppressed relay, part no 3171420.

This relay does not need to be provided with suppres-
sion components (back EMF diodes) as in the adjacent
illustration.
T9007432
Relay
Earthing
Small loads should be earthed to one of the earth termi-
nals in the distribution box.
Earthing to the chassis must not exceed 100 A continual

load
Alternator capacity
If the vehicle is equipped with large loads, the alternator
capacity must be increased, to supply the total load.
Telephones and 2–way radio

All antennas must be installed on the outside of the cab,
to minimise the risk of malfunctions, and to reduce the
field strength in the cab.
Portable telephones and 2–way radios with an output

power exceeding 2 W must be connected to external
antennas.
Connection of mobile telephones

A two-pin connector with +12 V from the radio voltage
converter and earth is available behind the place pre-
pared for a telephone, beneath the instrument panel.
The connector is live when the ignition key is in the radio
position.
Tachograph FM, FH, NH 10.00 4.20 1(3)
Tachograph
Connection, general
The seal must be broken when the tachograph is con-
nected. A new seal must be applied by an authorised
workshop.
Speed signal
The speed signal can be taken from pin E2.
The signal is a pure square-wave frequency signal,

where:
W
F = 3600 2v
F = frequency signal in Hz
W = no. of pulses per km (please refer to the tacho-

graph installation sign)
v = speed in km/h
Connected equipment must be calibrated to interpret this

speed.
Output E2 can either be used as a current source (high Current High level Low level
level) or can sink a connected voltage (low level).
0 mA 8V 0.8 V
2 mA >5.5 V - 8 V <2.5 V
Note: When the vehicle is stationary, the signal could be

high or low, depending on the input signal.
Distance signal
The distance signal available from pin C6, gives 4 pulses Current High level Low level
per metre.
0 mA 8V 0.8 V
2 mA >5.5 V - 8 V <2.5 V
The duty cycle is 20-80%.
Accuracy is better than 1% (the pulse frequency can be

irregular).
Page 2
1-day version
• Control for ”Driver 1” in waiting time/ work position =
EARTH
• Control for ”Driver 1” in pause-/rest position = OPEN
Cassette status (separate output signal)

An opening signal for the cassette (means possible
driver change) is available from pin C7. The signal state
varies between OPEN and HIGH (UHIGH ≥ UBATT – 3.5
V at 100 mA):
Cassette open with the ignition key in the DRIVE POSI-

TION
• When the cassette opens, the output signal goes

HIGH and remains high for 8 seconds, irrespective
of cassette position. If the cassette remains open af-
ter this, the output signal remains HIGH until the
cassette is closed or the ignition key is turned to the
stop position.
Cassette open with the ignition key in the in STOP PO-

SITION
• Cassette opening with the ignition key in the STOP

POSITION, is stored in RAM (the memory is not
permanent without battery voltage, however). When
the ignition key is turned to the DRIVE POSITION,
the output signal goes HIGH for ≥8 seconds and
then, if the cassette is closed, OPEN again.
Tachograph FM, FH, NH 10.00 4.20 3(3)
Status signal (telegram)

The serial asynchronous status signal (”telegram”),
transmits information about driver activity and cassette
status via pin C1 (part no. 3963289) – or C8 (part no.
3985789). Signal state varies between OPEN and
EARTH (U <1 V).
T3008949
This signal is also active with the ignition key in the Descrip- Signal Signal
STOP POSITION (0). The energy saving mode affects tion level
this, however, i.e. after 24 hours (30 in the GB version)
the unit goes into energy saving mode, irrespective of the 0 Start #1 Start bit 1 1
activity control position, if it has not been in operation or
1 Start#2 Start bit 2 0
the diagram card has not been changed during this time.
2 Bit#1 Bit 1 1
Operation: Speed or engine speed signal, or ignition key
in DRIVE POSITION, or switching of the activity control 3 Bit#2 Bit 2 0
position.
4 D0 Cassette X
Note: Cassette opening with the ignition key in the stop status
position is indicated for ≥ 8 next time the ignition key is
turned to drive position, irrespective of cassette position 5 D1 Driver activ- X
(bit D0 is set to 1). ity, bit 0
(This does not apply to 3985787-790, 3944727-730 and 6 D2 Driver activ- X
3171907-910. These indicate hatch opening in real time.) ity, bit 1
7 D3 Driver activ- X
ity, bit 2
8 D4 Driver activ- X
ity, bit 3
9 Bit#8 Bit 8 1
10 Stop #1 Stop bit 1 1
11 Stop #2 Stop bit 2 1
D0: Cassette status Bit Open Closed

D0 1 0
D1–D2: Driver 1, activity registration Bit Working Waiting Dwell N/A

time mode
D1 0 1 0 1
D2 1 0 0 1
D3–D4: Driver 2, activity registration. Bit Working Waiting Dwell N/A

time mode
D3 0 1 0 1
D4 1 0 0 1
Connection of extra equipment FM, FH, NH 10.00 4.30 1(34)
Connection of extra equipment

This section covers connection of prepared and non-
prepared equipment, installation and joining of electrical
cables, trailer connection, a list of switch signals com-
monly used in coachbuilding and the recommended
locations of switches on the instrument panel. Please
note the advice under Section 4.10 “Electrical installa-
tions, general” for safe and reliable installation.
Connection of prepared equipment

There is a wide range of optional equipment. If you order • Rotating beacon
your truck with this equipment already installed, the truck • Spotlamps on roof, with or without sun vizor
will be delivered with the necessary cable harnesses. • Spotlamps in bumper
Connection of equipment is then quick and reliable. • Fog lamp
Optional equipment can also be retrofitted. Installation
• Jericho horn
should then be done in accordance with the advice
• Compressed air horn
which accompanies the equipment, or the descriptions in
• Load indicator
this chapter.
• Anti-theft alarm
• PTO
Trucks can be delivered with the following, and other • Central lubrication
equipment: • Side marker lamps
• Refrigerator
• Working light • Twin speed limiters, such as for garbage trucks
Page 2
Side marker lamps

The cable harness for side marker lamps shall be con-
nected to the connector marked 1077, please refer to the
illustration. The connector is located on the right-hand
side of the chassis, at the same height as the gearbox.
Cable harness, part no. 1077608, is used between the

connector and the side marker lamps. This cable har-
ness is intended for four lamps. If the cable harness
needs to be extended, please do this as in Section 4.50
“Joining, cable routing and repairs”.
T9007331
1 Gearbox
2 Engine
Connection of non-prepared equipment

Non-prepared equipment is defined as equipment for
which the cable harnesses are not installed at the factory.
Connection
There is a special coachbuilder’s distribution box for op-
tional equipment, located between the driver’s and
passenger seats There is space for 11 extra relays, two
black fuse holders (each with space for 6 fuses) and
earthing terminals (ground).
The black fuse holders are for optional equipment. One

black fuse holder, or two if the coachbuilder’s distribution
box is ordered) are supplied with the truck (extra fuse
holders can be ordered and have Volvo part no.
1079095). Auxiliary equipment shall not be connected
via other existing fuse holders. These are exclusively in-
tended for the truck’s ordinary electrical system.
Cables for auxiliary equipment shall be installed in front
of the distribution box, please refer to Section 4.50
“Joining, cable routing and repairs”.
T3009624
Page 4
Connecting
Auxiliary equipment can be connected at three places in
the truck, depending on current consumption:
• A fuse holder can be put in an empty relay location

(part no. 3986188), please refer to the adjacent il-
lustration. The holder is intended for up to 3 x 15 A
fuses or 2 fuses in the outer cavities greater than 15
A, but not greater than 30 A fuses. If 30 A fuses are
used, they must not be loaded for more than 15
minutes at a time because of heat generation. Cable
area should be estimated at 7 A/mm2. If 30 A fuses
are used, the area should therefore be at least 6
mm2. Current supply for extra fuses can be obtained
from the B+ cab entry, please refer to Section 4.30
“Cab B + entry”. Fuses must only be continually T3009684
loaded with 80% of their rated current.
• Equipment with current drain greater than 12 A

shall be connected to the starter motor B+ terminal.
The exception is an auxiliary cable harness (part no.
3171480), which can be used for loads of up to 500
W (fused for 25 A), please refer to Section 4.30
“Connection of power-consuming auxiliary equip-
ment”.
• Equipment with current drain less than 12 A shall

be connected to one of the black, 6–pin fuse hold-
ers in the coachbuilder’s distribution box.
Note: Keep an eye on the total current loading of

each fuse!
Fuses in the right-hand, black fuse holder (56X) are: Fuse Fuse rated
current
1 15 A B+, from battery
3 15 A kl.15, from drive position
4 15 A kl.15, from drive position
5 5A kl.61, alternator related
6 5A kl.58, from parking lamps
Fuses in the left, black extra fuse holder (56P) are: Fuse Fuse rated
current
5 10 A Not connected
6 10 A Not connected
Note: These fuses must not be replaced by fuses with

higher rated current. Fuses must only be continuously
loaded with 80% of their rated current.
T9006145
Earth connections (grounding) of auxiliary equipment

shall be connected to the earth terminal on the driver’s
side of the distribution box.
T9007332
Page 6
Extra earthing terminals shall be screwed to the distribu-

tion box on the passenger’s side.
T9007333
Cab B + entry
The function of the entire electrical system depends on
ensuring that the B+ cab entry functions and has good
contact. For that reason, only one (1) extra cable termi-
nal is permissible. The nut should be torqued to 10 ± 2
Nm. The rubber cap on the cab entry must be replaced
after removal.
C9000146
Connectors for auxiliary equipment

There are two connectors for non-prepared auxiliary
equipment, XA and XB.
XA is located underneath the instrument panel. It is 4–

pin, with:
• Grey/black cable, kl.58. Live when the parking

lamps are lit. Supplied via fuse no. 33 (10 A) to-
gether with the nearside parking lamp circuit.
• Green/red cable, kl.15. Live when the ignition key is

in the drive position. Supplied via fuse no. 24 (10 A).
• White cable, earth/negative.
• Mating connector, part no. 1096613.
• Spade terminal 0.5-1.0 mm2, part no. 969780. Or-

dered separately.
• Spade terminal 1.0-2.5 mm2, part no. 969781. Or-

dered separately.
Note: Keep an eye on the total current drain from the T9006071
above-mentioned fuses! Connector XA
Page 8
Connector XB is behind the radio shelf (or correspond-

ing position if the truck does not have a radio shelf). It is
a 4–pin connector with:
• Red cable, B+. Live when the main switch is on.

Supplied from the coachbuilder’s fuse box, fuse 1
(15 A).
• Red/black cable, B+. Live when the main switch is

on. Supplied from the coachbuilder’s fuse box, fuse
2 (15 A).
• Blue/white cable. Live when the main headlamps

are on. This is only intended to control a relay. Sup-
plied from fuse 40 (7.5 A).
• White cable, earth/negative
• Mating connector, part no. 1096613
• Terminal 0.5-1.0 mm2, part no. 969780. Order sepa-

rately.
• Terminal 1.0-2.5 mm2, part no. 969781. Order sepa-

rately.
Note: Keep an eye on the total current drain from the T3008386
above-mentioned fuses! Connector XB
Cab transitions
The cab is supplied with holes in the front underneath
the windscreen for transitions to supply auxiliary equip-
ment. You can also order one or two additional holes for
transitions in the cab roof. There is a rubber bush in
each hole to seal it.
FM trucks are prepared for installation of a steering col-

umn on both sides of the cab. The transition in the cab
floor which is not used for the steering column can be
used as a cable transition. A plate screwed in place, with
a grommet, covers the unused steering column transi-
tion. Two more grommets can be installed here. Drill a
40 mm hole for each grommet and put a grommet (part
no. 8158472) in each drilled hole.
Note: Only use the grommets mentioned.
Note: Apply primer/anti-corrosive to the drilled area to

avoid corrosion.
T9007339
Cab transition on FM trucks

Page 10
There are no holes prepared for cables in the floor of

FH/NH trucks. The plate screwed to the floor to cover
the hole for the unused steering column transition lacks
grommets. It is permissible to put up to three grommets
there, however, in the same way as for FM trucks. All
holes must be drilled.
Note: Only use the grommets mentioned.

Note: Apply primer/anti-corrosive to the drilled area to
avoid corrosion.
T3009629
Cab transition on FH trucks
This is what you do to get full sealing in the front grom-

met (part no. 8158472), please refer to the illustration:
• Only use cables of circular cross section.
• Only run one cable through each hole.
• Use the correct cable diameter and cut each grom-

met at the correct location relative to the cable
diameter.
The small holes, located close to the large transition
holes, are sealed with rubber bushes. If an electric cable
is to be run through the holes, a grommet with seal must
be ordered, part no. 8141219. The grommet has space
for a cable of external diameter 6 mm. The seal in this
grommet is not closed, so it only seals when a cable is
run through the hole.
T3008209
The holes in the cab roof have Ø 60 mm. They are

punched at the front at 578 mm and 1208 mm centres
on the H1, H2 and H3 cabs.
T9006073
H1 cab
T9006114
H2 and H3 cab
The transition holes in the cab roof are provided with

rubber grommets, part no. 8143410, for 5 cables.
Each hole in the bushing is provided with a hose seal

which is closed at the top. Each closure is marked with
the diameter of cable it is intended for. Two holes are in-
tended for 5 mm cables and two are intended for 6 mm
cables.
The cab roof grommets be ordered as an optional vari-

ant when the truck is ordered.
T9006115
Page 12
Cable harnesses
There are two installation kits complete with cable har-
nesses for connecting auxiliary equipment which is not
already prepared. One type is intended for loads of less
than 1 A and the other is for loads of up to 12 A.
The installation kits contain a two-way switch without

symbol lens, please refer to wiring diagram in Section
4.60 “Wiring diagram”. These must be ordered sepa-
rately. The part numbers for symbol lenses is found in
Section 4.60 “Part number”.
For loads of less than 1 A

This cable harness must only be used for auxiliary
equipment with a current drain of less than 1 A. It is di-
mensioned to control relays, solenoid valves etc., but not
for power supply, and is supplied from terminal 15.
The cable harness is connected as follows:
• A, connected to terminal XA for auxiliary equipment,

please refer to Section 4.30 “Connectors for auxil-
iary equipment”. The total current drain from
terminal XA must not exceed 8 A.
• B, is connected to the switch. (The switch is not in-

cluded in the cable harness)
• E, is connected to the auxiliary equipment.
• Blue cable = equipment supply
• White cable = earth T9006262
The cable harness can be ordered from Volvo Parts AB,

part no. 8155662.
Note: Keep an eye on the total current drain from XA,

especially when more than one cable is connected.
For loads which are connected via the ignition switch

Current supply from terminal 15 means that the con-
nected components are live when the ignition is on.
This cable harness is intended for auxiliary equipment

with a current drain of between 1 and 12 A. The total cur-
rent drain from terminal XA must not exceed 8 A. (This
cable harness puts a load of about 4 W on terminal XA).
It is supplied via a spare fuse in one of the black fuse

holders in the coachbuilder’s distribution box, please re-
fer to Section 4.30 “Connecting”.
A Is connected to terminal XA for auxiliary equipment,

iary equipment”.
B Connected to the switch. (The switch is not included

in the cable harness.)
C Relay socket. Installed in the correct hole in the

coachbuilder’s distribution box. (The relay is not in-
cluded in the cable harness.)
D Connected to fuse 1 or 2 in the coachbuilder’s distri-

bution box 56X or fuse 1-4 in the coachbuilder’s T9006260
distribution box 56P.
E Connected to auxiliary equipment (blue cable 1.5

mm2 area).

part no. 8155663.

Page 14
For loads which need to be supplied from B+

Current supply from B+ means that current for con-
nected equipment is taken directly from the battery,
which means that components can be connected inde-
pendently of the ignition.
This cable harness is intended for auxiliary equipment

with a current drain of between 1 and 12 A.
It is supplied via a spare fuse in one of the black fuse

holders in the coachbuilder’s distribution box, please re-
fer to Section 4.30 “Connecting”.
A Is connected to terminal XA for auxiliary equipment,

iary equipment”.
B Connected to a switch. (The switch is not included

in the cable harness.)
C Connected to a free relay location in the coach-

builder’s distribution box, please refer to Section
4.30 “Connection”. (The relay is not included in the
cable harness.) T9006260
D Connected to fuse 1 or 2 in the coachbuilder’s distri-

bution box 56X or fuse 1-4 in the coachbuilder’s
distribution box 56P.
E Connected to auxiliary equipment (blue cable 1.5

mm2 area).

part no. 1078136.
Note: Equipment which is connected as above loads

the battery directly. Connection for a longer time with
the engine shut off can result in a flat battery.
Connection of power-consuming auxiliary equipment

This connection is used to connect a coffee brewer etc.
The cable harness for extra power supply (part no.

3171480, included in accessory kit part no. 3172933) is
connected as in the following diagrams. The cable har-
ness contains a fuse holder with a 25 A fuse. The two
free fuse locations in this fuse holder must not be used.
The fuse holder is installed in the coachbuilder’s plate
and the cables are then installed alongside the ordinary
cables.
Auxiliary equipment of up to 500 W may be connected

to the cable harness.
T3009637
Page 16
The connector polarity is shown in the adjacent diagram.

The mating insulator for the connector, part no. 964166,
with pins (2 pcs), part no. 973118, is installed on the
auxiliary equipment (included in the kit).
T9007275
Make the earth connection to the screw (2:1) located be-

side the climate unit on FH trucks and underneath the
climate unit on FM trucks. Torque the nut to 10 ± 2 Nm.
The illustrations below shows a left-hand drive FM and
FH, NH truck.
T3009638
C3000132
The positive cable is connected directly to the B+ cab

transition, please refer to Section 4.30 “Cab B + entry”.
Torque the fastener to 10 ± 2 Nm. Since this is an un-
fused cable directly from the battery, it is of considerable
importance that this cable is carefully clamped, to avoid
chafing.
Connection of extra spotlamps

The wiring diagrams below show how extra spotlamps
are connected. Connection can also be done without a
switch. The spotlamps are then switched on and off with
the dipswitch.
Each fuse may be loaded by up to 4 x 70 W lamps or 2

x 100 W lamps.
The maximum light flux is limited on some markets. On

trucks with factory-installed spotlamps and so-called EU
connection, extra foglamps will not work if installed.
There is a ready-made installation kit for fitting extra

lamps on the roof, which can be lit up when the main
beam is lit. A switch will be installed on the ”radio shelf”,
and pre-installed cables can be use.
The installation kit has part no. 8153673 and can be or-
dered from Volvo Parts
Note: The use of roof-mounted lighting may conflict with
applicable legal requirements in some countries.
The heavy lines in the adjacent wiring diagrams

show cables installed by the coachbuilder.
Page 18
Connection with assembly kit
T9007740
A Extra spotlamp, max 2x100 W C Switch, extra spotlamp

B Relay, extra spotlamp
Alternative connection without assembly kit
T9007433
A Extra spotlamp, max 4x70 W C Switch, extra spotlamp

B Relay, extra spotlamp
Page 20
Pin KF7 may be occupied in some trucks. In this case,

the terminal can be removed from the insulator and cut
off. Fit both cables to spade terminal, part no. 970777,
and connect them back again.
T3009639
Connection of rotating beacons

Connection of rotating beacons on the cab roof shall be
done as in the adjacent illustration.
A complete assembly kit, part no. 8153770, can be

ordered from Volvo Parts. This assembly kit contains ca-
bles, switch and relay for installation in the ”radio shelf”.
T9007741
Page 22
Connection of (snow) plough lamps

The following applies to connection of (snow) plough
lamps:
• A special switch must be used to change between

ordinary lamps and plough lamps.
• The ordinary main and dipped beam fuses should

either supply the ordinary lamps in the truck or the
plough lamps.
• The headlamps are disconnected when the plough

lamps are lit.
• The plough indicators and any side lamps work in

both modes.
Plough lamps should be connected in the following

stages:
Section 4.30 “1. Connection of indicators”
Section 4.30 “2. Connection of side lamps”
Section 4.30 “3. Disconnection of headlamps”
Section 4.30 “4. Connection of plough headlamps”
Each connection is described in greater detail in the fol-

lowing paragraphs.
1. Connection of indicators
Indicators are connected to in 5 and pin 11 in the insulat- Use one of the following spade terminals:
ing socket for the flasher relay. The location of the flasher
relay in the vehicle is shown in the illustration below. • Spade terminal 0.5-1.0 mm2, part no. 970776
• Spade terminal 1.1-2.5 mm2, part no. 970777
Undo and cot the spade terminal off the cable. Install
both cables in a new spade terminal. Then, finally, install The adjacent wiring diagram shows the location of extra
the terminal in the insulator. indicators. The heavy lines in the adjacent wiring dia-
grams show cables installed by the coachbuilder.
T9007341
9074 Vehicle control unit 3075 Relay, central locking

323 Flasher relay
Page 24
T9007340
323 Flasher relay 426 Indicators, left rear

422 Indicators, left front 427 Indicators, right rear
423 Indicators, right front A Extra indicators, left front, plough
B Extra indicators, right front, plough
2. Connection of side lamps

Connect the side lamp to receptacle insulators KA and
KK in distribution box as in the illustration below.
Connect the left-hand side lamp to pin KA4 and connect

the right-hand side lamp to pin KK4 as in the adjacent
wiring diagram. Install the cables in a spade terminal,
part no. 970776, and connect.
T9007342
Page 26
T9007343
A Side lamp, left, plough, 5 W B Side lamp, right, plough, 5 W
3. Disconnection of headlamps
The headlamps are disconnected by a relay. Sleeve in-
sulator KJ in the distribution box is used, please refer to
illustration Section 4.30 “2. Connection of side lamps”.
Disconnect the headlamps by using pin KJ10. Discon-

nect and cut off the spade terminals from the cables.
Extend and install the disconnected cables to a new re-
lay, terminal 87a. Install a new cable from terminal 30 on
the relay and connect it to KJ10 by means of a spade
terminal, part no. 970776. Put the relay in the coach-
builder’s plate.
Connection is shown in the adjacent wiring diagram. The

heavy lines in the adjacent wiring diagrams show ca-
bles installed by the coachbuilder.
T9007344
317 Relay, headlamp wiper A To the plough lamp switch

652L Headlamp wiper, left B Extra relay for headlamp disconnection
652H Headlamp wiper, right
Page 28
4. Connection of plough headlamps

Plough headlamps are connected to sleeve insulators
KE and KF in the distribution box as in illustration Sec-
tion 4.30 “2. Connection of side lamps”.
The left-hand dipped headlamp is connected to KE6 and

the left-hand main beam is connected to KF4. The left-
hand main beam is connected to KE2 and the right-hand
main beam is connected to KF5. Undo and cut the termi-
nal off the cable. Extend and install the disconnected
cables to a new relay, terminal 87a. Install a new cable
from terminal 30 on the relay and connect it to the insu-
lator by means of a spade terminal, part no. 970776. Put
the relay in the coachbuilder’s plate.
Connection is shown in the adjacent wiring diagram. The

heavy lines in the adjacent wiring diagrams show ca-
bles installed by the coachbuilder.
T9007345
A To headlamp wiper disconnection relay F Extra relay, main beam, right

B Switch, plough lamp G Extra plough headlamp, left
C Extra relay, dipped beam left H Extra plough headlamp, right
D Extra relay, main beam, left 400L Bulb, main and dipped beam, left
(2=dipped beam, 3=main beam)
E Extra relay, dipped beam, right 400R Bulb, main and dipped beam, right
(2=dipped beam, 3=main beam)
Page 30
Engaging power take–off

Manual gearbox
Each truck is delivered with the cables for connection of Part no.
one power take-off as standard. It is possible to order
the truck with the cables for two power take-offs. Solenoid valve 1078316
Switch 1077938
Micro relay 1078690
Symbol lens, please refer to Section 4.60 “Switches
and symbol lenses”
• Behind switch position A (11), there is a connector

marked 1149. Connect this to the power take-off
switch.
Switch position B (16–19 and 25–29) is possible po-
sitions for the 2:nd switch if two power take-offs are
used.
T9006962
• Micro relay, part no. 1078690, is installed in position

14 on the distribution box circuit board.
• The solenoid valve is installed on the bracket on the

battery box.
• There is a connection for the solenoid valve on the

solenoid valve bracket, marked 6024.
• Connect the 2–pin connector on the cable harness,

marked 6024, to the solenoid valve.
T9006187
When one or more power take-offs are retrofitted, order

the following items for each power take-off:
Gearbox mounted power take-off

• Install solenoid valve, part no. 8158342, in the
holder in the battery box.
• Cable harness between cab and solenoid valve, part

no. 8155967. Connect these ends between the sole-
noid valve and the cable harness, part no. 3172936.
• Cable harness, part no. 3172936. Installation in-

struction, part no. 3198236, can be ordered.
• Relay, part no. 3171420.
• Switch and lens, please refer to Section 4.60

“Switch”.
Engine mounted power take-off

• Cable harness between cab and solenoid valve, part
no. 8156885. Connect its ends between the engine
mounted power take-off bypass-valve and the cable
harness, part no. 3172936.
• Cable harness, part no. 3172936. Installation in-

struction, part no. 3198236, can be ordered.
• Relay, part no. 3171420.
• Switch and lens, please refer to Section 4.60

“Switch”.
Page 32
Geartronic gearbox
General
Connecting gearbox mounted power take-offs at PCS Part no.
Geartronic gearboxes differs from connection at manual
gearboxes. Single Double
PTO PTO’s
There is a possibility to have double gearbox mounted
power take-offs together with Geartronic gearboxes. Solenoid valve 1 2 1078316
If an engine mounted power take off is chosen, the origi- Switch 1 2 1077938
nal cable harness can be used. Micro relay 1 1 1078690
Cable harness 1 1 3987240
Terminal brace 1 3986730
Symbol lens, please refer to Section 4.60 “Switches
and symbol lenses”
Connection of switch
Single mounted power take-off
Behind the switch position A (11) there is a connector
marked 1149–1. Connect this to the switch for power
take-off.
T9006962
Dual mounted power take-offs

When dual mounted power take-offs are to be used, use
the connector marked 1149–2 for the 2:nd one. The con-
nector is located behind the dashboard. Switch position
B (16–19 and 25–29) is possible positions for the 2:nd
switch if two power take-offs are used.
T7008333
Connection of relay
Micro relay, part no. 1078690 is connected to position 14
at the circuit board in the electrical centre.
T9007844
Mounting of solenoid valve

Mount he soleniod valve, part no. 1078316 at the bracket
located at the battery box.

When dual power take-offs are used, another solenoid
valve, part no. 1078316 must be added and fitted to the
bracket at the battery box.
Connection of cable harness

A new cable harness should be fitted. In the right hand
side framerail, close to the gearbox (see picture), there
is a connector marked 6024. To find it, follow the cable
harness from the gearbox to the branch, where the con-
nector will be found. Connect suitable connector in the
new cable harness to existing connector 6024 in the
framerail, and the other end to the solenoid valve at the
battery box. The cable harness, part no. 3987240, can
be ordered from Volvo Parts.
T9007787
Page 34

There are two connectors in the solenoid end of the ca-
ble harness. Connect the 4–pin connector (6024A) to the
solenoid valve. The other connector marked 6024B must
be plugged with terminal brace, part no. Clamp the cable
if necessary.
Note: Connector 6024 in the factory mounted cable har-

ness must not be connected to the solenoid valve.
T9007788

When two power take-off is used, connect both connec-
tors 6024A and 6024B to each solenoid valve. Clamp
the cable if needed
Note: Connector 6024 in the factory mounted cable har-

ness must not be connected to the solenoid valve.
T9007786
Software
To be able to activate the power take-offs the control
units for the gearbox (TECU, MID 130) and gearlever
(GECU, MID 223) must be reprogrammed with software
specified for power take-offs.
This will be carried out with VCADSpro as follow:
• Choose ”Programming/conversion kit”
• Enter the part number for the conversion kit (soft-

ware) which is correct for the specific power take-off.
P/N 3099459 for single mounted power take off.
P/N 3099456 for dual mounted power take-offs.
• Reprogram both control units via “Replace ECU”.
After reprogramming the control unit for gearbox (TECU,

MID 130) must a calibration of the clutch and gearbox be
carried out, in order as described in the Service
information.
Trailer connection FM, FH, NH 10.00 4.40 1(6)
Trailer connection
Introduction
The tractor unit and trailer must be supplied by separate
fuses. Trailer connection must therefore be done as fol-
lows:
• Connect trailer connectors to the trailer distribution

box on rigid trucks.
• Cables are pre-installed from the trailer distribution

box to the cab.
Page 2
Trailer connectors
There are two different 7-pin trailer connectors, one for
trailer connection and the other for auxiliary equipment
on the trailer. The appearance of pin 1 differs, please re-
fer to the adjacent illustrations.
Connector 24N (component number 77 in the wiring dia-

gram in the service literature, group 37) ISO1185, in
used for trailer connection. The pins are intended for:
1 Earth, kl.31.
2 Tail lamp, left, 58L, Max 8 A, fuse 34.
3 Indicator, left, L, Max 3 x 21 W.

4 Brake lamp, 54, Max 6 A, fuse 6.
5 Indicator, right, R, Max 3 x 21 W.
6 Tail lamp, right, 58R, Max 8 A, fuse 36. T9006274
7 Unused pin. Cable, marked 54G, connected to the

coachbuilder’s distribution box, as in the adjacent il-
lustration.
T9007434
Connector 24S (component number 78 in the wiring dia- 6 Kl.15 via ignition, Max 8 A together with other equip-
gram in the service literature, group 37) ISO3731, is ment connected to the coachbuilder fuse box, fuse 3
used for auxiliary equipment on the trailer. The pins are in coachbuilder fuse box 56X.
intended for:
7 Rear fog lamp
1 Earth, kl.31.
2 Unused pin.
3 Reversing lamp, Max 8 A together with the tractor
unit reversing lamp, fuse 44. For connection of extra
(reinforced reversing lamp), please refer to Section
4.90 “Reverse gear”.
4 B+ from battery, Max 8 A together with other equip-
ment connected to the coachbuilder fuse box, fuse 1
in coachbuilder fuse box 56X.
5 Unused pin, cable connected to RC12 in right cab
transition E:
T9006275
15-pin trailer connection

There are also trucks which have a 15-pin ISO 12098
trailer connection. The standard stipulates the following
functionality:
Pin no. Function Description Recommended ca-

ble area
1 Indicator, left L 1.5 mm2
2 Indicator, right R 1.5 mm2
3 Rear fog lamp - 1.5 mm2
4 Earth connection 31 2.5 mm2
5 Parking lamp circuit, left 58L 1.5 mm2
6 Parking lamp circuit, right 58R 1.5 mm2
7 Brake lamps 54 1.5 mm2
8 Reversing lamp - 1.5 mm2
9 Power supply (+24 V) - 1.5 mm2
10 Sensor, wear, brake linings - 1.5 mm2
11 Pressure sensor, spring brakes - 1.5 mm2
12 Axle lift - 1.5 mm2
13 Return cable, pin no. 14 and 15 - 2.5 mm2
14 Reserved for data communication - -
15 Reserved for data communication - -
Page 4
Junction box for trailers

Junction boxes for trailers are only installed on RIGID
trucks and are installed in the right chassis member, 700
mm in front of the end of the chassis.
T9007015
The trailer junction box contains 12 terminals. The

cables connected from the cable harness have the fol-
lowing functions:
Pin in box Cable colour Function Pin in cab transition

1 black Tail lamp, left - Max 8 A RC2
2 brown Tail lamp, right - Max 8 A RC6
3 red Brake lamp, trailer - Max 6 A RC4
4 blue/grey Rear fog lamp RC14
5 yellow Indicator trailer, left - Max 3 x 21 W RC3
6 green Indicator trailer, right - Max 3 x 21 W RC5
7 yellow/grey Reversing lamp - Max 8 A together with the RC10
truck’s reversing lamp
8 red/black Brake lamp, tractor unit - Max 6 A together RA11
with the truck’s reversing lamp
9 white/black Indicator tractor unit, left - Tot. max 3x21 W to- RC15
gether with the truck’s rear indicators
10 green/black Indicator tractor unit, right - Tot. max 3x21 W RC16
together with the truck’s rear indicators
11+12 white Earth connection RC1/RC8
T9007014
Page 6
The trailer junction box also contains five cables from the Mark- Cable colour Function
cab cable harness which are not connected to any termi- ing
nal. They can be used for auxiliary equipment on the
trailer if they are connected to free pins in the trailer con- 78:2 grey/black Auxiliary equipment trailer
nector. They have the following markings and functions:
78:4 grey/red B+, fuse 1 in coachbuilder
fuse box 56X
78:5 green/grey Auxiliary equipment trailer
78:6 brown/grey Kl.15, fuse 3 in coach-
builder fuse box 56X
77:7 blue Auxiliary equipment trailer
Joining, cable routing and repairs FM, FH, NH 10.00 4.50 1(7)
Joining, cable routing and repairs

Joining
Two types of cable joints occur; moisture-proof for joining
outside the cab and not moisture-proof for joining inside
the cab.
Outside the cab

Moisture-proof cable joints must be used to join cables
outside the cab transition. Cable joints with DIN connec-
tors can be used in addition to Volvo’s connectors. The
following types of joints are available:
• Volvo’s moisture-proof joints (detachable)
• Round 4-pin moisture-proof DIN joints (detachable)
• Round 7-pin moisture-proof joints (detachable)
• Moisture-proof (permanent)
Volvo’s moisture-proof joints

Insulating sleeve
Dimension Part no.
Insulator housing 2-pin 8156798
Insulator housing 4-pin 3944551 T3009124
2
Bullet receptacle 0.5-1 mm 3944652
2
Bullet receptacle 1.5-2.5 mm 3944653
Cable seal, blue 0.5-1 mm2 3944654
2
Cable seal, 1.1-2.5 mm 3944655
red/brown T3009125
Blanking plug - 970771

Special grease Tube, 30 g 1161417
Page 2
Pin insulator
Dimension Part number
Bullet terminal 0.5-1 mm2 969830
T3009598
Bullet terminal 1.5-2.5 mm2 969832
Insulator - 1608765
Cable seal - 1608766
Blanking pin - 1608767
T3009599
Round 4-pin moisture-proof DIN joint

Insulating sleeve
Dimension Part no.
Insulator housing - 8159013
2
Bullet receptacle 1.5-2.5 mm2 8155903
T3009600
Cable seal, wine red 0.5-1 mm2 8155900
Cable seal, violet 1.1-2.5 mm2 8159012
Blanking plug, - 8155899
green
Pin insulator
Dimension Part number
Lock ring - 3963413
T3009601
2
Bullet terminal 1.5-2.5 mm 3963047
Cable seal, grey 0.5-1 mm2 3963410
2
Cable seal, yellow 1.1-2.5 mm 3986691
transparent
Round 7-pin moisture-proof joint

Insulating sleeve
Dimension Part no.
2
Cable seal, blue 0.5-1 mm2 970772
T3009602

transparent
Pin insulator
Dimension Part no.
Lock ring - 3963413
T3009603
2
Cable seal, blue 0.5-1 mm 970772
transparent
Moisture-proof joint (permanent)

Dimension Part no.
2
Butt splice 0.5-1 mm 8154513
Butt splice 1.0-2.5 mm2 8154542
Butt splice 2.5-6.0 mm2 945926
Shrink tubing with L= 65 mm 3090963
T3006565
adhesive and 2 ad-
hesive crosses
Page 4
Pin installation
The pin is installed by first sliding the seal over the ca-
ble. The pin is then crimped onto the insulation with a
suitable tool. The pin is slid into the insulation and the
seal is threaded over the insulation.
The complete moisture-proof joint can then be put into a

suitable pin insulator.
T3008912
Moisture-proof cable joint, pin
Installation of receptacles and pins in insulators

2
If Volvo’s older moisture-proof joints are used, they must

be filled with special grease, part no. 1161417 (tube 30
g). This is done to avoid contact problems caused by
damp. The procedure can also be used on Volvo’s new,
moisture-proof joints.
Note: The terminals for cab mounted fog lamps must
not be coated with any type of grease.
Crimp the terminals with a suitable tool. Put pins and re-
ceptacles in a suitable insulator. Please refer to Section T3009121
4.50 “Electrical tool box” as well.
Volvo’s older, moisture-proof 2-pin receptacle insu-
lators
Electrical tool box

Assembly and disassembly of the insulators, receptacles
and cables used by coachbuilders shall be done with
tools from an electrical tool box, part no. 9998582.
The tool kit contains cable seals, the necessary spade

terminals (receptacles and blades) with the associated
pliers and extractor, a tube of special grease etc.
The electrical tool box is self-explanatory. Further infor-

mation is available in the service information, group 37,
”Cable repairs”.
In the cab
Insulators for joining in the cab are 2, 4, 8 or 16-pin.
Unsealed joints, 2-16 pins, detachable

Insulating sleeve
Dimension Part no.
Insulator hous- 2-pin 1096616
ing
T9007435
ing
ing
ing
Terminal 0.5-1 mm2 970776
Terminal 1.5-2.5 mm2 970777
2
Terminal 2.6-3 mm 978359
Pin insulator
Dimension Part no.
ing
ing T3009605

ing
ing
Terminal 0.5-1 mm2 969780
2
Terminal 1.1-2.5 mm 969781
Crimp the terminals with a suitable tool. Put pins and re-
ceptacles in a suitable insulator. Please refer to Section
4.50 “Electrical tool box” as well.
Page 6
Cable installation
General instructions for cable installation are given in
Section 4.10 “Electrical installations, general”.
Cables for auxiliary equipment, which must pass the

distribution box, shall be clamped together with other ca-
bles in the marked areas in the illustration.
T9007171
At the front of the cab, the cables for auxiliary equipment

shall be run above the cab suspension to avoid mechan-
ical wear. A suitable route to the transition holes on the
bulkhead is shown in the adjacent illustration.
T9006117
Cables for auxiliary equipment shall be clamped under-

neath the ordinary cables on the chassis, at the front
section of the chassis F.
C3000175
T9006377
Repair
Cables must be replaced if there is major damage. Indi-
vidual, damaged conductors can be repaired with
components as in Section 4.50 “Moisture-proof joint
(permanent)”.
Use the crimping pliers, part no. 9812451.
Note: A hot air gun should be used during crimping.
T3006565
Repair of 1 cable
Please refer to the adjacent illustration.
Note: Adhesive crosses can be left out if only one ca-

ble is repaired.
T3006563
Repair of several cables

Please refer to the adjacent illustration.
T3006564
Switch FM, FH, NH 10.00 4.60 1(6)
Switch
Switches and symbol lenses
Switches are provided with light-emitting diodes for illu-
mination. They are combined with various symbol lenses
depending on function. Switches are designed for up to
1 A current density. If higher currents are used, a relief
relay must be used.
Part number
Switch insulator (part no. 1096577) and spade terminal
(part no. 970776 for cable area 0.5-1.0 mm2 and part no.
970777 for 1.0-2.5 mm2) for this, can be ordered from
Volvo Parts AB. The most common switches and symbol
lenses used in coachbuilding are:
Symbol Part no. Drg. no.

Function
lens Symbol lens Switch
Fog lamp, Front 1594556 8157752 1.1
Rear fog lamp 1594557 8157751 1.1
Fog lamp, Front/Rear 1594557 8157751 1.1
Spotlamp 8140797 8158621 1.10
Working lamp 1594558 8157751 1.1
Reversing lamp 1594559 8157751 1.1
Roof beacon 1594560 8157750 1.6
Power take-off, Engine side

1096473 1077938 1.10
Power take-off, Engine side 1096474 1077938 1.10
Power take-off, Flywheel dog clutch 8140806 1077938 1.10
Power take-off, Flywheel plate clutch

8140807 1077938 1.10
Power take-off, Gearbox dog clutch 1 8140808 1077938 1.10
Roof sign 1594583 8157752 1.1

Page 2
Symbol Part no. Drg. no.

Function
lens Symbol lens Switch
Trailing wheel operation 1594580 8157758 1.3
Sand spreading unit 1594563 8157751 1.1
Tipper, truck 1594575 8157757 1.2
Tipper, trailer 1594576 8157757 1.2
Tipper, side 1594577 8157757 1.2
Flap release, rear 1594569 8157753 (-757) 1.1 (1.2)
Flap release, left side 1594570 8157753 (-757) 1.1 (1.2)
Flap release, right side

1594571 8157753 (-757) 1.1 (1.2)
Crane 1594586 1077938 1.10
Tail lift 1594587 8157753 1.1
Diagonal plough 1594588 8157756 1.2
Plough lift, front 1594589 8157756 1.2
Plough lamp
1082050 8157751 (-752) 1.1
”Pusher” axle, lift 8151972 8157758 1.3
”Trailing-” + ”Pusher” axle, lift 8151971 8157758 1.3
Axle lift 8140818 8157758 1.3
Turntable lock 1077583 8157753 1.1
Un-printed ”Blank” 3963259 - -

Switch FM, FH, NH 10.00 4.60 3(6)
Wiring diagram
Drawing 1.1 – Switch
C3000476
T3008916
T3008917
Page 4
T3008918
T9007315
Drawing 1.6 – Switch, Warning lamp (109)
T3008920
Switch FM, FH, NH 10.00 4.60 5(6)
T3008921
T9007312
T9007313
Page 6
T3008924
T3008925
Brakes FM, FH, NH 10.00 4.70 1(6)
Brakes
The brake section covers joining and clamping, and con-
nection of a trailer.
Note: When any work is done on the brake system,
applicable national and local laws and regulations
must be observed.
T9006102
Safety measures
It is important to observe the following advice, to elimi-
nate the risk of damage and incorrect assembly:
• The brake circuits must not be modified.
• Mark up the relevant brake pipes and unions before

taking them apart, or make a sketch of the original
routes.
• Change brake pipes. Avoid making joints.
• Install the brake pipes so that they are protected

from damage.
• Brake pipes must be installed so that they are not

exposed to temperatures higher than + 95 C.
• Drain valves on air tanks must be easily accessible.
• Check brake system function after you have finished

the job.
• Sensor cables on trucks with ABS systems must not

be joined, they must be replaced complete.
Page 2
Joining
Brake pipes are joined by VIPS unions
VIPS stands for Volvo Insert Parts System.
A mounted VIPS union can not be taken apart without

being destroyed.
T9006212
The VIPS system consists of a complete set of nipples,

unions, couplings and connections for the brake system.
The most common nipples for joining and pipe connec-
tion are described below.
The male nipple with pipe connection is provided with

two O-rings A and B and a circlip C. O-ring A protects
against dirt and B seals.
T9006088
For pipe diameter (mm) Part no.

6 976444
8 976445
12 976446
16 981235
The female nipple with pipe connection is provided with

two grooves, 1 and 2. The male nipple must be pressed
in until it locks on groove 2.
T9006222
For pipe diameter (mm) Part no.

6 969288
8 969289
12 969290
16 981380
Brakes FM, FH, NH 10.00 4.70 3(6)
The groove for circlip C on the male nipple is chamfered

at the front. The circlip expands when installed and locks
even harder if you attempt to pull the union apart.
T9006090
The brake pipes are made of plastics material and are

available with Ø 4, 6, 8, 12 or 16 mm.
Maximum working pressure is 1.25 MPa (12.5 bar).
The minimum internal bend radius is 6 times the pipe

diameter.
T9006964
Diameter (D) Part no. Min radius

mm
4 980830 24
6 980831 36
8 980832 48
12 980833 72
16 980834 96
Equipment
Tools 9998222 and 9996955 are used to press the nip-
ples into the brake pipes. The tools consist of a pipe
holder and a counterhold with screw. The pipe holder
can be fixed to the counterhold with a screw.
T9006211
Tools 9998222 and 9996955.

Page 4
Work method
The safety precautions and restrictions as above must
be observed.
Mounted VIPS couplings can not be taken apart without

being destroyed. If a pipe has to be changed, the entire
coupling must be unscrewed and replaced by a new one.
Prevent dirt from getting in to the brake pipes. If neces-

sary, the pipes must be cleaned internally.
Stagger joints on adjacent brake pipes. This counteracts
the load concentration on the pipe/cable bunch and
makes inspection and possible disassembly easier.
Plastic pipes may be cut out of square by up to 1 mm,

except for 16 mm pipes where the maximum error is 1.5
mm. The pipe is fixed in a suitable hole in the pipe
holder, which is fixed to the counterhold, please refer to
Section 4.70 “Equipment”. The male nipple is pressed
into the pipe by means of the screw.
T9006091
Press the nipple in so far that the pipe is flush with its
edge. There must not be more than 1 mm clearance be-
tween the pipe and the edge of the nipple, except for 16
mm pipes where the clearance must not exceed 1.5 mm.
T9006092
The male nipple must be pressed in to lock position 2 on

the female nipple or the coupling will leak. This can only
be done when the pipe is not pressurised.
If the brake pipe is too short, where a VIPS coupling has

been removed, for example, it can be joined by a special
joining nipple, please refer to the tables in Section 4.70 T9006093
“Joining” above in this chapter.
Brakes FM, FH, NH 10.00 4.70 5(6)
Clamping
It is very important that the brake pipes are clamped in
such a way that no damage can occur. The damage
which could occur in incorrect clamping is:
• Chafing
• Deformation
• Bursting
• Damage caused by overheating
This is what you do to avoid damage:
• When an angle bracket is used, put the brake pipe

on top of the bracket.
• If the pipe is joined, put a clamp close to the joint.
• Suitable clamping distance is 300-500 mm.
• Avoid putting clamps on at different occasions, so
that clamps end up close to each other.
• Contact points where chafing could occur, should be
clamped to remove the danger.
• Use clamps of the correct dimension.
• Pipes and clamps must sit firmly after clamping.
• Clamps must not be tightened so hard that the
pipes are deformed.
• Make sure that the pipes are long enough, so that
they are not in tension.
• Avoid allowing pipes to cross each other, to prevent
chafing.
• Install and clamp the pipes well protected from the
heat from exhaust pipe and silencers.
When one or several pipes have to be extracted from a

bundle of pipes, clamp the pipes as follows:
• Install a clamp on the bundle, close to the point of

separation.
• Install a clamp on the separated pipes, close to the
point of separation.
T9006623
Page 6
Connection of trailers
Safety measures
Observe the following:
• Do not confuse the control and supply pipes.
• Use 12 mm pipes for both control and supply pipes.
• Use straight pipe fittings wherever possible.
Connection at control valve

Connect the control pipe to the control valve port ”22”.
Connect the supply pipe to the control valve port ”21”.
T9006204
Pneumatic equipment FM, FH, NH 10.00 4.80 1(1)
Pneumatic equipment
Connection
Air for auxiliary equipment shall be connected to the
manifold installed on the front of the battery box.
T9006102
If there is a need for a large volume of compressed air,

extra air tanks will be needed.
Compressed air hoses for auxiliary equipment should be

run alongside the ordinary air hoses in the truck. Avoid
installing them alongside electric cables and fuel pipes.
T9006186
Connection of extra air tanks for pneumatic suspension

Extra air tanks for pneumatic suspension are connected
via by-pass valve B and nipple A to the manifold shown
in the illustration on the right.
The by-pass valve ports are marked 1 and 2. Connec-

tion marked 1 should face nipple A.
Pos Description Part no.

A Nipple 976034
B Overflow valve 8159735
1
C Test nipple 1592924
1
Without extra air tanks
T3008926
Vehicle electronics FM, FH, NH 10.00 4.90 1(33)
Vehicle electronics
Introduction
A new electrical system is used on all FM, FH and NH
trucks. The new electrical system is constructed with a
vehicle control unit, an engine management unit and an
instrument control unit (instrument panel). These units
communicate with each other via two data buses (SAE
J1587 and SAE J1939). Control units for the gearbox, air
suspension etc. are also connected to these data buses.
Each control unit receives a large number of signals
from each component, such as engine speed from the
engine to the engine management unit. The signals are
posted on the data buses, where they are available to
the control unit / component which needs them. The lo-
cation of the various control units in the truck is shown in
Section 4.90 “Introduction”.
The new electrical system is common to all FM, FH and

NH, i.e. the same interface meets the coachbuilder, irre-
spective of whether it is an FM7 or an FH16.
The new electrical system gives fewer components, sen-

sors and cables. An increased amount of information is
now available on the data uses. This gives the coach-
builder new opportunities. One of these opportunities is
presented in this chapter.
More detailed information about the new electrical sys-

tem is available in the service literature, group 00
”Vehicle electronics -98”, and group 03, ”VCADS Pro
User’s Manual”. These manuals can be ordered from
Volvo dealers.
The vehicle control unit contains a number of parame-

ters, which can be selected and given different values by
the body builder, to suit customer requirements. Exam-
ples of these parameters are the speed of the power
take-off and maximum engine speed.
Page 2
The majority of parameter values are delivered de-

activated from the factory. They have to have values
allocated before they can be used. This is done by pro-
gramming with a PC, equipped with Volvo’s program
VCADS Pro. The various signals are divided into two
classes, vehicle parameters and customer parameters.
Customer parameters can be changed at once. Vehicle
parameters require a modem link to Volvo’s vehicle reg-
ister (VDA).
The PC is connected to the diagnostic connector on the

truck, located above the clutch pedal as in the adjacent
figure.
T3009445
Programming of the various parameters is described in

the service information, group 03, ”VCADS Pro User’s
Manual”.
If the coachbuilders are not able to program parameters

themselves, they can ask the dealer for help.
All signals are collected in a 15-pin and a 18-pin connec-

tor, referred to as the coachbuilder’s connector. Please
refer to the adjacent figure. The vehicle control unit,
VECU, is also shown in this illustration. This coach-
builder’s connector must be ordered when the truck is
ordered.
T3009673
VECU = Vehicle control unit

T9007346
Control units in vehicle, FH truck

1 Control unit for instruments 7b Control unit for transmission, Powertronic
2 Vehicle control unit 8 Control unit for airbag
3 Engine management unit 9 Control unit for immobilizer
4 Control unit for brake system 10 Control unit for climate unit
5 Control unit for air suspension 11 Control unit for extra heater, water
6 Control unit for gear linkage 12 Control unit for extra heater, air
7a Control unit for transmission, Geartronic
Page 4
Coachbuilder’s connector FA
The table below gives a brief description of the use of ”Active high” means that the function is activated if the
the various signals and a description of the coach- pin is connected to system voltage +24 V.
builder’s connectors. ”Active low” means that the function is activated if the
pin is connected to earth.
Pin Function/description Signal type/Polarity Cable

no. colour
1 Speed limiter 2. Digital electronic input, active low, - grey/red
Limits max speed to pre-set value. Default setting
20 km/h
2 Power take-off operation, Engine speed 1. Digital electronic input, active high, + blue/yellow
Activates pre-set engine speed 1.
3 Power take-off operation, Engine speed 2 Digital electronic input, active high, + blue/white
4 Power take-off operation, Engine speed 3 Digital electronic input, active high, + blue/green
5 Limitation of max. engine speed Digital electronic input, active high, + red/white
Activates limitation of pre-set maximum engine
speed.
6 Engine shut-off Digital electronic input, active low, - red/black
Engine stops when connection to earth is cut.
7 Information link SAE J1587/J1708. grey
A-line
8 Information link SAE J1587/J1708. orange
B-line
9 Speed signal Electronic output, + yel-
Simulated ”C3” speed signal, please refer to Max load 10 mA low/white
Section 4.20 “Tachograph”. A digital speed signal
can also be obtained, which changes polarity at
the selected speed.
10 Range gear position Output, 24 V. yel-
+24 V for low range gear. Max load 0.5 A. low/white
11 Shut off ride height control. Digital electronic input, active high, + yellow
No ride height control of the air suspension sys-
tem. Applied parking brake – entire vehicle,
released parking brake – no regulation at front.
12 Not connected
13 Output, +24 V. +24 V, kl.15, fuse no. 28. Max load 0.5 A green/red
Intended for activation of speed control 2.
14 Not connected
15 Not connected
Coachbuilder’s connector FB
The table below gives a brief description of the use of ”Active high” means that the function is activated if the
the various signals and a description of the coach- pin is connected to system voltage +24 V.
builder’s connectors. ”Active low” means that the function is activated if the
pin is connected to earth.
Pin Function/description Signal type/polarity Cables

no. colour
1 Engine speed signal, W Max load 0.5 A black
2 Reverse gear Input, negative/ Output, negative orange
Lights the reversing lamp during lowering. Also Max load 0.5 A
indication that reverse gear is engaged. Low
when reverse gear is engaged.
3 Low split gear Output, negative grey/white
Pulled negative for low split gear. Max load 0.5 A
4 PTO Output, +24 V. brown
Power take-off switch activated. +24 V when the Max load 0.5 A
power take-off is activated.
5 Parking brake Output, negative yellow
Pulled negative when the parking brake is ap- Max load 0.5 A
plied.
6 Brake lamps Output, negative red/white
Service or trailer brakes applied. Pulled negative Max load 0.5 A
during braking.
7 Central warning lamp Electronic input, active low, - pink
Permits the central warning lamp to be lit.
8 Horn Input, active low, - black
Activates the horn. Only when ignition is on.
9 Load lamp/turntable lighting Output, +24 V. blue
+24 V when load lamp/turntable lighting is lit. Max load 0.5 A
10 Constant speed/cruise control +24 V. black
Power supply to cruise control. (Is jumpered to pin 11 as standard). Ob-
serve the connection instruction when using.
11 Constant speed/cruise control Electronic output, +. Max. load 70 mA. Ob- black
Power supply to cruise control. serve the connection instruction when using.
12 Set - Digital electronic input, active high, + grey
Step-less engine speed reduction as long as the
input receives power supply.
13 Set + Digital electronic input, active high, + brown
Step-less engine speed increase as long as the
input receives power supply.
14 Resume Digital electronic input, active high, + yel-
Recalls set engine speed. low/black
15 Reversing lamp +24 V. Jumpered to pin 18 as standard. blue/black
+ 24 V when the reversing lamp is lit. Max. load 0.5 A.
16 Ignition lock kl.50 +24 V. Jumpered to pin 17 as standard. Min- red/white
Starting current from ignition lock. imum cable area 2.5 mm2.
Page 6
Pin Function/description Signal type/polarity Cables

no. colour
17 Starter motor kl.50 +24 V. Minimum cable area 2.5 mm2. red/white
Start current to starter motor (24 A for 7 litre en-
gine and 12 A for 12 litre engine and 16 litre
engine).
18 Reversing lamp Connected to chassis junction box / trailer yellow/grey
+24 V wen reversing lamp is lit connector 3.
When connecting, please refer to instruction
Section 4.90 “Reverse gear” below in this
chapter.
Wiring diagram, coachbuilder’s connector FA
T3009492
9074 Vehicle control unit 9073 Control unit, air suspension

9070 Engine management unit, range gear contact 147 Switch, indicators
(only VT gearboxes)
702/702B Combined instrument F28 Fuse no. 28
2074 Contact, low range (only VT boxes)
Page 8
Wiring diagram, coachbuilder’s connector FB
T9007347
660 Alternator 216 Contact, brake lamp

305 Relay, reversing lamp 547 Central warning lamp, indication and warning
lamps
217 Contact, reversing lamp 850 Horn
514 Indication lamp, low split 149 Switch, horn
214 Contact, indication lamp, low split F44 Fuse no. 44
6024 Solenoid valve, power take-off 303/304 Relay load lamp/turntable lamp
508 Warning lamp, parking brake 104/105 Switch load lamp/turntable lamp
200 Contact, warning lamp/parking brake 403/404 Bulb, load lamp/turntable lamp
308 Relay, brake light 405 Bulb, reversing lamp
150 Switch, ignition lock 36 Terminal screw, rear lamp junction box (pin
no. 7)
654 Starter motor 9074 Vehicle control unit
78 Extra socket, 7 pin (pin no. 3) 1135 Switch, Cruise control
A Diodes are needed if there are more than 3 C Supply to load lamp relay
power take-offs
B 36:7 only for rigid trucks
Page 10
Sleeves and insulators

This section covers sleeves and insulators used to con- All components can be ordered from Volvo Parts AB.
nect functions to the coachbuilder’s connector.
The receptacles and insulators area installed and re-
Coachbuilder’s connectors FA and FB are supplied com- moved by means of the electrical tool box, part no.
plete from the factory, i.e. with both receptacle insulators 9998582, please refer to Section 4.50 “Electrical tool
and pin insulators. Spade terminals for receptacle insula- box” as well.
tors are of standard type and must be ordered separately.
T9007348
Pos Description Part no.

1 Spade terminals (receptacles) for sleeve insulators FA and FB, for cables 0.5-1.0 970776
mm2
2 Spade terminals (receptacles) for sleeve insulators FA and FB, for cables 1.1-1- 970777
2.5 mm2
3 Spade terminals (receptacles) for VECU 978304
4 FA, Secondary locking 1078188
5 FB, Secondary locking 1078189
6 FA, Insulating sleeve 3944414
7 FB, Insulating sleeve 3944413
Engine related functions

Engine speed setting for power take-off operation
Engine speed can be controlled by means of the cruise
control lever. It is possible to operate at a constant en-
gine speed with the cruise control engaged, up to 15
km/h. This speed limit can be adjusted between 0 and
15 km/h. The default value is 12 km/h. Cables for signals
from the cruise control are pre-installed from the control
to the coachbuilder’s connector. These signals are:
• On; connection and disconnection of the function for

setting the engine speed for cruise control operation
• Set+; increasing the constant engine speed at which

the power take-off is used
• Set-; reducing the constant engine speed at which

the power take-off is used
• Resume; regain the pre-set engine speed for power

take-off operation
Engine speed can be increased or reduced gradually or

in steps. Step rate has a default value of 50 revs/step,
but this can be programmed to any desired value. Step-
ping is done by impulses (24 V) on the pin for Set+ and
Set-. A constant voltage on the Set+ and Set- pins gives
a constant increase or reduction of engine speed.
• If the default engine speed and cruise control speed

are increased at the same time, cruise control has
priority.
• Cruise control is terminated if the clutch or brake
pedals are depressed.
• When the engine is shut off with raised engine
speed, this will not be automatically re-started next
time the engine is started.
• Operation at raised engine speed is possible up to
12 km/h (for vehicles with automatic transmission, 5-
12 km/h).
• When a gear is engaged, on a vehicle with auto-
matic transmission, the engine goes back to idling
speed.
Connection of the function can be done in several ways.

Two suggestions are shown in the following two illustra-
tions.
Page 12
Suggestion 1
T9007436
1135 Switch, Cruise control 6024 Solenoid valve, power take-off

1149 Power take–off switch 9074 Vehicle control unit
A Cables installed by coachbuilder
Suggestion 2
T3009483
1135 Switch, Cruise control 6024 Solenoid valve, power take-off

1149 Power take–off switch 9074 Vehicle control unit
A Cables installed by coachbuilder
Page 14
Adjustable power take-off speed

Pins FA2, FA3 and FA4 each give a pre-set engine
speed. The engine speeds are adjustable and can be
set between 670 and 2000 rpm. Ramping and the type
of ramping to and from these speeds is adjustable. It is
also possible to set the time from when the pre-set en-
gine speed is de-activated until engine speed starts to
fall. Programming of parameters is described in the ser-
vice information, group 03, ”VCADS Pro User’s Manual”.
The engine speeds at which power take-off operation

takes place can be switch selected. Connection can be
done as in the adjacent illustration.
T3009494
Connection of pre-set engine speed switch for power

take-off operation
9074 Vehicle control unit
A number of conditions have to be met, for the above-

mentioned engine speeds to be activated:
• Power take-off engaged. See also Section 4.90

“PTO engaged”.
• Bake pedal released.
• Clutch pedal released (only for manual gearboxes).
• The vehicle speed is below a certain value, i.e. the

previously mentioned separately adjustable speed
between 0 and 15 km/h.
• Parking brake applied
• Automatic transmission in neutral, or if vehicle

speed is less than the set parameter
PTO_MIN_SPEED. Default value is 5 km/h, but can
be varied in the interval of 5 to 12 km/h.
• If any of the above conditions are not met, the

pre-set value will fall to idling speed. When the con-
ditions are then met, it is possible to choose
whether the engine speed should automatically re-
turn to the pre-set value or if a new activation of
engine speed is needed. The procedure is called
”flank triggering” and has parameter code RU.
The choice of parameters on the previous page which

have to be met for each working speed can be pro-
grammed.
Engine speeds are delivered from the factory pre-set to

800, 1000 and 1200 rpm. In addition, the following con-
ditions are set and activated:
• Clutch pedal
• Brake pedal released
• Parking brake released
• Power take-off disconnected
• No automatic resumption of engine speed, i.e. ”flank

triggering” is set to ON
It is possible to disable the accelerator when the power

take-off is activated, and the conditions for activation of
working speed are met. This is done by programming
the maximum working speed during power take-off oper-
ation to the same speed as the pre-set working speed.
• If the default engine speed and cruise control speed

are increased at the same time, cruise control has
priority.
• When the engine is shut off with raised engine

speed, this will not be automatically re-started next
time the engine is started.
• Operation at raised engine speed is possible up to

12 km/h (for vehicles with automatic transmission, 5-
12 km/h).
• When a gear is engaged, on a vehicle with auto-

matic transmission, the engine goes back to idling
speed.
If equipment in the superstructure is sensitive to high en-

gine speed, limitation of the maximum engine speed
should be activated, please refer to Section 4.90
“Limitation of maximum engine speed”.
Disconnect the exhaust back pressure regulator in all

power take-off operation.
Page 16
Extra speed limiter

It is possible to activate a second speed limit. This is
pre-programmed to 20 km/h, but can be set from any
speed to 20 km/h to the vehicle’s maximum speed. The
second speed limit is set by installing a switch. The illus-
tration is shown in the adjacent illustration.
T3009443

A Switch, speed limit 2
Variant designation ”SPEED-DU” is intended for garbage

trucks. A separate 6.3 mm blade terminal marked ”switch
platform” is then located behind the coachbuilder’s plate.
The terminal is connected via a cable to a switch
installed by the coachbuilder in a foot pedal in the super-
structure. This variant means that the second maximum
speed limit is activated and pre-set to 20 km/h.
When the function is activated, speed is limited to the

second maximum speed limit. On automatic transmis-
sions, it then becomes impossible to engage reverse
gear. If reverse gear is engaged on a manual gearbox,
the parking brake will be applied. On these vehicles, it
must not be possible to light the reversing lamp
manually, since a fault in the contact in the foot plate
would then be able to cause the parking brake to be ap-
plied when travelling. The wiring diagram, group 37 in the
service information, shows how the variant is connected.
Twin engine speed controls

It is possible to connect twin engine speed controls. The
cables are not pre-installed. Engine speed control no. 2
is activated by switching on an installed switch, C. Ca-
bles to engine speed control no 2 must be connected
directly to the vehicle control unit, please refer to the ad-
jacent figure.
There is a mechanical coupling between potentiometer,

D, and idling switch, B. The idling switch is either open
or closed, depending on throttle opening, i.e. dependent
on the output voltage from the potentiometer.
The following applies to the output voltage from the po-

tentiometer (in percent of supply voltage from PB26):
9-12% Idling (idling switch B is open).

14-18% Idling switch B is closed.
61-69% Max position, i.e. maximum throttle open-
ing is registered.
As the accelerator is depressed, the potentiometer resis- T9007349
tance increases from idling to maximum opening.

Twin controls could be arranged by using an ordinary ac-
celerator pedal and possibly modifying it to suit existing A Accelerator no 2
needs.
B Idler switch no 2
C Switch, accelerator no 2
D Potentiometer, 4 k
, ± 25%
Page 18
Limitation of maximum engine speed

It is possible to limit maximum engine speed to a pre-set
speed. This function is connected by connecting in a
switch, as in the adjacent figure.
When it is necessary to protect the superstructure from

excessive engine speed, this function must be used.
T3009479

A Switch, engine speed limit
Limitation of engine torque

Engine torque can be limited at two levels. The cables
are not pre-installed. Limitation is connected by means
of a switch. The cables shall be connected directly to the
vehicle control unit, please refer to the adjacent figure.
T3009444

B Switch, torque limitation 2
C Switch, torque limitation 1
Engine shut-off
The engine can be shut off from the superstructure, by
disconnecting pin FA6 in the coachbuilder’s connector
from earth. In this type of engine shut-off, the ignition will
remain on. This means that any power take-off will re-
main engaged on re-starting. Connection of engine
shut-off is shown in the adjacent figure. The engine
stops when the circuit is broken.
Note: If an emergency engine stop is needed, for

transporting dangerous goods for example, the ADR
variant should be specified when the vehicle is or-
dered.
T3009478

A Switch, engine shut-off
Remote engine start

Remote starting can be arranged from the superstruc-
ture. Remote starting is arranged by connecting as in the
adjacent figure. When you select relays and cable areas,
consider the starter motor current. The relay must be
able to manage 24 A for the 7 litre engine and 12 A for
the 12 and 16 litre engines. Volvo’s relay (so-called mini-
relay), part no. 3171420, is approved for this.
Further conditions and functions can be connected in se-

ries with breakers C and E.
Consider the cable areas!

Page 20
T9007350
Connection instruction for manual gearbox

150 Switch, ignition lock D Extra start relay
654 Starter motor E Press switch, gearbox neutral, please refer to
Section 4.90 “Neutral position”
C Switch, remote start F Press switch, parking brake
T3009489
Connection instruction for automatic transmission

150 Switch, ignition lock C Switch, remote start
654 Starter motor D Extra start relay
345 Relay, starter interlock, automatic transmis- E Press switch, parking brake
sion
Starter interlock relay

Vehicles can be provided with a starter interlock relay for
safety reasons. the adjacent figure shows how connec-
tion of such a relay, marked C in the illustration should
be done. The signals, i.e. the requirements which control
the relay, are up to the coachbuilder to decide.
Consider the starter motor current when you choose re-

lays and cable areas. The relay must be able to manage
24 A for the 7 litre engine and 12 A for the 12 and 16
litre engines. Volvo’s relay part no. 3171420, is approved
for this.
Consider the cable areas!
T9007351
150 Switch, ignition lock B Press switch, parking brake

654 Starter motor C Starter interlock installed by the coachbuilder
A Press switch, gearbox neutral, please refer
to Section 4.90 “Neutral position”.
Page 22
Signals on the information link

A number of signals can be retrieved from the informa-
tion link which connects the control units in the vehicle,
and can be used as desired. The signals on the informa-
tion link are accessible from the coachbuilder connector,
pin nos FA7 and FA8. The SAE J1587 standard specifies
how these messages are constructed and the informa-
tion which can be extracted from them. The SAE J1587
standard also specifies how to build an electrical inter-
face to retrieve the information and use it.
Examples of information, which can be taken from the

information link are:
• Coolant temperature
• Engine oil temperature
• Engine oil pressure
• Engine speed
• Accelerator pedal position
The engine management unit monitors these functions.

If there is a fault, a fault message is shown on the infor-
mation display on the left of the driver. This means that
the coachbuilder only needs to use this information if it is
needed for superstructure functions.
Gearbox related functions

Neutral position
Manual gearboxes, type S and SR gearboxes, shall be
provided with a pressure switch (part no. 3963475, T-
piece part no. 976284, 2 pcs VIPS nipples part no.
976444 and 2 pcs VIPS threaded couplings part no.
968696) on the range shift air hose, please refer to the
adjacent figure. The contact should be installed on the
chassis side, where the vibration level is lower than if
mounted on the gearbox. The sensor should be located
so that the hose extension is as short as possible. Avoid
sharp bends in the air hose.
T3009487
T9007274
Manual gearboxes, type S and SR gearboxes

Page 24
On gearboxes VT2014 and VT2514, a contact (part no.

1078494) can be installed to indicate neutral, please re-
fer to the adjacent figure. This contact will be closed
when the gearbox is in neutral.
If the truck has an automatic transmission (Geartronic

and Powertronic), there is information about neutral posi-
tion available on the SAE J1587 information link. The
structure of this signal can be obtained from the coach-
building dept., Volvo Truck Corporation.
T3009640
Gearboxes, type VT2014 and VT2514
Reverse gear
Reverse gear gives voltage on output FB15 in the coach-
builder’s connection. In standard trim, FB15 and FB18
are jumpered together. When connected as in the adja-
cent figure, this jumper is removed. The illustrations on
the next page show connection of one or two reversing
lamps. Each fuse may be subjected to a continual load
not exceeding 80% of the fuse’s rated current, i.e. 280
W for a 15 A. Please consider cable areas when dimen-
sioning the electrical system.
If it is necessary to connect the reversing lamp sepa-

rately, this should be connected to FB2, please refer to
the adjacent figure. The facility must not be used on ve-
hicles build with ”SPEED-DU”.
Fuse 1 and 2 in coachbuilder fuse box 56X and fuse 1-4

in coachbuilder fuse box 56P can be used. These fuse
boxes are located in the coachbuilder’s distribution box,
please refer to Section 4.30 “Connection of extra equip-
ment”.
The thick lines in the adjacent wiring diagrams show

cables installed by the coachbuilder.
Examples of connection of working lamp/reversing lamp
T9007352
56X/56P Fuse box in coachbuilder’s distribution box, A Bulbs, reversing lamp, max 4x70W, truck
please refer to Section 4.30 “Connection of
extra equipment”
217 Contact, reversing lamp, manual gearbox B Bulbs, reversing lamp, max 4x70 W, trailer
405 Bulb, reversing lamp C1 Extra reversing lamp relay, installed by coach-
builder, truck
78 Chassis connector, 7-pin extra, trailer con- C2 Extra reversing lamp relay, installed by coach-
nection builder, trailer
36 Terminal post, rear lamp junction box (only D (Separate) switch, manual lighting of revers-
rigid truck) ing lamp
305 Relay, reversing lamp E Installation on trailer
F44 Fuse no. 44
Page 26
Which gear
If the truck has an automatic transmission (Geartronic
and Powertronic), there is information about gear in use
on the SAE J1587 information link. The structure of this
signal can be obtained from the coachbuilding dept.,
Volvo Truck Corporation.
High or low split

The split sensor is connected to pin FB3 in the coach-
builder’s connection. If FB3 is low, then low split has
been activated. Please refer to the description of the
coachbuilder’s connection in Section 4.90
“Coachbuilder’s connector FA” and Section 4.90
“Coachbuilder’s connector FB”.
High or low range gear

Information about whether high or low range gear can
only be obtained on VT gearboxes. The signal is avail-
able from pin FA10 in the coachbuilder’s connection.
FA10 is low in low range gear.
Released clutch pedal

Information about released clutch pedal is available from
the SAE J1587/J1708 information link. Please refer to
Section 4.90 “Signals on the information link”, for infor-
mation about how this signal is converted to an electric
signal.
Other functions
Speed signal
Speed signal, simulated so-called C3 or a digital signal,
is available at FA9 in the coachbuilder’s connection.
The function must first be activated by setting parameter

function GT to ”YES”.
By allocating parameter code LV a value, a digital signal

can be obtained from FA9 instead (i.e. 0 V or 24 V de-
pending on whether the speed is higher or lower than
the value allocated to LV).
Section 4.20 “Tachograph” describes how this signal is

constructed
PTO engaged
When output FB4 in the coachbuilder’s connection is
high, the power take-off is engaged. Please refer to the
description of the coachbuilder’s connection in Section
4.90 “Coachbuilder’s connector FA”, Section 4.90
“Coachbuilder’s connector FB” and Section 4.90 “PTO
engaged”.
Information about whether the power take-off is engaged

is available from the SAE J1587/J1708 information link.
Please refer to Section 4.90 “Signals on the information
link”, for information about how this signal is converted to
an electric signal.
Applied parking brake

When the parking brake is applied, output FB5 in the
coachbuilder’s connection will be low. Please refer to the
description of the coachbuilder’s connection in Section
4.90 “Coachbuilder’s connector FA” and Section 4.90
Information about whether the parking brake is engaged

or not is available from the SAE J1587/J1708 information
link. Please refer to Section 4.90 “Signals on the infor-
mation link”, for information about how this signal is
converted to an electric signal.
Page 28
Applied service brake

A cable from the pressure switch for the parking brake to
output FB6 in the coachbuilder’s connection makes it
possible to obtain a signal about whether the service
brake is applied. FB6 is then low. Please refer to the de-
scription of the coachbuilder’s connection in Section
4.90 “Coachbuilder’s connector FA” and Section 4.90
Information about whether the service or trailer brakes

are engaged or not is available from the SAE
J1587/J1708 information link. Please refer to Section
4.90 “Signals on the information link”, for information
about how this signal is converted to an electric signal.
Remote control of air suspension

The coachbuilder’s remote control unit is connected to
joint BM, as in the adjacent figure. No cables are pre-
installed for this installation.
A fault code could be set if two switches for the same
function give different signals at the same time, which
would also mean that the function would fail.

T9007353
9073 Control unit, air suspension 9009/9010 Standard control unit, air suspension
A FM (right hand drive and left hand drive), FH and B FH and NH (left hand drive). Location of
NH (right hand drive). Location of BM joining BM joining piece BM: Inside left A-pillar
piece: Right hand side of engine housing in cab.
C Switch, air suspension remote control
Page 30
Switch-off ride height control, air suspension

Switching off the ride height control, air suspension, is
carried out in accordance with the adjacent figure. The
function must be activated in the control unit to function.
Activation is done with VCADS Pro, please refer to the
service information, group 03, ”VCADS Pro User’s Man-
ual”.
This is relevant when the rest position of the vehicle is

influenced by external equipment such as hydraulic
outriggers or a plough. When switch A is closed, the fol-
lowing applies:
• If the parking brake is applied, the level control is

switched off on both the front and rear axles.
• If the parking brake is released, the level control is

switched off only on the front axle.
The coachbuilder is responsible for making the driver
aware about when the ride height control is shut off. This
could be done by an information lamp on the instrument T9007742
panel.
9073 Control unit, air suspension
A Switch for shutting off ride height, air sus-
pension
Remote control of central locking

The central locking relay, 3075, is installed beneath the
coachbuilder’s plate, beside the vehicle control unit,
please refer to Section 4.90 “Introduction”. Remote con-
trol can be directly connected to central locking relay.
Locking is done by setting pin no. 10 on the relay low.
Unlocking is done by setting pin no. 12 on the relay low.
Pins nos. 10 and 12 are shown in the adjacent figure.
No cables are pre-installed for this installation.
Install the cables in spade terminal, part no. 970776, and

put them in sleeve insulator, locations 10 and 12.
T9007437
3075 Relay, central locking

F4 Fuse no. 4
6058D Motor, door lock, driver’s side
6058P Motor, door lock, passenger side
Page 32
Horn
The horn is activated when FB8 is earthed. The horn
only works when the ignition is switched on.
Electricity for working lamps

If several power-hungry working lamps are connected,
the fuse ratings must be considered. For this reason,
connect extra working lamps as in the figure on the
pages below. Each fuse must not be subjected to a con-
tinual load greater than 80% of its rated current, i.e. 280
W for a 15 A fuse. Please consider cable areas when di-
mensioning the electrical system.
Fuse 1 and 2 in coachbuilder fuse box 56X and fuse 1-4

in coachbuilder fuse box 56P can be used. These fuse
boxes are located in the coachbuilder’s distribution box,
please refer to Section 4.30 “Connection of extra equip-
ment”.

T9007355
104 Switch, load lamp A Working lamp/turntable lamp, max 4x70W

303 Relay, load lamp B Load lamp relay installed by coachbuilder
403/404 Bulb, load lamp/turntable lamp
Drawings FM, FH, NH 10.00 4.100 1(2)
Drawings
Pin location in tachograph connector
T3008906
Page 2
Location of switches
T9007743
1. Emergency flashers 16–19. On-board computer control or

switch as option
2. Fog lamp, Front/Rear
20–24. Radio, Dynafleet or switch etc.
3. Headlamp
4. Spotlamp 25–29. Radio
5. Turntable lighting/load lamp 30. Blocking valve
6. Electrically heated mirrors 31. Trailer brake
7. Bogy lift 32. Parking brake
8. Rheostat 33. Courtesy lamps (H2/H3)
9. Engine brake 34. Rotating beacon
10. Diff. lock, Axle/Wheel 35. Illuminated roof sign

11. Power take-off 1
36. Electrically operated sun roof
12. Electric cab tip pump
37. Plough lamps
13. Cigarette lighter/Extra 12 V outlet
38–52. Available
14–15. Headlamps, level adjustment or
switch as option

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What safety measures should be taken for electrical installations?

What safety measures should be taken for electrical installations?

What are the recommendations for installing extra cables?

What are the recommendations for installing extra cables?

Superstructure instructions

Volvo Truck Corporation

Drawings 4.100 10.00 x

Electrical installations, general

Fuses and cables

• Use the correct cable length. Excessive length in-

• Clamp cables securely, preferably alongside existing

• Sensor and breaker connection cables on

• Do not install cables where they could catch in, or

• Use a protective sheath for cables outside the cab.

• Use grommets at all hole transitions.

Cable too long

Cable too short

Clamping of cables to solenoid valves and cable joints

Clamping of cables to solenoid valve

Clamping of cable joints

Clamping of cables with a corrugated sheath

Tightening of solenoid valves

Shielding from electromagnetic interference

The vehicles are equipped with suppressed electrical

Connections must only be made to the special terminals

Auxiliary equipment installed must be provided with sur-

Electric motors, irrespective of size, must have suppres-

Volvo supplies a suppressed relay, part no 3171420.

Earthing to the chassis must not exceed 100 A continual

Telephones and 2–way radio

Portable telephones and 2–way radios with an output

Connection of mobile telephones

The signal is a pure square-wave frequency signal,

W = no. of pulses per km (please refer to the tacho-

Connected equipment must be calibrated to interpret this

Note: When the vehicle is stationary, the signal could be

The duty cycle is 20-80%.

Accuracy is better than 1% (the pulse frequency can be

• Control for ”Driver 1” in pause-/rest position = OPEN

Cassette status (separate output signal)

Cassette open with the ignition key in the DRIVE POSI-

• When the cassette opens, the output signal goes

Cassette open with the ignition key in the in STOP PO-

• Cassette opening with the ignition key in the STOP

Status signal (telegram)

D0: Cassette status Bit Open Closed

D1–D2: Driver 1, activity registration Bit Working Waiting Dwell N/A

D3–D4: Driver 2, activity registration. Bit Working Waiting Dwell N/A

Connection of extra equipment

Connection of prepared equipment

Side marker lamps

Cable harness, part no. 1077608, is used between the

Connection of non-prepared equipment

The black fuse holders are for optional equipment. One

• A fuse holder can be put in an empty relay location

• Equipment with current drain greater than 12 A

• Equipment with current drain less than 12 A shall

Note: Keep an eye on the total current loading of

Note: These fuses must not be replaced by fuses with