service manual trucks - heavy · note: indicates a procedure, ... windshield washer check valve,...

Service ManualTrucks

Group 363–500

Windshield Wiper System

VN, VHD

PV776-TSP143133

Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to August 2000.

The products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair methods.When this is believed to have a significant bearing on this manual, supplementary ser-vice bulletins will be issued to cover the changes.

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave the vehicle or component function in the manner intended.

Caution: Indicates an unsafe practice where damage to the product could occur.

Warning: Indicates an unsafe practice where personal injury or severe damage to theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP143133

© 2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral .................................................................................................... 3

Windshield Wiper System ..................................................................... 3

Tools ........................................................................................................ 5Special Tools ......................................................................................... 5

Design and Function ............................................................................. 7Windshield Wiper System Components .................................................. 7

The Windshield Washer System ......................................................... 8Graphic Display Control Buttons ......................................................... 10

Troubleshooting ................................................................................... 13Work Practices .................................................................................... 13Using the VCADS Pro Tool ................................................................. 13Windshield Washer Pump, Troubleshooting ........................................ 14Windshield Wiper Stalk Switch, Troubleshooting ................................ 16Windshield Wiper Motor, Troubleshooting ........................................... 19Intermittent Windshield Wipers, Troubleshooting ................................ 21

Models with Volvo Engines ............................................................... 21Intermittent Windshield Wipers, Troubleshooting ................................ 24

Models with Non-Volvo Engines ........................................................ 24Windshield Wiper Stalk/ Graphic Display Control Buttons, Trou-bleshooting .......................................................................................... 26

Service Procedures ............................................................................. 29Windshield Wiper Blade, Replacement ............................................... 29Windshield Wiper Arm, Replacement ................................................. 29Windshield Wiper Module, Replacement ........................................... 30Windshield Wiper Switch, Replacement ............................................. 31Windshield Wiper Motor, Replacement ............................................... 33Windshield Wiper Motor and Linkage Assembly, Replacement ......... 34Windshield Washer Pump, Replacement ............................................ 40Windshield Washer Fluid Fill Bottle, Replacement ............................. 41Windshield Washer Fluid Filter, Replacement .................................... 42Windshield Washer Check Valve, Replacement ................................. 42Windshield Washer Fluid Reservoir, Replacement (Battery BoxMount) .................................................................................................. 42Windshield Washer Fluid Reservoir, Replacement (Frame RailMount) .................................................................................................. 43

Feedback

Foldout A Windshield Wiper System

Foldout B Windshield Wiper System

Foldout C Windshield Wiper Stalk/ Graphic Display Control Buttons

Operation Numbers

1

Group 36 General

GeneralWindshield Wiper System

W3004393

This service information contains design, service and troubleshooting information onthe windshield wipers. It covers VN and VHD models. There are some differences inthe design of the wipers depending on engine model. For vehicles with Volvo engines,the wiper electronics are in the Vehicle ECU. For vehicles with other engines, the wiperelectronics are in a Wiper Control Module. Both of these modules are located in theTEC center in the center dash.

3

Group 36 Tools

ToolsSpecial Tools

The following special tools may be needed when troubleshooting the Windshield WiperSystem. When ordering these tools from Kent-Moore (800)-328–6657 or Volvo, quotethe specified number.

Note: For VCADS Pro tooling see most current VCADS Pro user manual.

W3004327

J-41133 5-pin breakout har-ness (Kent-Moore)

J-39200 Digital Multimeter(Kent-Moore)

J-44567 Probe Adapter (KentMoore)

9998551 60-Pin breakout box(Volvo)

J-43234 Adapter (Kent-Moore) J-43340 Overlay for 60-pinbreakout box (Kent-Moore)

5

Group 36 Design and Function

Design and Function

Windshield Wiper System Components

A windshield wiper stalk switch controls the windshieldwiper system used on VN/VHD series vehicles. Controlbuttons for the instrument cluster graphic display are in-tegrated into this switch.

Intermittent windshield wipers are pre-set to make a sin-gle sweep every 10 seconds. The interval can be set tobetween 1 and 10 seconds by moving the windshieldwiper stalk to the intermittent position, then to off, then tointermittent again when another sweep is desired.

W3004341

The intermittent windshield wiper function is controlled inone of two ways, depending on the engine. On vehicleswith Volvo engines, the Vehicle Electronic Control Unit(VECU) and intermittent windshield wiper relay are used.

W2002673

On vehicles with Cummins or Detroit engines, a wind-shield wiper control module is used.

W3003803

7


The Windshield Washer System

W3004333

Fig. 1: Frame Rail Mount

1 Windshield Washer Fluid Fill Bottle

2 Windshield Washer Pump

3 Windshield Washer Fluid Filter

4 Windshield Washer Check Valve

5 Windshield Washer Fluid Reservoir (Battery Box Mount)

8


W3004334

Fig. 2: Battery Box Mount

1 Windshield Washer Fluid Fill Bottle


3 Windshield Washer Fluid Filter

4 Windshield Washer Check Valve

5 Windshield Washer Fluid Reservoir (Frame Rail Mount)

9


The windshield washer fluid is added to the system at thefill bottle located on the left side cowl (1). Fill and venthoses run from the fill bottle to the fluid reservoir. The“battery box mount” fluid reservoir (5) is most commonlyused. This is the mounting location on all VN series. Thelocation is the same on the VHD series when the batterylocation is the same as VN. On the VHD series with al-ternate battery locations, the “frame rail mount” fluidreservoir (6) is located on the top of the left frame rail.

The windshield washer pump (2) is mounted to the fluidreservoir with the tip submerged in windshield washerfluid. Whenever windshield “wash” is requested, thepump delivers windshield washer fluid via hoses first toan in-line filter (3) and then through a one way checkvalve (4) to the spray nozzles in the windshield wiperarm assembly.

The “battery box mount” fluid reservoir has a capacity inexcess of 3 gallons, while the “frame rail mount” fluidreservoir capacity is considerably less. If the fluid levelbecomes low, an indicator will appear on the instrumentcluster graphic display and the yellow INFO telltale lightwill illuminate. There is a 10–second activation delay toallow for windshield washer fluid slosh.

T3008838

Low Washer Fluid Level Icon

Graphic Display Control Buttons

Control buttons for the instrument cluster graphic displayare integrated into the windshield wiper stalk . The fol-lowing commands are available:

1 “Esc” (Escape) is used to return to the previousmenu and cancel a setting/operation.

Note: Some models may have “Set” instead of“Esc.”

2 “↵ ” or “SELECT” confirms a highlighted selection ofa menu or character.

Note: Some models may have “Mode” option in-stead of “↵.”

3 “Up arrow” moves the cursor up and is used whensetting numerical values.

4 “Down arrow” moves the cursor down and is usedwhen setting numerical values.

T3008810

10


This service information focuses on the function andtroubleshooting of the control buttons only. If the instru-ment cluster graphic display does not respond to thecontrol buttons after it is determined that the control but-tons are working properly, see service information“Instrumentation VN, VHD”.

11

Group 36 Troubleshooting

Troubleshooting

Work PracticesBack-probing connectorsThe tests in this service information suggest taking mea-surements with digital multimeter J-39200 or equivalenttool by back-probing the connector pins. The followingprecautions should be observed when back-probing theconnectors:

• Use the pin-out charts in the “VN/VHD Series Elec-trical Schematics” or this bulletin to determine theexact location of measuring points. Note that alldrawings, unless noted, show the pins from the wireinsertion side of the connector.

• Use the digital multimeter test probes to contact themetal portion of the connector pins. Do not puncturethe wire insulation when probing. To avoid falsereadings and/or damage to the wiring connectorscomponent do not allow the test probes to contacteach other.

• Do not directly front-probe connector pins or cavi-ties. Front-probing connector cavities with theselarge probes may spread and damage the cavity/pinconnectors, resulting in intermittent faults.

W3003661

Using the VCADS Pro ToolThe VCADS Pro is a Windows 95® based tool that canbe used to perform various intermittent windshield wipertests. The following is a brief description of tests that areavailable:

• Intermittent Windshield Wiper, TestThe indicators on the VCADS Pro tool will illuminategreen when various windshield wiper functions areselected by the windshield wiper stalk switch orwhen various functions are active.

• Instrument Cluster, TestThis test confirms that the graphic display controlbuttons on the windshield wiper stalk are deliveringa signal. The indicator on the VCADS Pro tool will il-luminate green when the buttons “Esc”, “Select”,“Up Arrow” and “Down Arrow” are pressed.

For detailed information about VCADS Pro tool see themost current VCADS Pro user manual or the “Help”menu in the VCADS Pro tool.

Note: VCADS Pro is designed to access the electronicarchitecture of vehicles equipped with Volvo engines.Therefore, some tests are not available on vehiclesequipped with Cummins, Caterpillar or Detroit engines.

W0001632

13


Windshield Washer Pump, Troubleshooting

Before working on a vehicle, set the parking brakes,place the transmission in neutral and block thewheels. Failure to do so may result in unexpectedvehicle movement and can cause serious personal in-jury or death.

CAUTION

Possible damage to electrical components. Turn thevehicle ignition switch OFF before disconnecting orconnecting electrical components. Failure tode-energize circuits may result in electronic equip-ment damage.

GeneralPower to operate the windshield washer pump is sentvia a wire from the windshield wiper stalk switch. Thewindshield washer pump also contains a switch thatactivates the windshield washer fluid level icon on the in-strument cluster graphic display.

TroubleshootingIf the windshield washer pump indicator illuminates prop-erly in the “Intermittent Windshield Wiper, Test” (seepage 13), the windshield wiper stalk switch is deliveringa signal that is recognized by the vehicle’s electronicsystem.

Note: VCADS Pro test is not available on vehiclesequipped with Cummins, Caterpillar, or Detroit engines.See “Using the VCADS Pro Tool” page 13

W0001632

Due to its mounting location, the windshield washerpump must be removed to access the wiring harnessconnector.To remove the windshield washer pump:

1 Place a drain pan under the windshield washer fluidreservoir.

2 Use a screwdriver to pry the windshield washerpump assembly up and out of the windshieldwasher fluid reservoir.

Note: Windshield washer fluid will drain out of thereservoir when the windshield washer pump assem-bly is removed.

3 Disconnect the wiring harness connector.

W3003797

1. Screwdriver blade

14


Note: The windshield washer pump connector usesweather resistant type connectors that should not beback-probed. In order to avoid damage to the terminalsdo not insert the test probes into the terminal connectors.Perform the following tests by carefully contacting the ter-minal pins with multimeter J-39200 (or equivalent tool) :

Windshield Washer Pump, Troubleshooting

Function Key Position Measuring Point Expected Value Note Possible Cause (ifexpected valuenot correct)

Power Supplyfrom WiperStalk Switch

On C to alternateground with meter

12V Washerposition active

Fuse, connectors,or wiring fault inpower supply circuitfrom wiper stalkswitch

Ground Off A to alternateground with meter

<1 Connectors orwiring fault inground circuit

Washer fluidlevel signal toinstrumentcluster

On B / jumper wireconnection toalternate ground

Washer fluid levelicon on graphicdisplay active

Connectors orwiring fault in circuitto instrument clus-ter or instrumentcluster fault.

• If the measurements are outside the expected val-ues, refer to appropriate electrical schematics,group 37.

• Before replacing the windshield washer pump checkfor possible mechanical causes for failure such asobstructed windshield washer fluid hoses, filters,check valves or nozzles.

• If all measurements are correct, probable windshieldwasher pump failure.

15


Windshield Wiper Stalk Switch, Troubleshooting


CAUTION


GeneralThe windshield wiper stalk switch delivers direct outputsignals for wash, low, and high speed windshield wipers.It also delivers an intermittent wipe request to the VECU(Volvo engine) or windshield wiper control module (Cum-mins, Caterpillar or Detroit engines). When thewindshield wipers are switched off or stop in the intermit-tent position, a latching circuit in the windshield wipermotor keeps the windshield wipers in motion until theyreach the “park” position on the windshield.

Troubleshooting using the VCADS Pro ToolIf the indicators illuminate properly in the “IntermittentWindshield Wiper, Test” (see page 13), the windshieldwiper stalk switch is delivering a signal that is recognizedby the vehicle’s electronic system.

Note: This VCADS Pro test is not available on vehiclesequipped with Cummins, Caterpillar or Detroit engines.See “Using the VCADS Pro Tool” page 13

W0001632

Troubleshooting without using the VCADS Pro Tool

1. Gain access to the windshield wiper stalk switch con-nectors by removing the steering column cover.

W8002165

16


2. Locate the 2 windshield wiper stalk switch connectors(6–pin connector is for windshield wiper operation).

W3003799

The tests that follow should be performed by back-probing the windshield wiper switch connector pins withmultimeter J-39200 (or equivalent tool). Before perform-ing the tests, see “Back-probing Connectors” page 13.

Windshield Wiper Stalk Switch, Troubleshooting

Function Key Position Measuring Point Expected Value Note Possible Cause (ifexpected valuenot correct)

Power Supply On From C to alternateground with meter

12 V Fuse, Connectorsor wiring fault inpower supply circuitto wiper stalkswitch.

Wash On From B to alternateground with meter

12 V Wash positionactive

If "Power Supply"correct, probablewiper stalk switchfailure.

Low Speed Wipe On From D to alternateground with meter

12 V Low speedposition active


High SpeedWipe

On From A to alternateground with meter

12 V High speedposition active


17


12 V Wiper sweepingPark/Hold On From E to alternateground with meter

0 V Wiper at parkposition

1 Fuse,connectors, orwiring throughwiper motor.

2 Wiper motor.

IntermittentWipe

On From F to alternateground with meter

12 V Intermittentposition active



• If the windshield wiper stalk switch requires replace-ment, see the “Service Procedures” section.

18


Windshield Wiper Motor, Troubleshooting


CAUTION


GeneralThe windshield wiper motor receives operating signalsfor low and high speed operation directly from the wind-shield wiper stalk switch. Intermittent windshield wipersignals are received from the VECU, in vehiclesequipped with Volvo engines, or from the windshieldwiper control module, in vehicles equipped with Cum-mins, Caterpillar or Detroit engines.

Vehicles equipped with Volvo engines also use an inter-mittent windshield wiper relay to deliver signals. See“Schematics, Windshield Wiper System” Foldout B.

When the windshield wipers are switched off or stop inthe intermittent position, a latching circuit in the wind-shield wiper motor keeps the windshield wipers in motionuntil they reach the “park” position on the windshield.

TroubleshootingThe windshield wiper motor is located on the left sidebulkhead. The connector can be accessed with breakoutharness J-41133.

Note: The windshield wiper motor connector usesweather resistant type connectors that should not beback-probed. Back-probing these connectors will de-stroy the weather resistant seal. If the breakout harnesstooling is not available, the following test should be per-formed by carefully contacting the terminal pins withmultimeter J-39200 (or equivalent tool) after the connec-tor is disconnected. In order to avoid damage to theterminals do not insert the test probes into the terminalconnectors.

1 Install breakout harness J-41133 in series betweenthe windshield wiper motor connector and harnessconnector.

2 Use multimeter J-39200 (or equivalent tool) to per-form the following test.

W3003800

19


Windshield Wiper Motor, Troubleshooting

Function Key Position Measuring Point ExpectedValue

Note Possible Cause (ifexpected value notcorrect)

Power Supply On From E to alternateground with meter

12 V Fuse, Connectors orwiring fault in power sup-ply circuit to wiper motor.

Ground Off From C to alternateground with meter

<1 Connectors or wiringfault in ground circuit.

Low Speed Wipe On From A to alternateground with meter

12 V Wiper Switchlow speedposition active

1 Wiper Stalk Switch.

2 Connectors orwiring fault in lowspeed circuit fromwiper stalk switch.

3 Intermittent wiperrelay (Volvo engineonly).

High SpeedWipe

On From B to alternateground with meter

12 V Wiper switchhigh speedposition active

1 Wiper Stalk Switch.

2 Connectors orwiring fault in lowspeed circuit fromwiper stalk switch.

12 V Wiper switchoff

Park/Hold On From D to alternateground with meter

0 V Wiper at parkposition

If power supply correct,probable wiper motorfailure.


• Before replacing the windshield wiper motor, checkfor possible mechanical causes for failure such as adamaged or binding windshield wiper linkage as-sembly.

• If the windshield wiper motor requires replacement,see the “Service Procedures”.

20


Intermittent Windshield Wipers, TroubleshootingModels with Volvo Engines


CAUTION


GeneralThe Vehicle Electronic Control Unit (VECU) controls theintermittent windshield wipers on vehicles equipped withVolvo engines.When the intermittent windshield wiper request is re-ceived from the windshield wiper stalk switch, the VECUsupplies a ground to the Intermittent Windshield WiperRelay. A latching circuit from the windshield wiper motorgoes through the VECU, and only allows the windshieldwipers to “park” in the proper position on the windshield.If windshield “wash” is requested, the VECU will initiatea minimum wipe time. See “Windshield Wiper Systemwith Volvo Engine”, Foldout A.

Troubleshooting with VCADS ProIf the indicators illuminate properly in the “IntermittentWindshield Wiper, Test” (see page 13), the VECU is re-ceiving and delivering signals that are recognized by thevehicle’s electronic system.

Note: This VCADS Pro test is not available on vehiclesequipped with Cummins, Caterpillar, or Detroit engines.See “Using the VCADS Pro Tool” page 13.

W0001632


1 Remove the front dash panel to be able to accessthe VECU connectors.

W300379821


Note: If breakout harness tooling is not available,the tests should be performed by back-probing theVECU connector pins with multimeter J-39200 (orequivalent tool). See “Back-probing Connectors”page 13

2 Connect Breakout Box 9998551 with adapterJ-43234 in series between VECU wiring harnessconnector PA/PB and VECU connector PA/PB.

3 Install overlay J-43340 with the “30 PIN BREAKOUTHARNESS” side up. The overlay is color codedgreen for the PA connector pins/measuring pointsand blue for the PB connector pins/measuringpoints.

4 Use multimeter J-39200 (or equivalent tool) and per-form the following test:

Intermittent Windshield Wipers, Volvo Engines, Troubleshooting

Function KeyPostition

Measuring Point ExpectedValue

Note Possible Cause (ifexpected value notcorrect)

Intermittent WiperRequest

On From PA 10 (green)to alternate groundwith meter

12 V Wiper switch inintermittentposition

Fuse, connectors orwiring fault in powersupply circuit fromwiper stalk switch.

0 - 2 V Intermittentwipers inmotion

Ground forIntermittent WipeRelay

On From PB 16 (blue) toalternate ground withmeter

Intermittentwipers at hold.

1 Connectors orwiring fault incircuit throughintermittent wiperrelay.

2 Intermittent wiperrelay.

3 VECU.

12 V Intermittentwipers inmotion

Intermittent Wiper/Hold/Park

On From PA 9 (green) toalternate ground withmeter

0 V Intermittentwipers at hold

1 Fuse, connectorsor wiring fault incircuit from wipermotor.

2 Wiper motor.

Windshield WasherPosition

On From PA 11 (green)to alternate groundwith meter

12V Wiper switchwash positionactive

1 Wiper stalk switch.

2 Fuse, connectorsor wiring fault inwash circuit fromwiper stalk switch.

22


• If the measurements are outside the expected vales,refer to appropriate electrical schematics, group 37.

• If a problem with the VECU is suspected, refer to“Vehicle Electronic Control Unit, MID144” serviceinformation, Volvo Service Publication PV776–300–610.

23


Intermittent Windshield Wipers, Troubleshooting

Models with Non-Volvo Engines


CAUTION


GeneralThe Windshield Wiper Control Module controls the inter-mittent windshield wipers on vehicles equipped withCummins, Caterpillar or Detroit engines.

When the intermittent windshield wiper request is re-ceived from the windshield wiper stalk switch, thewindshield wiper control module supplies power to thewindshield wiper motor back through the windshieldwiper stalk switch. A latching circuit from the windshieldwiper motor, which only allows the windshield wipers to“park” in the proper position on the windshield, goesthrough the windshield wiper control module. If wind-shield “Wash” is requested, the windshield wiper controlmodule will initiate a minimum wipe time. See“Windshield Wiper System with Cummins, Caterpillarand Detroit Engine Schematic” Foldout A.

Troubleshooting

1 Remove the front dash panel and ash tray assemblyto access the windshield wiper control module.

W3003806

24


2. Use multimeter J-39200 (or equivalent tool) and per-form the test below by back-probing the windshield wipercontrol module connector pins. Before performing thetests, see “Back-probing Connectors” page 13.

Intermittent Windshield Wipers, Cummins, Caterpillar and Detroit Engines, Troubleshooting

Function KeyPosition


Note Possible Cause (if expectedvalue not correct)

Power Supply forWiper ControlModule

On From Pin-9 toalternate groundwith meter

12 V Fuse, connectors or wiringfault in power supply circuit towiper control circuit.

Ground Off From Pin-1 toalternate groundwith meter

<1 1. Connectors or wiring fault inground circuit.

Power Supply forIntermittentWipers (input)


12 V 1. Fuse, connectors or wiringfault in power supply circuit towiper control module.2. Wiper control module.

Power Supply forIntermittentWipers (output)



1. Fuse, connectors or wiringfault in power supply circuit towiper control module.2. Wiper control module.

IntermittentWiper Request


12 V Wiper switchin intermittentposition

Fuse, connectors or wiringfault in power supply circuitfrom wiper stalk switch.


IntermittentWiper -Hold/Park


0 V Intermittentwipers atHold/Park

1. Fuse, connectors or wiringfault in circuit from wiper motor.2. Wiper motor.

WindshieldWasher Position


12 V Wiper switchwash positionactive

1. Wiper stalk switch.2. Fuse, connectors or wiringfault in wash circuit from wiperstalk switch.


• If the windshield wiper control module requires re-placement, see the “Service Procedures” section.

25


Windshield Wiper Stalk/ Graphic Display Control Buttons, Trou-bleshooting

Before working on a vehicle, set the parking brakes,place the transmission in neutral and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

CAUTION

Possible damage to electric components. Turn the ve-hicle ignition switch OFF before disconnecting orconnecting electrical components. Failure tode-energize circuits may result in electronic equip-ment damage.

General

The windshield wiper stalk control buttons are used tomanually communicate with and manipulate the instru-ment cluster graphic display menus.The instrument cluster delivers 12 volts to the windshieldwiper stalk control buttons’ “common” terminal. Whenbuttons “Escape”, “Select”, “Up Arrow” or “Down Arrow”are pressed, 12 volt signals are sent back to the instru-ment cluster via individual wires.

Troubleshooting Using the VCADS Pro Tool

If the windshield wiper stalk control buttons functionproperly in the “Instrument Cluster, Test” (see page 13)and graphic display functions can be accessed, the wind-shield wiper stalk control buttons are working properly.

If the windshield wiper stalk control buttons do not func-tion properly in the “Instrument Cluster, Test” or graphicdisplay functions can not be accessed, perform the testbelow.

W0001632


1. Remove the 3 torx bolt that holds the steering columncover to access the windshield wiper stalk switch.

W8002165

26


2. Locate the two windshield wiper stalk switch connec-tors (8–pin connector is for the windshield wiper stalkcontrol buttons).

W3003799

3. Do the following tests by carefully back-probing thewindshield wiper stalk control button connector pins. Usemultimeter J-39200 (or equivalent tool). Before perform-ing the tests, see “Back-probing Connectors” page 13.

Windshield Wiper Stalk/ Graphic Display Control Buttons, Troubleshooting

Function KeyPosition


Note Possible Cause (if expectedvalue not correct)

Power Supplyfrom instrumentcluster

On/Off From A to alternateground with meter

12 V Fuse, connectors or wiring faultin power supply circuit frominstrument cluster.

Esc Buttonsignal toinstrumentcluster

On/Off From C to alternateground with meter

12 V "Esc"Button active

If "Power Supply from instrumentcluster" correct, probable wiperstalk switch failure.

Select Buttonsignal toinstrumentcluster

On/Off From E to alternateground with meter

12 V "Select"Button active


Up Arrow Buttonsignal toinstrumentcluster

On/Off From G to alternateground with meter

12 V "Up Arrow"Button active


Down ArrowButton signal toinstrumentcluster

On/Off From H to alternateground with meter

12 V "Down Arrow"Button active


27


• If the measurements are outside the expectedvalues, refer to appropriate electrical schematics,group 37.

• If the windshield wiper stalk control buttons operatecorrectly but the instrument cluster graphic displaydoes not function properly, refer to “Instrumentation– VN/VHD”.

• If the windshield wiper stalk assembly requiresreplacement, see the service procedure section.

28

Group 36 Service Procedures

Service Procedures3636-03-02-01Windshield Wiper Blade, Re-placement1Pull the windshield wiper arm awayfrom the windshield and angle thewindshield wiper blade to the arm asnecessary.

2

W3004323

Press the windshield wiper blade lockdown toward the windshield wiper armto release. Slide the windshield wiperblade out of the windshield wiper arm.

3Position the replacement windshieldwiper blade into the arm and slide upuntil it locks into position.

3637-03-02-01Windshield Wiper Arm, Re-placement

Removal

W3004332

1


Carefully disconnect the windshieldwasher fluid line connector at thewindshield wiper (1).

2Remove the windshield wiper armmounting nut (2).

3Pull the windshield wiper arm awayfrom the windshield to relieve thespring tension, then remove the wind-shield wiper arm assembly from theshaft.

29


Installation1Install the replacement windshieldwiper arm assembly onto the shaft. Besure to position the windshield wiperblade in the “park” position on thewindshield.

2Install the windshield wiper armmounting nut. Torque to 23 ± 3 Nm(17 ± 2 ft-lb).

23 ± 3 Nm(17 ± 2 ft-lb)

3Snap the windshield washer fluid lineconnector on the base.

3645-03-02-06Windshield Wiper Module, Re-placement

CAUTION

Possible damage to electric components. Turn the ve-hicle ignition switch OFF before disconnecting orconnecting electrical components. Failure tode-energize circuits may result in electronic equip-ment damage.

Removal1Turn the ignition key OFF.

2

W3002701

Remove the two bolts just above theashtray that attach the front cover ofthe TEC. Remove the front cover toaccess the module.

3Remove the ashtray from the ashtrayhousing. Remove the two screws fromthe ashtray housing, and remove thehousing.

30


4

W3002524

1 Central Door Lock Module

2 Windshield Wiper Module

Disconnect the module connector,remove the mounting screws and re-move the module.

Installation1Install the new module in the locationwhere the old module was installed.Bolt the module in place with 2 torxbolts. Torque to 4.0 ± 0.5 Nm (35 ± 4in-lb). Connect the module electricalconnector.

4.0 ± 0.5 Nm(35 ± 4 in-lb)

2Check the new module to verify thatthe system is operating correctly.

3Install the ashtray housing, using thetwo mounting screws. Torque thescrews to 1.5 ± 0.25 Nm (13.28 ± 2.21in-lb). Install the ashtray.

1.5 ± 0.25 Nm(13.28 ± 2.21in-lb)

4Install the front TEC cover. Torque thebolts to 2.5 ± 0.5 Nm (22.13 ± 4.43 in-lb).

2.5 ± 0.5 Nm(22.13 ± 4.43in-lb)

3638-03-02-01Windshield Wiper Switch, Re-placement

CAUTION

Possible damage to electronic components. Turn thevehicle ignition switch OFF before disconnecting orconnecting any electrical components. Failure tode-energize circuits may result in electronic equip-ment damage.

Removal1Turn the ignition key OFF and discon-nect the negative and positive batterycables.

2

W8002166

Remove the two clips at the bottom ofthe steering column cover.

31


3

W3002652

If possible, adjust the steering columnup toward you. Remove the frontsteering column cover by removing thethree torx bolts from the cover andsliding the rubber grommets off of thecover.

4

W8002165

If possible, adjust the steering columnforward and up. Remove the boltsfrom the rear column cover and re-move cover.

5

W3000652

Disconnect both electrical connectors.Remove the torx bolts on each side ofthe windshield wiper switch and re-move the switch.

32


Installation1

W3000652

Mount the windshield wiper switch tothe column with bolts on each side.Torque to 5 ± 0.8 Nm (44 ± 7 in-lb).Connect the electrical connectors.

5 ± 0.8 Nm(44 ± 7 in-lb)

2If possible, pull steering column backand up. Install front cover by installingtorx bolts. Torque to 5 ± 0.8 Nm (44 ±7 in-lb).

5 ± 0.8 Nm(44 ± 7 in-lb)

3If possible, pull steering column for-ward and up. Install rear cover ofsteering column by installing torx boltsand attaching rubber grommets atstalk switches. Torque to 5 ± 0.8 Nm(44 ± 7 in-lb).

5 ± 0.8 Nm(44 ± 7 in-lb)

4

W8002166

Install the two clips on the bottom ofthe steering column cover.

3631-03-02-01Windshield Wiper Motor, Re-placementRemoval1


Make certain the vehicle ignition isOFF before beginning this procedure.

33


2

W3000669

Disconnect the electrical connectorfrom the windshield wiper motor.

3Remove the nut from the linkage arm,and push the arm from the shaft.

4Push the linkage arm from the areawhere the windshield wiper motor ismounted to the housing for access tothe bolts. Remove the three bolts toremove motor.

Installation1Mount the motor to the housing withthree bolts. START all bolts beforetightening. Torque to 40–49 Nm (29–36 ft-lb).

40–49 Nm(29–36 ft-lb)

2

W3000669

Align the arm from the linkage to themotor. Replace the nut on the shaftand connect the electrical connector.Torque to 10–13 Nm (89–115 in-lb).

10–13 Nm(89–115 in-lb)

3Test the windshield wiper system toensure proper operation.

3631-03-02-05Windshield Wiper Motor andLinkage Assembly, Replace-ment

Removal1


Make certain the vehicle ignition isOFF before beginning this procedure.

34


2

W3000667

Remove four torx bolts from the stepon the right side of the cab, and re-move the step.

3

W3000662

Remove the upper tank fairing by re-moving four torx bolts.

4

W3000661

Remove five torx bolts from the topside of the right quarter fender sectionin the lower door frame and two boltsfrom the step bracket. Remove thequarter fender fairing section.

5

W3000663

Remove three screws from the rightside drip molding and remove themolding.

6Remove three torx bolts from the bot-tom of the right side mirror mountingarm.

35


7

W3000670

Remove the right side cowl panel byremoving bolts inside the door jamband around the cowl panel.

8Remove three screws from the dripmolding on the left side of the cab andremove the drip molding.

9

W3000665

Remove three torx bolts from bottomof the left side mirror mounting arm.

10

W3004328

Remove the two nuts shown to removethe windshield washer fluid fill bottle.

11

W3000671

Remove the left side cowl panel by re-moving the remaining bolts around thecowl section and inside the door jamb.

12Remove the windshield washer hose.

36


13

W3000997

Remove the windshield wiper arm nutfrom both arms and remove the wind-shield wiper arms.

14Remove the cowl panel under thewindshield by removing the linkageshaft caps and 11 torx bolts from thepanel.

15

W3000669

Disconnect the electrical connectorfrom the windshield wiper motor anddisconnect the hose to the windshieldwasher.

16Remove the windshield wiper motorand linkage assembly by removing thefive torx bolts from assembly.

Removal of windshield wiper motor fromlinkage assembly (if needed)

17Remove the nut from the motor linkagearm and push the arm from the shaft.

18Push the linkage arm away from thearea where the motor is bolted to thehousing. Remove three bolts from themotor, then remove motor.

Installation1If the motor was not removed from thelinkage assembly, skip to step four. Ifthe motor was removed, mount motoron linkage housing with three mount-ing bolts. START all bolts beforetightening. Torque to 40–49 Nm (29–36 ft-lb).

40–49 Nm(29–36 ft-lb)

2Install the shaft nut to the linkage arm.Make sure the shaft and transmissionarm are aligned so that the timing andplacement of the windshield wipers willbe properly aligned when the wind-shield wipers are in the OFF position.Torque to 10–13 Nm (90–115 in-lb.)

10–13 Nm(88.5–115 in-lb)

3

W3000669

Align the windshield wiper assembly tothe cowl, and install it with the five torxbolts. Torque to 23 ± 2.5 Nm (199 ±22 in-lb). Connect the electrical con-nector and windshield washer hose.

23 ± 2.5 Nm(199 ± 22 in-lb)

37


4Test the windshield wiper systembefore installing the body panels to en-sure proper operation of the system.

5

W3000673

Install the cowl panel with 11 torx bolts.Torque to 24 ± 4 Nm (212 ± 35 in-lb).

24 ± 4 Nm(212 ± 35 in-lb)

6

W3000997

Install the windshield wiper arms andconnect windshield washer hoses.Torque the arm nut to 23 ± 3 Nm (203± 26 in-lb).

23 ± 3 Nm(203 ± 26 in-lb)

7

W3000670

Install the right side cowl panel usingbolts on the outside and inside of thedoor jamb. START all bolts and alignthe cowl before tightening. Torque to24 ± 4 Nm (212 ± 35 in-lb)

24 ± 4 Nm(212 ± 35 in-lb)

8

W3000663

Install the right side drip molding withthree screws. Torque the top twoscrews to 1.2 ± 0.2 Nm (11 ± 2 in-lb),and the bottom to 3 Nm ± 0.5 (26 ± 5in-lb).

1.2 ± 0.2 Nm(11 ± 2 in-lb)3 ± 0.5 Nm(26 ± 5 in-lb)

9Install three bolts in the lower rightside mirror arm. Torque to 24 ± 4 Nm(18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

38


10

W3000671

Install the left side cowl panel usingbolts on the outside and inside of thedoor jamb. START all bolts and alignthe cowl before tightening. Torque to24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

11

W3004328

Install the windshield washer fluid fillbottle. START all bolts, then tightennuts. Torque to 24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

12

W3000664

Install the left side drip molding withthree screws. Torque the top twoscrews to 1.2 ± 0.2 Nm (11 ± 2 in-lb),and the bottom to 3 ± 0.5 Nm (26 ± 5in-lb).

1.2 ± 0.2 Nm(11± 2 in-lb)3 ± 0.5 Nm(26 ± 5 in-lb)

13Install three bolts in the lower left sidemirror arm. Torque to 24 ±4 Nm (18 ±3 ft-lb).

24.4 ± 4 Nm(18 ± 3 ft-lb)

14

W3000661

Install the right side quarter fendersection. START bolts, but do nottighten until after aligning. Torque to24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

39


15

W3000662

Install the tank fairing. START all bolts,then tighten after aligning fairing.Torque to 24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

16

W3000667

Install the step. START all four bolts,then tighten after aligning the step.Torque to 12 ± 1 Nm (106 ± 9 in-lb).

12 ± 1 Nm(106 ± 9 in-lb)

3635-03-02-01Windshield Washer Pump, Re-placement

Removal

1


Place a drain pan under the wind-shield washer fluid reservoir.

2

W3003797

Use a screwdriver to pry the wind-shield washer pump assembly up andout of the windshield washer fluidreservoir.

Note: Windshield washer fluid willdrain out of the reservoir when thewindshield washer pump assembly isremoved.

40


3Disconnect the wiring harness connec-tor.

4Cut the cable ties securing the hosesto the pump and remove hoses.

Installation

1Install the hoses onto the replacementwindshield washer pump and securewith cable ties.

2Connect the wiring harness connector.

3Press the windshield washer pumpdown into the reservoir until it is prop-erly seated.

4Fill the reservoir with new windshieldwasher fluid. Test for proper operationand leaks.

3634-03-02-11Windshield Washer Fluid FillBottle, Replacement

Removal

1

W3004328

Cut any cable ties that may securevent hoses to the windshield washerfluid fill bottle. Remove the two mount-ing nuts.

2Remove the fill bottle from its mount-ing location. If necessary, pour out anywindshield washer fluid and dispose ofproperly.

3Disconnect the reservoir fill hose atthe bottom of the windshield washerfluid fill bottle.

Installation

1Connect the reservoir fill hose to thereplacement windshield washer fluidfill bottle.

2Position the fill bottle in its mountinglocation and secure with mountingnuts. Secure any vent hoses that mayhave been removed with cable ties.

41


3634-03-02-12Windshield Washer Fluid Filter,ReplacementRemoval1Cut cable ties as needed to free thewindshield washer fluid filter

2Remove the inlet and outlet hosesfrom the filter.

Installation1Install the inlet and outlet hoses ontothe replacement filter.

2Secure with cable ties as needed.

3634-03-02-13Windshield Washer CheckValve, ReplacementRemoval1Cut cable ties as needed to free thewindshield washer fluid check valve.

2Remove the inlet and outlet hosesfrom the check valve.

Installation1Install the inlet and outlet hoses ontothe replacement check valve.

2Secure with cable ties as needed.

3634-03-02-09Windshield Washer FluidReservoir, Replacement (Bat-tery Box Mount)Note: It may be necessary to remove various cab com-ponents such as cab fairings or inner fenders to gain fullaccess and remove the windshield washer fluid reservoir.

W3004329

1 Top Hoses


3 Lower Mounts

4 Upper Mounts

Removal1


Disconnect the hoses on the top of thereservoir (1).

42


2

W3003797

Place a drain pan under the windshieldwasher fluid reservoir. Use a screw-driver to pry the windshield washerpump (2) up and out of the windshieldwasher fluid reservoir. Do not removethe hoses and electrical connector.


3Remove the lower mounting bolts (3).Remove the upper mounting bolts (4)including the upper battery box retain-ers and battery cable supports. Movethe battery cable assembly to the sideto allow removal of the windshieldwasher fluid reservoir.

Installation

1Position the replacement windshieldwasher fluid reservoir in its mountinglocation. Install and secure the mount-ing bolts with the upper battery boxretainers and battery cable supports.


3Connect the hoses on the top of thereservoir.


3634-03-02-10Windshield Washer FluidReservoir, Replacement (FrameRail Mount)Note: It may be necessary to remove various cab com-ponents such as cab fairings or inner fenders to gain fullaccess and remove the windshield washer fluid reservoir.

W3004330

1 Washer Pump Assembly

2 Top Hoses

3 Reservoir Mounting Bolts

43


Removal1

W3003797

1 Screwdriver blade

Place a drain pan under the wind-shield washer fluid reservoir. Use ascrewdriver to pry the windshieldwasher pump assembly up (1) and outof the windshield washer fluid reser-voir. Do not remove the hoses andelectrical connector.


2Disconnect the hoses on the top of thereservoir (2).

3Remove the reservoir mounting bolts(3) and remove the windshield washerfluid reservoir from the vehicle.

Installation1Position the replacement windshieldwasher fluid reservoir in its mountinglocation. Install and secure the mount-ing bolts.


3Connect the hoses on the top of thereservoir.


44

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

..........................................................................

..........................................................................

..........................................................................

..........................................................................

..........................................................................

..........................................................................

..........................................................................

Comments/proposals

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

................................................................................................................................................................................

Concerns Service Manual: ...............................................................................................................................

W3003804

Cummins, Caterpillar and Detroit Diesel Engines

W3003805

Foldout AWindshield Wiper System

Volvo Engines

W3003796

The simplified schematic and pin out charts should only be used to clarify the design features and trou-bleshooting procedures for this manual. For detailed, vehicle specific, schematics see “VN/VHD SeriesElectrical Schematics, Group 37”

Foldout BWindshield Wiper System

The simplified schematic and pin out charts should only be used to clarify the design features and trou-bleshooting procedures for this manual. For detailed, vehicle specific, schematics see “VN/VHD SeriesElectrical Schematics, Group 37”

W3003794

Foldout CWindshield Wiper Stalk/ Graphic Display Control Buttons

Operation Numbers

3631-03-02-01 Windshield Wiper Motor, Replacement . . . . . . . . . . . . . . . . . . . . . . 333631-03-02-05 Windshield Wiper Motor and Linkage Assembly, Replacement . . . . . . . . . . . 343634-03-02-09 Windshield Washer Fluid Reservoir, Replacement (Battery Box Mount) . . . . . . . 423634-03-02-10 Windshield Washer Fluid Reservoir, Replacement (Frame Rail Mount) . . . . . . . 433634-03-02-11 Windshield Washer Fluid Fill Bottle, Replacement . . . . . . . . . . . . . . . . . 413634-03-02-12 Windshield Washer Fluid Filter, Replacement . . . . . . . . . . . . . . . . . . . 423634-03-02-13 Windshield Washer Check Valve, Replacement . . . . . . . . . . . . . . . . . . 423635-03-02-01 Windshield Washer Pump, Replacement . . . . . . . . . . . . . . . . . . . . . 403636-03-02-01 Windshield Wiper Blade, Replacement . . . . . . . . . . . . . . . . . . . . . . 293637-03-02-01 Windshield Wiper Arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . 293638-03-02-01 Windshield Wiper Switch, Replacement . . . . . . . . . . . . . . . . . . . . . 313645-03-02-06 Windshield Wiper Module, Replacement . . . . . . . . . . . . . . . . . . . . . 30

Volvo Trucks North America, Inc.P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8

http://www.volvotrucks.volvo.com

PV776-TSP143133 () 8.2000 © Volvo Trucks North America, Inc., 2000

service manual trucks - heavy · note: indicates a procedure, ... windshield washer check valve,...

Documents