Volvo Trucks North America, Inc. Greensboro, NC USA This Service Bulletin replaces Service Bulletin 083 01, Special Tools, Group 3 Electrical Systems and Instrumentation VN, VHD VERSION2 (07.2004), Service Bulletin Trucks Date Group No. Page 12.2004 083 01 1(22) publication no. PV776 20 012524 Special Tools, Group 3 Electrical Systems and Instrumentation VN,VHD VERSION2 From build date 11.2002 Special Tools, Group 3 Electrical Systems and Instrumentation Updates to this Service Bulletin are indicated with a change bar. 9813194, Adapter page 3 9990008, Set of Test Pins page 3 9990020, Adapter page 4 9990025, Adapter page 4 9990062, Extension Cable page 5 9990137, Interface Adapter Cable page 5 9990151, Breakout Harness page 6 9998533, Adapter page 6 9998534, 4-Pin Breakout Harness page 7 9998567, Breakout Harness page 7 9998596, Adapter page 8 9998604, Adapter page 8 9990135, Antenna Breakout Box page 9 85104354, Alligator Clip Kit page 10 85104355, Headlamp Bulb Cover Removal Tool page 10 85104357, Headlamp Aiming Kit page 11 85104406, Overlay page 12 85104407, Overlay page 12 85105675, Overlay page 13 85104409, Overlay page 13 85104410, Overlay page 14 85104411, Overlay page 14 85107792, TESlite Enhanced Volmeter Leads page 15 BVA-34, System Analyzer page 15 PV776-20 019383 USA16263
Service Bulletin 12.2004 083 01 2(22) J38582-3, Terminal Remover page 16 J38751-301, DIN Terminal Remover page 16 J39200, Fluke 87 Multimeter page 17 J39916-A, Audio Diagnostic Kit page 17 J42018, DIN Terminal Remover page 18 J42449, Terminal Tool Kit, JAE Connectors page 18 J43052, DIN Terminal Remover page 19 J43143, Tie Strap Tensioner page 19 J43244, Relay Puller page 20 J44567, Probe Adapter Set page 20 J44701, Battery Tester Kit page 21 J46407, Auxiliary Valve Breakout Harness page 21 J47287, Adapter page 22
Service Bulletin 12.2004 083 01 3(22) 9813194, Adapter Tools Order number: 9813194 85104407, Overlay page 12 Variant / Component: VN, VHD VERSION2 Tool Class: 1 Essential Tool: 9813194 Adapter (Break Out Harness) is used to interface the Steering Wheel Module (SWM), Lamp Control Panel (LCP) and VECU PA Connector. 9990008, Set of Test Pins T4015499 W3004992 Order number: 9990008 J39200, Fluke 87 Multimeter page 17 Variant / Component: VN, VHD VERSION2 The 9990008 set of test pins are designed to access various connector types used in vehicle wiring. The pins test various connector types with a reduced chance of damage to sockets and pins in the connector. These test pins may also be used as a gauge to help determine if individual connector pins/sockets have sufficient clamping force to provide stable connections. The test leads included are compatible with the Kent Moore J39200 Fluke 87 Multimeter for circuit measurements.
Service Bulletin 12.2004 083 01 4(22) 9990020, Adapter Order number: 9990020 85104411, Overlay page 14 9990020 Adapter (Break Out Harness) is used to troubleshoot the Central Locking Module and Cruise Control Switches. 9990025, Adapter T0010644 Order number: 9990025 85104410, Overlay page 14 9990025 Adapter (Break Out Harness) is used to troubleshoot the Lighting Control Module (LCM) and Electronic Climate Control (ECC) module. T0010655
Service Bulletin 12.2004 083 01 5(22) 9990062, Extension Cable Order number: 9990062 T0010359 9990137, Interface Adapter Cable W0001694 Order number: 9990137 VCADS Pro and 9998534, 4-Pin Breakout Harness page 7 9990137 is used with 9998555 to connect the vehicle electronic system with VCADS Pro.
Service Bulletin 12.2004 083 01 6(22) 9990151, Breakout Harness W0002138 Order number: 9990151 w/ Eaton Transmission 9990151 is used to troubleshoot the vehicle speed sensor and wiring. 9998533, Adapter Order number: 9998533 85104406, Overlay page 12 9998533 Adapter is used to troubleshoot the VECU PB connector and Instrument Cluster. T0008353
Service Bulletin 12.2004 083 01 7(22) 9998534, 4-Pin Breakout Harness W0001692 Order number: 9998555 VCADS Pro and 9990137, Interface Adapter Cable page 5 9998555 is used for communication between the vehicle electronic system and VCADS Pro. 9998567, Breakout Harness T0008563 Order number: 9998567 9998567 Break Out Harness is used to access 7 Pin DIN connectors.
Service Bulletin 12.2004 083 01 8(22) 9998596, Adapter Order number: 9998596 85105675, Overlay page 13 9998596 Adapter is used to troubleshoot the Electronic Climate Control (ECC) system. T0010668 Note: Adapter 9998596 should be equipped with 5 break out connectors. Early production adapters were equipped with 4 break out connectors and were used with overlay 85104408. Early production adapters and overlay 85104408 should be scrapped. 9998604, Adapter Order number: 9998604 85104409, Overlay page 13 9998604 Adapter is used to troubleshoot the Steering Wheel Buttons and Contact Reel. T3011702
Service Bulletin 12.2004 083 01 9(22) 9998699, 62 Pin Breakout Box Order number: 9998699 or2 Various Adapters and Overlays 9998699 62 Pin Break Out Box is used to troubleshoot electrical components and wiring. T0010202 9990135, Antenna Breakout Box Note: 9998699 62 Pin Break Out Box has a maximum current carrying capacity of 3 amps. W3005860 Order number: 9990135 This tool is used to help with troubleshooting Volvo Link Antenna systems.
Service Bulletin 12.2004 083 01 10(22) 85104354, Alligator Clip Kit W0002121 Order number: 85104354 Set J39200, Fluke 87 Multimeter page 17 85104354 Alligator Clip Kit contains a positive clip (red) and negative clip (black) that are compatible with the J39200 Fluke 87 Multimeter test leads and other test leads that accept banana jack connectors. 85104355, Headlamp Bulb Cover Removal Tool Order number: 85104355 Variant / component: VNL VERSION2 85104355 Headlamp Bulb Cover Removal Tool is used to aid in the removal of the headlamp bulb cover on Projection Beam Headlamps. W0002157 Note: Early model VNL VERSION2 headlamp bulb covers are removed by turning clockwise. Later model bulb covers are removed in the normal counter-clockwise direction.
Service Bulletin 12.2004 083 01 11(22) 85104357, Headlamp Aiming Kit W0002134 Order number: 85104357 Variant / component: VNL VERSION2 85104357 Headlamp Aiming Kit is used to accurately aim the Projection Beam Headlamps. Note: Some local laws may require the use of electronic optical aiming equipment. If required follow the aiming procedures as instructed in the aiming equipment supplier s instructions.
Service Bulletin 12.2004 083 01 12(22) 85104406, Overlay Order number: 85104406 9998533, Adapter page 6 85104406 Overlay is used to troubleshoot the VECU PB connector and instrument cluster. 85104407, Overlay W0002125 Order number: 85104407 9813194, Adapter page 3 85104407 Overlay is used to troubleshoot the Steering Wheel Module (SWM), Lamp Control Panel (LCP) and VECU PA connector. W0002127
Service Bulletin 12.2004 083 01 13(22) 85105675, Overlay Order number: 85105675 9998596, Adapter page 8 85105675 Overlay is used to troubleshoot the Electronic Climate Control (ECC) system. W3005966 Note: Overlay 85105675 supercedes overlay 85104408. Overlay 85104408 was used with early production adapter 9998596 equipped with 4 break out connectors. Current adapter 9998596 should be equipped with 5 break out connectors. Discard of early production adapter and overlay 85104408. 85104409, Overlay Order number: 85104409 9998604, Adapter page 8 85104409 Overlay is used to troubleshoot the Steering Wheel Buttons and Contact Reel. W0002129
Service Bulletin 12.2004 083 01 14(22) 85104410, Overlay Order number: 85104410 9990025, Adapter page 4 85104410 Overlay is used to troubleshoot the Lighting Control Module (LCM) and Electronic Climate Control Module (ECC). 85104411, Overlay W0002130 Order number: 85104411 9990020, Adapter page 4 85104411 Overlay is used to troubleshoot the Central Locking Module and Cruise Control Switches. W0002126
Service Bulletin 12.2004 083 01 15(22) 85107792, TESlite Enhanced Volmeter Leads Order number: 85107792 Description TESlite 1 Enhanced Voltmeter Leads J39200, Fluke 87 Multimeter page 17 Tool 85107792, is designed to find corrosion or poor connections by applying a load to a circuit. Detailed instructions, cautions and warnings on the tool use are included with the tool and are also available at the TESlite web site: www.teslite.com. W7001326 Note: This tool is designed for use on analog voltage circuts only. BVA-34, System Analyzer W3004737 Order number: BVA-34 ES-2 (Stand) Tool class: 2 No The BVA-34 System Analyzer is a digital, carbon pile, battery load tester and starting/charging system analyzer. It is portable and designed for use in the heavy truck market. Optional tester stand, part number ES-2, is also available. For more information contact AutoMeter at (435) 283 4142 or visit their web site at www.autometer.com. 1 TESlite is a registered trademark of Sullivan Training Systems.
Service Bulletin 12.2004 083 01 16(22) J38582-3, Terminal Remover W3003475 Order number: J38582-3 No J38582-3 is necessary for removing the wiring terminals from the diagnostic connector. This tool can be ordered from Kent-Moore at The Deutsch part number is 114010. J38751-301, DIN Terminal Remover W0001541 Order number: J38751-301 DIN Terminal Remover for Small Terminals This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at
Service Bulletin 12.2004 083 01 17(22) J39200, Fluke 87 Multimeter Order number: J39200 Various test components Variant / component: VN,VHD VERSION2 This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at W2001014 J39916-A, Audio Diagnostic Kit W0001682 Order number: J39916-A Tool class: 2 No J39916 A CD and Cassette Audio Diagnostic Kit can be used to diagnose audio problems in any audio system with a cd or cassette player. The kit includes various high, medium, and low combination frequencies, testing devices for motor speed and speaker rattle, in addition to a cassette deck cleaner kit. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at
Service Bulletin 12.2004 083 01 18(22) J42018, DIN Terminal Remover W0001620 Order number: J42018 Please make note that the GM tool numbers are listed on the tool. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at J42449, Terminal Tool Kit, JAE Connectors Order number: J42449 kit J39200, Fluke 87 Multimeter page 17 Variant/ component: VN, VHD VERSION2 J42449 is used to probe the instrument cluster JAE connectors. They can also be used on other JAE type connectors. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at W0001430 J42449 Terminal Tool Kit contains two female and two male test probes. Individual tool numbers are: P/N Description Qty. J42449 1 J42449 2 J42449 10 1 Male Test Probes Female Test Probes Terminal Remover 2 2 1
Service Bulletin 12.2004 083 01 19(22) J43052, DIN Terminal Remover W0001546 Order number: J43052 This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at J43143, Tie Strap Tensioner W0001560 Order number: J43143 Tool class: 2 No Used for tie straps to set a predetermined torque to prevent over or under tightening. After the correct torque is reached, the tie strap is cut clean to prevent a jagged edge. Used on wire harnesses, airlines, heater hoses, etc. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at
Service Bulletin 12.2004 083 01 20(22) J43244, Relay Puller W0001917 Order number: J43244 J43244 is used to remove standard size or micro-relays, power relays, DRL modules, mini-circuit breakers, maxi-fuses, and most types of square or rectangular style electrical components. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at J44567, Probe Adapter Set Order number: J44567 set (1 red, 1 black) J39200, Fluke 87 Multimeter page 17 J44567 is used for connecting J39200 to make electrical measurements from breakout box pin out locations. These adapters provide a reliable contact surface for a correct multimeter reading. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at
Service Bulletin 12.2004 083 01 21(22) J44701, Battery Tester Kit W0001836 Order number: J44701 Tool class: 2 No The Accuracy Plus battery tester is a comprehensive hand held battery / starting / charging electrical system tester. It has capability of printing test results with the included Hewlett Packard infrared printer. The J44701 kit includes tester, J44700, and printer, 238598. The tester or printer may be ordered as separate tools if desired. Tool J44700, the complete kit J44701 or printer 238598 must be ordered directly from Kent Moore at J46407, Auxiliary Valve Breakout Harness W0002137 Order number: J46407 Variant / Component VN,VHD VERSION2 J46407 is used to interface the electrical connector to the air-operated auxiliary valve manifold. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at
Service Bulletin 12.2004 083 01 22(22) J47287, Adapter Order number: J47287 J39200, Fluke 87 Multimeter page 17 Variant / Component VN,VHD VERSION2 This tool is used with the Fluke 87 multimeter to check pressure transducers on the instrument cluster and Electronically Controlled Suspension (ECS) system. This tool can be ordered from Volvo by adding the prefix KEM to the tool number or directly from Kent-Moore at W7001332