FSB-322-002

SB-10054058-5712
Field Service Bulletin
Trucks
Volvo Trucks North America
Greensboro, NC USA
Date
11.13
Group
No.
Release
322 002 01
Page
1(7)
Charging System Voltage (Cummins ISX)
VN Models
FSB 322-002, Charging System Voltage
(November 2013)
On vehicles equipped with a Cummins ISX Engine built from January 1, 2010 to June 28,
2013 with the left front battery box location (not the stacked battery box or Dometic system
equipped vehicles), the voltage drop on the charging circuit may be higher than is
recommended when utilizing the voltage drop test with the Intellicheck tester. The voltage
drop is acceptable to charge the batteries but the test using the Intellicheck tester may show
failed or under specification.
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB322-002_V
Workshop
Foreman
Service Technicians
USA59343
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
322
002
01
Checking
On some vehicles, the Intellicheck tester can erroneously indicate excessive voltage drop in
the charging system. If the Intellicheck tester indicates too high a voltage drop, perform these
steps to determine if corrective action is needed:
•
•
Clean and tighten all power connections on the alternator, batteries and cables.
Repeat the test with the Intellicheck tester and record the voltage drop reading for positive
and negative.
•
Add the two readings: If the total is 0.60 V or less then the voltage drop is acceptable
no further action is needed.
If the total is greater than 0.60 V then perform the following procedure:
W3083778
Sample calculation A + B = ≤ 0.60 V
Example: 0.19 + 0.29 = 0.48 (Passed) No further action required.
Page
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Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
322
002
01
Required Parts
Quantity
Part Number
Description
24
980464
Cable Ties
2
983715
Nut (two may be required depending on vehicle build)
2
21650178
Buss Bar (two may be required depending on vehicle build)
1
22208970
Positive Cable
1
22218117
Ground Cable
Repair Procedure
Note: Information is subject to change without notice.
Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
You must read and understand the precautions and guidelines in Service Information,
group 30, "General Safety Practices, Electrical and Electronics" before performing this
procedure. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheel, and placing the transmission in neutral.
2 Raise the hood.
W8003184
Page
3(7)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
322
002
01
3 Remove chassis side fairing/battery box lid.
W8078449
4 Disconnect all cables from the negative battery terminals to prevent personal injury from
electrical shock and prevent damage to electrical components.
5 Remove the inner fender.
6 Overlay the new ground cable 22218117 in place over top of the existing chassis harness
and loosely cable tie in place. This cable should route from the engine ground stud to the
frame rail ground stud. Do not tighten at this time.
Page
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Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
322
002
01
7 Secure the cable at the frame rail ground stud.
Note: If more than 3 cables are located on this grounding point, use the 21650178 buss
bar to re-allocate the other cables for a more even distribution.
Note: Install the buss bar if needed over the largest cables and secure.
Tighten to 40± 6 Nm (29.5 ± 4.5 ft lb).
Note: Install the smaller cables on the buss bar stud and secure.
Tighten to 12 Nm (9 ft lb).
W3084050
1. Ground Stud
2. Buss Bar
3. Nut
4. Battery Cables
5. Fusible Link
6. Chassis Ground
Page
5(7)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
322
002
01
8 Secure the cable onto the existing engine ground stud.
Note: If more than 3 cables are located on this grounding point, use the 21650178 buss
bar to re-allocate the other cables for a more even distribution.
Note: Install the buss bar if needed under the 2 largest cables and secure.
Tighten to 19 ± 1 Nm (14 ± 0.7 ft lb).
Note: Install the smaller cables on the buss bar stud and secure.
Tighten to 12 Nm (9 ft lb).
9 Tighten cable ties and secure.
10 Lay the new alternator cable 22208970 onto the engine harness and route from the starter
to the alternator.
11 Loosely cable tie in place.
Note: Do not tighten at this time.
12 Remove the old positive cable from the alternator and cut the end off some distance back
from the alternator.
13 Install the new cable to the alternator and secure.
Tighten to 7.1± 0.8 Nm (5.2 ±0.6 ft lb).
14 Remove the alternator power cable from the starter solenoid and cut the end off some
distance back from the starter.
15 Install the new cable to the starter and secure.
Tighten to 25 ± 0.8 Nm (18 ±0.6 ft lb).
16 Tighten the cable ties and secure alternator power cable.
17 Install the inner fender.
18 Install all previously removed cables to the negative battery terminals.
Page
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Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
322
002
01
Page
7(7)
19 Coat all connections with corrosion inhibitor or similar product.
20 Install the chassis side fairing/battery box lid.
W8078449
21 Lower the hood.
Reimbursement
This repair may be eligible for reimbursement if a product failure was experienced within time and mileage limits of
the applicable Warranty coverage. Reimbursement is obtained via the normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
W
Labor Code
Checking Time Only
32202–0–01
0.3 hrs.
Primary Labor Code
includes Checking Time
32202–0–02
1.1 hrs.
Causal Part
983715
Volvo Trucks North America engages in a comprehensive program of testing and evaluating
to provide the best possible product. Volvo Trucks North America however, is not committed
to, or liable for updating existing vehicles.