S Se Errvviicce Eb Bu Ulllle Ettiin N T Trru Ucckkss: V Vo Ollvvo Ol Liin NKK K Kiitt,, Iin Nsstta Alllla Attiio On N
S Se Errvviicce Eb Bu Ulllle Ettiin N T Trru Ucckkss: V Vo Ollvvo Ol Liin NKK K Kiitt,, Iin Nsstta Alllla Attiio On N
Greensboro, NC USA
S erv ic e B ulletin Tr u c k s
Date Group No. Release Page
Repl: : This bulletin supersedes service bulletin 397-09 Volvo Link Kit, Installation dated 02.2012.
6.2012
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Volvo Link Kit, Installation Volvo Link VP, From Build Date 7.2009
Vo l v o L i n k K i t , I n s t a l l a t i o n
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W3029363
This bulletin contains information for the installation of the Volvo Link VP Communications System Kit 85121771. N o t e : Multiple antenna mounting solutions are contained within this bulletin. Review the bulletin and identify the antenna solution that you will be using prior to cab disassembly, as the amount of disassembly may differ depending on the chosen installation. Removal of the headliner is not necessary for in dash mounted antenna's. However, for optimum service performance, it is preferred to locate the antennas in the factory location.
Content
USA53866
Kit 85121771, Component Description, page 3 System Wiring Overview, page 4 Cab Disassembly, for Kit Installation, page 5 Communication System Control Unit, Installation, page 14 Communication System Harness, Installation, page 16 Antenna, Installation (Steel Roof Cabs), page 19 Antenna, Installation (All SMC Roof Cabs, except 630), page 22 Antenna, Installation (630 Cab), page 22 Antenna, Installation (Mounted in Dash), page 29
P V776-89060289
English Printed in USA
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Lower Antenna Cable, Installation, page 31 Upper Antenna Cable, Installation, Steel Roof Cabs, page 32 Upper Antenna Cable, Installation (All SMC Roof Cabs, except 630), page 33 Upper Antenna Cable, Installation (630 Cab), page 34 Fuses Requirements, page 35 System Programming, page 35 Cab Assembly, page 36
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7 Remove the gear selector electronic control unit (GSECU) and/or the door lock module (if equipped).
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9 Remove the speaker grille, speaker, right side grab handle and the dash panel.
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12 Remove the light control panel mounting screws. Remove the vent from the panel, pull panel forward and leave hanging.
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13 Remove both parking brake valve knobs. Remove the parking brake valve panel. Pull trim away from the dash to access the instrument cluster fasteners. 14 Gently pry straight down on the cluster's top trim panel to remove.
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15 Remove the 4 mounting screws. 16 Pull out the instrument cluster and disconnect the wiring harness and remove the cluster. 17 Remove the left grab handle upper mounting bolt. 18 Remove the driver and passenger side A-pillar trim panel.
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19 Remove the driver's door glass sun visor and the overhead storage compartment on both sides (disconnect the wiring harness to the auxiliary plug and the CB jack).
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20 Remove the metal mounting brackets for the overhead compartments. 21 Remove the coat hanger clip from behind the driver's seat. N o t e : Day cab only. 22 Remove the trim splitting the front and rear headliners. N o t e : This step is only necessary on 430 and 630 model cabs. 23 Remove the curtain rail. N o t e : This step is only necessary on sleeper cabs. 24 Remove the screws from around the front and sides of the headliner.
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D a y C a b Gently, pull the headliner down at the front, to allow access to the bottom side of the roof. S l e e p e r C a b Remove the front section of the headliner. N o t e : Be careful and try not to crease the headliner by pulling too far downward.
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Day Cab
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Sleeper Cab
26 If the vehicle is equipped with the Volvo Link Classic Communications system , remove the ECU, bracket and the wiring harness prior to installation of the new system. The VP system ECU can not be mounted with the other ECU and components in place.
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2 Place the SIM card (part no. 21443469) into the holder.
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3 Install the SIM card and the holder into the ECU. N o t e : With the SIM card in the holder, install with the SIM card face down into the ECU.
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4 Install the M5 spring nut (part No. 994944) to retain the ECU bolt.
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5 Install the ECU (part No. 21284312) through the radio opening, slide the ECU back into position and install the M5 x 16 bolt (part No. 971306) at the front of the ECU and torque to specification. N o t e : Two tabs are located on the back of the ECU. These tabs slide into existing slots that retain the rear of the ECU. N o t e : Screw the bolt into the spring nut (part No. 994944). 5.5 Nm (49 lb-in)
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Main Harness
You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. N o t e : Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. N o t e : Be sure to connect the antenna cables to the ECU prior to connecting the ECU wiring harness. Failure to do so will result in a ECU fault. 1 Install the profile/edge moulding (part No. 21657068) to protect from the wiring harness and antenna cable.
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2 Loosely install the wiring overlay (part No. 21340357) with tie straps (part No. 948211), routing it as seen in the accompanying illustration. Connect all wiring connections and tighten the tie straps. N o t e : The antenna cables should be connected to the ECU prior to connecting the wiring harness to the ECU.
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Radio Jumper
1 Disconnect the radio jumper harness from the main cab harness. 2 Remove the SAE J1939 terminating resistor from the port mounted near the FRC and install the resistor in the port found on the jumper harness. N o t e : Refer to number 5 in the accompanying illustration for the terminating resistors new location.
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3 Loosely install jumper harness (part No. 21356936) with tie straps (part No. 948211). Route it as seen in the accompanying illustration. Connect all wiring connections and tighten the tie straps. N o t e : DR (green splice) splice pack is located to the right of the steering column under the dash.
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1 DR (green splice) splice pack cavity: M 2 Dual 8 pin radio jumper connector end 3 16 pin cab harness connector end 4 MCVL2 connector 5 Port for SAE J1939 terminating resistor 6 SAE J1939 data link connector
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1 Distance between center line of holes 30 mm (1.2 in.) 2 Diameter of front hole 7 mm (0.28 in.) 3 Diameter of back hole 20 mm (0.80 in.) 3 Drill the front hole and enlarge the existing antenna hole. N o t e : The rear hole should be 20 mm (0.80 in.) and the front hole should be 7 mm (0.28 in.). Both holes have a tolerance of 0.1 mm ( 0.004 in.) 4 Install the antenna (part No. 21383947) and the retaining nut. Torque the nut to specification. 4 0.5 Nm (35 4 in-lb.)
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5 Connect the two antenna cables to the upper antenna cable. N o t e : The antenna cables are color coded. Connect like colors together.
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New Installation
You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. N o t e : Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible.
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1 Make measurements to identify the antenna mounting hole locations and mark the roof. Make all measurements, measuring inward from the outer edges of the third raised roof rib. Refer to figure 1. 1 Side to side center line of both holes 230 mm (9.05 in.) 2 Center line of rear antenna hole 75 mm (2.95 in.) 3 Center line of the front hole 105 mm (4.1 in.) 4 Front hole 7 mm (0.28 in.) 5 Rear hole 20 mm (0.80 in.)
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Figure 1
2 Drill the two holes for the antenna. N o t e : The rear hole should be 20 mm (0.80 in.) and the front hole should be 7 mm (0.28 in.). Both holes have a tolerance of 0.1 mm ( 0.004 in.). 3 Install the antenna (part No. 21383947) and the retaining nut. Torque the nut to specification. 4 0.5 Nm (35 4 in-lb.) 4 Connect the two antenna cables to the upper antenna cable. N o t e : The antenna cables are color coded. Connect like colors together.
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1 Antenna bracket rivets 2 Mount the antenna (part No. 21383947) to the antenna bracket (part No. 82364524) and torque retaining nut to specification. 4 0.5 Nm (35 4 in-lb.) 3 Mount the antenna bracket (part No. 82364524) to the roof with two rivets (part No. 8096788). 4 Connect the two antenna cables to the upper antenna cable. N o t e : The antenna cables are color coded. Connect like colors together. 5 Be sure to secure the antenna cables to the roof with tape.
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modify the overhead storage compartment support in the roof before mounting the antenna. Refer to Modifying the Overhead Storage Compartment Support, page 23 for more information.
Mo d i fy i n g th e Ov e rh e a d S to ra g e C o mp a rt me n t S u p p o rt
N o t e : These steps are only necessary for 630 cab trucks that are not equipped with the provisions to mount the antenna. If the holes exist in the overhead storage support continue with Installation (630 Cab), page 28 You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. N o t e : Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. N o t e : The illustrations in the following procedure are view from the top of the cab down. 1 Using a straight edge, make a line through the center line of the threaded inserts on the left side of the cab in the overhead storage compartment roof support.
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Figure 1
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2 Squaring off the line made in step 1, mark a line on the overhead storage compartment roof support through the center line of the threaded inserts.
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Figure 2
3 Make measurements and mark the ends of the antenna hole as seen in figure 3. N o t e : Square the measurement off of the center line of the second threaded insert. 200mm (7.9 in.), 310mm (12.2 in.)
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Figure 3
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4 Make measurements and mark the forward and rearward edges of the antenna hole as seen in figure 4. N o t e : Square the measurement off of the line made in step 1. 140mm (5.5 in.), 80mm (3.1 in.)
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Figure 4
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6 Cut out the antenna hole in the SMC, made from the marks in the previous steps. N o t e : It may be helpfully to drill holes in the four corners and then cut from hole to hole to remove the remainder of the material.
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Figure 5
7 Make measurements and mark the center line of the antenna cable hole as seen in figure 6. 495mm (19.5 in.)
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Figure 6
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8 Make measurements and mark the other center line of the antenna cable hole as seen in figure 7. 24mm (0.95 in.)
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Figure 7
9 Drill a 25mm (1 in.) hole for the antenna cable to pass through as seen in figure 8. Center the hole using the marks made in steps 6 and 7. 25mm (1 in.)
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Figure 8
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1 Antenna bracket rivets 2 Antenna base 2 Mount the antenna (part No. 21383947) to the antenna bracket (part No. 82364524) and torque retaining nut to specification. 4 0.5 Nm (35 4 in-lb.) 3 Fasten the antenna bracket (part No. 82364524) to the roof with two rivets (part No. 8096788). 4 Connect the two antenna cables to the upper antenna cable. N o t e : The antenna cables are color coded. Connect like colors together.
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1 Lower antenna cable routing to ECU 2 Antenna Bracket 3 Antenna 1 Using the antenna bracket (part No. 82364524) as a template, drill two 5.5 mm (3/16 in.) holes into the steel brace across the front of the HVAC system on the passenger side of the truck.
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2 Mount the antenna (part No. 21383947) to the antenna bracket (part No. 82364524) and torque retaining nut to specification. 4 0.5 Nm (35 4 in-lb.) 3 Mount the antenna bracket (part No. 82364524) to the brace with two rivets (part No. 8096788). 4 Connect the two antenna cables to the lower antenna cable. N o t e : The antenna cables are color coded. Connect like colors together. 5 Secure the antenna cables with tie straps (part No. 948211).
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2 Connect the cable to the two ECU connections. N o t e : The antenna cables are color coded. Connect like colors together.
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2 Connect the cable to the two ECU connections. N o t e : The antenna cables are color coded. Connect like colors together.
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Upper Antenna Cable, Installation (All SMC Roof Cabs, except 630)
You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. N o t e : Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. N o t e : The upper antenna cable is not needed if mounting the antenna in the dash location. 1 Connect the cable to the two lower cable connectors along the A-pillar. N o t e : The antenna cables are color coded. Connect like colors together. 2 Install and route the upper antenna cable (part No. 21385255), securing it with tape.
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1 Antenna bracket rivets 2 Antenna base nut 2 Feed the antenna cable through the round hole in the overhead storage support in the roof and then back through the antenna hole. 3 Press the grommet up into place in the roof
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4 Route the upper antenna cable (part No. 21385255), securing it with tape.
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5 Connect the cable to the two lower cable connectors along the A-pillar. N o t e : The antenna cables are color coded. Connect like colors together.
Fuses Requirements
1 Install two 5 amp fuse (part No. 3968158) in position F13 and F01 of the FRC.
System Programming
You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. N o t e : Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. N o t e : Do not perform programming until all parts of the kit have been installed and connected.
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1 Turn on the vehicles main power switch or connect the battery cables starting with the positive, then connect the negative cable. 2 Using the diagnostic tool, perform accessory kit number 85126285. 3 Using the diagnostic tool, perform 3972220301 MID 142 Control Unit, Programming. 4 Using the diagnostic tool, perform 3973070302 Volvo Link Sim I.D. Calibration. 5 Using the diagnostic tool, perform 3810220303 MID 140 ECU Programming. 6 Using the diagnostic tool, perform 2841220303 MID 128 ECU Programming.
Cab Assembly
You must read and understand the precautions and guidelines in Service Information, group 30, "General Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. N o t e : Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. N o t e : Be sure to connect the antenna cables to the ECU prior to connecting the ECU wiring harness. Failure to do so will result in a ECU fault. 1 Position the headliner and install the metal mounting brackets for the overhead compartments. 2 Install the front and side headliner mounting screws. 3 Install the driver and passenger side A-pillar trim panel. 4 Install the curtain rail. N o t e : This step is only necessary on sleeper cabs. 5 Install the trim, splitting the front and rear headliners. N o t e : This step is only necessary on 430 and 630 model cabs.
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6 Install the coat hanger clip from behind the driver's seat. 7 Install the metal mounting brackets for the overhead compartments. 8 Install the overhead compartment on the passenger side. 9 Install the overhead storage compartment on both sides (connect the wiring harness to the auxiliary plug and the CB jack) and the driver's door glass sun visor. 10 Install the left and right side grab handle upper mounting bolt. 11 Install dash panel, right side grab handle, speaker, and the speaker grille. 12 Connect and install the instrument cluster. 13 Install all the dash trim panels around the instrument cluster. 14 Install the left side under dash panel. 15 Install the lower center trim panel. 16 Install the GSECU and/or the door lock module (if equipped). 17 Install the radio and storage pocket. 18 Install the lower ash tray panel. 19 Install the upper front dash panel. 20 Install the fuse and relay center (FRC) panel and screws.