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Subject Section TP Number Illustrations Date
1 Introduction
Each Volvo Bus Electrical System Service Manual,
Section 3(37) is based on a set of schematic diagrams
for that particular bus model or version. These Service
Manuals contain the appropriate schematic diagrams,
component location information and brief circuit
descriptions. This OHP kit is intended to help users to
understand the way that these Manuals are organised
and in particular to describe the symbols used and how
the schematic diagrams should be read and interpreted.
2 Schematics framework
Every schematic diagram in the Electrical System Service
Manuals is drawn within a framework of horizontal
parallel lines, three at the top (the positive voltage lines)
and one along the bottom, representing the "ground"
line.
Eng 1 ( 18)
3 Current path system
Each bus version (B6, B7, B10M, B10L etc.) has a
complete master schematic diagram, but this is far too
large to be shown complete in each Manual, so it is split
into separate page-size sections, each showing one or
more functional areas. The complete schematic has a
continuous sequence of numbers running from left to
right across the top. This sequence starts with number
1 at the top left of the first page-size section of the
schematic. These are the "current path" numbers,
because most of them are aligned with the vertical lines
that carry current to and from the electrical components
on the diagrams.
Eng 2 ( 18)
5 The "+30" line from the master switch
The battery master switch (labelled 144) has to be
closed before the "+30" line can be supplied with voltage
from the "+" line, via an 80 ampére strip melt-type fuse
(labelled "34").
7 Ground connections
There are several different groups of current paths to
ground, that are electrically connected to each other
and finally to the bus chassis. Each of these connectors
is labelled: "31", "P4", "37A" etc.
Eng 3 ( 18)
8 Electrical battery master switch
On buses with an electrical battery circuit breaker (342A),
this is a special type of relay that operates as follows:
9 Location codes
On the diagrams, the approximate location of each
component is indicated by a letter code underneath the
underlined component number. As an example,
component (342A) here is in the battery box. The main
component location codes are:
Code Location
B Battery box
CC Chassis centre
CF Chassis front
CR Chassis rear
E Front electrical centre
I Instrument panel
M Engine/transmission area
P Pedal plate area
10 Connections
Symbols on the schematics identify different types of
single-wire connection. Permanent connections that
cannot be taken apart, such as ultrasonic welded
connections, are shown by large filled black circles (A).
The smaller filled black circles (B) represent bolted
connections.
Eng 4 ( 18)
11 9-pin, 25-pin, 35-pin and 55-pin
connector terminals
The most commonly used connectors are of the 9-pin
type. The terminals are numbered as shown, and the
connectors are shaped to prevent incorrect insertion of
the plug into the socket.
13 Relay terminals
The plug-in relays often have a diagram of their terminal
connections stamped or printed on the casing. This
diagram is repeated here, and shows that the coil is
connected between terminals 85 and 86. The pole
connection is to terminal 30, and the two contacts are at
terminals 87 and 87a. The schematic diagrams always
show relays in their de-energised state, when the pole
connection 30 is connected to the normally-closed
contact at terminal 87a.
Eng 5 ( 18)
14 Fuses
1 Blade melt-type fuses have a transparent plastic
casing, coloured to indicate the fuse rating, e.g. 5A
red, 10A blue. These are plug-in types, generally
associated with low-current devices.
15 Symbols 1 – Manually-operated
single-pole switches
Most of the component symbols are illustrated and
labelled in the Introduction to each Service Manual. The
following set of eleven "Symbol" illustrations shows
representative examples, grouped under headings that
indicate their uses.
126 Differential lock switch: with a built-in warning lamp. Note that
this switch has a built-in mechanical latch to keep the switch
closed. This latch is not present on the other rocker switches
on the instrument panel.
144 Battery master switch: rotary manual contact.
160B Engine stop button: sprung push-button with normally-closed
contacts. Note that there are two versions, with 2 and 4
terminals respectively, for use in different bus versions.
180 Emergency cut-out switch: push-button with detent. The red
cover prevents accidental operation.
Eng 6 ( 18)
16 Symbols 2 + Mechanically-operated
single-pole switches
200 Parking brake pressure switch: normally-open contact closes
when the preset pressure is reached.
217 Reversing lights contact: normally-open contact, closed by
mechanical pressure on the sprung piston at the end.
254 Engine compartment thermal break contact: normally closed
solid-state (transistor-type) contact opens when preset
temperature is reached.
256 Articulated bus turntable limit microswitch: normally-open
contact, closed by mechanical pressure on the roller moving
the arm.
Eng 7 ( 18)
18 Symbols 4 + Relays, circuit breakers
and solenoid valves
342B Starter motor circuit breaker: two-pole circuit breaker with
main coil and holding coil. The link between the two large
bolted terminals is the 250A fuse. The smaller terminals are
for the energising and holding coils. The function of this circuit
breaker is described in Illustration 8.
308R Auxiliary brake lights relay: standard single-pole relay. This is
the type of relay most commonly used in Volvo buses, and has
been described in more detail in Illustration 13.
6013 Wheel brake ABS solenoid valve: solenoid valve with two
operating coils.
19 Symbols 5 + Sensors
753 Engine speed sender: converts detected pulses into a voltage
signal proportional to the pulse rate, in this case engine
speed.
754A Brake circuit air pressure sender: converts air pressure into a
voltage signal proportional to the pressure.
756 Coolant temperature sender: converts temperature into a
voltage signal proportional to the temperature.
757 Fuel level sender: converts a liquid level (detected by the
orange-coloured sliding float) into a voltage signal propor–
tional to the level.
759 Coolant level sender: converts a liquid level (detected
between the two long probes) into a voltage signal propor–
tional to the level.
2063 Clutch position inductive switch: inductively senses the
proximity of a metal object (the projecting tab on the clutch
pedal arm) and acts as a solid-state (transistor-type) on-off
switch.
Eng 8 ( 18)
20 Symbols 6 + Electronic devices on
the main electrical centre
ABS control unit
AMP Amplifier: increases the current or voltage amplitude of a
variable electrical signal. Power amplifier transistors are
usually identified by having metal heat sinks that dissipate the
heat they produce.
SQ Squarer: converts sinusoidal waveform into square pulses by
applying extremely large amplification and then clipping off
the tops and bottoms of the sinusoidal waveform.
Eng 9 ( 18)
22 Symbols 8 + Actuators, motors and
alternators
6064 Electrical accelerator actuator: an electric motor driving a
rotary actuator to produce mechanical movement, with
feedback from a potentiometer to indicate and control the final
position of the mechanical actuator.
660 Alternator: voltage and current generating device.
6057 Speed limiting actuator: an electric motor driving a linear
actuator to produce mechanical movement.
Eng 10 ( 18)
25 Symbols 11 + Miscellaneous
components
805 Panel lamps rheostat (dimmer): a potentiometer. Its slider
and resistance coil can clearly be seen.
810A Air drier thermostatic heating element: a heating element,
often with a built-in thermostat to switch on if the temperature
falls below a certain level, or off if it rises too high, to prevent
overheating.
853 Buzzer: an audible alarm, normally located inside the
instrument panel.
950 Retarder electrical coils: heavy-duty magnetic coils.
Eng 11 ( 18)
78149-26
Eng 12 ( 18)
27 Circuit example 1 - Voltmeter
The remaining five illustrations in this kit show and block "702B" inside the instrument panel. Terminal 12
describe some typical circuit examples, in this case of this block leads to the positive terminal of the
taken from Section 3(37) Electrical System, B10M voltmeter.
Component Wiring Diagrams (from chassis no. 25184
onwards). The voltmeter negative terminal is connected to terminal
5 in the same block, where the ground path (green
The first example here is electrically the simplest circuit arrows and lines) begins. White wire 37AA goes to
in the chassis, for the voltmeter. The voltmeter part of permanent connection 37A, which is connected by
the circuit schematic is shown at the left, and the actual wire 37A to pin 9 on the 9-pin connector "EM". This is
location of the components is illustrated at the right. connected to a central permanent ground point "P4" on
Red arrows and lines indicate the path of the positive the main electrical centre, then via detachable terminal
voltage and green arrows and lines show the return "31" to the chassis of the bus, which completes the
path to battery negative. return path by being connected to battery negative.
The +30 line supplies fuse "14", an 8A fuse on the large The small OPTION diagram at the bottom of the
printed circuit board in the main electrical centre, when schematic shows that the voltmeter is optional, and
the manual battery master switch (144) is closed. when present is fitted into the lower right corner of the
instrument gauge panel, known as Combi 2.
The track on the printed circuit board from fuse "14"
continues to 9-pin connector "F", pin 9, and from there
the current passes through red (R) wire 14A to pin 8 of
another 9-pin connector, "EM". This in turn is connected
via permanent connection 14 and wire 14C to terminal
Eng 13 ( 18)
28 Circuit example 2 - Oil pressure
gauge and warning lamp
Now we have an extra colour for the arrows and lines: Taking each path in turn, lamp (503) in path 230 is
blue represents a voltage that may be at some level supplied with positive voltage from the "+15" line as
between the positive voltage supply and zero (ground). already described (red arrow and line). Wire 202A is
coloured blue here, since it is at an unspecified voltage
The general principle here is that in buses with the if the contact (202) is open (and the lamp is not lit), but
standard arrangement (shown in current path 230), is grounded by (202) when this contact closes to light
the oil pressure warning lamp (503) will light if the low the lamp. Note that this blue path passes through the
oil pressure contact (202) closes, which will happen if lamp check circuit between 25-pin connectors CC and
the oil pressure falls below 50 kPa. If the pressure is CD.
low enough for the contact (202) to close, white/brown
wire 202A will be grounded, completing the circuit to In the optional version, the oil pressure gauge (705)
light the warning lamp. The lamp is continuously receives its positive voltage from fuse "9" via the same
supplied with a positive voltage via 9-pin connector route as the lamp, until permanent connector 9, from
"EN" pin 4 and similar connector "C" pin 1 from fuse "9". where wire 9G feeds the gauge via terminal 4 on
This supply enters the instrument panel via terminal terminal block "702B" in the instrument panel. The
block "33" terminal 16 from permanent connector 9. other side of the gauge, where the voltage (and current)
can vary, is connected via "702B" pin 1 and 9-pin
In the optional version, an oil pressure gauge (705) is connector "EF" pin 7 to the oil pressure sender (7061).
fitted. The current through the gauge varies according The sender is grounded via white wire 37XH to
to the oil pressure sensed by the oil pressure sensor permanent connection 37X, wire 37X to ¬GA+ pin 5,
(7061). The amount of current flowing through the permanent ground connection "P4" and detachable
gauge thus represents the oil pressure, indicated on ground connection 31 to the bus chassis ground return.
the gauge dial.
The electronic switch has a separate ground path via
The gauge includes an electronic switch that closes if "702B" terminal 5, "EM" pin 9 as far as "P4". When it
the oil pressure (represented by the current flowing closes, this switch grounds lamp (503) via "702B"
through the gauge) falls to a level where the warning terminal 2, "ET" pin 1 and "EB" pin 2.
lamp (503) must be lit.
Eng 14 ( 18)
29 Circuit example 3 - lamp check
Sections of two separate schematics are needed to Lamp (562) for example is normally only lit when (7064)
explain the operation of the lamp check circuit. contact closes to signal that the pressure in the parking
brake circuit is greater than 860 kPa. The test voltage
Paths 35 to 41 are taken from the Feed Switch from "F1" however is permitted to reach the lamp via
schematic, since the feed switch is the component that connector "CC" pin 17 through the diode that connects
is used to perform the lamp check. the "F1" line to the printed circuit track from connector
"CD" pin 17. Each lamp has its own diode for testing.
Paths 179 to 199 are taken from the Warning Lamps
schematic, and include some of the lamps that are to In addition, the voltage from the fuse energises relay
be checked, together with the relay (RE1) that switches (RE1), which is grounded via "CA" pin 2 and common
the appropriate lamps to ground, to make sure they are grounding connection "P4" on the main electrical centre.
working. Most of the components on this schematic RE1 relay contact closes to ground all the lamps that
diagram are located on printed circuit boards in the light when they are grounded, such as (503), (543),
main electrical centre and the instrument panel, as (561), (5009) and (526). These lamps receive their
shown by the double lines. positive voltage from 8A resettable fuse "9" on the main
electrical centre, via 9-pin connector "EN" pin 4, common
The "+30" line voltage is fed to the feed switch (199) via "+30" permanent connector 9 and either terminal 16 on
resettable fuse "14" on the main electrical centre. The terminal block "33" or terminal 11 on terminal block
table shows the various positions to which the switch "702A", both being located in the instrument panel.
can be set; in this case the "C" position is used for lamp Once again each of these lamps has a diode to connect
checking, and this connects terminals 3 and 4 of the the ground via the RE1 relay contact to its connector
switch together, along with terminals 7 and 8. The "CD" track.
voltage now present at terminal 4 passes via 9-pin
connectors "EI" pin 8 and "CA" pin 6 to the 5A fuse "F1" Note that some of the lamps, (543) engine compartment/
in current path 198. luggage doors open for example, are normally lit by
grounding contacts in the body circuits, in this case
Fuse "F1" thus provides voltage to all the warning connected by the coachbuilder to 9-pin connector "KC"
lamps that need a positive voltage to light them, such pin 6.
as (562), (536) and (528). These are all grounded via
the printed circuit board track that leads to terminal 17
of terminal block "33" on the instrument panel.
Eng 15 ( 18)
30 Circuit example 4 - kneeling circuit
This is the type of relay-controlled circuit that is gradually the correct side front suspension air bellows, and
being replaced by digital control units, eliminating (6005B) closes the connection between the right and
much of the wiring and components. However, it is also left sections of the front suspension pneumatic
an example of a larger circuit. The schematic has circuit.Kneeling up is shown in the right hand schematic.
therefore been redrawn, the left hand part showing Once the bus is kneeling, inductive switch (2053)
relay operation during kneeling down, and with kneeling provides a ground connection at its terminal 1 for relay
up on the right. In each case the switches and relay (3013). When the top part of the kneeling switch (1102)
contacts are shown closed where appropriate. is pressed, positive voltage is supplied to 9-pin
connectors "CK" pin 7 and "KA" pin 6. A body-mounted
Kneeling down (the left hand schematic) is started by contact (for example on the door, that prevents kneeling
pressing the lower part of the kneeling switch (1102), up if it is open) then feeds this voltage to relay (3013)
which then supplies voltage from 8A fuse "15" to relay coil via body connector "KA" pin 5. (3013) energises to
(3009), which is grounded via inductive proximity switch connect the supply from fuse "15" to solenoid valve
(2052) until the bus reaches its lowest level, when it (6005), which raises the bus until switch (2053) de-
breaks the relay ground connection. If the optional energises relay (3013) at normal height. The diode
relay (3008) is fitted to the bus, this has to be energised between relay (3013) coil and its closed contact keeps
by a body-mounted connector before the bus can this relay energised even if the switch (1102) is released,
kneel down, as in its de-energised position it will to ensure that kneeling up continues to completion.
prevent relay (3009) from energising. The ground
connection for (3008) is via either body connector "KA" Note that the components on the main circuit board in
pin 4 or the parking brake pressure switch (200), which the electrical centre are associated with terminals on a
is closed if the parking brake has been set on. Relay test connector, so that the progress of the relay
(3008) may be replaced by a link instead, which sequencing can be monitored. For example, test
connects 9-pin connector "H" pin 3 to the printed circuit terminal 1 at the ground side of relay (3013) coil will
board track leading to relay (3009) coil. show zero volts relative to ground when the inductive
switch (2053) is operating, i.e. while the bus is kneeling
When (3009) energises, it supplies voltage to the 3 up, and at all other times will be "floating", not connected
kneeling down solenoid valves; (6001) prevents loss to ground.
of air from the suspension, (6005A) releases air from
Eng 16 ( 18)
450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467
+
+30
+15
5009 SEEABS/
SEEABS/ BRAKELIGHT
"15" #189 ZFGEARBOX
8A RETARDER RELAY#300
E #508,509
17 "CD"4 #501-507
9
GN/R BL R
W 9 "ED"1 9 "ED"5
9 "ABS"8 9 "ABS"2 9 "ABS"1 9 "ABS"5 9 "ABS"6 9 "ABS"4 9 "ABS"3 9 "ABS"9 9 "ABS"7
"40" "41"
9 "AEB"7 9 "AEB"8 9 "AEB"1 9 "AEB"5 9 "AEB"2 9 "AEB"3 9 "AEB"4 9 "JMP"1 9 "JMP"2 9 "JMP"3 9 "AEB"6 9 "JMP"4 9 "JMP"5
3025A
9008B
3024A
9008A
9008C
3024B
9008D
37L
27 9 8 26 1 25 19 11
9008
E
24 23 15 32 33 16 5 4 7 6 34 17 18 35 22 21
6013H
7057D
7057B
6013G
6013F
6013D
7054C
6013C
7057A
6013B
7054A
7054B
6013E
7054D
7057C
6013A
9 "AXL1"5 9 "AXL1"6 9 "AXL1"1 9 "AXL1"2 9 "AXL2"3 9 "AXL2"4 9 "AXL2"7 9 "AXL2"8 9 "AXL1"7 9 "AXL1"8 9 "AXL1"3 9 "AXL1"4 9 "AXL2"1 9 "AXL2"2 9 "AXL2"5 9 "AXL2"6
BL R GN W BL GN R W
BL W BL W
R R GN GN GN GN R R
GNRIGHT
RLEFT
BLAXLE1 TAPEMARKINGS
WAXLE2
YAXLE3
78149-31
Eng 17 ( 18)
32 Service literature
Each Volvo bus model has a specific Service Manual
containing circuit schematics and descriptions.
Particularly complex electrical systems are sometimes
covered in more detail in Service Bulletins and Service
Manuals for specific systems, such as automatic
transmissions, retarders, Electronic Diesel Control etc.
Eng 18 ( 18)