Electrical System BEA2

Volvo Bus Corporation
Bodybuilding Instruction
Gothenburg, Sweden
Buses and coaches
Sect. Group No Date
3 0 25 2007-04-11
Electrical system BEA 2

Applies to all models with BEA2
c3-0-25Electrical system BEA 22007-04-11

Production start
Week Model
435 B12B / B12BLE, B12M / B12MA
451 B7R / B7RLE, B9R, B7TL
509 B7L, B7LA
514 B9SALF
626 B9L/LA
633 B9TL 4x2
650 Pre-series B9TL 6x2
648 B9R
647 B9SALE
714 B12R
1 (92)
Bodybuilding instruction Sect. Group No Date
Buses and coaches 3 0 25 2007-04-11
Contents
Electrical system BEA 2 .................................................................................... 3
General ................................................................................................ 3
Precautionary measures ....................................................................... 3
Transport mounted equipment ........................................................................... 4
Main electrical distribution unit .......................................................... 4
Fuse exchange ................................................................................... 13
Batteries ............................................................................................. 14
Body builder connectors .................................................................... 14
Diagnostic connector ......................................................................... 16
Washer and wiper .............................................................................. 17
Relays for body functions .................................................................. 18
Outside temperature sensor ............................................................... 19
Enclosed material .............................................................................. 20
Control units ...................................................................................... 21
Cable harnesses ................................................................................. 25
Instrument .......................................................................................... 27
Body power supply .......................................................................................... 28
Power output from electrical distribution unit .................................. 28
Power output for heavy loads ............................................................ 29
Monitoring of alternators ................................................................... 29
Front and rear electrical distribution boxes ....................................... 29
Enclosed material, electrical distribution box ................................... 30
Front electrical distribution box with manual battery isolator .......... 34
Rear electrical distribution box with pre-heating relay ..................... 35
Legal demands ................................................................................................. 37
Direction indicators ........................................................................... 37
Body builder connectors, inputs and outputs ................................................... 38
Function description .......................................................................... 43
Lighting ............................................................................................................ 64
Lighting switch .................................................................................. 64
Diagnostic direction indicators .......................................................... 65
Trailer lamps ...................................................................................... 65
Lighting control unit, programming .................................................. 67
Explanation of signal types .............................................................................. 72
Recommended switches and illuminated plugs ............................................... 73
Rocker switches, V-Series Contura V ............................................... 73
Removable actuators ......................................................................... 73
Actuator removal tool ........................................................................ 74
Switches ............................................................................................. 79
Connectors for use with Contura V switches .................................... 82
Illuminated plugs, VP-Series Contura ............................................... 83
Mounting panel .................................................................................. 86
Appendix .......................................................................................................... 88
Cable harness for B9 SALF (Brazil) ................................................. 88
School bus warning lights for Australia (AUS-SPEC) ..................... 89
Bodybuilder connectors, inputs and outputs ..................................... 89
Function description .......................................................................... 91
Function coordination ........................................................................ 91
Requirement list ............................................................................................... 91
2 (92)
ELECTRICAL SYSTEM BEA 2

General
This document covers the Volvo Bus electric system BEA 2 (Bus Electrical
Architecture, version 2). Like previous electric system, BEA 2 is based on data
links and control units.
The control units communicate via both a fast control link J1939 and a slower
information link J1708/1587. Control signals are transmitted on the fast link,
and information and diagnostic signals are transmitted on the slow link.
The data links are recognized as twisted pair conductors.
Type of link Colours
Information link J1708/1587 Gray/orange
Control link J1939-1 Green/yellow
Kontrollänk J1939-2 Green/yellow
Kontrollänk J1939-3 Blue/black
Kontrollänk J1939-7 Blue/mauve
Kontrollänk Volcano Brown/pink
Precautionary measures
3-0-25 R01 Data links
• Do not install data links too close to sources of interference, such as electric
motors and generators.
• The data links must not be cut, joined, lengthened or modified in any other
way.
3-0-25 R02 Control units and other sensitive components
• Remove all control units or disconnect all connectors from the control units
before welding. Mark removed control units with the chassis ID so that they
are re-installed on the same chassis. The LCM, EBS, ECS and BBM-VECU
control units are now permanently fixed on the electrical distribution unit
and, if removed, must be refitted on the electrical distribution unit on com-
pletion of work. The connectors on the tachograph and alternators must also
be undone.
3-0-25 R03 Installation of control units during body building.
• The control units which do not fit inside the electrical distribution unit
should be installed together in an easily accessible location, as far as possi-
ble, and clearly marked on the panels which conceal the control units.
• A list of the control units that the bus is equipped with must be present in the
electrical distribution unit. The list must also specify where they are
installed.
3-0-25 R04 Cable harness and connectors
• Protect cable harnesses and connectors from dirt, weld spatter and mechani-
cal damage during body building.
• Cables delivered with the chassis must not be cut, joined, lengthened or
modified in any other way by the body builder. 3 (92)
• Handle the body builder connectors with greatest care. The electronics may
be sensitive to static electricity. Do not touch the pins directly or with con-
ducting tools.
TRANSPORT MOUNTED EQUIPMENT

Transport mounted equipment which is to be moved at body building is
described in section:
• See “Main electrical distribution unit” on page 4.
• See “Control units” on page 21.
• See “Cable harnesses” on page 25.
• See “Instrument” on page 27.
Main electrical distribution unit
3-0-25 R05 Location, electrical distribution unit
• The electrical distribution unit must be installed in a covered, clean, dry,
cool and easily accessible place, normally near the driver’s station.
The electrical distribution unit is 650 x 360 x 150 (H x W x D) mm. The circuit
boards are mounted on a 200 mm wide hinged plate, please refer to figure (1).
For further information, refer to BBI 3-0-26.
4 (92)
BB7 IB1 IB2 IB3 IB4 IB5
300 mm
BB6
GBX
EMS
ENG1
110 mm
ARTIC
150 mm
BOGIE
RA1
FH4
Fuse 33-48
ECS2
KH3
Relay 11-16
BS3
FH3
Fuse 49-64
FUEL
650 mm
KH2
Relay 7-10
EU4
FH2
Fuse 17-32
ECS1 Relay 17
KH1
BS2 Relay 1-6
FH1
BS1 Fuse 1-16
IB10
IB9
IB8
130 mm
IB7
IB6
3-0-25-027
360 mm
BB5 BB4 BB3 BB2 BB1
Figure 1 Main electrical distribution unit
5 (92)
Sektion FH1
PCB Fuse Amp Part No Function

Fuse No
F1 F1 5 969160 ECS
F2 F2 10 969161 BIC2
F3 F3 15 969162 Start Motor
F4 F4 20 978999 EBS
F5 F5 5 969160 Horn
F6 F6 5 969160 Parking brake release, emergency
F7 F7 15 969162 Gearbox ECU I-Shift
F8 F8 5 969160 Gear selector I-Shift
F9 F9 5 969160 Switchbox start/stop rear. Solenoid oil

separator.
F10 F10 5 969160 Fire alarm
F11 F11 10 969161 Dynafleet
F12 F12 5 969160 Body +30
F13 F13 10 969161 Spare
F14 F14 5 969160 BBM
F15 F15 15 969162 EECU
F16 F16 5 969160 VECU
Table 1: FH1, electrical distribution unit 20394200, version 2
FH1 KH1 FH2 KH2 FH3 KH3 FH4

Fuse 1-16 Relay 1-6 Fuse 17-32 Relay 7-10 Fuse 49-64 Relay 11-16 Fuse 33-48
Relay 17
3-0-25 118
Figure 2 Fuse and relay layout, electrical distribution unit 20394200, version 2
6 (92)
Sektion KH1
PCB Relay Relay No Part No Function
K1 K1 1078690 VECU / EECU
K2 K2 1078690 Inverted +15
K3 K3 1078690 ECS
K4 K4 1078690 I-Shift
K5 K5 - EGS
K6 K6 - EGS
Table 2: KH1, electrical distribution unit 20394200, version 2

Relay 17
3-0-25 118
7 (92)
Sektion FH2

Fuse No
F1 F17 5 969160 LED feed, dashboard switches.
F2 F18 5 969160 Alternator
F3 F19 10 969161 Hymer
F4 F20 10 969161 EBS
F5 F21 15 969162 Wiper, Washer
F6 F22 10 969161 Diva 5, Ecolife
F7 F23 5 969160 ACC
F8 F24 5 969160 BIC2
F9 F25 15 969162 Washer motor
F10 F26 5 969160 ECS
F11 F27 10 969161 G8-EGS
F12 F28 10 969161 Retarder, EGS, I-Shift, Ecomat 4,

Ecolife, Diva 5
F13 F29 5 969160 Body +DR
F14 F30 20 978999 Heating, fuel filter 7- and 9-litre

engines. Fuel/water separator
F15 F31 10 969161 Sensor, hydraulic oil lever. NOx-

sensor. UDS feed.
F16 F32 5 969160 Tachograph
K1 K17 20390648 Ignition +15

Relay 17
3-0-25 118
8 (92)
Sektion KH2
K1 K7 20374662 Start motor
K2 K8 20374662 VECU / EECU
K3 K9 20374662 Wiper/Washer
K4 K10 - Automatic gearbox

Relay 17
3-0-25 118
9 (92)
Sektion FH3

Fuse No
F1 F49 5 969160 Fuel cut off valve
F2 F50 10 969161 Retarder
F3 F51 5 969160 Radio
F4 F52 10 969161 Luggage Light
F5 F53 10 969161 Bogie valve, Heater water

separator
F6 F54 5 969160 Engine/Luggage hatch
F7 F55 10 969161 Fuel pressure sensor. Drainage

motor. Solenoid piston cooling.
Solenoid engine brake valve.
Fuel pump. Solenoid cooling
fan. Preheat relay.
F8 F56 10 969161 Engine brake
F9 F57 5 969160 Key switch
F10 F58 5 969160 FTM
F11 F59 10 969161 Spare
F12 F60 10 969161 Ecolife, ZF4
F13 F61 10 969161 Light luggage room
F14 F62 20 978999 Light sleep department
F15 F63 5 969160 Start motor control
F16 F64 10 969161 Spare

Relay 17
3-0-25 118
10 (92)
Sektion KH3
K1 K11 1078690 Prevent Start Engine
K2 K12 1078690 Luggage Light
K3 K13 1078690 Emergency switch
K4 K14 - Bogie
K5 K15 - RECU
K6 K16 - RECU

Relay 17
3-0-25 118
11 (92)
Sektion FH4

Fuse No
F1 F33 5 969160 BIC2
F2 F34 10 969161 Tachograph
F3 F35 25 969163 LCM
F4 F36 25 969163 LCM
F5 F37 25 969163 LCM
F6 F38 5 969160 Inverted +15
F7 F39 25 969163 DNOx2
F8 F40 - - Spare
F9 F41 20 978999 Radio
F10 F42 5 969160 Main Switch
F11 F43 - - Spare
F12 F44 25 969163 LCM
F13 F45 25 969163 LCM
F14 F46 25 969163 LCM
F15 F47 5 969160 Side marker L
F16 F48 5 969160 Side marker R

Relay 17
3-0-25 118
12 (92)
Fuse exchange
The transmission ECU (TECU) is protected with a 5 A fuse in the electrical dis-
tribution units, item number 20394200, delivered up to week 200707, see figure
(9). This isn’t sufficient for chassis fitted with Voith gearboxes. For this reason,
the fuse must be exchanged for a fuse with a higher rating. If the fuse blows, the
bus will come to a standstill.
In the electrical distribution unit, a label showing fuses, relays, and their loca-
tion can be found.
70394200
70394200
3-0-26 ba
Figure 9 Electrical distribution units, item number
3-0-25 R06 Fuse exchange, chassis number 117113 - 1125751

• The FH2 F6 5 A fuse is to be exchanged for a 10 A fuse.
• Label 20904938-01 (designated: "For 70394200 P02, December 2006") is to
be replaced by label 20904938-02. The label is to be placed in the electrical
distribution unit.
1.Allowing for the last few vehicles in this production run that may have had the 10 A fuse factory fitted.
13 (92)
Batteries
3-0-25 R07 Location, batteries
• Batteries must be placed in a cool, well-ventilated area. They must not be
exposed to heat from the engine's exhaust system, cooling system or other
source of heat.
Body builder connectors
BB1-BB5
BB6-BB7
Front 12 11 10 9 8 7
6 5 4 3 2 1
3-0-25-028
Figure 10 Body builder connectors
The body builder connectors are fitted so that the pins 6 and 12 are closest to the
front of the electrical distribution unit.
Body builder connector Location
BB1-BB5 Main electrical distribution unit top
BB6-BB7 Main electrical distribution unit right

long side
BB8 (Volvo multiplex lighting system) Close to the electrical distribution

unit
BB10 (only for buses with Volvo Close to the instrument

radio)
BB13 Main electrical distribution unit
BB14 Front electrical distribution unit close

to the batteries
BMUX (only for buses with To the left of Driver’s place

Volvo multiplex chassis electrical
system)
Table 8: Location, body builder connectors
14 (92)
Figure 11 Connector BB8, chassis (left) and body (right)
Figure 12 Connector BB10, chassis (left) and body (right)
Figure 13 Connector BMUX, chassis (left) and body (right)
15 (92)
Diagnostic connector
The 16-pin diagnostic connector (marked OBD2) is transport mounted in the
Driver’s place.
3-0-25 R08 Diagnostic connector
• The diagnostic connector is installed in a protected place underneath the
instrument panel (A), see figure (14), and should be:
- installed to the right of the steering wheel
- easy to locate
- easily accessible for connection to diagnostic tools
- possible to use when test driving the bus.
• The diagnostic connector anchorage must be dimensioned to withstand com-
pression and tensile forces of 30N.
The diagnostic connector can be placed in position (B), see illustration (14), on
condition that the hinges face upwards.
A
3-0-25 103
Figure 14 Location of diagnostic connector
OBD2
3-0-25 114
Figure 15 Diagnostic connector
16 (92)
Washer and wiper

The 16-pin connector (marked M01) for connection to the washer and wiper is
transport mounted by the Driver’s place.
Figure 16 Connector, washer-wiper, chassis (left) and body (right)
1 3 5 7 9 11 13 15
3-0-25-017
2 4 6 8 10 12 14 16
Figure 17 Pin location in the chassis connector
See wiring diagram GM in body building instruction 3-0-26 Wiring diagrams

BEA 2.
Connection
Pin Function Fuse
point
Wiper motor, windscreen (M01)
1 53A +15 supply 15 A
2 53B Switch position 2 (Low speed)
3 53 Switch position 1 (High speed)
4 31B Wiping after washing (Interval)
5 31 Ground
Washer pump motor, windscreen (M02)
12 Control signal
8 Ground
Washer pump motor, headlamp (M03)
6 30 +15 supply 10 A
9 56 +15 supply 10 A
14 S Control signal
Table 9: Washer-wiper
17 (92)
Connection
Pin Function Fuse
point
13 Ground
11 31 Ground
Table 9: Washer-wiper
High transient voltages from the windscreen wiper motor can damage the light
control module (LCM). For this reason, the adapter cable (A) (part no.
20925865) supplied with the chassis must be installed between the wiper motor
and the cable harness made by the body builder (B) from the 16-pin connector
(C). If it is not possible to connect the adapter cable supplied with the chassis to
the wiper motor used, the cable harness made by the body builder must be pro-
vided with two diodes (part. no. 20382270 or 1N5408). The diodes should be
located in the cable harness as close as possible to the wiper motor. One diode
must be connected with the cathode connected to 53A and the anode to 53, and
the other identical diode must be installed with the cathode connected to 53 and
the anode to GND. Please refer to 18.
1
2 1 1 GND
3
4 2 2 31B
5
6
7 3 3 53A
8
9 4 4
10
11
12 5 5 53
13
14
15 6 6 53B
16
3-0-25 110
C B A
Figure 18 Principle schedule for adapter cable
3-0-25 R09 Adapter cable with transient protection for LCM

• The enclosed adapter cable must be installed between the cable harness and
the windscreen wiper motor.
Relays for body functions
Relays without transient protection can damage electronic control units due to
their high transient voltages.
3-0-25 R10 Relay for body functions
Relays connected to body builder outputs must be one of the relays below, or an
equivalent product.
Volvo part. no. 20374662 (without holder) with a resistor for transient protec-
tion.
Volvo part. no. 9518230 (without holder) with a diode for transient protection.
Capacity: pulled 20 A resistive load, resting 10 A. Load 24 V, 2 W.
18 (92)
.
+
3-0-25 102
Figure 19 Relay for body functions
Outside temperature sensor

New legal demands, Euro 4.2, on the monitoring of exhaust emission control
systems are enforced on all new diesel powered vehicles registered as from
October 2007. Monitoring is performed by the OBD (On Board Diagnostic) sys-
tem. In the event malfunctions, non erasable fault codes, with information on
active error code time, will be stored for 400 days. In addition, the engine power
will be reduced until the malfunction has been taken care of. The legal demand
regarding exhaust emissions and with that the level of action of the OBD moni-
toring system is valid within a certain ambient temperature interval. The body-
builder is to fit an ambient temperature sensor. To safeguard correct temperature
readings, it is of vital importance that the sensor is fitted according to the
requirements below and that the temperature readings are checked against a ref-
erence temperature meter.
3-0-25 R11 Location of the outside temperature sensor
• The temperature sensor is to be placed in a sheltered and well ventilated
space close to the chassis centre line behind the front bumper within a space
measuring 200 x 200 x 300 mm, see (A) figure (20). The temperature sensor
is to be protected against spray and radiant heat from the road surface and
sources of heat such as defroster system and lamps. To ensure adequate ven-
tilation, the space must be open towards the rear.
• The temperature sensor bracket is to be manufactured of 1 mm sheet metal.
The circular attachment hole for the sensor is to measure 12 mm.
200
A
3-0-25 119
A
200 300
A
3-0-25 121
Figure 20 Location of the outside temperature sensor

19 (92)
3-0-25 R12 Checking outside temperature sensor reading

• The outside temperature sensor reading must be checked against a reference
sensor connected to a calibrated temperature meter. The reference sensor
should be placed in a tube covered in aluminium foil and attached to the left
hand side mirror or similar location. The outside temperature sensor may
deviate no more than 2ºC from the reading of the reference sensor, see (A)
figure (21).
• The check against the reference equipment is to be carried out on the first
bus of each production run and spot checked at intervals.
A
3-0-25 122
Figure 21 Reference meter sensor attached to mirror
Enclosed material
The following components are delivered with the chassis.
Position Poles Description Part no. No.

Main electrical 12 Connector 9162000 7
distribution unit Mounting FSH 9162008 1
Pins 9148079 70
Wiper 16 Connector 1096615 1
Pins 969781 16
Windscreen wiper Adapter cable with 20925865 1
motor/cable transient protection
harness for LCM
Instrument panel Lamp switch, refer 20466302 1
to page 64
Behind front Temperature sen- 20927970 1
bumper sora, refer to Out-
door
temp. page 47.
Sealing 1598753 2
Connector 1307048 1
Pins 949371 2
Table 10: Included material
a.The outside temperature sensor is packed in a separate bag.
20 (92)
Control units
LCM
EBS TECU-ZF
1 TECU I-shift
ECS TECU-Voith 2 TECU ZF ECOLIFE
J1939
BBM-VECU RECU
J1708 1, 2
EMS/EECU
Tacho G(S)ECU
SWM EGS UDS
Audio FTM/BIO
BIC Dynafleet
FMS
3-0-25 100
Figure 22 Transport mounted control units
LCM Hübner
EBS TECU-ZF
ECS TECU-Voith
J1939
BBM-VECU
J1708
EMS/EECU
Tacho
SWM
UDS
Audio FTM/BIO
BIC Dynafleet
FMS
3-0-25 101
Figure 23 Transport mounted control units, articulated rear engine bus
The ABS control unit has been discontinued and has been replaced by the EBS
control unit.
Control unit CECM-C is replaced by control unit BBM.
The ECS and TACHO control units now communicate on control link J1939
and information link J1708/1587.
Control unit BIC used to only communicate on information link J1708, it is now
also connected to control link J1939.
21 (92)
Location in
Transport
Control unit Description completed
location
vehicle
Audio Audio system Delivered In dashboard

separately
BBM Body Builder The Body Builder Module is a Electrical Electrical

Module control unit which replaces CECM- distribution distribution
C. The control unit controls unit unit
functions that are specific to a bus
chassis, such as the starter motor
function and the main switch. Body
builders who use the Volvo
multiplex chassis electrical system
must connect this to the BBM.
VECU and BBM are installed in the
same unit.
BIC Bus Instrument Instrument control unit. BIC version In dashboard In dashboard
Cluster 2 communicates on J1587 and
J1939.
BIO Bus Input-Output Universal control unit Max 0.5 m Max 0.5 m
from from
electrical electrical
distribution distribution
unit unit
Dynafleet Delivered In dashboard

with CKD
chassis/To
be ordered
separately.
EBS Electronic Brake Brake ECU with ABS function. Electrical Electrical
System Version 5 distribution distribution
unit unit
ECS Electronically Electronically controlled Electrical Electrical

Controlled suspension. Version 2. distribution distribution
Suspension Communicates on J1939/J1708. unit unit
EGS Easy Gear Shift Control unit for gear selector. Driver’s Next to gear
Independent system. The ECU is place, right selector
used with the following gearboxes: side
Manual electrical gearbox
Manual electrical gearbox with

retarder
Table 11: Control units
22 (92)
Location in
Transport
location
vehicle
EMS Engine Engine management unit At the engine At the engine

Management
System EMS is found on gas engine
variants
EMS2 is found on diesel engine

variants
FMS Fleet Control system for reading Max. 0.5 m Max. 0.5
Management standardised signals/data, using from from
System CAN. Introduced 2006. electrical electrical
distribution distribution
unit unit
FTM Fuel Tank Control unit for gas tank solenoid Tool box In body, see
Monitor valves BBI 2-2-1
Only for gas engine variants
GECU Gear selector Gear selector control unit for Driver’s Next to gear
Electronic automatic transmissions and I-shift place, right selector
Control Unit up to week 200611. side
GSECU Gear selector Gear selector control unit for Electrical Driver’s
Electronic automatic transmissions and I-shift distribution place
Control Unit as from week 200611. unit
LCM Light Control The Light Control Module controls Electrical Electrical
Module external lighting, wiper and dimmer. distribution distribution
unit unit
NOx ECU Measures the level of nitrogen Near the Near the
oxides in diesel engine emissions. exhaust exhaust
system system
PCM Pusher Control Hübner Turntable. Independent Rear Covered by

(Hübner) Module system. Articulated buses, only. electrical the head-
distribution lining behind
unit the body
bellow.
RECU Retarder Retarder ECU. The ECU is used At the Max. 1 m

Electronic with the following gearboxes: electrical from
Control Unit distribution electrical
Manual electrical gearbox with unit distribution
retarder unit
ZF manual gearbox with retarder
SWM Steering Wheel The Steering Wheel Module is a Below the Below the
Module control unit that controls the radio dashboard dashboard
(Volvo) buttons on the steering
wheel.
23 (92)
Location in
Transport
location
vehicle
TACHO Tachograph The Tachograph now In the In the

communicates on J1939 via VECU. dashboard dashboard
TECU, Transmission Control unit for automatic At the Max. 1 meter

Voith, ZF Electronic gearboxes. electrical from the
ECOMAT Control Unit distribution electrical
unit distribution
unit
TECU ZF Transmission Control unit for automatic On the On the

ECOLIFE Electronic gearboxes (fitted on the gearbox) gearbox gearbox
Control Unit
As from chassis number 115231 for
B9TL, the TECU ECU (ZF
ECOLIFE) is located on the
gearbox.
TECU Transmission Control unit for automatic On the On the
I-shift Electronic gearboxes (fitted to the gearbox) gearbox gearbox
Control Unit
TECU, Transmission Control unit for automatic At the rear Covered by

Voith, ZF Electronic gearboxes. Articulated buses, only. electrical the head-
Control Unit distribution lining behind
unit the body
bellow.
Voith Control unit for converting data Next to the Next to the
Gateway between the J1939 and J1587 links. TECU-Voith TECU-Voith
ECU ECU
UDS AdBlue (Urea) Control unit for AdBlue pump Chassis Chassis
Dosing System
Only for diesel engine variants
VECU Vehicle Vehicle ECU. The VECU and BBM In the In the
Electronic are installed in the same unit. electrical electrical
Control Unit distribution distribution
unit unit
24 (92)
Cable harnesses
Rear
Rear
Front
Driver and dashboard
3-0-25-015
Figure 24 Connectors for transport mounted harnesses
Three harnesses originating from the electrical distribution unit are transport
mounted and must be finally installed in the chassis by the body builder.
3-0-25 R13 Strapping of cables
• For security reasons, cable harness and cables mustn’t be strapped onto com-
pressed air tubes or fuel pipes.
25 (92)
15 m
3-0-25-011
Figure 25 Harness to rear part of chassis
On a rear-engined chassis, the harness length is 15 m from the electrical distri-

bution unit to a position in front of the rear axle.
3-0-25-012
10 m
Figure 26 Harness to rear part of chassis
On a mid-engined chassis, the harness length is 10 m from the electrical distri-

bution unit to a position in front of the engine.
7m
3-0-25-013
Figure 27 Harness to front part of chassis
5,5 m
3-0-25-014
Figure 28 Harness to Driver’s place and instrument panel
26 (92)
3-0-25 R14 Excess electrical cables

Excess electrical cables and wiring may fold back upon itself once. Cables may
not be folded back or looped more than once.
3-0-25-035
Figure 29 Strapping of excess electric cables
Instrument
Figure 30 Transport mounted instrument, variant Udash
3
4
5
6
switches
Figure 31 Transport mounted switch module, variant Udash
On the switch module there are (some switches are optional):

1 Emergency switch
2 Light switch (enclosed, but not mounted)
27 (92)
3 Main switch (operating the main relay)

Bogie unloading
4 Traction Control
5 Hill Start Aid (option)
Retarder (if there is no retarder control lever)
Differential lock (Diff Lock)
6 Levelling switch
7 Kneeling switch
Jackknife protection, shut off (articulated bus)
BODY POWER SUPPLY

Power output from electrical distribution unit
3-0-25 R15 +Bat, +30 and GND terminals
• The “+Bat”, “+30” and “GND” terminals mustn’t be used by the body
builder.
+Bat +30 GND
A A A
3-0-25-016
Figure 32 Power output from the electrical distribution unit
3-0-25 R16 Ground cables

• The body builder must check that all ground cables are correctly connected.
One ground cable connects the GND terminal on the electrical distribution
unit cabinet to the battery negative terminal. Another ground cable connects
the chassis frame to the same box.
• Tightening torque 9 Nm for the +Bat and +30 screws. Tightening torque
4 Nm for GND.
• The +Bat, +30 and GND cables must be clamped with rubber clamps (A),
see 32.
28 (92)
Power output for heavy loads

3-0-25 R17 Heavy loads
• The “+Bat” terminal on the main relay is supplied directly from the battery
and must only be used for loads which have to be working even when the
main switch is off. The power must be output through a relay controlled by
BB1:4 (low priority loads, relay) to avoid battery discharge.
Terminal “+30” on the battery switch is connected after the battery main switch
and is suitable for heavy loads. This also applies to the “+30” terminal in the
engine compartment.
• Heavy loads such as the AC system, auxiliary heater and lighting, which are
not absolutely necessary when the engine is not running, should be switched
off automatically when the engine is not running. This can be accomplished
with relays controlled by BB1:9 (alternator charging) or BB1:4 (low priority
loads, relay), for example.
• Loads which are only necessary when driving shall be supplied via relays
controlled by pin BB3:12 (+15 ignition). Power supplied during cranking.
Please refer to body building instruction, 3-0-10 Electrical system general, for
cable dimensions and general quality requirements for electrical systems.
Monitoring of alternators
The alternator monitoring function used should be able to function, irrespective
of the number of alternators the bus is equipped with. If a third alternator is
installed after delivery from the Volvo Bus Corporation, the L-signal from this
alternator must be connected to connector RA1:8, please refer to wiring sched-
ule 20904123, page AC. If no third alternator is installed, the DR signal must be
connected to RA1:8.
If an alternator is not charging, the warning lamp on the instrument panel is lit.
Front and rear electrical distribution boxes
The chassis is equipped with a electrical distribution box beside the battery box
(37) and one in the engine room (38 and 39).
The front electrical distribution box has a manual battery isolator. When
switched off (34), all loads on the chassis, apart from the ones connected to
BB14:1-3, are disconnected.
There are two variants of the rear electrical distribution box - with and without
pre-heating relay. The electrical distribution boxes contain connectors for the
electrical equipment in the bus. In general, the major loads should be connected
to the electrical distribution box closest to the load.
The new electrical distribution boxes will be introduced progressively during
2006:
29 (92)
Front electrical
distribution box
B7R week 200611
B7RLE week 200611
B9L week 200624
B9LA week 200624
B9R, VBoF week 200638
B9R, Brazil week 200717
B9S/SALF, VBoF week 200623
B9S/SALF, Brazil week 200710
B9TL 4x2 week 200616
B9TL 6x2 week 200616
B12B week 200711
B12BLE week 200711
B12BLEA week 200711
B12M week 200711
B12MA week 200711
B12MA (Brazil) week 200648
B12MBA (Brazil) week 200648
B12R (Brazil) week 200726
The rear electrical distribution boxes are always factory fitted. The front electri-
cal distribution box is factory fitted on variants equipped with the Volvo original
battery box. For variants not equipped with a battery box (variant UBBOX), a
bracket that, is to be fitted by the body-builder, is supplied with each chassis, see
figure (36).
Enclosed material, electrical distribution box
The following components are delivered with the electrical distribution box
Description Item no. Qty

Collar screw M8x40 947760 3
Washer 8.2x30 3183922 3
Rubber grommet 403877 3
Spacing sleeve 9x13x17 1257499 3
Nut M8 948645 3
30 (92)
3-0-25 R18 Installation of electrical distribution box

• To allow water to be drained, the electrical distribution boxes may only be
installed as in figure (33).
3-0-25 109
Figure 33 Installation of electrical distribution box
3-0-25 R19 Removal and re-installation of battery isolator knob

• If the battery isolator knob is removed, it must be re-installed with the switch
at its clockwise end position, as in (34).
ON
OFF
ON
OFF
3-0-25 108
Figure 34 Manual battery isolator
31 (92)
3-0-25 R20 Clamping of 70 mm2 and 90 mm2 cables

• 70 mm2 and 90 mm2 cables connected with an angled terminal must be
clamped with double rubber clamps (A), to prevent stress on the circuit
board, see (35). In all other cases, the cables must be clamped with one rub-
ber clamp.
2
1x <70 mm
2
}
70 mm
2
2x 90 mm
2
70 mm
3-0-25 111
Figure 35 Electrical distribution box, connection of cables with angled terminal
3-0-25 116
2
1x <70 mm
2
}
70 mm
2
2x 90 mm
2
70 mm
Figure 36 Electrical distribution box, connection of cables with angled terminal

(variant UBBOX)
32 (92)
3-0-25 R21 Max. permissible current drain from the electrical distribution box
• Max. permissible current drain from the electrical distribution box:
- in continuous operation: 300 A
- for max. 3 minutes: 750 A
- for max. 60 seconds: 2400 A
3-0-25 R22 Connection of AC fans
• AC fans with high power consumption are to be connected to the rear elec-
trical distribution box (located close to the generators) to avoid voltage drop
in the main battery cable.
AC fans with a nominal consumption of ≤50 A may be connected to the front
electrical distribution box.
3-0-25 R23 Connection of small loads
• BB14:1-3 is intended for alarms, clock and similar equipment which has to
function when the battery isolator has been switched off.
• The outputs must not be used for larger loads such as heaters etc.
• The loads connected to BB14:1-3 must never have a total continuous load of
more than 20 mA.
• The max load in table 12 must not be exceeded.
3-0-25 R24 Connection of 12 V equipment
• Equipment which requires 12 V must not be connected directly to one of the
batteries, it must be connected to one of the outputs on the electrical distribu-
tion box, via a DC/DC converter.
3-0-25 R25 Tightening torque
• The tightening torque for the connections in the electrical distribution box
must not be exceeded due to the risk of damage to the circuit board. Please
refer to 37, 38 and 39.
33 (92)
Front electrical distribution box with manual battery isolator
Max. Wiring
Fuse Description Item #
load diagram
F101 Chassis B+ 150 A AB 70301387
F102 Chassis +30 150 A AB 70301387
F103 Body +30 150 A AB 70301387
F104 Body +30 100 A AB 982320
F105 Body +30 50 A AB 982318
F106 Body +30 50 A AB 982318
28 Nm±5% 9 Nm±5% 2.2 Nm±5%
17 Nm±5%
9 Nm±5%
(F101)
3-0-25 104
(F102) (F104) (F106)

48±8 Nm 2.2 Nm (F103) (F105)
Figure 37 Front electrical distribution box with manual battery isolator
34 (92)
Rear electrical distribution box with pre-heating relay
Max. Wiring
load diagram
F201 Pre-heating relay 150 A AB 70301387
F202 Body +30 150 A AB 70301387
F203 Body +30 100 A AB 982320
F204 Body +30 50 A AB 982318
F205 Body +30 50 A AB 982318
F206 10 A AB 969161
F207 10 A AB 969161
F208 25 A AB 969163
F209 10 A AB 969161
F210 10 A AB 969161
F211 Pre-heating relay, pos 30 20 A AB 978999
F212 Mini-relay, pos 85 20 A AB 978999
F213 Miniature relay, pos 85 --- -
28 Nm±5% 9 Nm±5% 2.2 Nm±5%
17 Nm±5%
9 Nm±5%
(F212)
(F213)
(F211)
(F201)
(F206)
(F207)
(F208)
(F209)
(F210)
Variant EST-AID
3-0-25 105
(F202) (F204)
48±8 Nm 3.5±0. 7 Nm (F203) (F205)
Figure 38 Rear electrical distribution box (located in the engine room) with pre-
heating relay
35 (92)
Rear electrical distribution box without pre-heating relay
Max. Wiring
load diagram
F202 Body +30 150 A AB 70301387
F203 Body +30 100 A AB 982320
F204 Body +30 50 A AB 982318
F205 Body +30 50 A AB 982318
F206 10 A AB 969161
F207 10 A AB 969161
F208 25 A AB 969163
F209 10 A AB 969161
F210 10 A AB 969161
F211 20 A AB 978999
F212 Miniature relay, pos 85 20 A AB 978999
F213 Miniature relay, pos 85 --- -
28 Nm±5% 9 Nm±5% 2.2 Nm±5%
17 Nm±5%
9 Nm±5%
(F212)
(F213)
(F206)
(F207)
(F208)
(F209)
(F210)
(F211)
3-0-25 106
(F202) (F204)
(F203) (F205)
Figure 39 Rear electrical distribution box (located in the engine room) without
pre-heating relay
36 (92)
Rear electrical distribution box without pre-heating relay, B7R and

B7RLE
3-0-25 R26 Max. permissible current drain from the electrical distribution box, B7R and
B7RLE
• Max. permissible current drain from the electrical distribution box:
- in continuous operation: 300 A
- for max 3 minutes: 750 A
- for max 30 seconds: 1500 A
Max. Wiring
load diagram
1 AC 80 A AB ---
2 AC 100 A AB 982320
3 Pre-heating relay 150 A AB 70301387
4 Body +30 40 A AB ---
Tightening torque
M5 4 Nm
M8 20 Nm
M10 33 Nm
Tightening torque
3-0-25 117
M5 4 Nm
M8 20 Nm
M10 33 Nm
Figure 40 Rear electrical distribution box (in engine compartment) without pre-
heating relay, B7R and B7RLE
LEGAL DEMANDS
Direction indicators
3-0-25 R27 Blinking frequency
• There is a statutory demand that broken direction indicator lamps shall show
an increased blinking frequency. For this reason, incandescent indicator
bulbs must be used. The use of LEDs with resistors connected in parallel is
prohibited as the indicator blinking rate will not change if a LED goes out as
long as the resistor is intact.
37 (92)
BODY BUILDER CONNECTORS, INPUTS AND OUTPUTS

The signal types are explained in See “Explanation of signal types” on page 72..
For wiring diagrams, refer to body building instruction 3-0-26 Wiring diagrams
BEA 2.
Function Ref Pin Type Condition Max. load Diagram
Idle switch 1 BB1:1 LDO 0.75 A BA
Start disable 2 BB1:2 HDI BB
Fire alarm, body 3 BB1:3 HDI +30 BB
Low priority loads, relay 4 BB1:4 LDO 1A BB
Luggage hatch, open 5 BB1:5 HDI +15 BB
Safety belt indicator 6 BB1:6 LDI NA
Alarm, manual battery 7 BB1:7 HDO AA

isolator
Washer fluid low level 8 BB1:8 LDI NA
Alternator charging 9 BB1:9 HDO 0.25 A NA
Power and torque loss - 52 BB1:10 HDI BB

AC1 (Volvo 100%,
Denso AC1)
Parking brake applied 10 BB1:11 LDO +30 0.25 A BA
Disconnection of AC1 11 BB1:12 LDO 2A BB

compressor
Indoor temperature + 12 BB2:1 RES NA
Indoor temperature - BB2:2 GND ZC
Outdoor temperature + 13 BB2:3 RES NA
Outdoor temperature - BB2:4 GND ZC
D-CAN H 14 BB2:5 DATA BB
D-CAN L BB2:6 DATA BB
Horn 15 BB2:7 LDO IS

(contacts steering wheel
side)
Horn supply BB2:8 HDO 5A IS
Horn BB2:9 LDO IS

(contacts steer. wheel
centre)
Alarm 16 BB2:10 LDI GB
Emergency switch 17 BB2:11 HDO B+ 1A AA
Table 12: Body builder connectors
38 (92)
Signal 4 pulses/metre 18 BB2:12 PWM High level 8 V NB

C6 at 0 mA
High level
gives an output
voltage
between 5.5 V
and 8 V at 2
mA load.
Low level gives

0.8 V at 0 mA
Low level gives

an output
voltage below
2.5 V at 2 mA
load
Headlamps off 19 BB3:1 HDI GB
Prevent ECS action 20 BB3:2 HDI BB
Kneeling position 21 BB3:3 HDO 0.25 A FA
Cancel kneeling 22 BB3:4 LDI FA
Hazard warning lamps 23 BB3:5 LDI +15 GB
Daytime running light 24 BB3:6 HDO 0.5 A GB
Next stop indicator 25 BB3:7 LDI NA
Pram indicator 26 BB3:8 HDI NA
Starter motor not 27 BB3:9 HDO +15 0.25 A AB

activated
Speed signal C3 28 BB3:10 PWM 2A BA
+30 main switch (fuse 29 BB3:11 HDO +30 5A BB

F12)
+15 DR ignition (fuse 30 BB3:12 HDO +15 5A BB

F29)
Glass heating 31 BB4:1 HDI BB
Host call 32 BB4:2 HDI BB
Toilet fluid level 33 BB4:3 HDI BB
Toilet occupied 34 BB4:4 HDI BB
39 (92)
Door failure 35 BB4:5 HDI BB
Door brake, status 36 BB4:6 LDO 1A BB
Door brake, request 37 BB4:7 LDI EO
Speed signal 5 km/h 38 BB4:8 LDO 1A BA
Any door open 39 BB4:9 HDI +15 NA
Speed signal X km/h 40 BB4:10 LDO 1A BA
Dimmer, dashboard 41 BB4:11 PWM 2A GB

illumination
N/A BB4:12
Dipped beam. Left 42 BB5:1 HDO 2.92 A GB
Dipped beam. Right BB5:2 HDO 2.92 A GB
Direction indicator, front BB5:3 HDO 1.75 A GB

and side. Left
Direction indicator, front BB5:4 HDO 1.75 A GB

and side. Right
Fog lamps, front BB5:5 HDO 5.83 A GB
Additional main beam, BB5:6 HDO 0.25 A GB

relay output
End-outline marker, side BB5:7 HDO 0.625 A GB

marker, position lamps.
Left
End-outline marker, side BB5:8 HDO 0.625 A GB

marker, position lamps.
Right
Main beam 2. Left BB5:9 HDO 3.125 A GB
Main beam 2. Right BB5:10 HDO 3.125 A GB
Main beam 1. Left BB5:11 HDO 3.125 A GB
Main beam 1. Right BB5:12 HDO 3.125 A GB
Starter inhibitor, engine 43 BB6:1 LDI +15 BB

hatch
N/A BB6:2
Overload information 44 BB6:3 HDO 10A AC
+30 main switch (fuse 45 BB6:4 HDO +30 5A GA

F54)
Luggage hatch, open 46 BB6:5 HDI +15 BB
40 (92)
Luggage compartment 47 BB6:6 HDO 10 A BB

lamp
N/A BB6:7
N/A BB6:8
N/A BB6:9
N/A BB6:10
N/A BB6:11
Reverse warning signal, 48 BB6:12 HDO 0.25 A GA

relay output
Stop lamp. Right 49 BB7:1 HDO 1.75 A GA
Reversing lamps BB7:2 HDO 1.75 A GA
Direction indicator. Rear BB7:3 HDO 1.75 A GA

left
Direction indicator. Rear BB7:4 HDO 1.75 A GA

right
Extra direction indicator. BB7:5 HDO 1.75 A GA

Left
Extra direction indicator. BB7:6 HDO 1.75 A GA

Right
Rear position lamp. Left BB7:7 HDO 0.83 A GA
Rear position lamp. BB7:8 HDO 0.83 A GA

Right
End-outline marker, BB7:9 HDO 5A GA

side-marker lamps. Rear
left.
End-outline marker, BB7:10 HDO 5A GA

side-marker lamps. Rear
right.
Stop lamp, left and BB7:11 HDO 1.75 A GA

Category S3 stop lamps
Fog lamps, Rear BB7:12 HDO 1.75 A GA
Ref. 50 is for buses with Volvo multiplex body electric system.
41 (92)
End-outline marker 50 BB8:1 HDO 0.625 A GB

lamp.
Front left
End-outline marker BB8:2 HDO 0.625 A GB

lamp.
Front right
Extra main beam, relay BB8:3 HDO 0.25 A GB

output
Daytime running light, BB3:6 HDO 0.5 A GB

relay output
Ref. 51 is for buses equipped with Volvo radio
Remote control of extra 51 BB10:1 HDO 0.15 A IU

power amplifier (12 V)
N/A BB10:2 IU
+15 (12 V) BB10:3 HDO +15 5A IU
N/A BB10:4 IU
+30 (12 V) BB10:5 HDO +30 20 A IU
N/A BB10:6 IU
Ground BB10:7 GND IU
N/A BB10:8 IU
GSM mute BB10:9 IU
Power and torque loss - 52 BB13:1 HDI BB

(Volvo 50%)
Power and torque loss - BB13:2 HDI CL

(Denso AC2)
Power and torque loss - BB13:3 HDI CL

(Denso AC3)
Pinch protection 53 BB13:4 HDI FA
Not used BB13:5
Disconnection of AC2 11 BB13:6 LDO 2A CL

compressor
Disconnection of AC3 11 BB13:7 LDO 2A CL

compressor
Not used BB13:8
Not used BB13:9
Not used BB13:10
Not used BB13:11
42 (92)
Not used BB13:12
Not used BB13:13
Not used BB13:14
Not used BB13:15
Not used BB13:16
Not used BB13:17
Not used BB13:18
F111 54 BB14:1 HDO Body B+ 25 A AB
F110 BB14:2 HDO Body B+ 25 A AB
BB14:3 HDO
Not used BB14:4 AB
F109 BB14:5 HDO Body +30 10 A AB
F108 BB14:6 HDO Body +30 10 A AB
F107 BB14:7 HDO Chassis 5A AB

+30
J1708 A 55 BMUX:1 DATA XC
J1708 B BMUX:2 DATA XC
External main switch 56 BMUX:3 AA
External main switch BMUX:4 AA
Function description
1. Idle switch
Pin BB1:1 is an active low output (LDO).
The output is activated when the accelerator pedal is pressed down from idle
position to give increased engine power.
The function can be used to automatically switch off the lamps above the
Driver’s place when leaving a bus stop, for example.
2. Start disable
Pin BB1:2 is an active high input (HDI).
The function prevents engine starting from the Driver’s place and the engine
compartment, and activates a display symbol.
The function can be used to disable engine starting when the bus is connected to
an external supply of heat and compressed air, for example.
43 (92)
3. Fire alarm, body

The function activates the fire warning lamp, buzzer and STOP lamp.
The function can be used for fire detectors in luggage compartments, for exam-
ple. The indication on the instrument panel is the same as when the heat sensors
in the engine compartment are activated.
4. Low priority loads, relay

Battery voltage is monitored by the BBM control unit.
The output is activated in one of the following cases:
• After 30 minutes if the ignition is switched on and the engine is not running,
or if the battery voltage falls below 23.6 V.
• If the battery voltage falls below 25.4 V for more than 30 seconds and the
current drain in the bus is more than what is generated.
The output is deactivated when battery voltage exceeds 26.7 V and when engine
speed exceeds 1000 rpm for four seconds.
The output shall be used, via a relay connected to +30, to shut off low priority
loads such as fans, heaters and lamps which are not a legal requirement, when
the battery voltage becomes too low. This is to ensure sufficient battery capacity
for starting the engine.
5. Luggage hatch, open

The function warns of open luggage or service hatches.
The function activates a display symbol and the CHECK lamp if the parking
brake is applied. If the parking brake is released the display symbol, buzzer and
STOP lamp are activated.
The function requires the ignition to be on.
6. Safety belt indicator

Pin BB1:6 is an active low input (LDI).
The function lights the “Safety belt” lamp on the instrument panel.
7. Alarm, manual battery isolator

Pin BB1:7 is an active high output (HDO).
The function activates an alarm which warns that the manual battery isolator is
not switched off.
From the factory, this function is connected so that the alarm (Fire Alarm) is
activated when the ignition is switched off and the manual battery isolator is
switched on. The output deactivates the alarm when the ignition and manual
battery isolator are switched on.
44 (92)
8. Washer fluid level low

Pin BB1:8 is an active low input (LDI)
The function lights the “Washer fluid level low” lamp on the instrument panel.
9. Alternator charging
The output is activated when all generators are charging. The function shall be
used for automatic disconnection of heavy loads, such as fans, heaters and the
AC system when the alternator is not charging.
10. Parking brake applied

P The output is activated when the parking brake is applied.

The function can be used to give a warning if the driver leaves the Driver’s
place with the parking brake released, for example.
11. Disconnection of AC compressor

Pin BB1:12 is an active low output. See also BB13:6-7.
The function is used to switch off the AC compressor (Denso) or to reduce
power consumption (Volvo FK40) in situations where the engine needs all avail-
able power for acceleration.
The Denso compressors are started up one at a time by the AC control system
when the signal disappears. The Volvo FK40 compressor runs up to full power
when the signal disappears.
Note that this signal must only be used for temporary disconnection of the
Denso compressors or for temporary disconnection of the FK compressor reduc-
tion valve (if the compressor is equipped with a reduction valve). The signal
must not be used for temporary disconnection of the Volvo FK compressor.
The function is not available on B9L and B9LA.
45 (92)
12. Indoor temperature

The temperature sensor (Volvo part no. 20927970) of NTC type shall be con-
nected between pins BB2:1 and BB2:2 and shall be located in the body by the
body-builder.
The function (optional) is used to show the indoor temperature on the display.
The sensor is enclosed with the chassis when specified with the variant TEM-
PINT/TEMP-INT.
Chassis Body
+5 V
BB2:1
NTC
BB2:2
3-0-25-001
BIC
46 (92)
13. Outdoor temperature

The temperature sensor (Volvo part no. 20927970) of NTC type shall be con-
nected between pins BB2:3 and BB2:4 and be located by the body builder in a
protected but well ventilated position below the driver’s pedals.
The temperature sensor is enclosed with the chassis with the optional TEM-
PEXT or TEMP-EXT specification and the temperature is displayed in the BIC.
When specified with the UTEMPEXT specification, without temperature dis-
play in the BIC, the temperature sensor is not specified unless a Euro 4 engine is
fitted.
3-0-25 R28 Outdoor temperature sensor
• When Euro 4 engines are fitted, the temperature sensor is always enclosed
and must be fitted as information on the outdoor temperature is required by
the EMS ECU
Chassis Body
+5v
BB2:3
NTC
BB2:4
3-0-25-002
BIC
14. Communication link D-bus

Only for buses with Volvo multiplex body electrical system:
Pins BB2:5 (D-CAN H) and BB2:6 (D-CAN L) are intended for connection to
the D-bus control link.
47 (92)
15. Horn
If the horns installed require more then 5A, use a relay.
Chassis Body
Fuse 5 BB2:8
+24 V
BB2:7
Steering wheel
BB2:9
3-0-25-003
Chassis Body
+24 V
Fuse 5 BB2:8
+24 V Fuse
BB2:7
Steering wheel
BB2:9
>5A
3-0-25-029
48 (92)
16. Alarm
The function activates all direction indicators. Compare with pin BB3:5.
If the input is connected to ground, the direction indicators are switched on with
constant lamp. The lamp flashing frequency can be controlled by a pulsed input
signal.
17. Emergency switch

The output is activated when the emergency switch is activated.
The emergency switch stops the engine, switches off the main relay, activates
the hazard warning lamps (provided a relay is installed, see figure below) and
shuts the fuel cut off valve, if installed.
Emergency BB2:11
HDO K
LDI K
BB3:5 chassis 102130
The output can be used for activating security functions in the body, such as
opening the doors and switching on the emergency lamps.
18. Speed signal C6

Connector pin BB2:12 gives a signal of 4 pulses per metre. The function is
intended for the body builders who want to have the information on the destina-
tion sign change automatically. A converter is needed. Note, this function is
only available for buses equipped with a tachograph.
Chassis Body
Converter
BB2:12
≤ 2 mA
3-0-25-020
Tachograph
.
49 (92)
19. Headlamps off

The function turns off the Dipped beam.
20. Prevent ECS action

The function blocks the ECS system so that neither level control, raising, lower-
ing nor kneeling can be done. Any level control, raising, lowering or kneeling
that has been initiated will be brought to an end. Further control is blocked as
long as the Prevent ECS Action is active.
The function can be used with a handicap ramp. The function may then be acti-
vated by a switch on the dashboard or a sensor at the ramp.
21. Kneeling position

Pin BB3:3 is a high active output (HDO).
The output is activated when the vehicle is kneeling.
More precisely the output is activated when a certain solenoid valve in the ECS
system is closed. This solenoid valve is closed when kneeling front left or front
right is started. The output is active as long as kneeling continues. When the
vehicle has returned to normal level the solenoid valve is closed and the output
turns low.
This kneeling indication works for kneeling types involving the left or right side
of the front axle. The indication does not work when the vehicle curtseys on
both left and right sides of the front axle.
The function can be used to activate the door brake when the bus is kneeling. It
can also be used to block door opening at a bus stop before the vehicle is kneel-
ing.
22. Cancel kneeling

The vehicle returns to normal level when the input is activated.
The function can be used to let the bus return to normal level automatically
when the doors are closed, but must not remain with a constant input signal
when the doors are closed.
This function will be discontinued and replaced by an automatic return to nor-
mal level on release of the parking brake and presence of a signal from BB4:9 to
indicate that the doors have been closed. This function will be introduced as a
standard function but it will be possible to disable it by changing a parameter
(HXU) in the BBM ECU.
This change will take effect week 200650 for all chassis apart from those
intended for use with the Volvo body multiplex system. In this case, the change
will take effect week 200711.
50 (92)
23. Hazard warning lamps

The function activates all direction indicators. Compare connector pin BB2:10.
The function can be used for automatic warning when a ramp or lift is in opera-
tion, for example. The hazard warning lamps can also be activated with a switch
on the instrument panel.
24. Daytime running light

Pin BB3:6 is an active high output (HDO)
The output allows the use of separate daytime running lights instead of dipped
beam headlights as daytime running lights. The function will turn on the day-
time running lights when the engine is running and the parking brake has been
released. The signal must be output through a relay.
25. Next stop indicator

The function lights the “Stop” indication lamp on the instrument panel.
The function must be complemented with a holding circuit with reset function.
Chassis Body
+ 24 V
Next stop
function
BB3:7
Instrument cluster 3-0-25-022
51 (92)
26. Pram indicator

The function lights the “Pram” indication lamp on the instrument panel.
The function must be supplemented by a holding circuit with reset function.
Chassis Body
+24v
Instrument cluster
Pram
BB3:8 switch
function
3-0-25-023
27. Starter motor not energised
The output is used to temporarily disengage components that are sensitive to
transients generated when the starter motor is activated.
28. Speed signal C3

A speed sensor is located on the outgoing shaft in the gearbox. The vehicle ECU
processes the sensor signal and sends it on to pin BB3:10.
8.0 - 10.0 V / 150 mA

< 2.5 V 3-0-25-009
t
T
The vehicle speed [km/h] can be expressed as:

t
v = 225 × ---
T
16000
t = ---------------
k
k= number of pulses per km
29. +30 main switch (fuse F12)

The output can be used to shut down body functions when the main current is
switched off.
52 (92)
30. +DR ignition (fuse F29)

Pin BB3:12 is an active high output (HDO)
The output can be used to shut down body functions when the ignition is
switched off. Power supplied during cranking.
31. Glass heating

The function lights the “glass heating” indication lamp on the instrument panel.
32. Host call

The function lights the “host call” indication lamp on the instrument panel.
33. Toilet fluid level

The function lights the “toilet fluid level” indication lamp on the instrument
panel.
34. Toilet occupied

The function lights the “toilet occupied” indication lamp on the instrument
panel.
35. Door failure

The function lights the “door failure” indication lamp on the instrument panel.
36. Door brake, status

Pin BB4:6 is a low digital output (LDO).
The output may control any function when the door brake is active.
37. Door brake, request

The door brake function may be available on vehicles with automatic or I-shift
gearboxes, but not on vehicles with manual gearboxes. This function allows the
brakes to be lightly applied on all wheels.
The door brake has been added to give the driver an extra opportunity to have
the bus lightly braked with the engine running, but without needing to use the
service brake or parking brake. The function must only be used on level ground
(inclination < 5%) when the driver is sitting in the driver’s place. When acti-
vated below 5 km/h, the gearbox drive is disengaged, the engine speed is lim-
ited, and a lamp lights up on the instrument panel.
The door brake demand can be engaged in either of two ways:
- manual switch on instrument panel
- door open signal, see figure 41.
53 (92)
Forced disconnection of the door brake is possible by means of an override

switch in the event of an incorrect input signal, see figure (41). The switch
should be located in the electrical distribution box and be designed to supply an
HDI signal when in the “Off” position to pin BB4:5 in order to light the “Door
Failure” lamp on the instrument panel.
The following criteria have to be complied with to activate the door brake:
• Door brake requested (via connector pin BB4:7 or via data link from Volvo's
multiplex body system)
• Main switch On
• Ignition On
• Engine running
• The door must have been shut once after “Ignition on”. As from production
week 200649, there is no longer a need to shut the door for the door brake to
be activated.
• Vehicle speed < 5 km/h
• ABS mustn’t be active due to slippery roads. As from week 200649, the door
brake can be activated even if the ABS is active when braking.
• Enough air pressure (above level for low pressure warning)
The door brake is deactivated if the following criteria are complied with:
• Door brake not requested
• Gearbox in drive position
• Accelerator pedal moved from idling position
The door brake is also deactivated at:
• Ignition Off
Chassis Body
+24 V
BB4:7
Override
switch
3-0-25-005
EBS
Figure 41
54 (92)
38. Speed signal 5 km/h

The output is activated again when the speed has increased to 6 km/h and is
deactivated when the speed has been reduced to 5 km/h.
The function can be used for blocking doors.
39. Any door open

The function warns of an open door.
The function activates a display symbol and the CHECK lamp if the vehicle
speed is less than 5 km/h. If the speed is higher the display symbol, buzzer and
All switches are to be connected in parallel between the voltage feed and pin
BB4:9, see figure 42
This function is safety related and we recommend the bodybuilders to use this
function. The function requires the ignition to be on.
55 (92)
BB4:8
85 30
1
86 87 87A
10
+24V
85 30
11
2
+24V 1 3 86 87 87A
+24V
2
BB4:5 +24V
85 30
4
86 87 87A
12
+24V
85 30
5
86 87 87A
6
BB4:7
85 30
7
8
86 85 87A
BB4:9
+24V 3-0-25 112
Figure 42 Door brake, principle schedule
1 Relay, for blocking the doors at speeds above 5 km/h (local speed limits
may occur)
2 Switch, for forced disconnection of the door brake
3 Switch, for opening the doors
4 Relay, for opening the doors
5 Relay, for disconnection of the door opening demand
6 Solenoids, for opening the doors
7 Body
8 Relay, Door demand when doors are open
9 Switch, doors open
10 Switch, for closing the doors
11 Relay, for closing the doors
12 Solenoids, for closing the doors
56 (92)
40. Speed signal X km/h

The speed limit setting can be programmed with the VCADS Pro aftermarket
tool. Two parameters are involved in the function. Parameter DHN specifies the
speed limit at decreasing speed, and parameter DHO specifies the speed limit at
increasing speed.
When the speed has decreased to DHN the output is deactivated. The output is
activated again when the speed has increased to DHO.
Pre-set speed limit:
• Standard 20 km/h
• Mexico 100 km/h
According to the European Bus & Coach Directive it must be possible to open
the doors from the outside in case of an accident. The driver is able to block the
emergency opening function at speeds < 20 km/ h. As a legal requirement, the
function must automatically return to default position when the bus reaches 20
km/h again
41. Dimmer dashboard illumination

Pin BB4:11 is a PWM output.
The output is active when the lamp switch is in any of the ON positions.
57 (92)
42. Front lighting
8 6 7
4
2,8
12
10
3-0-25-018
5
7 3
9 11 5 1,7 3
Figure 43 Lighting front part, Terminal pins in body builder connector BB5
Pins Bulb [W] Failure Mode

Lighting Fault code
BB5 (rec.) Identifier (FMI)
1 Dipped beam. Left*) 70 MID 216 PSID 2 FMI 5, 6
2 Dipped beam. Right*) 70 MID 216 PSID 4 FMI 5, 6
3 Dir. indicator, front and side. Left 2 x 21 MID 216 PSID 13 FMI 5, 6, 12
4 Dir. indicator, front and side. Right 2 x 21 MID 216 PSID 14 FMI 5, 6, 12
5 Fog lamps, front 2 x 75 MID 216 PSID 5 FMI 5, 6
6 Additional main beam, relay output MID 216 PSID 7 FMI 4
7 End-outline marker, side marker, 3x5 MID 216 PSID 22 FMI 5, 6

position lamps. Left **)
8 End-outline marker, side marker, 3x5 MID 216 PSID 21 FMI 4

position lamps. Right**)
9 Extra main beam, relay output, left 75 MID 216 PSID 67 FMI 6
hand side
10 Extra main beam, relay output, 75 MID 216 PSID 68 FMI 5, 6

right hand side
11 Main beam. Left*) 75 MID 216 PSID 7 FMI 5, 6
12 Main beam. Right*) 75 MID 216 PSID 12 FMI 5, 6
Table 13: Terminal pins in body builder connector BB5
*) With or without broken bulb diagnostics, refer to table 18.
58 (92)
**) Without broken bulb diagnostics.

Note! Terminal pins with broken bulb diagnostics must be loaded by one bulb,
or a fault code will be set. For a description of Fault codes, refer to BBI 3-0-28.
43. Starter inhibitor, engine hatch

Connector pin BB6:1 is an active low input (LDI).
The function inhibits engine starting from the Driver’s place.
brake is applied. If the parking brake is released, the display symbol for open
engine hatch, the STOP symbol, the buzzer and the STOP lamp are activated.
The engine cannot be started from the Driver’s place if the engine hatch is open.
However, the engine can be started from the engine compartment if the parking
brake is applied. If the engine hatch is opened while the engine is running it will
continue to run.
The function is safety related and the body builder is recommended to always
use it. The function is available on rear engine variants, only. A fault code is set
when the engine is started from the engine room if the function is not connected.
44. Overload information

Overload information is not a standard feature and is available on artic and
biartic buses of the LOADIND variant, only.
The output is used to indicate that the bus is overloaded. The output is activated
when one of the doors is open and an overload has been indicated on at least 2
axles (artic bus) or 3 axles (biartic bus). The output turns low when the doors are
closed, the engine speed exceeds idle, and no overload is indicated.
45. +30 main switch (fuse F54)

Connector pin BB6:4 is an active high output (HDO).
The output can be used to shut down body functions when the main current is
switched off.
46. Luggage hatch, open

Connector pin BB6:5 is an active high input (HDI).
The function warns of open luggage or service hatches.
brake is applied. If the parking brake is released the display symbol, buzzer and
59 (92)
47. Luggage compartment lamp

Connector pin BB6:6 is an active high output (HDO).
The function can be used to switch on the luggage compartment lamp.
48. Reverse warning signal

The output may also be used to control a reverse warning signal used together
with the reversing lamp. The signal must be output through a relay.
49. Rear lighting
6 10
9
5
11
11
3
7
2
3-0-25-019
12 10
10
10
12 2 8 4 1 10
Figure 44 Lighting rear part, terminal pins in body builder connector BB7

Lighting Fault code
1 Stop lamp. Right*) 21 MID 216 PSID 11 FMI 5, 6
2 Reversing lamps*) 2x5 MID 216 PSID 8 FMI 5, 6
3 Direction indicator. Rear left 21 MID 216 PSID 15 FMI 5, 6
4 Direction indicator. Rear right 21 MID 216 PSID 16 FMI 5, 6
5 Additional direction indicator, left 21 MID 216 PSID 70 FMI 5, 6
6 Additional direction indicator, right 21 MID 216 PSID 71 FMI 5, 6
7 Rear position lamp. Left**) 5 MID 216 PSID 23 FMI 4
8 Rear position lamp. Right**) 5 MID 216 PSID 24 FMI 4
9 Side marker and position lamps, 5 MID 216 PSID 72 FMI 6

left**)
10 Side marker and position lamps, 5 MID 216 PSID 72 FMI 6

right**)
11 Stop lamp, left and category S3 21 + LED MID 216 PSID 10 FMI 5, 6
stop lamp*)
12 Fog lamps, Rear*) 2 x 21 MID 216 PSID 6 FMI 5, 6
Table 14: Terminal pins body builder connector BB7

60 (92)
*) With or without broken bulb diagnostics, refer to table 18.

Note! Terminal pins with broken bulb diagnostics must be loaded by one bulb,
or a fault code will be set. Also refer to .
For a description of Fault codes, refer to BBI 3-0-28.
50. Front lighting (Volvo multiplex lighting system)
2 3 1
3-0-25-026
Figure 45 Lighting front part, terminal pins in body builder connector BB8

Lighting Fault code
6 Daytime running light LED MID 216 PSID 76 FMI 4
Tabell 15: Stift karosskontakt BB3

Lighting Fault code
1 End-outline marker lamp. 5 MID 216 PSID 22 FMI 6

Front left**)
2 End-outline marker lamp. 5 MID 216 PSID 21 FMI 3, 4

Front right**)
3 Additional main beam, relay MID 216 PSID 7 FMI 3, 4

output**)
Table 16: Terminal pins body builder connector BB8
61 (92)
Not that BB5:7-8 mustn’t be used if lights have been connected to BB8:1-3.
For a description of Fault codes, refer to BBI 3-0-28.
51. Radio
Connection pin BB10:1 is an active high output (HDO). The output is intended
for remote control of an extra power amplifier giving +12 V when the radio
is on.
Pin BB10:3 is an active high output (HDO) giving +15 supply (12 V).
Pin BB10:5 is an active high output (HDO) giving +30 supply (12 V).
Pin BB10:7 gives ground connection.
Pin BB10:9 GSM mute.
52. Compensation of power and torque losses (Parasitic Losses)

when the AC compressor is connected.
Pins BB1:10 and BB13:1-3 are active high inputs.
The function compensates for torque losses, caused by connecting one or more
AC compressors, to make maximum permissible torque available again. The
function is only available on buses equipped with automatic transmission (Voith
and ZF).
Input BB1:10 registers the signal, which activates the magnetic coupling for the
compressor (Volvo FK or Denso no. 1). Input BB13:1 registers the signal, which
activates the Volvo FK compressor reduction valve (if the compressor is
equipped with a reduction valve). Together with the signal on BB1:10, the sig-
nal entering BB13:1 means that the Volvo FK compressor runs at half power.
Inputs BB13:2 and BB13:3 register the signals which activate the solenoid
clutch for Denso compressor no. 2 and 3.
The EMS and BBM unit software must be parametrised to determine the com-
pressor to be used.
Table 17 shows the connection of the sensor signals.
Connect
Volvo FK40 compressor Denso compressors
or
BB1:10 100% power Compressor no. 1
BB13:1 50% power ---
BB13:2 --- Compressor no. 2
BB13:3 --- Compressor no. 3
Table 17: Connection of sensor signals from the AC compressor
53. Pinch protection

Pin BB13:4 is an active high input.
If the pinch protection is activated when the bus is lowered more than 20 mm,
the bus returns to the suspension height it has before lowering. After 5 seconds
in the lowered position, the pinch protection is no longer activated by the ECS
62 (92)
control unit and the bus is not raised unless the pinch protection is then acti-
vated.
The “Pinch protection” symbol on the instrument panel lights up when the pinch
protection has been activated.
The driver can switch the function off via the menu system in the instrument
panel, and it remains shut off until the ignition is switched off.
54. 7-pin DIN connector on front electrical distribution box

Pins BB14:1-3 (F111 and F110) are intended for small loads which must have
power supply (B+) even when the manual battery isolator is switched off.
Examples of small loads are the clock and alarm, and the control units for the
heating etc. The loads connected to BB14:1-3 must not draw more than 20 mA
together at standstill. F111 and F110 should be given suitably small fuses.
Pins BB14:4-7 (F107-F109) are active high outputs (HDO) and provide +30
supplies when the manual battery isolator is switched on. The output can be
used to shut down body functions when the +30 power supply is switched off.
55. Information link body multiplex

Only for buses with Volvo's body multiplex electrical system.
Pins BMUX:1 (1708 A) and BMUX:2 (1708 B) are intended for connection to
the D-bus information link.
56. External main switch

Only for buses with Volvo's body multiplex electrical system
Pins BMUX:3 and BMUX:4 are intended for an external main switch.
63 (92)
LIGHTING
Lighting switch
Figure 46 Lighting switch
a Lighting off or daytime running light according to the variant chosen

b End-outline marker, side marker, position lamps.
c End-outline marker, side marker, position lamps. Dipped beam / main
beam.
d End-outline marker, side-marker, position lamps. Dipped beam / main
beam and extra main beam.
1 Main lamp switch
2 Indication, front fog lamp
3 Indication, rear fog lamp
4 Dimmer
5 Hazard warning signal
The front fog lamps are switched on/off when the main lamp switch (1) is
pushed inwards. The rear fog lamps are switched on/off when the main lamp
switch (1) is pulled outwards.
64 (92)
Diagnostic direction indicators

The direction indicator telltale lamp flashes at double frequency if a direction
indicator bulb is out of order. This is on condition that the lamps are connected
according to the sketch below. However, extra direction indicator lamps con-
nected to BB7:5 and BB7:6 are not included in the malfunction check.
BB7:6
BB5:4 BB7:4
LCM
BB5:3 BB7:3
BB7:5
3-0-25-006
Figure 47 Diagnostic direction indicators
Trailer lamps
BB7:5 BB7:6 BB7:9 BB7:11 +30 BB7:10
Relay 5A Trailer connector
54R 7 Not connected
54L 6 Side marker right

5A
0 C0 R 5 Direction indicator right
30 4 Stop lamp
L 3 Direction indicator left
C2 2 Side marker left
31 1 GND
cator
Figure 48 Connection of trailer lamps
If the bus is to be made ready for use with a trailer, pins BB7:5 and BB7:6 (extra
indicators) must be connected to a relay which controls the trailer indicators. Pin
BB7:11 (stop lamp) must be connected to a relay which controls the stop lamp.
The indicator tell-tale on the instrument panel only works if the trailer lamps are
connected and the indicator bulbs are intact. If there is no indication when the
trailer lamps are connected, this means that one of the indicator bulbs has failed.
Extra direction indicator lamps (BB7:5 and BB7:6) are not monitored.
65 (92)
Component Part number
Recommended flasher relay for connection 4 JA 005 355-001 (Hella)

to the trailer indicator lamps
Trailer socket 3171185 (Volvo)
Rubber shield 1590568 (Volvo)
Indication lamp 70377190 (Volvo)
Figure 49 Flasher relay
Figure 50 Trailer socket
66 (92)
Lighting control unit, programming

The Light Control Module (LCM) must be programmed to give the desired
functions. It is most efficient to do the programming when the chassis is manu-
factured, by including the desired variant strings in the production order. The
functions can also be adjusted afterwards by using the VCADS Pro or VBEST
tools.
When choosing variant strings in the table (18) do as follows. A variant must
always be chosen from each one of the variant families:
• Dipped beam,
• Main beam (standard),
• Additional main beam,
• Daytime running light,
• Front fog lamp front
• Front fog lamp rear
• Rear lights
• Retarder brake light.
Some combinations are not permissible which is seen in the table.
3-0-25 R29 Vehicle Identification Card (VIC)
• Prior to bodybuilding, the LCM programming must be matched with the
desired lighting configuration, see Vehicle Identification Card delivered with
each chassis. The VIC shows status at time of delivery.
Should the VIC and the LCM programming not match, bodybuilders must con-
tact the local Volvo Bus representative.
Figure 51 Vehicle Identification Card
67 (92)
Can not be
Variant Description Relevant output
combined with
Dipped beam
HL-BASIC Separate headlamps for dipped beam - BB5:1, 2

and main beam. H7 bulb. The dipped
beam and main beam headlamps are
on at the same time in the main beam
position.
HL-HID Xenon headlamps on dipped beam. -

These require high current when
switched on, so the body builders must
fit a relay. No broken bulb diagnostics.
The dipped beam and main beam
headlamps are on at the same time in
the main beam position.
HL-BiHID Bi-Xenon headlamps. These require

high current when switched on, so the
body builders must fit a relay. No
broken bulb diagnostics. The dipped
position.
HL-H4 The dipped beam (H4) is switched off -

when the main beam is switched on.
for bulbs with double filament which
would otherwise become too hot.
Main beam (standard)
HB-BASIC Main beam (halogen) with main beam - BB5:11, 12

flash to pass signalling in the same
lamps.
HB-HID Main beam Xenon with the flash to BB5:11, 12

pass signalling function in the output
for extra main beams. These require BB5:9, 10
high start current when switched on, so
the body builders must fit a relay. No
position.
Table 18: Lighting variants
68 (92)
Can not be
combined with
HB-BiHID Bi-Xenon with the flash to pass

signalling function in the output for
extra main beams. These require high
start current when switched on, so the
body builders must fit a relay. No
position. The main beam may be used
together with the additional main
beams and the flash to pass signalling
function.
HB-HID2 Main beam (Xenon) with the flash to - BB5:11, 12

pass signalling function on the main
beam output. These require high
current when switched on, so the body
builders must fit a relay. No broken
bulb diagnostics. The dipped beam
and main beam headlamps are on at
the same time in the main beam
position.
Additional main beam
DRIVL2 Main beam and additional main beam HB-HID BB5:9, 10, (6)
are both switched on when the lighting
switch main knob is in the “+position”.
Position “d” in figure (24).
DRIVL2EC Main beam is off when additional main HB-HID

beam is on and the main lighting
switch is in the “+position”.
DRIVL-3 Main beam, extra main beam and fog LOWB-DA2 BB5:9, 10 (6)
lamps connected to the fog lamp
output are all switched on at the same LOWB-DA6 BB5:5
time when the lighting switch main
knob is in the “+position”. FOGLF-W
UDRIVL No additional main beams. -
69 (92)
Can not be
combined with
Daytime running light (switched on by engine running)
LOWB-STD No daytime running light function
LOWB-DAY Automatically dipped beam, end- - BB5:1, 2,

outline marker, side marker and
position lamps. BB5:7, 8,
LOWB-DAR Automatically dipped beam with BB7:7, 8, 9, 10

reduced voltage to give about 80%
lower light intensity. Apart from this, the
same as LOWB-DAY.
LOWB-DA2 Front fog lamp, end-outline marker, DRIVL-3 BB5:5,

side-marker and position lamps.
FOGL-FW BB5:7, 8,
FOGL-ME BB7:7, 8, 9, 10
LOWB-DA3 Automatically dipped beam, end- BB5:1, 2,

outline marker, side marker and
position lamps. The dipped beam is BB5:7, 8,
switched off when the parking brake is
applied. BB7:7, 8, 9, 10
LOWB-DA4 For B12B and B9R, only.
Automatic daytime running light

without parking lamp. DRL is switched
off when the parking brake is applied.
LOWB-DA6 Automatic fog lamp without parking BB5:5

lamp
LOWB-DA7 Daytime running light and parking light. AUS-SPEC BB3:6

Engine must be running and the park-
ing brake must be released. A relay is
to be fitted to the output.
LOWB-DA8 Daytime running light. Engine must be AUS-SPEC BB3:6

running and the parking brake must be
released. A relay is to be fitted to the
output.
Front fog lamp (up to and including chassis number 116338)
FOGL-WB Standard DRIVL-3, LOWB- BB5:5

DA2
FOGL-ME Front fog lamps as daytime running -

light without any other lamps.
UFOGLAMP Without front fog lamps. -
70 (92)
Can not be
combined with
Front fog lamp, front (starting with chassis number 116339)
FOGLF-W Fog lamp front LOWB-DA2 BB5:5
DRIVL-3
UFOGLF Without front fog lamps front
Front fog lamp, rear (starting with chassis number 116339)
FOGLR-R Fog lamp rear BB7:12
UFOGLR Without rear fog lamps
Rear lights
TL-BAS Lighting with broken bulb diagnostics, BB7:1, 2, 11, 12

ref. table 14
TL-LED LED lighting without broken bulb

diagnostics, ref. table 14
Retarder brake light
BLA-EC Activates the brake lights at a deceler- BB7:1, 11

ation of 0.60 m/s2.
BLA-NEC Activates the brake lights on activation

of the retarder independent of the
retarder setting.
71 (92)
EXPLANATION OF SIGNAL TYPES
Chassis Body +24 V

+24 V +24 V
A
A
ECU ECU
HDO HDI Chassis Body

+24 V Chassis Body
+24 V +24 V
ECU ECU
3-0-25-004
LDO Chassis Body LDI
Figure 52 Signal types
The arrows in figure (52) indicate the signal type and not the direction of the
flow of current.
Type Description
HDI High Digital Input
The function is activated by +24 V.

HDO High Digital Output
The resistors (A) have a high resistance value. The output gives
+24 V when active.
Note! Current limitation varies between different control units

and output connections.
LDI Low Digital Input
The function is activated when the input is connected to ground.

LDO Low Digital Output
The output provides ground connection when active.
Note! Current limitation varies between different control units

and output connections.
PWM Pulse Width Modulation
In this context, PWM is used for signals which are modulated in

some way.
RES Input intended for sensors with variable resistance.
GND Signal ground
DATA Connection to data link
Table 19: Signal types
72 (92)
RECOMMENDED SWITCHES AND ILLUMINATED PLUGS

Volvo Bus recommends switches and illuminated plugs from Carling Technolo-
gies. The following pages describe a collection of switches, illuminated plugs
and accessories assigned with Volvo part numbers.
Web www.carlingtech.com
World Wide Corporate Carling Technologies, Inc.
Headquarters 60 Johnson Ave
Plainville, CT 06062-1177
860/793-9281
FAX: 860/793-9231
Rocker switches, V-Series Contura V

The removable actuators can be used with any of the rocker switches. All actua-
tors have a laser etched symbol and a bar shaped lens for the indicator lamp.
According to a new international switch standard (ISO 12214), the switch (if
mounted vertically) opens the circuit when the bottom of the switch at the bar
shaped lens is pressed (OFF).The switch closes the circuit when the top of the
switch at the symbol is pressed (ON).
Two (OFF-ON) and three-position (OFF-ON-ON) switches are used. The sec-
ond ON position of the three-position switch is often spring loaded. For exam-
ple, the first ON position may be used for the windscreen wipers and the second
ON position for the windscreen washers.
When the lamps are switched on, a yellow lamp colour is used to illuminate the
switch symbol. A green lamp colour is used for the bar shaped lens to indicate
that the switch is on.
Removable actuators
Figure 53 Actuator design
73 (92)
Actuator removal tool
3.99 [101.35]
TOP
INSERT POINTS UNDER ACTUATOR

.900 [22.86]
HOLD FLUSH ON BRACKET AND PUSH IN
TOP
Figure 54 Actuator removal tool
Description Carling part # Volvo part #
Removal tool VRT 70377144
74 (92)
Figure 55 Removable actuators
75 (92)
Figure 56 Removable actuators, continued
76 (92)
77 (92)
78 (92)
Switches
MATERIAL
TEST CUT
1.450 [36.83]
HOLE IN
ACTUAL
MOUNTING HOLE DIMENSIONS
.830 [21.08]
Figure 59 Switch design
79 (92)
Figure 60 Switches (Lamp 1 refers to the symbol lamp. Lamp 2 refers to the
indicator lamp.)
80 (92)
Figure 61 Switches, continued (Lamp 1 refers to the symbol lamp. Lamp 2

refers to the indicator lamp.)
81 (92)
Connectors for use with Contura V switches
Figure 62 Connectors for use with Contura V switches
Description Carling part # Volvo part #
Connector VC2 70369714
Connector JC1 70377146
82 (92)
Figure 63 Quick connect tab terminals for use with connectors above
Illuminated plugs, VP-Series Contura

The illuminated plugs have one or two oval shaped lenses depending on the
selected housing. The lenses are separate parts and are available with different
symbols.
Figure 64 Illuminated plug design
83 (92)
Figure 65 Indication lamp, components
Figure 66 Terminal pins for connector HP1-01
Figure 67 Indication lamp, lenses 1
84 (92)
Figure 68 Indication lamp, lenses 2
85 (92)
Mounting panel
Both the rocker switches and the illuminated plugs fit the same mounting panel.
The mounting panel can be designed to hold any number of switches. Empty
holes are covered with a mounting panel plug.
3.40[86.5]
2.30[58.4]
.186R[4.72]
VME VMM VME

(END) (MIDDLE) (END)
Figure 69 Contura mounting panel
+.008 +.2
-.000 -.0
2.02 [51.3]
PANEL THICKNESS:
+.008 +.2 TO LERANCE:
TEST CUT -.000 -.0
HOLE IN .062[1.57]
1.90[48.2]
AC TUAL .093[2.36]
MATERIAL .125[3.17]
.187[4.75]
.250[6.35]
.375[9.52]
PANEL OPENING (2) UNITS, SEE NOTE 1
NOTES:
1. FOR ADDITIONAL UNITS, ADD 1.03 [26.2] PER UNIT.
2. FOR MORE THAN 2 V-SERIES SWITCHES, ADD MIDDLE SECTION
Figure 70 Mounting hole dimensions
86 (92)
Figure 71 Contura mounting panel parts
87 (92)
Figure 72 Contura mounting panel plug
Figure 73 Mounting panel (Volvo)
Chassis with variant DASH-BAS have three mounting panels (Volvo) installed
on the instrument panel. The part no is 20563674 (Volvo).
Appendix
The appendix holds information on special vehicle or market specific equipment
and features.
Cable harness for B9 SALF (Brazil)
The B9 SALF is delivered with a cable harness for the side and rear mounted
lamps.
Table 1 lists the BB6 and BB7 connectors with pins and their corresponding
cable harness connectors with pins, see also table 12 for a comprehensive
88 (92)
body-builder connector table. Figure 74 shows the location of the cable har-
ness connectors.
Function Pin Pin, cable harness
+30 main switch (fuse F54) BB6:4 ML3:6, ML4:6
Luggage hatch, open BB6:5 ML3:1, ML4:1
Luggage compartment lamp BB6:6 ML3:2, ML4:2
Stop lamp. Right BB7:1 RL8:1
Reversing lamps BB7:2 RL8:6
RL9:6
Direction indicator. Rear left BB7:3 RL9:2
Direction indicator. Rear right BB7:4 RL8:2
Extra direction indicator. Left BB7:5 RL9:3
Extra direction indicator. Right BB7:6 RL8:3
Rear position lamp. Left BB7:7 RL9:4
Rear position lamp. Right BB7:8 RL8:4
End-outline marker, side-marker lamps. Rear left. BB7:9 ML4:3-5, ML4A:3-5, RL9:5
End-outline marker, side-marker lamps. Rear right. BB7:10 ML3:3-5, ML3A:3-5, RL8:5
Stop lamp, left and Category S3 stop lamps BB7:11 RL9:1
Fog lamps, Rear BB7:12 RL8:7, RL9:7
Table 1: Interface conversion table

8 12345
VECU ML3 ML3A RL8

BBM
EBS
FUEL
ECS
BB 6 7
LCM ML4 ML4A RL9
3-0-25-037
Figure 74 B9 SALF cable harness connectors
School bus warning lights for Australia (AUS-SPEC)

Australian school buses are equipped with alternating flashing wig-wag lights
and headlights to warn oncoming motorists of the presence of school children.
Bodybuilder connectors, inputs and outputs
The signal types are explained in See “Explanation of signal types” on
page 72..
89 (92)
For wiring diagrams, refer to Bodybuilding Instruction 3-0-26 Wiring diagrams

BEA 2, (wiring diagram GB).
School bus warning lamp BB3:5 LDI

switch Normally
used for
external
hazard.
Wig-wag output left BB3:6 HDO

Note!
Must be
output
through a
relay.
Wig-wag output right BB5:6 HDO

Note!
Must be
output
through a
relay.
Normally
used for
additional
high
beam.
Door open/closed BB4:9 HDI
Bulb [W] Failure Mode

Pins Lighting Fault code
(rec.) Identifier (FMI)
BB3:6 Wig-wag relay output right PSID 75 FMI 3, 4
BB5:6 Wig-wag relay output left PSID 74 FMI 3, 4
Table 3: Fault codes
90 (92)
Function description
The two pins used for the wig-wag lights, BB3:6 and BB5:6, are high digital
outputs (HDO).
With the ignition turned on and the light control switch in any position, the wig-
wag lights and the low beam headlamps are activated when the following condi-
tions have been fulfilled:
Activated lamps Switch Speed Door
Wig-wag lamps On 5 km/h or less Any door open
Low beam On ----------------------- Any door open
Table 4: Conditions for activation of wig-wag and low beam lamps
Note! The high beam headlamps cannot be used while the low beam headlamps
and wig-wag lamps are flashing.
The wig-wag lamps and the low beam headlamps are de-activated when one of
the following conditions have been fulfilled:
De-activated lamps Switch Speed Door
Wig-wag lamps Off ----------------------- 25 seconds after

doors closed
Low beam Off 5 km/h or more All doors closed
Table 5: Conditions for de-activation of wig-wag and low beam lamps
Bodybuilders may also choose to control the hazard lamps by means of a pulsed
signal (connected to BB2:10).
The power to the wig-wag lamps must be output through a relay controlled by
BB3:6 and BB5:6, respectively, for the wig-wag lamps to function.
Function coordination
The wig-wag lamps are not synchronised with the hazard lamps.
The school bus warning lamps have higher priory than all other lamps.
Fog lights cannot replace low beam headlights as school bus warning lights.
Requirement list
Requirement
number Requirement heading Page
3-0-25 R01 Data links 3
3-0-25 R02 Control units and other sensitive components 3
3-0-25 R03 Installation of control units during body building. 3
3-0-25 R04 Cable harness and connectors 3
3-0-25 R05 Location, electrical distribution unit 4
3-0-25 R06 Fuse exchange, chassis number 117113 - 112575 13
3-0-25 R07 Location, batteries 14
91 (92)
3-0-25 R08 Diagnostic connector 16

3-0-25 R09 Adapter cable with transient protection for LCM 18
3-0-25 R10 Relay for body functions 18
3-0-25 R11 Location of the outside temperature sensor 19
3-0-25 R12 Checking outside temperature sensor reading 20
3-0-25 R13 Strapping of cables 25
3-0-25 R14 Excess electrical cables 27
3-0-25 R15 +Bat, +30 and GND terminals 28
3-0-25 R16 Ground cables 28
3-0-25 R17 Heavy loads 29
3-0-25 R18 Installation of electrical distribution box 31
3-0-25 R19 Removal and re-installation of battery isolator knob 31
3-0-25 R20 Clamping of 70 mm2 and 90 mm2 cables 32
3-0-25 R21 Max. permissible current drain from the electrical distribution box 33
3-0-25 R22 Connection of AC fans 33
3-0-25 R23 Connection of small loads 33
3-0-25 R24 Connection of 12 V equipment 33
3-0-25 R25 Tightening torque 33
3-0-25 R26 Max. permissible current drain from the electrical distribution box, B7R and
B7RLE 37
3-0-25 R27 Blinking frequency 37
3-0-25 R28 Outdoor temperature sensor 47
3-0-25 R29 Vehicle Identification Card (VIC) 67
92 (92)

Electrical System BEA2

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Volvo Bus Corporation

Electrical system BEA 2

c3-0-25Electrical system BEA 22007-04-11

435 B12B / B12BLE, B12M / B12MA

451 B7R / B7RLE, B9R, B7TL

509 B7L, B7LA

633 B9TL 4x2

650 Pre-series B9TL 6x2

Buses and coaches 3 0 25 2007-04-11

Buses and coaches 3 0 25 2007-04-11

ELECTRICAL SYSTEM BEA 2

Type of link Colours

Information link J1708/1587 Gray/orange

Control link J1939-1 Green/yellow

Kontrollänk J1939-2 Green/yellow

Kontrollänk J1939-3 Blue/black

Kontrollänk J1939-7 Blue/mauve

Kontrollänk Volcano Brown/pink

Buses and coaches 3 0 25 2007-04-11

TRANSPORT MOUNTED EQUIPMENT

Buses and coaches 3 0 25 2007-04-11

BB7 IB1 IB2 IB3 IB4 IB5

BB5 BB4 BB3 BB2 BB1

Figure 1 Main electrical distribution unit

Buses and coaches 3 0 25 2007-04-11

PCB Fuse Amp Part No Function

F3 F3 15 969162 Start Motor

F6 F6 5 969160 Parking brake release, emergency

F7 F7 15 969162 Gearbox ECU I-Shift

F8 F8 5 969160 Gear selector I-Shift

F9 F9 5 969160 Switchbox start/stop rear. Solenoid oil

F10 F10 5 969160 Fire alarm

F11 F11 10 969161 Dynafleet

F12 F12 5 969160 Body +30

F13 F13 10 969161 Spare

F14 F14 5 969160 BBM

F15 F15 15 969162 EECU

F16 F16 5 969160 VECU

Table 1: FH1, electrical distribution unit 20394200, version 2

FH1 KH1 FH2 KH2 FH3 KH3 FH4

Buses and coaches 3 0 25 2007-04-11

PCB Relay Relay No Part No Function

K1 K1 1078690 VECU / EECU

K2 K2 1078690 Inverted +15

Table 2: KH1, electrical distribution unit 20394200, version 2

FH1 KH1 FH2 KH2 FH3 KH3 FH4

Buses and coaches 3 0 25 2007-04-11

PCB Fuse Amp Part No Function

F1 F17 5 969160 LED feed, dashboard switches.

F2 F18 5 969160 Alternator

F3 F19 10 969161 Hymer

F4 F20 10 969161 EBS

F5 F21 15 969162 Wiper, Washer

F6 F22 10 969161 Diva 5, Ecolife

F7 F23 5 969160 ACC

F8 F24 5 969160 BIC2

F9 F25 15 969162 Washer motor