Volvo Trucks North America

Greensboro, NC USA

D
Date

Service Bulletin Trucks

Group No. Page

11.2006

352

09

1(17)

Headlamps VNM VNM VERSION2 From build date 11.2002

Headlamps

W8003218

Contents Special Tools page 2 Headlamp, Adjustment page 3 Headlamp Lens, Replacement (One) page 14 Headlamp Bulb, Replacement (One) page 16

PV776-20177492

USA23178.ihval

Volvo Trucks North America Service Bulletin

Tools
Special Tools

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Date 11.2006

Group

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Page 2(17)

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J-25300D Hoppy Headlamp Aiming Kit

Volvo Trucks North America Service Bulletin

Service Procedures
3521-05-02-01 Headlamp, Adjustment VNM Headlamps
Note: The following procedure describes headlamp adjustment using the Hoppy B4A Suction Cup Headlamp Aiming Kit. Use of the Hoppy Headlamp Aiming Kit is the recommended method for aligning VNM headlamps. Vehicle Preparation Before beginning the headlamp aiming process, prepare the vehicle as follows:

Date 11.2006

Group

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Page 3(17)

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DANGER
PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. 1 Drive the vehicle onto a flat surface. It is not necessary that this surface be exactly level. 2 Remove any large amounts of mud or ice from the underside of the fenders. 3 Check whether tires are noticeably deflated and inflate if necessary. 4 See that there is no load in the vehicle other than the driver. 5 Rock the vehicle to equalize the springs. Check them for sag or broken leaves. 6 Make sure the cab suspension and the Volvo air suspension are fully inflated and that the air system pressure is 620 kPa (90 psi) or higher.

Volvo Trucks North America Service Bulletin

7 Clean the headlamp lenses and aiming pads.

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CAUTION

Some solvents and cleaners will attack and/or weaken the components of the B4A aimer. Thoroughly dry any object which has been cleaned with a solvent before attaching an aimer to it.

8 Check for bulb burnout, broken aiming pads, and proper beam switching. 9 Check to ensure that the hood is closed completely, and latched on both sides.

Volvo Trucks North America Service Bulletin

Floor Slope Calibration

Note: The headlamp aimers will not work correctly unless floor slope is taken into account. Calibration of floor slope should be done prior to aiming. However, if you regularly use one area to aim headlamps, rechecking floor slope is unnecessary. Permanently mark the area, calibrate slope for that area, and mark the setting for future reference.

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1 2 3 4 5 6 7 8 9

Date 11.2006

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W3002348

B4A Aimer Unit Piston Handle Level Vial Bubble Top Port Hole Unit Identification Horizontal Aim Port Hole Horizontal Aim Knob Vertical Aim Knob Vertical Aim Vial Floor Level Dial

1 Attach Calibration Fixtures to aimers. The fixtures will easily snap into place when properly positioned.

W3002349

1 Thumb Adjusting Screw

Volvo Trucks North America Service Bulletin

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Date 11.2006

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W3002350

Fig. 1: Floor Calibration (on passenger side only)

1 2 3 4 5 6 7 8 Unit A (rear tire) Unit B (front tire) Calibration Fixture Thumb Adjusting Screws Level Vial Bubble Top Port Hole Horizontal Knob Floor Level Dial

Place aimers at the center line of each wheel on the passenger side of the vehicle. Unit B must be placed at the front wheel on the passenger side with the target facing to the rear. Unit A must be placed at the rear wheel on the passenger side with the target facing front. 3 Level each unit by turning the thumb adjusting screw on each calibration fixture. Turn the screw either clockwise or counter-clockwise until the level vial bubble registers in a centered, level position.

Volvo Trucks North America Service Bulletin

W3002344

Date 11.2006

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4 Look into the top port hole of Unit A. Turn horizontal knob until the split image is aligned.

5 Transfer the plus or minus reading indicated on the horizontal dial to the FLOOR LEVEL DIAL on each aimer (press floor level dial inward to set reading).

W3002359

1 Horizontal Dial 2 Floor Level Dial

6 Remove calibration fixtures from the aimers.

Adaptor Assembly
1 Locate the correct parts needed to assemble the aimer for use on VNM headlamps. For aiming headlamps on a VNM series truck, always use the large adjustable black adaptors supplied with the Headlamp Aiming Kit. The adaptors will be attached last.

W3002345

1 2 3 4 5 6 7

Articulating Vacuum Cup Assembly O-Rings Extension Studs Vacuum Extension Plate Large Universal Adaptor Fixed Vacuum Cup B4A Aimer

Volvo Trucks North America Service Bulletin

2 Attach the vacuum extension plate assembly (1) to the fixed vacuum cup (2) on the B4A aimer. The fixed cup should be fully extended.

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W3002347

3 Squeegee the fixed cup into the round hole in the back of the vacuum extension plate.

W3002395

1 Vacuum Extension Plate 2 Fixed Vacuum Cup

4 Attach an extension stud (3) to the vacuum cup assembly. The threaded stud fastens between the vacuum cup extension plate (4) and the articulating vacuum cup assembly (1). The stud must be seated firmly against the O-ring (2) in the vacuum cup extension plate. Note: The B4A aimer kit includes 2 extension studs that can be placed between the vacuum cup extension plate and the articulating cup assembly. When using the aimer on the headlamps of the VNM Series trucks, only one extension is needed.
W3002351

1 2 3 4 5

Articulating Vacuum Cup O-rings Extension Stud Vacuum Cup Extension Plate Fixed Vacuum Cup

5 Install the articulating vacuum cup assembly onto the extension stud, making sure the O-ring is seated firmly against the vacuum cup. 6 Attach the large black adaptor to the B4A assembly.

Volvo Trucks North America Service Bulletin

Attaching the Aimer

Date 11.2006

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1 Note: For aiming headlamps on a VNM series truck, always use the large adjustable black adaptors supplied with the Headlamp Aiming Kit.

W3002361

Fig. 2: Attaching the B4A aimer 2 Align the large universal adaptor to the aiming pads on the lens (as shown in Figure 2). Note the numbers located on the pads of the lens. Move the adjustment rod for each pad until it agrees with the number located next to the pad. This procedure should be followed for the passenger side and driver side adaptors. 3 To adjust the adaptor rods to the required position, turn the rods to the neutral position and slide in or out to the proper setting.

W3002346

1 Neutral Position 2 Odd Number 3 Even Number

Volvo Trucks North America Service Bulletin

4 Turn the rod clockwise to lock in an odd number, and counter clockwise to lock in an even number. 5 Attach each aimer to the headlamps by pushing the piston handle forward, engaging the rubber suction cup. Immediately pull back the piston handle until it locks in place.

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W3002354

1 Piston Handle 2 Vacuum Release Button

6 Unit A should be attached to the drivers side headlamp, and Unit B to the passenger side. The sight openings on each aimer must face each other.

W3002372

1 2 3 4 5 6 7

Unit B Unit A Sight Openings Viewing Port Horizontal Dial Vertical Dial Level Bubble

Volvo Trucks North America Service Bulletin

Adjusting Headlamp Aim

Horizontal Aim
1 Note: For the VNM Series trucks, the horizontal and vertical headlamp screws must be adjusted from behind the headlamp. Due to the sensitivity of the aimer, adjustments must be made with the hood closed and secured. Adjustments to the headlamp screws must be made from under the hood. It is recommended that one person check alignment of the split image while another makes adjustments to the headlamp screws.

Date 11.2006

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W3002343

2 To set the horizontal aim (side to side), the horizontal dial should be set at zero.

W3002371

1 Viewing Port 2 Horizontal Dial

3 Check to see that the split image target lines are visible in the viewing port. If necessary, rotate each aimer slightly to locate the target. 4 Using an inverted torx socket, size E7, turn the horizontal adjusting screw located on the back of the headlamp.
W3002352

Volvo Trucks North America Service Bulletin

5 Turn the horizontal screw until the split image of the target line appears in mirrors as one solid line. To remove backlash, make final adjustment by turning screw clockwise.

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W3002370

6 Repeat these steps with the opposite aimer and headlamp.

Vertical Aim
7 The vertical dial should be set at zero.

W3002360

1 Level Bubble 2 Vertical Dial

Volvo Trucks North America Service Bulletin

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W3002369

Date 11.2006

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8 Turn the vertical adjusting screw behind the headlamp until the level of the bubble is centered between the lines. To remove backlash, make final adjustments by turning the screw clockwise.

9 Repeat the last two steps with the opposite aimer and headlamp. 10 Recheck target alignment on both aimers and readjust horizontal aim if necessary. 11 Remove the aimer by holding it securely and pressing the Vacuum Release button located on the piston handle.

W3002354

1 Piston Handle 2 Vacuum Release Button

Volvo Trucks North America Service Bulletin

3522-03-02-01 Headlamp Lens, Replacement (One)

DANGER

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Date 11.2006

Group

No.

Page 14(17)

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PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death.

Removal
1 Remove the dust cover from the headlight assembly.

W8001104

2 Remove the headlight bulb socket from the headlight lens assembly.

W8001126

3 Remove the nine headlight retaining screws and the headlight lens assembly.

Volvo Trucks North America Service Bulletin

Installation

Date 11.2006

Group

No.

Page 15(17)

352

09

1 Install the new headlight lens assembly into the hood, and align the adjuster screws through the hood. Install and tighten the nine retaining screws. 2 Install the headlight bulb socket assembly and reinstall the dust cover.

Volvo Trucks North America Service Bulletin

3511-03-02-01 Headlamp Bulb, Replacement (One)

1 unit, excludes headlight adjustment

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Date 11.2006

Group

No.

Page 16(17)

352

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DANGER
Before working on a vehicle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. 1 Remove the dust cover from the rear of the headlight assembly.

W8001104

2 Disengage the lock and remove the terminal connector from the bulb assembly.

W3004382

3 Turn the lock ring counter-clockwise to disengage, and pull out the bulb assembly.

Volvo Trucks North America Service Bulletin

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W3004383

Date 11.2006

Group

No.

Page 17(17)

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4 Note: Do not touch the replacement bulb glass with fingers or allow the glass to be contaminated. Failure to keep the glass clean will shorten its service life. Carefully remove the replacement bulb from the box. Use caution not to touch the bulb glass. Properly align the mounting tabs and install the bulb assembly into the socket. Push in until it is fully seated. Install the lock ring.

5 Install the terminal connector. Check that the locking tab is secure. 6 Install the dust cover.