PV776-TSP155509

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Service Manua

Trucks

Group 39350

TV/Video System

VN

PV776-TSP155509

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Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to June 2001.

The products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair methods.When this is believed to have a significant bearing on this manual, supplementary ser-

vice bulletins will be issued to cover the changes.

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave the vehicle or component function in the manner intended.

Caution: Indicates an unsafe practice where damage to the product could occur.

Warning: Indicates an unsafe practice where personal injury or severe damage to theproduct could occur.

Danger:Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP155509

2001 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in

retrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior written

permission of Volvo Trucks North America, Inc..

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Contents

General .................................................................................................... 3

General Information ................................................................................. 3

Tools ........................................................................................................ 5

Standard Tools ....................................................................................... 5

Design and Function ............................................................................. 6

TV/Video System ..................................................................................... 6

TV Mounting ........................................................................................ 6

TV Antenna ......................................................................................... 6

TV Speaker and Headphone Jack ...................................................... 8

Cable/Modem ...................................................................................... 9

Troubleshooting ................................................................................... 11

TV Antenna Troubleshooting ............................................................... 11

TV Speaker and Headphone Jack Troubleshooting ............................ 11

Service Procedures ............................................................................. 13

TV Antenna, Replacement .................................................................. 13

VN 610 .............................................................................................. 13TV Antenna, Replacement .................................................................. 16

VN 660 .............................................................................................. 16


VN 770 .............................................................................................. 22


VN 770 With Integrated Headliner ................................................... 34

TV Speaker/Headphone Jack, Replacement ...................................... 46

Feedback

Operation Numbers

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2

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Group 3 TV/Video System Gene

General

General Information

W3004

1 TV Antenna

2 TV/VCR

3 A/B switch

4 TV speaker5 Headphone Jack

6 Phone/Modem connection

7 Cable/Modem connection

The Volvo VN 610, 660 and 770 series vehicles may be equipped with various audio/video system prep kits to en-hance the use of driver supplied TV and /or VCRs. The kits may include:

Secure mounting provisions for the TV.

A TV Antenna hidden beneath the bunk headliner.

Remote TV speaker.

Cable TV and phone/modem connection for use when parked.

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4

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Group 3 TV/Video System Too

Tools

Standard Tools

Digital Multimeter (DMM)The Fluke 87 digital multimeter (P/NJ-39200) is availablefrom Volvo Parts or Kent-Moore at 18003286657.

W2001014

Trim Pad RemoverThe trim pad remover (P/NJ-38778) is available fromVolvo Parts or Kent-Moore at 18003286657.

W0001505

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Group 3 TV/Video System Design and Functi

In 770 vehicles built before June 2000, the televisionantenna is a flexible grid type antenna and is inter-grated into the center bunk headliner. A coaxial cableextends from the antenna in the bunk headliner andruns behind the cabinets on the passenger side. It isconnected to a television, located on the middle shelfof the cabinet on the passenger side.

W3004005

VN 770 TV Antenna (in vehicles built prior to June 2000)

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Group 3 TV/Video System Design and Function

TV Speaker and Headphone Jack

The VN 770 may be equipped with an optional remoteTV speaker and headphone jack, located in thesleeper control panel. If a headset is plugged into the

jack, the speaker will be muted. VN 770 vehiclesequipped with thePark and Viewoption will alsohave a phone/modem jack included in the sleeper

control panel.

W3004829

1 TV Speaker

2 Headphone Jack

3 Phone/Modem Jack

8

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Group 3 TV/Video System Design and Functi

Cable/Modem

The cable/modem prep kit is installed as an option to allow access to a phone/modem line and cable TV when parkeat truckstops, which provide that service.

W3004830

A receptable plug is installed into the air fairing on the drivers side of the vehicle to connect the phone/modem andcable TV line.

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Group 3 TV/Video System Design and Function

W3004831

VN 610

1 A/B Switch

2 To Cable

3 To TV

4 To Antenna

An A/B switch is mounted near the TV to select cable orthe vehicle antenna. Press A for Antenna. Press B forCable TV service from outside source.

A connector for a phone or modem is provided in thebunk control panel. (Note: For location in VN 770, seesection on TV Speaker and Headphone Jackpage 8.

W3004832

1 Phone/Modem Jack VN 610, 660 shown.

10

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Group 3 TV/Video System Troubleshooti

Troubleshooting

TV Antenna Troubleshooting

Suspected fault with the TV antenna assembly.Check the following:

1 TV - Connect the TV to a known working signalsource, such as a home cable TV coaxial. If recep-tion improves, the TV is unlikely to be at fault.

2 TV Antenna - Obtain a TV test antenna. Connectthe test antenna to the TV with the TV mounted inits normal location. Position the test antenna at theapproximate mounting location of the existingantenna. If reception improves, the TV antenna as-sembly is probably faulty.

Note:Note: Volvo P/N 20357698, (ribbon type TVantenna) may be used as a test antenna.

Note:Note: For more accurate testing, the vehicleshould be outside and away from any sources ofelectrical interference.

3 If it is determined that the antenna assembly isfaulty, check for proper connections at the coxial cble ends before replacing.

TV Speaker and Headphone Jack Troubleshooting

Note:The TV speaker and headphone jack must beconnected to a TV with remote speaker capability in or-der for it to function correctly.

Suspected fault with the TV speaker and head-phone jack assembly. Check the following:

1 Remove the bunk control panel to access thespeaker/jack assembly.

2 Visually inspect for obvious damage such as a torncone or faulty wiring connectors. Repair/replace asneeded.

3 Check the resistance value of the speaker with amultimeter. The specified resistance value is usuaprinted on the speaker.

4 Check the AC voltage at the A and B (+ and -)speaker terminals with a multimeter. With the TV oa small AC voltage should be present and increasproportionately with increases in the TV volumecontrol. If not correct, check the TV or wiring andconnections between the TV and speaker/jack as-sembly.

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Group 3 TV/Video System Troubleshooting

5

W3003097

The speaker may be tested with a 1.5 volt flashlight" battery by connecting one speaker terminal to the battery

negative post and momentarily touching the other speaker terminal to the positive post. The speaker should pro-duce a popwhen connected. If the speaker contains a capacitor, it will only poponce. Do not leave the batteryconnected.

12

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Group 3 TV/Video System TV Antenna, Replaceme

Service Procedures

3935-03-02-02TV Antenna, Replacement

VN 610

Before working on a vehicle, set the parking brakes,place the transmission in neutral and chock thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-

jury or death.

Removal

1Remove the mattress from the vehicle.

2

W8002514

Remove the upper right TV cabinet asfollows:Remove the TV support plate by re-moving the screws (1). Unplug theinterior light and power supply connec-tor (2). Remove the 4 wall mountingbolts (3). Remove the cabinet from thevehicle.

3

W8002513

Remove the upper left cabinet as fol-

lows:Remove the interior light connectorcover plate (1), with its 3 screws andunplug the light connector. Remove themounting screw covers and removethe 8 wall mounting bolts (2), includingthe one to the lower bunk tether (3).

4

W8002490

Remove the bunk curtain rail assem-bly.

5Remove the bunk headliner speakersas follows:Remove the speaker cover, the 4screws and finally disconnect the con-nector on the back.

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Group 3 TV/Video System TV Antenna, Replacement

6

W8002459

Remove the bunk headliner overheadlamp assembly. Disconnect the con-nector.

7Remove the right upper trim panel asfollows:

Remove the right lower bunk restrainttether bracket. Separate the interlockfasteners at the top to allow the trimpanel fold down.

Note:The panel doesnt have to becompletely removed. Its enough if it

just falls down a bit.

8Remove the 2 coat hooks from thecenter rear wall trim panel. Separatethe interlock fasteners at the top to al-

low the trim panel to be pulled back forremoval of the top rear wall trim panel.

9Remove the top rear wall trim panel asfollows:Remove the 2 snap covers andscrews.Separate the Velcro fasteners and re-move the panel from the vehicle.Use caution not to tear the panelaround the rear window seal.

10Remove the bezels around the left andright overhead storage bins over theseats.

11

W8002515

Remove the bunk headliner as follows:Remove the 2 Christmas tree fasten-ers and separate the interlockingfasteners as necessary.

Carefully work the bunk headliner outfrom under the front headliner andaway from the rear wall trim.Remove it from the vehicle. Use cau-tion not to crease the headlinermaterial.

12Note the position of the TV antennaassembly to be able to install the re-placement antenna correctly.Pull down gently on the front headlinerand pull back the vinyl tape as neces-sary to free the TV antenna and

remove it from the vehicle.

Installation

1Position the replacement TV an-tenna/coaxial cable into the propermounting location. Secure it with vinyltape.

2Carefully work the bunk headliner un-der the front headliner and behind therear wall trim. Secure with interlockand Christmas tree fasteners. Usecaution not to crease the headlinermaterial.

Note:Two people are required for thisstep.

3Install the bezels around the left andright overhead storage bins over theseats.

14

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4Install the top rear wall trim panel asfollows:Work the panel into position behindthe top of the center wall trim panel.Install the snap screws and covers.Engage the Velcro fasteners.Work the rear window seal around the

panel.

5Engage the interlock fasteners on thecenter rear wall trim panel. Install the2 coat hooks and torque the screws to3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb).

6Install the right upper trim panel as fol-lows:Work the interior light wiring throughthe panel.Position the panel and engage the in-terlock fasteners.Install the right lower bunk restrainttether bracket. Torque the bolt to 24 4 Nm (18 3 ft-lb).

24 4 Nm(18 3 ft-lb)

7

W8002459

Connect the bunk headliner overheadlamp connector and install the lamp.Torque the screws to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

8Install the bunk headliner speakers asfollows:Connect the connector on the backand install using the 4 screws. Torqueto 3 0.5 Nm (27 4 in-lb).Install the cover.

3 0.5 Nm(27 4 in-lb)

9

W8002490

Install the bunk curtain rail assembly.Torque the screws to 5 1 Nm (44 9inlb).

5 1 Nm(44 9 inlb

10

W8002513

Install the upper left cabinet as follows:Insert the interior light wiring throughthe cabinet access hole.Position the cabinet and install themounting bolts (2). Torque to 24 4Nm (18 3 ft-lb).Install the left lower bunk restrainttether bracket with spacer (3). Torqueto 24 4 Nm (18 3 ft-lb).

Install the lower bolt trim covers.Connect the light connector and installthe light connector cover (1). Torque to3 0.5 Nm (27 4 in-lb).

24 4 Nm(18 3 ft-lb)24 4 Nm(18 3 ft-lb)3 0.5 Nm(27 4 in-lb

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11

W8002514

Install the upper right cabinet as fol-lows:Insert the power supply and coaxialcable through the upper cabinet ac-

cess hole. Insert the light wire throughthe lower access hole.Install the 4 wall mounting bolts.Torque to 24 4 Nm (18 3 ft-lb).Connect the interior light and powersupply connector.Install the TV support plate. Torque the6 screws to 5 1 Nm (44 9 inlb).

24 4 Nm(18 3 ft-lb)5 1 Nm(44 9 inlb)

12Install the mattress in the vehicle.


VN 660


jury or death.

Removal

1Remove the mattress from the vehicle.

2Remove the upper right tower cabinetby removing the bolt and spacer be-tween the upper and lower cabinet.Then disconnect the power supplyconnector. Remove the 4 wall mount-ing bolts and remove the cabinet fromthe vehicle.

3

W8002490

Remove the bunk curtain rail assem-

bly.

Note:The curtains do not need to beremoved from the rail.

4Remove the upper bunk mountingbolts and remove the bunk from thevehicle.


16

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5

W8002457

Remove the upper bunk restraint byremoving the 2 bolts.

6Remove the rear wall interior trimpanel. It is held in place with Christ-mas tree and interlocking fasteners.Disengage fasteners and remove thepanel from the vehicle.

J-38778

7

W8002459

Remove the overhead lamp assemblyfrom the center rear headliner. Discon-nect the electrical connector.

8

W80024

Remove the 2 trim strips on each sideof the center bunk headliner.

9Remove the center bunk headliner. Itis held in place by Christmas tree andinterlocking fasteners. Disengage fas-teners and remove the panel from thevehicle.

J-38778

10

W8002456

Remove the right side upper bunksupport by removing the 2 screws tothe cover and the 2 screws to the

striker plate.

11Remove the right side lower bunk re-straint tether bracket.

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12

W8002930

Remove the right side center trimpanel as follows:Remove the front curtain rail from the

first 2 right side clips to allow removalof one panel bottom mounting screw,nylon spacer and curtain rail mountingclip (1).Remove one forward mounting screwwith curtain hold-back snap fitting.

13

W8002462

The panel is now held in place withChristmas tree and interlocking fasten-ers.Disengage fasteners and remove the

panel from the vehicle.

J-38778

14

W8002458

Remove the right side bunk windowtrim bezel.

15Remove the speaker assembly fromthe right side bunk headliner panel asfollows:Remove the speaker cover, removethe 4 screws and finally disconnect theconnector on the back.

16The right side bunk headliner panel isheld in place with an upper trim

support piece and Christmas tree fas-teners.Remove the panel as follows:Disengage fasteners, pull the wires outthrough the cut-out and remove thepanel from the vehicle.

J-38778

18

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17

W8002460

Note the position of the TVantenna/coaxial cable to aid in installa-tion.Pull back the vinyl tape securing theantenna and remove the antenna fromthe vehicle.

Installation

1

W8002460

Install the replacement TV an-tenna/coaxial cable into the propermounting position. Secure with thevinyl tape.

2Install the right side bunk headlinerpanel as follows:Place the panel in position and insertthe power supply and coaxial cablethrough the cut-out in the panel. Work

the panel behind the overhead storagecabinet and under the front headliner.After positioning the panel, install theupper trim support piece and secureall with Christmas tree fasteners.


3Install the speaker in the right sidebunk headliner panel as follows:Connect the connector on the back,install the speaker and torque the 4screws to 3 0.5 Nm (27 4 in-lb).Install the speaker cover.

3 0.5 Nm(27 4 in-lb

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4

W8002458

Install the right side sleeper windowtrim bezel. Torque the screws to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

5

W8002930

Install the right side center trim panelas follows:Note the position of the Christmas treeand interlocking fasteners.At the bottom of the panel, install themounting screw, nylon spacer and cur-tain rail mounting clip (1) through thehole in the panel trim material. Torqueto 5 1 Nm (44 9 in-lb).

Tuck the excess trim material underthe bottom edge of the panel. Installthe forward mounting screw with cur-tain hold-back snap fitting. Torque to 3 0.5 Nm (27 4 in-lb).Snap the front curtain rail into themounting clips.

5 1 Nm(44 9 in-lb)3 0.5 Nm(27 4 in-lb)

6Install the right side lower bunk re-straint tether bracket. Torque the boltto 24 4 Nm (18 3 ft-lb).

24 4 Nm(18 3 ft-lb)

7

W8002456

Install the right side upper bunk sup-port cover and striker plate. Torque thescrews to 10 1.5 Nm (7 1 ft-lb).

10 1.5 Nm(7 1 ft-lb)

8Install the center bunk headliner andsecure with Christmas tree and inter-locking fasteners.

9

W8002461

Install the 2 trim strips on each side ofthe center bunk headliner.

20

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10

W8002459

Connect the electrical connector forthe center bunk overhead lamp as-sembly, and install. Torque the screwsto 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

11

W8002455

Install the rear wall interior trim panelas follows:First pull back the rear section of theleft and right center trim panels (thiswill aid in installation).Noting the position of the Christmastree and interlocking fasteners, posi-tion the rear wall trim panel high on

the rear wall. Slide the panel down thewall and behind the lower trim panelAND behind the left and right centertrim panels.After the panel is properly positionedsecure with the Christmas tree and in-terlocking fasteners.


12

W8002457

Install the upper bunk safety restraint.Make sure the latch is on the righthand side. Torque the bolts to 68 7Nm (50 5 ft-lb).

68 7 Nm(50 5 ft-lb)

13Install the upper bunk by first securingthe hinge bracket upper bolts. Torque

to 24 4 Nm (18 3 ft-lb).Then secure the hinge bracket withthe upper bunk restraint using thelower bolt. Torque to 68 7 Nm (50 5 in-lb).


24 4 Nm(18 3 ft-lb)

68 7 Nm(50 5 in-lb

14Install the sleeper curtain rail assem-bly. Torque the screws to 5 1 Nm (44 9 in-lb).

5 1 Nm(44 9 in-lb

15Install the upper right tower cabinet bylifting the cabinet into position and in-serting the power supply wiring andcoaxial cable. Fit the cabinet over theHVAC duct at the rear of the cabinet.Install the 4 wall mounting bolts andtorque to 68 7 Nm (50 5 ft-lb).Install the through bolt and spacer be-tween the upper and lower cabinet.Torque to 12 2 Nm (106 18 in-lb).

68 7 Nm(50 5 ft-lb)12 2 Nm(78 1.5 ft-l

16Install the mattress in the vehicle.

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VN 770


jury or death.

Removal

1Remove the lower mattress/work sta-tion cushions from the vehicle.

2

W8002490


3

W8002928

Remove the following in both the rightand left sides:

Remove the shoulder harness mount-ing bolts (1).Pull back the upper rear of the doorseal to loosen the B pillar trim.Gently pull back the B pillar trim andremove the Christmas tree fastener (2)to the upper tower cabinets.

Note:Use caution not to crease thetrim panel.

J-38778

4Remove the bunk ladder assembly (if

equipped).

22

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5

W8002176

Remove the 4 bunk windowstrimbezels. There are 10 screws to be re-moved for each windows trim bezel.

6

W8002177

Remove the torx screws holding thecabinet below the lower right bunkwindows.

7

W8002178

Remove the 6 torx screws holding theducting from the bunk HVAC unit tothe right bunk fascia panel.

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8

W8002180

Remove the duct hose in the upperright tower cabinet from the right bunkfascia panel.

9Pull back the lower right trim panel toexpose the lower right bunk fasciapanel mounting screws. This panel issecured with Christmas tree and/or in-terlock fasteners.

J-38778

10

W8002179

Remove 5 torx screws, 3 along the topand 2 behind the trim panel, mountingthe vent fascia to the wall.Remove the eight nuts from the plasticstuds.Remove the fascia panel from itsmounting location and remove it fromthe vehicle.

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11

W8002492

Remove the upper right tower cabinetas follows:Remove any objects stored in the cab-inet.Unplug the power supply connectors.Remove the 5 bolts from the rear bot-tom wall (2).Remove the 8 bolts between the upperand lower cabinet (1).Pull the upper front trim panel back toexpose the upper front wall mountingbolt. Remove the bracket from the cab-inet that holds the interlock fastener.Pull back the B pillar trim to exposethe lower front wall mounting bolt.Remove the 5 wall mounting bolts (3).

12Remove the upper right tower cabinet

from its mounting location and out ofthe vehicle.

Note:This step requires 2 people.

13

W300210

Remove the refrigerator (if equipped).

Open the refrigerator door. Removethe 2 locks from the floor mounting rail.

14Slide the refrigerator out from thecabinet and disconnect the 12 V con-nector. Remove it from the vehicle.

15Remove the left tower cabinet drawerstops. Remove the sink plumbing andelectrical connectors (if equipped).Remove the drawer.

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16

W8002927

Remove the bunk master control panelmounting screws (1) from the left bunk

fascia panel.Remove the panel and disconnect the2 connectors at the top (2). Let thebunk master control panel hang fromthe wiring harness.

17Pull back the lower left trim panel toexpose the lower left bunk fascia panelmounting screws. The panel issecured with Christmas tree and/or in-terlock fasteners.

J-38778

18

W8002494

Remove the screws securing the leftbunk fascia panel to the wall and the

nuts securing the panel to the lefttower cabinet, and remove it from itsmounting location.Turn the bunk master control panel tofit through the cut out in the fasciapanel and remove the fascia panelfrom the vehicle.

26

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19

W8002929

Remove the upper left tower cabinetas follows:Remove any objects stored in thecabinet. Unplug the power supply con-nectors.Remove the 5 bolts from the rear bot-tom wall (2). Remove the 6 boltsbetween the upper and lower cabinet(1).

Note:The lower cabinet door hingesmay need to be temporarily removedto remove the 2 front bolts. Installhinges before removing the cabinet.

Pull the upper front trim panel back to

expose the upper front wall mountingbolt.Remove the bracket from the cabinetthat holds the interlock fastener. Pullback the B pillar trim to expose thelower front wall mounting bolt. Removethe 5 wall mounting bolts (3).

20Remove the upper left tower cabinetfrom its mounting location and out ofthe vehicle.

Note:This requires 2 people.

21

W8002497

Remove the upper bunk/roof restraintreceivers (1).

22

W8002459

Remove the front bunk headliner over-

head lamp assembly. Disconnect theconnector.

23Remove the 2 trim strips on each sideof the center bunk headliner.

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24

W3004837

Disengage the Christmas tree fasten-ers that secure the plastic supportstrips between the bunk center andside headliners (1). Use caution whenbending back the side headliner panelsnot to crease the material. Disengagethe 2 Christmas tree fasteners at thefront of the center bunk headliner (2).

J-38778

25The center bunk headliner is now heldin place with interlocking fasteners andthe mating headliner components. Be-gin at the front and carefully work theheadliner out of the mating headlinercomponents. Allow the front of theheadliner to droopdown allowing ac-cess to the TV antenna.

Note:Use caution not to crease theheadliner panels or mating compo-nents.

26

W3004740

Note the routing of the TV coaxialcable and antenna wires to aid in in-stallation. Carefully reach under theheadliner panels to access the ca-ble/antenna assembly. Remove the

vinyl tape enough to free the assemblyand remove from the vehicle.

Note:Use a step stool as needed toreach the antenna assembly under theheadliner. Use caution not to crease ordamage the headliner material.

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Installation

1Install the replacement cable/antennaassembly. Secure with vinyl tape.

2Note the location of the interlock fas-

teners before installation of the centerbunk headliner. Carefully work theheadliner into its mounting location.Use caution not to crease the head-liner panels or mating componentsduring installation. Engage the inter-lock fasteners when the headliner isproperly positioned.

3Install the plastic support strips be-tween the bunk center and sideheadliners and secure with Christmas

tree fasteners. Use caution whenbending back the side headliner pan-els not to crease the material. Engagethe 2 Christmas tree fasteners at thefront of the center bunk headliner.

4Install the 2 trim strips on each side ofthe center bunk headliner.

5

W8002459

Install the overhead lamp assembly asfollows:Connect the connector. Install the as-sembly and torque the 4 screws to 3 0.5 Nm (27 4.5 in-lb).Install the lamp cover.

3 0.5 Nm(27 4.5 in-lb)

6

W8002497

Install the upper bunk/roof restraint re-ceivers (1). Torque to 24 4 Nm (18 3 ft-lb).

24 4 Nm(18 3 ft-lb)

7Position the upper left tower cabinetinto its mounting location. Work thecabinet around trim panels and pullthe wiring through the cabinet as nec-essary.


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8

W8002929

Install the upper left tower cabinet as

follows:Start all cabinet mounting bolts beforebeginning tightening. Install the 5 wallmounting bolts. Torque to 24 4 Nm(18 3 ft-lb).Install the 6 bolts between the upperand lower cabinet. Torque to 24 4Nm (18 3 ft-lb).

Note:The lower cabinet door hingesmay need to be temporarily removedto install the 2 front bolts. Install hingesafter the bolts between the upper andlower cabinet have been tightened.

Install the 5 bolts to the rear bottomwall. Torque to 10 1.5 Nm (7 1 ft-lb).Torque all cabinet mounting bolts.Install the bracket that holds the inter-lock fastener to the cabinet. Securethe upper front trim panel with the in-terlock fasteners. Connect the powersupply connectors.

24 4 Nm

(18 3 ft-lb)24 4 Nm(18 3 ft-lb)10 1.5 Nm(7 1 ft-lb)

9

W8002494

Fit the bunk master control panelthrough the cut out in the left bunk fas-cia panel.Position the left bunk fascia panel intoits mounting location. Secure thepanel to the tower cabinets with theplastic stud nuts.Secure the panel to the wall withscrews. Torque to 3 0.5 Nm (27 4in-lb).

3 0.5 Nm(27 4 in-lb)

10Secure the lower left trim with Christ-

mas tree and/or interlock fasteners.

11

W8002927

Connect the bunk master control panelconnectors (2). Using the 6 screws (1),install the bunk master control panelinto the left bunk fascia panel.

30

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12Install the left tower cabinet drawer.Connect the sink plumbing and electri-cal connectors (if equipped).Install the drawer stops.

13

W3002102

Install the refrigerator (if equipped) asfollows:Place the refrigerator on the floor justin front of the cabinet.Connect the 12 V power supply, usingthe locking connector.Align the refrigerator mounting brack-ets with the floor tracks and slide it asfar back on the tracks as possible.Open the refrigerator door and installthe locks (1) in the floor mounting rail.Torque to 13 2 Nm (10 1.5 ft-lb).

13 2 Nm(10 1.5 ft-lb)

14Position the upper right tower cabinetinto its mounting location. Work thecabinet around trim panels and pullwiring through the cabinet as neces-sary.


15

W8002492

Install the upper right tower cabinet asfollows:Start all cabinet mounting bolts beforebeginning tightening.Install the 5 wall mounting bolts (3).Torque to 24 4 Nm (18 3 ft-lb).Install the 8 bolts between the upperand lower cabinet (1). Torque to 24 4 Nm (18 3 ft-lb).Install the 5 bolts to the rear bottomwall (2). Torque to 10 1.5 Nm (7 1ft-lb).Torque all cabinet mounting bolts.Install the bracket that holds the inter-lock fasteners to the cabinet. Securethe upper front trim panel with the in-terlock fasteners.Connect the power supply connectors.

24 4 Nm(18 3 ft-lb)24 4 Nm(18 3 ft-lb)10 1.5 Nm(7 1 ft-lb)

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16

W8002182

Position the right bunk fascia panelinto its mounting location. Secure thepanel to the tower cabinets with theplastic stud nuts. Secure the panel tothe wall with screws. Torque to 3 0.5Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

17

Secure the lower right trim with Christ-mas tree and/or interlock fasteners.

18

W8002180

Secure the duct hose in the upperright tower cabinet to the right bunkfascia panel.

19

W8002183

Install the duct from the bunk HVACunit to the right bunk fascia panel.Torque the screws to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

32

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20

W8002177

Install the cabinet below the lower rightbunk window. Torque the 3 bottomscrews to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

21

W8002458

Install the 4 bunk window trim bezels.Torque the screws to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

22Install bunk ladder assembly (ifequipped). Torque the bolts to 10 1.5 Nm (7 1 ft-lb).

23

W8002501

Install both right and left B pillar trimsas follows:Secure the B pillar trim to the uppertower cabinets with the Christmas treefasteners. Properly position the B pillartrim and reinstall the door seal to se-cure.Install the seat belt shoulder harnessmounting bolts. Torque to 68 7 Nm(50 5 ft-lb).


68 7 Nm(50 5 ft-lb)

24

W8002490

Install the sleeper curtain rail assem-bly. Torque the screws to 5 1 Nm (44 9 in-lb).

5 1 Nm(44 9 in-lb

25Install the lower mattress/work stationcushions in the vehicle.

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VN 770 With Integrated Head-liner


jury or death.

CAUTION

When installing the headliner, care should be taken

not to bend the antenna. Any defects in the antennacould cause permanent damage to the circuit boardtraces.

Removal

1Remove the lower mattress/work sta-tion cushions from the vehicle.

2

W8002490


3

W8002928

Remove the following in both the rightand left sides:

Remove the shoulder harness mount-ing bolts (1).Pull back the upper rear of the doorseal to loosen the B pillar trim.Gently pull back the B pillar trim andremove the Christmas tree fastener (2)to the upper tower cabinets.


J-38778

4Remove the bunk ladder assembly (if

equipped).

34

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5

W8002176

Remove the 4 bunk windowstrimbezels. There are 10 screws to be re-moved for each windows trim bezel.

6

W8002177

Remove the torx screws holding thecabinet below the lower right bunkwindows.

7

W8002178

Remove the 6 torx screws holding theducting from the bunk HVAC unit tothe right bunk fascia panel.

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8

W8002180

Remove the duct hose in the upperright tower cabinet from the right bunkfascia panel.

9Pull back the lower right trim panel toexpose the lower right bunk fasciapanel mounting screws. This panel issecured with Christmas tree and/or in-terlock fasteners.

J-38778

10

W8002179

Remove 5 torx screws, 3 along the topand 2 behind the trim panel, mountingthe vent fascia to the wall.Remove the eight nuts from the plasticstuds.

Remove the fascia panel from itsmounting location and remove it fromthe vehicle.

36

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11

W8002492

Remove the upper right tower cabinetas follows:Remove any objects stored in the cab-inet.Unplug the power supply connectors.Remove the 5 bolts from the rear bot-tom wall (2).Remove the 8 bolts between the upperand lower cabinet (1).Pull the upper front trim panel back toexpose the upper front wall mountingbolt. Remove the bracket from the cab-inet that holds the interlock fastener.Pull back the B pillar trim to exposethe lower front wall mounting bolt.Remove the 5 wall mounting bolts (3).

12Remove the upper right tower cabinet

from its mounting location and out ofthe vehicle.


13

W3002102

Remove the refrigerator (if equipped).Open the refrigerator door. Removethe 2 locks from the floor mounting rail.

14Slide the refrigerator out from thecabinet and disconnect the 12 V con-nector. Remove it from the vehicle.

15Remove the left tower cabinet drawerstops. Remove the sink plumbing andelectrical connectors (if equipped).Remove the drawer.

16

W8002927

Remove the bunk master control panelmounting screws (1) from the left bunkfascia panel.Remove the panel and disconnect the2 connectors at the top (2). Let thebunk master control panel hang fromthe wiring harness.

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17Pull back the lower left trim panel toexpose the lower left bunk fascia panelmounting screws. The panel issecured with Christmas tree and/or in-terlock fasteners.

J-38778

18

W8002494

Remove the screws securing the leftbunk fascia panel to the wall and thenuts securing the panel to the lefttower cabinet, and remove it from itsmounting location.Turn the bunk master control panel tofit through the cut out in the fasciapanel and remove the fascia panel

from the vehicle.

19

W8002929

Remove the upper left tower cabinetas follows:Remove any objects stored in thecabinet. Unplug the power supply con-nectors.Remove the 5 bolts from the rear bot-tom wall (2). Remove the 6 boltsbetween the upper and lower cabinet(1).

Note:The lower cabinet door hingesmay need to be temporarily removedto remove the 2 front bolts. Installhinges before removing the cabinet.

Pull the upper front trim panel back to

expose the upper front wall mountingbolt.Remove the bracket from the cabinetthat holds the interlock fastener. Pullback the B pillar trim to expose thelower front wall mounting bolt. Removethe 5 wall mounting bolts (3).

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27

W8002500

Note the routing of the TV coaxial ca-ble to aid in installation. Remove thevinyl tape as necessary to free the ca-ble.

28

W8002499

Disengage the 2 Christmas tree fas-teners at the front and the 3 at therear of the center bunk headliner.

J-38778

29The center bunk headliner is now heldin place with interlocking fasteners andthe mating headliner components. Dis-engage fasteners. Begin at the frontand carefully work the headliner out ofthe mating headliner components andremove from the vehicle. Use caution

not to crease the headliner panels ormating components during removal.


Installation

1Note the location of the interlockfasteners before installation of the re-placement center bunk headliner.

2Begin at the rear and carefully workthe replacement headliner into itsmounting location. Use caution not tocrease the headliner panels or matingcomponents during installation. En-gage the interlock fasteners when theheadliner is properly positioned.


3

W8002499

Engage the 2 Christmas tree fastenersat the front and the 3 at the rear of thecenter bunk headliner.

40

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4

W8002500

Route the TV coaxial cable and se-cure with the vinyl tape.

5Install the plastic support strips be-tween the bunk center and sideheadliners and secure with Christmastree fasteners. Use caution whenbending back the side headliner pan-els not to crease the material.

6Install the 2 trim strips on each side ofthe center bunk headliner.

7

W8002459

Install both overhead lamp assembliesas follows:Connect the connector. Install the as-sembly and torque the 4 screws to 3 0.5 Nm (27 4.5 in-lb).Install the lamp cover.

3 0.5 Nm(27 4.5 in-

8

W8002498

Secure the rear wall trim panel withthe 4 Christmas tree fasteners.

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9

W8002497

Install the upper bunk/roof restraint re-ceivers (1). Torque to 24 4 Nm (18 3 ft-lb).

Install the upper bunk/rear wall re-straint tongues (2). Torque to 68 7Nm (26 5 ft-lb).

24 4 Nm(18 3 ft-lb)68 7 Nm

(26 5 ft-lb)

10

W8002496

Position the bunk upper rear wall stor-age cabinet to its mounting location.Connect the speaker connectors andsecure the cabinet with the fasteners.Torque to 24 4 Nm (18 3 ft-lb).

24 4 Nm(18 3 ft-lb)

11Position the upper left tower cabinetinto its mounting location. Work thecabinet around trim panels and pullthe wiring through the cabinet as nec-essary.


12

W8002929

Install the upper left tower cabinet asfollows:Start all cabinet mounting bolts beforebeginning tightening. Install the 5 wallmounting bolts. Torque to 24 4 Nm(18 3 ft-lb).Install the 6 bolts between the upperand lower cabinet. Torque to 24 4Nm (18 3 ft-lb).

Note:The lower cabinet door hingesmay need to be temporarily removedto install the 2 front bolts. Install hingesafter the bolts between the upper andlower cabinet have been tightened.

Install the 5 bolts to the rear bottomwall. Torque to 10 1.5 Nm (7 1 ft-lb).Torque all cabinet mounting bolts.Install the bracket that holds the inter-lock fastener to the cabinet. Securethe upper front trim panel with the in-terlock fasteners. Connect the powersupply connectors.


42

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13

W8002494

Fit the bunk master control panelthrough the cut out in the left bunk fas-cia panel.Position the left bunk fascia panel intoits mounting location. Secure thepanel to the tower cabinets with theplastic stud nuts.Secure the panel to the wall withscrews. Torque to 3 0.5 Nm (27 4in-lb).

3 0.5 Nm(27 4 in-lb)

14Secure the lower left trim with Christ-

mas tree and/or interlock fasteners.

15

W8002927

Connect the bunk master control panelconnectors (2). Using the 6 screws (1),install the bunk master control panelinto the left bunk fascia panel.

16Install the left tower cabinet drawer.Connect the sink plumbing and electri-cal connectors (if equipped).Install the drawer stops.

17

W3002102

Install the refrigerator (if equipped) asfollows:Place the refrigerator on the floor justin front of the cabinet.Connect the 12 V power supply, usingthe locking connector.Align the refrigerator mounting brack-ets with the floor tracks and slide it asfar back on the tracks as possible.Open the refrigerator door and install

the locks (1) in the floor mounting rail.Torque to 13 2 Nm (10 1.5 ft-lb).

13 2 Nm(10 1.5 ft-l

18Position the upper right tower cabinetinto its mounting location. Work thecabinet around trim panels and pullwiring through the cabinet as neces-sary.


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19

W8002492

Install the upper right tower cabinet asfollows:Start all cabinet mounting bolts beforebeginning tightening.Install the 5 wall mounting bolts (3).Torque to 24 4 Nm (18 3 ft-lb).Install the 8 bolts between the upperand lower cabinet (1). Torque to 24 4 Nm (18 3 ft-lb).Install the 5 bolts to the rear bottomwall (2). Torque to 10 1.5 Nm (7 1ft-lb).Torque all cabinet mounting bolts.Install the bracket that holds the inter-lock fasteners to the cabinet. Securethe upper front trim panel with the in-terlock fasteners.Connect the power supply connectors.


20

W8002182

Position the right bunk fascia panelinto its mounting location. Secure thepanel to the tower cabinets with the

plastic stud nuts. Secure the panel tothe wall with screws. Torque to 3 0.5Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

21Secure the lower right trim with Christ-mas tree and/or interlock fasteners.

44

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22

W8002180

Secure the duct hose in the upperright tower cabinet to the right bunk

fascia panel.

23

W8002183

Install the duct from the bunk HVACunit to the right bunk fascia panel.Torque the screws to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb)

24

W8002177

Install the cabinet below the lower rightbunk window. Torque the 3 bottomscrews to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb

25

W8002458

Install the 4 bunk window trim bezels.Torque the screws to 3 0.5 Nm (27 4 in-lb).

3 0.5 Nm(27 4 in-lb

26Install bunk ladder assembly (ifequipped). Torque the bolts to 10 1.5 Nm (7 1 ft-lb).

Torque wren

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Group 3 TV/Video System TV Speaker/Headphone Jack, Replacement

27

W8002501

Install both right and left B pillar trimsas follows:Secure the B pillar trim to the uppertower cabinets with the Christmas treefasteners. Properly position the B pillartrim and reinstall the door seal to se-cure.Install the seat belt shoulder harnessmounting bolts. Torque to 68 7 Nm(50 5 ft-lb).


68 7 Nm(50 5 ft-lb)

28

W8002490

Install the sleeper curtain rail assem-bly. Torque the screws to 5 1 Nm (44 9 in-lb).

5 1 Nm(44 9 in-lb)

29Install the lower mattress/work stationcushions in the vehicle.

3935-03-02-01TV Speaker/Headphone Jack,ReplacementNote: The TV speaker/jack is equipped on VN 770 ve-hicles only.

Before working on a vehicle, set the parking brakes,place the transmission in neutral, and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-

jury death.

Removal

1Turn the ignition key OFF. Turn off thepower to the TV.

2Remove the six screws from thesleeper control panel. Pull the panelcover away from the bunk wall.

3

W3004368

Sleeper Control Panel, Rear View

1 Speaker Mounting Screws

2 TV Speaker Connector

3 TV Harness Connector

4 TV Jack

Disconnect the TV speaker and har-ness connector.

46

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Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

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Concerns Service Manual: ...............................................................................................................................

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Operation Numbers

3935-03-02-01 TV Speaker/Headphone Jack, Replacement . . . . . . . . . . . . . . . . . . . 46

3935-03-02-02 TV Antenna, Replacement . . . . . . . . . . . . . . . . . . . . . . 13, 16, 22, 34

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Documents

PV776-TSP155509