New Volvo FM and FH Truck Electrical Harnesses

Technical Data-Design and Compliance

General

The latest generation Volvo FM and FH trucks have an electrical system based on TEA2+ Data Bus
technology. This design is significantly different to the previous generation FM and FH trucks.

Located in the chassis is a Front Input/Output Module (FCIOM), a Central Chassis Input/Output
Module (CCIOM) and a Rear Chassis Input/Output Module (RCIOM). These modules control the
various chassis mounted electrical components located in their region.

A new high integrity corrugated harness cover (Monoflex) has been introduced with the new
electronic architecture.

The new electrical harnesses have been determined by Volvo to comply with the requirements of
Australian Standard AS 2809.1-2008.

Identifying New FM and FH Truck Chassis

The simplest method of identification is by chassis number. The new models use a “20000” series
chassis number and retain the original “D” prefix. Eg. D 201501.

Chassis VIN number is stamped into the right front chassis rail adjacent to the right front wheel. It
also appears on the vehicle ID and manufacturer’s plate located in the door aperture.

Harness Design

The new Monoflex harness material uses a 2 piece self-locking self-sealing corrugated outer
covering that allows greater harness filling for a given diameter. It uses the same snap lock branch
connecters as the previous generation tubular corrugated harness material.

PO Box Address Telephone Volvo Group Australia

916 Summer Park 36 Viking Dr +61 7 3258 7500 Pty Ltd
Qld Wacol ABN 27 000 761 259
Australia Qld 4076
IP67 rated cam lock connectors with double lip seals and wire entry grommet seals are used at
Input/Output modules. Other connectors use double lip seals and wire entry grommet seals.

The harness cover is taped with aerospace grade tape at close intervals. Close attention is paid to
cable support and routing in the chassis to maximise harness integrity.

Monoflex is a 2 piece self-locking, self-sealing cover material. It is totally different to “Split

Conduit” which is widely used in the Automotive Industry. “Split Conduit” has no sealing properties
at all and should not be used in reference to the new generation Volvo harness cover material.

Compliance

The previous model Volvo FM and FH truck corrugated harness material met both the International
Carriage of Dangerous Goods by Road (European ADR) and Australian Standard ASA2809.1-2008
requirements as referred to in Safe Load Pass (SLP) program. The new Monoflex material harnesses
have been designed to meet the same standards as the previous generation harnesses and have the
same functional requirements. The European ADR regulation covers vehicles intended to carry
explosives, low flash point liquids, flammable gases and mobile explosive mixing units (MEMU).

No change has been made to the harness material specification so the new harnesses will meet the
same technical demands as the previous tubular corrugated hose material.

The new harness material reduces bundle sizes giving safer more reliably packaged harness
installations. The risk of chafing is reduced.

The reduced harness bundle sizes improve access for bodybuilder electrical installation and
contribute to the reliability of secondary installations. The new harness material has been fully tested
by Volvo to meet the same high demands as the previous harness material by endurance testing, field
testing and rig testing.

Compliance Summary:

Complies with AS 2809.1                                                                                                 
Complies with ASNZS 61386.1:2012 Part1 and Part23                                              
Meets property requirements for: 
o Bending                                                                                                                  
o Flexing                                                                                                                    
o Collapse                                                                                                                  
o Bonding                                                                                                                  
o Thermal properties                                                                                              
o Electromagnetic compatibility                                                                                    
o Fire                                                                                                                          
o Ingress of water                                                                                                    
o Ingress of foreign solid objects (dust etc.)                                                        

Bev Gray Moffatt

Application Engineer - Volvo Group Australia

PO Box Address Telephone Volvo Group Australia

916 Summer Park 36 Viking Dr +61 7 3258 7500 Pty Ltd
Qld Wacol ABN 27 000 761 259
Australia Qld 4076