Sie sind auf Seite 1von 36

Service Manual

Trucks
Group 93
Release 04
Fault codes, Bodybuilder module

20 018859
Foreword
The descriptions and service procedures contained in this manual are based on designs
and methods studies carried out up to November 04.

The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is judged to have a significant bearing on this manual, supplementary service
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
reference to V.S.T. (Volvo Standard Times).

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

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

Note: Indicates a procedure, practice, or condition that must be followed in order to have
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 the
product could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could occur.

Volvo Truck Corporation


Göteborg, Sweden

Order number: 20 018859


Repl: Service Manual group 93 issue 03 TSP195029, service manual 930-03 issue 01

© 04 Volvo Truck Corporation, Göteborg, Sweden

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


retrieval system, or transmitted in any forms by any means, electronic,
mechanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Truck Corporation.
ENG16199
Contents
General .................................................................................................. 2
Bodybuilder module ............................................................................. 2
Location of bodybuilder module ........................................................... 2

Specifications ....................................................................................... 3
Signal description, BBM ....................................................................... 3

Tools ...................................................................................................... 8
Special tools, BBM ............................................................................... 8
Other special equipment, BBM ............................................................ 8

Malfunction ........................................................................................... 9
MID 249 Fault code table, BBM ........................................................... 9
MID 249 PID 29 Extra throttle control, percentage position ................. 11
MID 249 PID 29 Extra throttle control, percentage position, check ..... 12
MID 249 SID 230 Idle switch 1 ............................................................ 16
MID 249 SID 230 Idle switch 1, Check ................................................ 17
MID 249 SID 231 J1939 Control link BBM ........................................... 20
MID 249 SID 250 SAE J1708 Information link ..................................... 21
MID 249 SID 253 Calibration memory EEPROM ................................ 22
MID 249 PSID 200 J1939 Data link interupption, engine ECU ............ 23
MID 249 PSID 201 J1939 Data link interruption, vehicle ECU ............ 24
MID 249 PSID 202 J1939 Data link interruption, instrument ECU ...... 25
MID 249 PSID 204 J1939 Data link interruption, brake control unit ... 26
MID 249 PSID 205 J1939 Interruption data link, automatic gearbox
ECU ..................................................................................................... 27
MID 249 PSID 207 J1939 Data link interruption, gear selector
control unit ........................................................................................... 28
MID 249 PSID 230 Software error ....................................................... 29

Feedback

Operation Numbers

1
Group 930 CONTROL UNIT ADDITION General

General
Bodybuilder module
The Bodybuilder Module (BBM) is an extension of
the vehicle control unit (VECU) and is intended for
superstructures, for example cement mixers, refuse
trucks and mobile cranes. The bodybuilder module is
secured in a unit together with the vehicle control unit and
is positioned under the dashboard. From the bodybuilder
module, a 31–pin connector goes out to the chassis.
Extra connectors and space for relays can be found in the
bodybuilder control centre in front of the passenger seat.

T9008073

Location of bodybuilder module

T9008053

2
Group 930 CONTROL UNIT ADDITION Specifications

Specifications
Signal description, BBM
Bodybuilder module, breakout box connected between control unit and
cable harness, connector BBA
• Starting key in the drive position.

• Engine stationary.

• Voltage measuring using a multimeter.

U = DC current in volts (V)

Ubat = battery voltage


Measurement point in brackets indicates the terminal in
breakout box.
DI H = Digital signal with high activation.
If the voltage is >7.7 V the control unit interprets the
signal as active, and if the voltage is <3.5 V the signal
T9008051
Conditions: is interpreted as inactive.

DI L = Digital signal with low activation.


• Breakout box 9998699 connected to adapter 9998533
If the voltage is <3,5 V the control unit interprets the
between the control unit and the cable harness.
signal as active, and if the voltage is >7.7 V the signal
• Control unit connected. is interpreted as inactive.

Terminal Signal type Measurement Expected value Miscellane-


points ous.
BBA1 Engine speed, reduce BBA1-BBA12 U ≈ 0 V (inactive) DI H
(1-12) U ≈Ubat (active)
BBA2 Engine speed, increase BBA2-BBA12 U ≈ 0 V (inactive) DI H
(2-12) U ≈Ubat (active)
BBA3 Power take-off, engine speed control, BBA3-BBA12 U ≈ 0 V (inactive) DI H
position 3 (3-12) U ≈Ubat (active)
BBA4 Power take-off, engine speed control, BBA4-BBA12 U ≈ 0 V (inactive) DI H
position 1 (4-12) U ≈Ubat (active)
BBA5 Power take-off, engine speed control, BBA5-BBA12 U ≈ 0 V (inactive) DI H
position 4 (5-12) U ≈Ubat (active)
BBA6 Switch off, engine BBA6-BBA12 U ≈ 0 V (inactive) DI H
(6-12) U ≈Ubat (active)
BBA7 Activation of idle speed BBA7-BBA12 U ≈ 0 V (inactive) DI H
(7-12) U ≈Ubat (active)
BBA8 Auto neutral BBA8-BBA12 U ≈ 0 V (inactive) DI H
(8-12) U ≈Ubat (active)
BBA9 Extra gear selector forward BBA9-BBA12 U ≈ 0 V (inactive) DI H
(9-12) U ≈Ubat (active)
BBA10 Extra gear selector neutral BBA10-BBA12 U ≈ 0 V (inactive) DI H
(10-12) U ≈Ubat (active)
BBA11 Not used
BBA12 Control unit, earth terminal BBA12 ground U≈0V
BBA13 Control unit, supply voltage BBA13-BBA12 U ≈Ubat
(13-12)
BBA14 Digital input, reserved BBA14-BBA12 U ≈ 0 V (inactive) DI H
(14-12) U ≈Ubat (active)

3
Group 930 CONTROL UNIT ADDITION Specifications

Terminal Signal type Measurement Expected value Miscellane-


points ous.
BBA15 CAN-4, high BBA15-BBA12
(15-12)
BBA16 CAN-4, low BBA16-BBA12
(16-12)
BBA17 Engine speed, limit BBA17-BBA12 U ≈ 0 V (inactive) DI H
(17-12) U ≈Ubat (active)
BBA18 Power take-off 2, switch BBA18-BBA12 U ≈ 0 V (inactive) DI H
(18-12) U ≈Ubat (active)
BBA19 Power take-off 3, switch BBA19-BBA12 U ≈ 0 V (inactive) DI H
(19-12) U ≈Ubat (active)
BBA20 Power take-off 4, switch BBA20-BBA12 U ≈ 0 V (inactive) DI H
(20-12) U ≈Ubat (active)
BBA21 Extra gear selector reverse BBA21-BBA12 U ≈ 0 V (inactive) DI H
(21-12) U ≈Ubat (active)
BBA22 EOL BBA22-BBA12
(22-12)
BBA23 Digital input, reserved BBA23-BBA12 U ≈ 0 V (inactive) DI H
(23-12) U ≈Ubat (active)
BBA24 Neutral gear BBA24-BBA12 U ≈Ubat (inactive) DI L
(24-12) U ≈ 0 V (active)
BBA25 Motor torque moment, limit BBA25-BBA12 U ≈Ubat (inactive) DI L
(25-12) U ≈ 0 V (active)
BBA26 Vehicle speed, limit 2 BBA26-BBA12 U ≈Ubat (inactive) DI L
(26-12) U ≈ 0 V (active)
BBA27 Switch off, engine BBA27-BBA12 U ≈Ubat (inactive) DI L
(27-12) U ≈ 0 V (active)
BBA28 Low split gear BBA28-BBA12 U ≈Ubat (inactive) DI L
(28-12) U ≈ 0 V (active)
BBA29 Split box BBA29-BBA12 U ≈ 0 V (inactive) DI H
(29-12) U ≈Ubat (active)
BBA30 Digital input, reserved BBA30-BBA12 U ≈ 0 V (inactive) DI H
(30-12) U ≈Ubat (active)

4
Group 930 CONTROL UNIT ADDITION Specifications

Bodybuilder module, breakout box connected between control unit and


cable harness, connector BBB
• Starting key in the drive position.

• Engine stationary.

• Voltage measuring using a multimeter.

U = DC current in volts (V)

Ubat = battery voltage

Measurement point in brackets indicates the terminal in


breakout box.
DI H = Digital signal with high activation.
If the voltage is >7.7 V the control unit interprets the
T9008054
signal as active, and if the voltage is <3.5 V the signal
Conditions: is interpreted as inactive.
DI L = Digital signal with low activation.
• Breakout box 9998699 connected to adapter 9813194
If the voltage is <3,5 V the control unit interprets the
between the control unit and the cable harness.
signal as active, and if the voltage is >7.7 V the signal
• Control unit connected. is interpreted as inactive.

Terminal Signal type Measurement Expected value Miscellane-


points ous.
BBB1 Permitted remote start BBB1-BBA12 U ≈Ubat (inactive)
(1-12) U ≈ 0 V (active)
BBB2 Power take-off 2 BBB2-BBA12 U ≈Ubat (inactive)
(2-12) U ≈ 0 V (active)
BBB3 Power take-off 3 BBB3-BBA12 U ≈Ubat (inactive)
(3-12) U ≈ 0 V (active)
BBB4 Power take-off 4 BBB4-BBA12 U ≈Ubat (inactive)
(4-12) U ≈ 0 V (active)
BBB5 Voltage supply 4 BBB5-BBA12 U ≈Ubat
(5-12)
BBB6 Not used BBB6-BBA12
(6-12)
BBB7 Digital input, reserved BBB7-BBA12 U ≈ 0 V (inactive) DI H
(7-12) U ≈Ubat (active)
BBB8 Analogue input, reserved BBB8-BBA12 U ≈ 0-5 V
(8-12)
BBB9 Extra throttle control, analogue input BBB9-BBA12 U ≈ 0-5 V
(9-12)
BBB10 Power supply 1, extra throttle control BBB10-BBA12 U≈5V
(10-12)
BBB11 Digital input, reserved BBB11-BBA12 U ≈Ubat (inactive) DI L
(11-12) U ≈ 0 V (active)
BBB12 Extra throttle control, activation BBB12-BBA12 U ≈Ubat (inactive) DI L
(12-12) U ≈ 0 V (active)
BBB13 Digital input, reserved BBB13-BBA12 U ≈Ubat (inactive) DI L
(13-12) U ≈ 0 V (active)
BBB14 Analogue input, reserved BBB14-BBA12 U ≈ 0 V (inactive)
(14-12) U ≈Ubat (active)
BBB15 Not used BBB15-BBA12
(15-12)

5
Group 930 CONTROL UNIT ADDITION Specifications

Terminal Signal type Measurement Expected value Miscellane-


points ous.
BBB16 Warning signal, buzzer alarm BBB16-BBA12 U ≈Ubat (inactive)
(16-12) U ≈ 0 V (active)
BBB17 Not used BBB17-BBA12
(17-12)
BBB18 Warning signal, limit value monitor BBB18-BBA12 U ≈Ubat (inactive)
(18-12) U ≈ 0 V (active)
BBB19 Voltage supply 3 BBB19-BBA12 U ≈Ubat
(19-12)
BBB20 Not used BBB20-BBA12
(20-12)
BBB21 Power take-off, engine speed control, BBB21-BBA12 U ≈ 0 V (inactive)
position 2 (21-12) U ≈Ubat (active)
BBB22 Ground terminal for analogue power supply BBB22-BBA12 U≈0V
(22-12)
BBB23 Grounding BBB23-BBA12 U≈0V
(23-12)
BBB24 Analogue input, reserved BBB24-BBA12 U ≈ 0-5 V
(24-12)
BBB25 Voltage supply 5 BBB25-BBA12 U ≈ 6.5-9 V
(25-12)
BBB26 Voltage supply 2 BBB26-BBA12 U≈5V
(26-12)
BBB27 Digital input, reserved BBB27-BBA12 U ≈Ubat (inactive) DI L
(27-12) U ≈ 0 V (active)
BBB28 Speed signal/ BBB28-BBA12
limit value monitor (28-12)
BBB29 Digital input, Split Box BBB29-BBA12 U ≈Ubat (inactive) DI L
(29-12) U ≈ 0 V (active)
BBB30 Idle switch, extra throttle control BBB30-BBA12 U ≈ 0 V (inactive) DI H
(30-12) U ≈Ubat (active)

6
Group 930 CONTROL UNIT ADDITION Specifications

Bodybuilder module, breakout box connected between control unit and


cable harness, connector BBC
Conditions: • Engine stationary.

• Breakout box 9998699 connected to adapter 9998604 • Voltage measuring using a multimeter.
between the control unit and the cable harness.
U = DC current in volts (V)
• Control unit connected.
Ubat = battery voltage
• Starting key in the drive position.

Terminal Signal type Measurement Expected value Miscellaneous.


points
BBC1 SAE J1708 information link B BBC1 - ground U ≈ 0-5 V
BBC2 SAE J1708 information link A BBC2 - ground U ≈ 0-5 V
BBC3
BBC4 SAE J1939 control data link A BBC4 - ground U ≈ 2-5 V
BBC5 SAE J1939 control data link B BBC5 - ground U ≈ 0-3 V

7
Group 930 CONTROL UNIT ADDITION Tools

Tools
Special tools, BBM

9998699 9998533 9998604


Adapter for BBA. Blue contact Adapter for BBC, 10-pin. Green
Breakout box, 62-pin to orange connector contact to green connector

Other special equipment, BBM

9510060 9813194
Adapter for BBB. Green contact
Multimeter to white connector

8
Group 930 CONTROL UNIT ADDITION Malfunction

Malfunction
MID 249 Fault code table, BBM
MID: SID:
Message Identification Description (control unit Subsystem Identification Description (component
identification). identification).
PID: PSID:
Parameter Identification Description (parameter Proprietary Subsystem Identification Description (Volvo
identification (value)). unique component identification).

PPID: FMI:
Proprietary Parameter Identification Description (Volvo Failure Mode Identifier (fault type identification).
unique identification of parameter (value)).
For more detailed information concerning these
designations, see service information group 0 “Vehicle
electronics ’98”.

Fault code Component / function Failure Section


Mode
Identi-
fier
MID 249 PID 29 Extra accelerator control, 3, 4 “MID 249 PID 29 Extra throttle control, percentage
percentage position position” page 11
MID 249 SID 230 Idle validation switch 1 7 “MID 249 SID 230 Idle switch 1” page 16
MID 249 SID 231 SAE J1939 control data link BBM 2 “MID 249 SID 231 J1939 Control link BBM” page 20
MID 249 SID 250 SAE J1708 Information link 2 “MID 249 SID 250 SAE J1708 Information link” page
21
MID 249 SID 253 Calibration memory EEPROM 2, 14 “MID 249 SID 253 Calibration memory EEPROM”
page 22
MID 249 PSID 200 SAE J1939 open-circuit, data 9 “MID 249 PSID 200 J1939 Data link interupption,
link, engine control unit engine ECU” page 23
MID 249 PSID 201 SAE J1939 open-circuit, data 9 “MID 249 PSID 201 J1939 Data link interruption,
link, vehicle control unit vehicle ECU” page 24
MID 249 PSID 202 SAE J1939 open-circuit, data 9 “MID 249 PSID 202 J1939 Data link interruption,
link, instrument control unit instrument ECU” page 25
MID 249 PSID 204 SAE J1939 open-circuit, data 9 “MID 249 PSID 204 J1939 Data link interruption,
link, brake control unit brake control unit ” page 26
MID 249 PSID 205 SAE J1939 open-circuit, data link, 9 “MID 249 PSID 205 J1939 Interruption data link,
control unit automatic gearbox automatic gearbox ECU” page 27
MID 249 PSID 207 SAE J1939 open-circuit, data 9 “MID 249 PSID 207 J1939 Data link interruption,
link, gear selector control unit gear selector control unit” page 28
MID 249 PSID 230 Software error 4, 5, 12 “MID 249 PSID 230 Software error” page 29

9
Group 930 CONTROL UNIT ADDITION Malfunction

Failure Mode Identifier Table


SAE standard
Failure Display text SAE text
Mode
Identifier
0 Too high value Data applicable, but above normal working range.
1 Too low value Data is valid, but below the normal working area.
2 Incorrect data Intermittent or incorrect data.
3 Electrical fault Abnormally high voltage or short circuit to higher voltage.
4 Electrical fault Abnormally low voltage or short-circuit to lower voltage.
5 Electrical fault Abnormally low current or open circuit.
6 Electrical fault Abnormally high current or short-circuit to earth.
7 Mechanical fault Incorrect response from the mechanical system.
8 Mechanical or electrical fault Abnormal frequency.
9 Communication fault Abnormal update rate.
10 Mechanical or electrical fault Abnormally large variations.
11 Unknown fault Unidentifiable fault.
12 Component fault Faulty unit or component.
13 Incorrect calibration Values outside the calibration values.
14 Unknown fault Special instructions.
15 Unknown fault Reserved for future use.

10
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PID 29 Extra throttle control, percentage position


General information
Applies only to vehicles with an extra accelerator control, Cable harness: Varies with the design of the extra
e.g. dual control or hand throttle for optional equipment accelerator control. (See addition instructions)
on the vehicle.

Component: Varies with the design of the extra


accelerator control. (See addition instructions)

Fault code

FMI 3 FMI 4
Abnormally high voltage or short circuit to higher voltage. Abnormally low voltage or short-circuit to lower voltage.
Conditions for fault code: Conditions for fault code:
• The control unit registers voltage from the sensor • The control unit registers voltage from the sensor
exceeding 4.3 V. below 0.4 V.
Possible cause: Possible cause:
• Break in the earth lead.
• Break in supply cable.
• Signal cable short-circuited to higher voltage.
• Open circuit in signal lead.
• Faulty sensor.
• Faulty sensor.
• Idle speed contact defective
Reaction from the control unit:
• Contact resistance and oxidation.
Reaction from the control unit:
• Warning light is requested.

• The control unit disconnects the function. • The control unit disconnects the function.
Noticeable external symptoms:
Noticeable external symptoms:
• Warning lamp lights up. • Warning lamp lights up.

• The engine/system does not respond to acceleration • The engine/system does not respond to acceleration
from the extra accelerator control. from the extra accelerator control.

Appropriate check: Appropriate check:

• “MID 249 PID 29 Extra throttle control, percentage • “MID 249 PID 29 Extra throttle control, percentage
position, check” page 12 position, check” page 12

11
Group 930 CONTROL UNIT ADDITION Malfunction

93001-2
MID 249 PID 29 Extra throttle control, percentage position, check
Special tools: 9998533, 9998699
Other special equipment: 9510060, 9813194

NOTE!
• Check all the relevant connectors for bad contact,
contact resistance and oxidation. For a more detailed
description, see separate service information “Fault
tracing cables, connectors” under group 371.

Measurement at the component


between the connector and the
control unit
Note: If one of the values below is incorrect this could
also have caused the component to break down, in which
case the component must be checked.

Earth cable
1
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• Measure resistance using a multimeter.

• Control unit connected.

• Starting key in the stop position.

• Measurement to control unit

Measurement Expected value


points
BBB23-ground R≈0

9510060, 9813194
9998699

12
Group 930 CONTROL UNIT ADDITION Malfunction

Supply lead
2
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• The connector to the sensor for primary tank pressure


disconnected (if the vehicle is equipped with air
suspension).

• Voltage measuring using a multimeter.

• Control unit connected.

• Starting key in the drive position.

• Measurement to control unit

Measurement Expected value


points
BBB10-BBB23 U ≈ 4.3-6.5 V

9510060, 9813194
9998699

Signal lead
3
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• The connector to the sensor for primary tank pressure


disconnected (if the vehicle is equipped with air
suspension).

• Measure resistance using a multimeter.

• Control unit connected.

• Starting key in the stop position.

• Measurement to control unit

Measurement Expected value


points
BBB9-BBB23 R ≈ 80 -120 k

9510060, 9813194
9998699

Cable harness
4
For checking the cable harness, see service information
under group 371.

13
Group 930 CONTROL UNIT ADDITION Malfunction

Component check
Note: Faults in the component may be caused by faults in
the cable harness for the control unit. Therefore, carry
out a check of the cable harness before connecting a
new component.

Accelerator control sensor


1
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• Measure resistance using a multimeter.

• Starting key in the stop position.

• Measurement at the accelerator control sensor.

Measurement Expected value


points
BBB26-BBB23 R ≈ 3.2 -4.8 k
BBB9-BBB23 R ≈ 1.0-2.0 k (No acceleration)

9510060, 9813194
9998699

Checking sub-systems
Earth cable
1
Conditions:

• Measurement box with adapter connected between


control unit and cable harness.

• Measure resistance using a multimeter.

• Control unit connected

• Starting key in the stop position.

Measurement Expected value


points
BBB23-ground R≈0

9510060, 9813194
9998699

14
Group 930 CONTROL UNIT ADDITION Malfunction

Supply lead
2
Conditions:

• Measurement box with adapter connected between


control unit and cable harness.

• Voltage measuring using a multimeter.

• Control unit connected

• Starting key in the drive position.

Measurement Expected value


points
BBB10-BBB23 U ≈ 4-6 V

9510060, 9813194
9998699

Signal lead
3
Conditions:

• Measurement box with adapter connected between


control unit and cable harness.

• Voltage measuring using a multimeter.

• Control unit connected

• Starting key in the stop position.

Measurement Expected value


points
BBB9-BBB23 U ≈ 0.4-0.6 V (no acceleration)
BBB9-BBB23 U ≈ 2.6-3.8 V (full acceleration)

9510060, 9813194
9998699

15
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 SID 230 Idle switch 1


General information • Break in supply cable.
Applies only to vehicles with an extra accelerator control,
e.g. dual control or hand throttle for optional equipment • Open circuit in signal lead.
on the vehicle. This idling contact is directly connected to • Signal lead short-circuited to earth.
the extra accelerator control.
• Signal lead short-circuited to voltage.
Component: Varies with the design of the extra
accelerator control. (See addition instructions) • Defective switch

Cable harness: Varies with the design of the extra • Switch resistance and oxidation.
accelerator control. (See addition instructions) Reaction from the control unit:

Fault code • The control unit disconnects the function.

• Warning light is requested.


FMI 7 Noticeable external symptoms:
Incorrect response from the mechanical system.
Conditions for fault code: • Warning lamp lights up.

• If the signal from the idle switch is not available in the


• The engine does not react to acceleration with the
extra control.
interval 0–13%, the control unit interprets this as a fault
and a fault code is stored. Appropriate check:
Possible cause: • “MID 249 SID 230 Idle switch 1, Check” page 17.

16
Group 930 CONTROL UNIT ADDITION Malfunction

93002-2
MID 249 SID 230 Idle switch 1, Check
Special tools: 9998551, 9998533
Other special equipment: 9510060

NOTE!
• Check all the relevant connectors for bad contact,
contact resistance and oxidation. For a more detailed
description, see separate service information “Fault
tracing cables, connectors” under group 371.

Tests that can be carried out in the


PC tool
The following test is useful for closely examining the
component’s function:

• “27104–8 Extra throttle control, contacts and sensors,


test”

Measurement at the component


between the connector and the
control unit
Note: If one of the values below is incorrect this could
also have caused the component to break down, in which
case the component must be checked.

Supply lead
1
Note: The check below applies only to vehicles equipped
with extra accelerator control.
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• The connector to switch, cruise control disconnected.

• The connector to switch, exhaust brake disconnected


(if the vehicle is equipped with exhaust brake).

• The connector to switch, retarder disconnected (if the


vehicle is equipped with a retarder).

• The connector to the sensor for primary tank pressure


disconnected (if the vehicle is equipped with air
suspension).

• Voltage measuring using a multimeter.

• Control unit connected.

• Starting key in the drive position.

• Measurement to control unit

Measurement Expected value


points
BBB5-ground U ≈Ubat

9510060, 9813194
9998699

17
Group 930 CONTROL UNIT ADDITION Malfunction

Signal lead
2
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• Measure resistance using a multimeter.

• Control unit connected.

• Starting key in the stop position.

• Measurement to control unit

Measurement Expected value


points
BBB30-ground R ≈ 2.1 -3.1 k

9510060, 9813194
9998699

Cable harness
3
For checking the cable harness, see service information
under group 371.

Component check
Note: Faults in the component may be caused by faults in
the cable harness for the control unit. Therefore, carry
out a check of the cable harness before connecting a
new component.

Idle switch
1
Conditions:

• The connector to the sensor for extra accelerator


control disconnected.

• Measure resistance using a multimeter.

• Starting key in the stop position.

• Check against idle switch.

Measurement Expected value


points
BBB30-BBB5 R ≈ ∞ (no acceleration)
BBB30-BBB5 R ≈ 20-90 (full acceleration)

9510060, 9813194
9998699

18
Group 930 CONTROL UNIT ADDITION Malfunction

Checking sub-systems
Signal lead
1
Conditions:

• Measurement box with adapter connected between


control unit and cable harness.

• Voltage measuring using a multimeter.

• Control unit connected

• Starting key in the drive position.

Measurement Expected value


points
BBB30-BBB22 U ≈ 0 V (no acceleration)
BBB30-BBB22 U ≈Ubat (full acceleration)

9510060, 9813194
9998699

19
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 SID 231 J1939 Control link BBM


General information • Short circuit to frame on the wire between the BBM
SAE J1939 the data link is used to communicate with control unit and the other control units.
other control units.
• Short circuit to voltage on the wire between the BBM
Component: Bodybuilder control unit (9100) control unit and the other control units.

Cable harness: 1000 • Faulty BBM control unit.


Reaction from the control unit:
Fault code
• Warning light is requested.
FMI 2 Noticeable external symptoms:
Intermittent or incorrect data.
Conditions for fault code:
• Warning lamp lights up.

• Reduced functionality.
• If the control unit cannot communicate via the SAE
J1939 control data link, the control unit interprets this Appropriate check:
as a fault and a fault code is set.
• See service information group 371, “Fault tracing, Data
Possible cause: links”.

• Break in wire between the BBM control unit and the


other control units.

20
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 SID 250 SAE J1708 Information link


General information
Communication between the vehicle’s control units is the system status continually updated and available for
via information link SAE J1708. System control signals reading via the diagnostics socket.
are sent on control link SAE J1939. Information and
diagnostic signals are sent on the SAE J1708 information Component: A36 Control unit (BBM)
link. The link also functions as a back up system for
Cable harness: 1000
control link SAE J1939, if this control link should stop
working for any reason. Information link SAE J1708 keeps

Fault code
FMI 2
Intermittent or incorrect data.

Conditions for fault code:

• If the control unit registers faulty messages on the


information link, it interprets this as a fault and a fault
code is set.

Possible cause:

• A unit is not following the priority rules and is disrupting


messages.

• Intermittent short circuits on information link SAE


J1708.

Reaction from the control unit:

• Fault code set.

Noticeable external symptoms:

• Certain malfunctions can occur.

Appropriate check:

• Carry out fault tracing on the SAE J1708 data link,


see service information group 3711 “Data links, fault
tracing”.

• Check connectors, see service information group 371


“Cables and connectors, fault tracing”.

21
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 SID 253 Calibration memory EEPROM


General information
Checksums of the data set and other data in the control Component: A36 Control unit (BBM)
unit EEPROM memory are calculated on start up. The is
done to check that the stored data is correct. Cable harness: 1000

Fault code
FMI 2 FMI 14
Intermittent or incorrect data. Special instructions.

Conditions for fault code: Conditions for fault code:

• The data set has incorrect checksum. • A serious fault has been detected in the saved data.

Possible cause: Possible cause:

• Fault with the programming. • Faulty memory circuit.

• Faulty memory circuit. • Incorrect software.

Reaction from the control unit: Reaction from the control unit:

• Fault code set. • Fault code set.

• Yellow warning lamp requested. • Yellow lamp requested.

• Basic settings of the database are used. • Basic settings of the database are used and it cannot
be reprogrammed.
Noticeable external symptoms:
Noticeable external symptoms:
• Yellow warning lamp is lit.
• Yellow lamp lights up.
• Certain malfunctions can occur.
• Certain malfunctions can occur.
Appropriate action:
Appropriate action:
• Reprogram the data set.
• Reprogram the software and then reprogram the data
set.

22
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 200 J1939 Data link interupption, engine ECU
General information Possible cause:
The control units share important information on the SAE
J1939 control data link. If a control unit lacks information • Break in the SAE J1939 data link between the
from another control unit, this fault code will be used Bodybuilder module and the engine control unit.
to point out the control unit that is expected to send Reaction from the control unit:
information on the SAE J1939 control data link.
• Fault code set.
Fault code Appropriate check:

FMI 9 • Carry out fault tracing on the SAE J1939 control data
Abnormal update rate. link, see separate service information group 371 “Data
link fault tracing”.
Conditions for fault code:

• If the Bodybuilder module does not receive the


message from the engine control unit via the SAE
J1939 data link, the Bodybuilder module interprets this
as a fault and a fault code is stored.

23
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 201 J1939 Data link interruption, vehicle ECU
General information Possible cause:
The control units share important information on the SAE
J1939 control data link. If a control unit lacks information • Break in the SAE J1939 data link between the
from another control unit, this fault code will be used Bodybuilder module and the vehicle control unit.
to point out the control unit that is expected to send Reaction from the control unit:
information on the SAE J1939 control data link.
• Fault code set.
Fault code Appropriate check:

FMI 9 • Carry out fault tracing on the SAE J1939 control data
Abnormal update rate. link, see separate service information group 371 “Data
link fault tracing”.
Conditions for fault code:

• If the Bodybuilder module does not receive the


message from the vehicle control unit via the SAE
J1939 data link, the Bodybuilder module interprets this
as a fault and a fault code is stored.

24
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 202 J1939 Data link interruption, instrument ECU
General information Possible cause:
The control units share important information on the
SAE J1939 control data link. If a control unit is missing • Open-circuit in the SAE J1939 data link between the
information from another control unit, this fault code Bodybuilder module and the instrument.
is used to indicate the control unit that is expected to Reaction from the control unit:
transmit information via the SAE J1939 data link.
• Fault code set.
Fault code Appropriate check:

FMI 9 • Carry out fault tracing on the SAE J1939 control data
Abnormal update rate. link, see separate service information group 371 “Data
link fault tracing”.
Conditions for fault code:

• If the Bodybuilder module does not receive the


message from the instrument via the SAE J1939 data
link, the Bodybuilder module interprets this as a fault
and a fault code is set.

25
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 204 J1939 Data link interruption, brake control unit
General information • If the Bodybuilder module does not receive the
The control units share important information via data link message from the brake control unit within a certain
SAE J1939. If one control unit is missing messages from time via the SAE J1939 data link, the Bodybuilder
another control unit, this fault code is used to indicate the module interprets this as a fault and a fault code is set.
control unit that is expected to send the message via data
link SAE J1939. Possible cause:

• Open-circuit in the SAE J1939 data link between the


Bodybuilder module and the ANS/EBS control unit.
Fault code Reaction from the control unit:

FMI 9 • Fault code set.


Abnormal update rate.
Appropriate check:
Conditions for fault code:
• Fault trace SAE J1939 data link, see service
information group 371 “Data link fault tracing”.

26
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 205 J1939 Interruption data link, automatic gearbox
ECU
General information Possible cause:
The control units share important information on the SAE
J1939 control data link. If a control unit lacks information • Open-circuit in the SAE J1939 data link between the
from another control unit, this fault code will be used Bodybuilder module and the gearbox control unit.
to point out the control unit that is expected to send Reaction from the control unit:
information on the SAE J1939 control data link.
• Fault code set.
Fault code Appropriate check:

FMI 9 • Carry out fault tracing on the SAE J1939 control data
Abnormal update rate. link, see separate service information group 371 “Data
link fault tracing”.
Conditions for fault code:

• If the Bodybuilder module does not receive the


message from the gearbox control unit via the SAE
J1939 data link, the Bodybuilder module interprets this
as a fault and a fault code is set.

27
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 207 J1939 Data link interruption, gear selector control
unit
General information Possible cause:
The control units share important information on the SAE
J1939 control data link. If a control unit lacks information • Open-circuit in the SAE J1939 data link between the
from another control unit, this fault code will be used Bodybuilder module and the gear selector control unit.
to point out the control unit that is expected to send Reaction from the control unit:
information on the SAE J1939 control data link.
• Fault code set.
Fault code Appropriate check:

FMI 9 • Carry out fault tracing on the SAE J1939 control data
Abnormal update rate. link, see separate service information group 371 “Data
link fault tracing”.
Conditions for fault code:

• If the Bodybuilder module does not receive the


message from the gear selector control unit via
the SAE J1939 data link, the Bodybuilder module
interprets this as a fault and a fault code is set.

28
Group 930 CONTROL UNIT ADDITION Malfunction

MID 249 PSID 230 Software error


General information
The hardware and software contain check functions to Cable harness: 1000
identify any serious faults.
Component: A36 Control unit (BBM)

Fault code
FMI 4 FMI 5
Abnormally low voltage or short-circuit to lower voltage. Abnormally low current or open circuit.

Conditions for fault code: Conditions for fault code:

• The software has restarted in a uncontrolled way. • The software has been shut down incorrectly due to
loss of power.
Possible cause:
Possible cause:
• Disruption in the power supply.

• Incorrect software.
• Disruption in the power supply.

• Powerful electromagnetic interference. • The power supply has been cut without the starter key
remaining in the stop position for at least 10 seconds.
Reaction from the control unit:
• Fault in cable harness.
• Fault code set.
Reaction from the control unit:
• Yellow lamp requested.
• Fault code set.
Noticeable external symptoms:
Noticeable external symptoms:
• Yellow lamp lights.
• Fault codes are not saved.
• Some malfunctions can occur temporarily.
Appropriate action:
Appropriate action:
• Always turn the starter key to the stop position and wait
• Check connectors. See service information group 371 10 seconds before turning off the main switch.
“Cables and connectors, fault tracing”.
• Check connectors. See service information group 371
• Upgrade software. “Cables and connectors, fault tracing”.

29
Group 930 CONTROL UNIT ADDITION Malfunction

FMI 12
Faulty unit or component.
Conditions for fault code:

• A serious fault has occurred and the software has


restarted.

Possible cause:

• Incorrect software.

• Powerful electromagnetic interference.

• Faulty control unit.

Reaction from the control unit:

• Fault code set.

• Yellow lamp requested.

Noticeable external symptoms:

• Yellow lamp lights.

• Some malfunctions can occur temporarily.

Appropriate action:

• Upgrade software.

• If the fault remains, replace the control unit.

30
Feedback

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

To From

Volvo Parts AB .......................................................................


Dept. Technical Support Service 31820 .......................................................................

SE-405 08 GÖTEBORG .......................................................................

.......................................................................
Fax: +46 31 661060
.......................................................................
E-mail: support.tsc.tech@volvo.com
.......................................................................

.......................................................................

Comments/proposals
.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................
.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

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


Operation Numbers
The operation numbers used in this manual refer to V.S.T.

93001-2 MID 249 PID 29 Extra throttle control, percentage position, check .................................................................... 12

93002-2 MID 249 SID 230 Idle switch 1, Check ............................................................................................................... 17


Volvo Truck Corporation
Göteborg, Sweden

20 018859 English 1100.11.04 Printed in Sweden