Service Manual Trucks 36 Fault Codes Vehicle ECU MID 144 Volvo or Cummins Engine VN, VHD VERSION 2 Group
PV776-20 033671
Foreword The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to August 2005. 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 believed 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 an 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 an V.S.T. Each section of this manual contains specific safety information and warnings which must be reviewed before performing any procedure. If a printed copy of a procedure is made, be sure to also make a printed copy of the safety information and warnings that relate to that procedure. 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 Trucks North America, Inc. Greensboro, NC USA
Order number: PV776-20 033671 Repl: PV776–TSP196291
© 2005 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, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc.. USA17877
Contents Specifications ............................................................. 3 Vehicle ECU ............................................................... 3 Tools .......................................................................... 15 Special Tools ............................................................ 15 Troubleshooting ........................................................ MID 144 Vehicle Control Unit, Fault Codes .............. MID 144 PID 84 Vehicle Speed ................................ MID 144 PID 84 Vehicle Speed, Check .................... MID 144 PID 91 Accelerator Pedal Position (Percentage) ............................................................. MID 144 PID 91 Accelerator Pedal Position (Percentage), Check ................................................. MID 144 PID 150 PTO Output .................................. MID 144 PID 150 PTO Output, Check ...................... MID 144 PID 152 VECU, Number of Resets ............ MID 144 PID 191 Output Shaft Speed ..................... MID 144 PID 191 Output Shaft Speed, Check ......... MID 144 PPID 61 Engine Brake Switch ................... MID 144 PPID 61 Engine Brake Switch, Check ....... MID 144 PPID 69 Buffered Idle Validation Switch .... MID 144 PPID 69 Buffered Idle Validation Switch, Check ....................................................................... MID 144 PPID 70 Pedal Switches, Supply ............... MID 144 PPID 70 Pedal Switches, Supply, Check ... MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply ................................................ MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply, Check .................................... MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply .............................................
19 19 21 23 27 28 32 34 36 37 40 44 45 48 49 51 52 59
MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply, Check ................................. 70 MID 144 PPID 74 VECU Power Supply .................... 77 MID 144 PPID 74 Power Supply EECU/VECU, Check ....................................................................... 78 MID 144 SID 230 Idle Validation Switch 1 ................ 80 MID 144 SID 230 Idle Validation Switch 1, Check .... 81 MID 144 SID 231 J1939 Control Link ....................... 83 MID 144 SID 240 Program Memory ......................... 85 MID 144 SID 243 Cruise Control Set Switch ............ 86 MID 144 SID 243 Cruise Control Set Switch, Check 87 MID 144 SID 250 J1587/J1708 Information Data Link ........................................................................... 91 MID 144 SID 253 Calibration Memory EEPROM ..... 92 MID 144 PSID 4 Engine Brake Stalk Lever .............. 93 MID 144 PSID 4 Engine Brake Stalk Lever, Check .. 94 MID 144 PSID 200 J1939 Control Data Link Interruption, Engine ECU ......................................... 99 MID 144 PSID 202 J1939 Control Data Link Interruption, Instrument Control Unit ...................... 100 MID 144 PSID 204 J1939 Control Data Link Interruption, Brake Control Unit .............................. 101 MID 144 PSID 210 J1939 Control Data Link Interruption, Lighting Control Module (LCM) .......... 102 MID 144 PSID 214 J1939 Control Data Link Interruption, Bodybuilder Control Unit .................... 103 MID 144 SID 231 J1939 Control Link ..................... 104 Operation Numbers
61 69
1
2
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
Specifications Vehicle ECU Component Locations
W3005048
A17
VECU
PA
Connector, PA1 - 30 (green)
PB
Connector, PB1 - 30 (blue)
PC
Connector (green), J1587/1708 Information Data Link, and J1939 Control Data Link
Note: See corresponding (P)PID/(P)SID for location of components.
3
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
Description of Signals VECU, measurement box connected between VECU and wiring harness, connector PA Prerequisites: • Measurement box 9998699 and adapter 9813194 connected between VECU connector PA and wiring harness. • VECU connected. • Ignition key in DRIVE position. • Engine OFF. • Measure voltage using multimeter.
T0008364
B+ = battery voltage Connection
Signal type
Measuring points
Expected value
PA1
Cruise control SET-/COAST
PA1 - PA12
0V B+ (SET- active)
PA2
Cruise control SET+/ACCEL
PA2 - PA12
0V B+ (SET+ active)
PA3
Cruise control, ON/OFF
PA3 - PA12
0 V (OFF) B+ (ON)
PA4
Fuel priming
PA4 - PA12
0 V (OFF) B+ (ON)
PA5
Brake pedal
PA5 - PA12
B+ 0 V (brake pedal depressed)
PA6
Starting switch, start position
PA6 - PA12
0V B+ (ignition key in START position)
PA7
Starting switch, preheating position
PA7 - PA12
0V B+ (ignition key in preheat position)
PA8
Clutch pedal
PA8 - PA12
B+ 0 V (clutch pedal depressed)
PA9
not used
PA10
not used
PA11
not used
PA12
Ground connection, VECU
PA12 - ground
0V
PA13
Supply voltage, control unit
PA13 - PA12
0 V (ignition key in OFF position) B+ (ignition key in DRIVE position)
PA14
Starting switch, drive position
PA14 - PA12
0 V (ignition key in OFF position) B+ (ignition key in DRIVE position)
PA15
not used
PA16
not used
PA17
not used
4
Other
VOLVO only
VOLVO only
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Measuring points
Expected value
Manual fan switch
PA19 - PA12
0V B+ (manual fan switch ON)
PA20
Engine brake, switch no. 1
PA20 - PA12
0 V (ignition key in OFF position) See “Engine Brake Variants” page 13 (ignition key in ON position)
PA21
Engine brake, switch no. 2
PA21 - PA12
0 V (ignition key in OFF position) See “Engine Brake Variants” page 13 (ignition key in ON position)
PA22
reserved
PA22 - PA12
PA23
Idle validation switch 1
PA23 - PA12
0V B+ (accelerator pedal depressed)
PA24
Air conditioning, status switch
PA24 - PA12
0 V (no fan request from A/C) B+ (fan requested by A/C)
PA25
not used
PA26
not used
PA27
not used
PA28
not used
PA29
Power Take-Off, PTO switch
PA29 - PA12
0 V (switch OFF) B+ (switch ON)
PA30
Cruise control, RESUME
PA30 - PA12
0 V (RESUME inactive) B+ (RESUME active)
Connection
Signal type
PA18
not used
PA19
Specifications
Other
VOLVO only
5
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
VECU, measurement box connected between VECU and wiring harness, connector PB Prerequisites: • Measurement box 9998699 and adapter 9998533 connected between VECU connector PB and wiring harness. • Measurement box 9998699 and adapter 9813194 connected between VECU connector PA and wiring harness. • VECU connected. • Ignition key in DRIVE position. • Engine OFF. • Measure voltage using multimeter. T0008363
B+ = battery voltage Connection
Signal type
PB1
not used
PB2
not used
PB3
Idle validation switch signal to EECU (redundant)
PB4
not used
PB5
Voltage supply:
•
Cruise control switch
•
Engine brake switch
PB6
Vehicle speed sensor (+)
PB7
not used
PB8
Accelerator pedal, position
PB9
not used
PB10
Voltage supply:
•
Accelerator pedal sensor
•
Engine brake stalk switch
PB11
Parking brake, status
PB12
not used
PB13
not used
6
Measuring points
Expected value
Other
PB3 - PA12
0 V (accelerator pedal depressed) 4.0 - 6.0 V (accelerator pedal at idle)
Cummins only
PB5 - PA12
≈ B+
PB6 - PB20
0.3 - 9.5 V
PB8 - PA12
0.4 - 0.6 V (no acceleration) 2.6 - 3.8 V (full acceleration) 3.0 - 4.4 V (kickdown)
PB10 - PA12
4.7 - 5.3 V
PB11 - PA12
B+ (parking brake released) 0 V (parking brake applied)
Measurement requires that the output shaft from the gearbox is rotating. Measure the voltage of the signal’s minimum and maximum values.
Engine brake stalk switch - used only for Cummins EBR-CBJ6
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Connection
Signal type
PB14
not used
PB15
Relay voltage supply,
•
VECU, EMS (Volvo)
•
VECU (Cummins)
Specifications
Measuring points
Expected value
PB15 - PA12
B+ (ignition key in OFF position) 0 - 1 V (ignition key in DRIVE position)
Other
PB16
PTO output
PB16 - PA12
B+ (inactive) 0 V (active)
VOLVO only
PB17
Buffered idle validation switch
PB17 - PA12
0V B+ (accelerator pedal depressed)
VOLVO only
PB18
not used
PB19
Voltage supply:
PB19 - PA12
≈ B+
PB20 - PB6
0.3 - 9.5 V
Measurement requires that the output shaft from the gearbox is rotating. Measure the voltage of the signal’s minimum and maximum values.
PB22 - PA12
0V
Engine brake stalk switch - used only for Cummins EBR-CBJ6
PB24 - PA12
0.3 1.0 1.7 2.3 2.9 3.6
PB27 - PA12
B+ (brake pedal released) 0 V (brake pedal depressed)
•
Pedal switches
PB20
Vehicle speed sensor (-)
PB21
not used
PB22
Ground connection:
• •
Accelerator pedal Engine brake stalk switch
PB23
not used
PB24
Engine brake stalk switch position sensor
PB25
not used
PB26
not used
PB27
Brake pressure switch
PB28
not used
PB29
not used
PB30
not used
-
0.7 1.6 2.5 3.5 4.4 5.4
V (pos V (pos V (pos V (pos V (pos V (pos
1) 2) 3) 4) 5) 6)
Cummins ISX with EBR-CBJ6 only; see “Engine Brake Variants” page 13.
7
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
VECU, measurement box connected to wiring harness, connector PA Prerequisites: • Measurement box 9998699 and adapter 9813194 connected to connector PB on the wiring harness. • Measurement box 9998699 and adapter 9998533 connected to connector PA on the wiring harness. • Ignition key in OFF position (unless otherwise stated in the table). • Measuring resistance using the multimeter (unless otherwise stated in the table).
T0008365
B+ = battery voltage Connection
Signal type
Measuring points
Expected value
PA1
Cruise control, SET-/COAST
PA1 - PB5
∞ 0
(SET-active)
Cruise control, SET+/ACCEL
PA2 - PB5
∞ 0
(SET+ active)
PA3
Cruise control, ON/OFF
PA3 - PB5
∞ 0
(OFF) (ON)
PA4
Fuel priming switch
PA4 - PA12
∞ 0
(OFF) (ON)
PA5
Brake pedal
PA5 - PB19
0 ∞
(brake pedal depressed)
PA2
Other
VOLVO only
PA6
Starting switch, start position
PA6 - PA12
0 V (ignition key in DRIVE position) B+ (ignition key in START position)
Measure voltage using multimeter.
PA7
Starting switch, preheating position (II 1/2)
PA7 - PA12
0 V (ignition key in DRIVE position) B+ (ignition key in preheat position)
VOLVO only; measure voltage using multimeter.
PA8
Clutch pedal
PA8 - PB19
0 ∞
(clutch pedal depressed)
PA9
not used
PA10
not used
PA11
not used
PA12
Ground connection, VECU
PA12 - ground
PA13
Supply voltage, VECU
PA13 - PA12
0V B+ (Connect PB15 to ground)
Measure voltage using multimeter.
PA14
Starting switch, drive position
PA14 - PA12
0V B+ (ignition key in DRIVE position)
Measure voltage using multimeter.
PA15
not used
PA16
not used
PA17
not used
PA18
not used
8
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
Connection
Signal type
Measuring points
Expected value
PA19
Manual fan switch
PA19 - PA12
0V B+ (manual fan switch ON)
PA20
Exhaust brake, switch VCB / retarder, switch SET+
PA20 - PB5
∞ 0 (switch, exhaust brake in position 2 (VCB) or switch retarder, SET+ active)
See “Engine Brake Variants” page 13.
PA21
Exhaust brake, switch EPG / retarder, switch SET-
PA21 - PB5
∞ 0 (switch, exhaust brake in position 1 (EPG) or switch retarder, SET-active)
See “Engine Brake Variants” page 13.
PA22
reserved
PA23
Idle validation switch 1
PA23 - PB19
∞ 20 - 90 (accelerator pedal depressed)
PA24
Air conditioning, status switch
PA24 - PA12
0 (no fan request from A/C) > 100 k (fan requested by A/C)
PA25
not used
PA26
not used
PA27
not used
PA28
not used
PA29
Power Take-Off, PTO switch
PA29 - PA12
0 V (switch OFF) B+ (switch ON)
PA30
Cruise control, RESUME
PA30 - PB5
∞ 0
Other
VOLVO only
(RESUME active)
9
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
VECU, measurement box connected to wiring harness, connector PB Prerequisites: • Measurement box 9998699 and adapter 9998533 connected to connector PB on the wiring harness. • Measurement box 9998699 and adapter 9813194 connected to connector PA on the wiring harness. • Ignition key in OFF position (unless otherwise stated in the table). • Measure resistance using multimeter (unless otherwise stated in the table).
T0008365
B+ = battery voltage Connec tion
Signal type
PB1
not used
PB2
not used
PB3
Idle validation switch signal to EECU (redundant)
PB4
not used
PB5
Voltage supply:
• •
Switch cruise control Switch exhaust brake/retarder (SET+/-)
Measuring points
1 PB5 - PA1 2 PB5 - PA2 3 PB5 - PA3 4 PB5 - PA20
6 PB5 - PA30
Vehicle speed sensor
Other
Cummins only; no relevant measurement.
5 PB5 - PA21
PB6
Expected value
PB6 - PB20
1 ∞ 0 (SET-active) 2 ∞ 0 (SET+ active) 3 ∞ (OFF) 0 (ON) 4 See “Engine Brake Variants” page 13 5 See “Engine Brake Variants” page 13 6 ∞ 0 (RESUME active) 2.0 - 4.0 k
(magnetic VSS)
Verify VSS installed; with auto trans (Autoshift, Lightning, Freedom Line), VECU might receive VSS info over datalink instead.
PB7
not used
PB8
Accelerator pedal, position
PB9
not used
10
PB8 - PB22¹
1.0 - 2.0 k
(no acceleration)
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
Connec tion
Signal type
Measuring points
Expected value
Other
PB10
Voltage supply:
PB10 - PB22
Measurement at accelerator pedal¹: 3.2 - 4.8 k Measurement at engine brake stalk switch²: 1.7 - 2.5 k (pos 1) 1.3 - 2.0 k (pos 2) 1.1 - 1.7 k (pos 3) 0.9 - 1.4 k (pos 4) 0.8 - 1.2 k (pos 5) 0.7 - 1.1 k (pos 6)
See “Engine Brake Variants” page 13.
PB11 - PA12
∞ 0
PB15 - PA12
B+ 0 V (ground PB15, and listen for relay clicking sound)
Ignition key in DRIVE position
• •
Accelerator pedal sensor Engine brake stalk switch
PB11
Parking brake, status
PB12
not used
PB13
not used
PB14
not used
PB15
Relay, voltage supply
•
VECU, EMS (VOLVO)
•
VECU, (Cummins)
(parking brake released) (parking brake applied)
PB16
PTO output
PB16 - PA12
Ignition key in DRIVE position, switch PTO active, connect PB 16 to ground, listen for clicking sound from solenoid valve
VOLVO only
PB17
Buffered idle validation switch
PB17 - PA12
2.3 - 3.5 k
VOLVO only
PB18
not used
PB19
Voltage supply:
1 PB19 - PA5
1 0 ∞ (brake pedal depressed) 2 0 ∞ (clutch pedal depressed) 3 ∞ 20 - 90 (accelerator pedal depressed)
•
Pedal switches
2 PB19 - PA8 3 PB19 - PA23
PB20
Vehicle speed sensor (-)
PB20 - PB6
2.0 - 4.0 k
(magnetic VSS)
Verify VSS installed; with auto trans (Autoshift, Lightning, Freedom Line), VECU might receive VSS info over datalink instead.
PB21
not used
11
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
Connec tion
Signal type
Measuring points
Expected value
PB22
Ground connection:
1 PB22 - PB8¹
•
2 PB22 - PB10
1 1.0 - 2.0 k (no acceleration) 2 Measurement at accelerator pedal¹: 3.2 - 4.8 k Measurement at engine brake stalk switch²: 1.7 - 2.5 k (pos 1) 1.3 - 2.0 k (pos 2) 1.1 - 1.7 k (pos 3) 0.9 - 1.4 k (pos 4) 0.8 - 1.2 k (pos 5) 0.7 - 1.1 k (pos 6)
•
Accelerator pedal Engine brake stalk switch position sensor (Cummins ISX)
PB23
not used
PB24
Engine brake stalk switch position sensor
PB25
not used
PB26
not used
PB27
Brake pressure switch
PB28
not used
PB29
not used
PB30
not used
PB24 - PB22²
1.0 0.9 0.8 0.8 0.7 0.7
PB27 - PA12
3.5 V - B+ (brake pedal released) 0 V (brake pedal depressed)
Table Notes 1 2
12
Connector to engine brake stalk switch disconnected. Connector to accelerator pedal disconnected.
-
1.4 k 1.3 k 1.2 k 1.1 k 1.1 k 1.0 k
(pos (pos (pos (pos (pos (pos
Other
1) 2) 3) 4) 5) 6)
See “Engine Brake Variants” page 13
Cummins EBR-CBJ6 only
Measure voltage using multimeter.
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Specifications
Engine Brake Variants EBR Variant
Voltage
Voltage
Switch
Stalk
(A)
(A)
Voltage (A)
Pos
Pos
PA20 -
PA21 -
PB24 - PA12
PA12
PA12
0 V
0 V
0 V
B+
0 V
0 V
0 V
B+
B+
B+
0 V
0 V
0 V
B+
0 V
0 V
0 V
B+
HIGH
B+
0 V
D12D
OFF
(EBR-EPG)
ON
D12D (EBR-VEB)
n/a
OFF LOW
n/a
HIGH
ISL/ISC
OFF
(EBR-EXH)
ON
n/a
OFF
ISL (EBR-CBJ2)
LOW
n/a
OFF
0 V
0 V
ISX
LOW
B+
0 V
(EBR-CBJ3)
MED
0 V
B+
B+
B+
n/a
HIGH
n/a
n/a
n/a
n/a
n/a
OFF
ANY
0 V
—
ISX
ON
1
B+
0.3 - 0.7 V
(EBR-
ON
2
B+
CBJ6; with
ON
3
B+
6-position
ON
4
B+
2.3 - 3.5 V
stalk lever)
ON
5
B+
2.9 - 4.4 V
ON
6
B+
3.6 - 5.4 V
1.0 - 1.6 V n/a
1.7 - 2.5 V
Resistance
Resistance
(B)
(B)
PA20 - PB5
PA21 - PB5
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
Resistance (B) PB24 - PB22 (1)
Code)
n/a
n/a
n/a
n/a
n/a
0 (ATC) 100 (ATD)
“Notes” page 13
(2)
0 (ATC) n/a
50 (ATD)
(2)
100 (ATE) 0 (ATC) n/a
33 (ATE) 66 (ATD)
(2)
100 (ATF) —
0.9 - 1.3 k
0.8 - 1.2 k
0.8 - 1.1 k
0.7 - 1.1 k
0.7 - 1.0 k
1.0 - 1.4 k n/a
% EBR (Parameter
0 17 (ATC) 33 (ATD) 50 (ATE)
(2) (3)
67 (ATF) 83 (ATG) 100 (ATH)
Notes (A) (B) (1) (2)
Voltage measurements (VECU connected) Resistance measurements (VECU disconnected) Connector to accelerator pedal disconnected Parameter codes ATC through ATH correspond to parameter names CUMMINS_engine brake_SWITCH_POS1 through _POS6, and are used by the VECU to relate engine brake switch input(s) to the requested
engine brake % sent to the engine. These are Level 3 Programmable by the customer using VCADS Pro (with network connection). (3) EBR function is 0% whenever ON/OFF switch is OFF. When ON/OFF switch is ON, EBR function % is determined by stalk position.
13
14
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Tools
Tools Special Tools The following special tools are used to carry out fault tracing of components. For ordering instructions for special tools, refer to tool information, group 08.
9990014
9990020
9990062
62-pin cable adapter
Cruise control switch adapter
Extension cable (for 9990014)
9990151
9998533
9998534
Adapter between VECU, connector PB, and measurement box
Adapter for DIN connector
9990008
9998699
9998604
Set of testpins
Measurement box 62-unit
Adapter
Adapter, vehicle speed sensor
15
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Tools
88890016 Accelerator pedal switch
Overlay Part Numbers
85104406
85104407
85104409
Overlay (used with adapter 9998533)
Overlay (used with adapter 9813194)
Overlay (used with adapter 9998604)
85108489 Overlay (Used with adapter 88890016)
16
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Tools
Other Special Equipment
J39200 Multimeter
9813194 Adapter between VECU, connector PA, and measurement box 9998699
17
18
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Troubleshooting MID 144 Vehicle Control Unit, Fault Codes MID: Message Identification Description (identification of control unit).
SID: Subsystem Identification Description (identification of component).
PID: Parameter Identification Description (identification of parameter (value)).
PSID: Proprietary Subsystem Identification Description (Volvo unique identification of component).
PPID: Proprietary Parameter Identification Description (Volvo unique identification of parameter (value)).
FMI: Failure Mode Identifier (identification of error type).
Fault code
Component
FMI
Section
MID 144 PID 84
Vehicle speed
2, 5, 6
“MID 144 PID 84 Vehicle Speed” page 21
MID 144 PID 91
Accelerator pedal, percentage position
3, 4
“MID 144 PID 91 Accelerator Pedal Position (Percentage)” page 27
MID 144 PID 150
PTO output (Volvo only)
4
“MID 144 PID 150 PTO Output” page 32
MID 144 PID 152
VECU, number of resets
12
“MID 144 PID 152 VECU, Number of Resets” page 36
MID 144 PID 191
Output shaft speed
2, 5, 6
“MID 144 PID 191 Output Shaft Speed” page 37
MID 144 PPID 61
Retarder switches (Volvo only)
7
“MID 144 PPID 61 Engine Brake Switch” page 44
MID 144 PPID 69
Buffered idle validation switch (Volvo only)
4
“MID 144 PPID 69 Buffered Idle Validation Switch” page 48
MID 144 PPID 70
Pedal switches, supply
4
“MID 144 PPID 70 Pedal Switches, Supply” page 51
MID 144 PPID 71
Cruise control and engine brake, switch supply
4
“MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply” page 59
MID 144 PPID 72
Accelerator pedal and engine brake, sensors supply
3, 4
“MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply” page 69
MID 144 PPID 74
VECU power supply
3, 4
“MID 144 PPID 74 VECU Power Supply” page 77
MID 144 SID 230
Idle validation switch 1
7
“MID 144 SID 230 Idle Validation Switch 1” page 80
MID 144 SID 231
Control link SAE J1939
2
“MID 144 SID 231 J1939 Control Link” page 83
MID 144 SID 240
Program memory
2
“MID 144 SID 240 Program Memory” page 85
MID 144 SID 243
Cruise control, set switch
7
“MID 144 SID 243 Cruise Control Set Switch” page 86
MID 144 SID 250
Information link SAE J1708
2
“MID 144 SID 250 J1587/J1708 Information Data Link” page 91
MID 144 SID 253
Calibration memory EEPROM
2, 13
“MID 144 SID 253 Calibration Memory EEPROM” page 92
MID 144 PSID 4
Engine brake stalk lever (Cummins EBR-CBJ6 only)
3, 4
“MID 144 PSID 4 Engine Brake Stalk Lever” page 93
MID 144 PSID 200
Engine timeout
9
“MID 144 PSID 200 J1939 Control Data Link Interruption, Engine ECU” page 99 19
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Fault code
Component
FMI
Section
MID 144 PSID 202
Instrument timeout
9
“MID 144 PSID 202 J1939 Control Data Link Interruption, Instrument Control Unit” page 100
MID 144 PSID 204
ABS/EBS timeout
9
“MID 144 PSID 204 J1939 Control Data Link Interruption, Brake Control Unit” page 101
MID 144 PSID 210
LCM timeout
9
“MID 144 PSID 210 J1939 Control Data Link Interruption, Lighting Control Module (LCM)” page 102
MID 144 PSID 214
BBM timeout (VOLVO only, vehicles equipped with BBM)
9
“MID 144 PSID 214 J1939 Control Data Link Interruption, Bodybuilder Control Unit” page 103
FMI Table SAE standard FMI
20
Display text
SAE text
Value too high
Data valid, but above normal operating range.
1
Value too low
Data valid, but under normal operating range
2
Incorrect data
Intermittent or incorrect data.
3
Electrical faults
Abnormally high voltage or short circuit to higher voltage.
4
Electrical faults
Abnormally low voltage or short circuit to lower voltage.
5
Electrical faults
Abnormally low current or open circuit.
6
Electrical faults
Abnormally high current or short circuit to ground.
7
Mechanical fault
Incorrect response from mechanical system.
8
Mech. or electrical faults
Abnormal frequency.
9
Communication fault
Abnormal updating rate.
10
Mech. or electrical faults
Abnormally large variations.
11
Unknown fault
Unidentifiable error.
12
Component fault
Faulty unit or component.
13
Incorrect calibration
Calibration values outside the limits.
14
Unknown fault
Special instructions.
15
Unknown fault
Reserved for future use.
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PID 84 Vehicle Speed
W3006058
W3006059
General The Vehicle Speed Signal arrives at the VECU from one of three sources, depending on vehicle / transmission configuration:
• • •
Eaton-type Vehicle Speed Sensor (VSS) Automated Transmission without extra sensor Allison Transmission
In all cases, the origin of the Vehicle Speed Signal is a VSS sensor in the output shaft (tailshaft) of the transmission. Component: A17, VECU; B68 speedometer sensor.
21
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Fault code FMI 2
FMI 6
Intermittent or incorrect data.
Abnormally high current or short circuit.
Conditions for fault code: • The VECU can receive vehicle speed information over the J1939 Control Data Link from certain transmissions. This FMI will occur if the VECU is expecting such data but does not receive it.
Conditions for fault code: • If the VECU registers a current higher than 140 µA on any of the signal wires from the speed sensor, the VECU interprets this as a fault and a fault code is set.
Note: First read and correct fault codes from the transmission ECU, if applicable.
Possible cause: • Fault in wiring harness, control link. • Fault in vehicle speed sensor or VSS wiring to transmission ECU.
Possible cause:
• • • •
Signal wire short-circuited to higher voltage. Signal wire short-circuited to ground. Signal wires short-circuited to each other. Fault in sensor.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Reaction from the VECU:
Noticeable external symptom: • Yellow lamp lights up. • No vehicle speed in gauge. • No PTO or cruise control.
Noticeable external symptom:
Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37. • “MID 144 PID 84 Vehicle Speed, Check” page 23.
FMI 5 Abnormally low current or open circuit.
Conditions for fault code: • If the VECU registers a current lower than 90 µA on any of the signal wires from the speed sensor the VECU interprets this as a fault and a fault code is set. Possible cause:
• • • •
Poor contact, sensor connection. Switch resistance and oxidation. Break, signal wire. Fault in sensor.
Reaction from the VECU:
•
Yellow lamp lights up.
Noticeable external symptom:
• • •
No vehicle speed on gauge. No PTO. No cruise control.
Action:
•
22
“MID 144 PID 84 Vehicle Speed, Check” page 23.
• • • •
Yellow lamp lights up.
No vehicle speed on gauge. No PTO. No cruise control.
Action:
•
Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
•
“MID 144 PID 84 Vehicle Speed, Check” page 23.
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-08 MID 144 PID 84 Vehicle Speed, Check Special tools: 9990151, 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU, • •
speedometer, and brake control unit. Switch off the current in the vehicle before the connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
•
“Cruise control switch, test”
The test allows you to read the speed signal from the VECU.
Determination of Vehicle Speed Sensor Configuration The appropriate check of the system will depend on the configuration of the Vehicle Speed sensor and circuits. Use the following information to determine which system the vehicle has:
•
Eaton-Type Vehicle Speed Sensor Use this check whenever FMI 5 or 6 is present. This type of Vehicle Speed Sensor (VSS) will be found on the tailshaft of manual transmissions. It may also be found on some automated transmissions (Eaton Autoshift, Eaton Lightning) when two VSS are present in the tailshaft - one VSS will be wired directly to the Transmission ECU, the other will be wired to the VECU (circuits 550/551).
•
Automated Transmission without Extra Sensor If only one VSS is found on an automated transmission (Eaton Autoshift, Eaton Lightning) the VECU is receiving Outputshaft Speed information from the Transmission ECU over the J1939 datalink. All Meritor / ZF FreedomLine transmissions fall into this category.
•
Allison Transmission Use this section if the vehicle is equipped with an Allison MD or HD transmission.
23
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
•
Eaton-type Vehicle Speed Sensor (VSS)
For this type of VSS, 3 checks can be performed: 1 Prerequisites:
• • • •
Ignition key in OFF position. Measurement box inserted at VECU (disconnected at VECU side). Vehicle Speed Sensor at transmission connected. Measure resistance, harness side of PB6 – PB20, “looking toward” VSS.
• Measuring points
Expected value
PB6 - PB20
2.0 - 4.0 k 2 Prerequisites:
• • • •
Ignition key in OFF position. Measurement box inserted at VECU (disconnected at VECU side). Vehicle Speed Sensor at transmission disconnected. Make sure PB6 and PB20 are not shorted to ground, power, or each other.
• Measuring points
Expected value
PB6 - PB20
OL
PB6 - ground
OL
PB20 - ground
OL 3 Prerequisites:
• • • • •
Ignition key in ON position. Measurement box inserted at VECU (connected at VECU). Vehicle Speed Sensor at transmission connected. Vehicle must be stationary. Measure voltage across PB6 – PB20.
Measuring points
Expected value
PB6 - PB20
1.25 - 1.75 Vdc (average) varying between approx. 1.0 and 2.0 V
24
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
•
•
Troubleshooting
Automated Transmission without Extra Sensor 1
If two Vehicle Speed Sensors (VSS) are present in the transmission’s tailshaft and the PID 84 fault code set by the VECU is FMI 5 or 6, use the troubleshooting for the Eaton-type Vehicle Speed Sensor (above).
2
If only one VSS is present in the tailshaft (or if none are visible, as is the case with the Meritor / ZF FreedomLine), then the VECU is receiving its information over the J1939 Control Data Link. Another way to tell that the VECU is receiving the information over the Data Link is by the FMI that the VECU is using. For example, if the fault code is PID 84 FMI 2, this indicates that the VECU is expecting the data over the J1939 Control Data Link but is not receiving it.
3
In these cases, troubleshoot any fault codes in the transmission ECU first. If the trouble remains, refer to troubleshooting information for the SAE J1939 Control Data Link, group 37.
Allison Transmission 1
The Vehicle Speed information from Allison Transmissions can be obtained one of two ways:
•
A hardwire connection from the Allison ECU (Black connector, pin 30, circuit A215) to the VECU (PB6, circuit 550). This signal is a square-wave reproduction of the VSS located in the Allison’s tailshaft.
•
Over the J1939 Control Data Link. (NOTE: even if obtaining the information over the Data Link, the hardwire connection may still be in place.) In either case, troubleshoot any fault codes in the Allison transmission ECU first.
2
If the PID 84 fault code in the VECU is FMI 2, this indicates that the VECU is configured to receive the VSS information over the J1939 Control Data Link. If the problem remains, refer to troubleshooting information for the SAE J1939 Control Data Link, group 37.
3
If FMI 2 is not indicated, or there are no fault codes present in the VECU but a speed-related problem still exists, troubleshoot the hardwire connection between the Allison Transmission ECU and the VECU. Refer to Service Information, group 37.
25
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of Component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
•
Eaton-Type Vehicle Speed Sensor (VSS)
For the Eaton-type VSS, one check can be performed at the VSS: Prerequisites: • Vehicle Speed Sensor at transmission disconnected. • Measure resistance of sensor using tool 9990151. Measuring points
Expected value
A-B
2.0 - 4.0 k
•
Automated Transmission without Extra Sensor
No relevant measurements; refer to the appropriate service literature for the transmission manufacturer.
•
Allison Transmission
No relevant measurements; refer to the appropriate service literature for the transmission manufacturer.
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 23).
26
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PID 91 Accelerator Pedal Position (Percentage)
W3006772
W3006776
General Information Component: B25 sensor, accelerator pedal; A17, VECU
Fault Codes 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: • If the VECU receives a signal from the sensor that is higher than 4.3 V, the control unit interprets this as a fault and a fault code is set.
Conditions for fault code: • If the VECU receives a signal from the sensor that is lower than 0.4 V, the control unit interprets this as a fault and a fault code is set.
Possible cause: • Open circuit, ground cable. • Signal wire short-circuited to higher voltage. • Faulty sensor. • Idle switch 1 faulty. • Switch resistance and oxidation.
Possible cause: • Open circuit, supply cable. • Open circuit, signal cable. • Signal wire short-circuited to ground. • Faulty sensor. • Switch resistance and oxidation.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Noticeable external symptom: • Yellow lamp lights up. • Engine/system does not respond to full acceleration.
Noticeable external symptom: • Yellow lamp lights up. • Engine/system does not respond to full acceleration.
Action: • “MID 144 PID 91 Accelerator Pedal Position (Percentage), Check” page 28.
Action: • “MID 144 PID 91 Accelerator Pedal Position (Percentage), Check” page 28.
27
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-09 MID 144 PID 91 Accelerator Pedal Position (Percentage), Check Special tools: 8510848, 99998533, J39192, 88890016, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the connectors are disconnected.
•
Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful to check component function:
• Accelerator pedal switches and sensors, test • MID 144, pinout test Measurement at the component’s connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Ground wire 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Connector to engine brake switch disconnected (if equipped). • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
4 - alt ground
88890016 J39200
28
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Supply wire 2 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Connector to engine brake switch disconnected (if equipped). • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement to the VECU. Measuring points
Expected value
6-4
4.3 - 6.5 V
88890016 J39200
Signal wire 3 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Connector to engine brake switch disconnected (if equipped). • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5-4
80 - 120 k
88890016 J39200
Wiring harness 4 Check the wiring harness; refer to Service Information, group 37.
29
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
Accelerator pedal sensor 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Measurement box with adapter connected to the accelerator pedal sensor. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at the accelerator pedal sensor. Measuring points
Expected value
6-4
3.2 - 4.8 k
6-5
1.0 - 2.0 k
(no acceleration)
88890016 J39200
Check of subsystem Ground wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB (blue) and wiring harness. • Measuring the resistance using the multimeter. • VECU connected. • Ignition key in OFF position. Measuring points
Expected value
PB22 - ground
9998533 , 9998699 J39200
30
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Supply wire 2 Prerequisites: • Measurement box with adapter connected between VECU connector PB (blue) and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB10 - PB22
4-6V
9998533 , 9998699 J39200
Signal wire 3 Prerequisites: • Measurement box with adapter connected between VECU connector PB (blue) and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB8 - PB22
0.4 - 0.6V (no acceleration) 2.6 - 3.8 V (full acceleration)
9998533 , 9998699 J39200
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 28).
31
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PID 150 PTO Output (Volvo engines only)
W3005531 W3005549
General Information Note: Parameters are set by bodybuilders in aftermarket. Component: A17, VECU; K07 relay, PTO; S28 dash switch, PTO; Y18A solenoid, PTO.
Fault code FMI 4 Abnormally low voltage or short circuit to lower voltage.
Conditions for fault code: • If the VECU registers a voltage lower than 2.3 V when the function is inactive, the control unit interprets this as a fault and a fault code is set. Possible cause: • Open circuit, supply cable forward to relay. • Cable between relay and control unit short-circuited to ground. • Open circuit, cable between relay and control unit. • Faulty relay. • Switch resistance and oxidation. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • “MID 144 PID 150 PTO Output, Check” page 34.
32
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
General Information Note: Parameters are set by bodybuilders in aftermarket. Component: A17, VECU; K07 relay, PTO; S28 dash switch, PTO; Y18A solenoid, PTO.
Fault code FMI 4 Abnormally low voltage or short circuit to lower voltage.
Conditions for fault code: • If the VECU registers a voltage lower than 2.3 V when the function is inactive, the control unit interprets this as a fault and a fault code is set. Possible cause: • Open circuit, supply cable forward to relay. • Cable between relay and control unit short-circuited to ground. • Open circuit, cable between relay and control unit. • Faulty relay. • Switch resistance and oxidation. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • “MID 144 PID 150 PTO Output, Check” page 34.
33
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-01 MID 144 PID 150 PTO Output, Check (Volvo engines only)
Special tools: 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the connectors are disconnected.
•
Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Ground wire 1 Prerequisites: • Connector to relay K07 removed. • Adapter connected to the VECU. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
PB16 - ground
3.4 M
998533 , 9998699 J39200
Wiring harness 2 Check the wiring harness; refer to Service Information, group 37.
34
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
Relay 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Ignition key in DRIVE position. • Switch PTO active. • Check of the solenoid valve. Earth
Checks
PB16 - ground
Listen for sound from the relay
9998533 , 9998699 J39200
Check of subsystem Ground wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Switch PTO active. Measuring points
Expected value
PB16 - PB19
B+ (relay inactive) 0 V (relay active)
9998533 , 9998699 J39200
35
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
MID 144 PID 152 VECU, Number of Resets
W3005048
General Information The software in the VECU contains an internal checking function that restarts the control unit when there is a fault in the execution of the software. PID 152 contains information about how many such restarts that have been made. Component: A17, VECU.
Fault code FMI 12 Faulty unit or component.
Conditions for fault code: • If an internal software fault occurs an info code is set. Possible cause: • The system has been restarted due to an internal software fault. Reaction from VECU: • Fault code is set. • The system is restarted.
36
Troubleshooting
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PID 191 Output Shaft Speed
W3006058
W3006059
General The Output Shaft Speed Signal arrives at the VECU from one of three sources, depending on vehicle / transmission configuration:
• • •
Eaton-type Vehicle Speed Sensor (VSS) Automated Transmission without extra sensor Allison Transmission
In all cases, the origin of the Output Shaft Speed Signal is a VSS sensor in the output shaft (tailshaft) of the transmission. Component: A17, VECU; B68 speedometer sensor.
37
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Fault code FMI 2 Intermittent or incorrect data.
Conditions for fault code: • The VECU can receive vehicle speed information over the J1939 Control Data Link from certain transmissions. This FMI will occur if the VECU is expecting such data but does not receive it. Note: First read and correct fault codes from the transmission ECU, if applicable.
Possible cause: • Fault in wiring harness, control link. • Fault in vehicle speed sensor or VSS wiring to transmission ECU. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. • No vehicle speed in gauge. • No PTO or cruise control. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37. • “MID 144 PID 191 Output Shaft Speed, Check” page 40.
FMI 5 Abnormally low current or open circuit.
Conditions for fault code: • If the VECU registers a current lower than 90 µA on any of the signal wires from the speed sensor the VECU interprets this as a fault and a fault code is set. Possible cause:
• • • •
Poor contact, sensor connection. Switch resistance and oxidation. Break, signal wire. Fault in sensor.
Reaction from the VECU:
•
Yellow lamp lights up.
Noticeable external symptom:
• • •
No vehicle speed on gauge. No PTO. No cruise control.
Action:
• 38
“MID 144 PID 191 Output Shaft Speed, Check” page 40.
Troubleshooting
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
FMI 6 Abnormally high current or short circuit.
Conditions for fault code: • If the VECU registers a current higher than 140 µA on any of the signal wires from the speed sensor, the VECU interprets this as a fault and a fault code is set. Possible cause:
• • • •
Signal wire short-circuited to higher voltage. Signal wire short-circuited to ground. Signal wires short-circuited to each other. Fault in sensor.
Reaction from the VECU:
•
Yellow lamp lights up.
Noticeable external symptom:
• • •
No vehicle speed on gauge. No PTO. No cruise control.
Action:
•
Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
•
“MID 144 PID 191 Output Shaft Speed, Check” page 40.
39
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-28 MID 144 PID 191 Output Shaft Speed, Check Special tools: 9990151, 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU, • •
speedometer, and brake control unit. Switch off the current in the vehicle before the connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
•
“Cruise control switch, test”
The test allows you to read the speed signal from the VECU.
Determination of Output Shaft Speed Sensor Configuration The appropriate check of the system will depend on the configuration of the Vehicle Speed sensor and circuits. Use the following information to determine which system the vehicle has:
•
Eaton-Type Vehicle Speed Sensor Use this check whenever FMI 5 or 6 is present. This type of Vehicle Speed Sensor (VSS) will be found on the tailshaft of manual transmissions. It may also be found on some automated transmissions (Eaton Autoshift, Eaton Lightning) when two VSS are present in the tailshaft - one VSS will be wired directly to the Transmission ECU, the other will be wired to the VECU (circuits 550/551).
•
Automated Transmission without Extra Sensor If only one VSS is found on an automated transmission (Eaton Autoshift, Eaton Lightning) the VECU is receiving Outputshaft Speed information from the Transmission ECU over the J1939 datalink. All Meritor / ZF FreedomLine transmissions fall into this category.
•
Allison Transmission Use this section if the vehicle is equipped with an Allison MD or HD transmission.
40
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
•
Eaton-type Vehicle Speed Sensor (VSS)
For this type of VSS, 3 checks can be performed: 1 Prerequisites:
• • • •
Ignition key in OFF position. Measurement box inserted at VECU (disconnected at VECU side). Vehicle Speed Sensor at transmission connected. Measure resistance, harness side of PB6 – PB20, “looking toward” VSS.
• Measuring points
Expected value
PB6 - PB20
2.0 - 4.0 k 2 Prerequisites:
• • • •
Ignition key in OFF position. Measurement box inserted at VECU (disconnected at VECU side). Vehicle Speed Sensor at transmission disconnected. Make sure PB6 and PB20 are not shorted to ground, power, or each other.
• Measuring points
Expected value
PB6 - PB20
OL
PB6 - ground
OL
PB20 - ground
OL 3 Prerequisites:
• • • • •
Ignition key in ON position. Measurement box inserted at VECU (connected at VECU). Vehicle Speed Sensor at transmission connected. Vehicle must be stationary. Measure voltage across PB6 – PB20.
Measuring points
Expected value
PB6 - PB20
1.25 - 1.75 Vdc (average) varying between approx. 1.0 and 2.0 V
41
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
•
•
Troubleshooting
Automated Transmission without Extra Sensor 1
If two Vehicle Speed Sensors (VSS) are present in the transmission’s tailshaft and the PID 191 fault code set by the VECU is FMI 5 or 6, use the troubleshooting for the Eaton-type Vehicle Speed Sensor (above).
2
If only one VSS is present in the tailshaft (or if none are visible, as is the case with the Meritor / ZF FreedomLine), then the VECU is receiving its information over the J1939 Control Data Link. Another way to tell that the VECU is receiving the information over the Data Link is by the FMI that the VECU is using - if the fault code is PID 191 FMI 2, this indicates that the VECU is expecting the data over the J1939 Control Data Link but is not receiving it.
3
In these cases, troubleshoot any fault codes in the transmission ECU first. If the trouble remains, refer to troubleshooting information for the SAE J1939 Control Data Link, group 37.
Allison Transmission 1
The Output Shaft Speed information from Allison Transmissions will be obtained one of two ways:
•
A hardwire connection from the Allison ECU (Black connector, pin 30, circuit A215) to the VECU (PB6, circuit 550). This signal is a square-wave reproduction of the VSS located in the Allison’s tailshaft.
•
Over the J1939 Control Data Link. (NOTE: even if obtaining the information over the Data Link, the hardwire connection may still be in place.) In either case, troubleshoot any fault codes in the Allison transmission ECU first.
42
2
If the PID 191 fault code in the VECU is FMI 2, this indicates that the VECU is configured to receive the VSS information over the J1939 Control Data Link. If the problem remains, refer to troubleshooting information for the SAE J1939 Control Data Link, group 37.
3
If FMI 2 is not indicated, or there are no fault codes present in the VECU but a speed-related problem still exists, troubleshoot the hardwire connection between the Allison Transmission ECU and the VECU. Refer to Service Information, group 37.
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of Component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
•
Eaton-Type Vehicle Speed Sensor (VSS)
For the Eaton-type VSS, one check can be performed at the VSS: Prerequisites: • Vehicle Speed Sensor at transmission disconnected. • Measure resistance of sensor using tool 9990151. Measuring points
Expected value
A-B
2.0 - 4.0 k
•
Automated Transmission without Extra Sensor
No relevant measurements; refer to the appropriate service literature for the transmission manufacturer.
•
Allison Transmission
No relevant measurements; refer to the appropriate service literature for the transmission manufacturer.
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 23).
43
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PPID 61 Engine Brake Switch (Volvo engines only)
W3005532
W3005545
General Information Component: A17, VECU; S07, engine brake switch, selector type. EPG 2-position Volvo Engine Brake (OFF/ON) VEB 3-position Volvo Engine Brake (OFF/50%/100%)
Fault code FMI 7 Incorrect response from mecanical system.
Conditions for fault code: • If the VECU receives signals for PA20 active and PA21 inactive at the same time, the control unit will interpret it as a fault and a fault code will be set. Possible cause: • Faulty switch. • Fault in wiring harness. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Engine brake cannot be activated. • Yellow lamp lights up. Action: • “MID 144 PPID 61 Engine Brake Switch, Check” page 45.
44
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-04 MID 144 PPID 61 Engine Brake Switch, Check Special tools: 9990008, 9998699 Other special equipment: 9813194, J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for checking component function:
• Exhaust brake function, test • MID 144, pinout test Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Signal wire, engine brake switch 1 Note: The check below applies only to vehicles equipped with Volvo Engine Brake. Prerequisites: • Connector to engine brake switch disconnected. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
2.1 - 3.1 k
(VCB)
6 - ground
2.1 - 3.1 k
(EPG)
9990008 J39200
Wiring harness 2 Check the wiring harness; refer to Service Information, group 37.
45
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the component should also be made before connecting a new component.
Check of engine brake switch 1 Note: The check below applies only to vehicles equipped with Volvo Engine Brake (EBR-VEB). Prerequisites: • Connector to switch, for engine brake disconnected. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at switch for engine brake. Measuring points
Expected value
1-6
∞ 0 0
1-5
∞ (VCB and EPG inactive, if the vehicle is equipped with VCB) 0 (VCB active, if the vehicle is equipped with VCB)
(EPG inactive) (EPG active) (VCB active, if the vehicle is equipped with VCB)
9990008 J39200
46
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of subsystem Signal wire, engine brake switch 1 Note: The check below applies only to vehicles equipped with Volvo Engine Brake (EBR-VEB). Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA21 - PA12
0 V (EPG inactive) B+ (EPG active) B+ (VCB active, if the vehicle is equipped with VCB)
PA20 - PA12
0 V (VCB and EPG inactive, if the vehicle is equipped with VCB) B+ (VCB active, if the vehicle is equipped with VCB)
9998699 , 9813194 J39200
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 45).
47
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PPID 69 Buffered Idle Validation Switch (Volvo engines only)
W3005546
W3005533
General Information The function is used to be able to drive the vehicle at increased idling speed if a fault has occurred in the data links to the engine ECU. Component: A14, EECU; A17, VECU.
Fault code FMI 4 Abnormally low voltage or short circuit to lower voltage.
Conditions for fault code: • If the output signal from the buffered idle validation switch deviates from the input signal from idle switch 1, the control unit interprets this as a fault and a fault code is set. Note: The fault code is set first when the accelerator pedal is depressed.
Possible cause: • Signal cable short-circuited to ground. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • “MID 144 PPID 69 Buffered Idle Validation Switch, Check” page 49.
48
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-10 MID 144 PPID 69 Buffered Idle Validation Switch, Check (Volvo engines only)
Special tools: 9990014, 9990062, 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Signal cable 1 Prerequisites: • EECU’s connector disconnected. • Measurement box connected to the VECU. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement at the VECU. Measuring points
Expected value
EB15 - ground
0 V (no acceleration) B+ (full acceleration)
9990014 , 9990062 J39200
Wiring harness 2 Check the wiring harness; refer to Service Information, group 37.
49
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
Buffered idle validation switch 1 Prerequisites: • EECU connector disconnected. • Measurement box connected to the EECU. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at the EECU. Measuring points
Expected value
EB15 - EB59
2.3 - 3.5 k
9990014 , 9990062 J39200
Check of subsystem Note: If measurement box 9990014 (with adapter 9990062) is already connected to connector EB at the EECU, the check can more simply be carried out from here. Connect the measurement box between EECU connector EB and wiring harness. Connect a multimeter to the measurement box and measure the voltage (EB4 EB9). See the expected values below.
Signal cable 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB17 - PB22
0 V (no acceleration) B+ (full acceleration)
9998533 , 9998699 J39200
50
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PPID 70 Pedal Switches, Supply
W3006774
W3006777
General Information Voltage supply to pedal switches. Note: If vehicle is not equipped with a clutch pedal, clutch switch (S58) may be replaced with a jumper wire from the factory. Leave jumper wire in place and perform troubleshooting on circuit as if clutch switch were installed (with switch closed). Component: A17, VECU; S58, position switch, clutch pedal; S59, position switch, brake pedal; B25, sensor, accelerator pedal.
Fault code FMI 4 Abnormally low voltage or short circuit to ground.
Conditions for fault code: • If the VECU registers a voltage lower than 3.0 V on the supply cable, the control unit interprets this as a fault and a fault code is set. Possible cause: • Supply wire short-circuited to ground. • Signal wire for idle switch 1 short-circuited to ground. • Signal wire for brake switch short-circuited to ground. • Signal wire for clutch switch (if the vehicle is equipped with clutch pedal) short-circuited to ground. • Faulty switch. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • “MID 144 PPID 70 Pedal Switches, Supply, Check” page 52. 51
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-11 MID 144 PPID 70 Pedal Switches, Supply, Check Special tools: 88890016, 9998533, 9990008, 9998699 Other special equipment: 9813194, J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the connectors are disconnected.
•
Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
• • •
Accelerator pedal switches and sensors, test Cruise control switch, test MID 144, pinout test
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Supply wire, idle validation switch 1 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Adapter connected to accelerator pedal. • The following other pedal connectors disconnected:
• • • •
• •
Brake pedal switch (two sockets). Clutch pedal switch (if equipped with clutch pedal). Measure voltage using multimeter. VECU connected. Ignition key in DRIVE position. Measurement to the VECU.
Measuring points
Expected value
3 - ground
B+
88890016 J39200
52
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, idle validation switch 1 2 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Measurement box with adapter connected to the VECU. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
1 (common) - ground
2.1 - 3.1 k
88890016 J39200
Supply wire, brake pedal switch 3 Prerequisites: • Connector to the brake pedal switch (two sockets) disconnected. • The following other pedal connectors disconnected:
• • • •
• •
Accelerator pedal sensor. Clutch pedal switch (if equipped with clutch pedal). Measure voltage using multimeter. VECU connected. Ignition key in DRIVE position. Measurement to the VECU.
Measuring points
Expected value
C (common) - ground
B+
9990008 J39200
53
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, brake pedal switch 4 Prerequisites: • Connector to the brake pedal switch (two sockets) disconnected. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
NO (normally open) - ground
2.1 - 3.1 k
9990008 J39200
Supply wire, clutch pedal switch 5 Prerequisites: • Connector to the clutch pedal switch (two sockets) disconnected (if the vehicle is equipped with clutch pedal). • The following other pedal connectors disconnected:
• • • •
• •
Accelerator pedal sensor. Brake pedal switch (two sockets). Measure voltage using multimeter. VECU connected. Ignition key in DRIVE position. Measurement to the VECU.
Measuring points
Expected value
C (common) - ground
B+
9990008 J39200
54
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, clutch pedal switch 6 Prerequisites: • Connector to the clutch pedal switch (two sockets) disconnected (if equipped with clutch pedal). • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
NO (normally open) - ground
2.1 - 3.1 k
9990008 J39200
Wiring harness 7 Check the wiring harness; refer to Service Information, group 37.
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
Idle validation switch 1 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Measurement box with adapter connected to the accelerator pedal sensor. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at the accelerator pedal sensor. Measuring points
Expected value
1-3
∞ (no acceleration) 20 - 90 (full acceleration)
88890016 J39200
55
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Brake pedal switch 2 Prerequisites: • Connector to the brake pedal switch (two sockets) disconnected. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at brake pedal switch. Measuring points
Expected value
“C” - “NO”
0 ∞
(brake pedal at rest) (brake pedal depressed)
9990008 J39200
Clutch pedal switch 3 Prerequisites: • Connector to the clutch pedal switch (two sockets) disconnected (if the vehicle is equipped with clutch pedal). • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at the clutch pedal switch. Measuring points
Expected value
“C” - “NO”
0 ∞
(clutch pedal at rest) (clutch pedal depressed)
9990008 J39200
56
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of subsystem Supply wire, pedal switches 1 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB19 - PA12
B+
9998533 , 9998699 , 9813194 J39200
Signal wire, idle validation switch 1 2 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA23 - PA12
0 V (no acceleration) B+ (full acceleration)
9998533 , 9998699 J39200
57
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, brake pedal switch 3 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA5 - PA12
B+ (brake pedal at rest) 0 V (brake pedal depressed)
9998533 , 9998699 J39200
Signal wire, clutch pedal switch 4 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA8 - PA12
B+ (clutch pedal at rest) 0 V (clutch pedal depressed)
9998699 , 9813194 J39200
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 52).
58
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply
W3005548
W3005650
General Information Voltage supply to switch for cruise control and engine brake control. Component: S07 engine brake switch, selector type; S24 engine brake stalk switch (Cummins EBR-CBJ6 only); S25 switch unit, cruise control.
59
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Fault code FMI 4 Abnormally low voltage or short circuit to lower voltage.
Conditions for fault code: • If the VECU registers a voltage lower than 3.0 V on the supply cable, the control unit interprets this as a fault and a fault code is set. Possible cause: • Supply wire short-circuited to ground. • Signal wire for cruise control, SET+/SET/RESUME/ON, short-circuited to ground. • Signal wire for engine brake switch (if the vehicle is equipped with engine brake), EPG/VCB, short-circuited to ground. • Signal wire for engine brake stalk switch (if equipped with engine brake), short-circuited to ground. • Faulty contact or switch. • Switch resistance and oxidation. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. • All functions in the cruise control cannot be used. • All functions for engine brake cannot be used. • Engine does not respond to full acceleration. Action: • “MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply, Check” page 61.
60
Troubleshooting
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-12 MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply, Check Special tools: 9990008, 9998533, 9998699 Other special equipment: 9813194, J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
• Cruise control switch, test • Engine brake function, test Measurement at the component’s connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Supply wire, cruise control switch 1 Prerequisites: • Connector to Cruise control switch disconnected. • Measurement box with adapter connected to the VECU. • Connector to engine brake switch disconnected (if the vehicle is equipped with engine brake). • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement to the VECU.
61
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Measuring points
Expected value
1 - ground
B+
9990008 , J39200
Signal wire, Cruise control switch 2 Prerequisites: • Connector to Cruise control switch disconnected. • Measurement box with adapter connected to the VECU. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
2.1 - 3.1 k
(SET+)
3 - ground
2.1 - 3.1 k
(RESUME)
2 - ground
2.1 - 3.1 k
(ON)
4 - ground
2.1 - 3.1 k
(SET-)
9990008 , J39200
Supply wire, engine brake switch (Volvo engine) 3 Note: The check below applies only to vehicles equipped with Volvo Engine Brake (EBR-VEB). Prerequisites: • Connector to dash engine brake switch disconnected. • Connector to Cruise control switch disconnected. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement to the VECU. Measuring points
Expected value
1 - ground
B+
9990008 , J39200
62
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, engine brake switch 4 Note: The check below applies only to vehicles equipped with Volvo Engine Brake (EBR-VEB). Prerequisites: • Connector to dash engine brake switch disconnected. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
2.1 - 3.1 k
(VCB)
6 - ground
2.1 - 3.1 k
(EPG)
9990008 , J39200
Supply wire, engine brake switch stalk lever (Cummins engine) 5 Note: The check below applies only to vehicles equipped with engine brake stalk switch (Cummins EBR-CBJ6). Prerequisites: • Connector to stalk lever, engine brake disconnected. • Measurement box with adapter connected to the VECU. • Connector to Cruise control switch disconnected. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement to the VECU. Measuring points
Expected value
1 - ground
B+
9990008 , J39200
63
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, engine brake switch lever (Cummins engine) 6 Note: The check below applies only to vehicles equipped with engine brake stalk lever (Cummins EBR-CBJ6). Prerequisites: • Connector to stalk lever, engine brake disconnected. • Measurement box with adapter connected to the VECU. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
3 - ground
∞ (OFF) 2.1 - 3.1 k (ON)
9990008 , J39200
Wiring harness 7 Check the wiring harness; refer to Service Information, group 37.
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
64
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Switch for the cruise control 1 Prerequisites: • Connector to Cruise control switch disconnected. • Measurement box with adapter connected to switch cruise control. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at switch cruise control. Measuring points
Expected value
1-5
∞
(SET+ inactive)
(SET+ active)
∞
(RESUME inactive)
(RESUME active)
∞
(OFF)
(ON)
(RESUME active)
∞
(SET- inactive)
(SET- active)
∞
(SET+ active)
1-3
1-2
1-4
9990008 , J39200
Check of the dash switch for engine brake (Volvo engines) 2 Note: The check below applies only to vehicles equipped with Volvo Engine Brake (EBR-VEB). Prerequisites: • Connector to dash engine brake switch disconnected. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at dash switch for engine brake. Measuring points
Expected value
1-6
∞ 0 0
1-5
∞ (VCB and EPG inactive, if the vehicle is equipped with VCB) 0 (VCB active, if the vehicle is equipped with VCB)
(EPG inactive) (EPG active) (VCB active, if the vehicle is equipped with VCB)
9990008 , J39200
65
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of stalk lever for the engine brake (Cummins engine) 3 Note: The check below applies only to vehicles equipped with engine brake stalk lever (Cummins EBR-CBJ6). Prerequisites: • Connector to stalk lever, engine brake disconnected. • Measurement box with adapter connected to stalk lever, engine brake. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at stalk lever, engine brake. Measuring points
Expected value
1-3
∞ 0
(OFF) (ON)
9990008 , J39200
Check of subsystem Supply wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB5 - PA12
B+
9998533 , 9998699 , 9813194 , J39200
66
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, Cruise control switch 2 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA2 - PA12
0 V (SET+ inactive) B+ (SET+ active)
PA30 - PA12
0 V (RESUME inactive) B+ (RESUME active)
PA3 - PA12
0 V (OFF) B+ (ON) B+ (RESUME active)
PA1 - PA12
0 V (SET - inactive) B+ (SET- active) 0 V (SET+ active)
9998533 , 9998699 , 9813194 , J39200
Signal wire, engine brake switch (Volvo engine) 3 Note: The check below applies only to vehicles equipped with Volvo Engine Brake (EBR-VEB). Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA21 - PA12
0 V (EPG inactive) B+ (EPG requested) B+ (VCB requested, if equipped)
PA20 - PA12
0 V (VCB and EPG inactive, if equipped) B+ (VCB requested, if equipped)
9998699 , 9813194 , J39200
67
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, engine brake switch stalk lever (Cummins engine) 4 Note: The check below applies only to vehicles equipped with engine brake stalk lever (Cummins EBR-CBJ6). Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PA20 - PA12
0 V (OFF, inactive) B+ (ON, active)
9998699 , 9813194 , J39200
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 61).
68
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply
W3006773 W3006778
General Information Supply voltage to sensors for accelerator pedal and engine brake stalk lever. (Engine brake stalk lever is used only with Cummins EBR-CBJ6.) The sensors are supplied with a reference voltage of 5.0 V. Each change of the accelerator pedal’s angle controls
the input signal to the VECU. For normal values, see table page 75. Component:B25 accelerator pedal sensor; S24 engine brake stalk lever (Cummins EBR-CBJ6 only); A17, VECU.
Fault codes 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: • If the VECU registers a voltage higher than 5.7 V on the supply wire, the control unit interprets this as a fault and a fault code is set.
Conditions for fault code: • If the VECU registers a voltage lower than 4.7 V on the supply wire, the control unit interprets this as a fault and a fault code is set.
Possible cause: • Open circuit, ground wire. • Supply wire short-circuited to higher voltage. • Open circuit, supply wire. • Faulty sensor. • Switch resistance and oxidation.
Possible cause: • Supply wire short-circuited to ground or lower voltage. • Faulty sensor.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. • Engine does not respond to full acceleration. • No engine brake affect.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. • Engine does not respond to full acceleration. • No engine brake effect. Action: • “MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply, Check” page 70.
Action: • “MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply, Check” page 70.
69
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-13 MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply, Check Special tools: 85108489, 9998533, 88890016, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
• Control auxiliary brake, test • Accelerator pedal switches and sensors, test Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Ground wire, accelerator pedal 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Adapter connected to the accelerator pedal connector. • Connector to engine brake switch disconnected (if equipped). • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
4 - ground
88890016 , J39200
70
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Supply wire, accelerator pedal 2 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Adapter connected to accelerator pedal connector. • Connector to engine brake switch disconnected (if equipped). • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement to the VECU. Measuring points
Expected value
6 - ground
4.3 - 6.5 V
88890016 , J39200
Signal wire, accelerator pedal 3 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Adapter connected to accelerator pedal connector. • Connector to engine brake switch disconnected (if equipped). • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
80 - 120 k
88890016 , J39200
71
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Ground wire, engine brake stalk lever (Cummins engine) 4 Note: The check below applies only to vehicles equipped with engine brake stalk lever (Cummins EBR-CBJ6). Prerequisites: • Connector to engine brake switch disconnected. • Connector to the accelerator pedal sensor disconnected. • Adapter pin connected to engine brake, stalk lever connector. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
9990008 , J39200
Supply wire, engine brake stalk lever (Cummins engine) 5 Note: The check below applies only to vehicles equipped with engine brake stalk lever (Cummins EBR-CBJ6). Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Engine brake stalk lever switch disconnected. • Adapter pin connected to engine brake, stalk lever connector. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. • Measurement to the VECU. Measuring points
Expected value
4 - ground
4.3 - 6.5 V
9990008 , J39200
72
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, engine brake, stalk lever (Cummins engine) 6 Note: The check below applies only to vehicles equipped with engine brake stalk lever (EBR-CBJ6). Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Engine brake stalk lever switch disconnected. • Adapter pin connected to engine brake, stalk lever connector. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
6 - ground
80 - 120 k
9996899 , J39200
Wiring harness 7 Check the wiring harness; refer to Service Information, group 37.
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
Accelerator pedal sensor 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Adapter connected to the accelerator pedal sensor. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at the accelerator control sensor. Measuring points
Expected value
6-4
3.2 - 4.8 k
5-4
1.0 - 2.0 k
(no acceleration)
88890016 , J39200
73
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Switch for engine brake stalk lever (Cummins engine) 2 Note: The check below applies only to vehicles equipped with engine brake stalk lever (EBR-CBJ6). Prerequisites: • Connector to engine brake switch disconnected. • Measurement box with adapter connected to engine brake switch. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at engine brake stalk lever. Measuring points
Expected value
4-5
1.7 - 2.5 k
(pos 1)
1.3 - 2.0 k
(pos 2)
1.1 - 1.7 k
(pos 3)
0.9 - 1.4 k
(pos 4)
0.8 - 1.2 k
(pos 5)
0.7 - 1.1 k
(pos 6)
1.0 - 1.4 k
(pos 1)
0.9 - 1.3 k
(pos 2)
0.8 - 1.2 k
(pos 3)
0.8 - 1.1 k
(pos 4)
0.7 - 1.1 k
(pos 5)
0.7 - 1.0 k
(pos 6)
6-5
J39200
Check of subsystem Ground wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. Measuring points
Expected value
PB22 - ground
9998533 , 9998699 , J39200
74
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Supply wire 2 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB10 - PB22
4.5 - 5.5 V
9998533 , 9998699 , J39200
Signal wire, accelerator pedal 3 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB8 - PB22
0.4 - 0.6 V (no acceleration) 2.6 - 3.8 V (full acceleration)
9998533 , 9998699 , J39200
75
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire, engine brake, stalk lever (Cummins engine) 4 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • VECU connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB24 - PB22
0.3 1.0 1.7 2.3 2.9 3.6
-
0.7 1.6 2.5 3.5 4.4 5.4
V V V V V V
(pos (pos (pos (pos (pos (pos
1) 2) 3) 4) 5) 6)
9998533 , 9998699 , J39200
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 70).
76
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PPID 74 VECU Power Supply
W3006779 W3006775
General Information Component: Rly 4 EMS power; A17, VECU; F71 Fuse, VECU power; FB01 fuse, FB05 fuse, battery 1; G01 battery.
Fault code FMI 3
FMI 4
Abnormally high voltage or short circuit to higher voltage.
Abnormally low voltage or short circuit to lower voltage.
Condition for fault code: • If the voltage from relay 4, VECU pin PB15 is greater than 1V, the VECU will interpret it as a fault and a fault code will be set.
Condition for fault code: • If the voltage from relay 4, VECU pin PB15 is less than 0V, the VECU will interpret it as a fault and a fault code will be set.
Possible cause: • Short-circuit to higher voltage. • Faulty relay.
Possible cause: • Open circuit, cable from relay. • Fault in relay.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Noticeable external symptom: • Yellow lamp lights up.
Noticeable external symptom: • Yellow lamp lights up.
Action: • “MID 144 PPID 74 Power Supply EECU/VECU, Check” page 78.
Action: • “MID 144 PPID 74 Power Supply EECU/VECU, Check” page 78.
77
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-05 MID 144 PPID 74 Power Supply EECU/VECU, Check Special tools: 9990008, 9996899, 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Ground wire 1 Prerequisites: • Relay EMS disconnected • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
85 - ground
0.5 M
9990008 J39200
Wiring harness 2 Check the wiring harness; refer to Service Information, group 37.
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
78
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Relay EMS 1 Prerequisites:
•
Measurement box with adapter connected between VECU connector PB and wiring harness.
• •
Ignition key in OFF position. Check of the relay EMS.
Earth
Checks
PB15 - ground
Listen for clicking (relay active)
9998533 , 9998699
Check of subsystem Ground wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measure voltage using multimeter. • The control unit connected • Ignition key in OFF position. Earth
Checks
PB15 - PB22
B+ (relay inactive) 0 V (ground PB15 and listen for relay clicking; relay active) Note: When relay is active, fuse F71 is supplied with 12 V which then supplies PA13 with voltage. 9998533 , 9998699
79
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 SID 230 Idle Validation Switch 1
W3006780
W3006772
General Information Component: B25 Sensor, accelerator pedal; A17, VECU
Fault code FMI 7 Incorrect response from mechanical system.
Conditions for fault code: • If the signal from the idling switch is not available in the interval 0 - 13 %, the control unit interprets this as a fault and a fault code is set. Possible cause: • Open circuit, supply cable. • Open circuit, signal cable. • Signal cable short-circuited to ground. • Signal cable short-circuited to voltage. • Faulty switch. • Switch resistance and oxidation. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. • Engine does not respond to full acceleration. Action: • “MID 144 SID 230 Idle Validation Switch 1, Check” page 81.
80
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-18 MID 144 SID 230 Idle Validation Switch 1, Check Special tools: 88890016 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
• •
Accelerator pedal switches and sensors, test MID 144 pinout test
Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Supply wire 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Measurement box with adapter connected to the VECU. • The following other pedal connectors disconnected:
• • • •
• •
The brake pedal switch (two sockets). The clutch pedal switch (if equipped). Measure voltage using multimeter. VECU connected. Ignition key in DRIVE position. Measurement to the VECU.
Measuring points
Expected value
3 - ground
B+
88890016 , J39200
81
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire 2 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Measurement box with adapter connected to VECU. • Measure resistance using multimeter. • VECU connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
1 - ground
2.1 - 3.1 k
88890016 , J39200
Wiring harness 3 Check the wiring harness; refer to Service Information, group 37.
Check of component Note: Faults in the component can be caused by faults in the wiring harness to the control unit. Therefore, a check of the wiring harness also should be made before connecting a new component.
Idle validation switch 1 1 Prerequisites: • Connector to the accelerator pedal sensor disconnected. • Measurement box with adapter connected to the accelerator pedal sensor. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at the accelerator pedal sensor. Measuring points
Expected value
1-3
∞ (pedal at idle) 20 - 90 (pedal off idle)
88890016 , J39200
82
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 SID 231 J1939 Control Link General Information The system’s control signals are sent via J1939 Control Data Link. Information and diagnostic signals are sent via J1587/1708 Information Data Link. The link also functions as a reserve system for the J1939, if the Control Data Link does not function for any reason. Component: A17, VECU
83
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Fault code FMI 2 Intermittent or incorrect data. Note: Connection of the measurement box and adapter to the VECU’s "PA" connector may result in a ’ghost’ fault code (SID231 / FMI 2) resulting from the adapter’s effect on the J1939 CAN_2 link (pins PA-15 and PA-16). If the fault was not present before connection of the measurement box, ignore the code and erase all inactive fault codes following testing.
Conditions for fault code: • If the VECU does not receive confirmation for the messages on the control link, the control unit interprets this as a fault and a fault code is set. Possible cause: • Loose connection. • Open circuit, the control link. • Switch resistance and oxidation. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
FMI 12 Faulty unit or component. Note: This fault code is normally not caused by errors in the VECU.
Conditions for fault code: • If the expected messages are not available from a control unit on the control link the VECU interprets this as a fault and a fault code is set. Possible cause: • Open circuit, communication cable. • Switch resistance and oxidation. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
84
Troubleshooting
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 SID 240 Program Memory
T2012704
General Information At start-up a checksum is calculated for the software in the VECU flash memory. This is compared with a previously stored checksum to check that the software is correct. Component: A17, VECU
Fault code FMI 2 Intermittent or incorrect data
Conditions for fault code: • If the checksum calculated at start-up does not agree with the previously saved checksum, the VECU interprets this as a fault and a fault code is set. Possible cause: • Software fault. • Faulty memory circuit. Reaction from VECU: • The control unit continuously restarts. Noticeable external symptom: • Yellow lamp is lit by the instrument control unit since the VECU does not respond to the call. • The vehicle can only be run at increased idling speed.
85
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 SID 243 Cruise Control Set Switch
W3005580 W3005540
General Information Component: S02 Switch unit, cruise control.
Fault code FMI 7 Incorrect response from mechanical system.
Conditions for fault code: • If the VECU receives the signals for SET+ and SETat the same time, the control unit interprets this as a fault and a fault code is set. Possible cause: • Signal wire short-circuited to voltage. • Faulty switch. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. • The cruise control function does not work. The speed cannot be set, but if the speed has been set previously it can be resumed with RESUME. Action: • “MID 144 SID 243 Cruise Control Set Switch, Check” page 87.
86
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-20 MID 144 SID 243 Cruise Control Set Switch, Check Special tools: 9990020, 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
• Cruise control switch, test • MID 144 pinout test Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate.
Supply wire 1 Prerequisites: • 14–pin connector (green) to Cruise control switch disconnected. • Measurement box with adapter connected to the VECU. • Measuring voltage using the multimeter. • Control unit connected. • Ignition key in drive position. • Measurement to the VECU.
87
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Measuring points
Expected value
1 - ground
B+
9996899 , 9990020 , J39200
Signal wire 2 Prerequisites: • Connector to Cruise control switch disconnected. • Measurement box with adapter connected to the VECU. • Measure resistance using multimeter. • Control unit connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
2.1 - 3.1 k
(SET+)
3 - ground
2.1 - 3.1 k
(RESUME)
2 - ground
2.1 - 3.1 k
(ON)
4 - ground
2.1 - 3.1 k
(SET- )
9996899 , 9990020 , J39200
Wiring harness 3 Check the wiring harness; refer to Service Information, group 37.
88
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component.
Signal wire, Cruise control switch 1 Prerequisites: • Connector to Cruise control switch disconnected. • Measurement box with adapter connected to the VECU. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at switch cruise control. Measuring points
Expected value
5 - 4 (against switch)
∞
(SET+ and SET- inactive)
∞
(ON and SET+ active)
∞
(RESUME active and SET+ active)
∞
(ON and SET- active)
∞
(RESUME active and SET- active)
9996899 , 9990020 , J39200
89
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of subsystem Signal wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PA and wiring harness. • Measuring voltage using the multimeter. • Control unit connected. • Ignition key in drive position. Measuring points
Expected value
PA1 - PA12
B+ (OFF and SET- active) 0 V (OFF and SET+ active) 0 V (ON and SET+ active) 0 V (RESUME active and SET+ active)
PA2 - PA12
B+ (OFF and SET+ active) 0 V (OFF and SET- active) 0 V (ON and SET- active) 0 V (RESUME active and SET- active)
9813194 , 9998699 , J39200
90
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 SID 250 J1587/J1708 Information Data Link General Information The non-critical communication between the vehicle’s control units and the display on the instrument’s gauges is carried out via J1587/1708 Information Data Link. The system’s critical control signals are sent via the J1939 Control Data Link. Information and diagnostic signals are sent via J1587/1708 Information Data Link. The link also functions as a reserve system for the J1939 Control Data Link, if the Control Data Link does not function for any reason. J1587/1708 Information Data Link keeps the system status continually updated and makes this information available for reading via the diagnostics socket. Component: A17, VECU.
Fault code FMI 2 Intermittent or incorrect data.
•
If the VECU is unable to send it’s messages onto the databus after several attempts, the VECU will use this fault code to flag a possible physical fault with the datalink.
Conditions for fault code: • If the VECU registers incorrect messages on the information link the control unit interprets this as a fault and a fault code is set. Possible cause: • Several units are sending at the same time on the information link. Reaction from VECU: • Fault code is set. • Yellow lamp is requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
91
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 SID 253 Calibration Memory EEPROM
T2012704
General Information At start-up a checksum is calculated for the data set in the control unit’s EEPROM memory. This is compared
with a previously stored checksum to check that the data set is correct.
Fault code FMI 2
FMI 13
Intermittent or incorrect data.
Calibration values outside the limits.
Conditions for fault code: • If the VECU receives an error in calculating the checksum in the calibration memory the control unit interprets this as a fault and a fault code is set.
Conditions for fault code: • If the checksum for the data set calculated at start-up does not agree with the previously saved checksum, the VECU interprets this as a fault and a fault code is set.
Possible cause: • Faulty memory circuit. • Error when programming. Reaction from VECU: • Fault code is set. • Red lamp is requested. Noticeable external symptom: • Red lamp lights up. • The vehicle can only be driven at increased idling speed.
92
Possible cause: • Incorrect data set. • Faulty memory circuit. Reaction from VECU: • Fault code is set. • Red lamp is requested. Noticeable external symptom: • Red lamp lights up. • The vehicle can only be driven at increased idling speed.
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PSID 4 Engine Brake Stalk Lever (Cummins engine; applies only to EBR-CBJ6.)
W3005544
T3015745
General Information Component: S24 Stalk lever, engine brake A17, VECU
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: • If the VECU registers a voltage higher than 4.8 V, the control unit interprets this as a fault and a fault code is set.
Conditions for fault code: • If the VECU interprets a voltage below 0.2 V as a fault and a fault code is set.
Possible cause: • Open circuit, ground cable. • Signal cable short-circuited to voltage. • Faulty switch. • Switch resistance and oxidation.
Possible cause: • Open circuit, supply cable. • Open circuit, signal cable. • Signal cable short-circuited to ground. • Faulty switch. • Switch resistance and oxidation.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Reaction from VECU: • Fault code is set. • Yellow lamp is requested.
Noticeable external symptom: • Yellow lamp lights up. • Engine brake cannot be activated.
Noticeable external symptom: • Yellow lamp lights up. • Engine brake cannot be activated.
Action: • “MID 144 PSID 4 Engine Brake Stalk Lever, Check” page 94.
Action: • “MID 144 PSID 4 Engine Brake Stalk Lever, Check” page 94.
93
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
3649-21-03-25 MID 144 PSID 4 Engine Brake Stalk Lever, Check Special tools: 9998533, 9998699 Other special equipment: J39200
NOTE! • Read off the other fault codes for the VECU. • Switch off the current in the vehicle before the •
connectors are disconnected. Check for loose connections, switch resistance, and oxidation. For information concerning fault tracing of wires and connectors, refer to Service Information, group 37.
Tests Using PC Tool The following tests are useful for closely examining the component’s function:
• Engine brake, function test • MID 144 pinout test Measurement at component connector to VECU Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should also be made if any of the measurement values deviate. Note: It may be necessary to temporarily remove the connector from its mounting location to perform the following checks. 1 Disconnect the connector at the switch for the engine brake. 2 Disconnect the connector at the accelerator pedal sensor.
94
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Ground wire 3 Prerequisites: • Back-probe the connector at the designed cavity. • Measure resistance using multimeter. • Control unit connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
5 - ground
≈0
9998699 J39200
Supply wire 4 Prerequisites: • Back-probe the connector at the designed cavity. • Measuring voltage using the multimeter. • Control unit connected. • Ignition key in drive position. • Measurement to the VECU. Measuring points
Expected value
4 - ground
≈ 4.3 - 6.5 V
9998699 J39200
Signal wire 5 Prerequisites: • Back-probe the connector at the designed cavity. • Measure resistance using multimeter. • Control unit connected. • Ignition key in OFF position. • Measurement to the VECU. Measuring points
Expected value
6 - ground
0.8 - 1.2 k
J39200
Wiring harness 6 Check the wiring harness; refer to Service Information, group 37. 95
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of component Note: Faults in the component can be caused by faults in the wiring harness of the control unit. Therefore, a check of the wiring harness should also be made before connecting a new component. Note: It may be necessary to temporarily remove the connector from its mounting location to perform the following checks.
Engine brake switch 1 Prerequisites: • Connector to engine brake switch connected. • Back-probe the connector at the designated cavity. • Measure resistance using multimeter. • Ignition key in OFF position. • Measurement at stalk lever. Measuring points
Expected value
4-5
1.7 - 2.5 k
(pos 1)
1.3 - 2.0 k
(pos 2)
1.1 - 1.7 k
(pos 3)
0.9 - 1.4 k
(pos 4)
0.8 - 1.2 k
(pos 5)
0.7 - 1.1 k
(pos 6)
1.0 - 1.4 k
(pos 1)
0.9 - 1.3 k
(pos 2)
0.8 - 1.2 k
(pos 3)
0.8 - 1.1 k
(pos 4)
0.7 - 1.1 k
(pos 5)
0.7 - 1.0 k
(pos 6)
6-5
J39200
96
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Check of subsystem Ground wire 1 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measuring resistance using multimeter. • Control unit connected. • Ignition key in OFF position. Measuring points
Expected value
PB22 - ground
≈0
9998533 , 9998699 J39200
Supply wire 2 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measuring voltage using multimeter. • Control unit connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB10 - PB22
≈4-6V
9998533 , 9998699 J39200
97
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
Signal wire 3 Prerequisites: • Measurement box with adapter connected between VECU connector PB and wiring harness. • Measuring voltage using multimeter. • Control unit connected. • Ignition key in DRIVE position. Measuring points
Expected value
PB24 - PB22
0.3 - 0.7 V (pos 1) 1.0 - 1.6 V (pos 2) 1.7 - 2.5 V (pos 3) 2.3 - 3.5 V (pos 4) 2.9 - 4.4 V (pos 5) 3.6 - 5.4 V (pos 6)
9998533 , 9998699 J39200
Verification Using the PC tool, check that the fault has been corrected (see “Tests Using PC Tool” page 94).
98
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PSID 200 J1939 Control Data Link Interruption, Engine ECU General Information The control units share important information on the J1939 Control Data Link. If a control unit lacks messages from another control unit, this fault code will be used to point out the control unit that is expected to send messages on the J1939 Control Data Link.
Fault code FMI 9 Abnormal updating rate.
Condition for fault code: • If the VECU does not receive any messages on the J1939 Control Data Link from the EECU within a certain time, the control unit will interpret this as a fault and a fault code is set. Possible cause: • Fault in J1939 Control Data Link between EMS control unit and VECU Reaction from VECU: • Yellow lamp requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
99
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PSID 202 J1939 Control Data Link Interruption, Instrument Control Unit General Information The control units share important information on the J1939 Control Data Link. If a control unit lacks messages from another control unit, this fault code will be used to point out the control unit that is expected to send messages on the J1939 Control Data Link.
Fault code FMI 9 Abnormal updating rate.
Condition for fault code: • If the VECU does not receive any messages concerning time/date on the J1939 Control Data Link from the instrument within a certain time, the control unit will interpret this as a fault and a fault code is set. Possible cause: • Fault in J1939 Control Data Link between instrument and VECU Reaction from VECU: • Yellow information lamp requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
100
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PSID 204 J1939 Control Data Link Interruption, Brake Control Unit General Information The control units share important information on the J1939 Control Data Link. If a control unit lacks messages from another control unit, this fault code will be used to point out the control unit that is expected to send messages on the J1939 Control Data Link.
Fault code FMI 9 Abnormal updating rate.
Condition for fault code: • If the VECU does not receive any messages on the J1939 Control Data Link from the brake control unit within a certain time, the control unit will interpret this as a fault and a fault code is set. Possible cause: • Fault in J1939 Control Data Link between ABS/EBS control unit and VECU Reaction from VECU: • Yellow lamp requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
101
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PSID 210 J1939 Control Data Link Interruption, Lighting Control Module (LCM) General Information The control units share important information on the J1939 Control Data Link. If a control unit lacks messages from another control unit, this fault code will be used to point out the control unit that is expected to send messages on the J1939 Control Data Link.
Fault code FMI 9 Abnormal updating rate.
Condition for fault code: • If the VECU does not receive any messages on the J1939 Control Data Link from the light control module within a certain time, the control unit will interpret this as a fault and a fault code is set. Possible cause: • Fault in J1939 Control Data Link between LCM control unit and VECU Reaction from VECU: • Yellow lamp requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
102
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
Troubleshooting
MID 144 PSID 214 J1939 Control Data Link Interruption, Bodybuilder Control Unit (Volvo engines only)
General Information The control units share important information on the J1939 Control Data Link. If a control unit lacks messages from another control unit, this fault code will be used to point out the control unit that is expected to send messages on the J1939 Control Data Link.
Fault code FMI 9 Abnormal updating rate.
Condition for fault code: • If the VECU does not receive any messages on the J1939 Control Data Link from the bodybuilder module within a certain time, the control unit will interpret this as a fault and a fault code is set. Possible cause: • Fault in J1939 Control Data Link between BBM control unit and VECU Reaction from VECU: • Yellow lamp requested. Noticeable external symptom: • Yellow lamp lights up. Action: • Troubleshoot J1939 Control Data Link; refer to Service Information, group 37.
103
Group 36 Fault Codes, VECU, MID 144, Volvo or Cummins Engine
MID 144 SID 231 J1939 Control Link General Information Internal resets are a normal function of the VECU and are closely monitored and reported when a problem exists. This reset can be due to either an internal or external problem.
Fault Code FMI 4 Abnormally low voltage or short circuit to lower voltage Condition for fault code:
• If the VECU detects an abnormal reset the control unit will interpret this as an error and a fault code is set. Possible cause: Inconsistent power supplied to the VECU (EMS relay) Poor ground circuitry to the VECU
• •
Reaction from VECU: Yellow lamp requested
•
Noticeable external symptom: Yellow lamp in cluster Fault code is set
• •
Actions: Check the power supply circuit(s) to the VECU for uninterrupted battery voltage • Check for: (Damaged wiring, loose connections at connectors/splices, loose/bent pins, corrosion, etc.) • Check the ground circuit for good continuity • Check for: (Damaged wiring, loose connections at connectors/splices, loose/bent pins, corrosion, etc.)
•
FMI 12 Abnormal Reset Condition for fault code:
• If the VECU detects an abnormal reset the control unit will interpret this as an error and a fault code is set. Possible cause:
• Possible software failure Possible hardware failure Reaction from VECU: Yellow lamp requested Yellow lamp in cluster
• •
Noticeable external symptom: Fault code is set
•
Actions: Replace the VECU’s main software using VCADS Pro (Do this first before replacing the VECU to see if this resolves the problem) • Replace the VECU control unit (Do this last after all other checks have been exhausted)
•
104
Troubleshooting
Operation Numbers 3649-21-03-08 MID 144 PID 84 Vehicle Speed, Check ................................................................................................... 23 3649-21-03-09 MID 144 PID 91 Accelerator Pedal Position (Percentage), Check ........................................................... 28 3649-21-03-01 MID 144 PID 150 PTO Output, Check ..................................................................................................... 34 3649-21-03-28 MID 144 PID 191 Output Shaft Speed, Check ......................................................................................... 40 3649-21-03-04 MID 144 PPID 61 Engine Brake Switch, Check ....................................................................................... 45 3649-21-03-10 MID 144 PPID 69 Buffered Idle Validation Switch, Check ....................................................................... 49 3649-21-03-11 MID 144 PPID 70 Pedal Switches, Supply, Check ................................................................................... 52 3649-21-03-12 MID 144 PPID 71 Cruise Control and Engine Brake, Switch Supply, Check ........................................... 61 3649-21-03-13 MID 144 PPID 72 Accelerator Pedal and Engine Brake, Sensors Supply, Check ................................... 70 3649-21-03-05 MID 144 PPID 74 Power Supply EECU/VECU, Check ............................................................................ 78 3649-21-03-18 MID 144 SID 230 Idle Validation Switch 1, Check ................................................................................... 81 3649-21-03-20 MID 144 SID 243 Cruise Control Set Switch, Check ............................................................................... 87 3649-21-03-25 MID 144 PSID 4 Engine Brake Stalk Lever, Check .................................................................................. 94
Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115
Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com
PV776-20 033671 (USA) 08.2005 © Volvo Trucks North America, Inc., 2005
